ROADS & TRANSPORT

AUTHORITY

‫ ﺗطوﯾر وﺻﻠﺔ اﻷﺻﺎﯾل‬- ‫ ﺗﺣﺳﯾﻧﺎت ﻣﺣور اﻟﺷﯾﺦ راﺷد‬- 1060/2‫ط‬

PROJECT: R1060/2
– IMPROVEMENT OF SHEIKH RASHED
DEVELOPMENT OF AL ASAYEL LINK

TENDER DOCUMENT

VOLUME 2 – PART I – BOOK 1

RTA SPECIFICATIONS (ROAD WORK)

EMPLOYER: CONSULTANT:

Roads & Transport Authority AECOM Middle East Ltd.

Roads Department P.O. Box 51028
P.O. Box 118899 Dubai – U.A.E.
Dubai – U.A.E.

RTA MAY 2024

 R1060/2 - Improvement of Sheikh Rashed – Development of Al Asayel link
Tenderer & Contract Conditions

PROJECT R1060/2:
IMPROVEMENT OF SHEIKH RASHED –
DEVELOPMENT OF AL ASAYEL LINK

GENERAL INDEX

VOLUME 1 - TENDERER & CONTRACT CONDITIONS

VOLUME 2 - SPECIFICATIONS

 PART I - RTA SPECIFICATIONS

o BOOK 1 – ROAD WORKS

o BOOK 2 – SERVICE WORKS & APPENDICES

 PART II - DM SPECIFICATIONS

o BOOK 1 - DM GENERAL SPECIFICATIONS, PART-1

o BOOK 2 - DM GENERAL SPECIFICATIONS, PART-2

& APPENDICES

Volume 3 - BILL OF QUANTITIES

Volume 4 - DRAWINGS

Volume 5 - GEOTECHNICAL INVESTIGATION REPORT

May 2024 Tender Document 1

 VOLUME 2

Standard Specifications
For Construction of Roads in Dubai Emirate
DEPSS-10

Part 1: Road Works

Part 2: Services Works

Roads and Transport Authority

Dubai Emirate

March 2017
 PREFACE

Standard Specifications for the Construction of Roads and Bridges in Dubai Emirate

This new version of the Standard Specifications is prepared to be used solely for the
Construction of Roads and Bridges in Dubai Emirate. All the projects pertain to Roads and
Transport Authority and others pertain to Private sectors roads networks shall be governed by
these specifications as per the decree of his highness Sheikh Mohammed bin Rashid Al
Maktoum No. 5 for the year 2005. The updated specifications are cited as "DEPSS-10"
indicating “Dubai Emirate Projects Standard Specifications issued in the year 2010.

These specifications shall be considered as an original part of the contract and tender documents
upon all parties to the contract. All construction contracts of the Dubai Roads are also governed
by this updated version of specifications.

Primarily, the Units of International System (SI) are mainly used in the updated version of the
specifications DEPSS-10 and a conversion table is provided to be used as a reference of units
conversions when different units are used.

Terms used throughout this specification shall have the same meaning as those defined in
accordance with:

BS 6100 2.4.1 2008 “Glossary of building and civil engineering terms. Civil Engineering,
Highway, railway and airport engineering. Highway Engineering”
BS 6100 2.2.1 2008 “Glossary of building and civil engineering terms. Civil engineering.
Substructures. Earthworks. Foundations. Tunnels. Substructures and foundations”
 METRIC TO ENGLISH CONVERSION FACTORS
Symbol When You Know Multiply By To Find Symbol
LENGTH
µm micrometers 3.9 x 10-5 inches in
mm millimeters 0.039 inches in
m meters 3.28 feet ft
m meters 1.09 yards yd
km kilometers 0.621 miles mi
AREA
2
mm square millimeters 0.0016 square inches in2
2
m square meters 10.764 square feet ft2
m2 square meters 1.195 square yards yd2
ha hectares 2.47 acres ac
2
km square kilometers 0.386 square miles mi2
VOLUME
mL milliliters 0.034 fluid ounces fl oz
L liters 0.264 gallons gal
3
m cubic meters 35.31 cubic feet ft3
m3 cubic meters 1.308 cubic yards yd3
MASS
g grams 0.035 ounces oz
kg kilograms 2.202 pounds lb
Mg megagrams 1.1023 short tons T
(or "t") (or "metric ton") (2000 lb)
TEMPERATURE (exact)
ºC Celsius 1.8C +32 Fahrenheit ºF
temperature temperature
ILLUMINATION
lx lux 0.0929 foot-candles fc
cd/m2 caldela/m2 0.2919 foot-Lamberts fl
MISCELLANEOUS

J joule 0.7376 foot·poundforce ft·lbf

N newtons 0.225 poundforce lbf
kPa kilopascals 0.145 poundforce lbf/in2
per square inch

SI is the symbol for the International System of Units.

Appropriate rounding should be made to comply with Section 4 of ASTM E 380.
 VOLUME 2
Part 1: Road Works
TABLE OF CONTENTS

Section Description

1 GENERAL

2 SITE CLEARNCE AND EARTHWORKS

3 PAVEMENT CONSTRUCTION

4 CONCRETE WORKS

5 ANCILLARY WORKS

6 WORKS IN CONNECTION WITH SERVICES

7 ROADWAY LIGHTING AND TRAFFIC SIGNALS

8 PILE FOUNDATION
Section 1
General
 1 SECTION 1 GENERAL

TABLE OF CONTENT

1/1 SITE ESTABLISHMENT .................................................................................... 2

1/2 SITE OFFICE FOR THE ENGINEER ................................................................. 2
1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR..................................... 3
1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR .............. 3
1/5 CONTRACTOR’S SITE ORGANISATION.......................................................... 3
1/6 SURVEYING EQUIPMENT ................................................................................ 4
1/7 LABORATORY TESTING .................................................................................. 4
1/8 PROGRAMME OF WORKS ............................................................................... 5
1/9 WORK SITE, SETTING OUT AND CROSSSECTIONS ..................................... 6
1/10 PROJECT SIGN BOARDS ................................................................................ 7
1/11 PROJECT PHOTOGRAPHS.............................................................................. 8
1/12 QUALITY OF MATERIALS AND SUPPLY ......................................................... 8
1/13 APPROVAL BY THE ENGINEER .................................................................... 11
1/14 EXISTING SERVICES AND SERVICE DIVERSIONS ..................................... 11
1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND
PROPERTIES .................................................................................................. 14
1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL ..................................... 15
1/17 TEMPORARY DIVERSION OF TRAFFIC ........................................................ 16
1/18 FIRE PRECAUTIONS ...................................................................................... 16
1/19 SAFETY OFFICERS ........................................................................................ 17
1/20 CONTRACT DRAWINGS AND DOCUMENTS ................................................ 17
1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND
MAINTENANCE INSTRUCTIONS ................................................................... 18
1/22 RECORD DRAWINGS ..................................................................................... 19
1/23 ACCOMMODATION WORKS .......................................................................... 19
1/24 PUBLICITY ...................................................................................................... 19
1/25 TIDYING AND CLEARING THE SITE .............................................................. 20
1/26 SOIL INVESTIGATION .................................................................................... 20
1/27 WORKS FREE FROM WATER........................................................................ 20
1/28 OTHER CONTRACTORS ON SITE ................................................................. 20
1/29 MAJOR EQUIPMENT AND PLANT ................................................................. 20
1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI . 32

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 1

 2 SECTION 1 GENERAL

1/1 SITE ESTABLISHMENT

1/1.1 The Contractor shall provide sites for the plant and workshops necessary
for the construction of the Works and shall pay any rents, easements and
license fees levied in connection therewith. Roads & Transport Authority’s
(RTA) formal approval to the site for the Contractor’s plant and workshop
must be received prior to occupying the proposed site.

1/1.2 Site offices for the Engineer and the Contractor shall be erected on a site
proposed by the contractor and approved by Roads & Transport Authority
and as shown in the Drawings. No Contractor’s plant and workshops will
be permitted within this compound.

It is the Contractor’s responsibility to obtain all necessary No Objection

Certificate for the occupation of the sites.

1/1.3 The Contractor shall construct suitable entry and exit roads to and within
the compound and provide a covered parking area as specified in
Appendix-C. The Contractor shall take all necessary precautions to avoid
storm water flooding within the compound and accesses.

1/1.4 The Engineer’s office shall be erected and fully equipped to the
satisfaction of the Engineer.

1/1.5 Within one month after the Completion of the Whole of the Works and in
accordance with the provisions of Clause 1/2.1 the whole area of the
compound shall be reinstated to its original condition and all rubbish and
refuse removed.

1/1.6 The Contractor’s proposed access routes to and within the site shall be
provided and maintained as agreed with the Engineer. The Engineer may
at any time withdraw his approval for the use of any route and may order
such widening, strengthening or repair work as he considers necessary.

1/1.7 The Contractor shall employ at his own cost watchmen for the security of
the site establishment.

1/2 SITE OFFICE FOR THE ENGINEER

1/2.1 The site offices for the Engineer shall comply with the requirements
included in Appendix-C. The offices shall be available in full working order
to the satisfaction of the Engineer within the period stipulated to
commence the works in the Tender (Clause 4) and remain so until one
month after the Completion of the Whole of the Works.

1/2.2 The Contractor shall retain on site for the exclusive use of the Engineer all
codes and standards referred to in the Specification which shall remain in
the custody of the Engineer for his exclusive use until completion of the
whole of the works but shall remain the property of the Contractor.

1/2.3 All Keys for the Engineer’s site offices shall be held by the Engineer until
such offices are removed.

1/2.4 The Contractor shall, at his own cost, provide the Engineer and his staff

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 2

 3 SECTION 1 GENERAL

with daily cleaning attendance and two full time for serving refreshments,
car cleaning etc.

1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR

1/3.1 The Contractor shall make provision for installation, maintenance and
removal at the completion of the works, of his offices, sheds, and shelters.
He shall provide and maintain at his own cost sanitary facilities on site, first
aid and fire fighting equipment, drinking water facilities, electricity and
telephone for the duration of the Contract.

1/3.2 The Contractor shall be responsible for the security of the site and the
safety of public and adjoining property and shall be liable for any claims
arising from loss or damage suffered. He shall employ watchmen for this
purpose.

1/3.3 All temporary accommodation shall be maintained in an efficient condition

during the period of the Contract and shall be available for inspection by
the Government Medical Officer of Health. The Contractor must comply
immediately with any instruction given by the Medical Officer for cleaning,
disinfestations and maintenance of any building to a hygienic and sanitary
condition.

1/3.4 The Contractor shall confine his apparatus, the storage of materials and
the operations of his workmen to the limits indicated by law, ordinances,
permits or direction of the Engineer. The Contractor shall erect temporary
fences as required by the Engineer. The site boundary lines shall be to the
approval of the Engineer.

1/3.5 The Contractor shall provide and maintain water, electricity and power
required for the works including that required by the Sub-Contractors. Pay
all charges and bear all costs for the necessary temporary installation
including pipework, pumps, water tankers, storage tanks, generating
equipment, etc. and remove on completion and make good all work
disturbed.

1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR

1/4.1 The Contractor shall make provision for the installation, maintenance up to
the completion of the works and removal of fully equipped workshops and
stores. The Contractor shall also provide all necessary construction plant,
equipment and tools necessary for the proper execution of the works. Plant
shall include, but not be limited to, concrete and asphalt manufacturing
plant, mobile plant and sundry equipment required for any particular trade
necessary for the execution and completion of the works. All plant and
equipment required for the Contract is subject to the approval of the
Engineer.

1/5 CONTRACTOR’S SITE ORGANISATION

1/5.1 The Contractor shall perform the setting out of the works as described in
the Drawings and Specification.
1/5.2 The Contractor shall provide the Engineer with all necessary assistance in
checking the setting out of the works and interpreting any information used

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 3

 4 SECTION 1 GENERAL

by the Contractor for this purpose including the supply of a minimum 2

chainmen as and when required by the Engineer.
1/5.3 The Contractor shall also provide the Engineer with similar assistance in
carrying out additional surveying works should these be found necessary
for the proper execution of the works.

1/5.4 The Contractor shall also provide all assistance as required by the
Engineer for the measurement of the works for monthly valuation, Monthly
Laboratory Report and for the final payment certificate and also for
recording the progress of the works.

1/5.5 The Contractor shall be responsible for all follow up and co-ordination with
all service authorities (Electricity, Water, Drainage, Street Lighting,
Telephone, Horticulture, etc.).

1/5.6 The Contractor shall provide subject to the approval of the Engineer,
qualified and sufficient number of the Engineers, Quantity Surveyors,
Supervisors, Employees and skilled and non-skilled workmen for his
supervision of the works and site administration.

1/5.7 The Contractor shall provide all unskilled labour and all necessary tools as
directed by the Engineer.

1/5.8 If at any time before the commencement or during the progress of the
work, the Engineer decides that for the proper execution of a specified part
of the works, shop drawings are necessary, these drawings shall be
prepared by the Contractor and submitted to the Engineer for approval
according to sub-section 1/21. Such drawings must be provided at least
14 days prior to the commencement of the relevant work on site.

The Contractor shall not proceed with the above mentioned work until
these shop drawings are approved by the Engineer. The Contractor shall
not be entitled to any extra payment or extension of time for the
preparation of the shop drawings.

1/6 SURVEYING EQUIPMENT

1/6.1 The Contractor shall supply and maintain in full working order during the
progress of the works the surveying equipment specified in Appendix-C
herein, and the supply of expendable surveying material as required from
time to time in connection with the works. All equipment specified shall be
new and shall remain in the custody of the Engineer for his exclusive use
until Completion of the Whole of the Works but shall remain the property of
the Contractor.

1/7 LABORATORY TESTING

1/7.1 Testing of all materials and completed works shall be carried out in
accordance with DM Administrative Decision No. 160 for 2000 by:

1 Dubai Municipality – Dubai Central Laboratory (D.C.L) in accordance

with Appendix “A1”.

2 Independent Laboratory in accordance with Appendix “A2”.

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 4

 5 SECTION 1 GENERAL

1/7.2 The Contractor shall provide the Engineer with all referenced ASTM, BS
Standards or any other standard indicated or referred to within the testing
requirements of the Contract Specifications.

1/7.3 At least 24 hours notice shall be given to DCL before any tests are to be
carried out.

1/7.4 The contractor must make due allowance for the time required for any
testing within his planning and program.

1/8 PROGRAMME OF WORKS

1/8.1 The Contractor shall submit to the Engineer for approval a Critical Path
Programme and other supporting documentation of the works within the
time stipulated in the Conditions of Contract together with details of
equipment, procedures and method of work which the Contractor intends
to utilize and to follow. Due allowance must be made within the
Programme for:

 Traffic detour scheme preparation, planning, phasing, submittal and

approval.
 Maintenance of accesses to all the residential, recreational,
business and institutional premises affected by the works.
 Any restraints and restrictions imposed by Service Authorities or
the Police.
 Activities of other Contractors (v) The pavement wearing course
and road marking to be laid at such a time to avoid damage by
other construction activities.
 Protection and relocation of existing services as may required
based on the information gathered from Trial Trenches and as
directed by the concerned services authority.
 Obtain NOC’s from all Services Authorities.
 Coordination & cooperation with other Contractors working in the
same area.
 Obtaining approvals from the Engineer & RTA.
 Working during month of Ramadan & works during rainy days.

1/8.2 The Contractor shall in accordance with the Conditions of Contract, submit
a comprehensive plant schedule which shall include the proposed dates of
arrival or establishment on site for each major item. Plant shall not be
brought to or removed from site without prior approval of the Engineer.

1/8.3 In addition to the Critical Path Programme, the Contractor shall if required
by the Engineer provide a detailed bar chart schedule to be used by the
Engineer for monitoring the progress of works.

1/8.4 Furthermore, the contractor shall submit to the Engineer a daily work
Programme showing the activities to be undertaken for the day including
laboratory tests and survey checks at least 1 day in advance.

1/8.5 A monthly progress and material testing reports shall be submitted to RTA

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 5

 6 SECTION 1 GENERAL

roads department. Material report shall contain monthly summaries on

testing, test results, testing frequency and statistical analysis for the results
of the tested material. Also, the material report shall contain a detailed
analysis for the results of tested materials and action taken related to non-
compliance of the test results.

1/8.6 The Contractor has to submit to the Engineer an updated weekly or bi-
weekly progress report based on the approved Clause 14 Programme
using the actual dates and estimated % age completed for each activity.

1/8.7 The contractor is not allowed to give priority in the program for the areas
that have physical obstructions and he has to start the construction for the
open areas.

1/8.8 If the Contractor failed, due to lack or poor details, to get the approval of
the Engineer and RTA on the submitted programme within a period of 90
days from the commencement date of the project, the Contractor's Monthly
Payments may be reduced or completely stopped.

1/9 WORK SITE, SETTING OUT AND CROSSSECTIONS

1/9.1 The Employer, through the Engineer, shall handover to the Contractor the
work site in parts/sections according to priority mentioned in the
programme of work and as detailed on the drawings. The work site means
all land and other locations which the Employer passes to the Contractor to
construct the Works mentioned in the Contract.

1/9.2 The Contractor is responsible for all the setting out of line and levels of the
Works and shall employ adequate qualified staff to carry this out.

1/9.3 Before the commencement of the Works, the Contractor will be supplied
with the information necessary to establish the lines and levels of the
Works. The engineer has to show on the drawings all the survey markers
established but can give no warranty for their existence at the start of the
Contract nor will accept responsibility for replacing any survey markers
found to be missing. Where survey markers have been established by the
Engineer, the Contractor shall check the accuracy of their position and
level and shall immediately notify the Engineer of any discrepancies.
However, it is the Contractor’s sole responsibility to coordinate with Dubai
Municipality Planning & Survey Department and follow their regulations to
get the values (E, N & levels) for sufficient numbers of survey stations
within or near the work site.

1/9.4 All setting out throughout the Works must be related to the Dubai
Municipality Datum Levels. Any Temporary Bench Mark (T.B.M.) to be
fixed on the site shall be tied into the Dubai Municipality Datum.

1/9.5 The Contractor shall, as soon as practicable, supply the Engineer with
records in approved form relating to all reference pegs and bench marks
and shall keep such records up to date by formal notice to the Engineer.

1/9.6 All survey reference pegs shall be carefully preserved except where
construction requires their removal, and before such removal, the approval

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 6

 7 SECTION 1 GENERAL

of the Engineer & DM Planning & Survey Department shall be obtained.

1/9.7 Before commencing work on any section of the Works, the Contractor shall
survey and level the original ground surface and shall prepare plans and
cross-sections accordingly. These shall, when finally agreed, be signed by
the Engineer and Contractor as truly representing the configuration of the
areas in question before the commencement of the Work. The preparation
of the cross-section drawings shall comply with Clause 1/21.

1/9.8 All setting out shall be approved in writing by the Engineer before work
may commence. The centerlines are to be checked by the Dubai
Municipality Survey Section and approved by the Engineer.

1/9.9 When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of
certain work. The templates will be in accordance with the specifications
and drawings where such are provided. All templates must be approved
and shall be maintained in good order to provide the section required for
the entire works. Templates may be checked from time and any
deficiencies noted shall be rectified immediately. The Contractor shall also
supply straight edges and lines when required to control the work.

1/9.10 The Engineer will, if he deems it necessary, revise the line or grade and
will require the Contractor to adjust the stake-out accordingly.

1/9.11 Where directed by the Engineer, the Contractor shall take such levels and
dimensions as may be required for the purpose of measurement prior to
disturbance of the ground. These shall be agreed between the Contractor
and the Engineer before any surface is disturbed or covered up.

1/9.12 Any change of the ground elevation resulting from compaction or other
works provided for in the Contract Documents shall be deemed included in
such works and paid for within the tender prices listed in the Bill of
Quantities. The Contractor shall consequently in no way be entitled to any
additional payment or claim whatsoever.

1/10 PROJECT SIGN BOARDS

1/10.1 The Contractor shall provide, supply, erect and maintain the requirements
of the project sign boards at location approved by the Engineer, RTA and
Services Authorities. Minimum two sign boards of project sign boards shall
be provided or as described in the Contract.

1/10.2 Project Sign Boards shall be signwritten by a skilled signwriter or any other
methods approved by the Engineer and RTA to show the details described
in the Contract plus any other relevant details to the approval of the Roads
& Transport Authority and the Engineer.

1/10.3 Within one month of completion of the (Whole of the) Works, and after the
works are handed over to the client and respective services authorities.
The Project Sign Boards shall be dismantled and removed by the
Contractor.

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 8 SECTION 1 GENERAL

1/11 PROJECT PHOTOGRAPHS

1/11.1 The Contractor shall arrange to have monthly record photographs of the
Works taken. These photographs shall cover such extent of the Works as
the Engineer shall direct. The days upon which the photographs are taken
shall be decided by the Engineer.

1/11.2 The Contractor shall provide the Engineer with one set of the monthly
progress photographs of digital format with dates marked / imprinted on it.

1/11.3 One set of photos of digital format to be prepared / processed by an

approved professional. A label giving a brief description shall be affixed in
the bottom right-hand corner of each photo. These photos should be
submitted on a CD for easy future reference.

1/11.4 The Copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of
exposure. The photographs shall not be used for any other purpose
whatsoever without the Employer’s approval.

1/12 QUALITY OF MATERIALS AND SUPPLY

1.12.1 Unless otherwise stated or approved by the Engineer all materials used in
the Works shall be new and of the best quality as specified in the Contract.

1/12.2 All materials and equipment specified in the contract documents which are
to be incorporated in the works must be obtained from or through a Dubai
Emirate supplier and or manufacturer who must be registered and licensed
by the Dubai Municipality. If such specified materials or equipment is not
available from the Dubai Emirate market then any other source is
acceptable subjected to the conditions set in the subsections below.

1/12.3 Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a ‘Certificate of Guarantee” signed by the authorised
representative of the manufacturer. Such Certificate shall state that the
materials specifications and test results are in compliance with the
specified requirement of the pertinent designations of the most recent
edition of ASTM or any other approved equivalent National Standard
unless otherwise directed. Falsification of such Certificates, Materials,
Specifications or Test Results shall be just cause for the rejection of the
materials.

1/12.4 The borrow pit location if not designated in the Contract Documents shall
be approved by the Roads & Transport Authority. The Contractor shall
exercise a continuous quality control upon the extracted material to confirm
its suitability for use.

No material shall be supplied to the site before the Engineer’s approval of

the type of equipment which the Contractor intends to use in the borrow
pit, and for the method of work.

1/12.5 The Contractor shall select rock quarries and shall submit laboratory tested
and accepted samples, within two months before their use, in order for the
Engineer to determine their conformity with the related specifications. The
Contractor shall exercise a continuous quality control upon the extracted

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 8

 9 SECTION 1 GENERAL

material to confirm its continued suitability for use.

No material shall be supplied on the site before the Engineer’s approval of

the type of equipment which the Contractor intends to use in the quarry,
and for the method of work.

1/12.6 The Engineer’s acceptance of the materials does not relieve the Contractor
of his total responsibility to carry on with additional investigations in order
to obtain and supply during the progress of the works uniform material
conforming to the Specifications.

1/12.7 The Contractor shall be responsible for payment of royalties, if any, arising
due to obtaining of materials for use in the Works. No separate payment
will be made by the Employer as a royalty for materials for use in the
Works.

1/12.8 Wherever in the Specifications tests on materials, tests on completed work

and construction control tests are called for or implied, they shall be carried
out according to, and the materials shall comply with, the requirements of
the Specifications (latest edition) with the priority of latest edition of
standard shall be as follows:

a. UAE & DM Standards

b. International Standard such as ISO
c. National Standard such as BSI & DIN
d. Others as stated in this Specification such as ASTM, etc.

The Contractor shall provide for the exclusive use of the Engineer copies
of each and any codes of practice, international standards, test methods
etc. relevant to the works. In addition the Contractor shall retain on site for
the use of the Engineer all manufacturers literature relating to all the
products to be used in the works, current BSI Handbook No. 3 and the
Manufacturers installations instructions for all relevant products, materials
components and installations.

1/12.9 Where specific material or equipment is referred to in the Contract, it is

intended only to indicate the acceptable standard. The Contractor may
offer alternative materials or equipment of an equal standard. The
Contractor must submit a statement listing proposed alternatives together
with such information and samples as the Engineer may require to satisfy
himself that the alternatives offered are of equal quality to the items
specified. The cost of submitting such samples will be borne by the
Contractor. Acceptance or rejection of any submitted alternative materials
in no way could entitle the Contractor for any additional cost and/or time
extension or whatsoever.

1/12.10 The Contractor will be required to produce documentary evidence that all
materials which are not available in the local market and which have to be
imported have been ordered sufficiently in advance to ensure that no delay
to the works occur. As soon as orders have been placed, copies of such
orders shall be submitted to the Engineer. The Contractor shall be
responsible for delays as a consequence of late ordering.

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 10 SECTION 1 GENERAL

1/12.11 Should the Engineer discover in the Works any materials other than those
approved, he may order their removal from the site and replacement with
approved materials at no cost to the Employer and in compliance with
Standard Specifications.

1/12.12 All specified materials incorporated in the Works shall be fixed or applied
strictly in accordance with the manufacturer’s printed instructions.

1/12.13 The Bills of Quantities shall NOT be used as a basis for ordering materials
and the Contractor is entirely responsible for assessing the quantities of
materials to be ordered.

1/12.14 All materials or manufactured items shall be carefully loaded, transported,

unloaded and stored in an approved manner, protected from damage and
exposure to weather or dampness during transit and after delivery to the
Site. Damaged material or manufactured items damaged during and after
fixing in position shall be removed, repaired or replaced by and at the
Contractor’s expense.

1/12.15 The Contractor shall erect and maintain ample temporary and weather
proof sheds for proper storage and protection of his own and sub-
contractor’s materials. Cement and other perishable material shall have
floors raised 150mm off the ground. The Contractor shall clear away on
completion and make good all areas disturbed.

1/12.16 Prior to ordering or delivering any material or manufactured items to the

site, the name and address of the supplier(s) and, where required by the
Engineer, adequate samples, sample schedules and manufacturer’s
certificates of all the materials and goods to be used in the Works shall be
submitted to the Engineer for approval and in the case of rejection further
samples shall be submitted until such are approved. The cost of submitting
all such samples shall be borne by the Contractor. All products/materials
shall have approved National Certificate of conformance similar to B.S.I.
Quality Kite Mark or National Agreement Certificate such as BBA for non-
standard products and systems to be approved by the Engineer and shall
be verified by DCL.

All products/materials shall be certified by Dubai Central Laboratory of

Dubai Municipality (DM) or by an accredited certification body approved by
DMDCL.

1/12.17 If judged necessary by the Engineer, the samples shall be tested for
compliance at DCL in accordance with Appendix A1 or in a laboratory
accredited in accordance with Appendix A2 of this Specification and Dubai
Municipality Administrative Decision No. 160:2000.

1/12.18 All materials and equipment specified in the Contract Documents which
are to be incorporated into the Works must be obtained from or through a
Dubai Emirate Supplier and or Manufacturer who must be registered and
licensed by the Dubai Municipality. If such specified materials or
equipment is not available from the Dubai Emirate then any source is
acceptable subject to approval from the Engineer and RTA.

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 11 SECTION 1 GENERAL

1/12.19 Approval of a source does not mean that all the materials in the source is
approved. No source of supply shall be changed without Engineer's prior
approval. Approved samples shall be retained on site for comparison with
products and materials used in the works and shall be removed when no
longer required by the Engineer.

1/12.20 Any material requiring certification as per RTA regulations shall not be
used unless certified by DM-Dubai Central Laboratory or by an accredited
certification body approved by DMDCL.

1/13 APPROVAL BY THE ENGINEER

1/13.1 The Contractor shall give adequate notice in writing to the Engineer
requesting inspection and approval of various stages of construction of the
Works. Unless stated otherwise in the Contract a notice period of not less
than four hours of normal working time shall be given before the work is
ready for final inspection. The Contractor shall supply printed forms for this
purpose. Further stages of work shall not proceed until the Contractor has
received the written approval of the Engineer.

1/13.2 The Contractor shall give the Engineer details of the source of materials to
be incorporated into the Works. Reasonable notice must be given by the
Contractor to allow the Engineer to carry out such tests and enquiries as
may be appropriate before giving approval.

1/13.3 When items to be incorporated into the Works are to be manufactured or

fabricated off-site the Contractor shall give the Engineer not less than
seven days notice in writing of the commencement of such work.

1/13.4 Where the approval of the Engineer is required under this specification,
such approval shall not in anyway relieve the Contractor of his duties or
responsibilities under the Contract.

1/14 EXISTING SERVICES AND SERVICE DIVERSIONS

1/14.1 The positions of all public and privately owned services shown on the
drawings have been based on the records of various utilities and Public
Authorities and must be regarded as approximate. The Contractor must
verify this information and satisfy himself as to the exact nature and
position of all such apparatus. The Engineer does not guarantee the
accuracy of the information given on the drawings and no warranty is given
or implied.

1/14.2 The Contractor shall take into account the current laws and Latest
recommended measures regarding the safety of service lines, together
with any amendment or additions thereto. The Contractor shall include in
his tender for anything in these laws considered to have a monetary value.

1/14.3 The cost of locating or verifying the location of existing services, liaison
with the various Service Authorities and complying with the above shall be
borne by the Contractor unless provided for elsewhere in the Contract.

1/14.4 Before opening the ground for any purpose, the Contractor must notify all

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 12 SECTION 1 GENERAL

concerned parties by issue of formal “Notice of Intent” and must obtain

information by Formal Notice regarding the location of all services. The
Complete responsibility for obtaining this information rests with the
Contractor.

1/14.5 Notice of Intent” shall be circulated to all concerned parties including the
following: Roads & Transport Authority Roads Department Dubai Electricity
and Water Authority Emirates Telecommunication Corporation. Roads &
Transport Authority Street Lighting Section Dubai Municipality Drainage
and Irrigation Department Roads & Transport Authority Horticulture
Section Consultants for Water, Electricity and Drainage Departments.

1/14.6 Drawings and notices shall be sent in duplicate one of which shall be
retained by the addressee and the other returned to the sender duly
marked to show underground services. “Notice of Intent” will be given 14
(fourteen) days in advance of the proposed Works. In the event that the
work is not started within 8 (eight) weeks of the date of the “Notice of
Intent”, it will be deemed to have lapsed. A further Notice of Intent will then
be submitted.

1/14.7 The Contractor shall furnish copies of the above Notices of Intent to the
Engineer. The Contractor shall acquaint himself with the position of all
existing services and must obtain clearance from the relevant authority
before commencing any work in a particular area. Written evidence of such
clearance shall be provided to the Engineer by the Contractor. If any
underground service is encountered unexpectedly, excavation shall cease,
and the Engineer’s Representative shall be notified immediately.
Emergency work, as necessary, shall be put in hand without delay and
without prejudice to the indemnity of the Employer.

1/14.8 The Contractor shall prepare records and CAD drawings showing position,
levels and types of each existing service including manholes, joint boxes
and inspection chambers etc. All record drawings shall be prepared using
a Computer Aided Drafting program approved by the Engineer.

CD’s containing the drawings data to be supplied to the Engineer in the

approved digital format for incorporation in the final record drawings.

1/14.9 The Contractor shall take any and all measures reasonably required by
any public or concerned Authority for the support and full protection of all
mains, pipes, cables and other apparatus during the progress of the
Works, and shall construct and provide to the satisfaction of the Authority
concerned, all works necessary for the prevention of damage or
interruption of services.

If in the execution of the Works, by reason of any subsidence caused by,

or any act of neglect or default of the Contractor, any damage to any
apparatus or any interruption of, or delay to the provision of any service is
caused, the Contractor shall report it to the Engineer immediately and bear
and pay the cost reasonably incurred by the Authority concerned in making
good such damage and shall make full compensation to the Authority for
any loss, sustained by reason of such interruption or delay.

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1/14.10 The Contractor shall familiarize himself and all his employees with the
dangers of working in or near live sewers and at sewage treatment works;
in particular the risks of physical injury from the exposure to poisonous
gases, of bacterial infection from contact with sewage and of exposure to
poisonous gases, which may be given off by the sewage. Hydrogen
sulphide and methane are prevalent in the sewers in Dubai, and can exist
in excavations where septic sewage from collection tanks is allowed to
seep into groundwater. In the context of this clause the term sewer
includes irrigation mains and drains carrying ground water and/or storm
water.

1/14.11 The Contractor shall, at all times during the progress of the Works, afford
facilities to properly accredited agents of any Public or Utility Authority for
access to all or any of their apparatus situated in or under the site, as may
be necessary for inspecting, reporting, maintaining, removing, renewing or
altering such apparatus in connection with the construction of the Works or
any other purpose whatsoever.

1/14.12 The Contractor will be fully responsible for ensuring observance of the
above regulations of his sub-contractors.

1/14.13 Where any utility or service works are to be constructed under a separate
contract by the Employer within the Site and concurrent with the execution
of the Works, the Contractor shall cooperate with the other Contractor and
shall coordinate his construction operations to avoid interference with the
other Contractor’s operations.

1/14.14The Contractor shall prepare and furnish all necessary shop drawings of
the works required to complete the adjustment of apparatus to finished
grade or specified level. The drawings must be approved by the concerned
Utility Authorities and the Engineer prior to commencement of any work at
the site. Measurement shall be for each utility facility adjusted to finish
grade or level approved by the Engineer.

The Contractor must allow in his rates for services installations for the
production of combined service drawings covering the whole of the
Contract area. The drawings must show both existing services located by
trial pits and coordinated by survey and all proposed new services. The
drawings are to identify interface problems prior to production of working
drawings.

Drawings must be prepared using a Computer Aided Drafting program

approved by the Engineer, Diskettes containing the drawing data of the
original service locations and those containing the drawing data of the
relocated original services and of the new service locations together with
their protection area to be supplied to the Engineer for incorporation in the
final record drawings in the approved digital format.

1/14.15 The Contractor shall prepare CADD shop drawings for utility protection
work and obtain the approval of the appropriate Authority and Engineer
before commencing with construction.

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 14 SECTION 1 GENERAL

1/14.16 The Contractor shall relocate certain utilities to service reservation areas
as specified in the Contract. This work may only include the construction of
necessary protective housing (e.g. box culverts, slabs, concrete encased
sleeves etc.) in the service reservation areas for utility lines to be
relocated, or this work may include necessary protective housing as
described above and, in addition the relocation of specific utility lines to the
service reservation areas. In both cases the Contractor shall complete the
necessary survey to establish the lines and levels, prepare shop drawings
and submit them to the Engineer for his review and approval. The
Contractor shall obtain approval from the concerned Authority before
commencing this work.

1/14.17 Any public or private service for water, electricity, drainage, etc. affected
by the Works shall not be interrupted without the written permission of the
Engineer. Such permission will be withheld until suitable approved
permanent or temporary alternative service has been provided by the
Contractor or by the owner of the utility or his agents.
1/14.18 For temporary traffic diversions as may be required for the construction of
road crossings, full liaison with the Roads & Transport Authority and Dubai
Police shall be required and the requirements of Clause 1/16 and 1/17
complied with.
1/14.19 Due allowance (s) must be given by the Contractor when preparing the
Programme of Works to comply with this Clause 1/14.

1/14.20 The contractor shall comply with the latest specifications set by various
services authorities for the provision of new services and/or locating,
relocating, protecting, diverting of the existing services.

1/14.21 The contractor shall survey of all the existing services corridors in the
vicinity of the project limits and submit it to the Engineer for approval, in
particular, the gas pipelines reservation which may run along the boundary
of the project if any. No temporary road works are to be undertaken over
the gas pipelines or below DEWA overhead power lines without obtaining
an NOC from the proper service authority. The use of heavy equipment
shall be limited to where no impact can be caused to the gas pipeline or
other services.

Any damage to the services within these areas shall be reported

immediately to the concerned authority and then repaired as per the
approved method of construction at the cost of the contractor and to the
satisfaction of the relevant services authority as described in section 1 of
these specifications.

1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND

PROPERTIES
1/15.1 The Contractor shall take all necessary precautions to protect buildings,
fences, roads, passages, culverts and other apparatus if found and he
shall not demolish or remove any of these works except according to
specific instructions by the Engineer. In the case of existence of buildings,
ditches, excavations or any other work adjacent to the Site, the Contractor
shall make necessary arrangements and take precautions for their support
and protection at his own expense.

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 15 SECTION 1 GENERAL

1/15.2 The responsibility lies with the Contractor for the repair and return to the
previous condition of items to which the Contractor’s works have caused
damage. Also, also, it is the responsibility of the contractor to tie-in the new
footpath if any, to the existing footpath, smoothly and neatly and to the
satisfaction of the Engineer.

1/15.3 The Contractor shall not be permitted to use earth works of already
executed roads. Also, the contractor shall extend all ducts out of the
asphalt works wherever required and to the satisfaction of the Engineer.

1/15.4 It is the Contractor’s responsibility to ensure that continuous access is

maintained to all properties adjacent to the works throughout the Contract
period to the Engineer’s satisfaction.

1/15.5 In pursuance of his obligations under the Conditions of Contract, the

Contractor shall whenever required or directed by the Engineer cover up
and protect the works from weather and from damage by his own or other
workmen performing subsequent operations. He shall provide all
necessary dust sheets, hoardings, barriers and guard rails, waterways, etc.
and clear away same at completion. The Contractor shall take all
reasonable and proper steps for the protection of all places on or about the
works which may be dangerous to his workmen or any other persons or to
traffic. The Contractor shall provide and maintain warning signs, warning
lamps and barricades as necessary in all such places.

1/15.6 The Contractor shall furnish and place fresh or brackish water at his own
expense for dust control when and where construction operations require it
and at locations where specifically directed by the Engineer due to
conditions created by the Contractor or his construction operations.

1/15.7 Existing roads, accesses to houses, buildings, etc., and any new roads,
whether part of the Works or not, which are being used by the Contractor’s
constructional traffic shall be kept clean and clear of all dirt, mud and
material dropped from vehicles or from tyres and any damage caused shall
be repaired at the Contractor’s expense. The Contractor shall provide,
maintain and use as directed by the Engineer, suitable equipment
including mechanical road sweepers solely for this purpose throughout the
course of the works.

1/15.8 The contractor shall prepare road furniture inventory before

commencement of works and shall hand over to the client all materials
removed from the site as per this inventory (scrap reusable).

1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL

1/16.1 The Contractor shall provide, erect and maintain such traffic signs, lamps,
barriers, traffic control signals, lighting units, road markings and other such
measures as may be necessary for the construction of the works.

1/16.2 The Contractor shall, after consultation with Engineer and all concerned
departments in RTA, prepare a scheme of traffic management for carrying
out the works. Such proposals shall be submitted to the Engineer for his

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 16 SECTION 1 GENERAL

written approval not less than 30 days before the planned implementation
of each proposal. Prior to commencing any individual diversion or traffic
control the Contractor shall provide to the Engineer details of his overall
scheme of traffic control or diversions for the entire project giving his
programme of diversions etc. All diversions must be approved by the
Traffic Police and Roads & Transport Authority Roads Department prior to
implementation.

1/16.3 The Contractor shall not commence any work which affects the public
highway until all approved traffic safety measures conforming to RTA
Standards are fully operational to the satisfaction of the Engineer.

1/16.4 Temporary traffic signs conforming to RTA Standards and approved by

Roads & Transport Authority Roads Department shall be of good design
and sound construction using reflective sign face material. They shall have
a minimum face dimension of 900mm.
1/16.5 The Contractor shall maintain all signs, lamps, barriers, traffic control
signals and road markings in a clean and legible condition and shall
position, re-position, cover or remove them as required by the progress of
the works.

1/16.6 The Contractor shall be entirely responsible for complying with the
requirements of and coordinating with the Dubai Police Traffic Department
and Roads & Transport Authority Roads Department in relation to the
above.

1/16.7 Traffic diversion is a lump sum item and will be paid as per the Contract
BOQ without any possibility for any claims whosoever due to change of the
scope. The Contractor has to consider this work and any expected
requirements as part of the Contractor's risks.

1/17 TEMPORARY DIVERSION OF TRAFFIC

1/17.1 The Contractor shall construct temporary diversion ways wherever the
construction of the works will interrupt existing public or private roads or
rights of way.

1/17.2 Diversions must be constructed in advance of any interference with the

existing right of way and the subsequent traffic management, safety and
control must be in accordance with Clause 1/16 and as directed by the
Engineer.

1/17.3 The contractor is fully responsible for diversions maintenance and he shall
undertake whatever is necessary to maintain all diversions fully operational
i.e. 24 hours a day and over the entire period of the project.

1/18 FIRE PRECAUTIONS

1/18.1 Adequate precautions shall be taken against fire throughout all the
Contract’s and Subcontractor’s operations. Quantities of flammable
materials on site shall be kept to an absolute minimum, and shall be
properly handled and stored. Gasoline and other flammable liquids as well

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 17 SECTION 1 GENERAL

as pressurized gas tanks shall be stored in and dispensed from safety

containers; however, storage of such containers shall not be within the
offices building. Except as otherwise provided herein, the Contractor shall
not permit fires to be built or open type heating devices to be used in any
part of the work.

1/18.2 Construction practices, including cutting and welding, and protection of

adjacent materials during construction shall be in accordance with good
standard practices for such work. The Contractor shall provide a sufficient
number of approved portable fire extinguishers distributed around the
buildings and construction site.

1/18.3 The Contractor shall make arrangements for periodic inspection by the
local fire authority and shall co-operate with said authority to promptly carry
out their recommendations at his own expense.

1/19 SAFETY OFFICERS

1/19.1 The Contractor shall inform the Engineer in writing within two weeks of the
start of works the names of responsible people resident on the site who will
be undertaking the duties of Safety Officers and Safety Supervisors on
Site. The Contractor shall also provide detailed written responsibilities and
duties of the safety officers and safety supervisors to the engineer and
shall be subjected to the Engineer approval. Safety Officers shall be in
continuous attendance on site 24 hours a day, one in the day shift and one
in the night shift, throughout the Contract period.

1/20 CONTRACT DRAWINGS AND DOCUMENTS

1/20.1 The Works shall be executed in accordance with the Drawings, other
contract drawings and other such information that may be issued or
approved by the Engineer. The Contractor will be furnished with one set of
transparencies of the original drawings, in addition to an extra digital copy
of the drawings free of charge.

The works shall be executed in accordance with the drawings, other

contract drawings and other such information that may be issued or
approved by the Engineer.

The Contract documents are complementary and represent one unit and
any requirements mentioned in any part of the documents are considered
as mentioned in all other parts. If there is any discrepancy between the
different parts of the Contractor documents, the Engineer is the sole party
who has the authority to interpret and clarify the action to be taken and this
will not, at any case, entitle the Contractor for any additional cost or time
extension or whatsoever.

The Contractor will be furnished with A3 size of the Contract drawings in

addition to an extra digital copy on a CD free of charge.

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 18 SECTION 1 GENERAL

1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND

MAINTENANCE INSTRUCTIONS

1/21.1 For any work or part thereof as requested, the Contractor shall supply four
(4) copies of shop/working drawings for approval by the Engineer. All
working drawings shall be A1 size folded to A4 size. An extra digital copy
of the working drawings should be submitted on a CD for easy future
reference or for further extra copy production.

1/21.2 For all above mentioned drawings, the Engineer shall return to the
Contractor one (1) copy with any necessary corrections for resubmittal or
marked with approval.

1/21.3 At the end of the project, the Contractor shall submit to the engineer 2 sets
of printed copies and one digital copy on a CD for all the approved shop
drawings.

Monthly progress report as well as final materials reports both containing

the prescribed summary of testing frequency shall be submitted to the
Engineer and RTA for review.

1/21.4 In additions, the Contractor shall provide the Engineer with all information,
scale drawings and every assistance so that the Engineer can prepare
drawings of work as executed to form a complete record of the finished
work.

All drawings must be prepared using a Computer Aided Drafting system

approved by the Engineer.

Drawings shall be plotted by the Contractor as required by the

Specification.

Diskettes containing the drawings data are to be supplied to the Engineer

in the approved digital format.

1/21.5 The Contractor shall record the exact location of all services apparatus
excavated during the works and shall submit drawings to the Engineer
showing such information for incorporation by the Engineer into the Record
Drawings.

1/21.6 The cost related to the production of the drawings, either during
construction or at the time of delivery of the final account (for which 1
negative + 3 copies of all attachments are necessary), shall be borne
directly by the Contractor, and no separate payment shall be in anyway
considered.

1/21.7 Within sixty (60) days of the date of field staking, the Contractor shall
submit to the Engineer for his approval the plotting of the original and final
earthwork cross-sections, together with the area and volumetric earthwork
computations.
1/21.8 The Contractor’s cross-section shall be on transparent cross-section
sheets for print reproduction. CD’s containing the drawings data are to be
supplied to the Engineer in the approved digital format.

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 19 SECTION 1 GENERAL

1/21.9 On final approval of the Contractor’s cross-sections, the Contractor shall

give the Engineer the original transparent tracings and three (3) prints of
the same along with approved volumetric earthwork computations (in A4
size and bound). The contractor shall also supply to the engineer all data
and drawings on CD’s in the approved digital format If the Contractor fails
or refuses to submit cross-sections within the specified time, the Engineer
may withhold payment for all or any part of the earthwork quantities
involved. All cross-sections shall be plotted on A1 size Drawing folded to
A4 size.

1/22 RECORD DRAWINGS

1/22.1The Contractor is fully responsible for preparing the as built drawings for
the whole works undertaken within the project scope of work.. The
contractor, in close coordination with the Engineer, shall prepare accurate
record drawings showing works as executed complete with existing and
finished levels (top invert and formation levels plans cross and longitudinal
sections locations of all junctions manholes inlets, extent of concrete bed
and structures and all other measures necessary to form a complete
pictorial record of the finished work).

The exact locations with dimensions of existing and new service ducts,
cables, pipes, etc shall be clearly shown on the drawings. All negatives of
record drawings prepared by the Engineer shall be dated and signed by
the Contractor and the Engineer as being a true record of the Works ‘as-
built”. The contractor shall also provide to the engineer all data and
drawings on CD’s in the approved digital format.

The final payment certificate will not be issued to the contractor until all the
above have been received by the Engineer.

1/23 ACCOMMODATION WORKS

1/23.1 The Contractor will be responsible for making all necessary arrangements
with owners and occupiers for carrying out accommodation works,
including, where necessary, access onto or across private land.

1/23.2 Where, in the opinion of the Engineer, the convenience or amenity of an

owner or occupier or of the public generally is affected by the Works, the
Engineer may order the Contractor to complete any accommodation work,
or part of an accommodation work, with the utmost expediency and
irrespective of the Contractor’s overall programme for the Works.

1/24 PUBLICITY
1/24.1 The Contractor or any agents or servants in his employ shall not give any
information concerning Works for publication in the press or on radio,
television or cinema screen or elsewhere without the written approval of
the Engineer.

1/24.2 No advertisements shall be erected within the Site by the Contractor or any
subcontractor without written approval of the Employer. Should any
advertisement be erected within the site without such prior approval the
Engineer may instruct the Contractor to remove it forthwith. Should such

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 20 SECTION 1 GENERAL

an instruction fail to be carried out within 24 hours, the Engineer may

remove the advertisement and charge the cost to the Contractor.

1/24.3 All advertisement within the site shall be removed within one month of the
date of Certificate of Substantial Completion of the Works, unless the
Employer agrees in writing for any advertisement to remain for a further period.

1/25 TIDYING AND CLEARING THE SITE

1/25.1 The Contractor shall maintain the Site in a clean and orderly condition free
from accumulation of waste materials and rubbish during the entire
construction period to the satisfaction of the Engineer.

1/25.2 On completion the entire site within the Right of Way are to be cleared of
all construction materials and temporary buildings, etc. to the satisfaction
of the Engineer.

1/26 SOIL INVESTIGATION

1/26.1 Any information given about soils investigations carried out is for the
Contractor’s assistance only. It is the Contractor’s responsibility to check
and confirm the existing ground conditions and in particular the likelihood
of encountering water during the course of sub-surface construction.

1/27 WORKS FREE FROM WATER

1/27.1 Except where in the opinion of the Engineer, the route of the work
necessitates underwater construction, the Contractor shall execute all
works in the dry, and shall construct any temporary drains, water courses,
pumping and other works that may be necessary for the purpose. The
Contractor shall have included for the cost of all operations necessary to
comply with this Clause within his tender.

1/28 OTHER CONTRACTORS ON SITE

1/28.1 The Contractor must extent full cooperation by way of liaison and
coordination with other Contractors who may be operating within the site of
the works engaged in essential work for the Government of Dubai.

1/29 MAJOR EQUIPMENT AND PLANT

1/29.1 GENERAL

Equipment shall mean, where mentioned in these Specifications, all

machines, tools, equipment and all necessary parts for its operation and
maintenance. Also, the laboratory tools and instruments and/or equipment
necessary for the proper construction of the road and the proper
completion of all the works.

The Contractor, shall submit, as stipulated in the “Instructions to Tenderer”

a detailed list of plant equipment which he shall undertake to bring to the
site to carry out the work. The list shall include for each piece of
equipment, the type, size, quantity, manufacturer, model, identification
number and year of manufacture. The Contractor shall supply all plant and

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 21 SECTION 1 GENERAL

equipment necessary for the construction of each phase of the work and it
must be on the site, inspected and approved by the Engineer prior to the
commencement of the particular phase of work. Any plant or equipment of
portion thereof, which becomes worn or defective shall be immediately
repaired or replaced to the satisfaction of the Engineer.

1/29.2 COMPACTING EQUIPMENT

The compaction equipment for earthwork may be towed or self-propelled

and shall include a suitable combination of tamping rollers, grid rollers,
segmented pad rollers, vibrating rollers, pneumatic rollers and other
compaction equipment that can satisfactorily and uniformly obtain the
required compaction.

i Tamping or Sheepfoot Rollers:

Tamping or sheepfoot rollers shall consist of metal rollers, drums,
or shells surrounded by metal studs with tamping feet projecting not
less than sixteen and one-half (16.5) centimeters from the surface
of the roller, drum or shell. Tamping feet shall be spaced not less
than fifteen (15) centimeters or more than thirty (30) centimeters
measured diagonally centre to centre and the cross section area of
each tamper foot, measured perpendicularly to the axis of the stud,
shall be not less than twenty-five and eight-tenths (25.8) square
centimeters. The weight of tamping rollers shall be such that when
fully loaded, the load on each tamper foot will be determined by
dividing the total weight of the roller (loaded) by the number of
tamper feet in one (1) row parallel to the axis of the roller.

ii Pull-Type Steel Rollers:

Pull-type steel rollers shall have not less than one and two-tenths
(1.2) meter effective width of roller and shall be designed and
constructed so that the weight per linear centimeter of roller can be
varied from thirty five and seven-tenths (35.7) kilograms to at least
fifty-three and six-tenths (53.6) kilograms.

iii) Self-Propelled Steel Rollers:

The power mechanism shall be capable of propelling the roller
smoothly and without jerking when starting, stopping, or reversing
directions free from backlash, loose link motion, faulty steering
mechanism and worn king bolts. The steering mechanism shall
have no lost motion, shall operate readily and permit the roller to be
directed on the alignment desired. The faces of all rollers shall be
smooth and free from defects which mark the finished road surface.
Rollers shall be equipped with water tanks and sprinkling devices
which shall be used for wetting the roller to prevent adherence of
the placed material.

Two-axle tandem steel rollers shall weigh not less than eight (8)
tones or more than twelve (12) tones and shall have a weight per
centimeter width of roll between 35 Kg and 70 Kg.

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 22 SECTION 1 GENERAL

Three axle tandem steel rollers shall weigh not less than eleven
(11) tons. Three axle tandem roller shall be so constructed that the
roller, when locked in position for all treads to be in one plane, are
held with a rigidity which will satisfy the following test under full
load; with the weight of the roller supported on the central roller, the
tread of the central roller shall not be more than three (3)
millimeters above the plane tangent to the tread of the end roller.
With the weight of the roller supported on the end rollers, the tread
of the central roller shall not be more than six (6) millimeters below
the plane tangent to the treads of the end roller.

iv) Trench Rollers:

The trench roller shall be of an approved type and shall weigh not
less than fifty-three and six tenth (53.6) kilograms per centimeter of
width and shall be equipped with water and sprinkling device that
shall be used for wetting the roller to prevent adherence of the
placed material.

iv) Pneumatic-Tyred Rollers:

The tyres on the front and rear axles shall have wide smooth treads
and shall be staggered to provide complete coverage of the entire
area which the roller travels. The tyres shall be inflated to a
pressure that has been approved by the Engineer and the pressure
shall be reasonably uniform in all tyres. The Contractor shall
provide a suitable gauge for determining air pressure in the tire.
Light self-propelled pneumatic-tyred rollers shall be so constructed
so that they may be loaded to provide a gross weight of at least
forty (40) kilograms per centimeter of width of tire tread.
Heavy self-propelled pneumatic-tyred rollers shall be constructed
so that they can be loaded to provide a gross weight of not less
than twenty five (25) tones and they shall have tyre pressures of 6-
6.3 Kg/Cm2.

vi) Vibration Compactors: Equipment using principle of vibration as a

tamping force shall be in good mechanical condition and shall be
capable of transmitting forceful vibrations or impacts to the various
materials placed in construction. The equipment may be the roller
or pad type or a combination of roller and pad type. Vibrating
compactors shall be of the type and force approved by the
Engineer.

1/29.3 HAULING AND WEIGHING EQUIPMENT

i) Hauling Equipment:
Hauling equipment for aggregate shall consist of vehicles having dump
bodies suitable for dumping materials in a windrow or in spreader boxes.
The bodies shall be so constructed that their volume measurement can be
accurately determined. They shall be so constructed and maintained to
prevent loss of materials during hauling operations.

The equipment shall be provided with dump controls that can be operated
from the driver’s seat. The bodies of hauling equipment using public roads
shall be fitted with tarpaulins to prevent the nuisance of spillage.

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 23 SECTION 1 GENERAL

ii) Weighing Equipment:

Weighing equipment for truck-hauled material shall consist of accurate and
reliable platform scales and they shall be accurate to one percent throughout
the range of use. The scale shall have a platform of adequate length to
weigh the longest truck or truck-trailer combination which is in use on the
Project, in one operation. Scales shall be inspected and sealed or certified
by an approved scale company, as often as the Engineer deems necessary
to ensure their accuracy. The seal or certification shall show the date of the
inspection. Where no approved scale company exists or at the option of the
Engineer, the Contractor shall check and adjust the scale in the presence of
the Engineer in the method recommended by the manufacturer and/or
approved by the Engineer. It is the Contractor’s responsibility to have
sufficient standard test weights for each scale on the Site.

The Engineer, as often as he deems it is necessary, shall direct the

Contractor to check and adjust any scale on site to ensure its accuracy. The
Contractor, shall when directed by the Engineer, make weight comparisons
with other permanently located scale that met with the approval of the
Engineer. These weight comparisons shall be for the purpose of providing
information on the performance of the Contractor’s scale and will not be
used as a basis for adjusting the scale.

The approaches to the scale platform shall be maintained by the Contractor

to the satisfaction of the Engineer.
The Contractor shall furnish a suitable weather tight building to enclose the
indicating mechanism and shall have adequate lighting for the scale
operator’s use.
The Contractor shall on hand not less than ten (10) twenty-five (25) kilogram
weights for testing the scale.

iii) Controlled Water Distribution Equipment:

Equipment for distribution of water shall consist of distributors or tanks
equipped with spray bars and, when required, pumps to operate under
pressure. The pumps shall be of sufficient capacity to provide uniform and
adequate distribution. They shall be mounted on pneumatic-tyre trailers
pulled by pneumatic-tyred equipment. The minimum capacity of any tank
shall be four (4) cubic metres where applicable.

The distributor equipment shall be constructed to permit accurate and

uniform distribution of the desired quantities of water per unit of surface
area. The control valves shall be constructed to permit full closing and to
prevent leakage. The water control valves shall be constructed to operate
from the driver’s seat or provisions made for an additional operator to
operate the control valve while the equipment is traveling at the proper
speed for distribution.
1/29.4 MAIN PLANT FOR BITUMINOUS PAVING WORKS

i) Equipment for Heating Bituminous Materials:

Equipment for heating bituminous materials shall be of adequate capacity to
heat the material properly by circulating the bituminous material around the
system of heated coils or pipes, or by circulating the bituminous material
through a system of coils or pipes enclosed in a heated jacket or other

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 23

 24 SECTION 1 GENERAL

approved means.

The heating device shall be constructed so that it will prevent the direct
flame from a burner from striking the surface of the coils, pipes or jackets
through which the bituminous material is circulated. The heating device shall
not be operated in a manner that will injure the bituminous material.

Tankers or trucks received on the work which have defective coils, or from
which the coils have been removed, will be rejected by the Engineer unless
some satisfactory auxiliary means can be provided by the Contractor for the
heating of the bituminous material without the introduction or moisture. The
use of any equipment for the agitation of bituminous material to aid in
heating will be prohibited if it injures or in any way changes the
characteristics of the bituminous material or introduces free steam or
moisture into the tank containing the bituminous material.

Tanker or truck connections for transferring bituminous material from tankers

to distributors, supply tanks, or storage tanks shall be constructed so that
they cannot be used for any other purpose. The use of a tanker or truck
connection or any other equipment by means of which free steam can be
introduced directly into the bituminous materials as a means of agitation or
auxiliary heating will be prohibited.

ii) Bitumen Distributor Equipment:

Equipment for the distribution of bituminous materials shall be equipped with

the following appliances or devices:

Tachometers-Pressure Gauge -Adjustable Length Spray Bars -Separate

Power Unit & Pump on distributing System -Heating Coils and Burner -
Thermometer well and Accurate Thermometer -Measuring Sticks -Quick
Opening Gate in dome

All distributors and supply tanks shall be mounted on dependable motor

trucks or trailers equipped with pneumatic tyres. The units shall be so
designed to ensure that no rutting or other injury to the road surface will
result. The distributor shall have pneumatic tyres of such width and number
that the load produced on the road surface shall not exceed one hundred
and ten (110) kilograms per linear centimeter of the width. They will be
sufficiently powered to maintain the desired speed of the equipment during
operation.

The manometer designating the speed of the truck shall be a separate

operating unit attached to the truck equipped with a larger gauge
approximately fourteen (14) centimeters in diameter and graduated in units
so that the speed of the trucks can be determined within limits of
approximately three (3) metres per minute or equivalent thereto. The gauge
shall be so located that it can be easily read at all times by the driver of the
distributor.
The distributor shall be equipped with either a tachometer, calibrated to
indicate revolutions per minute, attached to the pump shaft or a pressure
gauge, calibrated to indicate kilograms per square centimeter placed in the
distributing system, by which the flow of bitumen may be regulated.

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 25 SECTION 1 GENERAL

The spray bars shall be constructed to permit adjustment for length in

increments of thirty (30) centimeters for any length up to seven (7) metres, to
permit vertical adjustment of all nozzles to the desired height above the road
surface conforming to the roadway crown, and to permit lateral shifting of the
entire spray bar during operation. The spray bars and nozzles shall be
constructed to prevent clogging of the nozzle during the intermittent
operation and to provide positive and immediate cut-off when distribution of
oil ceases, thus preventing dripping of oil from the bar.

The power unit and pump distribution systems shall have a capacity of not
less than nine hundred fifty (950) litres per minute, shall be equipped with a
by-pass into the supply tank and shall be capable of distributing a uniform
and constant flow of bituminous material through all nozzles at a pressure
between one and one quarter (1.25) and three and one-half (3.5) kilograms
per square centimeter.

The entire distributor assembly shall be so constructed and operated to

ensure accurate distribution of bituminous material at rates of from two-
tenths (0.2) to seven and five tenths (7.5) litres per square metre with
uniform pressure, and with an allowable variation from any specified rate not
to exceed one tenth (0.1) litres per square metre. Minimum capacity of the
distributor shall be four thousand (4,000) litres.

iii) Calibration and Check of Distributors:

All distributors shall be calibrated and checked before being used on the
work. The calibration of the tank will be done by the Contractor in the
presence of the Engineer by the method prescribed by the manufacturer
and/or directed by the Engineer.

The operation of the distributor will be checked by the Engineer the first time
it is used and as often as he deems it necessary thereafter, and when the
operation is found to be satisfactory, a new certificate will be issued.

iv) Stationary Mixing Plants:

Stationary mixing plants shall consist of measuring and proportioning

equipment and mixing equipment. They shall also include dryers when
aggregates are furnished that contain moisture in excess of the amounts
permitted for mixing. The measuring and proportioning equipment shall
consist of a system of hoppers and scales designed for proportioning and
measuring by batch weights or of continuous flow equipment so designed
and operated that the flow of materials can be accurately and continuously
regulated and so arranged to permit easy and accurate checking of the rate
of flow on a weight basis. For continuous flow mixing the proportioning
equipment may be at the stockpile site so that the individual aggregate may
be blended prior to entering the drier. The drier shall be capable of drying
and heating the mineral aggregates to specification requirements.

The proportioning devices for the bituminous materials and aggregates shall
be so synchronized that proper proportioning will be obtained at all times.

The design of the mixing chambers shall provide adjustment to permit a

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 26 SECTION 1 GENERAL

mixing period of sufficient duration to produce a thorough and uniform mix.

The approval of and continued use of a stationary plant shall be contingent
upon its ability to proportion and mix satisfactorily the several materials in
adequate quantity for the proper progress of the work.

v) Hot Mix Plant:

All equipment shall meet the approval of the Engineer, shall be kept in good
working condition, shall meet the requirements herein specified and shall be
of sufficient capacity to produce and process not less than eighty (80) tons of
mixed material per hour. All plants used by the Contractor for the preparation
of bituminous mixes and (Plant Mix) prepared mixes shall conform to all the
requirements of these Specifications except that scale requirements shall
apply only where weight proportioning is used, and in addition batch mixing
plants and continuous plants shall conform to the special requirements of
these specifications.

vi) Requirements of all Plant

Uniformity:

The plants shall be so designed, co-ordinated and operated to produce a

uniform mixture.

Scale:

Scales for any weight box or hopper may be of either the beam or springless
dial type and shall be of a standard make and design, accurate to one (1)
percent of the maximum load that may be required.

When scales are of the beam type, there shall be a separate beam for each
size of aggregate. There shall be provided a “Tell-tale Dial” that will start to
function when the load being applied is within fifty (50) kilograms of that
desired. Sufficient vertical movement shall be provided for the beams to
permit the telltale dial to function properly. Each beam shall have a

locking device so designed and located that the beam can easily be
suspended or thrown into action.

Dial scales shall be springless, of a standard make, and of such size that the
numeral on the dial can be read at a distance of at least (8) metres. The dial
shall be of a compounding type having full complement of index. Pointers so
placed as to give excessive parallax errors shall not be used. The scales
shall be substantially constructed, and those that easily get out of
adjustment shall be replaced with other makes when so ordered. All dials
shall be so located as to be plainly visible to the operator at all times.

Scales shall be inspected and sealed or certified as often as the Engineer

may deem necessary to ensure their continued accuracy. The initial
inspection shall be done by an approved scale company, or by the
Contractor in the presence of the Engineer by the method prescribed by the
manufacturer and/or as directed by the Engineer. The Contractor shall have

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 27 SECTION 1 GENERAL

on hand not less than ten (10), twenty-five (25) kilograms weights for testing
the scales.

Equipment for Preparation of Bituminous Material: Tanks for the storage of

bituminous material shall be equipped to heat and hold the material at the
required temperature. The heating shall be accomplished by steam coils,
electricity, hot coils, or other approved means so that the flame shall be in
contact with the tank.

The circulating system for the bituminous material shall be designed to

ensure proper and continuous circulation during the operating period.

Provision shall be made for measuring and sampling storage tanks. Storage
tanks shall have sufficient capacity to provide for continuous operation. The
storage tanks shall be calibrated and equipped with a device whereby the
Engineer may determine the amount of asphalt on hand at any time.

Feeder for Drier: The plant shall be provided with accurate mechanical
means for uniformly feeding the aggregate into the drier so that uniform
production and uniform temperature will be obtained. A separate mechanical
feeder equipped with an adjustable gate opening shall be provided for each
individual aggregate being combined to produce the total aggregate. The
feeders and gate shall be so constructed and equipped that a continuous
and uniform flow of each material will be ensured. They shall also be
installed in such a manner as to be readily accessible for calibrating at all
times.
Drier: The plant shall include a drier or driers which continuously agitate the
aggregate during the heating and drying process. The drier shall be capable
of drying and heating the mineral aggregate to specification requirements.
The burners shall be of such capacity, and they shall be so constructed and
operated that complete combustion of the fuel is obtained.
Screens: Plant screens, capable of screening all aggregates to the specified
sizes and proportions and having normal capacities in excess of the full
capacity of the mixer, shall be provided.

Bins: The plant shall include storage bins (cold & hot) of sufficient capacity to
supply the mixer when it is operating at full capacity. Bins shall be arranged
to ensure separate and adequate storage of appropriate fractions of the
mineral aggregates. Separate dry storage shall be provided for Portland
Cement, hydrated lime, or other similar material when used and the plant
shall be equipped to feed such material into the mixer.

Each bin shall be provided with overflow pipes, of such size and at such
location as to prevent backing up of material into other compartments or
bins. Each compartment shall be provided with its individual outlet gate,
constructed so that when closed there shall be no leakage. The gate shall
cut off quickly and completely. Bins shall be so constructed that samples can
be readily obtained. Bins shall be equipped with adequate tell-tale devices to
indicate the position of the aggregates in the bins at the lower quarter point.

The minimum number of bins shall include at least one bin for each different
stockpile of material being used. Intermixing of material from different
stockpiles in one bin or on the ground shall not be permitted.

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 28 SECTION 1 GENERAL

Bituminous Control Unit: Satisfactory means, either by weighing or metering

shall be provided to obtain the proper amount of bituminous material in the
mix within the tolerance specified. Means shall be provided for checking the
quantity or rate of flow of bituminous material into the mixer. Suitable means
shall be provided for maintaining the specified temperature of the bituminous
material in the pipelines, metres, weight buckets, and spray bars.

Thermometric Equipment: An armored thermometer of adequate range in

temperature reading shall be fixed in the bituminous feed line at a suitable
location near the charging valve at the mixer unit.

The plant shall also be equipped with either an approved dial-scale mercury-
actuated thermometer, an electric pyrometer, or other approved
thermometric instrument so placed at the discharge chute of the drier as to
register automatically or indicate the temperature of the heated aggregates.

All plants whether continuous or batch type shall be equipped with two
recording thermometers. These instruments shall be provided with dust-
proof cases, long leads, and automatic recording mechanism capable of
recording the desired temperature for a period of twenty-four (24) hours on a
chart not less than twenty (20) centimeters in diameter, or on a continuous
sheet. The chart for either type shall be graduated in hours, minutes, and
degrees of temperature. The maximum time graduation shall be fifteen (15)
minutes and the maximum temperature graduation shall be five (5) degrees
centigrade. Hours on the chart shall be designated as a.m or p.m.

The temperature recording thermometers should be installed on points or a

framework, separate from plant, to eliminate plant vibration.

They shall be located in a manner to provide easy access to the case and
chart. The bulb of one instrument shall be installed in the hot asphalt line as
close as is practicable to the spray bar discharge, the bulb of the second
recording thermometer shall be installed in the hot aggregate bin which
contains the fine aggregate. The bulb shall be located where the hot
materials will flow over it during the proportioning operation and shall not be
located near the corners of the bin or at locations where the material will
collect or pack around it.

The Engineer reserves the right to pass judgment upon the efficiency of
thermometric instruments.

Control of Mixing Time: The plant shall be equipped with positive means to
govern the time of mixing and to maintain a constant time unless changed by
order of the Engineer.

Dust Collectors: The plant shall be equipped with a dust collector

constructed to waste or return uniformly to the hot elevator all or any part of
the material collected as desired.

Safety Requirements: Adequate and safe stairways to the mixer platform

and sampling points shall be provided and guarded ladders to other points
shall be placed at all points where accessibility to plant operations is
required. Accessibility to the top of truck bodies shall be provided by a
platform or other suitable device to enable the Engineer to obtain sampling

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 28

 29 SECTION 1 GENERAL

and mixture temperature data. A hoist or pulley system shall be provided to

raise scale calibration equipment, sampling equipment and other similar
equipment from the ground to the mixer platform.

All gears, pulleys, chains, sprockets, and other dangerous moving parts shall
be thoroughly guarded and protected. Ample and unobstructed space shall
be provided on the mixing platform. A clear and unobstructed passage shall
be maintained at all times in and around the truck loading area. The area
shall be kept free from dropping from the mixing platform.

vii) Specification Requirements for Batching Plants Weigh Box or Hopper

The equipment shall include a means for accurately weighing each size of
aggregate in a weigh box or hopper suspended on scales and of ample size
to hold a full batch without hand raking or running over. The gate shall close
tightly so that no material is allowed to leak into the mixer while batch is
being weighed. Asphalt plants shall meet requirements in accordance with
ASTMD995 & ASTMD290.

Bituminous Control: The equipment used to measure the bituminous

material shall be accurate to plus minus five-tenths (0.5) percent. The
bituminous material bucket shall be a non tilting type with a loose sheet
metal cover. The length of the discharge opening or spray bar shall be not
less than three-fourths (3/4) the length of the mixer and it shall discharge
directly into the mixer.

The bituminous material bucket, its discharge valve or valves and spray bar
shall be adequately heated. Steam jackets, if used, shall be efficiently
drained and all connections shall be so constructed that they will not
interfere with the efficient operation of the bituminous scales.

The capacity of the bituminous material bucket shall be at least fifteen (15)
percent in excess of the weight of bituminous material required in any batch.
The plant shall have an adequately heated quick-acting, nondrip, charging
valve located directly over the bituminous material bucket.

The indicator dial shall have a capacity of at least fifteen (15) percent in
excess of the quantity of bituminous material used in a batch.

The dial shall be in full view of the mixer operator. The flow of bituminous
material shall be automatically controlled so that it will begin when the dry
mixing period is over and all of the bituminous material required for one
batch will be discharged in not more than fifteen (15) seconds after the flow
has started.

The section of the bituminous line between the charging valve and the spray
bar shall be provided with a valve and outlet for checking the metering
device.

Mixer: The batch mixer shall be an approved type capable of producing

uniform mixture. If not enclosed, the mixer box shall be equipped with a dust
hood to prevent loss of dust.

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 30 SECTION 1 GENERAL

The clearance of blades from all fixed and moving parts shall not exceed two
and one-half (2.5) centimeters unless the maximum diameter of the
aggregate in the mix exceeds three (3) centimeters, in which case the
clearance shall not exceed three and eight-tenths (3.8) centimeters.

Control of Mixing Time: The mixer shall be equipped with an accurate time
lock to control the operations of a complete mixing cycle. It shall lock the
weigh box gate after the charging of the mixer until the closing of the mixer
at the completion of the cycle. It shall lock the bituminous material bucket
throughout the dry mixing period and shall lock the mixer gate throughout
the dry and wet mixing periods.

The dry mixing period is defined as the interval of the time between the
opening of the weigh box gate and the start of introduction of bituminous
material. The wet mixing period is the interval of time between the start of
introduction of bituminous material and the opening of the mixer gate.

The control of the timing shall be flexible and capable of being set at
intervals as necessary for mixing time throughout the total mixing cycle. A
mechanical batch counter shall be installed as a part of the timing device
and shall be so designed as to register only completely mixed batches.

Automation and Recording of Bituminous Concrete Plants. The plants shall

be equipped with an automatic mass measuring cycling and monitoring
systems approved by the Engineer. Recording equipment shall monitor the
batching sequence of each component of the mixture and produce a printed
record of these operations. For each day's production the Engineer shall be
provided a clear, legible copy of the recording. There should be provisions
so that scales may not be manually manipulated during the printing process.

viii) Special Requirements for Continuous Mixing Plants Aggregate

Proportioning: Continuous Mixing Plants are not recommended for Roads &
Transport Authority projects.

Weight Calibration of Aggregate Feed: The plant shall include means for
calibration of gate opening by weighing test samples. Provisions shall be
made so that materials fed out of individual orifices may be bypassed to
individual test boxes.

The plant shall be equipped to conveniently handle individual test samples

weighing not less than one hundred (100) kilograms. Accurate scales shall
be provided by the Contractor to weigh test samples.

Weight Calibration of Bituminous Material: The bituminous discharge line

shall be equipped with suitable valves and a bypass so that the asphalt
pump of meter may be readily calibrated. For each change of stockpiles, the
plant shall be recalibrated.

Synchronization of Aggregate Feed and Bituminous Material Feed:

Satisfactory means shall be provided to afford positive interlocking control
between the flow of aggregate from the bins and the flow of bituminous
material from the meter or other proportioning device. This control shall be
accomplished by interlocking mechanical means or by any other positive

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 30

 31 SECTION 1 GENERAL

method satisfactory to the Engineer.

Mixer: The plant shall include a continuous mixer of an approved type,

adequately heated and capable of producing a uniform mixture. It shall be
equipped with a discharge hopper with dump gates which will permit rapid
and complete discharge of the mixture.

The paddles shall be adjustable for angular position on the shaft and
reversible to retard the flow of the mix. The mixer shall have a
manufacturer’s plate giving the net volumetric contents of the mixer at the
several heights inscribed on a permanent gauge. Charts shall be provided
showing the rate of feed of the aggregate per minute for the aggregate being
used.

Bituminous-mix Paver: Bituminous-mix pavers shall be self-contained,

power propelled units, provided with automatically controlled activated
screed or strike-off assembly, heated for the full width of the screed if
necessary, and capable of spreading and finishing courses of bituminous
plant mix material at least 300 millimeter more than the width of one lane
applicable to the specified typical section and thickness shown on the plans.

Pavers used for shoulders and similar construction shall be capable of

spreading and finishing courses of bituminous plant mix material in widths on
the plans. Pavers shall be capable of laying one hundred (100) tons per
hour.

The machines shall employ mechanical devices such as equalising runners,

straight-edge runners, evener arms, or other compensating devices to adjust
the grade and confine the edges of the mixer to true lines without the use of
stationary side forms.

The paver shall be equipped with a distribution system to place the mixer
uniformly in front of the screed.

The screed or strike-off assembly shall effectively produce a finished surface

of a required evenness and texture without tearing, shoving or gouging the
mixture.

The paver shall be capable of being operated, when laying mixture, at

forward speed consistent with satisfactory laying of the mixture.

The automatic controls for the paver shall be automatic linkage arrangement
so that through the process of automatically adjusting the screed, the
thickness of asphaltic mixtures can be placed and finished to predetermined
grade and a uniform crown or cross-section.

The paver shall be equipped with automatic screed controls with sensors
capable of sensing grade from an outside reference line, sensing the
transverse slope of the screed, and providing the automatic signals that
operate the screed to maintain grade and transverse slope.

Manually controlled bituminous-mix pavers may be used only with the written
consent of the Engineer.

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 32 SECTION 1 GENERAL

A manually controlled bituminous-mix paver shall be of the self-propelled

type with spread and strike-off facilities designed to spread the mixture in
such a manner that no supplemental shaping will be required.

It shall be self vibrator capable of spreading the mixture evenly, producing a

finished surface of the required thickness, density, smoothness and texture
without segregating, tearing, shoving, or gouging the mix.

Screeds must be constructed so as not to follow minor irregularities in the

base and must be readily adjustable to control accurately the depth spread.

No manually operated bituminous-mix paver shall be delivered to the site

prior to its approval by the Engineer.

Self-Propelled Aggregate Spreader: Self-propelled aggregate spreader shall

be approved design supported by at least four (4) wheels equipped with
pneumatic tyres on two (2) axles. The aggregate spreader shall be equipped
with a means of applying the larger cover coat material to the surface ahead
of the smaller cover coat material and with positive control so that the
required amount of material will be deposited uniformly over the full width of
the bituminous material. Other types of aggregate spreaders may be used
provided they accomplish equivalent results and are approved by the
Engineer.

1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI

The average prevailing local conditions at Dubai City shall be assumed as follows
(Table 1-1):

Table 1- 1: local conditions at Dubai City

Serial Parameter Limit or Value
1. Max. Ambient Temperature 55 deg.C

2. Min. Ambient Temperature 1 deg.C

3. Design Ambient Temperature 50 deg.C

4. Max, Metal Temperature under sun 85 deg.C

5. Min. Barometric Pressure 998 mb

6. Max. Ambient Humidity 100%

7. Ambient Humidity 20%

8. Design Ambient Humidity 80% Max

9. Design Wind Velocity 160 Km/hr.

10. Average Yearly Rainfall 80 mm -150 mm

The climate of Dubai is relatively mild from November to April, and hot from May

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 32

 33 SECTION 1 GENERAL

to October with high relative humidity.

Under certain combinations of the above climatic conditions considerable

condensation may take place.

Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with
the extremely high ambient humidity, can produce severe corrosion problems.

Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance, but attention should be paid to the fact that sudden heavy rainfalls in
a very short period of time can occur.

The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 Km/hr. and sand storms and
dust storms occur in the summer months.

Volume 2, Part 1, General Specifications-Roads Works March 2017 Page 33

 Section 2
Site Clearance
and Earthworks
 1 SECTION 2 SITE CLEARANCE AND EARTHWORKS

TABLE OF CONTENT

2/1 SITE CLEARANCE DESCRIPTION .................................................................. 2

2/2 SURVEY BEFORE COMMENCEMENT............................................................ 2
2/3 DEMOLITION REQUIREMENTS ...................................................................... 2
2/4 GENERAL SITE CLEARANCE ......................................................................... 3
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS 4
2/6 ROAD SIGNS ................................................................................................... 4
2/7 DISPOSAL OF HISTORICAL ARTIFACTS ....................................................... 4
2/8 DISPOSAL OF SURPLUS MATERIAL .............................................................. 5
2/9 EXCAVATION FOR ROAD CONSTRUCTION ................................................. 5
2/10 CLASSIFICATION OF EXCAVATION ............................................................... 5
2/11 EXCAVATION REQUIREMENTS ..................................................................... 6
2/12 BORROW PIT SITE .......................................................................................... 8
2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS
MATERIALS..................................................................................................... 9
2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION .................................. 13
2/15 EMBANKMENT CONSTRUCTION ................................................................. 13
2/16 EMBANKMENT FOUNDATION ...................................................................... 14
2/17 PLACING AND COMPACTION REQUIREMENTS ......................................... 15
2/18 MOISTURE CONTROL REQUIREMENTS ..................................................... 17
2/19 TESTING METHODS ...................................................................................... 18
2/20 MINIMUM TEST REQUIREMENTS ................................................................ 18
2/21 CRUSHED STABILISING MATERIAL ............................................................. 20
2/22 GEOTEXTILE FABRIC ................................................................................... 21
2/23 EXCAVATION FOR STRUCTURES ............................................................... 23

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 1

 2 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/1 SITE CLEARANCE DESCRIPTION

2/1.1 This work shall consist of the removal, wholly or in part, and satisfactory
disposal of all buildings, fences, structures, abandoned pipelines, and any
other obstruction which are not designated or permitted to remain within
the clearing project limits designated on the plans. It shall also include the
salvaging of designated materials and backfilling the resulting trenches,
holes and pits.

2/2 SURVEY BEFORE COMMENCEMENT

2/2.1 Prior to starting the site clearance, the Contractor shall carry out a
thorough survey of buildings, structures, fences, trees, etc. that are to be
removed. The Engineer shall be fully informed of the results of this survey
and the amount and extent of the demolition and site clearance shall then
be agreed with the Engineer.

2/3 DEMOLITION REQUIREMENTS

2/3.1 The Contractor shall in a careful manner, raze, remove and dispose of all
buildings and foundation structures, fences and other obstructions or any
portions of which are within the Right-of-Way, except utilities and those
for which other provisions have been made for removal. All
designated salvageable material shall be removed, without unnecessary
damage, in sections or pieces which may be readily transported, and shall
be stored by the Contractor at specified places within the project limits or
at designated storage areas as directed by the Engineer. All such
salvageable material shall be deemed the property of the Employer.

2/3.2 Foundations of building structures shall generally be removed to a depth of

1 m below ground level or more if considered necessary by the Engineer.

2/3.3 Where shown on the drawings or where directed by the Engineer,

underground structures, culverts, chambers and foundations other than
building foundations shall be removed to such a level as may be indicated
on the drawings or directed by the Engineer.

2/3.4 Where directed by the Engineer, the Contractor shall excavate in trench
and break out redundant pipe ducts and surrounds. Every precaution
should be taken to avoid breaking or damaging the pipes that are to be
removed and either salvaged or reused. The pipes shall be stored when
necessary so that there will be no loss or damage before relaying.

The Contractor will be required to replace sections lost from storage or

damage by negligence or by the use of improper methods in their removal.

2/3.5 Trenches and pits resulting from demolition and site clearance below
ground level shall be properly cleaned out (including pumping) and filled
with suitable material and compacted in accordance with the relevant

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 3 SECTION 2 SITE CLEARANCE AND EARTHWORKS

Specifications up to subgrade level or as otherwise directed by the

Engineer.

2/3.6 Where required, the Contractor shall be responsible, prior to demolition,

for the disconnection of all services and clearance from the Dubai
Municipality and all Service Authorities.

2/3.7 Where shown on the drawings or otherwise directed by the Engineer, all
fences, walls or boundary structures to be erected or reinstated shall be
done in the same kind and form as the one it is intended to replace. The
wall, fence or boundary structure shall be made to match the remaining
existing portions. All materials and workmanship shall be in accordance
with the relevant standards and specifications contained herein.

2/4 GENERAL SITE CLEARANCE

2/4.1 Before commencing any excavation or fill, the area located within the
clearing project limits designated on the plans and drawings, shall be
cleared of all trees, stumps, roots, bushes, vegetation, debris, materials or
other obstructions.

2/4.2 Before removal of any trees or shrubs the Contractor shall obtain written
consent from Dubai Municipality Horticultural Section at least two weeks in
advance of the planned removal.

2/4.3 The Engineer's approval of any removal of trees and undergrowth must be
obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of
in tips off site (Sub section 2/8). Holes left by stumps or roots shall, within
one week, be filled with suitable material, and compacted to the Engineer's
satisfaction in accordance with Specification Clause 2/17.

2/4.4 GHAF TREES

2/4.4.1 Ghaf Trees are a protected species in the United Arab Emirates they are
to be pruned or moved under the complete supervision and written
approval of Dubai Municipality Horticulture Section.

2/4.4.2 Trees may only be moved if they represent an absolute obstruction to the
works and no diversion of services or the road alignment is possible.

2/4.4.3 The Contractor is responsible for ensuring attendance by the Horticulture

Section and provision of at least the following plants:

i) Mobile crane of sufficient capacity with slings etc. to enable the lifting of
the particular trees in question.
ii) Excavator to carry out excavation prior to tree removal.
iii)Low Bed trailer and tractor or similar to transport the removed
tree/trees to either Mushrif Park or the Dubai terminal of the
Dubai to Al Ain Road, whichever is the nearer to the site.

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 4 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/4.4.4 The above plant will be required at both the original and new tree sites.
The Horticulture Department may also require the provision of a supply of
potable water for irrigation of the tree prior to its removal.

2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED

BY THE WORKS

2/5.1 Attention is directed to the Contractor's obligations under law and under
this Contract with regard to damage, particularly with regard to protection
of property, plants and landscape and to responsibility for damage claims.

2/5.2 Existing highways, improvements, facilities, adjacent property, services,

and trees and plants designated for preservation shall be protected from
injury or damage which could result from the Contractor's operations.

2/5.3 The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.

2/6 ROAD SIGNS

2/6.1 All existing road signs, street name plates, gantry cantilever and like
effected by the works are to be recorded (size, dimension, condition.etc)
and carefully taken down and stored on site for reuse as directed by the
Engineer. Signs to be re-erected shall be cleaned, provided with new
fixings where necessary and the posts re-painted in accordance with the
Specifications. Redundant signs shall be transported to the stores or
depots of relevant Authorities. Any sign, street name plate or the like
damaged by the Contractor during his operation shall be repaired or
replaced at the Contractor's cost.

2/7 DISPOSAL OF HISTORICAL ARTIFACTS

2/7.1 Where specified, certain materials arising from the site clearance and
excavation are to remain the property of the Employer. All fossils,
antiquities and other objects of interest or value which may be found or
uncovered on the site shall remain or become the property of the
Employer and upon discovery of such an object the Contractor shall
forthwith:

a. Use his best endeavors not to disturb or damage the object.

b. Cease work which would endanger the object or prevent or impede its
removal.
c. Inform the Engineer of the discovery and precise location of the object.

2/7.2 The Engineer will issue instructions on the procedure to be adopted which
may include conditions to permit the examination, excavation or removal
of the object by a third party.

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2/8 DISPOSAL OF SURPLUS MATERIAL

2/8.1 Subject to the provision of Clause 27.1 of the Conditions of Contract Part I
and of the Specification, all materials arising from site clearance which are
surplus to or unsuitable (Section 2/13.3) for use in the Works shall become
the property of the Contractor and shall be disposed of by him either off the
Site to an approved tip or if directed or otherwise agreed by the Engineer
on the Site in an approved manner.

2/8.2 Following consultation with Dubai Municipality Public Health Department,

the Engineer and RTA, the Contractor shall propose two sites for disposal
of unsuitable or surplus material, one of which shall be specified as having
priority and which must be filled before the second is used, together with a
separate location where hard debris, such as concrete, building rubble,
kerbing, road pavement, etc. shall be disposed of. The Contractor shall
seek approval for all the proposed sites from the Dubai Municipality before
work commences and disposal at such sites shall be at no extra cost to the
Employer.

2/8.3 The Contractor has to prepare and submit to the Engineer Earth Work
Cross Section and calculate the total quantity of cut material and total
quantity of filled material.

If the filled material found more than cut material then the Engineer in
coordination with RTA will arrange to provide fill material to the project from
any of RTA running project if available. If not available, then the Contractor
can use the item of imported material.

If the cut material found more than the fill material, then the surplus material
if suitable has to be disposed to one of RTA running project as directed by
RTA. If not available the Contractor can dispose the surplus material at an
approved dumping area.

2/9 EXCAVATION FOR ROAD CONSTRUCTION

2/9.1 This work shall consist of excavating the roadway and borrow pits,
removing and satisfactorily disposing of all materials taken from within the
limits of the Work. It shall include all dewatering, excavation, shaping and
sloping as necessary for the construction, preparation and completion of all
embankments, cuttings, subgrade, shoulders, slopes, gutters, intersections,
approaches and private entrances, as directed, and in conformity to the
alignment, grades, and cross-sections shown on the plans or established
by the Engineer.

2/10 CLASSIFICATION OF EXCAVATION

2/10.1 Excavated material shall be classified as:

- Roadway Excavation.
- Borrow Excavation.

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2/10.2 Roadway excavation includes all material of whatsoever nature, suitable

or unsuitable, excavated within the limits of the Right of Way for the
preparation of the road bed. All such material after deduction for material
declared unsuitable by the Engineer shall be considered to be available for
use at locations requiring fill. Roadway excavation shall be sub classified
as Common Excavation and Rock Excavation.

2/10.3 Authority to identify and define the physical characteristics which determine
the classification as "Common Excavation" and "Rock Excavation" in
accordance with the intent of the following provisions shall be vested in the
Engineer.

2/10.4 Common Excavation-' shall consist of the excavation and satisfactory

disposal (subject to Clause 2/15.3) of all soils, certain strata and individual
rock boulders less than 1 cubic meter in volume. Strata which are altered
and weathered and are in place, but which are not firm enough, or in the
opinion of the Engineer are not rigid enough to have all the characteristics
of rock excavation shall be classified as common excavation.

2/10.5 Rock Excavation - shall consist of the excavation and satisfactory disposal
(subject to Clause 2/15.3) of all unaltered and unweathered firm and rigid
igneous, metamorphic and sedimentary solid rock and boulders exceeding one
cubic metre in volume that in the opinion of the Engineer are impracticable to
remove by heavy mechanical excavating equipment (e.g. Cat.D8) or by heavy
duty hydraulic ripper, or by approved pneumatic tools.

These type of rocks would normally be removed by blasting with explosives, or

by heavy duty hydraulic breakers or by drilling and broaching with wedges and
sledge hammers if removed by hand.

2/10.6 Borrow Excavation - If the demand for fill material exceeds the quantity of
suitable material obtained from the necessary roadway excavation then
suitable material shall be imported to the worksite from an approved borrow pit.
The excavation, haulage and discharge of material in its final place from a
borrow pit shall be classified as Borrow Excavation.

2/11 EXCAVATION REQUIREMENTS

2/11.1 All materials removed from an excavation shall be used in the formation of
the embankment, shoulders and at such other places as directed, unless it
is declared unsuitable and ordered to be sent to the disposal site by the
Engineer. No excavated material shall be wasted without written
permission from the Engineer, and when such material is to be wasted, it
shall be hauled to the approved disposal site (Clause 2/8) or as otherwise
directed by the Engineer.

Material suitable for top soil, base material, mineral aggregate or other
specified purpose, encountered in excavation, shall be reserved in
stockpile, if so directed, until it can be placed in its proper position in the
roadway during construction. When specified or designated, top soil shall
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 7 SECTION 2 SITE CLEARANCE AND EARTHWORKS

be used as cover on embankment slopes to aid the regrowth of vegetation

or other purposes.

2/11.2 Excavated materials wasted by the Contractor without written permission of

the Engineer shall be replaced by the Contractor at his own expense.

2/11.3 During the construction of the roadway, the prepared formation shall be
maintained in such condition that it will be well drained at all times.

2/11.4 Rock, shale and other unsuitable material encountered in cuts shall be
excavated to the lateral limits and depth indicated on the plans or as
otherwise directed. Any excess breakage below the depth shown on the
plans or as otherwise directed will not be paid for. Backfill of the excess
breakage shall be approved suitable material and shall have the same
density requirements as specified by the Contract and shall be at the
expense of the Contractor. If the backfill of the excess breakage area
designated by the Engineer is to be a crushed aggregate concrete or other
special aggregate the entire cost of the backfill of the excess breakage
shall be at the expense of the Contractor. Undrained pockets shall not be
left in the surface of the rock, but they shall be treated as directed by the
Engineer.

2/11.5 All slopes, except in solid rock or other material which, in the judgment of
the Engineer, require a modified slope, shall be trimmed accurately to the
slopes shown on the cross-sections drawings, and care must be exercised
that no material shall be loosened beyond the required slopes. Side
ditches if required shall be excavated in conformity to line, grade, and
cross-section as shown on the Drawings or as directed by the Engineer.

2/11.6 In cut areas, excavation shall be for the full construction width down to
'earthworks formation level'. For a further depth of 15 cm the existing
material shall be scarified, watered as necessary, mixed and compacted to
not less than 95% of maximum dry density as determined by BS 1377 Part
4 : 1990 (Method 3.5 or 3.6, AMD 13925:2002). Field density shall be
determined by BSI BS 1377-9, AMD 17229 (2007)

2/11.7 In fill and embankments, an 'improved subgrade layer', using specified

material, shall be placed to bring the embankment level up to 'top of
improved subgrade level' The improved subgrade layer shall be compacted
to not less than 95% maximum dry density BS 1377 Part 4 : 1990 (Method
3.5 or 3.6, AMD 13925:2002). Field density shall be determined by BSI BS
1377-9 AMD 17229 (2007)

2/11.8 The technical requirements of the specifications for ‘Excavation for

Structures” (Sub-Section 2/23) shall be complied with works include cutting
of 1.5m or more in depth.

2/11.9 Where excavation to 'earthworks formation level' (i.e. the earthwork

formation level is the level of the last layer of the earthworks which can be
either “subgrade” or Improved Subgrade), results in a formation or slopes of
unsuitable soil, the Engineer may require the Contractor to remove the
unsuitable material to a depth directed and backfill to the finished graded

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 8 SECTION 2 SITE CLEARANCE AND EARTHWORKS

section with approved material compacted in accordance with specified

requirements for embankment construction.

The suitability of the existing subgrade shall be investigated up to 0.5m

below the formation level or more than 0.50m below the formation level if
the existing subgrade contains unsuitable material as defined in the clause
2/13.3 below. In this case, subgrade preparation shall be as follows:

 If the CBR of the subgrade at the formation level is satisfying the

minimum requirements, a further depth of 15cm of the existing
subgrade shall be scarified, watered, mixed as necessary and
compacted as described in clauses 2/16 and 2/17 below.

 If the CBR of the subgrade at the formation level does not satisfy
the minimum requirements, a minimum thickness as specified in the
drawings or as directed by the Engineer shall be removed and
replaced with an equal thickness of improved subgrade material and
compacted as described in clauses 2/16 and 2/17 below.

The Contractor shall conduct his operations in such a way that the
necessary cross-sectional measurements can be taken and agreed with the
Engineer before the backfill is placed.

2/11.10 When the Contractor is required or is directed to excavate unsuitable

material in fill areas, following general clearance of the area (see
Specification Subsection 2/16 "Embankment Foundation"), the depth to
which these unsuitable materials are to be removed will be determined by
the Engineer. The Contractor shall so schedule the work so that authorized
cross-sections can be taken before and after the material has been
removed.

2/11.11 All slopes, lines and grades shall be true, correct, and accurate and
according to those on the drawings or otherwise directed and approved by
the Engineer. The 'earthworks formation level' in cuts shall be accurate to
the authorized profile grade to plus or minus two (2) centimeters and, for
'top of improved subgrade' level, plus or minus one (1) centimeter. Where
discrepancies are found in the Work the Contractor shall make necessary
corrections.

2/11.12 The Engineer will check all or any part of the Work, as he deems
necessary, to determine conformance to the lines, grades, elevations and
cross-sections.

2/12 BORROW PIT SITE

2/12.1 The Contractor shall obtain approval from the Employer for the location of
the borrow pit site. The Contractor shall be responsible to determine the
quantities and quality of the available material in the approved borrow site
to meet the requirements of the Contract. When required the borrow area
shall be cleared and grubbed in accordance with the requirements of
Section 2/1.

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 9 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/12.2 The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such
notice from the Employer, the Contractor shall immediately cease removing
material from said borrow site. In the event the Employer revokes approval
of the borrow site, the Contractor shall locate a new borrow pit site as
specified above.

2/12.3 The Contractor shall not claim any additional payment for any costs by
reason of the necessity of changing borrow site locations due either to the
shortage of the supply of borrow material available from the borrow pit site
approved by the Employer, or due to the Employer's decision to revoke
approval of the borrow site where the Contractor is obtaining borrow
material for the Works.

2/12.4 The Contractor shall leave borrow pits in a condition acceptable to the
Employer and to the Engineer.

2/12.5 The Contractor will be solely responsible for ascertaining the location of
such approved borrow areas during the tender preparation stage.

Locations, distances to the work site and haulage from such approved
borrow areas shall be taken into consideration when preparing the unit
tender price for Borrow Excavation.

2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF

EARTHWORKS MATERIALS

The following definitions of earthwork materials shall apply: -

2/13.1 Top Soil shall be fertile, friable soil containing organic matter free from
subsoil, refuse, tree roots, noxious weeds, clay lumps and stones
recovered from well drained arable land. The soil shall be free draining, non
toxic and capable of sustaining healthy plant growth. The properties of
Topsoil shall be as described in Table 2-1 below.

Table 2- 1: The properties of Topsoil material

MATERAL Specified Limits Test Method
TYPE Characteristics
Organic content Less than 2% BS 1377: Part 3:
1990: Method 3,
AMD 9028:1996
Topsoil
PH Value Min 7 - Max 9 BS 1377: Part 3:
1990: Method 9,
AMD 9028:1996

2/13.2 SUITABLE MATERIAL

Suitable Material for earthworks shall comprise all material obtained from
excavations within the works or from borrow pits approved by the Engineer
and acceptable in accordance with the Contract for use in the Works.

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 10 SECTION 2 SITE CLEARANCE AND EARTHWORKS

Suitable material for earthworks shall be an approved soil that meets the
following specifications listed in Table 2-2:

Table 2- 2: Specifications of suitable material for earthworks

MATERAL Specified Limits Test Method
TYPE Characteristics
Passing 63mm Max 100% BS1377: Part 2: 1990
Test 9.2,AMD
9027:1996
Passing 0.075mm Max 20% BS1377: Part 2: 1990
Test 9.2, AMD 9028:
1996
Liquid Limit Max 40% BS 1377: Part 2: 1990:
Test 4.5, AMD 9028:
1996
Plasticity Index Max 6%* BS1377 Part 2 1990
Clause 5.4, AMD 9027-
1996
Weighted PI Max 400 Calculation (PI x
(PIx0.425)* %passing 0.425mm)
Linear shrinkage Max 3% BS1377 Part 2 1990
Clause 6.5, AMD 9027-
1996.
Soaked CBR (95% Min 10%** BS1377 Part 4: 1990
Suitable fill
compaction) Min 15% (Method 7), AMD
material
13925:2002
Free swell Max 1.5% BS 1377 Part 5 1990
AMD 8260: 1994
Organic content Less than 2% BS 1377: Part 3: 1990:
Method 3, AMD
9028:1996
Acid soluble Chloride BS1377:P3:1990:M7.3
Max2%. AMD 9028: 1996
Acid soluble Sulphate BS1377:P3:1990:M5.5,
Max2% AMD 9028: 1996
Organic matter content BS 1377:P3:1990 M3,
Max2% AMD 9028: 1996
Water soluble Chloride BS1377:P3:1990:M7.2,
AMD 9028: 1996
Total Max 5%
Water soluble Sulphate BS1377:P3:1990:M5.5
AMD 9028-1996
PH of the Soil BS 1377: P3:1990: M9,
Min 7 - Max 9 AMD 9028: 1996

* PI less than 6 has been retained as requested by DCL. However where PI

exceeds 6 the concept of Weighted Plasticity Index (WPI) has been introduced
to control the influence of PI on material performance. ** WPI = PI x % passing
0.425mm sieve.
** A minimum soaked CBR = 10% shall only apply to material 0.5m below finished
formation level.

2/13.3 UNSUITABLE MATERIAL

Unsuitable material shall comprise but not be restricted to: -

- Rock particles exceeding 63 mm in size.
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 11 SECTION 2 SITE CLEARANCE AND EARTHWORKS

- Material containing greater than 2% organic material such as stumps

and other perishable material as determined according to BS1377
Part 3: 1990 method 3, AMD 9028:1996.
- Material susceptible to spontaneous combustion.
- Soils of liquid limit exceeding 40% (BS 1377 Part 2 1990 Clause 4.5,
AMD 9027:1996), and plasticity index exceeding 6 (BS 1377 Part 2
1990 Clause 5.4, AMD 9027:1996)
- Materials containing more than 20% by weight passing Sieve Size
0.075mm determined by BS 1377: Part 2: 1990 Clause 9.2, AMD
9027:1996
- Materials containing more than 5% of water soluble salts by weight of
dry soil. BS 1377 Part 3:1990, (Method 7.2 and 5.5, AMD 9028-1996)
for water soluble chloride and sulphate respectively.
- Any other material which the Engineer may deem to be unsuitable for
earthworks.
The complete range of chemical tests, test methods and specifications shall
be as mentioned in Table 2-3 below:

Table 2- 3: Existing Material – Soil (Unsuitable for Filing)

Test Method Specifications
Acid soluble Chloride BS 1377:P3:1990:M7.3,
More than 2%.
AMD 9028:1996
Acid soluble Sulphate BS 1377:P3:1990:M5.5,
More than 2%
AMD 9028:1996
Organic matter content BS 1377:P3:1990 M3,
More than 2%
AMD 9028:1996
Water soluble Chloride BS 1377:P3:1990: M7.2,
AMD 9028:1996
Total >5%
Water soluble Sulphate BS 1377:P3:1990:M5.5
AMD 9028-1996
PH of the Soil BS 1377: P3:1990: M9,
<7 or >9
AMD 9028:1996

2/13.4 IMPROVED SUBGRADE

Material for an improved subgrade layer shall meet the requirements listed
in Table 2-4 below:

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 12 SECTION 2 SITE CLEARANCE AND EARTHWORKS

Table 2- 4: Improved subgrade material requirements

MATERA Specified Limits Test Method
L TYPE Characteristics
Improved Passing 63mm Max BS 1377: Part 2: 1990 Clause
Subgrade 100% 9.2, AMD 9027:1996
Passing 0.075mm Max 20% BS 1377: Part 2: 1990 Clause
9.2, AMD 9027:1996
BS 1377: Part 2: 1990: Test
Liquid Limit Max 40% 4.5, AMD 9027:1996
BS 1377 Part 2 1990 Clause
Plasticity Index Max 6% 5.4,AMD 9027-1996
Soaked CBR (95% BS 1377 Part 4: 1990 (Method
compaction) Min 30% 7), AMD 13925-2002

A chemical analysis of the proposed material shall be carried out to satisfy

the following requirements:

 The material shall be shown to have an acid soluble sulphate content of

2% or less and chloride content in the form of acid soluble chloride of
2% or less by dry weight. The applicable test methods should be in
accordance with BS 1377 Part3 (Method 5.5, AMD 9028:1996) and BS
1377 Part3 (Method 7.3, AMD 9028:1996).
 When approved by the Engineer, a sulphate content greater than that
specified may be acceptable when the carbonate content is in the
region of 30-40% (BS 1377, Part3, (Method 6.3, AMD 9028:1996).
 Higher chloride contents may be tolerated provided that the ratio of
(carbonate+sulphate) to chloride contents is maintained at
approximately 15:1.
 When approved by the Engineer a sulphate content greater than that
specified may be acceptable when the carbonate content is in the
region of 30 - 40% (BS 1377 Part 3: 1990 Method 6.3 AMD 9028-1996).
 The moisture content of the material before compaction shall not vary
by more than +/- 3% of the optimum moisture content when tested in
accordance with BS 1377: Part 2 : 1990 Test 3.2, AMD 9027:1996.
 The material for improved subgrade shall be approved soil with a
plasticity index not exceedingly 6 (BS 1377 Part 2 1990 Clause 5.4,
AMD 9027:1996) and liquid limit shall not exceed 40% when tested
according to (BS 1377: Part 2: 1990 Clause 4.5, AMD 9027:1996).

2/13.5 No excavated suitable material shall be removed from the Site without the
Engineer's written permission. Should the Contractor be permitted to
remove suitable material from the site to suit his operational requirements,
and then he shall make good any consequent deficit or filling arising there
from at his own expense.

2/13.6 Dune sand if used shall not contain more than 2% organic matter (BS
1377:P3:1990 M3, AMD 9028:1996) and may contain up to 20% of stone
fragments or cobbles exceeding 20mm but not more than 63mm in size.

2/13.7 Layers of dune sand between layers of granular materials shall not be
allowed.

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2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION

2/14.1 The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in-situ state or during handling and
placing or in its final compacted state. Unsuitable or faulty plant shall be
removed from the work site and borrow pits at the order of the Engineer.

2/14.2 The plant and equipment used for earthworks construction shall be
maintained in good working condition for the duration of the works. The
Contractor shall apply adequate quantities of plant and equipment
necessary for the proper execution of the works in an expeditious manner.

2/14.3 Main plant and equipment shall meet the requirements outlined in Clause
1/29 of these Specifications.

2/15 EMBANKMENT CONSTRUCTION

2/15.1 This work shall consist of constructing roadway embankment with suitable
material, including the preparation of the areas upon which they are to be
placed and the placing and compacting of approved material within
roadway areas where unsuitable material has been removed. All
operations will be performed in accordance with the Specifications and in
conformity with the lines, grades, thickness and typical cross-sections
shown on the drawings or as established by the Engineer.

2/15.2 Compaction equipment shall conform to the number and type outlined in
the Contractor's detailed programme of work as approved by the Engineer
and satisfactory performance shall be the basis for such approval.

2/15.3 All materials derived from excavation shall be used in the embankment
unless otherwise declared unsuitable by the Engineer.

2/15.4 Prior to the commencement of embankment, the Contractor shall construct

trial compaction of at least 50m in length. The soils used in the trials shall
be those encountered along the line of the road as approved by the
Engineer and/or those originating from the approved borrow pit. The object
of the trials is to determine the ability of the contractor’s equipment and
processes to meet the requirements of this specification. Steel and
Pneumatic rollers shall be used for the embankment construction. The
Engineer may order additional compaction trials when he deems them
necessary.

2/15.5 During the construction of embankments, the Contractor shall control and
direct construction traffic uniformly over the full width of the embankment
Damage to compacted layers by construction traffic shall be made good by
the Contractor at his own expense.

2/15.6 The Contractor shall be responsible for the stability of all embankments and
shall replace all sections which, in the opinion of the Engineer, have been
damaged or displaced due to carelessness or neglect on the part of the

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 14 SECTION 2 SITE CLEARANCE AND EARTHWORKS

Contractor, or due to natural causes, such as storms, and not attributable to

the unavoidable movement of the natural ground upon which the
embankment is made. During construction, the roadway shall be kept
shaped and drained at all times. When unsuitable material has been
placed in the embankment, its removal shall be at the expense of the
Contractor. Throughout the duration of the Contract all damage to
completed earthworks attributable to rain and rainfall run-off or to any other
cause shall be made good by the Contractor without delay and whenever
possible within 24 hours of such damage occurring.

2/16 EMBANKMENT FOUNDATION

2/16.1 All debris, unsuitable material and vegetable matter shall be removed from
the surface upon which the embankment is to be placed and the cleared
surface shall be completely broken up by ploughing, scarifying or stepping
to a minimum depth of twenty (20) centimeters.

2/16.2 The foundation material shall be adjusted to a moisture content within the
moisture range of + 3% of the optimum moisture content and compacted to
not less than ninety-five (95) percent of the Maximum Dry Density as
determined by BS 1377 Part 4: 1990 (method 3.5 or 3.6, AMD 13925:
2002) where the embankment is less than one and a half (1.5 m) meters
below subgrade; and compacted to not less than ninety three (93) percent
of the maximum dry density as determined by BS 1377 Part 4: 1990
(Method 3.5 or 3.6, AMD 13925: 2002) ) where the embankment is more
than one and a half (1.5 m) meters below the subgrade.

In dry cohesionless soils (e.g. dune sand) where conventional sand

replacement measurement of field density cannot be undertaken, the
suitability of compacted layers shall be determined using the Clegg Impact
Soil Tester in accordance with ASTM D5874-02(2007) . A minimum Impact
Value (CIV) =8 (which corresponds to a CBR value of 8%) shall be
achieved.

2/16.3 If the original surface upon which the embankment is to be placed is an old
roadbed, the surface shall be ploughed scarified or broken up. All
aggregate particles shall be reduced to a maximum size of 63 mm. A well-
mixed and uniform layer surface shall be produced. The embankment
layers shall be compacted according to Subsection 2/16 requirements,
regardless of the height of the embankment to be placed, and compacted
to a density not less than ninety five (95) percent of the maximum dry
density as determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6, AMD
13925: 2002).

2/16.4 Where an embankment is to be placed on appreciably sloping ground, this

surface shall be benched in steps or trenched in accordance with the
Engineer's instructions, including if necessary any under draining of the
affected part of the site.

2/16.5 In circumstances where backfill has to be deposited below standing water.

In such cases the Contractor shall use only an approved granular material
of maximum size not greater than 37.5 mm and which on analysis by
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 15 SECTION 2 SITE CLEARANCE AND EARTHWORKS

sieving (BS 812: Part 103: Section 103.1:1985, cl.7.2 or 7.3, AMD 6003:
1989, or BS 1377: Part 2: 1990: 9.2 or 9.3, AMD 9027: 1996 or latest
edition) complies with the requirements of Table 2-5 below. Such material
shall have a "ten percent fines" value of not less than 5 tones when tested
in accordance with BS 812: 1990 P111 and BS EN 1097-2-1998, AMD
16684: 2006 and may be deposited below water without the associated use
of compaction plant.

2/16.6 Free Draining Backfill

In circumstances where backfill has to be deposited below standing water
in embankment construction, approved granular material shall conform to
the following (Table 2-5):

Table 2- 5: Approved granular material requirements

MATERAL Specified Limits Test Method
TYPE Characteristics
Passing 37.5mm Max 100% BS 1377: Part 2: 1990 Clause
9.2 or 9.3, AMD 9027: 1996
or BS 812: Part 103: Section
103.1:1985, cl.7.2 or 7.3,
AMD 6003: 1989.
Passing 10 mm Max 100% BS 1377: Part 2: 1990 Clause
9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
Passing 5 mm Max 85% BS 1377: Part 2: 1990 Clause
Free 9.2 or 9.3 or BS 812: Part 103:
draining Section 103.1:85 cl.7.2 or 7.3,
backfill AMD 6003: 1989.
Passing 0.600 Max 45% BS 1377: Part 2: 1990 Clause
mm 9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
Passing 0.075mm Max 5% BS 1377: Part 2: 1990 Clause
9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
10% Fines Value Min 5 BS 812: 1990 P111 and /or BS
tones EN 1097-2-1998, AMD 16684:
2006

2/17 PLACING AND COMPACTION REQUIREMENTS

2/17.1 Only approved materials shall be used in the construction of embankments.

2/17.2 In the formation of the embankment it is strictly forbidden to push the

excavated materials from the side of the road to the embankment by means
of bull dozers.

2/17.3 The fill material shall be delivered and spread in layers not exceeding 250
mm thickness after compaction. The layers of fill shall be graded, leveled,
pulverized and mixed, with water added as necessary, to ensure
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 16 SECTION 2 SITE CLEARANCE AND EARTHWORKS

homogeneous conditions through the full depth of the uncompacted layer.

For field density testing refer to specification sub-section 2/19.

2/17.4 The compacted density of the fill shall be equal to or greater than as
required under Clause 2/16.2 as determined by BS 1377 Part 4: 1990
(Method 3.5 or 3.6, AMD 13925: 2002).

Dune Sand, if found suitable and approved by the Engineer, may be used
as fill material up to a level of 1.5m from bottom of sub-grade. Dry
compaction (at natural moisture content) of 25cm lifts (tested every 15cm)
can be adopted.

In dry cohesionless soils (e.g. dune sand) where conventional sand

replacement measurement of field density cannot be undertake, the
suitability of the compacted fill layer shall be determined using the Clegg
Impact Soil Tester in accordance with ASTM D5874 - 02(2007). A minimum
Impact Value (CIV)=8 (which corresponds to a CBR value of 8%) shall be
achieved.

2/17.5 The material to be imported for the "improved subgrade layer" to be

constructed above "earthworks formation level" up to "top of improved
subgrade" level as shown on the drawings shall conform to the
Specification Sub-Section 2/13 Para 4.

2/17.6 All slopes, lines and grades shall be true, correct, and accurate and
according to those shown on the Drawings or otherwise directed and
approved by the Engineer. The "earthworks formation level" in
embankments shall be accurate to the authorized profile grade to plus or
minus two (2) centimeters and, the 'top of improved subgrade' level, plus or
minus one (1) centimeter for 3 locations maximum each 100 m interval.
Selected material shall be placed wherever required. Where discrepancies
are found in the work the Contractor shall make necessary corrections in a
manner approved by the Engineer.

2/17.7 Grade, level, shape and compact the embankment surface to a uniform
cross-section. At the end of each day's operations, all ruts and depressions
that could hold water should be eliminated.

2/17.8 Hauling, grading and leveling equipment passage should be distributed

over the width and length of each layer of material to avoid channelization.
This action should be practiced during all stages of the road construction.

2/17.9 Use a tamping foot roller to compact embankment side slopes by walking
with a dozer, or by over-building the fill and then removing excess material
to the final slope line. For steeper slopes, compact the slopes as
embankment construction progresses.

2/17.10 In cases where placing embankment is on one side of abutments (bridge

construction), wing walls, piers, or culvert headwalls, use the recommended
compaction methods that prevent excessive pressure.

2/17.11 In cases where placing embankment material is on both sides of a concrete

wall or box structure, conduct operations so compacted embankment

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 17 SECTION 2 SITE CLEARANCE AND EARTHWORKS

material is at the same elevation on both sides of the structure under

construction.

2/17.12 Place embankment material in horizontal layers not exceeding 250mm in

compacted thickness. In cases where material composed predominately of
boulders and rock fragments of size more than 25centimeter, incorporate
oversize boulders or rock fragments into the embankment layers by
reducing the size of these boulders or placing them individually.

2/17.13 in cases where material composed predominately of boulders or rock

fragments too large for 25 centimeter layers, these materials may be placed
in layers up to 60cetimeters thick. Incorporate oversize boulders or rock
fragments into the 600mm layer by reducing them in size or placing them
individually. Place sufficient earth and smaller rocks to fill the voids.

2/17.14 Ditches, Slope, grade, and shape ditches. Remove all projecting roots,
stumps, rock, or similar matter. Maintain all ditches in an open condition
and free from leaves, sticks, and other debris. Complete slopes, ditches,
culverts, and other underground minor structures before placing aggregate
courses. Slope, shape, and finish as follows:

(a) Slopes. Leave all earth slopes with uniform roughened

surfaces, with no noticeable break as viewed from the road.
Except in solid rock, the bottoms and tops of all slopes including
the slopes of drainage ditches shall be “rounded to remove
sharp angular faces. If a slide or slip out occurs on a cut or
embankment slope, remove or replace the material, and repair
or restore all damage to the work. Bench or key the slope to
stabilize the slide. Reshape the cut or embankment slope to an
acceptable condition..
(b) Shaping: shape the subgrade to a smooth surface to the cross
section and to the cross section required. Shape slope to
gradually transition into slope adjustment without noticeable
breaks. At the ends of cuts and embankments, adjust slope in
the horizontal and vertical planes to blend into each other or into
natural ground.
(c) Finishing. Remove all material larger than 50mm from the top
15 centimetres of the roadbed. Remove unsuitable material
from the roadbed, and replace it with suitable material.

2/18 MOISTURE CONTROL REQUIREMENTS

2/18.1 When the moisture content of the embankment soil does not fall within +
3% of the optimum moisture content, water shall be added and thoroughly
mixed into the soil, by approved methods or the material shall be aerated,
whichever is needed to adjust the soil to the proper moisture content.

2/18.2 The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide moisture content in the
soil within the required range plus a reasonable amount to compensate for

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 18 SECTION 2 SITE CLEARANCE AND EARTHWORKS

evaporation and other unavoidable losses. Water added in excess of this

amount shall be considered as excess water and must be removed by
aeration or other suitable means as directed by the Engineer. Satisfactory
methods and sufficient equipment shall be used for the furnishing and
handling of the water so that there will be no undue loss due to evaporation
or waste. If water is added to cut areas or borrow pits, the surface of the
areas or pits shall be maintained in such a manner that will prevent undue
loss of moisture and segregation.

2/18.3 Use of saline water for earthworks will only be permitted if the percentage
of water soluble salts in the compacted fill does not exceed 5% by weight of
dry soil when tested in accordance with BS 1377 Part 3 : 1990 tests 5 & 7,
AMD 9028:1996 for SO3+Cl).

2/18.4 For subgrade material moisture range refers to sub clause 2/13.4.

2/19 TESTING METHODS

2/19.1 A dry density moisture content relationship test in accordance with BS 1377
Part 4 : 1990 (method 3.5 or 3.6, AMD13925-2002 ) will be made for each
type of soil to be used in the construction of the work to determine the
Maximum Dry Density, the Optimum Moisture Content and the Moisture
Range required of the soil for satisfactory compaction. The Field Density
and actual Moisture Content of the compacted embankment shall be
determined by field tests according to BS 1377 Part 9: 1990 (method 2.1 or
2.2), AMD17229-2007.

2/19.2 Insitu density of dune sand shall be determined in accordance with B.S.
1377 Part 9 Test 2.1 or 2.2:1990, AMD 17229: 2007. However, where
conventional sand replacement measurement of field density cannot be
undertaken the suitability of the fill material shall be determined using the
Clegg Impact Soil Tester in accordance with ASTM D5874 - 02(2007). A
minimum Impact Value (CIV) = 8 (which corresponds to a CBR value of
8%) shall be achieved.

2/20 MINIMUM TEST REQUIREMENTS

2/20.1 For the Contractor's general guidance, the following tests will be required
prior to use, and during the construction of the embankment and of the
subgrade.

EMBANKMENT

2/20.2 Soil samples for Soil classification according to BS 1377: Part 1 and Part 2:
1990 latest edition, laboratory moisture/density relationship tests and
California Bearing Ratio shall be taken prior to use, from any proposed
source of material. Each sample shall represent not more than 5,000 Cu.m
of stockpiled material or part of as directed by the Engineer. Sampling shall
be in accordance with ASTM D75: 2009, BS 1377 Pt 1: 1990 and BS
5930:1999.
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 19 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/20.3 For every completed layer of fill, at least FOUR (4) field density tests shall
be performed for every unit of carriageway (One unit being 2250 Sq.m.) or
as directed by the Engineer. Every compacted layer shall be compacted to
not be less than 95% of MDD.

IMPROVED SUBGRADE

2/20.5 Samples for Soil classification, laboratory moisture density relationship

tests and CBR tests shall be taken prior to use, from any proposed source
of material. Each sample shall represent not more than 3,000 Cu.m of
stockpiled material or as part of as directed by the Engineer.

2/20.6 For every completed layer of subgrade, three field density tests shall be
performed on each unit of carriageway. (One unit being 1500 Sq.m) or as
directed by the Engineer.

2/20.7 The frequency of field compaction tests on the shoulders shall be three
every unit constructed or as directed by the Engineer (One unit being 1500
Sq.m).

ROCKFILL
2/20.8 Where embankments to be compacted are formed of material consisting
predominantly of rock fragments of such size that the material cannot be
placed in layers of the thickness prescribed without crushing, pulverizing or
further breaking down the pieces resulting from normal excavation
methods, the material may be placed in the embankment in layers not
exceeding a thickness twice the average size of the larger rocks, except
that no layer shall exceed 600 mm of loose measurement.

Materials shall be carefully placed so that all large stones will be well
distributed and the voids completely filled with smaller earth, sand or gravel
to form a solid embankment. Each layer shall be bladed or leveled with
motor grader, bull dozer or similar equipment capable of shifting and
forming the layer into a neat and orderly condition. No. rocks larger than
eighty (80) mm in any dimension shall be placed in the top one hundred
and fifty (150) mm of the embankment unless otherwise noted on the
drawings. Conformance to these provisions and compaction in a manner
and to a point of consolidation approved by the Engineer will be considered
as fulfillment of the requirements for the type of compaction shown on the
drawings.
Normally, compaction tests will not be performed in these areas but the
Engineer reserves the right to test compaction in some other manner if he
deems a test necessary to ensure consolidation. Each layer must be
approved by the Engineer before the next layer is placed.

Embankments, which are formed of materials that contain rock but also
sufficient compatible material other than rock or other hard material to
make rolling feasible, shall be placed and compacted in the manner and to
the point of consolidation approved by the Engineer. Moisture shall be

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 20 SECTION 2 SITE CLEARANCE AND EARTHWORKS

added as directed by the Engineer. Compaction tests will be made

wherever the Engineer determines they are feasible and necessary. Each
layer must be approved by the Engineer before the next layer is placed.

2/21 CRUSHED STABILISING MATERIAL

2/21.1 In the event the foundation on which the embankment or the subgrade
materials will be laid is saturated by water and unstable, the Engineer may
decide to lay crushed granular material to stabilize the foundation.
Stabilising crushed material shall not be laid directly on ground soil but it
shall always be laid on Geotextile fabric covering the area to be stabilised
as shown on the drawings or directed by the Engineer.

2/21.2 Such stabilising crushed material when tested in accordance with BS EN

933-1:1997 or BS 1377 Part 2: 1990 method 9.2 or 9.3 latest edition, shall
have the following gradation listed in Table 2-6:-

Table 2- 6: Stabilising crushed material gradation

SIEVES (mm) % PASSING
50 100
25 80 - 100
12.5 60 - 85
5 40 - 70
2 20 - 50
0.85 5 - 25
0.425 0 - 10
0.180 0 - 2

2/21.3 The stabilising crushed material shall have the following characteristics
shown in Table 2-7 below:-

Table 2- 7: Stabilising crushed material characteristics

Material characteristic Limit

Los Angeles Abrasion (ASTM C-131:2006 or Not more than 30% loss
ASTM C-535:2009)
Bulk Specific Gravity (ASTM C-127:2007 Not less than 2.65
and C-128:2007a)
Absorption (ASTM C-127:2007 and Not more than 2.0%
C-128:2007a)

2/21.4 The stabilising crushed material will be laid in layers of 15 cm and

compacted until the foundation is fully stabilised such that the total
thickness of the stabilising layer shall not be less than 30 cm. Only after
inspection and approval by the Engineer the Contractor may be allowed to
continue the construction of the embankment with other layers of
embankment material and/or subgrade material. The Engineer may
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 21 SECTION 2 SITE CLEARANCE AND EARTHWORKS

decide, after having taken the levels of the existing water table in the area,
and keeping in consideration the finished road levels, to excavate portions
of the foundation saturated by water, disposing of the excavated material,
and replacing it with stabilising crushed material.

2/21.5 Before starting any stabilising of the foundation the Engineer will instruct
the Contractor specifying the areas to be stabilised and the final levels to
be reached with the stabilising crushed material.

2/21.6 Alternative methods of soft area treatment which may be directed by the
Engineer are:

1) Non-friable boulders of sizes between 150-300mm shall be end

dumped over the soft area and rolled until the area is stabilized to
the satisfaction of the Engineer. Further stones of 10-70 mm size
shall be rolled into the area until all the areas are leveled and well
blinded.
2) Crushed rock material free from dirt, organic matter, shale and
any other deleterious material. The acceptance criteria shall be
as follows (Table 2-8):

Table 2- 8: Acceptance criteria Crushed Rock Material

Grading (BS EN 933-1 and BS 1377 Part 2 method 9.2 or 9.3:
1990, AMD 9027: 1996)
Sieve (mm) % Passing
150 mm 100
100 mm 80 - 100
37.5 mm -
25 mm 20 - 50
19 mm -
9.5 mm 0 -15

Physical Requirements
All aggregate materials shall comply with the requirements of sections
2/20.8 and 2/21 of the General Specifications in addition to the following:

Soundness(Magnesium Sulfate, 5 cycles), tested according to (ASTM C

88-2005) = 12% Max

2/22 GEOTEXTILE FABRIC

2/22.1 In areas where the Engineer deems the use of Geotextile fabric necessary,
the Contractor shall furnish and place Geotextile fabric as specified and as
directed by the Engineer.

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 22 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/22.2 The Geotextile fabric furnished by the Contractor shall be of an approved

grade suitable for placement over fine sand. The Geotextile fabric shall be
a woven or non-woven fabric consisting only of long chain polymeric
filaments or yarns formed into a stable network such that the filaments or
yarns retain their relative position to each other. The fabric shall be
stabilised against ultra violet light, inert to commonly uncounted chemicals
and chemical properties of the insitu soil and water, and it shall conform to
the following minimum requirements Table 2-9:

Table 2- 9: Geotextile fabric specifications

Weight (DIN 53854) 140 g/m2
Thickness under load (2KN/sq.m) 0.7 mm
(DIN 53855)
Tensile Strength (200mm width) 1.6 KN
ASTM D1682
Puncture Resilience (DIN 54307) 1.5 KN
Permeability (DIN 60500) 50 L/sq.m/s
Ultraviolet Stability ASTM 4355 50% after 750 hours
exposure
Burst Strength ASTMD4632 & ASTM3786 2.1 KN

2/22.3 The surface to receive the Geotextile fabric shall be prepared to a relatively
smooth condition free of obtrusions, depressions, and debris. The
Geotextile fabric shall not be laid in a stretched condition, but shall be laid
loosely with the long dimension parallel to the centerline of the roadway. In
the event that the width of the proposed area for fabric requires more than
one panel width of fabric, the panels shall be overlapped a minimum 15
percent of the panel width. Longitudinal joints in the fabric shall have an
overlap of 50cm. To prevent slippage of the overlapping fabric, the areas
of overlap shall be stabilised as approved by the Engineer with pins, anchor
blocks, or aggregate piles. In the event construction machinery is used to
place the fabric, the working platform for the machinery shall be the soil and
not the previously laid fabric.

2/22.4 Prior to placement of the stabilising crushed material the Contractor shall
spread a layer of sand over the Geotextile fabric as directed by the
Engineer. A 5cm thick layer of Crushed Sand which grading limits are
shown below shall cover the Geotextile fabric.

Table 2- 10: Crushed Sand grading

Sieve opening mm % Passing
4.75 100
2.00 66 - 92
0.425 30 - 50
0.150 12 - 28
0.075 5 - 15
Alternatively, Dune sand can be used for blinding and protecting the Geotextile
from puncture or tearing provided the required properties are met.

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 23 SECTION 2 SITE CLEARANCE AND EARTHWORKS

The aggregate material shall not be dumped directly on the fabric, nor
shall haul trucks be run on the fabric. The aggregate shall be spread by
a wheeled front-end loader.

The blade or bucket shall be kept sufficiently high so that the aggregate is
not being pulled over the fabric, but being dropped at a minimum height to
the satisfaction of the Engineer.

2/22.5 Fabric damaged or displaced before or during installation or during

placement of overlaying aggregate material shall be replaced or repaired to
the satisfaction of the Engineer at the Contractor's expense.

2/23 EXCAVATION FOR STRUCTURES

2/23.1 This work shall consist of all excavation for structures, culverts, headwalls,
catch basins, manholes, inlets, and retaining walls and shall include all
necessary clearing and grubbing, all necessary bailing, drainage, pumping,
sheeting, strutting and the construction of coffer dams or cribs, if found
necessary, and their subsequent removal; also the disposal of all material
obtained from such excavation and backfilling to the level of the original
ground; it shall include the removal of that portion of existing structures
below the ground which is necessitated by the construction of the new
structure.

2/23.2 Prior to commencing any structural excavation work 1.5 meters or more in
depth, the Contractor shall design and submit to the Engineer for review
and approval, within a minimum period of 1 week before the intended
commencement date, detailed working drawings of the structural
excavation support member materials, sizes, spacing and engineering
calculations to validate their design, including the maximum theoretical
deflections of the support members. The system shall be designed in such
a manner that no raker struts or any other support members extend through
surfaces exposed in the finished construction, and no shoring or bracing is
placed under permanent structures.

2/23.3 The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation
and removal and concrete placement, the anticipated equipment loads,
surcharge loads of any description, the maximum design loads to be
carried by various members of the support system and strut preload forces.

2/23.4 If the structure support system proposed includes tieback anchors, the
Contractor's submittal drawings shall show the profile of the soil in which
each anchor is to be installed, the design load for the full depth of the
excavation, the maximum design and proof loads, surcharge loads of any
description; equipment loads, forces at various stages, support during
installation and removal, and the criteria proposed for deformations under
proof loads. Where a proposed system of tieback anchors projects beyond
the vertical projection of the Contract limit lines shown on the Drawings on
to the adjoining property, the permission of the owner shall be obtained in
writing and such permission submitted to the Engineer at the time the shop
drawings of the support systems are submitted.

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 24 SECTION 2 SITE CLEARANCE AND EARTHWORKS

2/23.5 At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the
hydrostatic pressure and lower the ground water levels below excavation
levels, as required for the safe and proper execution of the work and which
will result in obtaining a stable, dry subgrade for the execution of
subsequent operations. The Contractor shall design dewatering methods
and settling basins so that no critical amounts of soil, sand or silt are
removed during either the initial operations or the construction operations.
Complete working drawings showing the type of dewatering and ground
water control system proposed shall be submitted to the Engineer for his
review.

2/23.6 The Contractor's submittal drawings shall show the arrangement, location
and depths of the proposed dewatering system if required. A complete
description of the equipment and materials to be used and the procedures
to be followed shall be shown, together with the standby equipment,
standby power supply and the proposed location or locations of points of
discharge of water. Any required dewatering system design shall also
include the measures taken to prevent damage due to settlement of
pavement, utilities, sewers, buildings and other structures outside the
excavation but within the area affected by the procedures.

2/23.7 The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Professional
Engineer approved by the Engineer specializing in this type of design work.
Approval of the designs and shop drawings shall not relieve the Contractor
of the adequacy and performance of these temporary works.

2/23.8 Preconstruction Inspection prior to the beginning of construction, the

Contractor and the Engineer shall make a detailed inspection of all adjacent
buildings, pavements, wells and other structures in order to determine its
pre-construction condition and the Contractor shall prepare, for the
Engineer's approval, a typed Inspection report of the findings.

2/23.9 The Report shall include photographs, drawings and sketches with levels
and dimensions illustrating the structures condition, noting in particular any
existing damage or structural inadequacy. Deficiencies and damage shall
be suitably marked on the structure such that it is not permanently defaced.

2/23.10 Three copies of the Report shall be submitted for the approval of the
Engineer. Once approved, five additional copies shall be supplied to the
Engineer.

2/23.11 The Contractor shall notify the Engineer sufficiently in advance of the
beginning of any excavation so that cross-sectional elevations and
measurements may be taken of the undisturbed ground. The natural
ground adjacent to the structure shall not be disturbed without the
permission of the Engineer.

2/23.12 Trenches or foundation pits for structures or structure footings shall be

excavated to the lines and grades or elevations shown on the drawings, or
as ordered by the Engineer. They shall be of sufficient size to permit the
placing of structures or structure footings of the full width and length shown.

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 25 SECTION 2 SITE CLEARANCE AND EARTHWORKS

The elevations of the bottoms of footings, as shown on the Drawing shall

be considered as approximate only and the Engineer may order, in writing,
such changes in dimensions of elevations of footings as may be deemed
necessary, to ensure a satisfactory foundation.

2/23.13 Unless otherwise provided for in the Drawings or Contract Documents or

directed by the Engineer Structural excavation shall be carried out for a
width of at least 500mm beyond the horizontal outside limits of the
foundation, footing, box culvert or structural member to which the
excavation relates. Concrete blinding or sub-foundations are not to be
considered as structure for the purpose of defining such excavation.

2/23.14 If during the progress of the work, loose or improperly compacted soil is
encountered below the structural foundation levels, or adjacent thereof,
which is the result of prior removal of utilities or structures, such material
shall be completely removed within the limits as directed by the Engineer,
backfilled with suitable material and it should be not less than 95% of the
maximum dry density as determined by BS 1377 Part 4 : 1990 (method 3.5
or 3.6, AMD 13925: 2002). Any previous excavations encountered which
would in the opinion of the Engineer be detrimental to load distribution of
new foundations to the underlaying soil, shall be excavated and backfilled
with Class 25 concrete (clause 4/15).

2/23.15 After each excavation is completed, the Contractor shall notify the
Engineer, for approval of the depth of excavation and the character of the
material, prior to further structural works. Any over excavation shall be
backfilled with Class 25 concrete (clause 4/15) at the Contractors expense.

2/23.16 All rock or other hard foundation material shall be cleaned of all loose
material and cut to a firm surface, either level, stepped, or serrated as
directed by the Engineer. All seams or crevices shall be cleaned and
grouted. All loose and disintegrated rock and thin strata shall be removed.

When the footing is to rest on material other than rock, excavation to final
grade shall not be made until just before the footing is to be placed and
special care shall be taken not to disturb the excavation. When the
foundation material is soft or otherwise unsuitable as determined by the
Engineer, the Contractor shall remove the unsuitable material and backfill
with approved granular material. This foundation fill shall be placed and
compacted in 150mm layers up to the foundation elevation and compacted
to not less than 95% of the maximum dry density as determined by BS
1377 Part 4 : 1990 (method 3.5 or 3.6, AMD 13925: 2002).

The placing of concrete shall follow as closely as practicable the structural

excavation.

2/23.17 Control of Ground Water- Prior to the commencement of construction at

any particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area
which in the opinion of the Engineer is likely to be affected by the
dewatering. The number, location and depth of all standpipes shall be to
the satisfaction of the Engineer.

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 26 SECTION 2 SITE CLEARANCE AND EARTHWORKS

- The Contractor shall check ground water levels at weekly or

where instructed by the Engineer, more frequent intervals and
submit within 24 hours written reports to the Engineer in a form
to be agreed.
- In the case of uncontrolled flow of water into any excavation, the
Engineer reserves the right to order an immediate cessation of
work and to order the Contractor to take immediate action to
control the inflow of water. Such actions and remedial works
shall be to the Engineer's approval.
-
2/23.18 Notification of Damage - The Contractor shall notify the Engineer
immediately of any movement or any damage not noted in the
pre-construction report, to any structure. The Contractor shall immediately
cease his construction operations in the vicinity and shall take immediate
action to prevent further movement or damage. The Contractor shall keep
the Engineer fully informed of all such action.

2/23.19 Remedial and Preventive Works - Should remedial works be necessary

due to damage caused to the structure or should the Engineer direct the
contractor to carry out any works necessary to prevent damage to the
structure due to the Contractor's construction works, the Contractor will
present, without delay, detailed drawings and specifications, as necessary,
showing his proposed remedial or preventive works for the Engineer's
approval.

In either case the Contractor will suspend all construction activities in the
vicinity of the structure until such time as the remedial or preventive works
are carried out to the Engineer's satisfaction at the Contractor's expense.

2/23.20 Post Construction Inspection - On completion of, but prior to final

acceptance of the works, the Contractor and the Engineer shall re-examine
the structure to determine any change from the original conditions. The
Contractor shall supply to the Engineer for approval five copies of a report
describing measures he proposes to take to correct any damage which
resulted from the construction of the works. The approved corrective
measures shall be carried out by the Contractor at his expense, to the
Engineer's satisfaction before final acceptance of the works.

2/23.21 Utilisation of Excavated Materials - All excavated material determined as

suitable by the Engineer, shall be utilised as backfill or roadway fill. The
surplus material shall be disposed of as specified in sub-section 2/8
paragraph 2. Excavated material shall not be deposited, at any time, so as
to endanger the partly finished structure or cause an obstruction of any
kind. All unsuitable material shall be disposed of to disposal sites that have
been approved for use.

2/23.22 Backfill - Excavated areas around structures shall be backfilled with

excavated materials or imported granular material approved by the
Engineer. Backfill materials shall be placed in horizontal layers not
exceeding 20cm in depth after compaction, or as directed by the Engineer,
and compacted to not less than 95% of the maximum dry density as
determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6, AMD 13925:
2002). The field density shall be determined by BS 1377 1990 Part 9:

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 27 SECTION 2 SITE CLEARANCE AND EARTHWORKS

(Method 2.1 or 2.2, AMD 17229: 2007). Each layer of material shall be
moistened or dried as required to enable thorough compaction as specified.
Backfill shall be placed to the original ground level or as indicated on the
drawings.

The specifications for chemical tests shall be as mentioned in the Table

given on this page

Table 2- 11: Sub Base, Road Base, Wet Mix specifications

Test Method Specifications

Acid soluble Chloride BS 812:P 117:1988 1.0% max
Acid soluble Sulphate BS EN 1744-1:1998 0.5% max
Organic matter content BS 1377: P3:1990 0.2% max
M3

2/23.23 Backfill or embankment shall not be placed behind the walls of concrete
structures or rigid frame structures until the top slab is placed and cured.
Backfill and embankment behind abutments when held at the top of the
superstructure shall be carried up simultaneously behind opposite
abutments. Backfill shall be carried up equally on either sides of box
culverts.

2/23.24 For frequency of testing of backfill material refer to sub-section 2/20.

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 Section 3
Pavement Construction
 SECTION 3 PAVEMENT CONSTRUCTION
1

TABLE OF CONTENTS

3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS .................................... 3

3/2 TESTING OF AGGREGATES ........................................................................... 3
3/3 APPROVAL AND INSPECTION OF AGGREGATES ....................................... 3
3/4 STORAGE OF AGGREGATES ......................................................................... 4
3/5 TIDYING-UP OF QUARRY AREA ..................................................................... 5
3/6 GRANULAR SUB-BASE .................................................................................... 5
3/7 AGGREGATE ROADBASE DESCRIPTION ..................................................... 8
3/9 SPREADING (AND MIXING) AGGREGATE ROADBASE.............................. 10
3/10 COMPACTION OF AGGREGATE ROADBASE ............................................. 11
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE ............................. 11
3/12 FINISHING OF AGGREGATE ROADBASE .................................................... 12
3/14 WET MIX MACADAM ROADBASE, DESCRIPTION ...................................... 13
3/15 WET MIX MACADAM ROADBASE MATERIAL .............................................. 13
3/16 TRANSPORT AND SPREADING WET MIX MACADAM ROADBASE .......... 15
3/17 COMPACTION TRIALS OF WET MIX MACADAM ROADBASE ................... 15
3/18 COMPACTION OF WET MIX MACADAM ROADBASE ................................. 16
3/19 FINISHING OF WET MIX MACADAM ROADBASE........................................ 16
3/20 MINIMUM TEST REQUIREMENTS FOR WET MIX MACADAM ROADBASE
.......................................................................................................................... 17
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION ...................................... 17
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE ............... 17
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE ......................... 19
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE ............................ 19
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES ........... 20
3/26 BITUMEN BINDER ........................................................................................... 22
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES......................................... 23
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS............................ 27
3/29 PREPARATION OF BITUMEN BINDER ......................................................... 28
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX ........ 28
3/31 PREPARATION OF BITUMINOUS MIX .......................................................... 28
3/32 SURFACE PREPARATION ............................................................................. 29
3/33 PLACING OF THE MIX .................................................................................... 29
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE ......................... 32
3/35 BITUMINOUS LEVELLING COURSE ............................................................. 33
3/36 THICKNESS CORES ....................................................................................... 33
3/37 COMPACTION OF BITUMINOUS LAYERS.................................................... 34
3/38 RE-ROLLING OF BITUMINOUS COURSES .................................................. 35
3/39 CONTACT SURFACES ................................................................................... 35
3/40 JOINTS IN BITUMINOUS PAVING ................................................................. 36
3/41 PROTECTION OF COMPACTED LAYER ...................................................... 39
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES ............................... 39
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES ............................. 40
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS .................................. 41
3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES .. 42
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS ............................... 43
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES ............. 43
3/48 BITUMINOUS PRIME COAT ........................................................................... 43
3/49 BITUMINOUS TACK COAT ............................................................................. 45

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 SECTION 3 PAVEMENT CONSTRUCTION
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3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT ......... 46

3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION .............. 46
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT .......... 47
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT ......... 48
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE
TREATMENT ................................................................................................... 48

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 SECTION 3 PAVEMENT CONSTRUCTION
3

3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS

3/1.1 All aggregates for use in the construction of the pavement Layers shall be
obtained only from sources approved by the Engineer.

3/1.2 The contractor shall have determined the location, suitability and quantity of
material available before tendering as well as the cost and the amount of
work required to extract, crush, screen and clean the material and the length
of haul to the job site.

3/1.3 The Contractor shall provide the Engineer, within thirty (30) days prior to the
scheduled beginning of the crushing and screening operations, with a
complete report on the origin and composition of all stone and/or gravel
aggregates to be used in the Work (Aggregate Resources Report/
Petrographic Study, ASTM C295). All materials shall comply with the
specified requirements for the various aggregates.

3/1.4 The source and manufacture of the aggregates which will meet the
requirements of the Specification is the sole responsibility of the Contractor.
It is also the contractor's sole responsibility to manufacture such aggregates
at the rates and in the quantities required to complete the work within the
specified Contract Period.

3/1.5 The approval of the Contractor's crushing and screening plant equipment by
the Engineer shall in no way relieve the Contractor of the responsibility of
producing aggregates which meet the Specifications and in the quantities
required for the completion of the work within the specified Contract Period.

3/1.6 No aggregate producing equipment shall be put into operation prior to the
approval of the equipment by the Engineer. If after the equipment is put into
operation it fails to perform as proposed, the Contractor shall provide
additional equipment or replace the original equipment with more suitable
equipment, as may be directed by the Engineer.

3/1.7 The Contractor shall commence crushing and screening of aggregate

immediately after the Contractor receives approval of his aggregate sources.

3/2 TESTING OF AGGREGATES

3/2.1 Testing to ascertain the properties of all aggregate materials shall be carried
out in accordance with Clause 1/7.

3/3 APPROVAL AND INSPECTION OF AGGREGATES

3/3.1 All sources of aggregates shall be quality tested by the Contractor and, if
satisfactory, approved by the Engineer prior to the processing of material
from such sources. An individual source of aggregate is deemed to be a
particular location within a quarry or borrow pit where material of a constant
specific gravity is obtained (with possible variation due to minor changes in
characteristics of rock). Test certificates obtained by the Contractor or test

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 SECTION 3 PAVEMENT CONSTRUCTION
4

performed by the Contractor at his expense are intended to assist him in his
estimate of the location, extent and quantities which will comply with the
Specifications, when properly processed, and will in no way obviate the
need for future testing by the Engineer.

3/3.2 Only materials from approved sources shall be processed for incorporation
into the work. Approval of specific sources of materials shall not be
considered as final approval and acceptance of materials from such
sources. The presence of weathered materials discovered in the quarry
areas shall be a cause of rejection of the source of materials.

A quarry is defined as an open excavation or pit from which stone is

obtained by digging, cutting, or blasting. It includes all the materials, whose
chemical, physical and mechanical properties are adversely affected by any
inclement weather in addition to the contamination from the surrounding
environment.

3/3.3 After having received approval of specific sources of material the Contractor
cannot change these without prior written approval of the Engineer.

3/3.4 All processed materials shall be tested and approved before being stored on
the site or incorporated in the works and may be inspected and tested at any
time during the progress of their preparation and use. Questionable
materials, pending laboratory testing and subsequent approval shall not be
unloaded and incorporated with materials previously approved and
accepted.

Questionable materials are defined as material contaminated adversely by

the inclement weather. It is the material that is suspected to be considered
as unsuitable for road works and must be tested for suitability requirements
and stockpiled separately on site prior to it’s use.

3/3.5 If the grading and quality of the material delivered to the site does not
conform to the grading and quality as previously inspected and tested, or
does not comply with the Specifications, the Engineer reserves the right to
reject such material at the site of the work.

3/3.6 Samples must meet all test requirements as specified under the
Specifications. The Contractor shall permit the Engineer to inspect any and
all material used or to be used, at any time during or after its preparation, or
while being used during the process of the work or after the work has been
completed. All such materials not complying with the required specifications,
whether in place or not, shall be rejected and shall be removed promptly
from site The Contractor shall supply, or arrange with any producers or
manufacturers to supply, all necessary material, labour, tools and equipment
for such inspection.

3/4 STORAGE OF AGGREGATES

3/4.1 The stockpile site shall be prepared by clearing and smoothing and must be
approved by the Engineer. Prior to any stockpiling of aggregates, cross-

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 SECTION 3 PAVEMENT CONSTRUCTION
5

sections of the stockpile site shall be taken and control points established for
use in determining the quantity of subsequently stockpiled material.

3/4.2 The equipment and methods used for stockpiling aggregates and for
removing aggregates from the stockpiles must be approved by the Engineer
and shall be such that no segregation of the aggregate will result and no
foreign material will contaminate the aggregate.

3/4.3 Material shall be stored in a manner that will ensure preservation of their
specified quality and fitness for the work. They shall be placed on hard,
clean surfaces and, when required by the Engineer they shall be placed
under cover. Stored materials shall be located in such a manner to facilitate
prompt inspection and control.

Private property shall not be used for storage purposes without written
consent of the owner or lessee and payment to him, if necessary, at the
Contractor's expense.

3/4.4 The centre of the storage area shall be elevated and sloped to the sides in
order to provide proper drainage of excess moisture. The material shall be
stored in such a way to prevent segregation and to allow proper control of
moisture. Aggregate stockpiles shall be built up in layers not exceeding one
(1) meter. The height of each stockpile shall be limited to a maximum of five
(5) meters.

3/4.5 Sufficient material must be stored in stockpiles to allow for testing and
approval of such materials prior to use in the works.

3/5 TIDYING-UP OF QUARRY AREA

3/5.1 The Contractor shall tidy up the quarry areas on completion and ensures
that side slopes are not steeper than 1 to 2 and in a condition acceptable to
the Employer and to the Engineer.

3/6 GRANULAR SUB-BASE

3/6.1 DESCRIPTION

Granular sub-base shall consist of furnishing, spreading, and compacting

sub-base in accordance with the details shown on drawings and these
Specifications.

3/6.2 MATERIALS,TESTS AND STANDARDS

Granular sub-base material for Road sub-base shall consist of hard, durable
natural/screened gravel, recycled or crushed stone, and shall be free from
clay balls or other deleterious substances. Granular sub-base shall be well
graded and lie within the grading envelope stated below when tested in
accordance with BS 1377: Part 2: 1990: Test 9.2, AMD 9027: 1996.

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 SECTION 3 PAVEMENT CONSTRUCTION
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The material should have a minimum soaked CBR value of 30% at 95% of
maximum dry density and should comply with Clause 3/6.4. Organic matter
content (BS 1377 Part 3: 1990 Method 3, ADM 9028:1996) shall not exceed
0.2%.
The grading of granular subbase is dependent upon the maximum sized
aggregate and shall comply with Grading A or B listed in Table 3-1 as
determined from BS 1377: Part 2: 1990, AMD 9027:1996: Test 9.2:-

Table 3- 1: Grading requirements for granular subbase

Sieve Size Percent Passing Percent Passing
Gradation A (Note 1) Gradation B (Note 2)
50.0 mm - 100
37.5 mm 100 75- 100
25.4 mm 70-100 55- 85
20 mm 60- 90 50- 80
10 mm 45- 75 40- 70
5 mm 30- 60 30- 60
2.36 mm 20- 50 20-50
0.60 mm 10-30 10-30
0.075 mm 0-10 0- 10
Note 1: Gradation A will provide a more density, better compaction and binding and
mainly fits requirements of heavily trafficked roads
Note 2: Gradation B is preferred for subgrade of low CBR

3/6.3 SUBBASE CONSTRUCTION

Road sub-base material shall be delivered to the roadbed as uniform

mixture and shall be spread in layers or windrows. Segregation shall be
avoided and the sub-base shall be free from pockets of coarse or fine
materials.

Each road sub-base layer shall be spread by finisher and or grader or other
approved mechanical methods, watered, shaped to a compacted thickness
not exceeding 150 mm and compacted to the required grade and cross-
section. If the contractor can demonstrate that compaction and compaction
test requirements can be achieved in layers exceeding 150mm but not more
than 170mm, approval may be sought from the engineer.

Route hauling equipment shall be uniformly distributed over the full width of
the surface to minimize rutting or uneven compaction.

Compaction shall be accomplished over the full width of each layer by

compacting from the sides to the center, parallel to the centerline of the
road.

Along curbs, headers, walls, and all places not accessible to the roller,
compact the material with approved vibratory rollers or compactors.

At the time of compaction, the moisture content of the laid material shall not
vary by more that + 2 % from the optimum moisture content.

The granular sub-base shall be compacted to not less than 95 % of the

maximum dry density determined in accordance with BS 1377 Part 4: 1990,
AMD 13925: 2002, Method 3.6. Particle size analysis of soils for sieve

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 SECTION 3 PAVEMENT CONSTRUCTION
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analysis of fine and coarse aggregate shall be carried out in accordance

with BS 1377: Part 2: 1990: Test 9.2.
.
The surface on completion of compaction shall be well closed, free from
movement under compaction plant and free from ridges cracks or loose
material. The finished surfaces of the road sub-base shall not vary at any
point more than 10 mm above or below the grade established by the
Engineer.

The road sub-base shall be maintained in a condition satisfactory to receive

any subsequent base or surfacing material. Sub-base which does not
conform to the above requirements shall be reshaped or reworked, watered
and thoroughly re-compacted to conform to the specified requirements.

3/6.4 RELEVANT TEST AND STANDARDS

The standards listed in these specifications shall be the latest version at

time of use. The latest version may differ from the version listed at time of
writing of these General Specifications. The following tests should be carried
out and the materials shall conform to the following requirements (Table 3-
2):

Table 3- 2: Test properties for subbase

TEST STANDARD LIMIT

Sampling ASTM D75: 2009 --

Los Angeles Abrasion ASTM C131-2006 or 30 % max.

ASTM C535-2009
Soundness (Magnesium ASTM C88-2005 12 % max.
Sulphate Solution -5 cycles)

Liquid Limit BS 1377 Part 2: 1990 35 % max.

Test 4.5 and 9.3 AMD 9027-1996

Plasticity Index BS 1377 Part 2: 1990 6 max.

Test 5.4, AMD 9027-1996

Linear Shrinkage BS 1377:Part 2: 1990, Method 6.5, 3 % max.

AMD 9027-1996

Soaked CBR at 95 % of BS 1377 Part 4: 1990 30 % min.

Maximum dry density (96 Test 7, AMD8259:1995&AMD
hour soaked) 13925-2002.

Sulphate Content BS EN 1744-1:1998 0.5 % max.

(Acid soluble)

Chloride Content BS 812: 1988: Part 117 1 % max.

(Acid soluble)
Sand Equivalent Value ASTM D-2419-2009 25% min

Organic Matter Content BS 1377 Part 3:1990 Method 3, 0.2%

AMD 9028-1996 maximum

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 SECTION 3 PAVEMENT CONSTRUCTION
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3/6.5 MINIMUM TEST REQUIREMENTS FOR GRANULAR SUBBASE

One sample every 3000 cu m of stockpiled or part of as directed by the

Engineer shall be tested for Grading, Plasticity Index, Maximum Dry Density,
and Loss Angeles Abrasion (Table 3-3).

Where the contractor can demonstrate product uniformity, less frequent

sampling to every 5000 cu. m of stockpiled may be approved by the
engineer with firm adherence to the same requirements and testing
frequency for the 3000 cu.m.
.
A minimum of four in-situ density tests shall be made in every Lot
(Approximately 1500 sq.m) of granular sub-base laid or as directed by the
Engineer.

Table 3- 3: Table 1 Testing frequencies for subbase

TEST FREQUENCY
Sampling One per 3000 cu.m
Grading One per 3000 cu.m
Liquid Limit One per 3000 cu.m
Plasticity Index One per 3000 cu.m
Linear Shrinkage One per 3000 cu.m
Los Angeles Abrasion One per 3000 cu.m
Maximum Dry Density (Proctor) One per 3000 cu.m
Soundness (Magnesium Sulphate Solution - 5 cycles) One per 3000 cu.m
Soaked C.B.R. at 95 % of Maximum dry density One per 3000 cu.m
Organic Matter Content One per 3000 cu.m

3/7 AGGREGATE ROADBASE DESCRIPTION

3/7.1 This work shall consist of furnishing and placing one or more courses of
aggregate, including binder soil if required, on a prepared subgrade or
sub-base in accordance with sub-section 3/8 to 3/13 of the Specifications, in
conformity with the lines, grades, thickness and typical cross-sections
shown on the drawings or established by the Engineer.

3/8 AGGREGATE ROADBASE - MATERIAL TESTS AND STANDARDS

3/8.1 All aggregate roadbase material shall be free from dirt, shale or other
deleterious matter and shall be of such quality that it will bind readily to form
a stable aggregate roadbase.

3/8.2 The standards listed in these specifications shall be the latest version at
time of use. The latest version may differ from the version listed at time of
writing of these general specifications. The requirements for aggregate
roadbase are listed in Table 3-4 below:

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 SECTION 3 PAVEMENT CONSTRUCTION
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Table 3- 4: Test properties for aggregate road base

TEST STANDARD REQUIREMENT

Sampling ASTM D75: 2009

Liquid Limit BS 1377 Part 2: 1990 25% maximum

Test 4.5 and 9.3 AMD 9027-
1996

Plasticity Index BS 1377 Part 2: 1990 6 maximum

Test 5.4, AMD 9027-1996

Sand Equivalent ASTM D-2419 - 2009 40 minimum

Loss by Abrasion ASTM C-131:2006 or 25% maximum*

C-535:2009

Flakiness Index BS EN 933-P3-1997, AMD 35 maximum

14866: 2004
Elongation Index BS812 : 1990 Part, Section 35 maximum
105.2

Soundness (Magnesium ASTM C88: 2005 Course aggregate

Sulphate) (5 cycles) = 12% max

Fine Aggregate =
10% max

Organic Matter Content BS 1377 Part 3 : 1990 Method 0.2% maximum

3,AMD 9028-1996

Acid Soluble Chlorides BS 812: 1988 Part 117 1% maximum

(Combined Aggregate)

Acid Soluble Sulphates BS EN 1744-1:1998 0.5% maximum

(Combined Aggregate)

Soaked CBR BS 1377 : Part 4 : 1990: Test 80% minimum

7, ,AMD 8259:1995 & AMD
13925-2002

Aggregate Crushing BS 812-P110:1990 25% maximum

Value

Water Absorption STM C128-2007a & C127- 2.0% maximum

2007 (Coarse aggregate)
2.3% maximum
(fine aggregate)

Maximum Dry Density BS 1377 Part 4 : 1990 2.3 minimum

(MDD) (method 3.5 or 3.6,
AMD13925-2002 )

* This limit for Loss of Abrasion (LOA) is adopted as most of the existing materials have
Max Dry Density of 2.3Mg/Cu.m and exhibit LOA values that ranges from 10% to 18%
as per DCL rerecords.

3/8.3 The gradation limits when tested in accordance with BS 1377: Part 2: 1990:
AMD 9027: 2002 Test 9.2 shall be as follows (Table 3-5): -

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 SECTION 3 PAVEMENT CONSTRUCTION
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Table 3- 5: Grading requirements for aggregate road base

SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 70 – 100
28 mm 55 - 85
20 mm 50 - 80
10 mm 40 - 70
5 mm 30 - 60
2.36 mm 20 - 50
0.425 mm 10 - 30
0.075 mm 5 - 15

Aggregate roadbase shall consist of uniform mixtures of gravel and/or

crushed/recycled gravel with sand, silt and clay, conforming to the specified
gradation limits.

3/9 SPREADING (AND MIXING) AGGREGATE ROADBASE

3/9.1 Aggregate roadbase shall be spread on subgrade or sub-base which has

been approved by the Engineer. Aggregate roadbase which has been
placed on a subgrade or sub-base not approved by the Engineer shall be
removed at the Contractor's expense.

The material shall be spread using a paving machine or motor grader

operated with a mechanism which levels off the material at an even depth
and without delay. If necessary, the material may be a spread with the
grader as and when approved by the Engineer. The road base aggregate
course shall not be placed when the underlying surface is muddy, or when it
is raining or dusting

3/9.2 Aggregate road base shall be spread by finisher and or grader or other
approved mechanical methods, watered, shaped to a compacted thickness
not exceeding 150 mm and compacted to the required grade and cross-
section. If the contractor can demonstrate that compaction and compaction
test requirements can be achieved in layers exceeding 150mm but not more
than 170mm, approval may be sought from the engineer.

3/9.3 The material shall be handled in a manner which avoids segregation.

Segregated materials shall be remixed until uniform. Suitable precautions
shall be taken to prevent rutting of the subgrade or sub-base during the
spreading of aggregate road base materials.

No hauling or placement of material will be permitted when, in the judgment

of the Engineer, the weather or road conditions are such that the hauling
operations will cause cutting or rutting of the subgrade or cause
contamination of aggregate roadbase material.

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3/10 COMPACTION OF AGGREGATE ROADBASE

3/10.1 The moisture content of the aggregate roadbase material shall be adjusted
prior to compaction, by watering with approved sprinkler trucks or by drying
out, as directed by the Engineer, to that required to obtain the specified
density for aggregate roadbase.

Aggregate roadbase shall be compacted to not less than Ninety Eight (98)
percent of the maximum dry density, as determined according to BS 1377:
Part 4: Test 3.6 at a moisture content between ± 1.5 % of the O.M.C. The
field density and actual moisture content shall be determined according to
BS 1377: Part 9: 1990: Test 2.2., AMD 8264:1995.

3/10.2 The aggregate roadbase shall be compacted by means of approved

compaction equipment progressing gradually from the outside of the road
towards the centre with each succeeding pass uniformly overlapping the
previous pass. Rolling shall continue until the entire thickness of each layer
is thoroughly and uniformly compacted to the specified density.

Rolling shall be accompanied by sufficient grader speeding in a manner

approved by the Engineer, to ensure a smooth surface free from ruts or
ridges and having the proper section and crown.

3/10.3 The surface of the material shall on completion of compaction be well

closed, free from movement under the compaction plant and free from
compaction planes, ridges, cracks, or loose material.

3/10.4 Any areas inaccessible to normal compaction equipment shall be

compacted by means of mechanical tampers until satisfactory compaction is
obtained.

3/10.5 The Contractor shall program his operations to avoid the drying out of the
sub-base during construction. If any layer of aggregate roadbase material,
or part thereof, is permitted to dry out after compaction, or does not conform
to the required density or finish, the Contractor shall, at his own expense,
rework, water and re-compact the material, as directed by the Engineer, to
the density specified, before the next layer of aggregate roadbase or
subsequent pavement layers is placed.

3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE

3/11.1 If directed by the Engineer, prior to the commencement of the aggregate

roadbase operations, the Contractor shall construct trial lengths not to
exceed 50 meters. The materials used in the trials shall be those approved
for use as aggregate roadbase, and the equipment used shall be that
according to the Contractor's approved detailed program of work.

3/11.2 Trial lengths may not form part of the permanent works but may be
permitted in the construction of temporary detours of sufficient length.

3/11.3 The objective of these trials is to determine the adequacy of the Contractor's
equipment, the loose depth measurements necessary to result in the

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 SECTION 3 PAVEMENT CONSTRUCTION
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specified compact layers depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.

3/11.4 The Contractor may proceed with the aggregate roadbase work only after
the methods and procedures established in the compaction trials have been
approved by the Engineer.

3/12 FINISHING OF AGGREGATE ROADBASE

3/12.1 Immediately prior to the placing of the first layer of the next pavement
course on to the aggregate roadbase the final layer of aggregate roadbase
shall be at the specified density and to the required grade and section.

In order to maintain these requirements while placing the next course it may
be necessary mechanically sweep or clean with compressed air to remove
the loose material and if necessary to water and reshape the surface of the
aggregate roadbase. This work shall be at the Contractor's expense.

3/12.2 The surface of the finished aggregate roadbase will be tested with a three
(3) meter straightedge by the Engineer at selected locations. The variations
of the surface from the testing edge of the straight edge between any two (2)
contacts with the surface shall at no point exceed ten (10mm) when placed
on or parallel to the centre line or ten (10mm) when placed perpendicular to
the centre line of the roadway.

The aggregate cross section as shown on the drawings shall not vary by
more than ten (10) millimeters from the required elevation. All humps and
depressions and thickness deficiencies exceeding the specified tolerance
shall be corrected by removing the defective work or by adding new material
as directed by the Engineer.

Shallow patching of an area without scarifying the surface to permit proper

bonding of the added material will not be permitted.

3/13 MNIMUM TEST REQUIREMENTS FOR AGGREGATE ROADBASE

A minimum of four in-situ Density tests shall be made per unit (1000 sq. m)
of aggregate roadbase laid or as directed by the Engineer.

Also, One sample every 3000 cu m of stockpile or part of as directed by the

Engineer shall be tested for Grading, Plasticity Index, Maximum Dry Density,
and Loss Angeles Abrasion.

Where the contractor can demonstrate product uniformity less frequent

sampling to every 5000 cu. m may be approved by the engineer. The details
are shown in Figure 3-6 below:-

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Table 3- 6: Frequency of testing for aggregate road base

TEST FREQUENCY
Sampling One per 3000 cu.m
Liquid Limit One per 3000 cu.m
Plasticity Index One per 3000 cu.m

Sand Equivalent One per 3000 cu.m

Loss by Abrasion One per 3000 cu.m

Maximum Dry Density (Proctor) One per 3000 cu.m
Flakiness Index One per 3000 cu.m

Elongation Index One per 3000 cu.m

Soundness (Magnesium Sulphate) (5 cycles) One per 3000 cu.m

*Organic Matter Content One per 3000 cu.m
Acid Soluble Chlorides (Combined Aggregate) One per 3000 cu.m

Acid Soluble Sulphate (Combined Aggregate) One per 3000 cu.m

Soaked CBR One per 3000 cu.m

Aggregate Crushing Value One per 3000 cu.m
Water Absorption One per 3000 cu.m

3/14 WET MIX MACADAM ROADBASE, DESCRIPTION

3/14.1 This work shall consist of furnishing and placing one or more courses of high
quality crushed aggregate, bound by means of carefully controlled moisture
content, on the prepared subgrade or sub-base in conformity to the line,
level and thickness shown on the drawings or as directed by the Engineer.

3/15 WET MIX MACADAM ROADBASE MATERIAL

3/15.1 The coarse aggregate shall consist of crushed rock (each particle shall have
a minimum of one crushed face - DCL Test Method DMS-8:2001) and the
fine aggregate shall be crushed rock or naturally occurring material. The
aggregate shall conform to the following gradation (Table 3-7):

Table 3- 7: Grading for wet mix macadam

SIEVE SIZE (BS) PERCENT PASSING

50 mm 100
37.5 mm 95 – 100
20 mm 60 – 80
10 mm 40 – 60
5 mm 25 – 40
2.36 mm 15 – 30
0.6 mm 8 – 22
0.075 mm 2–8

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The particle size shall be determined in accordance with the requirements of

BS 1377 Part 2: 1990 (Method 9.2 or 9.3), AMD 9027:1996.

3/15.2 The gradation shall be adjusted as required or as directed by the Engineer

within the above limits to ensure the mix has adequate binding properties.

3/15.3 The standards listed in these specifications shall be the latest version at
time of use. The latest version may differ from the version listed at time of
writing of these General Specifications. Wet Mix road base material shall
have physical properties which comply with the following values (Table 3-8):

Table 3- 8: Test properties for Wet Mix Macadam

TEST LIMIT

Sampling ASTM D75: 2009

Liquid Limit BS 1377: Part 2: 1990 : Test 4.5, AMD 9027:96 25 % max.
Linear Shrinkage (BS 1377 Part 2: 1990 Method 6.5), AMD 9027:96 3 % max.
Plasticity Index BS 1377: Part 2: 1990: Test 5.4, AMD 9027:96 6 max.
Aggregate Crushing Value (BS 812: 1990 P 110) 30 % max.
Water Absorption (ASTM C128: 2007a / C127 : 2007) 2.0 %
max.
Flakiness Index (BS EN 933: Part 3, 1997 AMD 14866: 2004) 30% max.
Elongation Index (BS 812: 1990 Part 105, Section 105.2) 30% max.
Los Angeles Abrasion Loss (ASTM C-131:06 or C-535:09) 30 % max.
*Soundness Loss (ASTM C 88:2005) 5 cycles 12 % max
(Magnesium Sulphate)
*Organic Matter Content (BS 1377 Pt 3: 1990 Method 3, AMD 9028: 0.2 %
1996) max.
Chloride Content (Acid Soluble) BS 812: 1988 Part 117 1% max.
Sulphate Content (Acid Soluble) BS EN 1744-1:1998 0.5% max.
Sand Equivalent (ASTM D-2419:2009). 45 min
CBR on Remolded Samples after 4 days soaking at 100% of the 80%
maximum dry density (BS 1377: Part 4 : 1990: Test 7, AMD 13925: minimum
2005)

Maximum Dry Density (MDD), BS 1377 Part 4: 1990 (method 3.5 or 2.3
3.6, AMD13925-2002 ) minimum

3/15.4 The moisture content of the Wet Mix Macadam at the time of laying shall be
the optimum + 1 %. Water required to achieve this moisture content shall
be added at the mixing plant. Moisture determination shall be in accordance
with BS 1377: Part 2: 1990: Test 3.2,AMD 9027:96.

3/15.5 The mixing water should be clear, visually clean and free of matter harmful
to the pavement i.e. soluble salts. Sweat water can be used. Water of
questionable quality should comply with the chemical limitations listed in

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Table 3-9. Water shall be sampled in accordance with BS EN 1008:2008

latest edition.

Table 3- 9: Chemical requirements for mixing water

ITEM LIMIT TEST METHOD

Chloride as CL 250 ASTM D512-04

Sulphate as SO4 350 ASTM D516-07
Alkali Carbonates and Bicarbonates 500 ASTM D513:2006
Total Dissolved Solids including 2000 BS 1377 Part 3:Test
items 1,2 &3 above 1990 AMD 9028(1996)
pH 7-9 ASTM D 1293:2005

3/16 TRANSPORT AND SPREADING WET MIX MACADAM ROADBASE

3/16.1 Transport vehicles carrying the plant mixed material shall have a capacity
suited to the output of the mixing plant and the site conditions and be
capable of discharging cleanly. Material when mixed shall be removed at
once from the mixer transported directly to the point where it is to be laid
and protected from the weather both during transit from the mixer to the
laying site and whilst waiting tipping. The mixture shall be transported from
the plant in vehicles that maintain moisture content and prevent segregation
and loss of the fine material

3/16.2 The material shall be placed and spread evenly. The material shall be
spread using a paving machine or spreader box operated with a mechanism
which levels off the material at an even depth and without delay. Except
where otherwise specified, the material shall be laid and compacted in
layers of maximum compacted thickness of 150mm.

3/17 COMPACTION TRIALS OF WET MIX MACADAM ROADBASE

3/17.1 If directed by the Engineer, prior to the commencement of the Wet Mix
Macadam Roadbase operations, the contractor shall construct trial lengths,
not to exceed 50 meters. The materials used in the trials shall be those
approved for use as Wet Mix Macadam Roadbase and the equipment used
shall be that according to the Contractor's approved schedule of work.

3/17.2 Trial lengths may not form part of the permanent works but may be
permitted in the construction of temporary detours of sufficient length.

3/17.3 The objective of these trials is to determine the adequacy of the Contractor's
equipment, the loose depth measurements necessary to result in the
specified compacted layer depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.

3/17.4 The Contractor may proceed with the Wet Mix Macadam Roadbase work
only after the methods and procedures established in the compaction trials
have been approved by the Engineer.

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3/18 COMPACTION OF WET MIX MACADAM ROADBASE

3/18.1 The material shall be compacted to a field density equal to 100% of

maximum dry density value obtained when tested in accordance with BS
1377: Part 4 : Test 3.7 : 1990, AMD 13925-2002.

Field Density tests shall be carried out in accordance BS 1377: Part 9: 1990:
Test 2.2-AMD 8264-1995; AMD 17229-2007

3/18.2 Compaction shall be completed as soon as possible after the material has
been spread.

3/18.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.

3/18.4 The surface of any layer of material shall on completion of compaction be

well closed free from movement under compaction plant and free from
compaction planes, ridges, cracks or loose material. All loose, segregated
or otherwise defective areas shall be made good to the full thickness of layer
and re-compacted.

3/18.5 Where directed by the Engineer a Sieve analysis shall be carried out on the
material recovered from 5 consecutive field density tests. Where this sieve
analysis shows oversize material content of 10 % or greater the area of
construction will be removed and the source of the material rejected until
further notice. Where considered necessary other areas of work which were
carried on using material from the same source shall be tested in a similar
manner.

3/19 FINISHING OF WET MIX MACADAM ROADBASE

3/19.1 Immediately prior to the placing of the first layer of the next pavement
course on to the Wet Mix Macadam Roadbase, the final layer of Wet Mix
Macadam Roadbase shall be at the specified density and to the required
grade and section. In order to maintain these requirements while placing
the next course, it may be necessary to water and reshape the surface of
the Wet Mix Macadam Roadbase. This work shall be at the Contractor's
expense.

3/19.2 The surface of the finished Wet Mix Macadam Roadbase will be tested with
a three (3) meter straight edge by the Engineer at selected locations. The
variations of the surface from the testing edge between any two (2) contacts
with the surface shall at no point exceed ten (10) millimeters when placed on
or parallel to the centre line, or ten (10) millimeters when placed
perpendicular to the centre line of the roadway. The Wet Mix Macadam
Roadbase shall be compacted to the thickness and cross sections as shown
on the drawings and shall not vary by more than ten (10) millimeters from
the required elevation.

All humps and depressions and thickness deficiencies exceeding the

specified tolerance shall be corrected by removing the defective work or by

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adding new material as directed by the Engineer. The following additional

requirements are to be complied with:

 The straight edge shall not have any supports enabling it to rest on
the surface.
 The plus tolerance of 10mm from the required elevation is not
applicable if read in conjunction with the thickness requirements of
asphaltic courses, Clause 3/44 unless design finished level is
revised, if agreed by the Engineer, to enable to obtain the required
thickness of the asphaltic courses in a smooth grading in the affected
road length.

3/19.3 Before placing the next construction layer or applying prime coat, the Wet
Mix Macadam roadbase shall be mechanically swept then cleaned with
compressed air to remove loose material. As soon as possible after
cleaning of the surface, the Wet Mix roadbase shall be sealed by the
application of a prime coat as specified. Should the surface of the material
be allowed to dry out before the seal is applied, it shall be lightly watered
and re-compacted immediately prior to spraying with prime coat.

In the event of a section of wet mix roadbase failing to comply, either by

level or degree of compaction, and where the full depth of the layer has
been allowed to dry out, it shall be removed and replaced at the Contractor's
expense, with fresh material. Watering and re-mixing in place will not be
permitted.

3/20 MINIMUM TEST REQUIREMENTS FOR WET MIX MACADAM

ROADBASE
3/20.1 One sample every 1,000 cu. m. or part of as directed by the Engineer shall
be tested for Grading Plasticity Index, Sand Equivalent value, Maximum Dry
Density, C.B.R. and Loss by Abrasion.

3/20.2 Three insitu density tests shall be made per unit (750 sq.m.) of each layer of
carriageway and three insitu density test per unit (450 lin.m.) of shoulder or
as directed by the Engineer.

3/20.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.

3/21 BITUMINOUS PAVING COURSES, DESCRIPTION

3/21.1 This work shall consist of the construction of the following hot mix
bituminous courses which shall be either Asphaltic Concrete or Dense
Bitumen Macadam as shown on the drawings. Bituminous Paving Courses
shall consist of coarse aggregates, fine aggregates, filler material, and
bitumen binder.

3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE

3/22.1 Coarse aggregates, which is the material retained on a 4.75 mm sieve, shall
consist of crushed rock or crushed gravel. It shall be clean, hard, tough,

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durable and sound, and shall be of uniform quality and free from
decomposed stone, shale, clay, lumps and other deleterious substances.
Sampling of coarse aggregate shall be in accordance with ASTM D75: 2009.

3/22.2 Crushed gravel for use as coarse aggregate shall consist of the product
obtained by crushing material that has first been screened in such a manner
that not less than ninety (90) percent of the material to be crushed is
retained on an ASTM 3/8” sieve.

3/22.3 Percentage of partially crushed faces with minimum one crushed face shall
be 100% by weight of each stockpile of aggregate. In addition, at least 85%
by weight of each separate stockpile of aggregate shall have all faces
crushed. This 85% value may be reduced to 50% for certain categories of
road where indicated on the drawings. Crushed face determination shall be
as per DCL Test Method DMS 7: 2001 and DMS 8:2001.

3/22.4 Each stockpile of coarse aggregate shall have properties which comply with
the following values (Table 3-10): -

Table 3- 10: Properties of coarse aggregate for bituminous paving course

TEST LIMIT

Los Angeles Abrasion Loss(ASTM C-131:06 or C-535:09)

 Base Course and Binder Course 30% max.
 Wearing Course 25% max.
Aggregate Crushing Value (BS 812 : 1990 P 110)
 Base Course and Binder Course 25% max.
 Wearing Course 20% max.
Soundness Loss (ASTM C88 : 2005) – ‘5 cycles’, Magnesium 10% max.
Sulphate
Acid soluble Chlorides (BS 812 : 1988 Part 117) 0.1% max.
Acid soluble Sulphates (BS EN 1744-1:1998) 0.5% max.
Flakiness Index (BS EN 933- Part 3,1997: AMD 14866: 2004)
 Base Course and Binder Course 30 max.
 Wearing Course 25 max.
Elongation Index (BS 812 : 1990 P 105, Section 105.2)
 Base Course and Binder Course 30 max.
 Wearing Course 25 max.
Water Absorption (ASTM C127 : 2007) 2.0% max.

3/22.5 Reclaimed Asphalt Pavement material (RAP) shall be obtained from milling
or excavation of existing asphalt pavements. RAP shall be crushed and
screened as necessary to ensure a maximum size no greater than the
maximum size of asphalt being produced and to achieve a reasonably well
graded, free flowing, and consistent product. RAP shall not be subject to
material properties above.

RAP shall be free of foreign materials such as bound or unbound granular

base, broken concrete or other contaminants.

Prior to use, RAP shall be placed in separate stockpiles not exceeding

100 tones. Each stockpile shall represent a Lot, and test results shall be
traceable between the Lot and asphalt mix containing the relevant RAP.

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RAP that has been stockpiled for some time and has bound together in
some way shall be reprocessed, to ensure that it is in a free flowing state at
the time of use.

The proportion of RAP in the total mix shall not exceed 20% and the final
grading of combining RAP and virgin quarry aggregates shall conform to the
requirements of Table 3-14 “Aggregate Grading for Asphaltic Concrete”
outlined in Clause 3/25.2 to follow.

3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE

3/23.1 Fine aggregate shall consist of the material passing a 4.75 mm sieve.

3/23.2 Fine aggregate including filler shall be obtained from 100% crushed gravel
or crushed rock pre-screened to exclude natural uncrushed fine material or
weathered unsound fines.

The use of dune sand shall not be permitted.

3/23.3 Fine aggregates shall have properties which comply with the following
values (Table 3-11): -

Table 3- 11: Properties of fine aggregate for bituminous paving course

TEST LIMIT

Soundness Loss (ASTM C-88: 2005)-“5 cycles”, 10 % max.

Magnesium Sulphate
Plasticity Index, (BS 1377:Part 2 : 1990:Test 5, AMD Non Plastic
9027: 1996)
Acid Soluble Chlorides, (BS 812 : 1988 Part 117) 0.1% max.
Acid Soluble Sulphates, (BS EN 1744:1998) 0.5% max.
Water absorption, (ASTM C-128: 2007a) 2.3% max.

Sampling of fine aggregate shall be in accordance with ASTM D75: 2009.

3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE

3/24.1 When the combined grading of the coarse and fine aggregates is deficient in
material passing the ASTM No.200 sieve, mineral filler shall be added as
approved by the Engineer at the Contractor's expense.

3/24.2 Mineral filler shall consist of finely ground particles of limestone or cement in
accordance with ASTM D242:2009. It shall be thoroughly dry and free from
organic substances and clay and meet the grading requirements following
(Table 3-12): -

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Table 3- 12: Grading requirement for mineral filler

MINERAL FILLER

B.S. SIEVE ASTM SIEVE SIZE PERCENTAGE BY

MASS PASSING
600 micron No. 30 100
300 micron No. 50 95 - 100
150 micron No. 100 90 - 100
75 micron No. 200 70 - 100

Grading shall be in accordance with ASTM D 546:2005. Relative density test

as per BS EN 1097: Part 3.

3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES

3/25.1 The combined mineral aggregate shall meet the following physical
requirements (Table 3-13): -

Table 3- 13: Physical requirements of the combined mineral aggregates

TEST LIMIT
Sand Equivalent ASTM D2419-2009 determined after 65 minimum
all processing except for addition of asphalt binder
Plasticity Index BS 1377:Part 2 : 1990:Test 5, AMD Non Plastic
9027 1996

3/25.2 When tested according to ASTM C136: 2006 or BS EN933-1:1997, AMD

15907: 2006, the combined mineral aggregate shall conform to Table 3-14
for Asphaltic Concrete and Tables 3-15, 3-16 and 3-17 for Dense Bitumen
Macadam:-

Table 3- 14: Aggregate grading for Asphaltic Concrete (AC)

SIEVE SIZE TOTAL PASSING (BY WEIGHT)

SQUARE OPENINGS
ASTM BASE COURSE BINDER WEARING
COURSE COURSE
37.5 mm 100
25 mm 80 - 100 100 100
19 mm 62 - 92 80 - 100 86 – 100
12.5 mm - 63 - 85 69 – 87
9.5 mm 45 - 75 57 - 77 58 – 78
4.75 mm 30 - 55 40 - 60 40 – 60
2.36 mm 20 - 40 25 - 45 25 – 45
0.85 mm 15 - 30 15 - 30 15 – 30
0.425 mm 10 - 22 10 - 22 10 – 22
0.18 mm 6 - 15 6 - 15 6 – 15

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0.075 mm 2-8 2-8 2–8

Table 3- 15: Aggregate grading for Dense Bitumen Macadam (DBM) Asphalt Base
Course

B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR GRAVEL

mm Percentage by Mass Passing
50 100
37.5 95 - 100
28 70 - 94
14 56 - 76
6.3 44 - 60
3.35 32 - 46
0.300 7 - 21
0.075 2-8
Note: The aggregate shall be in a surface dry condition prior to mixing.

Table 3- 16: Aggregate grading Dense Bitumen Macadam (DBM) Asphalt Base Course
based on layer thickness

B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR GRAVEL

mm Percentage by Mass Passing for Finished Thickness of
Base Course
65 – 80mm 50 - 60mm 35 - 45mm

50 100 - -
37.5 95 – 100 100 -
28 70 – 94 90 - 100 100
20 - 71 - 95 95 - 100
14 56 – 76 58 - 82 65 - 85
10 - - 52 - 72
6.3 44 – 60 44 - 60 39 - 55
3.35 32 – 46 32 - 46 32 - 46
0.300 7 – 21 7 - 21 7 - 21
0.075 2–8 2-8 2-8

Table 3- 17: Aggregate grading for Dense Bitumen Macadam (DBM) Wearing Course
based on layer thickness

B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR GRAVEL

mm Percentage by mass Passing for Finished Thickness of
Wearing Course
35 – 50 mm 25 – 30 mm 20 mm

28 100 - -
20 95 - 100 100 -
14 70 - 90 95 - 100 100
10 55 - 75 70 - 90 95 - 100
6.3 40 - 60 45 - 65 55 - 75

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3.35 25 - 40 30 - 45 30 - 45
1.18 15 - 30 15 - 30 15 - 30
0.075 2-6 2-6 2-6

3/25.3 The grading given in Tables 3-14, 3-15, 3-16 and 3-17 represent the
extreme limits which shall determine suitability of aggregate for use from all
sources of supply. The aggregate as finally selected for use in the work
shall have a grading within the limits designated in Tables 3-15, 3-16 and 3-
17 as appropriate and for Table 3-14 may with the Engineer's agreement.

3/25.4 The coarse aggregate, shall show no detrimental amount of stripping when
tested in accordance with ASTM D1664: 1985. The minimum value of non
stripped area shall be 95%. If stripping occurs, the aggregate shall be
rejected and an approved method of treatment specified to change the
material from a hydrophilic to a hydrophobic state as directed by the
Engineer, or an approved additive shall be used with the bituminous binder.

3/25.5 When necessary to improve the coating of aggregate by bitumen, additives

of approved type will be added to the bituminous material in such
percentage as required to obtain satisfactory results in the affinity with
bitumen test performed in accordance with ASTM D1664: 1985. The
approved additive will be used in accordance with Technical Specifications
issued by the manufacturer and approved by the Engineer after appropriate
testing.

3/25.6 No extra payment will be made for required anti-stripping additives.

3/26 BITUMEN BINDER

3/26.1 Bitumen Binder for the "Bituminous Paving Courses" shall be Bitumen
Binder penetration grade 60 - 70 unless otherwise specified as 40 - 50.

3/26.2 The bitumen shall be prepared by refining crude petroleum by suitable

methods and shall be homogeneous, free from water and shall not foam
when heated to 175 degrees C (347 F).

3/26.3 Bitumen penetration grade 60 - 70 and 40 - 50 shall conform to the

requirements of Table 3-18. Sampling shall be in accordance with ASTM
D140.

3/26.4 A sample of the bitumen that the Contractor proposes to use in the work,
together with a statement as to its source and properties shall be submitted
to and approved by the Engineer at least 45 days before the asphalt work
begins.

3/26.5 No bitumen other than that represented by the approved sample shall be
used by the Contractor except with the written consent of the Engineer.
Blending of bitumen from different refineries will not be permitted.

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Table 3- 18: Properties of bitumen binder for asphalt mixes

60 - 70 PEN 40 - 50 PEN
TEST ASTM MIN. MAX. MIN. MAX.
Penetration 0.1 mm D5: 2006 60 70 40 50
at 25 deg.C, 100g, 5 sec.
Specific Gravity D70: 2009 - - - -
Flash Point, Cleveland D92: 2005a 232 - 23 -
Open Cup, deg. C. 2
Ductility at D113: 2007 100 - 10 -
25 deg.C, cm 0
Solubility trichloro D2042: 2009 99 - 99 -
ethylene, %
*Thin film oven D1754: 2009 - 0.80 - 0.80
3.2mm, 163 deg.
C, 5 hr loss on heating %
*Penetration D5: 2006 52 - 55 -
of residue
% of original
Ductility of D113: 2007 50 - - -
residue at
25 deg C
5 cm/min. cm
Kinematic Viscosity D2170: 2007 240 - 28 -
(Centistokes) 0
at 135 deg.C
Softening Point
Ring & Ball, deg C D36: 2006 48 52 51 55

3/26.6 For Asphaltic Concrete the percentage range of bitumen by weight of total
mix to be added to the aggregate shall be as prescribed in Table 3-19: For
Dense Bitumen Macadam the range shall be as prescribed in Table 3-22.

Table 3- 19: Bitumen content for Asphaltic Concrete (AC) Layers

PAVEMENT COURSE BITUMEN PERCENTAGE BY WEIGHT OF

TOTAL MIX INCLUSIVE OF TOLERANCES

Base 3.2 to 4.4

Binder 3.4 to 4.4
Wearing 3.4 to 4.4

3/27 JOB MIX FOR BITUMINOUS PAVING COURSES

3/27.1 The mix approved for use in the works shall be designed using Marshall
tests and field trials with the following recommendations taken into account:-

- For base course, the combined aggregate mix shall be modified by

substituting all aggregate sizes over 25 mm with an equal weight of
aggregate sizes in the next lower grading sizes as specified in Tables
3-14, 3-15, 3-16 and 3-17.

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- The combined aggregate gradation should be adjusted within the

allowable limits to achieve maximum stability whilst not going below
the minimum requirement for void content.

- The minimum bitumen binder content according to the results of the

Marshall Method of Mix Design should be used provided that it will still
satisfy the durability, the stability and the void content requirements.

- Prior to final approval, the proposed job mix, but with a bituminous
content at the upper percentage limits shall be compacted to refusal,
(400, 500 and 600 blows) and the resulting voids in the mix shall not
be less than 2% for asphaltic concrete or 3% for DBM.

- The final job mix must display the Marshall characteristics specified in
Table 3-21 for Asphaltic Concrete and Table 3-22 for Dense Bitumen
Macadam.

3/27.2 Determination of VIM, VMA & VFB shall be in accordance with DMS 9:
2001.

3/27.3 At least thirty (30) days prior to the date the Contractor intends to begin
production of plant-mix "Bituminous Paving Course" Mixes and after
receiving approval of the aggregates and bitumen from the Engineer, the
Contractor shall make a written request for the approval of the job-mix
formula from the Engineer. The job-mix formula will be prepared by the
Contractor under the supervision of the Engineer in the Laboratory. The job-
mix design and calibration factor for the mix shall be checked at the Dubai
Central Laboratory.

3/27.4 The laboratory job mix formula shall fix a single definite percentage of
aggregate passing each required sieve size, a single definite percentage of
bitumen binder to be added to the aggregate, a specified target temperature
at which the mix is to be emptied from the mixer, and a specified target
temperature at which the mix is to be delivered to the works site. For
tolerance limits applicable refer to Table 3-20.

3/27.5 The laboratory job mix formula shall be used for the basis of approval of the
job standard mixture.

3/27.6 Trials areas having lengths of at least 50 m to the specified layer thickness
shall be laid outside the area of the permanent work by the Contractor for
the Engineer's approval, before the start of the permanent work. At least
two samples of non-compacted material from the trial area shall be taken in
accordance with ASTM D979: 2001 and shall be analyzed in the presence
of the Engineer to determine the aggregate grading and binder content.
Stability, flow, Marshall Density and voids shall be determined for Marshall
Specimens which are made from Plant/Site mixtures. The results shall be
submitted to the Engineer and shall be approved by him before further
mixing or lying is carried out.

3/27.7 Trial areas may form part of a temporary traffic detour subject to the
approval of the Engineer. The compaction trials according to sub-section
3/42 should be performed on the trial mixes. If the trial areas form part of

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 SECTION 3 PAVEMENT CONSTRUCTION
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the temporary traffic detour they shall not be paid for under the relevant Bill
item.

3/27.8 Should the laboratory job mix formula after passing the mixing plant and laid
and compacted with approved plant fail to produce a satisfactory trial area,
the mix proportions may be modified by agreement with the Engineer, as
necessary and within the requirements of Table 3-20, 3-21 and 3-22 as
applicable to produce a mix of satisfactory workability and acceptable
surface finish subject to the mix being rechecked in accordance with the
preceding Clauses of 3/27. After approval of the trial area by the Engineer
this mix shall be designated the 'Job Standard Mix' and shall thereafter be
the approved mix.

3/27.9 All mixes produced shall conform to the Job Standard Mix approved by the
Engineer, within the ranges of tolerance specified in Table 3-20 (within the
limits of Table 3-14, 3-19 and 3-21 for Asphaltic Concrete and Tables 3-15,
3-16, 3-17 and 3-22 for Dense Bitumen Macadam). Each day the Engineer
shall take as many samples of the materials and mix as he considers
necessary and minimum of one sample for every 300 tons laid or part
thereof for checking their required characteristics. When unsatisfactory
results or changed conditions make it necessary, the Engineer shall instruct
the Contractor to establish a new job-standard following approval of the new
mix design in accordance with the preceding Clauses of 3/27.

3/27.10 Should a change in a material be encountered or should a change in a

source of material be made, a new Job-standard Mix shall be submitted by
the Contractor in accordance with the preceding Clauses of 3/27 and
approved by the Engineer before the mix containing the new material is
delivered. Job materials will be rejected if they are found not to have the
characteristics required by the approved Job Standard Mix.

Table 3- 20: Job mix tolerance

Characteristics Tolerance
Aggregate retained on 4.75mm sieve or larger +/- 5%
Aggregate passing 4.75mm sieve and retained on +/- 4%
0.85mm sieve
Aggregate passing 0.85mm sieve and retained on +/- 2%
0.075mm sieve
Aggregate passing 0.075mm sieve +/-1.0%
Bitumen Binder +/-0.2%
Temperature of mixing and placing +/- 10oC

3/27.11 In the event, any bituminous mix that is currently being used in another
running RTA/DM project, is proposed by the contractor for approval of using
that mix in this contract, then prior to according the approval or otherwise,
Engineer will ensure that:

1. Copies of all test reports pertaining to the proposed mix submitted by the
contractor comply with the Specification requirements as stated in this
contract and
2. The proposed mix complies with clause 3/27 of this contract.

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Table 3- 21: Properties of mix for Asphaltic Concrete (AC)

PROPERTIES BITUMINOUS BITUMINOUS BITUMINOUS
BASE BINDER WEARING
COURSE COURSE COURSE

Number of Compaction blow 75 75 75

at each end of specimen

Cycles for Gyratory 80 80 80

compaction
(ASTM D6925:2009)
Stability (Marshall) 9800 9800 11760
Minimum (N)
(ASTM D2726:2008)
Flow (Marshall) mm 8 - 16 8 - 16 8 - 16
in 0.25 mm
(ASTM D2726:2008)

Stiffness, minimum 1225 1225 1225

(N/0.25 mm)
(ASTM D2726-2008)
Percent air voids 4-8 4-8 4-8
(DMS 9:2001)
Percent voids in 13 14 15
mineral aggregate,
minimum % (V.M.A)
(DMS 9:2001)
Percent voids filled 50 - 65 50 - 70 50 - 70
with bitumen (V.F.B).
(DMS 9:2001)
Loss of Marshall Stability in Max.25% Max. 25% Max. 25%
accordance with DMS 10:
2001
Filler/Bitumen Ratio 0.6 - 1.5 0.6 - 1.5 0.6 - 1.4

Table 3- 22 Properties of mix for Dense Bituminous Macadam (DBM)

BASE COURSE WEARING COURSE

TEST MIN. MAX. MIN. MAX.

Marshall specimens No. 75 - 75 -

of Comp. Blow each end
of specimen
Cycles for Gyratory 80 80
compaction
(ASTM D6925:2009)
Voids in Mix (%) 7 11 6 9
(DMS 9:2001)
Voids in Mineral 14 20 14 20
Aggregate (%)
(DMS 9:2001)
Minimum Stability (N) 7350 - 9800 -

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 SECTION 3 PAVEMENT CONSTRUCTION
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(ASTM D2726:2008)
Flow, 0.25mm 8 16 8 16
(ASTM D2726:2008)
Stiffness, minimum 919 - 1225 -
(N/0.25 mm)
(ASTM D2726:2008))
Bitumen Content 3.2 4.0 3.5 4.1
(% of total mix).
(ASTM D6307 - 05
(METHOD A))
Voids Filled with 47 60 48 60
Bitumen (%)
(DMS 9:2001)
Loss of Marshall stability - 25% - 25%
(DMS 10: 2001)

Samples of bituminous paving course mixes shall be taken from the mixing
plant and/or behind the paver prior to compaction, as per ASTM D979: 2006
of latest edition check compliance with the approved job mix requirements
including Tables 3-14, 3-19, 3-20 and 3-21 for asphaltic concrete and Tables
3-15, 3-16, 3-17, 3-19, 3-20 and 3-22 for Dense Bitumen Macadam.

3/27.12 The density of the compacted mixes shall be related to the daily Marshall
Density which shall be determined by making four Standard Marshall
Specimens from samples of the mix taken from the mixing plant or paver.
The density of each sample shall be determined and compared with the
mean value. Any individual result which varies from the mean by more than
0.015 gm/cc shall be rejected. Marshall Tests shall be repeated on a daily
basis to establish the daily Marshall Density for that particular day's
production. The daily Marshall Density shall not vary from the Job Mix
Design Density by more than + 1.0%.

3/27.13 The assistance of the Engineer in the preparation of the job standard mix in
no way relieves the Contractor of the responsibility of producing a
bituminous mix meeting the requirements of the Specifications.

3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS

3/28.1 Method statement and equipment list shall be according to the type and
number outlined in the Contractor's detailed Programme of Work, as
approved by the Engineer. Requirements for major plant are outlined in
Clause 1/29 of these Specifications.

3/28.2 In addition to the above requirements, trucks used for hauling bituminous
mix shall have tight, clean, smooth metal beds which have been thinly
coated with a minimal amount of paraffin oil, lime solution, or other approved
material to prevent the mix from adhering to the beds. When required by the
Engineer, each vehicle shall be equipped with a canvas cover or other
suitable material of such size as to protect the mix from the weather.

3/28.3 Rolling equipment shall be self-propelled. The wheels on the rollers shall be
equipped with adjustable scrapers and the rollers shall have water tanks and

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 SECTION 3 PAVEMENT CONSTRUCTION
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sprinkling apparatus, which shall be used to keep the wheel wet and prevent
the surface material from sticking.

3/29 PREPARATION OF BITUMEN BINDER

3/29.1 The heating of the bitumen binder for mixing and compacting shall be in
accordance with ASTM D6926: 2004 or ASTM D6927:2006.

3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX

3/30.1 i. Coarse and fine aggregate shall be stored at the asphalt plant in such
a manner that the separate stockpiles will not become intermixed. The
stockpiles shall be of sufficient size to provide a minimum quantity of
one week's continuous production of asphalt mix. Taking into
consideration the frequency of aggregate testing as mentioned in
Clause 3/47.2 aggregates brought to the asphalt plant to supplement
stocks should be tested and approved prior to placing in the existing
approved stockpiles.

ii. The cold bins shall be calibrated with the materials to be used and the
settings shall be such as to produce a combined gradation in
accordance with the job mix formula. The proportioning shall be such
that surpluses and shortages in the hot bins will not cause breaks in
the continuous operation. All the above shall be as approved by the
Engineer.

iii. The materials shall be heated so that their temperature is within ±8

deg.C of the temperature needed to satisfy the viscosity requirements
of the asphalt cement. The moisture content of the heated and dried
materials shall not exceed 0.5 per cent. The quantity of materials fed
through the drier shall in all cases be held to an amount which can be
thoroughly dried and heated within the limits specified.

3/30.2 Immediately after heating, the aggregate or aggregates shall be screened

into at least five (5) sizes and conveyed into separate bins ready for
batching and mixing with bituminous material. When the aggregates
supplied are of such size and grading that separating into five (5) bins is
impractical, the number of required separations may be reduced to four (4)
or to three (3) with the approval of the Engineer. The efficiency of the
screening operations shall be sufficient to produce, at plant operating
capacity, gradations in each of the sizes of heated and dried aggregates
which are reasonably uniform and result in the production of a mix
complying with the limits specified for the aggregate gradation.

3/31 PREPARATION OF BITUMINOUS MIX

3/31.1 Dried aggregate as specified and prepared as prescribed above shall be

combined in the plant conforming to ASTM D 995 - 02 in the approved
proportions. The bitumen binder shall be introduced into the mix in the
proportion specified by the job-mix formula.

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3/31.2 The initial mixing time will be designated by the Engineer. Mixing time may
be increased by the Engineer if additional time is necessary to obtain a
homogeneous mix and satisfactory coating.

3/31.3 The batch plants, timing shall begin at the start of the introduction of the
bitumen into the Pugmill.

3/31.4 The length of mixing time for continuous plants will be determined by the
following formula or other approved methods:-

Pugmill dead load capacity in Kg

Mixing time in seconds = ------------------------------------------
Pugmill output in Kg/second

3/31.5 The temperature of the aggregate immediately prior to mixing shall be within
 8 deg.C of the temperature of the asphalt cement and the temperature of
the aggregate and asphalt prior to mixing shall be approximately that of the
completed mix as defined in the job mix formula approved by the Engineer.
The mix temperature shall be within the limits set out in the job mix formula
when emptied from the mixer.

3/32 SURFACE PREPARATION

3/32.1 When the Bituminous Mix is placed on a prepared roadbase and whether or
not a prime coat is designated on the Drawings, the Granular Roadbase
shall be even and firm and within the construction tolerances specified for
the roadbase to the satisfaction of the Engineer.

3/32.2 When the paving layer is constructed on an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust. In
addition any loose, broken or shattered bituminous material along the edges
of the existing surface shall be removed, and the exposed subgrade and a
sufficient width of the shoulder adjacent to the edge of the existing surface
to receive the new bituminous mix shall be shaped, bladed, compacted and
broomed and primed to provide a uniform firm subgrade for the new surface
course.

3/32.3 The existing bituminous surface, base, or subgrade shall be removed if

broken, shattered, or unstable. The areas shall be excavated to a depth as
directed by the Engineer, and refilled with the Bituminous Mix according to
the Specifications.

3/32.4 Prior to the placing of the mix, when designated on the Drawings or directed
by the Engineer, a prime coat or tack coat shall be applied to the roadbase
or surface in accordance with the Specification for Prime Coat or Tack Coat.

3/33 PLACING OF THE MIX

3/33.1 All bituminous mixes shall be introduced to the paver at a temperature not
less than 135 deg.C and not more than 163 deg.C. Mixes outside this
temperature range shall be discarded.

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3/33.2 The bituminous mix shall be spread and finished to crown and grade by
automatically controlled bituminous paver. Bituminous mix may be spread
and finished by hand methods only where machine methods are impractical
as determined by the Engineer.

3/33.3 The automatically controlled paver shall lay the bituminous mix without
tearing the surface and shall strike a finish that is smooth, true to cross-
section, uniform in density and texture, free from hollows, transverse
corrugations and other irregularities.

3/33.4 The paver shall be operated at a speed which will give the best results for
the type of paver being used and which co-ordinates satisfactorily with the
rate of delivery of the mix to the paver, to provide a uniform rate of
placement without intermittent operations of the paver.

The mixture shall be laid upon an approved surface, spread and struck off
to the required grade elevation. When paving widths of one or two traffic
lanes, the entire width shall be placed by one paver in one pass;
longitudinal joints will not be permitted. When paving widths of more than
two traffic lanes, two pavers shall operate in echelon so that the entire width
of the roadway is covered in one pass. The second paver shall follow as
closely as possible behind the first paver so that the temperature of the
mixture in the advance lane will not fall below 80oC. Each paver shall be
fully manned at all times that paving operations are in progress.

Plant production, the number of trucks, and the speed of the asphalt
paver(s) shall be such as to insure delivery of the mixture to the project in
sufficient quantities and at such intervals as to permit the paving operation.
Failure to maintain such delivery shall be cause for the Engineer to suspend
the work.

When delivery of material is delayed so that a paver remains idle for more
than 30 minutes or when the temperature of the mix falls below the
minimum specified in Section 3/33.1 of the general specification, the paver
shall be moved away from the end of the lane and the material in place fully
compacted. When adequate material is at hand to insure against further
delay, the material at the end of the partially completed lane shall be cut
back and a transverse joint constructed.

If a void should appear on the asphalt mat after it has been screeded, the
contractor shall place asphalt mixture by hand in the void and rake out all
large aggregate. The Contractor must minimize stepping over the fresh mat
of asphalt during laying.

Spillage of mix in front of the paver is not permitted.

The truck bed shall be raised slowly. When the mix is dumped too rapidly,
segregation occurs as course aggregates will roll down the side of the
loads.

The hydraulic system of the truck-bed hoist should be frequently inspected

to guard against hydraulic fluid leakage. Such a leakage on the roadway
surface will prevent good bonding between the roadway and the new mat.

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Bumping the Paver - When an end dump truck is used to deliver mix to the paver,
the driver must back the truck up to the lay down machine but stop just short of the
push rollers on the front of the paver. Once the truck has come to a halt and the
driver has released the brakes on the vehicle, the paver operator should start the
machine moving forward picking up the stopped truck.

3/33.5 The mix shall be delivered to the paver in time to permit completion of
spreading, finishing and compaction of the mix during daylight hours.

3/33.6 Joints Construction and Compaction

When new asphalt is laid against existing or old asphalt, the following
specifications shall be considered with regard to the longitudinal joints:

 Longitudinal and transverse joints in succeeding courses shall be offset

from the joint in the underlying course be not less than fifteen (15)
centimeters stepping progressively as shown on the Plans or as directed
by the Engineer.
 The longitudinal joint in the surface course shall be coincident with the
last lines.
 Longitudinal joints shall be always located out of the wheel paths.
 Transverse joints shall be carefully constructed and thoroughly
compacted to provide a smooth riding surface. Joints shall be straight
edged to check smoothness. If the line of joint is formed with a
bulkhead, it shall form a straight line and vertical face. If a bulkhead is
not used to form the joint, the joint shall be made by sawing the
compacted mixture a sufficient back of the end of the placement to
assure full thickness of the pavement at the joints; the material ahead of
the sawed joint shall be removed.
 In either case, the joint shall be painted with a thin coat of tack coat
before the fresh material is placed against it. Cross rolling, unless
prohibited by field conditions is required to obtain through compaction of
these joints.
 Where longitudinal joints are constructed, and due to the required
maintenance of traffic or to unforeseeable conditions, the temperature of
the mixture at the longitudinal edge of the strip first laid becomes less
than 80oC, the edge shall, prior to paving the adjacent strip, be painted
with a thin coat of tack coat. If the edge of the joint is not vertical, it shall
be saw cut to a vertical face.

3/33.7 The leading half of half roadway paving shall not get ahead of the trailing
half of the pavement by more than one (1) average full-day of paving and, in
no case, shall the leading half be more than one half (1/2) kilometer ahead
of the trailing half without the written permission of the Engineer. If the
Contractor fails to comply with this requirement, the Engineer may suspend
paving on the leading half until such time, as the Contractor shall pave the
trailing half to a point approximately even with the leading half.

3/33.8 Unless otherwise directed by the Engineer, where successive layers are to
be placed, the surface of the existing layer shall be swept clean with a
power broom, or by other means as approved by the Engineer, and a tack
coat applied. Tack coat may not be required where the delay between

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courses laying is less than 48 hours and when the surface is fresh and clean
and at the discretion of the Engineer. The rate of application of tack coat
2
shall range between 0.25 to 0.4 L/m .

3/33.9 Asphaltic concrete mixes, shall be laid at an un-compacted thickness such

that, after rolling the thickness of the compacted layer shall be not less than
2.5 times the maximum aggregate size or :-

Base Course : Min. 6 cm Max. 10 cm

Binder Course : Min. 6 cm Max. 8 cm
Wearing Course : Min. 5cm Max. 6 cm

However, DBM thicknesses shall be as specified in Tables 3-16 and 3-17.

3/33.10 The maximum thickness for layers may be increased when such increase is
more adaptable to total pavement thickness and when in the opinion of the
Engineer it is not detrimental to placement and compaction achievement.

3/33.11 Pre-paving conference. At least 14 days before the start of paving

operations, a pre-paving conference shall be arranged by the contractor to
coordinate attendance all concerned parties and other applicable
subcontractors and submit and prepare to discuss the following:

1. Proposed schedule of paving operations.

2. List of all equipment (excavation, compaction, laydown, haul, Pugmill,

etc.), and personnel used in the production and construction of the
work.

3. Proposed traffic control plan for paving operations including provisions

for pavement drop-offs and moving operations.

4. Contractor quality control plan for paving and sampling and testing.

5. Procedures for constructing the control strip including placing, finishing,

compacting, and smoothness procedures.

6. On the first day of production, produce sufficient mix to construct a 30-

meter long control strip, one-lane wide, and at the designated lift
thickness. Construct the control strip on the project at an approved
location.

7. Construct the control strip using mix production, lay-down, and

compaction procedures intended for the entire mix. Cease production
after construction of the control strip until the asphalt concrete mix and
the control strip are evaluated and accepted.

3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE

3/34.1 The Contractor shall make the necessary survey required for the reference
grade. When the survey is approved by the Engineer, the Contractor shall
erect and maintain an approved reference string line and operate the paver
to conform to the reference string line for the initial layer and/or any other
layers as directed. Elevation control point stakes for the first layer of

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 SECTION 3 PAVEMENT CONSTRUCTION
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bituminous paving course shall be set at a maximum spacing of twenty (20)

meters. For subsequent layers, control points shall be set at ten (10) meters
maximum spacing. The Contractor shall furnish and maintain an approved
mobile string line for all layers not laid with the erected string line. The string
line shall be erected parallel to the reference grade, and the bituminous mix
shall be spread at a constant elevation above, below or at the string line
elevations as directed.

3/34.2 The use of the automatically controlled bituminous paver, to provide both
longitudinal and traverse control, shall include the furnishing and maintaining
of a string line, fixed or mobile, by the Contractor. The longitudinal and
traverse controls shall operate independently of each other, to the extent
that the surface of the bituminous mix will conform to the string line and will
be uniform in cross-section and crown.

3/34.3 The Contractor shall establish the centre-line points and shall maintain the
location of the points until the completion of the surfacing or as directed.
When directed by the Engineer, the Contractor shall erect a string line, to be
used as a guide for the finishing machine, in order to maintain a uniform
edge alignment. If any other method is proposed by the Contractor, it shall
first be approved by the Engineer.

3/35 BITUMINOUS LEVELLING COURSE

3/35.1 A leveling course, consisting of a layer of bituminous material of variable

thickness may be used to eliminate irregularities in existing surfaces or
bases and to vary existing cross-section elements of roadways.

3/35.2 In areas where leveling courses are required, as shown in the Drawings or
determined by the Engineer, the Contractor shall make a survey of the
existing surface or base. When the survey is approved, the Engineer will
determine and inform the Contractor of the precise locations and thickness
of leveling course to obtain the smoothest possible riding surface. Upon
receipt of the locations and thickness from the Engineer, the Contractor shall
proceed with the placement of the Leveling Course.

3/36 THICKNESS CORES

3/36.1 The depth of each bituminous paving course shall be measured by cored
samples. The Contractor shall furnish and operate an approved core drill for
cutting samples from the compacted mix on the road. The equipment shall
be capable of cutting the mix without shattering the edges of the specimen
or otherwise disturbing the density of the specimen. The nominal size of the
cored samples shall be ten (100mm) in diameter for binder course and
wearing course and fifteen (150mm) in diameter for base course and road
base. Samples shall be obtained in accordance with ASTM D979:2001 (06)
in sets of two (2) from the same location of the road.

3/36.2 Cores extracted for thickness measurement may be used for density
determination and density samples may be used for thickness
measurements. Determination of thickness and density of core samples
shall be determined in accordance with ASTM D3549: 2003 & ASTM D1188:
2007 or ASTM D2726: 2005a respectively and as required by Engineer.

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3/37 COMPACTION OF BITUMINOUS LAYERS

3/37.1 After spreading and strike off, and as soon as the mix conditions permit the
rolling to be performed without excessive shoving or tearing, the mixture
shall be thoroughly and uniformly compacted. Rolling will not be prolonged
to an extent that cracks appear.

3/37.2 Rollers shall be of the steel-wheel and pneumatic tire type and shall be in
good condition, capable of reversing without backlash, and shall be
operated at speeds slow enough to avoid displacement of the bituminous
mix. The number and weight of rollers shall be sufficient to compact the mix
to the required density while it is still in a workable condition. The use of
equipment which results in excessive crushing of the aggregate will not be
permitted. A minimum of three (3) rollers, two (2) steel-wheel and one (1)
pneumatic-tyre type, shall be used with each spreading operation for each
lane. However, the number of rollers required for proper compaction is
based on the square meter area placed rather than the production or
delivery tonnage

3/37.3 The Contractor shall provide adequate back-up equipment for use in the
event of mechanical failure, all to the satisfaction of the Engineer.

3/37.4 Initial or breakdown rolling shall be undertaken by means of either a tandem

power steel roller or three-wheel roller followed by a pneumatic-tyre roller or
as agreed by the Engineer. Rolling shall begin as soon as the mix will bear
the roller without undue displacement. Rolling shall be longitudinal,
beginning at the low side of the spread of material and proceeding toward
the high side, overlapping on successive passes by at least one half (1/2)
the width of the near wheels. Alternate passes of the roller shall be of
slightly different lengths.

3/37.5 The motion of the roller shall at all times be slow enough to avoid
displacement of the mix. Roller speed should be limited to around 4.5kph
and to prevent adhesion of the mix to the rollers, the wheels of the rollers
shall be kept properly moistened with water, but an excess of water will not
be permitted. Under no circumstances shall the use of diesel fuel or any
other asphalt stripping agent be used for preventing adhesion of the asphalt
to the roller wheels.

3/37.6 Final compaction and finish rolling shall be undertaken by means of a

tandem power steel roller, unless otherwise directed. When the specified
density is not obtained, changes in the size and/or number of rollers shall be
made as corrective measures, to satisfy the density requirements.

3/37.7 Rollers shall be operated by competent and experienced roller men and
shall be kept in operation continuously if necessary, so that all parts of the
pavement will receive substantially equal compaction at the time desired.
The Engineer will order the mixing plant to cease operation at any time
proper rolling is not being performed.

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3/37.8 The compacted bituminous layers density requirements shall be equal to or

greater than ninety eight (98) percent of the average Marshall density of
each day's production for wearing course and ninety seven (97) percent of
the average Marshall density of each day's production for asphaltic
roadbase, base course and binder course. However, densities in excess of
101.8% shall not be permitted.

3/37.9 Any mix that becomes loose, broken, mixed with foreign material, or which is
in any way defective in finish or density, or which does not comply in other
respects with the requirements of the Specification shall be removed,
replaced with new materials, and finished in accordance with the
Specifications.

3/38 RE-ROLLING OF BITUMINOUS COURSES

3/38.1 Should any bituminous course fail to achieve the specified density, at the
discretion of the Engineer re-rolling may be allowed subject to the following
conditions:-

a. The densification to be achieved shall be 1% or less.

b. Only PTR's to be used weighing no greater than 18 tons.

c. Re-rolling can only be undertaken immediately after density test results

become available and shall be subject to the direction of the engineer.

d. Re-rolling to take place at the time of the day when the asphalt has
attained its maximum natural temperature, to be determined by
periodic temperature checks of the asphalt with a temperature gauge.

e. Re-rolling to be applied for a maximum of two hours.

f. Re-rolling to be carried out in the presence of the Engineer's

Representative.

g. The section of the works in question shall be cored for density

determination immediately after the completion of re-rolling. Re rolling is
to take place immediately upon receipt of initial reports from Laboratory.

h. If after re-testing, the density achieved is 0.5% below the specified

density, the asphaltic material will be accepted in the works subject to a
20% reduction to the billed rates. If, on the other hand, the density is
greater than 0.5% below the specified density, the asphaltic material
shall be removed and new material to the specification laid at the
Contractor's cost.

3/39 CONTACT SURFACES

3/39.1 Contact surfaces between the bituminous paving and of kerbing, gutters,
manholes, and other appurtenances shall be painted with a thin uniform
coating of tack coat as approved by the Engineer.

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3/40 JOINTS IN BITUMINOUS PAVING

3/40.1 In widening and lane construction, when new asphalt is laid against
existing or old asphalt, the following specifications shall be considered
with regard to the longitudinal joints:

 Longitudinal joints shall be always located out of the wheel paths. I.e.
the joint should be close enough to the lane edge.
 Offsetting technique shall be used (Figure 3-1) to avoid construction
joints in the wheel path. Longitudinal and transverse joints in
succeeding courses shall be offset from the joint in the underlying
course be not less than hundred and fifty (150) millimeters stepping
progressively as shown on the Plans or as directed by the Engineer.
By all means, the joint shall not be located more than 450mm from
the pavement /lane edge.


Figure 3-1: Pavement layers offsetting technique

 The longitudinal joint in the surface course shall be coincident with

the lane lines.
 Transverse joints shall be carefully constructed and thoroughly
compacted to provide a smooth riding surface.
 Joints shall be straight edged to check smoothness. If the line of
joint is formed with a bulkhead, it shall form a straight line and
vertical face. If a bulkhead is not used to form the joint, the joint shall
be made by sawing the compacted mixture a sufficient back of the
end of the placement to assure full thickness of the pavement at the
joints; the material ahead of the sawed joint shall be removed. In
either case, the joint shall be painted with a thin coat of tack coat
before the fresh material is placed against it.
 In all cases, compacting the longitudinal joint from the cold side of
the joint, should be avoided.
 The joint compaction shall be according to the following procedures:

o For a pneumatic tire roller, the centre of the outside tire should
be placed directly over the top of the joint. Lane 1 is the cold
mix while lane 2 is the hot mix (Figure 3-2).

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 SECTION 3 PAVEMENT CONSTRUCTION
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Figure 3-2: Proper placement for a Pneumatic tire roller over the longitudinal
joint

o For a steel wheel roller, the majority of the weight of the drum
should be placed on the lane 2 side (hot mix) with only about
150mm (6 inches) extended over the first lane (cold mix) as
shown in Figure 3-3 below.

Figure 3-3: Proper placement for a Steel wheel roller over the longitudinal joint

 Random Cross and diagonal rolling shall be avoided during the

compaction of the joints.

 Where longitudinal joints are constructed, and due to the required

maintenance of traffic or to unforeseeable conditions, the
temperature of the mixture at the longitudinal edge of the strip first
laid becomes less than 80oC, the edge shall, prior to paving the
adjacent strip, be painted with a thin coat of tack coat. If the edge of
the joint is not vertical, it shall be saw cut to a vertical face.

 Joints between old and new pavement or between successive day's

work shall be properly made, to ensure thorough and continuous
bonding between the two pavements. All construction joints in
previously laid material shall be constructed by cutting the material
back vertically for its full depth to expose a fresh surface.

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3/40.2 Before placing the fresh mix against a cut joint or against old pavement, the
contact surface shall be sprayed or painted with a thin uniform coat of tack
coat.

 Where a finishing machine is used, the longitudinal joint shall be

made be overlapping the screed on the previously laid material for a
width of at least three (30) millimeters and depositing a sufficient
amount of mix so that the joint formed will be smooth and tight.

 Where a reinforcement fabric is specified for use on longitudinal

joints, the reinforcement fabric shall meet the following criteria:

Item Criteria
Raw material Polyester
Coating Bituminous or as per manufacturer’s
recommendation
Weight of Fabric (g/mm2) 240
Mesh size (mm) 30 x 30
Ultimate strength BS6906 P1 50 longitudinal, 50 transverse
(kN)
Elongation at break BS6906 P1 12 longitudinal, 14 transverse
(%)
Strength at 3% elongation BS
12 Longitudinal, 10 transverse
6906 P1

The application requirements of the reinforcement geogrid shall be strictly in

accordance with the manufacturer’s recommendations. It shall include for the
application of a suitable tack coat to the surface prior to installation. In addition, it shall
be tensioned and fixed in place with an approved pinning bolt system specifically
manufactured for the purpose.

Longitudinal and transverse overlap where applicable shall be terminated towards the
direction of laying to avoid snagging on the paver.

Field testing for joint density

 The Contractor shall perform a joint density evaluation for each sub lot at the
random sample locations selected for in place air void testing.
 Density testing shall be according to ASTM D1188:2007 or ASTM
D2726:2005a. Following the procedures used to measure the performance
properties of the bituminous mix outlined in clauses 3/47.3, 3/47.4, and 3/47.5 in
the General Specifications, the density of both the asphalt mat and the
construction joint can be measured. The following procedure is suggested:

Acceptance criteria
 At each location, the Contractor shall perform a joint density testing at 200mm
(8 inches) from a mat edge that will become a longitudinal joint. This reading will
be compared to density value taken on the interior of the mat more than 600mm
(2 feet) from the mat edge. The evaluation fails when:


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o The density at the 200mm offset from the mat edge is more than
0.045gm/cc (48 kg/cubic meter) below the interior mat density.
o The density at the 200mm offset from the mat edge is 3% less than the
interior mat density,
o The theoretical maximum density at the 200mm offset from the mat edge
is less than 90% of the theoretical maximum density measured at the
interior mat density.

 The Contractor shall investigate the cause of failure and take corrective actions
during production to improve the joint density.
 Production of the hot mix asphalt shall cease when two (2) consecutive
evaluations fail unless otherwise approved by the Engineer.
 The Contractor shall make changes to the hot mix, the compaction procedure or
placement process before production is resumed.
 The Contractor may produce enough mixture to place approximately 750 linear
meters of pavement one (1) paver width wide. Two (2) joint density evaluations
shall be performed within these 750 linear meters of production and if both
evaluations are acceptable, the Contractor may resume normal operations.
However, if one (1) or both of the joint density evaluations fail, the Contractor
shall make additional changes as approved by the Engineer and an additional
750 linear meters of pavement shall be laid and evaluated as before. This
procedure of placing.
 The evaluating of 750 linear meters sections will be continued until both joint
density evaluations pass.
 The Engineer may require the Contractor to implement different joint
construction methods or provide special joint making equipment to improve joint
density.
 Normal production and joint density verification will resume when both joint
density evaluations pass. Although it is the Contractor’s responsibility to perform
joint density evaluations, the Engineer may make as many independent joint
density verifications as deemed necessary at the random sample locations. The
Engineer’s results will be used to determine joint density when available.

3/41 PROTECTION OF COMPACTED LAYER

3/41.1 The Contractor shall protect all sections of newly compacted pavement from
traffic until they have hardened sufficiently to the approval of the Engineer.
On heavily trafficked roads during the summer months a minimum period of
7 days must elapse before the newly compacted pavement is trafficked.

3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES

3/42.1 Prior to the commencement of the bituminous paving operations, the

Contractor shall construct trial lengths, of at least 30 metres. The materials
used in the trials shall be those approved for use in the bituminous paving
courses and the equipment used shall be that according to the Contractor's
approved detailed Method Statement and equipment list and the programme
of work.

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3/42.2 The object of these trials is to determine the adequacy of the Contractor's
equipment, the loose depth measurements necessary to result in the
specified compacted layer depths, and the relationship between the number
of compaction passes and the resulting density of the material.

3/42.3 The Contractor may proceed with the bituminous paving operations only
after the method and procedures established by the compaction trials have
been approved by the Engineer.

3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES

3/43.1 At final compaction the finished surfaces of the individual layers shall fall
within the following maximum tolerances, measured with a 3 m straightedge
laid in any direction.

- Base Course 6 mm
- Binder Course 4 mm
- Wearing Course 4 mm

3/43.2 The Rideability of the finished wearing course when tested with a Laser Road
Surface Testing Machine shall have an IRI (International Roughness Index) not
exceeding the following values:

 New Construction
o Freeway, Expressway, Arterials and Collectors:

Average value over a 400 meter section  0.90 m/km

o Local Roads (Residential, Commercial and Industrial)

Straight Edge Measurement is required

 Pavement Rehabilitation
o Freeway, Expressway, Arterials and Collectors

 One layer of asphalt :

Average value over a 400 meter section  1.10

 Two layers of asphalt

Average value over a 400 meter section  1.00

o Local Roads (Residential, Commercial and Industrial)

Straight Edge Measurement is required

Peak individual value over a 25 meter section shall be  1.5 m/km (Not
more than 2 values per 400 meters). This applies to both new road
construction and rehabilitation works.

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The amplitude of the longitudinal profile of the road, filtered between (a)
1 meter and 3.3 meters and (b) 3.3 meters and 13 meters shall not
exceed the following values:

1m to 3.3 m  1.8 mm
3.3 m to 13 m  4.0 mm

3/43.3 All humps and depressions exceeding the specified tolerance shall be
corrected by removing the defective work and replacing it with new
material as directed by the Engineer at the Contractors cost.

3/43.4 Directional ramps on bridges or interchanges and tunnels with widely

spaced joints of more than 25m should be tested, unless otherwise
instructed, and shall have an IRI not exceeding the following values:

 Average value over a 400 meter section  0.90 m/km

(Flexible Pavement)
 Average value over a 400 meter section  1.20 m/km
(Rigid Pavement)

3/43.5 Individual roughness readings at joints in rigid pavement shall be

excluded during processing the roughness data.

3/43.6 Ramps, Loops, U Turn lanes, shoulders and other links with a length
less than the 400m or those roads sections constructed of closely
spaced joints shall be excluded. Also, the adjacent partial lanes to the
existing road widening with pavement transition at construction tie-ins
shall be excluded from roughness testing.

3/43.7 Tolerance on finished surface levels shall be:-

Road surface (Wearing course) +/- 4 mm

Base courses +/- 6 mm

3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS

3/44.1 The thickness of the bituminous paving courses shall be determined in

accordance with ASTM D3549: 2003.

3/44.2 For the purpose of establishing an adjusted unit rate for bituminous paving
courses, units to be considered separately are defined as three hundred
(300) linear meters in each traffic lane. The last unit in each lane shall be
three hundred (300) meters plus the fractional part of three hundred (300)
meters remaining. At least three (3) samples of cores in sets of two (2) shall
be taken at random from each unit being sampled (i.e. six cores per unit).

3/44.3 Other areas such as intersections, entrances, crossovers, ramps, etc. will be
considered as one unit and the thickness of each unit shall be determined
separately. Small irregular unit areas may be included as part of another
unit. At such point as the Engineer may select in each unit, three (3)
samples of cores in sets of two (2) shall be taken for each unit of bituminous

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paving course. One unit shall represent an area of not more than 1125
sq.m.

3/44.4 If all the core samples (sets of two (2)) so taken are not deficient by more
than three (3) mm from the specified thickness, full payment will be made. If
any core sample/s (set of two (2)) is deficient by more than three (3) mm
from the specified thickness, two (2) sets of additional core samples shall be
taken from the area represented and if the average of the three (3) sets of
two (2) core samples is not deficient by more than three (3) mm from the
specified thickness, full payment will be made.

If the average thickness of three (3) cores in sets of two (2) from each set is
deficient by more than three (3mm), but not more than ten (10mm), or fifteen
(15) percent (whichever is less), from the specified thickness, an adjusted
unit price as provided in the Bill of Quantities will be paid for the area
represented by these cores in sets of two (2).

3/44.5 In calculating the average thickness of each bituminous paving course,

measurements which are in excess of the specified thickness by more than
three (3mm) will be considered as the specified thickness plus three (3mm),
and measurements which are less than specified thickness by more than ten
(10mm) or fifteen (15) percent (whichever is less), will not be included in the
average.

3/44.6 When the measurement of any core sample/s (set of two (2)) is less than
specified thickness by more than ten (10mm), or fifteen percent (whichever
is less), the actual thickness of the bituminous paving course in this area will
be determined by taking additional core sample/s (set of two (2)) at not less
than three (3) meters intervals parallel to the centre-line in each direction
from the affected location until, in each direction, core sample/s (set of two
(2)) is found which is not deficient by more than ten (10mm), or fifteen (15)
percent (whichever is less). Asphalt areas which are deficient by more than
ten (10) mm or 15% (whichever is less) shall be removed and replaced at
the Contractor's expense. Exploratory core sample/s (set of two (2)) for
deficient thickness may be used in average for adjusted unit price. (Refer to
the Bill of Quantities - Preambles for Pavement Construction for price
adjustments).

3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES

3/45.1 The density of the mix as placed and compacted on the road shall be
determined from cores cut from the compacted courses on the road at
locations specified by the Engineer. Samples shall be obtained in
accordance with ASTM D979: 2001 in sets of two (2) from the same location
on the road.

The frequency of testing shall be three (3) sets of samples per traffic lane
per three hundred (300) linear meters per layer or a minimum of one (1) set
per day for shorter runs, or as directed by the Engineer and such additional
tests to determine limits of area deficient in density, or those over
compacted out of the acceptable range for retest. The density of these
samples will be referred to as "Road Density".

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3/45.2 The Contractor shall cut the samples with an approved core drill in the
presence of the Engineer. The equipment shall be capable of cutting the
material without shattering the edges of the specimen. The nominal size of
the samples shall be ten (100mm) in diameter for binder course and wearing
course and fifteen (150mm) in diameter for base course and road base.

3/45.3 All test holes shall be filled and made good with approved material by the
Contractor at his expense.

3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS

3/46.1 Hot bituminous mix shall be placed when the air temperature is eight (8)
degrees C or above and when the weather is not dusty, foggy or rainy and
when the existing surface is free from moisture. Bituminous mix shall not be
placed during sand storms.

3/46.2 No paving operations shall be started if rain is imminent.

3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES

3/47.1 Bitumen Material: One sample shall be tested for penetration and
softening point (ring and ball method) test every 80 tones or part thereof.

3/47.2 Aggregate: One sample for each stockpile every 2,000 cu.m. or part
thereof shall be taken and all the required tests shall be performed.

3/47.3 Bituminous Mix: One sample of mix shall be obtained from at least every
300 tones or part thereof and tested for bitumen content in accordance with
ASTM D6307: 2005 (Ignition Method), grading (ASTM D5444: 2005).
Density in accordance with ASTM D1188: 2002 or D2726: 2005 and as
required by the Engineer. Stability in accordance with ASTM D6927: 2006
and voidage contents in accordance with DMS 9: 2001 shall be determined
on Marshall Specimens.

3/47.4 Loss of Marshall Stability shall be tested for at least every 7,000 tons shall
be in accordance with DMS 10: 2001.
3/47.5 Thickness cores and compaction cores shall be taken as specified in Clause
3/44 and 3/45 respectively.

3/48 BITUMINOUS PRIME COAT

3/48.1 Bituminous Prime Coat shall consist of supplying and applying liquid asphalt
to a previously prepared and approved subgrade or subbase, aggregate
base course or wet mix road-base in accordance with this Specification.

3/48.2 Material for Prime Coat shall be:-

Liquid Asphalt for prime coat shall be medium curing cut back asphalt
MC-70 conforms to the requirements of ASTM D2027-97(2004) as modified

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by Table 3-23 or as directed by the Engineer. Sampling shall be in

accordance with ASTM D140:2009. One sample shall be tested every 5
tones or part thereof.

Table 3- 23: Properties of bituminous prime coat

MEDIUM CURING LIQUID

TEST ASTM Ref. MIN. MAX.
Saybolt Furol Viscosity, at 50 deg.C. D88 : 2007 60 120
sec.
Flash Point, Tag open Cup, deg.C. D3143:2008 38 -
Distillation: Distillate (% of total D402 : 2008
distillation to 360 deg.C)
 To 225 deg C D2026-97 (2004) - 20
 To 260 deg C D2026-97 (2004) 20 60
 To 316 deg C D2026-97 (2004) 65 90
Residue from distillation 55
to 360 deg.C, percent by
volume difference
Tests on residue from
distillation :
- Penetration 25 deg.C, D5:2006 120 250
100g 5 seconds, 0.1 mm.
- Ductility 25 deg.C, cm D113:2002 100 -
- - Solubility in trichloroethylene % D2042:2009 99 -
- Water percent D95:2005 - 0.2

3/48.3 Prime coat shall be applied at a rate of not less than 0.75 litres per square
metre and not more 1.0 litre per square metre.

3/48.4 The exact rate of application, which may be varied to suit field conditions,
will be determined by the Engineer following trials to be carried out by the
Contractor.

3/48.5 The surface to be prime coated shall be uniformly smooth and firm and true
to the grades and cross-sections shown on the drawings within specified
tolerances, and so maintained throughout prime coating. Prime coat shall
not be placed on a soft, uneven base. Any holes, depressions or
irregularities shall be repaired by the removal of loose and unsuitable
material and its replacement with suitable material compacted to produce a
dense, even surface of uniform texture. When required, the surface to be
primed shall be lightly bladed and compacted and the Engineer may instruct
a light application of water to facilitate penetration. Priming will not be
permitted when the surface is wet.

3/48.6 Prime coat shall not be applied when the ambient temperature is less than
13 deg. C or during rain, fog, dust storms or other unsuitable weather. The
application temperature for MC-70 liquid asphalt shall be between 50 deg. C
and 80 deg. C as approved by the Engineer. It shall be applied to one lane
of the carriageway width at a time. When applied in two or more lanes there
shall be a slight overlap along adjoining edges. Overlapping will not be

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permitted at transverse joints and thick paper shall be used to protect the
previous application.

3/48.7 Traffic shall be kept off the prime coat until it has penetrated the subgrade or
roadbase and fully cured and should be left undisturbed for a period of
minimum 48 hours or as otherwise directed by the Engineer

3/48.8 The Contractor shall furnish and spread at his cost sufficient clean fine sand,
of an approved quality, to blot up areas which show an excess of prime coat.

3/48.9 The primed surface shall be maintained in a good, clean condition at all
times until the next course is placed. Any surface irregularities or holes in
the primed surface, however caused, shall be repaired and corrected to the
Engineer's satisfaction.

3/49 BITUMINOUS TACK COAT

3/49.1 Bituminous tack coat shall consist of supplying and applying emulsified
asphalt diluted with an equal quantity of water (1:1) to a previously prepared
bituminous base course or binder course or to an existing bituminous
surface, in accordance with this specification.

3/49.2 The materials for bituminous tack coat shall be slow setting emulsified
asphalt, grade SS-1h (anionic) conforming to the requirements ASTM D977:
2005. Sampling shall be in accordance with ASTM D140: 2009 and testing
in accordance with ASTM D244: 2009. The sampling frequency shall be one
sample for every 5 tones or part thereof for testing.

3/49.3 The tack coat (diluted emulsion) shall be applied in quantities of not less
than 0.3 liters per square meter and not more than 0.5 liters per square
meter.

3/49.4 Immediately before applying the tack coat, all loose material, dirt, clay or
other objectionable material, shall be removed from the surface with a power
broom or blower supplemented with hand brooms, as directed by the
Engineer. After the cleaning operation, and prior to the application of the
tack coat, an inspection of the area to be coated will be made by the
Engineer.

3/49.5 The application temperature for the tack coat shall be between 10 deg. C
and 60 deg. C as directed by the Engineer. The material should not be
applied when the ambient temperature is less than 13 deg. C or during rain,
fog, dust storms or other unsuitable weather.

3/49.6 After application, the surface shall be allowed to dry to the proper condition
of tackiness, or as otherwise directed by the Engineer, to receive the
following pavement course. Time must be allowed for emulsion to break or
cure (i.e.to turn from brown (the surface is slick) to black (the surface
becomes sticky) prior to placing hot mix on it. The length of time required for
this to happen will depend on the weather. In good paving weather, it will
take only few minutes. In marginal weather, it may take several minutes.
Tack coat shall be applied only so far in advance to pavement courses, or

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as otherwise directed by the Engineer, to obtain the proper condition of

tackiness Time and traffic constraints usually do not allow long cure times,
but, whenever found practical, the time allowed for the curing of tack shall
be maximized and the Contractor shall protect the tack coat from damage
during this period.

3/49.7 If the completed tack coat is damaged by rain or dust, it shall be allowed to
dry, cleaned by power broom or blower and, if required by the Engineer, an
additional light application of tack coat shall be applied. No additional
payment shall be made for this work.

3/49.8 Where, in the opinion of the Engineer, a tack coat is not necessary, the
Contractor shall clear, at his expense the existing surface free of dust and
other deleterious material as indicated in clause 3/49.4 above.

3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT

3/50.1 A self-powered pressure distributor should be used for applying asphalt

mixture. The distributor shall have pneumatic tires of such width and
number that the load produced on the base surface shall not exceed 110 Kg
per centimeter of tire width, and shall be so designed and equipped as to
distribute the bituminous material uniformly at even heat on variable width of
surface at readily determined and controlled rates from 0.2 to 7.5 liters per
sq.m. with a pressure range of 1.25 Kg to 5.2 Kg per sq.m. and with an
allowable variation from any specified rate not exceeding 5 percent.
Distributors and booster tanks shall be so maintained at all times that no
dripping of bituminous material will occur from any part of the equipment.
3/50.2 Distribution equipment shall include an independently operated bitumen
pump, technometer pressure gauges, volume measuring devices, a
thermometer for reading the temperature of tank contents, and a hose
attachment for applying bituminous material to spots unavoidably missed by
the distributor. The distributor shall be equipped for circulation and agitation
of the bituminous material during the heating process.

3/50.3 The equipment for heating shall consist of steam coils and equipment for
producing steam, so designed that steam will not be introduced into the
material. In the event of storage tanks being used, an armored thermometer
with a range from 10 deg.C to 150 deg.C shall be fixed to the tank so that
the temperature of the bituminous material may be determined at all times.

3/50.4 Other heating facilities may be used subject to the approval of the Engineer.

3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION

3/51.1 This work shall consider of a wearing surface composed of a bituminous

prime followed by two (2) applications of bituminous seal coats with each
seal coat receiving an application of cover material in accordance with the
Specifications and in conformity with the lines shown on the drawings or
established by the Engineer.

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3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT

3/52.1 PRIME COAT

The prime coat shall be medium curing cut-back asphalt grade MC-70. The
rate of application shall be between 0.75 to 1.20 litres per square metre or
as specified by the Engineer.

3/52.2 SEAL COAT

The seal coat shall be 85/100 as per ASTM D946 penetration grade
bitumen. The bitumen may be cut back with up to 2% by weight of kerosene
to improve adhesion to the stone. The characteristics of the bitumen are
shown in Table 3-24 following:-

Table 3- 24: Characteristics of the bitumen used for surface treatment

85 - 100 AS PER ASTM D946-2009 PENETRATION GRADE BITUMEN

TEST METHOD OF MIN. MAX.
TESTING (ASTM)
Penetration at 25 deg.C,100 g, 5 D5: 2006 85 100
sec, 0.1 mm.
Flash Point, Cleveland Open D92: 2005a 232 -
Cup, deg.C
Ductility at 25 deg.C, cm D113: 2007 100 -
Solubility in trichloro ethylene, % D2042: 2009 99 -
Thin film oven test 3.2mm, 163 D1754:2009 1.0
deg.C 5 hour loss on heating,
percent
Penetration of residue percent of D5-2006 47 -
original
Ductility of residue at 25 deg.C 5 D113:2007 75 -
cm/min cm

3/52.3 COVER MATERIAL

Aggregate for cover material shall be screenings of crushed stone which are
clean, tough, durable and free from dirt and other objectionable matter. The
percentages of wear shall not be more than thirty (30) as determined by
ASTM C-131:2006. When subjected to five (5) cycles of magnesium
sulphate soundness testing, as determined by ASTM C-88:2005, it shall
have a weight loss not greater than ten (10) percent. Aggregate shall have
a flakiness index of not more than 30 (BS EN 933-Part 3) and an elongation
index of not more than 30 (BS812: Part 105: Section 105.2) and Aggregate
Crushing Value (ACV) of not less than 20% (BS 812: 1990 P110). No less
than sixty (60) percent by weight of crushed stone shall consist of crushed
pieces having two or more faces produced by fracture when tested by DM
standard test method DMS 8: 2001. Aggregate shall conform to the
following gradations (Table 3-25) and shall be approved by the Engineer.

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Table 3- 25: Gradation for double bituminous surface treatment

DOUBLE BITUMINOUS SURFACE TREATMENT

Sieve 19 12.5 9.5 6.3 4.75 2.0 0.60 0.075

Opening
(mm)
Sieve 3/4" 1/2" 3/8" 1/4" No.4 No.10 No.30 No.200
No.
First 100 70-90 0-15 - 0-2 - - -
Course
Second - - 100 90-100 60-85 0-25 0-5 0-2
Course

3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT

3/53.1 The equipment used by the Contractor shall include a power broom or a
power blower, or both; a self propelled, pneumatic-tyred roller, or steel-
wheeled tandem roller (4 to 8 tons) or both; self-propelled aggregate
spreading equipment that can be adjusted to spread accurately the specified
amount per square meter; a bitumen distributor and equipment for heating
the asphaltic materials.

3/53.2 Other equipment may be used in addition to the specified equipment when
approved or requested by the Engineer.

3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE

TREATMENT

3/54.1 HEATING OF BITUMINOUS MATERIALS shall be with equipment as

specified. The use of any method or agitation or heating that introduces free
steam or moisture into the bituminous material is prohibited. Materials
heated to temperatures above twenty eight (28) degrees C higher than the
maximum application temperature specified shall be considered as
overheated and shall be rejected until the material can be resampled and
retested. The reacceptance or final rejection will be made by the Engineer
on the same requirements under which the material was originally tested.

5/54.2 If aggregates are deemed by the Engineer to be dusty or dirty they shall be
washed after which their use shall not be permitted until all free water has
evaporated or been drained.

3/55 APPLICATION OF DOUBLE BITUMINOUS SURFACE TREATMENT

3/55.1 After the prime coat has been applied and has thoroughly penetrated the
surface and cured as specified, the Contractor shall apply 85/100
penetration bitumen and shall apply the cover material and roll and
manipulate the surface, all in accordance with the requirements specified
hereinafter. The material shall be uniformly applied at the rate designated to
the surface being sealed.

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3/55.2 Bituminous material shall be applied by means of a pressure distributor in a

uniform, continuous speed over the section to be treated and within the
temperature range specified. The quantity of bituminous material to be used
per square meter shall be within the limits hereinafter specified and as
directed by the Engineer.

3/55.3 A strip of building paper, at least one (1) meter in width and with a length
equal to that of the spray bar of the distributor plus thirty (30) centimeters,
shall be used at the beginning of each spread. The paper shall be removed
and disposed of in an approved manner. The distributor shall be moving
forward at proper application speed at the time the spray bar is opened.
Any skipped areas or deficiencies shall be corrected in an approved
manner. Junctions of spreads shall be carefully made to ensure a smooth
riding surface.

3/55.4 The length of spread of bituminous materials shall not be in excess of that
which trucks loaded with cover coat material can immediately cover.
3/55.5 The spread of bituminous material shall not be more than fifteen (150mm)
wider than the width covered by the cover coat material from the spreading
device. Under no circumstances shall operations proceed in such manner
that bituminous material will be allowed to chill, set up, dry or otherwise
impair retention of the cover coat.

3/55.6 The distributor, when not spreading, shall be so designed that the spray bar
or mechanism will not drip bituminous material on the surface of the traveled
way.

3/55.7 Distribution of the bituminous material shall be so regulated and sufficient

bituminous material must remain in the distributor at the end of each
application so that there will be a uniform distribution of bituminous material.
In no case shall the distributor be allowed to expel air with the bituminous
material thereby causing uneven coverage.

3/55.8 The angle of the spray nozzles and the height of the spray bar shall be so
adjusted and frequently checked so that uniform distribution is ensured. If
the raise of the spray bar as the load is removed is excessive and
contributes to drilling and streaking of the seal course, the frame of the
distributor shall be blocked or snubbed to the axle of the truck to maintain a
constant height of the spray bar above the road surface. The distribution
shall cease immediately upon any clogging or interference of any nozzle and
corrective measures shall be taken before distribution is resumed.

3/55.9 APPLICATION OF AGGREGATE

Immediately following the application of the bituminous material, cover

material shall be spread with an approved aggregate spreader in quantities
as specified by the Engineer and within the limits specified herein.
Spreading shall be accomplished in such a manner that the tyres of the
trucks or aggregate spreader at no time contact the uncovered and newly
applied bituminous material.

3/55.10 The operations of distributing bituminous material shall not be in excess of

one hundred (100) linear metres ahead of the spreading of the aggregate.

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 SECTION 3 PAVEMENT CONSTRUCTION
50

3/55.11 Procedures of starting, stopping or turning of any piece of equipment which

results in displacement of the cover material or damage to the seal courses
shall be prohibited.

3/55.12 The spreading equipment shall be of such width and arrangement that as
the aggregate is placed, complete coverage will be obtained. No brooming,
dragging or blading of the cover material shall be permitted prior to initial
rolling. Any rearrangement of the cover material shall be done by hand
methods. Overlapping the applications of cover material shall be avoided
and all spillage shall be removed from the surface. Before rolling, the
bituminous material shall be uniformly covered.

3/55.13 The rates of application for bituminous material and aggregate for "Double
Bituminous Surface Treatment" shall be within the following limits:

Table 3- 26: Rates of application of Asphalt and aggregate for Double Bituminous
Surface Treatment
Asphalt Aggregate
85/100 Pen

KG/SQ.M. KG/SQ.M.
MIN. MAX. MIN. MAX.
First application (Course) 0.70 1.10 12.5 15.0
Second application (Course) 0.70 0.90 6.5 8.5

3/55.14 MANIPULATION

Immediately after the application of bituminous material and aggregate to

the road surface and after the aggregate has been rearranged as may be
necessary to provide uniform and complete coverage, the surface shall be
sufficiently rolled with an approved pneumatic-tyred roller to embed the
aggregate thoroughly into the bituminous material. Sufficient rollers shall be
provided such that the initial rolling consisting of a single pass of a 10 - 12
ton tandem steel wheel roller followed by at least two (2) complete coverage
with the pneumatic-tyred roller shall be completed within thirty (30) minutes
after the cover material is applied. The rollers shall be operated on each
coverage so that each succeeding trip of the roller will overlap at least fifty
(50) percent of the width of the previous trip. No blading or dragging of the
aggregate will be permitted for the first seal coat. Any rearrangement of the
cover material before or during the initial rolling shall be done by approved
hand methods. Rolling shall be continued after the rolling specified above is
completed until a maximum amount of the aggregate is satisfactorily
embedded in the bituminous material. Pneumatic-tyred rollers shall be
operated at a maximum speed of eight (8) kilometers per hour.

3/55.15 SECOND SEAL COAT

Unless otherwise designated on the drawings, or directed by the Engineer,

the second seal coat shall not be applied for 48 hours after the application of
the first seal coat.

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 SECTION 3 PAVEMENT CONSTRUCTION
51

3/55.16 Immediately prior to the second application of bituminous material for

sealing, the surface shall be cleaned in an approved manner of all dust and
excess cover material which is not embedded in the first application of
bituminous material for sealing. Care shall be exercised not to dislodge any
cover material which is embedded in the bituminous material. The second
seal coat shall be applied as previously specified. Brooms or drag brooms
shall not be used to shift the cover material until the initial rolling with the
pneumatic-tyred roller is completed and until the bituminous material has
cooled and set up sufficiently to hold the cover material, preferably not
earlier than the day following the application of the second seal coat. Any
rearrangement of the cover material during the initial rolling shall be done by
approved hand methods.

3/55.17 The rolling shall be longitudinal and shall commence at the outer edge of the
shoulder and then progress towards the inner edge. Rolling shall continue
until the entire surface has been completely covered at least three (3) times
with a pneumatic tyred roller. Maximum speed of rollers shall be as
previously specified.

3/55.18 ADDITIONAL MANIPULATION OF COMPLETED SURFACES

The Contractor shall manipulate the surface for a period of five (5) days after
the second seal coat has been applied. The manipulation shall consist of
the application of additional aggregate or additional dragging and rolling or
all of these operations to portions of the surface that, as determined by the
Engineer, require such additional treatment.

The manipulation shall also include the dragging and one (1) complete
rolling over the entire surface each day from the time the surface is
completed until and including the fifth (5th) day after. A light blade equipped
with a broom drag shall be operated immediately ahead of the roller
throughout all rolling during the manipulation period. The daily dragging and
rolling under manipulation may be omitted, if in the opinion of the Engineer,
the weather and roadbed conditions are such that the dragging and rolling
would not be beneficial to the surface.

3/55.19 Aggregate and additional manipulation ordered by the Engineer, in this

work, will not be paid for separately but will be considered subsidiary to the
item of 'Double Bituminous Surface Treatment" included in the "Bill of
Quantities".

3/55.20 Except for times when it is necessary for hauling equipment and/or pilot
trucks to travel on the newly applied seal coat, traffic of all types shall be
kept off the seal coat until it has had time to set properly. The minimum
traffic free period shall be 24 hours.

3/55.21 WEATHER LIMITATIONS

Surface treatment operations shall be carried on only when the surface is

dry, when the atmospheric temperature is above fifteen (15) degrees C, and

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 SECTION 3 PAVEMENT CONSTRUCTION
52

when the weather is not dusty, foggy or rainy. The above requirements may
be waived, but only when so directed and in writing by the Engineer.

3/56 PROTECTION OF ADJACENT STRUCTURES

FROM BITUMEN SPLASHING

3/56.1 When bituminous materials are being applied, the surface of all structures,
wheel guards, guard rail, kerbs and gutters, and other roadway
appurtenances shall be protected in an approved manner to prevent them
from being splattered with bituminous material or marred by equipment
operation. In the event that any appurtenances become splattered or
marred, the Contractor shall at his own expense, remove all traces of
bituminous materials, and repair all damage, and leave the appurtenances
in an approved condition.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 52

 Section 4
Concrete Works
 1 SECTION 4 CONCRETE WORKS

TABLE OF CONTENTS

4/1 CEMENT .................................................................................................................... 2

4/2 AGGREGATES GENERAL REQUIREMENTS ......................................................... 6
4/3 FINE AGGREGATES ............................................................................................... 10
4/4 COARSE AGGREGATE FOR CONCRETE ............................................................ 11
4/5 COMBINED AGGREGATE ...................................................................................... 11
4/6 WATER FOR CONCRETE ...................................................................................... 12
4/7 APPLICABLE TESTS AND CODES ........................................................................ 13
4/8 REINFORCEMENT BARS ....................................................................................... 16
4/9 BAR SCHEDULES AND SHOP DRAWINGS ......................................................... 17
4/10 BAR CUTTING AND BENDING .............................................................................. 17
4/11 PLACING AND FIXING REINFORCEMENT ........................................................... 17
4/12 WELDED WIRE FABRIC ......................................................................................... 18
4/13 SPACER BLOCKS ................................................................................................... 18
4/14 ADMIXTURES .......................................................................................................... 18
4/15 CONCRETE MIX SPECIFICATION ........................................................................ 19
4/16 CONCRETE MIX DESIGN....................................................................................... 21
4/17 QUALITY CONTROL ............................................................................................... 23
4/18 CONCRETE DESIGN LIMITS ................................................................................. 27
4/19 CONSISTENCY OF CONCRETE............................................................................ 27
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS ...................................... 28
4/21 ASSEMBLY AND HANDLING MATERIALS ........................................................... 28
4/22 MIXING CONCRETE ............................................................................................... 29
4/23 READY MIXED CONCRETE ................................................................................... 30
4/24 TRANSPORT AND PLACING ................................................................................. 31
4/25 COMPACTION OF CONCRETE ............................................................................. 33
4/26 CONSTRUCTION JOINTS ...................................................................................... 33
4/27 CURING OF CONCRETE........................................................................................ 34
4/28 EARLY LOADING .................................................................................................... 35
4/29 CONCRETING AT NIGHT ....................................................................................... 35
4/30 CONCRETING IN HOT WEATHER ........................................................................ 36
4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE .......................................... 38
4/32 FORMWORK............................................................................................................ 39
4/33 CLASSES OF FINISH .............................................................................................. 43
4/34 MORTAR .................................................................................................................. 44
4/35 EXTENT OF POURS ............................................................................................... 45
4/36 POST-TENSIONED CONCRETE WORKS ............................................................. 45

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 2 SECTION 4 CONCRETE WORKS

Concrete work shall consist of furnishing all materials and constructing structures of the
forms, shapes and dimensions shown on the Drawings or as directed in accordance with
the details shown on the Drawings and these Specifications.

4/1 CEMENT
4/1.1 ORDINARY PORTLAND CEMENT

Ordinary Portland cement shall conform to the requirements of BS EN 197-

1:2000, Class 42.5N or ASTM C150:09 Type I and with the following
amendments: -

 The acid soluble alkali level measured as Na2 0+0.658 K20 shall not
exceed 0.6% by weight determined by the test method described in BS EN
196 Part 2: 2005.

 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in
accordance with BS 4550: Part 3 Section 3.8:1978.

 The Tricalcium Aluminates content shall lie within the range of 4% to 13%
when tested according to the method BS EN 196-2: 2005

 The specific surface (fineness) shall be not greater than 375 .m²/Kg and
not less than 280.m²/Kg when tested as described in BS EN 196-2 : 2005

 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2: 2005.

4/1.2 BLENDED CEMENT

Where Ordinary Portland Cement Type 1, which conforms to ASTM C

150:2009 and amendments mentioned in Clause 4/1.1 is used, blended
cement which conforms to one of the following may be substituted.

 .ASTM C 595:09 Type IP or Type IP (MS)

 ASTM C 1157 Type GU or MS

4/1.2.1 The blended cement shall conform to one of the followings:

 ASTM C 595:09 Type IP or Type IP (MS) where 15 to 25 % Class F Fly

ash has been blended with Portland Cement Type 1 (ASTM C150).
Portland Cement Type 1 shall be low alkali cement conforming to the
chemical requirements listed in Table 2, in ASTM C 150:2009 Standard.

 ASTM C 1157:09 Type GU or Type MS which conform to Option R (i.e.

Low Reactivity with Alkali-Reactive Aggregate).

4/1.2.2 Unless otherwise approved by the Engineer, the product of only one factory of
any brand and type of Portland cement shall be used on each project.

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 3 SECTION 4 CONCRETE WORKS

The contractor shall provide the proper means for cement storage and
protection against dampness and cement which has become partially set or
which contain lumps of caked cement will not be permitted.

Cement salvaged from discarded or used bags shall not be used.

Blended cement containing fly ash shall not be used in bridge decks.

4/1.2.3 FLY ASH

If Fly Ash is recommended for concrete works, it shall conform to the

requirements of ASTM C618:89, Class C or Class F.

All Chemical requirements for Fly Ash Class C and Class F listed in ASTM C
618: 89 Table1-A shall apply, with the exception of footnote A.

 Class C fly ash will not be permitted where sulfate resistant cement is
required.

 Fly ash shall be from a pre-approved source.

 The fly ash intended for use on the project shall have been tested and
accepted prior to its use.

 Pre-approval shall include submission of a report from the supplier

confirming that the fly ash is form a source that conforms to the
requirements of Toxicity Characteristic Leaching Procedure (TCLP)
adopted in the UAE.

 The supplier’s submission shall include a detailed report with the results of
TCLP testing for heavy metal and other contaminants in the fly ash.

 The testing report shall include a list of the contaminant tested and the
allowable limits for each contaminant.

 A new report shall be submitted for each pre-approved source annually.

Additional TCLP testing may be required when the Department suspects
that the fly ash source may have become contaminated.

 For any source of fly ash that has not been pre-approved, the Contractor
shall notify the engineer of the source 30 days prior to use in the project.

 The fly ash shall be subject to sampling and testing by the Engineer.

 Test results that do not meet the physical and chemical requirements may
result in the suspension of the use of fly ash until the corrections
necessary have been taken to insure that the material meets the
specifications.

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 4 SECTION 4 CONCRETE WORKS

4/1.2.4 GROUND GRANULATED BLAST FURNACE SLAG (GGBS)

 If GGBS is recommended for concrete works, it shall conform to the requirements

of ASTM 595:09 or ASTM C 989:09.

The chemical requirements for the GGBS listed in ASTM 595:09 must be met.

4/1.3 SULPHATE RESISTING CEMENT :

Sulphate Resisting Cement shall comply with BS 4027 – 1996, Class 42.5N or
ASTM C150:09 Type V. In addition the cement shall comply with the
following:-

 The acid soluble alkali level measured as (Na2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN 196-2 :
2005

 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in
accordance with BS 4550:1978: Part 3 Section 3.8.

 The specific surface shall be not greater than 375 m²/Kg and not less than
280 .m²/Kg when tested as described in BS EN 196: Part 6: 1992.

 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2 : 2005

 The Tricalcium Aluminate content shall be 3.5% max when tested

according to the method BS EN 196-2 : 2005

4/1.3 MODERATE SULPHATE RESISTING PORTLAND CEMENT:

Moderate Sulphate Resisting Portland Cement shall comply with ASTM

C150:09 Type II. It shall also comply with Clause 4/1.2. In addition, the
cement shall comply with the following:-

 The acid soluble alkali level measured as (Na2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN196 – 2
2005
 The specific surface (fineness) shall not be greater than 375 sq.m/Kg and
not less than 280 sq.m/Kg when tested as described in BS EN 196: Part 6:
1992.
 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2 : 2005
 Contain not less than 4% and not more than 8% proportion of tricalcium
aluminate by weight when tested according to the method BS EN 196-2 :
2005
 Contain less than 2.7% proportion of Sulphur trioxide by weight according
to the method ASTM C563-07 or ASTM C114-09.

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 5 SECTION 4 CONCRETE WORKS

For any type of cement, the following physical & mechanical test shall also be
included:

 Consistency in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005

 Setting time in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005
 Soundness in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005
 Compressive Strength BS EN 196-1: 2005

The characteristic values of Mechanical and physical requirements are given

in Table 4-1 below:

Table 4- 1: Mechanical & physical properties of cement

Compressive Strength MPa Initial Soundness

Strength Early Strength Standard Strength Setting (expansion)
Class Time
2 days 7 days 28 days min. mm

32.5 N - ≥ 16.0 ≤ 52.5

≥ 32.5 ≥ 75
32.5 R ≥ 10.0 -
42.5 N ≥ 10.0
≥ 42.5 ≤ 62.5 ≥ 60 ≤ 10
42.5 R ≥ 20.0 -
52.5 N ≥ 20.0 -
≥ 52.5 ≥ 45
52.5 R ≥ 30.0 -

4/1.4 GENERAL
Each cement batch shall bear manufacturer's name and batch number. Type
of cement shall be the same as mentioned in the approved analysis report.
Each separate consignment of cement shall be tested by the manufacturer
before delivery and certified copies of such tests shall be supplied to the
Engineer before any part of the consignment is used in the works. The
Engineer reserves the right to order a re-test of cement at any time. Approval
of cement does not relieve the Contractor of the responsibility to produce
concrete of the specified strength.

4/1.5 Cement shall be delivered to site in bulk, or with the Engineer's approval, may
be supplied in sealed bags which shall bear the manufacturer's name and the
date of manufacture. Each consignment shall be accompanied by a copy of
the manufacturer's batch test certificate and certificate of guarantee.

4/1.6 Each consignment of cement shall be kept separate, identified and used in
order of delivery.

4/1.7 Any consignment not used within 2 months from the date of manufacture will
not be allowed to be used in the works.
4/1.8 One brand only of cement as approved by the Engineer shall be used
throughout the works unless otherwise authorized by the Engineer in writing.

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 6 SECTION 4 CONCRETE WORKS

4/1.9 Each cement batch shall bear manufacturer’s name and batch number

 Type of cement shall be the same as mentioned in the approved analysis

report.
 Each separate consignment shall be tested by manufacture before
delivery.
 Certified copies of batch test certificate and certificate of guarantee shall
be supplied to the Engineer before any part of the consignment is used in
the works.
 The Engineer reserves the right to order a re-test of cement at any time
 Approval of cement does not relieve the Contractor of the responsibility to
produce concrete of the specified strength.
 Cement shall be delivered to site in bulk, or with the Engineer’s approval,
may be supplied in sealed bags bearing manufacturer’s name and date of
manufacture.
 Each consignment shall be kept separate, identified and used in order of
delivery.
 Any consignment not used within 2 months from the date of manufacture
will not be allowed to be used in the works.

4/2 AGGREGATES GENERAL REQUIREMENTS

4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 "Concrete
aggregates from natural sources" and the fine aggregate shall also comply
with Dubai Municipality Administrative Order No. 143/91.

4/2.2 The aggregates used in the permanent works shall be crushed materials
obtained only from approved sources. Where natural gravel sources are
approved, then it shall be crushed such that it contains at least two crushed
faces.

4/2.3 Before any material from a particular source is used, the Contractor shall
obtain representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.

4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works.
Part of each sample will be required for concrete trial mixes and part shall be
retained for comparison with subsequent deliveries.
4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102:1989.
4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the
narrowest dimension between sides of the member for which the concrete is to

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 7 SECTION 4 CONCRETE WORKS

be used and not larger than 3/4 of the maximum clear distance between
reinforcing bars.
4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry
approved by the Engineer.
4/2.9 Unless otherwise authorized by the Engineer coarse aggregate shall be
delivered to site in separate sizes according to the maximum specified
aggregate size for each grade of concrete.
4/2.10 Aggregates shall meet the requirements of Table 4.2.
4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.3
or as directed by the Engineer.

Table 4- 2: Limits for physical, chemical & mechanical properties of aggregates for
concrete

SR. KIND OF TEST METHODS PERMISSIBLE LIMITS

No REQUIREMENT
FINES COARSE
1. Grading BS EN 933-1:97 Standard Standard
(Dry): AMD 15907:
2006
2. Material finer Than
0.075 mm for :
 Natural, uncrushed BS EN 933-1: 97 , max.3% max.1%
/crushed AMD 15907: 2006
or ASTM C117:
2004 (Wet)
 Crushed rock BS EN 933-1: 97: max.7% max.1%
AMD 15907: 2006
or ASTM C117:
2004 (Wet)
3. Clay lumps and friable ASTM C142: 09 max.1% max.1%
particles
4. Light weight pieces ASTM C123: 04 max.0.5% max.0.5%
5. Organic impurities for ASTM C40 : 2004 The color of
fine aggregate the
Supernatant
liquid is
lighter than
standard
color
solution
6. Water absorption ASTM C128 : max.2.3% max.2.0%
2007a ASTM C127
: 2007
7. Specific Gravity ASTM C128 : min.2.60 min.2.60
(apparent) 2007a
ASTM C127 : 2007
8. Shell content in BS EN 933-7:1998 max.10%
aggregates coarser
than 4 mm , Note 1

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 8 SECTION 4 CONCRETE WORKS

SR. KIND OF TEST METHODS PERMISSIBLE LIMITS

No REQUIREMENT
FINES COARSE
9. Particle shape
 Flakiness index BS EN max.25*
933:3:1997,AMD
14866: 2007
 Elongation index BS 812:90, Part max.25
105 : Section 105.2
*The index shall be max. 25 for combined aggregates but should not exceed more
than 30 for individual sizes.
9a. Partially crushed faces DMS 8 : 2001 100%.
of coarse aggregate
with at least one
crushed face.
10. Acid soluble BS 812:1988, Part
Chlorides, CL, 117

For reinforced
concrete made with:

 SRPC cements max.0.03% max.0.01%

 OPC & MSRPC max.0.03% max.0.02%

cements
For mass concrete
Made with:

SRPC cements max.0.03% max.0.02%

OPC & MSRPC max.0.03% max.0.04%
cements
For pre-stressed max.0.03% max.0.01%
concrete & steam
Cured structural
concrete
11. Acid soluble BS EN 1744- max.0.3% max.0.3%
sulphate, S03 1:1998
12. Soundness, MgS04, ASTM C88 : 2005 max.12% max.12%
(5 cycles)

13. Mechanical Strength

 10% fines value or BS 812:90, Part min100KN
111
 Impact value BS 812:90, Part max.30%
112: AMD 8772:
1995
 Los Angeles ASTM C131 : 2006 max.25%
Abrasion ASTM C535 : 2009
14. Drying Shrinkage BS EN 1367-Part max.0.03%
4:1998
15. Potential reactivity- ASTM C289:2007 Innocuous Innocuous
Of Aggregates, “Standard Test
Note 2 Method for
Potential Alkali-
Silica Reactivity of
Aggregates
(Chemical

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 9 SECTION 4 CONCRETE WORKS

SR. KIND OF TEST METHODS PERMISSIBLE LIMITS

No REQUIREMENT
FINES COARSE
Method)”
or
ASTM test ASTM
C1260-07

6 month -
ASTM C227:2003 expansion
“Standard Test 0.10% max.
Method for
Potential Alkali
Reactivity of
Cement-Aggregate
Combinations
(Mortar-Bar
Method)”

or ASTM test
ASTM C1260-07
(Note 3)

Note 1 : There is no requirement of shell content in sands passing 4 mm sieve size.

Note 2 : Aggregates may initially be assessed for its reactivity in accordance with ASTM
C289 and if potential reactivity is indicated, then mortar bar tests in accordance
with ASTM C227 shall be carried out.
Note 3: Limit of ASTM C1260 should be changed from 0.10% expansion at 14 days to
21days.

Table 4- 3: Frequency of routine tests on aggregates

SR. KIND OF REQUIREMENT-TEST TEST FREQUENCY RATE

No METHOD
3
1. Grading - BS EN 933-1:1997: AMD Per 2,000m
15907: 2006
2. Material finer than 0.075 mm - BS - do -
EN 933-1: 1997 or ASTM C117:2004
3
3. Clay lumps and Friable Particles - Per 2,000m
ASTM C 142:1997 (04)
3
4. Organic impurities - ASTM C Per 2,000m
40:2004
5. Water absorption - ASTM C128 : - do -
2007a/C127 : 2007
6. Specific Gravity - ASTM C128 : - do -
2007/C127 : 2007
7. Shell content - BS EN 933-7:1998 - do -
8. Particle shape BS 812 :1990 Section - do -
105 Part 105.1.& Section 105 Part
105.2
3
9. Acid soluble chlorides, CL Per 2,000m
Qualitative - BS 812 : 1988 Part 117,
Appendices A/B
Quantitative-BS 812 : 1988 Part 117, Each 12 concrete days if result is

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 10 SECTION 4 CONCRETE WORKS

SR. KIND OF REQUIREMENT-TEST TEST FREQUENCY RATE

No METHOD
Appendix C more than 75% of the limit and each
month if result is less than 75% of the
limit.
3
10. Acid soluble sulphates, Per 2000m or Each 24 concrete days
S03 - BS EN 1744-1:1998 if result is more than 75% of the limit
& each 2 months if result is less than
75% of the limit whichever is less.
3
11. Soundness, Mg S04 (5 cycles)- Each 48 concrete Days or 2,000 m
ASTM C88 : 2005

12. Mechanical Strength

3
 10% Fines or impact value - Each 72 concrete Days or 6,000m
BS 812 Parts 111, 112:
1990
 Los Angeles abrasion - - do -
ASTM C 131, 2006/C
535: 2009
13. Moisture variation in sand – by Twice daily
Moisture Meters

14. Drying Shrinkage At the start of the project and

BS 812 Part 120: 1989: AMD 8773: whenever there is a change in the
1995 source of supply.
15. Potential Reactivity: of aggregates

 ASTM C289:2007 of aggregate- At the start of the project and

Chemical Method)” wherever there is a change in the
source of Supply.
 ASTM C227:2003 of Cement At the start of the project and
aggregate combination wherever there is a change in the
source of Supply
 ASTM C 586:05 - of Carbonate At the start of the project and
wherever there is a change in the
source of Supply
3
16 Light weight pieces test (ASTM C Per 2,000 m
123: 2004)

Note1 : Drying Shrinkage and potential reactivity of aggregates shall be determined initially
at the start of the project or whenever there is a change in the source of supply.
Note 2: The salt content of water should be taken into account in the relevant limits for the
concrete.
Note 3: Frequency of testing may be amended by the Engineer based on previous test results
or new requirements

4/3 FINE AGGREGATES

4/3.1 The gradation of fine aggregate shall be in accordance with BS EN

12620:2002: AMD 15333: 2004 or latest edition.

4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to
allow inspection and tests to be carried out.

4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand.

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 11 SECTION 4 CONCRETE WORKS

4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.

4/4 COARSE AGGREGATE FOR CONCRETE

4/4.1 Coarse aggregate shall be prepared as single sized aggregate and blended to
produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS EN 12620: 2002.

4/4.2 Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall not be used.

4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.

4/5 COMBINED AGGREGATE

4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be
combined in proportions as specified in BS EN 12620:2000 and as approved
by the Engineer. However, in no case shall materials passing the 0.075mm,
sieve exceed three (3) percent by weight of the combined aggregate.

4/5.2 The combined aggregate gradation used in the work shall be as specified,
except when otherwise approved or directed by the Engineer. Changes from
gradation to another shall not be made during progress of the work unless
approved by the Engineer.

4/5.3 ADHESIVE

The mortar/adhesive shall be applied to the walls with a suitable notched

trowel strictly in accordance with the adhesive manufacturer's
recommendation. Adhesive shall have the following properties:

Test Requirements Test Method

Tensile Adhesion Strength
≥1.5 N/mm² GSO ISO 13007-2: 4.4.4.2
(28 days)
Tensile Adhesion Strength
≥1 N/mm² GSO ISO 13007-2: 4.4.4.3
after water immersion
Tensile Adhesion Strength
≥1 N/mm² GSO ISO 13007-2: 4.4.4.4
after heat aging
Open time: Tensile Adhesion GSO ISO 13007-2: 4.4.4.
≥ 1 N/mm² after not
Strength
less than 30min
Shear Bond Strength (28
>2.1 N/mm² ANSI 118.4 F-5.1.1
days)
Slip ≤0.5 N/mm² GSO ISO 13007-2
Compressive Strength ≥17 N/mm² ANSI 118.4
Transverse Deformation 2.5 – 5 mm Class
GSO 180 13007-2
S1
Hardness (72 Hrs) 50-60 ASTM D2240

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 12 SECTION 4 CONCRETE WORKS

4/5.4 GROUTS

Before grouting, all tiles must be firmly set, all paper and glue removed from
face of mounted tile and all spacers, strings, ropes, and pegs removed. Grout
to be a proprietary mix based on Portland cement, silica sand mixture and
selected additives with the color selected from the manufacturers range. The
grout shall be water repellent and incorporate anti-mould technology. The
grout shall have the following properties

Test Requirements Test Method

Abrasion resistance ≤1000 mm³ GSO ISO 13007-4

Flexural Strength >2.5 N/mm² GSO ISO 13007-4

Compressive >15 N/mm2 GSO ISO 13007-4

strength
Shrinkage <3mm GSO ISO 13007-4

Reduced Water GSO ISO 13007-4

absorption after 30 ≤2.0 9
minutes

Joints shall be sufficiently wide to enable the grout to be inserted without

undue difficulty, to fill the full depth of the joints achieving solid joints as much
as practicable without voids or cavities where water could collect.

4/5.5 CERAMIC TILES

All the tiles required for the project shall be sourced from a single
manufacturer operating a quality system for production of ceramic tiles, which
is registered to ISO 9000. The tiles shall be manufactured as per the EN
14411/159 or ISO 13006 as directed by the Engineer and verified by firing at
temperatures not less than 1200oC. the contractor/supplier shall provide
detailed drawings for the wall tile patterns.

The fully glazed tiles of 1st choice quality having the following properties shall
be used for the works.

Test Requirements Test Method

Water Absorption 2.0% maximum EN 99/BS EN ISO 10545-3
Modulus of Rupture >27 N/mm² EN 100/BS EN ISO 10545-4
Scratch Resistance on Moh. scale 5-6 EN 101
Thermal Shock Resistance Required BS EN ISO 10545-9:1996
Stain Resistance At least Class 2 EN 122
Density 2.4 gm/cm²

4/6 WATER FOR CONCRETE

4/6.1 The Contractor shall make his own arrangement and obtain approval for the
supply of water.

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 13 SECTION 4 CONCRETE WORKS

4/6.2 The mixing water should be clear, apparently clean and free from matter
harmful to concrete in its fresh or hardened state. Potable water can be used.
Water of questionable quality should comply with the physical tests of Table 4-
3 and chemical limitation listed in Table 4-4. Water shall also meet the
requirement of BS EN 1008:2002

4/6.3 The temperature of water for concrete should not be less than 5 degree
Celsius or more 25 degree Celsius. Water may be cooled to not less than 5
degree Celsius by the gradual addition of chilled water or ice but on mixing, no
ice particles should be present in the mix.

Alternatively, flaked ice may be used. The ice to be used should be crushed
and should be the product of frozen water which complies with acceptance
criteria of Tables 4-4 and 4-5.

4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to
cause discoloration of the concrete.

Sources of Water shall be maintained at such depth and the water shall be
withdrawn in such a manner as to exclude silt, mud, grass and other foreign
matter.
Table 4- 4: Acceptance criteria & physical tests for mixing water

Test Limits ASTM Test

Compressive strength, min.% 90 C 109 : 2008

control at 7 days
Setting time, deviation from from 1:00 early to 1:30 C 191 :2008
control, h: min. later

Table 4- 5: Chemical Limitations for mixing water

Max. Concentration, Limit, ppm Test Method

1. Chloride as C1 250 ASTM D 512: (2004) or

BS EN 1008:2002
2. Sulphates as SO4 350 ASTM D 516:2002 or
BS EN 1008:2002
3. Alkali carbonates and 500 ASTM D 513:2006 or
bicarbonates BS EN 1008:2002
4. Total dissolved solids,
including
1, 2 & 3 above 2000 BS 1377 : Part 3 : 1990:
Test 8: AMD 9028: 1996
5. PH min.7/ max. 9 ASTM D1293 : 1999

4/7 APPLICABLE TESTS AND CODES

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 14 SECTION 4 CONCRETE WORKS

4/7.1 All concrete, aggregate, cement, steel and water shall be tested during the
construction as per frequency in Tables 4-3 and 4-6 or as directed by the
Engineer.

All test samples shall be supplied by the Contractor at his expense. Samples
shall be obtained in accordance with BS 812,102: 1989, BS EN 1008:2002,
BS 1881:1983 AMD 6095: 1989 and BS EN 196: Part 7: 2007.

Testing shall be at the frequencies stated above or relevant standards. All

sampling shall be carried out by the Engineer.

Table 4- 6: Frequency of routine testing

Sampling Test Frequency

ITEM Test Method
Method Rate
a. Cement
As per BS EN 196-7: BS EN 196-7 BS EN-196 Each 250 ton of
2007 concrete poured.
b. Steel
1. Deformed S. Bar BS EN 15630 BS EN 15630 Each size 100 ton
as per BS Part 1:2002 Part 1:2002 as per the BS
4449:2005 BS 4449:1997 or BS standards
Or BS 4449:1997 4449:1997
2. Strand as per BS 5896 and BS 5896 - As per Clause
BS 5896:1980 and ASTM APPENDIX A 23.3 of
ASTM 416:A416M:20 BS 5896
416:A416M:2006 06
if needed
c. Concrete
1. Air content, as per BS EN 12350- BS EN Once at the time
BS EN 12350- 1:2009 12350- of mix design of
7:2000 7:2000 concrete or as
directed by the
Engineer.
2. Flexural strength BS EN 12350- BS EN Once at the time
of Prism as per BS 1:2009 12390:2000 of mix design of
EN 12390-5:2000 concrete or as
directed by the
Engineer.
3. Bleeding as per BS EN 12350- ASTM C One at the time of
ASTM C232:2009 1:2009 232:2009 mix design of
concrete or as
directed by the
Engineer.
4. Splitting Tensile of BS EN 12350- ASTM C- One at the time of
Conc. Cylinder as 1:2009 496:2004 mix design of
per ASTM C- concrete or as
496:1996 & others directed by the
Engineer.
3
5. Depth of Water BS EN 12350- BS EN Each 2000m of a

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 15 SECTION 4 CONCRETE WORKS

Sampling Test Frequency

ITEM Test Method
Method Rate
Penetration (BS 1:2009 12390- particular grade
EN 12390 P- 8:2009 of structural
8:2000) concrete or as
directed by the
Engineer.
3
6. ISAT as per BS BS EN 12350- BS 1881 - Each 2000m of a
1881-p-208:1996 1:2009 208:1996 particular grade
of structural
concrete or as
directed by the
Engineer.
3
7. Water absorption BS EN 12350- BS 1881- Each 2000m of a
of Hardened 1:2009 122:1983 particular grade
Conc. As per BS of structural
1881 P122 concrete or as
directed by the
Engineer.
3
8. Rapid chloride BS EN 12350- ASTM C Each 2000m of a
permeability 1 :2009 1202:2009 particular grade
of structural
concrete or as
directed by the
Engineer.
9. Slump test - as BS EN 12350- BS EN From each transit
per BS EN 12350- 1:2009 12350- mixture load
2:2000 2:2009 arrived at site
10. Concrete Mix BS EN 12350- All mixes are to be
Design (Mixing 1:2009 designed once for
and Sampling in verification and
the lab) as per BS approval.
1881 P125 &
(Sampling) as per
BS EN 12350-
1:2009 (on site)
11. Kerbs-as per BS BS 7263 BS 7263 Sample to be
7263 taken from each
batch of upto 1000
kerb in whole
consignment
d. Water
Water Quality BS EN BS EN 1008- For DEWA WD no
1008:2002 :2002 test is required or
other than DEWA
twice a week or as
directed by the
Engineer.

4/7.2 WORKABILITY

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 16 SECTION 4 CONCRETE WORKS

Workability shall be assessed by the following tests the requirements for which
shall be as specified elsewhere in the documents.

 Slump test shall be performed according to BS EN 12350-2:2009

 Compaction factor shall be performed according to BS EN 12350-

4:2009

 Vebe time shall be performed according to BS EN 12350-3:2009

 Flow test shall be performed according to BS EN 12350-5:2009

4/7.3 COMPRESSION TEST

The Compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS EN 12390-3:2009. Sampling, making test cubes and curing of
cubes shall be in accordance with BS EN (12350-1:2009 and 12390-1:2009)
respectively.

4/8 REINFORCEMENT BARS

4/8.1 All reinforcement bars shall be of a deformed type in accordance with

BS 4449:2005 except that plain bars may be used where specifically indicated
on the Drawings. Plain bars shall be in accordance with
BS 4449:2005.

4/8.2 All steel reinforcement shall conform to the requirements of the Specifications
for Deformed High Yield Steel Bars grade 460 Type 2, unless otherwise
shown on the Drawings or specified by the Engineer.

4/8.3 Certification. Three (3) copies of a mill test report shall be furnished to the
Engineer for each lot of steel reinforcement bars and a sample of each
proposed reinforcement bar for use on the project shall be provided.

4/8.4 Identification. The bars in each lot shall be legibly tagged by the manufacturer
and/or fabricator before being offered for inspection. The tag shall show the
manufacturer's test number and lot number and other applicable data that will
identify the material with the certificate issued for that lot of steel.

4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the
heat number or numbers from which each size of bar in the shipment was
fabricated.

4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site. The Contractor shall provide a certificate
confirming that samples taken from the bars delivered to the works pass all the
required tests. The frequency of sampling and the method of quality control
shall be in accordance with BS 4449 – 2005.

4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,
paint, grease, oil or other foreign substance, fins, or tears. There shall be no

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 17 SECTION 4 CONCRETE WORKS

evidence of visual flaws in the bars, test specimens or on the sheared ends of
the bars.

4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil,
grease, salt and other deleterious materials and where pitting has occurred the
causes and products thereof. Repeated blasting may be required when the
reinforcement is in position, or partially cast in. Partially set concrete adhering
to exposed bars during concreting operations shall be removed.

4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown

on the drawings. Only approved concrete spacers shall be used. The
concrete shall be of similar grade to the main concrete and shall have non
metallic ties.

4/9 BAR SCHEDULES AND SHOP DRAWINGS

4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules
and adjust them if necessary to the approval of the Engineer. Bar schedules
shall show the weight of each bar, the total weight of each bar size and the
total weight of bars, and bending diagrams for bars in accordance with BS
4466.

4/9.2 The Contractor shall provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of revised bar schedules or for the completion of
the works.

4/9.3 The approval of working drawings, or revised bar schedules by the Engineer
shall in no way relieve the Contractor of responsibility for the correctness of
such drawings or schedules.

4/10 BAR CUTTING AND BENDING

4/10.1 Reinforcement shall be cut and bent in accordance with BS 8666:2005.

Cutting or bending by the application of heat is not permitted. Welding of
reinforcement shall only be permitted when approved in writing by the
Engineer. If such approval is given then the workmanship shall be in
accordance with BS EN 1011. The Contractor shall submit full technical
details of his proposed procedures prior to seeking approval.

4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.

4/11 PLACING AND FIXING REINFORCEMENT

4/11.1 Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar
intersections shall be tied together using 1.2mm diameter steel wire or No. 18

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 18 SECTION 4 CONCRETE WORKS

gauge stainless steel wire as indicated on the drawings and the ends of the
tying wire shall be turned into the main body of the concrete.

4/11.2 Metal supports, approved by the Engineer, shall be provided and used to
retain the reinforcement at proper distances from the forms. Supports under
horizontal bars at the bottom of base slabs shall be spaced at not more than
eighty (80) diameters of the bar. All reinforcement shall be so rigidly
supported and fastened that displacement will not occur during construction.
Reinforcing steel shall be inspected in place and must be approved by the
Engineer before any concrete is deposited.

4/11.3 No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.

4/11.4 Reinforcement temporarily left projecting from the concrete at construction or

other joints shall not be bent out of position during the periods in which
concreting is suspended, except with the approval of the Engineer.

4/12 WELDED WIRE FABRIC

4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform
to the following requirements:

- Dimensions. Welded steel wire fabric shall conform to the size and
dimensions shown on the Drawings.
- Properties. Wire fabric furnished under this specification shall conform to
the requirements for "Welded Steel Wire Fabric for Concrete
Reinforcement" BS 4483 or equivalent.

4/13 SPACER BLOCKS

4/13.1 Spacers as approved by the Engineer shall be of such material and design as
will be durable, not lead to corrosion of the reinforcement and not cause
spalling of the concrete cover.

4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the
mix proportions of the surrounding concrete so far as is practicable with a view
to being comparable in strength, durability and appearance.

4/14 ADMIXTURES

4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used.
4/14.2 Where the use of admixture had been agreed by the Engineer, they shall
conform to the requirements of Type A, Type D, Type F or Type G as specified
in ASTM C494:2008 and shall be used in strict accordance with the
manufacturer's instructions.

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 19 SECTION 4 CONCRETE WORKS

Preliminary tests of cube strength and other tests shall be carried out using the
combination of aggregates cements and admixtures proposed for use.
4/14.3 The Contractor shall be entirely responsible for the use of any approved
admixtures.
4/14.4 Approved methods and equipment shall be used for dispensing and
incorporating the admixture into the concrete. The dispensing unit shall be
designed so that the discharge of the admixture is visible.

4/14.5 The use of an admixture containing chlorides, inorganic sulphates or other

corrosive agents will not be permitted.

4/14.6 Plasticizers and super-plasticizers shall not contain substance, which adversely
affect the durability and performance of the concrete.

4/14.7 If two or more admixtures are used simultaneously in the same concrete mix,
data including manufacturer certificate shall be provided to assess their
interaction and ensure their compatibility

4/15 CONCRETE MIX SPECIFICATION

4/15.1 Concrete shall be as shown in the Table 4-7. The number of mixes may
require to be increased.
The criteria given in this Table are designed to produce concrete of the
required strength and durability.
If the maximum aggregate size is 10 mm then the cement content stipulated
for the class of concrete given in Table 4-7 shall be increased by 40 Kg per
m3. All concrete mixes shall be verified by DM – DCL.

Table 4- 7: Table of mixes without admixtures or additives

Concrete Max.Size Min. Max. Free Characteristic

Class Agg Cement Water/Cement Cube Strength
content Ratio (CCS)

mm. kg.per m3 7-day 28-day

N/mm2 N/mm2
50/20 20 450 0.40 37 50
45/20 20 400 0.40 33 45
40/20 20 370 0.40 30 40
37/20 20 350 0.45 26 37
35/20 20 330 0.45 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15

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 20 SECTION 4 CONCRETE WORKS

The CCSs are for concrete which has been cured at a temperature of 20
degrees C + 2 degree C, and are the values below which no more than 5% of
the test results fall. The 7-day strengths shall be used only as a guide.

4/15.2 Concrete shall comply with BSI BS EN 206-1:2000. Sampling for test
purposes shall comply with BS EN 12350-1:2000, AMD 11031:2000 (on site)
& BS 1881 Part 125:1986, AMD 6107: 1989 (in laboratory).

If air entertainment is specified, the average air content at the time of placing
measured in accordance with BS EN 12350-7:2009 shall be:

Concrete containing 20mm Maximum size aggregate 5%

Concrete for water-retaining shall be watertight and shall comply with the
recommendations of BSI BS EN 206-1:2000.

Concrete for paving or precast units shall be tested to BS EN 12390: Part 5:

2000, AMD 15438: 2004 and shall have minimum flexural beam strength of
3.5N/mm2 at 28 days. If the concrete has a specified CCS of 40N/mm 2 or
greater, then the minimum flexural strength shall be 4N/mm2.

If concrete specimens are cured at higher temperatures or for longer periods

than BS EN 12390-1:2000, AMD 15437: 2004 requires, the adjusted CCS
shall be calculated as follows:

100f'/f = A + B log {24D (T+12)/1000}

where:

f’ = adjusted CCS
f = specified CCS
T = curing temperature
D = age at testing in days
A&B = are coefficients given in Table 4-8 below.

The above equation applies only to OPC, MSRPC and SRPC.

Table 4- 8: Coefficients for adjustment for curing temperatures

Recorded Cube Strength N/mm2 A B

Less than 15 10.0 67.5
From 15 to 35 20.0 60.0
Greater than 35 30.0 52.5

This calculation may be applied for curing at temperatures up to 27 degrees C.

Before placing concrete the Contractor shall obtain approval of the mixes
proposed for each class of concrete and the average target strengths. The
mixes shall be designed to achieve the minimum workability and maximum
durability for the Contractor to place and compact the concrete with the
equipment proposed for use. The mean strength shall exceed the CCS by a
margin of 1.64 times the standard deviation expected from the concreting

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 21 SECTION 4 CONCRETE WORKS

plant, except that no standard deviation less than 3.5 N/mm 2 shall be used as
a basis for designing a mix. Unless otherwise approved a standard deviation
of 7 N/mm2 shall be used for initial mixes.

4/15.3 The ultimate compressive strength of the concrete shall be determined on test
specimens obtained and prepared in accordance with BS EN 12390-1:2000,
AMD 15437:2004.

4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of
concrete (shown on the drawings) is denoted by the 28 day characteristic cube
strength and the maximum size of aggregate.

4/15.5 The chloride and Sulphate levels in the concrete mix shall comply with the
following requirements:-

Table 4- 9: Maximum Limits of acid soluble Chloride and Sulphate content as a

percentage by Weight of Cement in the Mix.

CHLORIDES AS SULPHATES AS
TYPE OF CONCRETE
Cl SO3
ACCORDING TO BS-1881 : 1988 PART 124
Amd 01:1998 Amd 06:2002
a. For reinforced concrete
if made with 0.1% 3.70 (Note 2)
OPC/MSRPC
if made with SRPC 0.1% 3.70 (Note 2)
b. Prestressed concrete & 0.10 3.70
Heat-cured reinforced
concrete
c. For mass concrete
if made with 0.60 3.70
OPC/MSRPC
if made with SRPC 0.12 3.70

Note 1: BS EN 196-21: 1992 Clause 8, Method of Testing Cement Part 21 will be used
to determine the percentage of chloride by weight of cement. The OPC and
MSRPC cements can also contain chlorides, the relevant standard BS EN 197-
1 allows up to 0.1% Cl. Therefore any chloride content present in the cement
has to be taken into account while computing total Cl in the mix. In case the
cement contains the maximum limit of 0.1% Cl, then the aggregates, water and
admixtures used for pre-stressed concrete or heat cured reinforced concrete
should be absolutely free of chlorides.

Note 2: Suggest to SO3 content to be 3.5% for cement Type 1&2 tested in
accordance to BS EN -197-2000. For cement types 3 and 4, SO3 content to be
4%.

4/16 CONCRETE MIX DESIGN

TRIAL MIXES

4/16.1 Preliminary laboratory tests shall be carried out to determine the mixes to
satisfy the specification with the approved materials.

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 22 SECTION 4 CONCRETE WORKS

Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:

a) Bleeding in accordance with ASTM C232: 2007 (non-vibrating) shall not

exceed 0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5:1997
c) Air content if applicable BS EN 12350: P7: 2009.
d) Free water/cement ratio.
e) Workability BS EN 12350-2:2009
f) Chloride permeability shall be maximum 2,000 coulombs, when tested in
accordance with ASTM C-1202: 2007.
g) Fresh and hardened concrete densities BS EN (12350-6:2000 and
12390-7:2009) respectively.
h) Compressive strength BS EN 12390-3:2009.
i) Depth of Water Penetration Test BS EN 12390 Part 8: 2009
(maximum 10 mm at 28 days)
(maximum 15 mm at 7 days).
j) The Initial Surface Water Absorption Test as per BS 1881: P-208: 1996.
Maximum permissible limit for ISAT is 0.2 ml/m2/sec
k) Water absorption of Hardened concrete as per BS 1881: P122: 1983:
AMD 6108:1989 and the maximum permissible limit shall be 2.0%.

If the values obtained are unacceptable, the mixes shall be re-designed.

4/16.2 At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS
1881: 1983.

Samples of concrete incorporating the reinforcing details to be used shall be

cast and examined, before hardening using hand tools, and after hardening by
coring to assess the mixes. Cores shall be taken in accordance with BS EN
12504-1:2000.

Trial mixes shall be made on each of three days; the workability shall equate
to the designed target value. Six cubes from each mix shall be taken, three for
test at 28 days.

Further trial mixes shall be made if the range (the maximum minus the
minimum of the three cube results in any batch) exceeds 15% of the average
of that batch, or if the range of the three batch averages exceeds 20% of the
overall average of the batches.

The mixes shall be tested to determine the following properties:

a) Bleeding in accordance with ASTM C232: 2007
b) Air content if applicable BS 12350: P7: 2009.
c) Free water/cement ratio

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 23 SECTION 4 CONCRETE WORKS

d) Tensile strength in accordance with BS EN 12390-6:2000. Splitting

tensile strength of concrete cylinder shall be in accordance with ASTM
C496: 1996. Flexural strength of concrete prism in accordance with BS
EN 12390: P5.

e) Compressive strength

The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be
acceptable before the mix is approved. Otherwise the mix shall be
re-designed.

4/16.3 The Engineer will review the Contractor's trial-mixes and test the test cubes at
seven (7) and twenty-eight (28) days. The Engineer will then determine which
of the trial mixes shall be used. If none of the trial mixes for a class of
concrete meets the Specifications, the Engineer will direct the Contractor to
prepare additional trial-mixes. No class of concrete shall be prepared or
placed until its job-mix proportions have been approved by the Engineer.

4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to
the Contractor in establishing those proportions, in no way relieves the
Contractor of the responsibility of producing concrete which meets the
requirements of these Specifications.

4/16.5 The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face
intended for use in the works.

4/16.6 All costs connected with the preparations of trial-mixes and the design of the
job-mixes shall be borne by the Contractor.

4/16.7 In the event, any Concrete mix that is currently being used in another running
RTA/DM projects, is proposed by the contractor for approval of using that mix
in this contract, then

1. Prior to according the approval or otherwise, the Engineer must ensure

that all copies of test results pertaining to another running RTA/DM project
submitted by that contractor comply with all specifications as stated in this
contract and

2. shall also ensure that the proposed mix complies with clause 4/16 by
verifying that proposed mix at DCL

NOTE: Any mix that is obsolete & currently not in use shall not be
accepted at all for re-approval.

4/17 QUALITY CONTROL

4/17.1 TEST CUBES

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 24 SECTION 4 CONCRETE WORKS

Cubes shall be manufactured in an on-site laboratory, specially equipped for

the purpose, in controlled conditions. They shall be made, cured, stored,
transported and tested to BS EN (12390-1:2000, AMD 15437:2004 and
12390-3: 2009). The method of compacting cubes shall be as approved and
shall be means of vibrating table in the laboratory or 25mm vibrating poker on
site.

4/17.2 SAMPLING CUBES

A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each
day. The standard deviation shall be calculated from at least 40 individual
cube results each representing separate batches of similar concrete produced
by the same plant under the same supervision. The current margin for the
plant shall be thus established as 1.64 times the standard deviation.

Thereafter one sample shall be taken at random for each class of concrete in
accordance with Clause 4/31 of the Specification.

In addition to the above requirements, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of
a single pour.

From each sample three cubes shall be made for testing at 28 days and three
for testing at 7 days for control purposes.

Six cylinder samples shall also be taken to determine the split tensile strength
of the concrete 3 at 7 days and 3 at 28 days, as specified in ASTM C496:
2004. These samples shall be taken from every 100 batches, but at least
once a week during concreting operations, and shall coincide with samples
taken for test cubes.

The frequency of sampling may be required to be varied if directed by the

Engineer.

The procedures shall be repeated when materials or design mixes are

changed.

4/17.3 CUBE STRENGTH RESULTS

The results will be acceptable if:

i) The average strength determined at the age of 28 days from a sample of

three or more cube test results exceed the Characteristic Cube Strength
(CCS) which is the 28 days cube strength obtained in the approved trial
mix by 0.5 times the current margin,
ii) No individual result of the sample is less than the specified Characteristic
Cube Strength (CCS) minus 3 N/mm2).
iii) Number of individual results in the sample below the specified
Characteristic Cube Strength (CCS) is not more than one.

If the above criteria is not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate :

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 25 SECTION 4 CONCRETE WORKS

i) Cutting and testing cores from placed concrete.

ii) Non-destructive testing of placed concrete.
iii) Load-testing relevant structural units.
iv) Cutting out and replacing defective concrete.

If the range of individual cube strengths made from the same sample
exceeds 15% of the mean, then the method of making, curing and
testing cubes shall be checked. In the event of a sample having a range
exceeding 20%, then the result shall be unacceptable and the Engineer
may order any of the following actions:

a) Changing the mix.

b) Improving quality control.
c) Cutting and testing cores from placed concrete.
d) Non-destructive testing of placed concrete.

In the event of cutting and testing of cores are required, the Contractor
shall cut cores from approved locations and test them to BS 1881- Part
120:1983 as modified by BS 6089:1981.

4/17.4 DURABILITY TESTS

Concrete shall be tested for durability properties by undertaking absorption

and permeability tests where appropriate, or directed by the Engineer, as
directed below:

Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out
between 28 and 32 days in accordance with BS 1881 Part 122 : 1983, AMD
6108:1989. The upper acceptable limit for absorption after 30 minutes shall
be 2%.

Effective permeability tests in accordance with the method described in BS EN

12390 Part 8: 2009 shall be carried out. The maximum acceptable penetration
at seven days shall be 15 mm and the maximum acceptable penetration at 28
days shall be 10mm.

Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried
out.

Maximum permissible limit for ISAT is 0.2 ml/m2/sec.

In addition to the above, the following specifications shall be satisfied:

1. Initial Surface Absorption Test (ISAT) shall be carried out on prototype

samples of different components of the structure before the mix design or
manufacturing method is approved. The prototype samples shall be short
sections of not less than 1.0m x 1.0m x full thickness. The samples shall
be fully reinforced and cast in similar environment as the actual structure.

The ISAT tests shall be carried out in accordance with BS 1881-208:1996

between 28-40 days after casting the samples and the maximum value

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 26 SECTION 4 CONCRETE WORKS

shall not exceed the following limits at 10 minutes after starting the test:

In-situ construction: Less than 0.20 ml/m2/s.

2. In addition to ISAT, the chloride permeability of the concrete shall be

determined using cores taken from the prototype samples cast for ISAT, in
accordance with ASTM C1202: 2009 “Electrical Indication of Concrete’s
Ability to Resist Chloride Ion Penetration”. The following limits shall not be
exceeded.
 In-situ construction: 2000 coulombs
 Underwater construction: 1000 coulombs.

3. The concrete will be deemed to comply with the permeability requirements

of this specification if all test results comply with the following:

a) ISAT results for unprotected surfaces:

Limit given in paragraph 1 above.
b) ISAT results for protected surfaces:
One fifth of the limits for the unprotected surfaces.
c) Rapid Chloride Permeability test results for unprotected
surfaces:
Limit given in paragraph 2 above.
d) Rapid Chloride Permeability test results for protected surfaces:
Charge passed should be less than 500 coulombs.

4. If any of the ISAT and the rapid chloride permeability test result of
unprotected or protected surfaces of a sample failed to meet the above
requirements, then all the concrete work represented by such sample shall
be deemed not to comply with the permeability requirements.

5. If, in the opinion of the Engineer, the concrete which has failed to meet the
permeability requirements of this specification is likely to cause durability
problems, three cores shall be cut from the area represented by failed
samples for additional ISAT and rapid chloride permeability testing. The
actual location shall be decided by the Engineer.

6. The cost of cutting and testing cores and any resultant delay shall be
borne by the Contractor regardless of whether the permeability of the
deposited concrete proves to be satisfactory or not.

7. Where the permeability test results found by testing the three cores taken
from the structure is confirmed as not complying with the permeability
requirements, then the Engineer may instruct that further cores to be cut
and tested in order to determine the full extent of the defective concrete
and further investigations to be carried out.

8. Defective concrete shall be cut out and replaced or alternative remedial

action shall be taken, as the Engineer directs, and the cost of such work
and any resultant delay shall be borne by the Contractor.

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4/17.5 OTHER TESTS

When instructed by the Engineer, concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and
tested in accordance with Test 5 of BS 1881 (1970) Part 5. The maximum
acceptable limits shall be:

Drying Shrinkage : 0.05%

Wetting Expansion : 0.03%

Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.

The air content of air-entrained concrete shall be determined (ASTM C231:

2009a) for each batch produced until consistency has been achieved, when
batches may be tested. The maximum value shall not exceed 2%.

Compaction factor, slump, vebe or other workability tests shall be carried out
as required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree of workability shall be as for
the trial mixes; permitted tolerances shall be in accordance with BS 5328:
2000.

4/18 CONCRETE DESIGN LIMITS

4/18.1 The following will be designated by the Engineer within the limits of the
Specifications.

a) The minimum Cement content in kg. per cubic metre of concrete.

b) The maximum allowable water/cement ratio including surface moisture,

but excluding water absorbed by the aggregates.

c) Slump or Slumps designated at the point of delivery.

d) Changes requested by the Contractor in mix proportioning previously
approved shall be made only with the agreement of the Engineer.

e) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as
directed by the Engineer. No additional payment shall be made for the
added cement.

f) Failure of the mixed concrete to meet specifications as determined by

the Engineer will be grounds for the Engineer to reject the concrete.

g) Bleeding limitations when tested in accordance with ASTM C232 : 2007.

4/19 CONSISTENCY OF CONCRETE

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 28 SECTION 4 CONCRETE WORKS

4/19.1 The consistency of concrete shall be determined in the field by the Slump
Test. The consistency of concrete at the time of delivery will be designated by
the Engineer and shall not vary by more than 25mm from the designated
consistency.

4/20 TOLERANCES IN PROPORTIONING THE MATERIALS

4/20.1 CEMENT

In the case of bagged cement it shall be measured as packed by the

manufacturer: a sack of cement shall weigh fifty (50) kilograms. Measurement
for proportioning all cement shall be accurate to within two (2) percent
throughout the range of use. Only full bags, undamaged or unbroken will be
permitted.

4/20.2 WATER

The mixing water shall be measured by weight or by volume. In either case

the measurement shall be accurate to within one (1) percent throughout the
range of use.

4/20.3 AGGREGATE

The aggregates shall be measured by weight to an accuracy within two (2)

percent through-out the range of use.

4/21 ASSEMBLY AND HANDLING MATERIALS

ASSEMBLY

4/21.1 Aggregates shall be assembled in such quantities that sufficient material

approved by the Engineer is available to complete any continuous pour
necessary for any element. The batching site shall be of adequate size to
permit the stockpiling of sufficient, unsegregated materials, having proper and
uniform moisture content, to ensure continuous and uniform operation.
Aggregates shall enter the mixer in a manner approved by the Engineer and in
such a manner to ensure that no matter foreign to the concrete or matter
capable of changing the desired proportions is included. In the event two (2)
or more sizes or types of coarse or fine aggregates are used on the same
project, only one (1) size or type of each aggregate may be used on one
continuous concrete pour.

STOCKPILING Of AGGREGATES

4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation
of material, to ensure uniform moisture content and to provide uniform
conditions for proportioning plant control.

4/21.3 The use of equipment or methods of handling aggregates which result in the
degradation and contamination of the aggregates is strictly prohibited.

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 29 SECTION 4 CONCRETE WORKS

Bulldozers with metal tracks shall not be used on coarse aggregate stockpiles.
All equipment used for handling aggregates shall be approved by the
Engineer.

4/21.4 Stockpiling of aggregates shall be in the manner approved by the Engineer,

and in addition, every precaution shall be taken to prevent segregation.
Segregation shall be prevented by making no layer higher than one and
one-half (1.5) metres and if two (2) or more layers are required, each
successive layer shall not be allowed to "cone" down over the next lower layer.

4/21.5 Aggregates shall not be stockpiled against the supports of proportioning

hoppers and weighing devices.

SEGREGATION

4/21.6 Segregated aggregates shall not be used until they have been thoroughly
remixed and the resultant pile is of uniform and acceptable gradation at any
point from which a representative sample is taken. The Contractor shall
re-mix aggregate piles when ordered by the Engineer.
TRANSPORTING Of AGGREGATES

4/21.7 If aggregates are to be transported from a central proportioning plant to the

mixer in batch-boxes or dump trucks, such equipment shall be of sufficient
capacity to carry the full volume of materials for each batch of concrete.
Partitions separating batches shall be approved by the Engineer and shall be
adequate and effective to prevent spilling from one compartment to another
whilst in transit or being dumped.

CEMENT

4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor
or in a silo and shall be delivered in quantities sufficient to ensure that there is
no suspension or interruption of the work of concreting at any time. If stored in
sheds, each consignment shall be kept separate and distinct.

4/22 MIXING CONCRETE

4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in
BS 1305: 1974 and checked against accurate weights and volumes when
required by the Engineer.

4/22.2 The mass of cement and of aggregate indicated by the mechanism employed
shall be within a tolerance of 2% of the respective mass per batch agreed by
the Engineer. The mass of the fine and coarse aggregates shall be adjusted
to allow for the free water contained in them. The water to be added to the
mix shall be reduced by the quantity of free water contained in the fine and
coarse aggregates, which shall be determined by the Contractor by a method
approved by the Engineer immediately before mixing begins and further as the
Engineer requires.

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 30 SECTION 4 CONCRETE WORKS

4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch
type mixer manufactured in accordance with BS 1305: 1974. Where
appropriate the batch capacity, method of loading, mixing time and drum
speed shall conform to the details furnished in accordance with the
requirements of BS 3963: 1974 for the mix which corresponds most closely to
the mix proportions being used. The mixing blades of pan mixers shall be
maintained within the tolerances specified by the manufacturer of the mixer
and the blades shall be replaced when it is no longer possible to maintain the
tolerance by adjustment. The period of mixing, judged from the time that all
the ingredients including water are in the mixing drum shall be as ordered by
the Engineer's representative but shall not be less than 2 minutes or 20
revolutions of the drum whichever is the longer.

All plants shall be equipped with an approved automatic cycling and

monitoring system installed as part of the batching equipment. The system
shall include equipment for accurately proportioning the various components
of the mixture by mass. Admixtures may be measured volumetrically. The
automatic proportioning system shall be capable of consistently delivering
each constituent within the tolerances specified. All records of batches shall
show the batch weights, the batch number, the day, the month, the year and
the time of day to the nearest minute for each batch. This information shall be
imprinted on the record so that each batch may be permanently identified.
The Engineer will be provided with a clear and legible copy of all batch records
for concrete supplied for the project.

4/22.4 Mixers which have been out of use for more than 30 minutes shall be
thoroughly cleaned before any fresh concrete is mixed.

4/22.5 The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.

4/22.6 The Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between
its discharge from the mixer and compaction in its final position. Precautions
shall include the shading of aggregate stockpiles and the use of chilled water.

4/23 READY MIXED CONCRETE

4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be
used only with the agreement of the engineer and shall comply with all
requirements of the Contract.

4/23.2 The Concrete shall be carried in purpose-made agitators, operating

continuously, or truck mixers. The concrete shall be compacted and in its final
position within 1 hour of the introduction of cement to the aggregates, unless a
longer time is agreed by the Engineer. The time of such introduction shall be
recorded on the delivery note together with the weight of the constituents of
each mix.

4/23.3 When truck mixed concrete is used, water shall be added under the
supervision, either at the Site or at the central batching plant as agreed by the
Engineer but in no circumstances shall water be added in transit.

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 31 SECTION 4 CONCRETE WORKS

4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing
and discharge performance shall comply with the requirements of BS 4251.
Mixing shall continue for the number and rate of revolutions recommended in
accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer's instructions, mixing shall continue for not less than 100
revolutions at a rate of not less than 7 revolutions per minute.

4/23.5 Pumping concrete through delivery pipes may be permitted but only with the
prior approval of the Engineer.

4/23.6 Re-mixing of concrete which has commenced to set shall not be allowed and
in no case shall such concrete be used in the Works.

4/23.7 Coarse aggregate shall be kept in identified stockpiles from which samples
can be collected and tested as specified.

4/23.8 The concrete supplier is required to certify that the Cl content in the mix being
delivered is within the limits specified in Clause 4/15.5. The Cl and SO3
content shall be checked at frequent intervals.

4/24 TRANSPORT AND PLACING

4/24.1 The method of transport and placing concrete shall be to the approval of the
Engineer. Concrete shall be so transported and placed that contamination,
segregation or loss of the constituent materials does not occur. A backup plant
to be proposed by the contractor to be used in case of emergency,
4/24.2 All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.

No concrete work shall be stopped or temporarily discontinued within forty-five

(45) centimeters of the top of any finished surface, unless such work is
finished with a coping having a thickness less than forty-five (45) centimeters
in which case the joint shall be made at the under edge of the coping.

Concrete in simple slab spans shall be placed in one (1) continuous operation
for each span, unless otherwise indicated on the drawings or approved by the
Engineer.

4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15
concrete shall be laid to a minimum of 75 mm thickness unless otherwise
specified on the drawings. This blinding shall be suitably cured prior to
subsequent concrete placement. The blinding shall be clean and free from
any dust or impurities prior to subsequent concrete placement.

4/24.4 No concrete shall be placed in a foundation until the extent of excavation and
the character of bearing material have been approved and no concrete shall
be placed in any structure until the placement of reinforcing steel and the
adequacy of the forms and falsework have been approved.

4/24.5 Concrete shall not be placed in any part of the Works until the Engineer's
approval has been given. If concrete has not started within 24 hours of such

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 32 SECTION 4 CONCRETE WORKS

approval being given, approval shall again be requested. Concreting shall

then proceed continuously over the area between construction joints. Fresh
concrete shall not be placed against in-situ concrete which has been in
position for more than 30 minutes unless a construction joint is formed in
accordance with the Specification. When the concrete has been in place for 4
hours, or less as directed by the Engineer, further concrete shall not be placed
against it for a further 20 hours.

4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg. C
unless otherwise specified. Concrete shall be compacted in its final position
within 30 minutes of discharge from the mixer unless carried in purpose made
agitators operating continuously, when the time shall be within one hour of the
introduction of cement to the mix and within 30 minutes of discharge from the
agitator.

4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited
in horizontal layers to a compacted depth not exceeding 400mm where
internal vibrators are used or 300mm in all other cases.

4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 2m. When trunking or chutes are used they
shall be kept clean and used in such a way as to avoid segregation. Where
steep slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of
the movement. Chutes and the use of chutes must be approved by the
Engineer. All chutes shall be kept clean and free from coating of hardened
concrete by thoroughly flushing with water after each run. The water used for
flushing shall be discharged clear of the concrete already in place.

4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be

placed in position by tremies, or by pipeline from the mixer.

4/24.10 Full details of the method proposed shall be submitted in advance to the
Engineer and his approval obtained before placing begins. Where the
concrete is placed by the tremie, its size and method of operation shall be in
accordance with BS 8004. During and after concreting under water, pumping
or dewatering operations in the immediate vicinity shall be suspended until the
Engineer permits them to be continued.

4/24.11 Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement
against which concrete is to be placed shall be shielded against the direct rays
of the sun and shall be sprayed with water to prevent excessive absorption by
the surfaces of water from the fresh concrete.

4/24.12 A complete record shall be kept of the date, time, temperature and conditions
of placing the concrete in each portion of the work and shall be available for
inspection by the Engineer at any time.

4/24.13 Unless otherwise shown on the drawings all concrete placed below ground
level shall have a minimum protection to its outside faces as follows:

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 33 SECTION 4 CONCRETE WORKS

Underside- Protected by the laying of a grade 1000 approved polyethylene

sheeting on the blinding concrete. The sheeting shall be returned up the
outside faces of the concrete and suitably sealed.

Sides- Coated with 3 coats of an approved bitumen rubber latex emulsion

flexible damp and vapour-proof liquid membrane conforming to BRE Digest
No. 54.

4/25 COMPACTION OF CONCRETE

4/25.1 All concrete shall be compacted to produce a dense homogeneous mass.

Unless otherwise agreed by the Engineer, it shall be compacted with the
assistance of vibrators. Sufficient vibrators in serviceable condition shall be on
site so that spare equipment is available in the event of breakdown. A 50mm
diameter internal vibrator shall be deemed capable of compacting 20 Cu.
m./hr. Internal vibrators shall be capable of producing not less than 10,000
cycles per minute.

4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion
vibrators are used, contact with reinforcement and all inserts shall be avoided.

4/25.3 Concrete shall not be subject to vibration between 4 and 24 hours after
placing.

4/25.4 Vibrators shall be so manipulated as to work the concrete thoroughly around

the reinforcement and embedded fixtures and into corners and angles of the
forms. Vibrators shall not be used as a means to cause concrete to flow or its
position in lieu of placing. The vibration at any point shall be of sufficient
duration to accomplish compaction. After initial set of the concrete, the forms
shall not be jarred and no strain shall be placed on the ends of projecting
reinforcement.

4/25.5 Vibrating is required to be done immediately as the concrete is placed.

Vibrators are required to be inserted and withdrawn vertically and should not
be dragged through the concrete. When concrete is poured in layers, the head
of the vibrator is required to penetrate through the top layer and partially
through the layer underneath to ensure joint between two poured concrete.

4/26 CONSTRUCTION JOINTS

4/26.1 The position and detail of any construction joints not described in the Contract
shall be subject to the approval of the Engineer and shall be so arranged to
minimise the formation of shrinkage cracks.

4/26.2 The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organised to ensure that the above mentioned interval shall not be exceeded.

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 34 SECTION 4 CONCRETE WORKS

4/26.3 When the continuous placement of concrete in any structural member is

interrupted or delayed, for any reason, for a period long enough for the
previously partially placed concrete to take its initial set, the Engineer shall
declare such joint a cold joint and the Contractor shall immediately remove the
previously partially placed concrete from the forms. No extra payment will be
made for the initial placement or the removal of concrete which is wasted
because of a cold joint. The Engineer may suspend all or any part of
subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.

4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the
drawings, keys shall be as made by embedding water soaked beveled timbers
in soft concrete. The key shall be sized as shown on the details, or as
directed by the Engineer, which shall be removed when the concrete has set.
In resuming work the surface of the concrete previously placed shall be
thoroughly cleaned of dirt, scum, laitance or other soft material with stiff wire
brushes, and if deemed necessary by the Engineer, shall be roughened with a
steel tool. The surface shall then be thoroughly washed with clean water and
painted with a thick coat of neat cement mortar, after which the concreting
may proceed.

4/26.5 Expansion joints shall be constructed at the locations, of the materials and to
the dimensions shown on the drawings.

4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal
and if the formwork extends above the joint on the exposed face, it shall be
cleaned of adhering concrete before the next lift is placed. The concrete
placed immediately above a horizontal construction joint shall not be the first
batch through the mixer and shall be thoroughly compacted and worked
against the existing concrete.

4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand
shall, wherever possible, be well worked into them immediately before the
fresh concrete is placed.

4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting
above the lift being cast shall be adequately supported to prevent movement
of the bars during the casting and setting of the concrete.

4/26.9 Wherever possible laitance and all loose material shall be removed while the
concrete is still green and no further roughening shall then be required.
Where this is not possible, it shall be removed by mechanical means provided
the concrete has been in position for more than 24 hours. The roughened
surface shall then be washed with clean water.

4/27 CURING OF CONCRETE

4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be
protected from the harmful effects of weather, including rain and rapid
temperature changes, and from drying out. The methods of protection shall be
subject to the Engineer's approval. The Engineer's approval will be conditional
upon the proposed curing method proving to be satisfactory on site. Only

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 35 SECTION 4 CONCRETE WORKS

water curing shall be allowed for bridges and retaining walls which shall be
continuously cured for a minimum of 14 days.

4/27.2 The method of curing used shall minimize the loss of moisture from the
concrete. On concrete surfaces which are to be water-proofed, and for bridge
superstructures including piers, abutments, retaining walls and culverts curing
membranes shall not be used. Details of all curing methods to be used shall
be subject to the approval of the Engineer.

4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete
surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimize
evaporation. The hessian sheeting shall be maintained continuously damp for
a minimum period of 14 days after casting. The water used for this purpose
shall be of the same quality as that allowed in mixing the concrete.

4/27.4 Whenever approved by the Engineer, membrane curing or wet curing of

concrete with an approved liquid may be used as an alternative to curing with
water except that membrane curing liquid shall not be applied to surfaces of
concrete from which the shuttering has been stuck, until the concrete has
been inspected and approved by the Engineer's representative.

4/27.5 Concrete curing compound shall be of an approved type which shall be readily
distinguishable upon the concrete surface for at least four hours after
application. The color, if any, shall become inconspicuous within seven days
after application.

4/28 EARLY LOADING

4/28.1 Concrete shall at no time be subject to loading, including its own weight, which
will induce a compressive stress in it exceeding 0.25 of its compressive
strength at the time of loading or of the specified 28 day strength whichever is
lower.

4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of
the Engineer.

4/28.3 No superstructure load shall be placed upon finished piers or abutments until
the Engineer so permits, but in no case shall any load of any kind be placed
until the curing has been completed. The Contractor shall not place any
temporary loads on deck slabs. Bridge deck slabs shall be opened to traffic or
construction equipment only when so permitted by the Engineer.

4/29 CONCRETING AT NIGHT

4/29.1 No concrete shall be mixed or placed when the light is insufficient, unless an
adequate and approved artificial lighting system is operated and such night
work is approved by the Engineer.

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 36 SECTION 4 CONCRETE WORKS

4/30 CONCRETING IN HOT WEATHER

4/30.1 When the rate of evaporation of surface moisture from concrete is expected to
approach 1 Kg/m2 per hour (estimated from the chart in Figure 4-1a or Figure
4-1b) or when the shade air temperature is 35 deg. C and rising, precautions
shall be taken, including the following:-

a. Dampening the forms.

b. Reducing the concrete temperature to the lowest practical level by

procedures such as:-

i. Shading the aggregate.

ii. Cooling the mixing water before use.

iii. Screening the mixing plant and transporting vehicles from wind,
rain and sun.

c. Erecting wind breaks and sunshades at the concrete placing location.

d. Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.

e. Minimizing evaporation (particularly during the first few hours subsequent

to placing the concrete) by suitable means such as applying moisture by
fog spraying.

Alternatively, the following equation developed by ACI can used to predict

evaporation rates:

E = (Tc2.5 – rTa2.5)(1 + 0.4V) × 10–6 (in.-lb units)

E = 5([Tc + 18]2.5 – r[Ta + 18]2.5)(V + 4) × 10–6 (SI units)

where
E = evaporation rate, lb/ft2/h (kg/m2/h);
Tc = concrete temperature, °F (°C);
Ta = air temperature, °F (°C);
r = relative humidity in percent/100; and
V = wind velocity, mph (km/h).

Readily solved using commonly available calculators, the equation provides results nearly
identical to those found using the nomographs in Figure 4-1a or Figure 4-1b.

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 37 SECTION 4 CONCRETE WORKS

4/30.2 All precautions to be taken shall be subject to the Engineer's approval and the
Contractor shall demonstrate that all approved precautions are available for
use prior to the Engineer granting approval to any concreting operation.

4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor
shall concrete be mixed or placed when the shade air temperature is 40 deg.C
or above, or is expected to reach such a level during concreting, without
special permission from the Engineer.

To use this chart:-

 Enter the air temperature (c)

move up to relative humidity
(b).
 Move right to concrete
temperature (c).
 Move down to wind
velocity (d).
 Move left read approx.
rate of evaporation (e).

Figure 4-1a: Effect of concrete, air temperature, relative humidity and wind on rate of evaporation of
surface moisture from concrete in SI Units (Source, ACI, 1999)

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 38 SECTION 4 CONCRETE WORKS

To use this chart:-

 Enter the air temperature (c)

move up to relative humidity
(b).
 Move right to concrete
temperature (c).
 Move down to wind
velocity (d).
 Move left read approx.
rate of evaporation (e).

Figure 4-1b: Effect of concrete, air temperature, relative humidity and wind on rate of evaporation of
surface moisture from concrete in US Unit, (Source, ACI, 1999)

4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE

4/31.1 Any one set of 6 cubes for each class of concrete and for each particular
application represent a maximum quantity of concrete as shown in Table 4-10.
The point of sampling of fresh concrete shall be at delivery into the
construction unless otherwise directed by the Engineer. Each set of cubes
shall be made from a separate batch.

4/31.2 Portland Cement: One 2 Kg sample for quality test shall be taken from each
1,700 bags or equivalent weight in accordance with BS EN 196 - 7: 2007.

4/31.3 Water: One 1 - gallon sample shall be obtained prior to use from each source
and at least once every week for quality testing.

Table 4- 10: Sample Rate

TYPE OF STRUCTURE SAMPLING TO REPRESENT

A VOLUME OF M3
1. Critical structures e.g. masts, 10
cantilevers, columns
2. Intermediate structures e.g. beams, 50
slabs, bridge decks
3. Heavy concrete construction e.g. 100
breakwaters, solid rafts

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 39 SECTION 4 CONCRETE WORKS

4/32 FORMWORK

CONSTRUCTION

4/32.1 Formwork shall include all temporary or permanent forms required for forming
the concrete, together with all temporary constructions required for their
support.

4/32.2 All formwork shall be of such quality and strength as will ensure rigidity
throughout the placing, ramming, vibration and setting of the concrete without
visible deflection.

4/32.3 All formwork shall be so constructed that there shall be no loss of material
from the concrete. After setting, the concrete shall be in the position and of
the shape and dimensions prescribed. The finished surface of exposed
concrete shall be of a quality specified on the drawings and approved by the
Engineer.

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 40 SECTION 4 CONCRETE WORKS

4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all
exposed edges shall be beveled by using dressed, mill-cut, triangular molding,
having twenty (20) millimeters sides.

All curved surfaces shall be formed with approved plywood or steel.

The Contractor shall in all cases request the approval of the formwork by the
Engineer's representative in sufficient time to allow an inspection to be made
and shall not commence concreting until such approval is obtained. The
period between the Contractor's request for approval and his intention to
commence concreting shall be not less than one clear normal working day and
the Engineer's representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.

Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

4/32.5 Where internal metal ties are permitted, they or their removable parts shall be
extracted without damage to the concrete and the remaining holes filled with
mortar. No permanently embedded metal part shall have less than 40 mm
cover to the finished concrete surface or the specified cover to the
reinforcement whichever is the greater.

4/32.6 The Contractor shall submit to the Engineer for his approval strength and
deflection calculations and drawings of the formwork he proposes to use. The
Contractor shall ensure that adequate time is given to enable the Engineer to
examine the calculations and drawings and also to inspect the formwork
before concrete is placed within it.

FALSEWORK

4/32.7 Detailed drawings for falsework and centering shall be prepared by the
Contractor and submitted to the Engineer for approval. The drawings must be
approved by the Engineer before the work is started.

4/32.8 The Contractor shall submit to the Engineer for approval at least one (1)
month before commencing work, details of his proposed system of falsework,
including detailed drawings and calculations. Falsework shall be capable of
accommodating temperature changes without causing damage to the
concrete.

4/32.9 Falsework and centering shall be designed and constructed to provide the
necessary rigidity to support all loads placed upon it without appreciable
settlement or deformation. Falsework columns shall be supported on wood or
metal bases to support all falsework that cannot be founded on rock, shale or
thick deposits of other compact material in their natural beds. Falsework shall
not be supported on any part of the structure, except the footings, without the
written permission of the Engineer.

The number and spacing of falsework columns, the adequacy of sills, caps
and stringers and the amount of bracing in the falsework framing shall be
subject to approval of the Engineer.

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 41 SECTION 4 CONCRETE WORKS

4/32.10 All timber shall be of sound wood, in good condition and free from defects that
might impair its strength. If the vertical members are of insufficient length to
cap at the desired elevation for the horizontal members, they shall preferably
be capped and frames constructed to the proper elevation. Ends of the
vertical members shall be cut square for full bearing to preclude the use of
wedges. If vertical splices are necessary, the abutting members shall be of
the same approximate size, the ends shall be cut square for full bearing, and
the splices shall be scabbled in a manner approved by the Engineer.

4/32.11 All steel members shall be in good condition, free from damage, kinks,
corrosion or any other defect which might impair their strength.

4/32.12 The Contractor shall compute the form settlement and deflection required for
bridges so that when the final settlement is complete, the structure will
conform to the required camber, section and grade as shown on the drawings.

4/32.13 The Engineer will check and approve the Contractor's computations. Long,
tapered hardwood wedges or screw jacks shall be used in all falsework
construction and shall be so placed that they can be adjusted to give proper
form alignment. The Contractor shall, if required by the Engineer, provide
means for adjusting forms to offset any excessive settlement, if screw jacks
are used, they shall be adequately braced and secured in such a manner that
will prevent tipping of the jacks in any direction.

4/32.14 The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent
observer to observe and correct the settlement.

4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In

computing vertical loads, a weight of twenty four hundred (2,400) kilograms
per cubic meter shall be assumed, and not less than thirteen hundred and
sixty (1,360) kilograms per cubic meter shall be assumed in computing
horizontal pressure.

4/32.16 The Engineer may refuse permission to proceed with other phases of the work
if he deems the falsework unsafe or inadequate to support properly the loads
to which it will be subjected.

4/32.17 The review or approval of falsework drawings by the Engineer or permission to

proceed with the work shall not relieve the Contractor of the responsibility for
successful erection or satisfactory results.

TOLERANCE

4/32.18 The formwork shall be set to such lines and levels as to ensure that the
following tolerances are not exceeded in the structures as cast.

- For all buried concrete. + 25mm - 12mm

In addition, for concrete surfaces

that are to be waterproofed,
abrupt irregularities in the surface
finish shall not exceed 3mm.

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 42 SECTION 4 CONCRETE WORKS

- For soffit edge beams and +/- 3mm but not more
sides of parapet plinths than 3mm in 3.5m.

- For all other concrete +/- 6mm but not more than 3mm in
3.5 m.

PREPARATION OF FORMWORK BEFORE CONCRETING

4/32.19 The inside surfaces of forms shall, except for permanent formwork, or unless
otherwise agreed by the Engineer, be coated with a release agent approved
by the Engineer. Release agents shall be applied strictly in accordance with
the manufacturer's instructions and shall not come into contact with the
reinforcement. Different release agents shall not be used in formwork to
concrete which will be visible in the finished works. A panel shall be
constructed utilizing the proposed release agent for the Engineer's approval.
The surface of the panel shall not exhibit discoloration or any significant retard
of the surface mortar strength.

4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All
formwork shall be inspected and approved by the Engineer before any
concrete is placed in it but such approval shall not relieve the Contractor of his
responsibilities for the safety, accuracy or efficiency of the work.

REMOVAL OF FORMWORK

4/32.21 The Engineer shall be informed in advance when the Contractor intends to
strike any formwork.

4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and
strength for it to withstand the effects of striking, including the effect of thermal
shock or the loss of surface durability upon premature exposure, and to be
able to withstand the resulting stresses without adverse effects.

4/32.23 The time at which the formwork is struck shall be the Contractor's
responsibility but the minimum periods between completion of placing
concrete in a section of the works and the removal of forms shall be as
follows:-

Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days
Removal of props (beams and slabs) 14 days
Soffits of precast beams 7 days

4/32.24 Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props are to be left in place
when the soffits forms are removed, these props shall not be disturbed during
the striking.

4/32.25 Formwork shall be removed without damage to the concrete.

4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and

made good to the satisfaction of the Engineer.

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 43 SECTION 4 CONCRETE WORKS

4/33 CLASSES OF FINISH

FORMED SURFACES

4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.

4/33.2 Class F1: As struck.

4/33.3 Class F2: The irregularities in the finish shall be no greater than those
obtained from the use of wrought thicknessed square edged boards arranged
in a uniform pattern. The finish is intended to be left as struck but
imperfections such as fins and surface discoloration shall, if required, be made
good by methods approved by the Engineer.

4/33.4 Class F3: The formwork shall be lined with a material approved by the
Engineer to provide a smooth finish of uniform texture and appearance. This
material shall leave no stain on the concrete and shall be so joined and fixed
to its backing that it imparts no blemishes. It shall be of the same style and
obtained from only one source throughout.

4/33.5 The Contractor shall make good any imperfections in the finish as required by
the Engineer. Internal ties and embedded metal parts will not be allowed.

4/33.6 Class F4 : The requirements for Class F4 are as for class F3 except that
internal ties and embedded metal parts will be permitted. The ties shall be
positions as described in the Contract or as agreed by the Engineer.

4/33.7 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish shall
be protected from rust and stains of all kinds.

4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed
surfaces of concrete to Class F2, F3 and F4 finish shall form a regular pattern
with horizontal and vertical lines continuous throughout each structure and all
construction and movement joints shall coincide with these horizontal or
vertical lines.

4/33.9 REMEDIAL TREATMENT OF SURFACES

An inspection of the concrete surface shall be carried out immediately after

removing the formwork, and any remedial treatment to surfaces proposed by
the Contractor shall be submitted to the Engineer for approval and shall be
carried out without delay. Portions of the structure which can not be finished
or properly repaired to the satisfaction of the Engineer shall be removed.

4/33.10 Any concrete, the surface of which has been treated before being inspected by
the Engineer, shall be rejected.

UNFORMED SURFACES

4/33.11 Class U1 Finish. The concrete shall be uniformly leveled and screeded to
produce a plain surface as described in the Contract. No further work shall be
applied to the surface unless it is used as a first stage for a Class U3 finish.

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 44 SECTION 4 CONCRETE WORKS

4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent
laitance from being worked to the surface, a Class U1 finish shall be floated by
hand or machine sufficiently to produce a uniform surface free from screed
marks.

4/33.13 Class U3 Finish. When the moisture has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a
Class U1 finish shall be steel-trowelled under firm pressure to produce a
dense, smooth uniform surface free from trowel marks.

4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved
waterproofing systems. The concrete shall be uniformly leveled and screeded
to produce a plain surface. When the concrete has sufficiently hardened to
prevent laitance being worked to the surface it shall be floated to produce a
uniform surface free from screed marks and exposed aggregate. Finally the
surface shall be textured by brushing or otherwise to the waterproofing
manufacturer's requirements as agreed by the Engineer. The accuracy of the
finished surface shall be such that it does not deviate from the required profile
by more than + 5 mm over a 3 m gauge length or have any abrupt
irregularities more than 3 mm.

SPECIAL FINISHES

4/33.15 Where special finishes are specified in the drawings or in a particular

specification the Contractor shall make trial panels for the formed finishes
specified for inspection and approval by the Engineer.

4/34 MORTAR

4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing

plasticizers shall not be overmixed. Mixers shall be kept clean at all times.

4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall
not be used in the work and shall be removed immediately from the site.
Mortar shall be prepared in the following proportions with the addition of a
minimum quantity of water for workability.

4/34.3 MORTAR (3:1)

Sand/Cement mortar (3:1) shall be composed of one part of cement to three

parts of sand by volume. This type of mortar shall be used in block work
where high strength is required.

4/34.4 MORTAR (4:1)

Sand/Cement with plasticizer mortar (4:1) shall be composed of one part of

cement to four parts of sand with a mixture of an approved plasticizing agent,
added in accordance with the manufacturer's instructions.
4/34.5 The sand used in mortar must be dry when proportioning. Allowance for
bulking shall be made when gauging by volume. The mean compressive
strength at 28 days for each mortar shall conform to BS 5628: Part I.

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 45 SECTION 4 CONCRETE WORKS

4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both
as specified in BS 1200: 1976.

4/35 EXTENT OF POURS

4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimize thermal and shrinkage
strains.

4/35.2 For walls, the length of panel placed at one time shall not exceed 6 m,
adjacent panels shall not be placed within 2 days, but shall be placed as soon
as practicable thereafter. Subsequent vertical lifts shall not be poured within 2
days.

4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
sequence of panels. 'Chequerboard' placing shall be avoided. Adjacent
panels shall not be placed within 3 days, and then only provided that the
concrete in the first pour has cooled down to below 38 degrees centigrade or
ambient temperature. Placing of adjacent panels shall take place as soon as
practicable after the above criteria have been satisfied. Panels shall be 5 m x
5 m and any pour exceeding 25 m 2 will only be considered for approval if
substantiated by calculations.

4/36 POST-TENSIONED CONCRETE WORKS

4/36.1 General

This work includes, but not by way of limitation, supplying and fixing formwork,
falsework and temporary works; supplying, testing and placing prestressing
steel with all accessories, metal ducts and anchors; supplying concrete of the
class as indicated on the Drawings or specified herein and transporting and
placing it in prepared forms; tamping, vibrating, finishing and curing the
concrete; pointing and jointing with cement mortar; post-tensioning
prestressing steel; pressure grouting ducts; all in accordance with the
specifications and Contract Documents. Post-tensioned concrete work shall
be as indicated on the Drawings, as specified herein and/or included in the
Bills of Quantities.

4/36.1.1 Standards and Codes

Standards and codes shall be as specified in Section 4, Concrete Works of

the General Specifications, and the following in their latest edition shall apply
and govern all works related to post tensioned concrete.

ASTM: American Society for Testing and Materials

A416: Uncoated Stress-Relieved Strands

4/36.1.2 Submittals

1. Shop Drawings - Shop drawings shall be submitted to the Engineer for

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 46 SECTION 4 CONCRETE WORKS

approval in accordance with Section 4/9 of General Specifications and as

specified herein. All submissions must be thoroughly checked by the
Contractor for numerical and conceptual errors before submitting to the
Engineer for approval.

Supplementing the requirements for shop drawings specified in Section 4/9,

the Contractor shall include with the shop drawings a description of the
equipment to be used and the procedure for constructing post-tensioned
concrete work. The type and size of ducts and method of holding the ducts in
position, tendon sizes, jack clearances and procedures, stressing sequences,
grout connections and vents, anchorage details and bonding and grouting
procedures shall also be indicated.

Any delays in the Engineer granting his approval consequent to incomplete,

late, inadequate or unchecked submissions shall be entirely the Contractor’s
responsibility.

2. Certificates - Certificates from the manufacturers shall be furnished to the

Engineer certifying that the materials and equipment to be provided comply
with the requirements of these specifications.

3. Test Reports - The Contractor shall furnish to the Engineer six (6) copies of
test reports and certificates as specified herein, unless otherwise directed by
the Engineer.

4/36.1.3 Quality Assurance

1. In the event the Contractor proposes to perform the post-tensioned concrete

work with his own forces, the Contractor shall submit all details of his
qualifications as specified herein and as required by the Engineer for approval
by the Engineer of the Contractor to perform the work.

2. In the event the Contractor is unable to provide acceptable and adequate

information of his qualifications to perform this work and is rejected by the
Engineer for the post-tensioned concrete work, the Contractor will be required
by the Engineer/Employer to subcontract such works.

3. The Contractor will be required to submit to the Engineer for review and
approval, the following information regarding his qualifications or those of the
proposed subcontractor:

a) The Contractor shall submit the name and address of the proposed
organization or subcontractor, along with a complete and detailed
description of their qualifications and experience in the performance of
post-tensioned concrete work.

b) The named proposed organization or subcontractor shall submit

evidence acceptable to the Engineer that the organization or
subcontractor is experienced in the field of prestressing systems.
Further, the Contractor or proposed subcontractor shall submit data
acceptable to the Engineer that they have, within the last five years,
performed such construction or work comparable to the post-tensioned
concrete works as specified in these Particular Specifications and
indicated on the Drawings. The Contractor shall confirm this experience

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 47 SECTION 4 CONCRETE WORKS

by citing a minimum of two projects comparable to the current projects

which have been successfully accomplished.

c) Approval by the Engineer of the Contractor’s organization or the

subcontractor for the performance of the post-tensioned concrete works
shall not relieve the Contractor of overall responsibility for such work.

d) In the event the Contractor or an approved subcontractor demonstrates

an inability to perform the work as specified in this Section for Post-
Tensioned Concrete Works subsequent to the approval by the
Engineer, the Engineer reserves the right to rescind such approval and
require that the Contractor submit the name of another subcontractor to
perform the work. All re-submittals shall comply with the requirements
specified herein and all Contract Documents.

4/36.1.4 Sampling and Testing

1. Concrete - Concrete sampling, testing and frequency of testing shall be in

accordance with Section 4, Part 1, Concrete Works, and as amended in
Clause 4/17.

2. Prestressing Steel - All reels of prestressing steel shall be accompanied

by an inspection and test certificate furnished by the supplier indicating the
number of reels in the shipment represented by the certificate, modulus of
elasticity, stress/strain curves, tensile strength, relaxation test results and
strand chemical composition.

For each certificate furnished, a sample, as described herein, shall be

furnished to the Engineer for testing purposes.

The Contractor shall make arrangements with the vendor to furnish the
Engineer, samples as selected at random from the lot of reels represented
by each certificate. Samples shall be not less than 1.20m in length.

All samples submitted shall be accompanied by a certification from the

vendor certifying that the samples were taken from and are representative
of, the lot of reels to be furnished.

All of the above samples shall be tested by an approved laboratory well in

advance of the anticipated date of use. The Contractor shall make no
claim for additional compensation if his work is delayed awaiting approval
of the materials testing.

4/36.1.5 Scheduling of Post-Tensioned Concrete Works

The scheduling of all post-tensioned concrete work shall be such that

construction of each individual superstructure unit can be completed within
a 90-day period commencing with the first concrete pour through
completion of the post-tensioning and duct grouting operations unless
otherwise indicated on the Drawings, or directed by the Engineer.

The Contractor shall have sufficient materials on hand prior to

commencing work on any given superstructure unit to ensure completion
of the unit within the specified 90-day period.

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 48 SECTION 4 CONCRETE WORKS

4/36.1.6 Materials, Delivery, Storage and Handling

Prestressing steel shall be protected from physical damage and corrosion

at all times from manufacture to grouting or encasing in concrete.
Physically damaged post-tensioning steel will be rejected by the Engineer.
The development of visible rust or other results of corrosion will be cause
for rejection by the Engineer.

Prestressing steel shall be packaged in containers or shipping forms for

the protection of the steel from physical damage and corrosion during
shipping and storage. The manufacturer shall place a corrosion inhibitor,
which prevents rust or other results of corrosion directly to the steel, and in
the package or form, or shall use a corrosion inhibitor carrier type
packaging material. Corrosion inhibitor shall have no deleterious effect on
steel or concrete or bond strength of steel to concrete.

Shipping packages shall be clearly marked with a statement that the

packages contain high-strength post-tensioning steel, and that care is to
be used in handling; and that shows the type, kind and amount of
corrosion inhibitor contained, including the date packaged and safety
instructions for use. Reel identification tags showing all the relevant details
for the reel shall be securely placed both on the inside and outside of the
packaging.

4/36.2 Concrete and Materials

The concrete and other materials to be furnished and included in the

construction of all Post-Tensioned Concrete Works shall be as specified
herein.

4/36.2.1 Post-Tensioning Systems

1. Post-tensioning systems for concrete box girders shall be of internationally

recognized types acceptable to the Engineer, as indicated on the
Drawings, and as specified in these Particular Specifications.
a) All the anchorage devices must be certified and have been tested
according to the acceptance test requirements for highly aggressive
environments as given in AASHTO Division II – Construction Part
10.
b) Strands shall be uncoated, seven wire, high-tensile, cold drawn, low
relaxation complying with ASTM A416, Grade 270.
c) Wire shall be uncoated, stress-relieved, cold drawn, round, high
tensile steel, complying with ASTM A421:2006, and having a
minimum tensile strength of 1,650 x 106 N/m2. Wire shall not be oil
tempered.
d) Anchorage assemblies, jacks, gauges, grout fittings, and other
related equipment and accessories shall be standard with the
system manufacturer and approved by the Engineer.
e) Ducts for bonded post-tensioning strand shall be flexible,
galvanized, interlocked, mortar and grout tight, and fabricated of not

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 49 SECTION 4 CONCRETE WORKS

lighter than 28 gauge steel. Ducts shall be at least 6 mm larger than

the nominal diameter of the strand or wire bundles and the cross
sectional area shall be at least twice that of the net steel area. The
ducts shall have grout openings at each end, and shall be vented at
high points of the ducts at piers.
f) Epoxy bonding agent: complying with the national and international
standards and specifications (latest edition).
g) Bituminous protective coating complying with the national and
international standards and specifications (latest edition).

2. Post-tensioning systems of other manufacturers which are comparable

and equal in all respects to the specified systems may be used, provided
the proposed alternative post-tensioning systems have the prior approval
of the Engineer. The Engineer will be the sole judge as to whether or not
any proposed alternative system of post-tensioning is comparable and
equal to the specified systems.

4/36.2.2 Concrete

Concrete for post-tensioned concrete work shall be Class 45/20 (unless

otherwise indicated on the Drawings) specified in Section 4, Concrete
Works, of these General Specifications.

4/36.2.3 Reinforcement Steel

Reinforcement steel shall comply with the requirements of Section 4,

Concrete Works, of these Standard Specifications and where specifically
indicated on the Drawings or directed in the Particular Specifications.

4/36.2.4 Duct Grout Materials

1. Grout admixture shall be a balanced blend of expanding, fluidifying,

and water-reducing agents containing no calcium chloride, nitrates or
other chemicals causing steel corrosion.

2. Portland cement shall be as specified in Section 4 of General

Specifications.

3. Water shall comply with the requirements of Section 4, Concrete

Works, of these General Specifications.

Properties of Grout - Duct grout shall comply with the requirements given
in the relevant sections of the Specifications with regard to the
following:

 fluidity and bleeding in the plastic condition

 volume change when hardening
 strength when hardened
The tests are specified in Section4, Clause 4/36.2.5.

Fluidity - The fluidity of grout during the injection period shall be

sufficiently high for it to be pumped effectively and adequately to fill

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 50 SECTION 4 CONCRETE WORKS

the duct without excessive segregation, but sufficiently low to expel

the air and any water in the duct.

When tested by the methods given in Section PS 4/36.2.5 the grout

shall have the values given in Table 4-11.

Table 4- 11: Fluidity Test Requirements

FLUIDITY(S)
30 min. after mixing or at
Test Immediately end of injection period At duct
Method After Mixing (see Note 1) Outlet
Immersion > 30 < 80 > 30
Tube
Cone < 25 < 25 > 10
Note1: Mixing time shall be measured from the point when all the
materials are in the mixer.

Bleeding - The bleeding of the grout shall be sufficiently low to prevent

excessive segregation and settlement of the grout materials, when tested
by one of the methods given below in Section4, Clause
4/36.2.5.

The grout shall not be subject to bleeding in excess of 2% after 3 hours or

4% maximum when measured at 18C in a covered cylinder approximately
100mm diameter with a height of grout of approximately 100mm, and the
water shall be reabsorbed by the grout during the 24 hours after mixing.

Volume Change - The volume change assessed may be either increased

or decreased. When tested in accordance with the methods given in
Section 4, Clause 4/36.2.5 the volume change of the grout shall be within
the range 0% and +3%. For grouts with expanding agents there shall be
no decrease in volume.

Strength - The compressive strength of grout may be assessed using

either of the specimen shapes and sizes given in Table 4-12 and using the
corresponding procedure given in the same table.

In either case the compressive strength shall be not less than the
compressive strength of the surrounding concrete at 7 and 28 days.

Table 4- 12: Compressive Strength Specimens

Specimen Shape Specimen Dimensions (mm) Test Procedure

Prism 40 x 40 x 160 PS 4/36.2.5
Cylinder 100 dia x 80 height PS 4/36.2.5

Batching and Mixing of Grout - The proportions of materials used in the

mix may be selected on the basis of prior documented experience with
similar materials and equipment, and under comparable field conditions

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 51 SECTION 4 CONCRETE WORKS

(weather, temperature, etc.) and shall be verified by tests made on the

grout before grouting begins.

The water content shall be the minimum necessary to obtain the required
workability for proper placement and under no circumstances shall the
water/cement ratio exceed 0.44. The water content of any admixtures
shall be taken into account when calculating the water/cement ratio. The
materials shall be batched by weight with an accuracy of +2% for cement
and admixtures and +1% for water.

All materials shall be batched by mass except in the case of water which
may be batched by mass or volume.

Mixing shall be carried out mechanically to obtain a homogeneous and

stable grout with the plastic properties given in the Specification.

Depending upon environmental or material influences (eg. Temperature,

configuration of the tendon and the properties of the cement use), the w/c
ratio shall be kept as low as possible having regards to the required plastic
properties of the grout.

A sufficient amount of material shall be batched to ensure complete

grouting of a duct making due allowance for overflow. The grout shall be
mixed in a machine capable of producing a homogenous grout and after
mixing, keeping the grout in slow continuous agitation, until it is ready to be
pumped into the duct, Water shall be added to the mixer first, followed by
the cement and if agreed by the Engineer, admixtures. The batch
quantities of cement and admixtures may be added as a whole or in part in
sequence until the total quantities are added.

Temperature at Grouting - Records shall be kept of the maximum and

minimum air temperatures and the temperature of the members to be
grouted.

Ambient temperature during grouting shall not be above 35Co.

Grout temperature at duct inlet and outlet shall not be above 32oC during
mixing or pumping. If necessary cold water shall be used for grout mixing
to maintain recommended temperature.

4/36.2.5 The Testing of Grout

The following tests, listed below, shall comply with the requirements of the
following standards:

a) UAE & DMs Standards, if any

b) International Standards “ISO, BS, ASTM, etc.)

1. General Conditions - The grouts shall be tested by competent

personnel experienced in the subject, and in laboratory conditions of
temperature and humidity as follows:

Temperature (20 ± 2) oC

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 52 SECTION 4 CONCRETE WORKS

Humidity > 65% R.H.

The grout for the tests shall be made from the materials specified in
and mixed in accordance with the requirements of these Specifications.
The temperature of the freshly mixed grout is to be given in all test reports.

2. Fluidity Test - Immersion Method (BS EN-445:2007)

Principle - The tests consists of measuring the time a plunger

needs to drop through a defined amount of grout in a tube.
Apparatus
a) Calibrated immersion equipment according to Figure 4-2.
b) Wooden measuring rod according to Figure 4-2.
Calibration Procedures - The immersion equipment shall be calibrated
with glycerol (analytical grade) having a density of 1.23 T/M3 at 20oC. The
temperature of the room, immersion equipment and glycerol shall be (20 +
1) oC during the calibration.
The cylinder shall be filled with about 1.9 litres of glycerol up to
approximately 250mm below the rim. After filling the immersion equipment
the glycerol shall be allowed to rest for about 1 hour. The plunger then
shall be immersed to expel any air bubbles from the glycerol, which may
have been introduced during the filling of the cylinder.

After one hour the plunger shall be positioned so that its stop on the tail
rod lies on the spacer placed at the top of the tube. The spacer shall then
be pulled away to allow the plunger to sink to the top of the tube. The
immersion time (the time taken for the plunger to sink) shall be recorded in
seconds to the nearest second.

The calibration shall be repeated at least 3 times.

The mean value of all measured immersion times shall be (34 + 1)s. If the
mean value deviates for this figure, the weight of the plunger shall be
increased where t > 35s or reduced where t < 33s. This is done by varying
the quantity of the lead pellets in the plunger. Repeated calibration
procedures shall be delayed for at least 30 minutes to ensure expulsion of
any air bubbles that may be have been introduced during a preceding
calibration procedure.

Test Procedure

Preparation - The immersion equipment shall be calibrated before it is

used. Calibration of the immersion equipment shall be performed
subsequently once a year and/or after any damage.Directly before the test,
the inside of the tube and the plunger shall be slightly wetted.

Procedure - The cylinder shall be filled with approximately 1.9 liter of grout
up to approximately 260mm below the rim, so that on introduction the
plunger is fully immersed when its stop on the tail rod lies on the spacer
placed at the top of the tube. The spacer should be pulled away to allow
the plunger to sink to the stop on the tube. Thereafter the plunger should
be raised back to its initial position, the spacer inserted and again pulled
away.

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 53 SECTION 4 CONCRETE WORKS

Figure 4- 2: Immersion equipment for determining the immersion time

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 54 SECTION 4 CONCRETE WORKS

The immersion time shall be measured, i.e. the time it takes for the plunger
to sink to the point where its tail stop touches on top of the tube. The
immersion times of the grout shall be measured immediately after the
mixing process and after a further 30 minutes. For the latter test, unused
grout from the same mix as that used for the former immersion test shall
be used. The grout is to be kept in motion while carrying out all tests.
Each test shall be carried out three times in succession with the same
filling.

Reporting the Results - The result shall be reported as the average of the
immersion times to the nearest second of the second and third immersion,
i.e ignoring the first immersion time.

3. Fluidity Test - Cone Method

Principle - The fluidity of grout, expressed in seconds, is measured by the

time necessary for a stated quantity of grout to pass through the orifice of
the cone, under stated conditions.

Apparatus - The following apparatus is required for the test:

a) Cone - A cone of dimensions shown in Figure 4-3. The cone shall

be robust and manufactured from materials not reactive with any
duct grout materials specified in these Specifications. The volume
of the cone (excluding the cylindrical portions at top and bottom)
shall be 1.7 liters + 10%.
b) Sieving Medium - The sieving medium aperture shall be 1.5mm
and the medium shall be fitted as shown in Figure 4-3.
c) Stopwatch
d) Container of 1 litre capacity.

Test Procedure

Preparation - The cone shall be mounted with its axis vertical and its
largest diameter uppermost. The sieving medium shall be fixed at the
position indicated in Figure 4-3. During the test the cone shall be
prevented from vibrating. The container under the cone outlet. All
surfaces of the cone shall be clean and slightly moistened. Close the
lower cone orifice.

Procedure - Pour 1.5 liters of the grout through the sieving medium into
the cone sufficiently slowly to prevent the build-up of air in the grout in the
cone. Open the lower cone orifice and at the same time, start the
stopwatch. Measure the time taken to the nearest 0.5s to fill the container.
The presence of lumps on the sieving medium shall be reported. Two
tests shall be carried out, the first immediately after the grout is mixed and
the second 30 minutes thereafter or alternatively at the end of the grouting
period.

Reporting of Results - Report the time taken to the nearest 0.5s. Report
also the presence of lumps.

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 55 SECTION 4 CONCRETE WORKS

Figure 4- 3: Cone for Fluidity Test

4. Bleeding Tests

Principle - The test consists in measuring the quantity of water remaining

on the surface of the grout which has been allowed to stand protected from
evaporation.

Apparatus - A transparent I00 ml cylinder 25mm in diameter and 250mm

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 56 SECTION 4 CONCRETE WORKS

in height graduated in ml. Alternatively a transparent cylinder 50mm in

diameter and 200mm in height graduated in mm.

Procedure

Preparation - Place the cylinder on a surface free from shocks or

vibration. The grout used may be from the same batch as that used for the
fluidity test.

Procedure for 25mm diameter cylinder

Pour 95ml to l00mI of grout into the cylinder. Note the precise level of the
grout (v) ignoring the meniscus. After 3 hours, measure the quantity of
water on top of the grout (vl) taking appropriate measures to prevent
evaporation. The test is carried out on one sample of grout.

Procedure for 50mm diameter cylinder

Pour grout into the cylinder to a height of approximately 150mm. Note the
height to the top of the grout (h) ignoring the meniscus.
After 3 hours, measure the height of water on top of the grout (hl) taking
appropriate measures to prevent evaporation. The test is carried out on
one sample of grout.

Reporting of Results - Bleeding at the end of 3 hours is given by:

vl /v x I00% for 25mm diameter cylinder, and

hl/h x 100% for 50mm diameter cylinder

where
vl is the volume of water on the surface of the grout after 3
hours (in ml)
v is the initial volume of grout (in ml)
hl is the height of water on the surface of the grout after 3
hours (in mm)
h is the initial height of grout (in mm)

The report shall state the temperature at the time of test.

5. Volume Change Test

Principle - Testing shall be in accordance with the FIP (Federation

International de La Precontrainte) Guide for Good Practice Procedures.
The volume change is measured as a percentage of the volume of grout
between the start and the end of the test. The test measures mainly the
volume change caused by segregation or expansion. The grout used in
this test may have been used for the bleeding test (see Test 4).

Cylinder Method

Apparatus - A transparent cylinder 50mm in diameter and 200mm in

height as required for test 4.

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 57 SECTION 4 CONCRETE WORKS

Procedure - Place the cylinder on a surface free from shocks and

vibration. Fill it with the grout to a height (h). Twenty four hours after filling
the cylinder measure the height (h2) to determine the change in volume.

Reporting of Results - The volume change at the end of 24 hours is

given by:

(h2 – h)/h x 100%

where
h = is the initial height of grout (in mm)
h2 = is the height of grout after 24 hours (in mm)

Can Method
Apparatus
a) Three cans, 120mm high and approximately 100mm in diameter,
with lids capable of preventing the loss of moisture.
b) Measuring rod or sliding calipers
c) Plates
 Stop plate for placing on the can with a diameter of 120mm
(see Figure 4-4)
 Stop plate for placing on the grout with a diameter of 96mm
(see Figure 4-5)
d) Filling gauge 100mm high

Procedure - Place the cans on a surface free of vibration and heat

radiation and store for 24 hours. Immediately after mixing pour the grout
into each can using the filling gauge, to a depth of 100mm. The
measurement of the distance from the top edge of the can to the top of the
grout is to be taken:

 immediately after the containers are filled and

 24 hours after the containers are filled by one of the following methods:

a) Measurement with the Stop Plate on the Can - immediately after

the cans have been filled with grout, measure the distance
between the surface of the grout and the stop plate on the can in at
least six places with the depth gauge (first measurement). The
marking must coincide with the top edge of the can (reference
point). Then the cans are sealed by covering with the lid weighted
with approximately 300g until the second measurement is carried
out 24 hours after the filling of the cans.

b) Measurement with the Stop Plate on the Grout - Immediately

after filling the cans, put the stop plate (Figure 4-5) on the fresh
grout and measure with the depth gauge the distance between this
plate and the top edge of the can in at least six places (first
measurement). Then the cans are sealed. The second
measurement shall be carried out 24 hours after the filling of the
cans. In the second measurement the distance between the stop

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 58 SECTION 4 CONCRETE WORKS

plate and the top edge of the can is measured at the same places
as for the first measurement. After the second measurement the
cans are sealed as before, and used as necessary for the
compression strength tests (6).

Figure 4- 4: Plate on the Can

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 59 SECTION 4 CONCRETE WORKS

Figure 4- 5: Plate on the Grout

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 60 SECTION 4 CONCRETE WORKS

Reporting of Results - The difference of the average values between first

and second measurement(s) in mm corresponds at I00mm grout level to
the volume change in percent and is reported as the percentage change in
volume. Report the percentage change in volume as the average of the
three containers to the nearest 0.1 %. Report increase of volume as (+)
and decrease
as (-).

6. Compression Strength Test

a) Compression Strength Test - Prism

Principle of the test - The compression strength of grout in this

test (which is an adaptation to grouts of the mechanical tests described in
BS EN 196-1: 2005) is determined on the broken halves of prisms.

Apparatus
i) Mixer for grout in accordance with the requirements of these
Specifications for hatching and mixing of grout.
ii) Air conditioned cabinet at (20 + 1) oC and (95 ± 5) % relative
humidity.
iii) Test machine and the device in accordance with 4.7 and 4.8 of B.S.
EN 196-1: 2005.
iv) Metal molds in accordance with 4.5 of BS EN 196-1: 2005.
v) Metal straight edge in accordance with figure 3 of BS EN 196-1:
2005.

Procedure

Moulding of the Test Specimens - File moulds and accessories shall

be prepared and the specimens made in accordance with BS EN 196-
1, with the exception noted below.

Each mould (fitted with a hopper) shall be filled with the prepared
grout. As an exception to the procedure in B.S. EN 196-1: 2005 and in
view of the liquidity of the grout the test specimens shall not be
subjected to any vibration or shock so as to prevent rapid deterioration
of the grout (loss of grout, drying out, bleeding or sedimentation).

Remove the hopper gently. Immediately strike off the excess grout
with the metal straight edge held almost vertically and moved slowly,
with a transverse sawing motion once in each direction. Smooth the
surface of the specimens using the same straight edge held almost
flat.
Label or mark moulds to identify the specimens.
Curing of Test Specimens - The curing of test specimens shall be
carried out in accordance with BS EN 196- 1: 2005, until they are
tested.

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 61 SECTION 4 CONCRETE WORKS

Compression Test - The compression tests shall be carried out in

accordance with BS EN 196- 1: 2005. The compression strength shall
be measured on six test specimens from three prisms broken in
flexure.
Reporting of Results - The report shall provide all the results of the
compression tests, in MPa. The value obtained for each test shall be
the mean of the individual results.

b) Compression Strength Test - Cylinders

Principle - The compressive strength of grout in this test is determined
on the three cylinders used in the volume change test given in Test 5.

Apparatus

i) The cans as described in Test 5.

ii) An air conditioning cabinet as described in Test 6.
iii) A compression test machine as described in BS EN 196-1: 2005
iv) Implements for sawing and grinding test specimens.

Procedure
After measuring the volume change (see 5.) the three cylinders shall
be stored in the air conditioning cabinet at (20 + 1) oC until they are to
be prepared for test. Immediately prior to test the specimens shall be
carefully demolded.
Each specimen is prepared for test by sawing through the cylinder
near the upper surface and then grinding both circular surfaces of the
cylinder until the disc to be loaded in the test has a thickness of 80mm.

Each specimen shall then be placed in the compression test machine

and loaded, at a uniform rate of 0.5 MPa/s, on its ends until the
maximum load (Fc) is reached.

Reporting of Results - The compressive strength Rc is calculated in

MPa from:

Rc = Fc/A
where

Fc = is the failure load,

A = is the cross sectional area and shall be measured on
three specimens, the mean value of which shall be
reported as the compressive strength.

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 62 SECTION 4 CONCRETE WORKS

7. Frequency of Testing - The testing of the grout made from certified

or otherwise quality assured materials shall be carried out prior to the
start of grouting operations and at the following minimum of testing in
the course of grouting.

Bleeding: 2 tests per day. One sample is to be taken at

the mixer and one sample at the duct outlet
when the grout there has a satisfactory fluidity
value.

Volume Change: 1 test per day.

Strength: 1 test per 7 days or a minimum of two tests per

grouting operation whichever is greater.

Fluidity: To be tested at outlet and inlet for each duct

during grouting operation.

4/36.2.6 Built-In Materials

The Contractor shall furnish and install all built-in materials and items as
indicated on the Drawings, as specified herein and as directed by the
Engineer.

Built-in materials shall include, but not by way of limitations, all inserts,
hardware or similar items as indicated on the Drawings or specified in the
Particular Specifications.

4/36.3 Construction

The construction of all Post-Tensioned Concrete Works shall be as

specified herein.

4/36.3.1 Post-Tensioned Method Statement

The Contractor shall submit, to the Engineer for review, complete details of
the method, materials and equipment he proposes to use in the
prestressing operations, including any additions or rearrangement of
reinforcement steel from that indicated on the Drawings.

Such details shall outline the method and sequence of stressing and shall
include complete specifications and details of the prestressing steel and
anchoring devices, working stresses, anchoring stresses, type of ducts,
and all other data pertaining to the prestressing operation, including the
proposed arrangement of the prestressing steel in the members, pressure
grouting materials and equipment.

The Contractor shall not cast any member to be prestressed before the
detailed shop drawings are complete and approved by the Engineer.

4/36.3.2 Formwork and Falsework

1. Formwork, shoring, and removal of forms shall be as specified in

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 63 SECTION 4 CONCRETE WORKS

Section 4, Concrete Works, of the General Specifications and as

further specified herein.

2. Formwork shall be marine plywood for all superstructure concrete

work. Treated commercial plywood may be used for internal vertical
and inclined web surface. Treatment of plywood shall be by way of 3
coats of polyurethane varnish or similar approved materials

3. The deck slab forms and all related formwork for concrete box girder
construction, including all supporting falsework, shall be designed
and constructed in order to facilitate removal of all formwork
materials from within the cells of the concrete box girders. The deck
forms shall be suspended from the girder stems which shall be
stripped of all forms prior to placing the deck forms. The deck slab
forms shall in no way interfere with the required concrete bond
between the deck slab and the girder stems.

Stay-in-place deck forms will be permitted for the deck slab of

concrete box girder construction, provided they are galvanized steel
or other non-combustible material acceptable to the Engineer which
will not deteriorate in any way. Further, such stay-in-place deck
forms shall not increase the volume of concrete, the depth of the
deck slab or reduce the dimension of concrete coverage over the
reinforcement steel.

The Contractor shall submit samples of the proposed form material

and all details and design for the use of stay-in-place deck forms.
The decision of the Engineer shall be final for acceptance or rejection
of stay-in-place forms.

A 3cm slip joint shall be placed transversely in the deck forming

between each diaphragm to eliminate resistance of the deck forms to
deck shortening during prestressing.

The Contractor shall submit shop drawings and design calculations

for the forms, and falsework to the Engineer for approval prior to
commencing work.

Prior to erecting falsework for the deck superstructure the Contractor

shall confirm by way of testing the bearing capacity and expected
amount of settlement of the supporting ground.

4. Falsework and forms shall be set to provide the structural camber

indicated in the Drawings for long-term deflection, falsework
settlement, and shall comply with the required lines and grades.

5. Where indicated on the Drawings, the Contractor shall include all

formwork required to produce the concrete surface ornamental
pattern on the vertical surface of the box section of the post-
tensioned concrete Works as indicated on the Drawings, as specified
herein and as approved by the Engineer. The marine plywood forms
supporting the bottom slab of the box girder shall be arranged in a
regular brick pattern as approved by the Engineer.

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 64 SECTION 4 CONCRETE WORKS

The Contractor shall include in his shop drawing submittal all details
and a full description of all formwork proposed by the Contractor to
produce the concrete surface ornamental pattern. All details and
proposed methods and formwork material shall be subject to
approval by the Engineer.

The construction of all formwork required to produce the concrete

surface ornamental pattern shall comply with the applicable
requirements of Section 4, Concrete Works, of these Standard
Specifications and as specified herein. All formwork shall produce a
smooth, even surface with clean, straight, true and unbroken lines at
the concrete surface ornamental pattern.

4/36.3.3 Placing Post-Tensioning Systems

1. Anchorage devices, ducts, tendons and other appurtenant post-

tensioning equipment and accessories shall be accurately positioned
in the forms and secured in place as indicated on the drawings and
approved shop drawings. Installation of the post-tensioning system
shall be coordinated with the placement of reinforcing steel and
embedded items as specified elsewhere in these Standard
Specifications. Care shall be exercised to keep ducts and tendons
free of form coating compounds and other substances which might
break or reduce the concrete bond.

2. Field measurements of vertical locations of centers of gravity of the

tendons shall not vary by more than 6 mm from the dimensions
indicated on the Drawings.

4/36.3.4 Concrete Box Girders - The sequence for placing concrete for the cast-
in-place, multi-cell, concrete box girders at bridges shall be as follows:

1. First, the bottom slab, the exterior and interior web portions and the
diaphragm portions shall be placed monolithically as indicated on the
Drawings and as specified herein;

2. Second, the roadway or top slab shall be placed.

Vertical construction joints in all portions of the multiple cell box girders
shall be minimized and, where proposed, shall preferably be placed 0.2 of
the span length on either side of supporting pier. Dependent upon the
volume of the concrete, additional vertical construction joints may be used
all subject to the approval of the Engineer.

A concrete pour sequence plan shall be prepared by the Contractor for

each superstructure and submitted to the Engineer for approval prior to
commencing any bridge superstructure work. The pour sequence plan
shall show the locations of all construction joints which shall be bonded
joints as specified herein. Concrete pours within each element shall be
alternated to eliminate shrinkage to the greatest extent possible.

The placing of concrete in each pour shall start at the low point and shall
proceed upgrade, unless otherwise permitted by the Engineer.

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 65 SECTION 4 CONCRETE WORKS

4/36.3.5 Mixing and Placing Concrete

1. Concrete work for box girder superstructure construction shall

comply with the applicable provisions of Section 4, Concrete Works,
of these General Specifications and the Particular Specifications,
herewith.

2. Prior to placing concrete, tendon profiles shall be rechecked to

ensure that proper location and concrete cover will be maintained.
Any ducts found to be damaged shall be repaired or replaced as
directed by the Engineer.

3. Prior to placing forms for box girder deck slabs, the Contractor shall
demonstrate, to the satisfaction of the Engineer, that either the
prestressing steel is free and unbonded in the duct or, in the event
prestressing steel has not yet been placed, that all ducts are
unobstructed.

4. The Contractor shall exercise care during concrete placement to

prevent concrete from entering anchorage hardware. Concrete shall
be placed in such a manner that tendon alignment and reinforcement
positions are maintained, and concrete shall be vibrated with
particular attention at tendon anchorage locations to ensure optimum
compaction and penetration at these points.

5. Curing of concrete shall be in accordance with Section 4, Concrete

Works, of these General Specifications.

6. The Contractor shall keep a record showing the date and time of
placement of cast-in-place, post-tensioned concrete in each portion
of the structure. This record shall be available for examination at all
times by the Engineer. Upon completion of construction of each
structure, two copies of such records shall be submitted to the
Engineer.

4/36.3.6 Stressing Operations

1. Post-tensioning of cast-in-place concrete shall be performed as soon

as the last placed concrete has attained a cube compressive
strength of 36 Newtons per square millimeter, or as specified on the
Drawings, or more based on the results of two cube tests.

2. The Contractor shall provide, at no additional cost to the Client, a

Team of one Engineer and two Technicians who are skilled in the
post-tensioning method to give such aid and instruction in the use of
the prestressing equipment and installation of the prestressing steel
as may be necessary to obtain the specified results.

3. Prestressing tendons in continuous span post-tensioned structures

shall be tensioned by jacking at each end of the tendon or at one end
of tendons as indicated on the Drawings. Prestressing tendons in
single span post-tensioned structures may be tensioned by jacking

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from one end only as directed by the Engineer.

4. All post-tensioning shall be by means of hydraulic jacks equipped

with accurate reading calibrated hydraulic pressure gauges to permit
the stress in the prestressing steel to be computed at any time. A
certified calibration curve shall be furnished with each jacking system
and independently calibrated master gauge shall be provided on site.
In the event inconsistencies occur between the measured elongation
and the jack gauge reading, the jack gauge shall immediately be
recalibrated. In the event still further discrepancies occur, the cause
shall be determined and reported to the Engineer. An agreement
within five percent shall be satisfactory.

5. The Drawings indicate jacking locations of the tendons. Proper

allowance shall be made for friction losses and one tendon from
each bridge or each of tendons with similar configuration shall be
checked for friction loss at the very start of the post-tensioning.

a) In case the friction losses in tests exceed the computed losses,

all wires shall be relieved and lubricated with water-soluble oil
and retensioned.

b) Each tendon shall be stressed until either the required

elongation or the maximum force is reached. Elongation is the
preferred method of stress determination wherever possible.
The tendons shall be tensioned by jacking to the total forces
indicated on the Drawings.

6. The post-tensioned prestressing steel shall be anchored at an “initial

stress” that will result in the ultimate retention of working forces or
stresses of not less than those indicated on the drawings, but in no
case shall the prestressing steel be tensioned above 80 percent of
the ultimate tensile strength of the wire or strands.

7. Prior to post-tensioning any member, the Contractor shall

demonstrate to the satisfaction of the Engineer that the prestressing
steel is free and unbonded in the duct.

8. The Contractor shall keep records of the elongation and tension

applied to each tendon, and this record shall be submitted to the
Engineer promptly upon the completion of stressing of each member.
At the time of stressing the first member, the stresses in the individual
tendons shall be checked to establish a procedure for ensuring uniform
results. At any later time, a recheck may be ordered by the Engineer if
it appears that the design stresses are not being obtained. The
Contractor shall have written permission from the Engineer before
capping any prestressing anchorage.

9. The effective prestress force “Pf” indicated on the Drawings represents

the force required after all losses of prestress have occurred. The
prestress losses due to creep and shrinkage of concrete, relaxation of
prestressing steel and elastic shortening are assumed to be 227N per
sq. mm, and friction is accounted for using wobble and curvature

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 67 SECTION 4 CONCRETE WORKS

coefficients of k = 0.0017 per meter and  = 0.20. Losses due to an

anchor set of 6 mm have been added in case a grip type anchorage is
used.

4/36.3.7 Grouting of Tendons

1. General - After the tensioning of all tendons has been completed

and the total retained stress is equal to or exceeds that indicated on
the Drawings, for each member, and the steel strands or wires have
been anchored, the annular space between the conduit and the
tendons shall be grouted.

2. Grouting - Tendons shall be grouted within 7 days after tensioning

but not before 8 to 12 hours after tensioning. The tendons shall be
protected against corrosion by a plug at each end to prevent the
passage of air, and such plugs shall be left in place until the tendon
is grouted.

3. Grout Mixture - The grouting mixer and pump shall be in top

mechanical condition and of such size and capacity to ensure
continuous grouting of the largest tendon until it is completed and
shall be capable of grouting to a pressure of at least
1.07N per sq. mm. The Contractor shall submit his mix design as per
the requirements of PS 4/16 and the recommendation of the
admixture manufacturer for the approval of the Engineer.

4. Equipment - The grouting equipment shall include a mixer capable

of continuous mechanical colloidal mixing which will produce a grout
free of lumps and undispersed cement. The equipment shall be able
to pump the mixed grout in a manner which will comply with all
provisions of these Standard Specifications. Accessory equipment
which will provide for accurate solid and liquid measures shall be
provided to batch all materials such as flow meter or similar approved
method.

The pump shall be a positive displacement type and be able to

produce an outlet pressure of at least 10.5kg per sq. cm. The pump
shall have seals adequate to prevent introduction of oil, air or other
foreign substance into the grout, and to prevent loss of grout or
water.

a) A pressure gauge having full scale reading of no greater than

2.15N per sq. mm shall be placed at some point in the grout
line between the pump outlet and the duct inlet.

b) The grouting equipment shall contain a screen having clear

openings of 3.2 mm maximum size to screen the grout prior to
its introduction into the grout pump. If a grout with a thixotropic
additive is used, a screen opening of 4.8 mm is satisfactory.
This screen shall be easily accessible for inspection and
cleaning.

c) The grouting equipment shall utilize gravity feed to the pump

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 68 SECTION 4 CONCRETE WORKS

inlet from a hopper attached to and directly over it. The hopper
shall be kept at least partially full of grout at all times during the
pumping operation to prevent air from being drawn into the
post-tensioning duct.

d) Under normal conditions, the grouting equipment shall be

capable of continuously grouting the largest tendon on the
project in no more than 20 minutes.

e) The Contractor shall furnish and maintain back-up equipment

and such additional equipment to ensure continuous,
uninterrupted grouting of all tendons. Such back-up equipment
shall be equal to the main grouting equipment and shall be
prepared and ready to operate at the start of any grouting
operations. The Contractor shall submit a description of all
grouting equipment including back-up equipment for approval
by the Engineer prior to commencing work specified in this
Section of these Particular Specifications.

5. Mixing of Grout - Water shall be added to the mixer first, followed by

Portland cement and admixture, unless otherwise required by the
admixture manufacturer.

a) Mixing shall be of such duration as to obtain a uniform

thoroughly blended grout, without excessive temperature
increase or loss of expansive properties of the admixture. The
grout shall be continuously agitated until it is pumped.

b) Water shall not be added to increase grout flowability which has

been decreased by delayed use of the grout.

c) Proportions of materials shall be based on tests made on the

grout before grouting is begun, or may be selected based on
prior documented experience with similar materials and
equipment and under comparable field conditions (weather,
temperature, and similar factors). The water content shall be
the minimum necessary for proper placement.

6. Grouting - Flushing of metal ducts shall be optional. Water used for

flushing ducts may contain slaked lime (calcium hydroxide) or quick-
lime (calcium oxide) in the amount of 12gm per liter.

7. Injection of Grout - All grout and high point vent openings shall be
open when grouting starts. Grout shall be allowed to flow from the
first vent after the inlet pipe until any residual flushing water or
entrapped air has been removed, at which time the vent shall be
capped or otherwise closed. Remaining vents shall be closed in
sequence in the same manner.

a) The pumping pressure at the tendon inlet shall not exceed 1.8N
per sq. mm.

b) If the actual grouting pressure exceeds the maximum

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 69 SECTION 4 CONCRETE WORKS

recommended pumping pressure, grout may be injected at any

vent which has been or is ready to be capped, as long as a
one-way flow of grout is maintained. If this procedure is used,
then the vent which is to be used for injection shall be fitted with
a positive shutoff.

c) When one-way flow of grout cannot be maintained as outlined

in the above paragraph, the grout shall be immediately flushed
out of the duct with water.

d) Grout temperature shall be pumped through the duct and

continuously wasted at the outlet pipe until no visible slugs of
water or air are ejected and the efflux time of the ejected grout
shall not be less than the injected grout. To ensure that the
tendon remains filled with grout, the outlet and/or inlet shall be
closed. Plugs, caps or valves thus required shall not be
removed or opened until the grout has set.

e) Grout temperature at duct inlet and outlet shall not be above

32°C during mixing or pumping. If necessary, the mixing water
shall be cooled. Grouting shall not proceed when shade
temperature exceeds 35Co.

f) Grouted tendons or girders shall not be disturbed for 48 hours

after grouting and grouting test results shall be satisfactory as
per manufacturer recommendations before any further step.

4/36.3.8 Protection of End Anchorages

1. As soon as possible after tensioning and grouting is completed,

clean exposed end anchorages, wires and other metal accessories
of rust, displaced mortar, grout and other such materials, then apply
to all such dry metal surfaces a heavy, unbroken coating of epoxy
bonding agent.

2. Install tight-fitting forms and hold in place securely against the

previously placed concrete.

3. After applying epoxy bonding agent, apply a patching mortar

prepared by mixing one part type V, Portland cement to three parts
of clean sand (ASTM C33: 2007) measured by volume, and sufficient
water to provide a stiff but workable consistency. Apply the patching
mortar, and manipulate, finish and cure as specified in Section 4,
Concrete Works. After mortar patches have cured, apply two heavy
brush coats of bituminous protective coating material, applied as
recommended by the manufacturer, including the recommended
thickness.

4/36.3.10 Access Doors

Access doors shall be installed in post-tensioned box girders as located

and as detailed on the Drawings.

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 70 SECTION 4 CONCRETE WORKS

All access doors shall be fabricated of steel shapes, plates and

accessories complying with Section 5/45 - Metal Works and Drawings. All
steel shall be galvanized. Access or cover shall be made of GRP to be
mounted to steel frame.

The furnishing and installing of access doors as indicated on the Drawings

and specified herein will not be measured or paid for separately but shall
be considered a subsidiary obligation to and included in the various
concrete Items of work included in the Bills of Quantities.

4/36.3.11 Vent Pipes

The Contractor shall include the unplasticized polyvinylchloride (PVC) vent

pipes in the cells of the concrete box girders as indicated on the Drawings.

The vent pipes shall be of the size as indicated on the approved shop
Drawings and shall be PVC extruded from one hundred percent virgin
materials. The pipe material shall be new and homogeneous throughout
and free from visible cracks, holes, foreign materials, blisters, wrinkles and
dents.

All vent pipes shall be anchored in an approved manner so as to prevent

displacement or movement during the placement of concrete. No
separate payment for vent pipes will be made by the Client.

4/36.3.12 Opening Bridges to Traffic

No equipment or vehicular traffic will be allowed on any bridge

superstructure until the post-tensioning and grouting operation is
completed, falsework has been removed, and all concrete has been cured
for the time required in these Particular Specifications, or as further
directed by the Engineer.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 70

 Section 5
Ancillary Works
 1 SECTION 5 ANCILLARY WORKS

TABLE OF CONTENTS

5/1 PAVING DESCRIPTION................................................................................................. 2

5/2 PAVING BLOCKS ........................................................................................................... 2
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS.................................................. 2
5/4 BLOCK LAYING REQUIREMENTS ............................................................................... 2
5/5 KERBS DESCRIPTION .................................................................................................. 3
5/6 MATERIALS AND MANUFACTURE OF KERBS .......................................................... 4
5/7 KERB LAYING ................................................................................................................ 4
5/8 PAVEMENT MARKING DESCRIPTION ........................................................................ 5
5/9 MATERIALS FOR PAVEMENT MARKINGS ................................................................. 6
5/10 APPLICATION OF THERMOPLASTIC .......................................................................... 7
5/11 PERFORMANCE REQUIREMENTS AND TESTING .................................................... 8
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS .................... 8
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..) ................................. 8
5/14 ROAD SIGNS, DESCRIPTION ...................................................................................... 9
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS ....................................................... 9
5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS ............................................ 9
5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR ................................................... 9
5/18 PAVEMENT REPAIRS ................................................................................................. 10
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS .......................................... 10
5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS.................... 12
5/21 METAL BEAM GUARD RAIL SAFETY FENCING ....................................................... 12
5/22 HEAVY DUTY CAT'S EYES (REFLECTIVE STUDS) ................................................. 13
5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS ................................................... 13
5/24 REFLECTIVE STUDS MINIMUM MECHANICAL ........................................................ 13
5/25 REFLECTIVITY............................................................................................................. 13
5/26 INSTALLATION OF REFLECTIVE STUDS ................................................................. 13
5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION........................................ 14
5/28 MATERIALS FOR STONE PITCHING ......................................................................... 14
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING ................................. 14
5/30 GABIONS ...................................................................................................................... 15
5/31 CHAIN LINK FENCING ................................................................................................ 16
5/32 STEEL AND METAL WORK ........................................................................................ 17
5/33 ALUMINIUM FOR PARAPETS..................................................................................... 17
5/34 FASTENINGS FOR ALUMINIUM PARAPETS ............................................................ 17
5/35 PAINT AND OTHER PROTECTIVE COATINGS ........................................................ 17
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES .......................................... 18
5/37 RUBBERISED BITUMEN EMULSION ......................................................................... 21
5/38 WATERSTOPS ............................................................................................................. 21
5/39 PREFORMED JOINT FILLERS.................................................................................... 21
5/40 COLD APPLIED JOINT SEALANT .............................................................................. 22
5/41 BRIDGE DECK EXPANSION JOINT ........................................................................... 22
5/42 LOCKABLE MEDIAN BOLLARD .................................................................................. 23
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED CONCRETE
SURFACES.............................................................................................................................. 23
5/44 BRIDGE BEARINGS .................................................................................................... 25

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 2 SECTION 5 ANCILLARY WORKS

5/1 PAVING DESCRIPTION

5/1.1 This work shall consist of covering certain areas (footpaths, parking areas, etc.)
with paving blocks in accordance with the Specifications, the Drawings and the
Engineer's instructions.

5/2 PAVING BLOCKS

5/2.1 Paving blocks shall be concrete blocks, colored where specified, laid on a sand
laying course. Their thickness shall be 6 cm on sidewalks and 8 cm on parking
areas unless otherwise shown on the Drawings or instructed by the Engineer.

5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS

5/3.1 The materials, dimensions and tolerances, test for compressive strength, test for
water absorption and certificate of compliance for paving blocks shall conform to
the BS EN 1338: 2003. Water absorption and abrasion resistance shall be carried
out in accordance with the requirements of the particular specification.

5/4 BLOCK LAYING REQUIREMENTS

LAYING COURSE

5/4.1 The laying course shall consist of sharp black sand containing not more than 3%
material finer than 75 micron by weight and not more than 10% retained on 4 mm
sieve. The sand shall be obtained from a single source, allowed to drain before
use and shall be covered with suitable sheeting to minimize moisture changes.
(Permissible sulphate (as SO3) and chloride (as CL) shall not exceed 0.3% and
0.5% respectively) (Expressed as a percentage by weight) when tested to BS EN
1744-1: 1998: and BS 812 Part 117: 1988 Appendix C respectively.

5/4.2 The profile of the laying course before compaction shall be similar to that of the
finished surface. During laying, the sand shall be uniform in moisture content and
shall be carefully, screened to form a smooth compacted surface to receive the
paving blocks. The maximum deviation from the design levels shall be +5 mm.

5/4.3 The edge restraints to the paved area shall be laid in advance of the laying
course and all permanent obstacles within the area, such as manhole covers,
shall be adjusted to the correct finished levels.

SURFACE COURSE

5/4.4 The paving blocks shall be laid on the sand laying course in such manner as not
to disturb the blocks already laid. Each block shall be placed firmly against its
neighbour so that they fit closely together. The joints between blocks shall not
exceed 3 mm. Laying of the paving blocks shall commence at right angles to the
main pavement axis starting at one end of the area. The paving blocks shall be
laid in a herringbone pattern unless otherwise shown on the drawings or
instructed by the Engineer at 45o to the main pavement axis.

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 3 SECTION 5 ANCILLARY WORKS

5/4.5 Where blocks do not fit the edge restraints or other obstructions such as
manholes the gaps shall be filled using cut blocks.

5/4.6 Blocks shall be cut using only a mechanical block splitter.

5/4.7 Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall
be checked after laying the first three rows of blocks and thereafter at regular
intervals. If joints begin to open the blocks shall be knocked together using a
hide mallet.

5/4.8 After each 20 sq.m. or such area that has been agreed with the Engineer, has
been laid the blocks shall be compacted to the required levels using a plate
vibrator.

5/4.9 The plate vibrator shall have a plate area of 0.20 to 0.35 sq.m. and have a
compaction force of 12-24 Kn and a frequency of approximately 75 to 100 Hz.

5/4.10 A minimum of two passes of the plate vibrator shall be made in each direction,
i.e. at 90 degrees to each other. Vibration shall continue until no further
compaction of the sand layer is apparent. The laying course shall have a
compacted thickness of 50 mm. Fine dry sand with a particle size of 0.3mm shall
then be brushed over the paving, and further passes of the plate vibrator made in
each direction, until the sand is no longer absorbed into the joints.

5/4.11 The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.

5/4.12 No paving shall be left uncompacted overnight except for the 1 m strip at the
temporarily unrestrained edge.

5/4.13 On completion, the finished surface level, shall be within 5 mm of the design level
and the maximum deviation within the compacted surface, measured by a 3 m
straight edge shall not exceed 3 mm. The level of any two adjacent blocks shall
not differ by more than 1 mm. Any areas of paving which do not comply with
these tolerances shall be removed, the sand laying course adjusted and the
paving blocks relaid to the correct levels.

5/5 KERBS DESCRIPTION

5/5.1 This work shall consist of the construction of kerbs in accordance with the
Specifications and in conformity with the lines, grades and typical sections shown
on the Drawings or established by the Engineer. These Specifications refer to the
following types of precast kerbs to be constructed: Non-Mountable Kerbs,
Dropped Kerb, Heel Kerb, Quadrants and Flush Kerb.

All Kerbs and edgings shall be hydraulically pressed and shall comply with the
requirements of BS 7263: 2001 Part 1. They shall be uniform in color, free from
cracks, flaws or other defects and they shall have well defined arises.

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 4 SECTION 5 ANCILLARY WORKS

5/6 MATERIALS AND MANUFACTURE OF KERBS

5/6.1 Materials shall conform to the requirements specified in Part 4 "Concrete" of the
Specifications and as specified herein.

5/6.2 Kerbs shall be prepared with a concrete mixture containing not less than 400
Kg/m3 of Sulphates Resisting Portland Cement. The aggregate shall meet the
requirements of the General Specifications for concrete work.

5/6.3 Sampling shall be done as per BS 7263: 2001: Part 1: latest edition.

5/6.4 Non-Mountable Kerb, Dropped Kerb, Flush Kerb and Heel Kerb elements shall
only be precast from concrete produced in a fully automatic batching plant.

5/6.5 The Consultant shall collect samples as per standard sampling method and
submit them for testing. All results shall pass before commencing this work.

5/6.6 Elements shall be manufactured to the dimensions shown on the Drawings.

5/6.7 Non-Mountable and Dropped Precast Kerbs shall be formed by elements 900 mm
long where required to be laid in straight lines but may be reduced to 250 mm
long or curved kerbs shall be used where required to be laid to curves depending
on the radii of the curves.

5/6.8 The finished product shall be of solid appearance with clean planar faces, be free
of segregation, honeycombing, pits, broken corners or other defects and there
shall be no evidence of external rendering.

5/6.9 Bull noses and curved faces shall be of constant radius with a smooth change
from radius to plain face.

5/6.10 Tolerances of manufacture shall be three (3) millimeters in any one dimension
and end faces shall be truly perpendicular to the base.

5/6.11 Transverse strength and water absorption requirements shall be in accordance

with BS 7263: 2001: Part 1 or BS EN 1339:2003, AMD 16467:2006.

5/7 KERB LAYING

5/7.1 Elements shall be set to the lines and grades shown on the Drawings. Under no
circumstances will it be permitted for levels to be set by direct measurement from
pavement layers.

5/7.2 Unless otherwise indicated, elements shall be laid either directly onto a wet
concrete base or on to a sand/cement (3:1) mortar bedding, two and half (2.5)
centimeters thick, on a previously laid concrete base on approved subgrade. The
dimensions of the base shall be as shown on the Drawings. The concrete base
shall be constructed of Concrete Class 25/20.

5/7.3 Unless otherwise indicated, after kerbs units have been laid a contiguous backing
of Concrete Class 25/20 shall be poured for the elements using steel forms.

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 5 SECTION 5 ANCILLARY WORKS

5/7.4 No pavement layers shall be laid against kerbing until such time as the backing is
complete, back filled and approved by the Engineer.

5/7.5 Joints between radius kerbs, shall have a clear width of four (4) millimeters and
be filled with a sand/cement (3:1) mortar with one fifth (1/5) part hydrated lime
and sufficient water to make the mixture plastic and easily smoothed. A grooving
tool shall be used to produce a smooth, circular section groove not more than
three (3) millimeters deep in all joints. Grouted joints shall be cured by an
approved method to the Engineer's satisfaction. Joints between straight kerbs
shall not be filled.

5/7.6 Immediately after any concrete is in place and for 7 days thereafter the kerbs,
base backing and mortared joints shall be fully cured and protected from drying
out and against the harmful effects of weather, including rain and rapid
temperature changes. The method of protection shall be subject to the Engineer's
approval. The use of colored curing membranes will not be permitted. Concrete
not properly cured and protected will be rejected and shall be removed from the
works.

5/7.7 At each 9 meters or as directed by the Engineer or shown on the Drawings, the
joint between kerbs shall be filled with an approved joint filler 10 mm thick to form
an expansion joint. The filler shall extend through the kerb, bed, backing and
channel, and shall be trimmed to the finished shape of the kerb and channel.

5/7.8 At access points the kerbs, including the bed backing, shall be dropped to show a
face of 75 mm or as otherwise shown on the Drawings.

5/7.9 At the end of any kerb run, the end kerb section shall be sloped down to ground
level, if applicable, and angled away from the road at 30 degrees.

5/7.10 All kerbs shall be thoroughly cleaned of all extraneous material prior to approval.

5/7.11 Kerbs shall be laid within a tolerance of plus or minus three (3) millimeters, at
each end of an element, to the lines and grades given on the Drawings.

5/7.12 All kerbs shall be painted unless otherwise directed by the Engineer. (Refer to
Sub-section 5/13 of paint).

5/7.13 Any excavated surface for the concrete bedding shall be watered and compacted
to a minimum of 95% maximum Dry Density (BS 1377 Part 9: 1990 Method 2.2,
AMD 17229: 2007).

5/8 PAVEMENT MARKING DESCRIPTION

5/8.1 This work shall consist of supplying thermoplastic road marking material for
marking of the pavement as outlined herein. It shall include the marking of the
centerline, the shoulder strip or edge, the barrier lines, the cross walks and any
other markings required on the pavement for the control and direction of the
traffic. Refer to the Roads and Transport Authority (RTA) “Dubai Traffic Control
Devices Manual”.

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 6 SECTION 5 ANCILLARY WORKS

5/8.2 The pavement markings shall be painted on the road to the dimensions and in
the location as shown on the Drawings or as directed by the Engineer.

5/8.3 The Contractor shall set out the markings and obtain the Engineer's approval
before commencing the work.

5/9 MATERIALS FOR PAVEMENT MARKINGS

5/9.1 The materials used shall conform to the B.S. (British Standard) specification for
Road Marking Materials (Superimposed type) BS EN 1824:1998, (part I) & where
modified in this Specification. Glass Beads shall be in accordance with BS EN
1423:1998.

5/9.2 The road marking material shall consist of light colored aggregate, pigment &
extender, bound together with hard wearing resins, plasticized with oil as
necessary.

5/9.3 The grading of various ingredients shall be such that the final product, when in a
molten state, can be sprayed on the surface in accordance with BS 3262 Part
3:1989.

5/9.4 The aggregate shall consist of light colored silica sand, calcite, calcined flint or
quartz, in accordance with paragraph 3 of BS 3262 (Part I).

5/9.5 Glass Beads incorporated in the mixture shall be minimum 70% of spherical &
free from flaws and not less than 80 percent shall be transparent glass. The
grading of the Glass Beads shall be as stated in BS 6088. (Class A).

5/9.6 The pigment material shall be titanium dioxide (in accordance with clause 4 of BS
3262 (Part I), and shall not be less than 10% by weight of the mix for white
pigment.

The lead chromate content of the road marking material shall not exceed 5% by
mass. A suitable yellow pigment should be substituted for all or part of the
titanium dioxide where yellow pigment material specified.

5/9.7 The extender shall be whiting powder added to assist the dispersion the pigment
and impart body to the mixture (in accordance with paragraph 2.3 of BS 3262
Part 1).

5/9.8 The binder shall not contain more than 5 percent of resin or other acidic material,
it shall consist mainly of hydrocarbon resins plasticized with mineral oil.

5/9.9 The viscosity of the melted binder at the spraying temperature must be such as to
produce a thermoplastic mix of the required spraying properties.

5/9.10 The composition and proportion of constituents of the laid material as found on
analysis shall comply with the requirements of Table 5-1 of BS 3262 (Part 1),
reproduced below:

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 7 SECTION 5 ANCILLARY WORKS

Table 5- 1: The composition and proportion of constituents of the pavement marking

material

Constituents Percent by Mass of Total Mixture

Minimum Maximum

Binder (resin & oil) 18 22

Aggregate, pigment, Extender & Glass 78 82
Beads
Solid Glass Beads 20 -

5/9.11 The grading of the combined aggregate, pigment, extender and where specified
Solid glass beads sampled in accordance with BS EN 1824:1998 shall be as
follows:

a. 100% by mass passes a 2.8mm BS 410 test sieve

b. 65% to 95% by mass passes a 0.600mm BS 410 test sieve.

5/9.12 Capacity of each container shall be not less than 20Kg or not more than 110Kg.

5/9.13 Each container shall be clearly marked with the manufacturer’s name, batch
number and date of manufacture. (Refer to BS EN 1824:1998).

5/9.14 Container shall be made of a material, which does not contaminate the contents
and will protect the contents from contamination.

5/10 APPLICATION OF THERMOPLASTIC

5/10.1 Application shall be by mobile sprayer, either hand propelled or self-propelled.

5/10.2 The road surface shall be dry, and free from loose, detritus, mud, or other
extraneous matter. Where old paint or thermoplastic materials are present, the
manufacturer shall be consulted as to whether or not the surface is suitable.

5/10.3 A tack coat should not be necessary when the thermoplastic is applied to
carriageways. Where it is considered necessary to use a tack coat, this shall be
rubberized type recommended by the manufacturer of the thermoplastic material.

5/10.4 In addition to the glass beads included in the mix, and additional quantity of glass
beads (Class B) shall be sprayed on the thermoplastic line at the time of
application. The rate of application shall be at the rate of about 0.5 Kg/m 2.

5/10.5 The thermoplastic material shall be applied in intermittent or continuous lines of

thickness 1.2 ± 0.3mm. For special lettering, arrows or symbols the material shall
be applied by hand methods. The finished lines shall be free from raggedness at
all edges and be true in place with the road surface. The upper surface shall be
level, uniform and free from streaks, blisters, lumps and other defects.

5/10.6 Application of thermoplastic material to new pavement construction should be

preceded by wire brushing to remove bitumen rich surface mortar. Sufficient
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 8 SECTION 5 ANCILLARY WORKS

compatible mineral oil plasticizer should be incorporated in the thermoplastic

material to reduce levels of early shrinkage in the material and subsequent
cracking of the asphaltic pavement structure.

5/11 PERFORMANCE REQUIREMENTS AND TESTING

5/11.1 The thermoplastic material shall meet the following performance requirements
(Table 5-2):

Table 5- 2: Thermoplastic material performance requirements

THERMOPLASTIC MATERIAL

Property Minimum Maximum

(Note1)
Relative Density BS 3262 : P3:1989, 1.85 -
o
tested at 250 C.
Softening Point BS EN1427:07,BS 2000:07, Part 58 95
Luminance BS EN (White as delivered) 70
1824:1998
(White as re-melted) 65
(Yellow as delivered) 50 -
(Yellow as re-melted) 45 -
Heat Stability (White) 65 -
(BS EN 1824:1998) (Yellow) 45 -
Flow Resistance after 48 hours - 25
BS EN 1824:1998
Skid Resistance BS EN 1824:1998 45 -
Note 1: the value assigned for the relative density of the thermoplastic material outlined in clause 5.3.2.3 of the
Dubai Traffic Control Devices Manual shall be replaced by the value listed in the above table.

5/11.2 The above tests shall be carried out at Dubai Municipality Central Laboratory
(DCL).

5/11.3 Road marking works must be executed by an approved and qualified contractor.

5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS

5/12.1 The Contractor shall control the traffic in such a manner as to protect the freshly
marked surface from damage. The traffic control shall be so arranged as to give
minimum interference to the travelling public, Signs, barricades, flagmen and
control devices shall be supplied by the Contractor and a system of spaced
warning flags or blocks shall be used to protect the fresh marking until it has dried
as required. Any lines, strips or marking, which become blurred or smeared by
the traffic, shall be corrected by the Contractor at his own expense. Time required
to ensure appropriate drying of the fresh mark shall be referred to the
manufacturer’s instructions, standards and shall be approved by the Engineer
according to weather conditions or other parameters.

5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..)

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 9 SECTION 5 ANCILLARY WORKS

5/13.1 Road marking paint shall be by an approved manufacturer. It shall be suitable for
applying by brush or mechanical means to cement concrete or bituminous
pavement to give a chemically stable film of uniform thickness and shall be either
chlorinated rubber, epoxy or alkyd based.

5/13.2 White paint shall contain not less than 6% by mass of titanium dioxide as a
pigment, conforming to type A (anatase) or type R (rutile) specified in BS 1851.

5/13.3 Yellow paint shall be standard color BS 381C No.355, except where an
alternative shade has been specified in the Contract, and contain not less than
6% by mass of a suitable yellow pigment.

5/13.4 The paint shall be supplied fresh and ready for use in sealed containers and
stored in accordance with the manufacturer's instructions. The paint shall be
applied without the use of thinners or other additives.

5/13.5 Paint shall be applied at a covering rate recommended by the manufacturer and
approved by the Engineer.

5/13.6 Where markings are to be reflectorised with ballotini, it shall be sprayed uniformly
on to the wet paint film at the rate of 400 - 500 g/m2. Ballotini shall comply with
the requirements of BS 3262: 1989 Clause 15.

5/13.7 Road marking materials shall only be applied to surfaces which are clean and
dry. Markings shall be free from raggedness at their edges and shall be uniform
and free from streaks. Carriageway lane and edge lines shall be laid by approved
mechanical means to a regular alignment.

5/14 ROAD SIGNS, DESCRIPTION

(Refer to Roads and Transport Authority “Dubai Traffic Control Devices
Manual" Chapter 5, All Clauses)

5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS

(Refer to Roads and Transport Authority “Dubai Traffic Control Devices
Manual" Chapter 5, All Clauses)

5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS

(Refer to Roads and Transport Authority “Dubai Traffic Control Devices
Manual" Chapter 5, All Clauses)

5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR

(Refer to Roads and Transport Authority "Dubai Traffic Control Devices
Manual" Chapter 5, All Clauses)

Shop drawings that include all the details of the road sign design, material,
installation procedures and road signs construction works outlined in clauses
5/14, 5/15, 5/16 and 5/17 shall be submitted to Traffic Department for a prior
approval.

Traffic information signs works must be executed by an approved and qualified

contractor.

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 10 SECTION 5 ANCILLARY WORKS

5/18 PAVEMENT REPAIRS

5/18.1 This work shall consist of the various types of repairs to existing pavement
described herein, necessary to correct structural failures, grade elevations, and
deterioration and/or to prepare the existing pavement surface prior to placing
bituminous pavement overlays. The Engineer on site shall investigate and find
out causes of failure and he shall instruct the Contractor on the type of repair.
The Contractor shall provide assistance in such investigation as instructed by the
Engineer.

5/18.2 The materials required for the various pavement repair items shall be as specified
and shall be in accordance with the requirements of Section 3 of these
Specifications.

5/18.3 The Contractor shall be responsible for the supply of all the equipment and labour
necessary to perform the work described for the various types of pavement repair
items in accordance with these Specifications and as directed by the Engineer.

5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS

REPAIR OF POTHOLES (ISOLATED HOLES IN THE PAVEMENT OF LESS

THAN ONE SQUARE METRE)

5/19.1 The Contractor shall cut the failed pavement back to solid material with
pneumatic asphalt cutting tools. Make the cut square or rectangular with faces
straight and vertical. One pair of faces shall be at right angles to the direction of
traffic.

5.19.2 Remove the cut pavement and loose unsuitable material from the hole and cart
away and dispose at a location designated by the Engineer.

5/19.3 If soil is removed, fill the excavation with granular road-base material which has
been premixed to optimum moisture content. Place the material in 150 mm layers
and compact each layer to not less than 98% of the maximum dry density as
determined according to BS 1377 Part 9: 1990: AMD 17229: 2007, Method
2.1/2.2 with mechanical compactors. The same treatment is to be applied on
subsoil before filling the excavation with granular roadbase material.

5/19.4 Wire broom clean the cut edges of the pavement and paint with tack coat.

5.19.5 Prime the compacted soil or the upper surface of the roadbase layer with a light
coating of prime coat as directed by the Engineer.

5/19.6 Fill the hole with Bituminous Base Course and/or Wearing Course as appropriate
and compact in lifts not exceeding 5 cm to the same level as the adjacent
surface. Vibratory compactors shall be used to compact the hot-mix bituminous
layer.

5/19.7 Check levels of the patch with a straight edge and make corrections as directed
by the Engineer.

REPAIR TO FAILED PAVEMENT

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 11 SECTION 5 ANCILLARY WORKS

5/19.8 The Contractor shall cut the failed pavement to solid material with pneumatic
asphalt cutting tools. Make the cut square or rectangular with faces straight and
vertical. One pair of faces shall be at right angles to the direction of traffic.
Vertical faces may be stepped where instructed by the Engineer.

5/19.9 Remove the cut pavement and excavate the underlying soil to a depth of not less
than 300 mm. The Engineer may, when deemed necessary order substantially
greater depths of excavation payable as common excavation. Cart away and
dispose all cut pavement and excavated soil at a location designated by the
Engineer.

5/19.10 Thoroughly compact the subsoil with mechanical compactors to not less than
98% of Modified Proctor Density in accordance with the standard test methods
given in Section 2 of the Specification.

5/19.11 Fill the excavation to the bottom of the pavement with granular roadbase material
which has been premixed to the optimum moisture content. Place the materials in
150 mm layers and compact each layer to not less than 98% Modified Proctor
Density with mechanical compactors in accordance with the standard test
methods given in Section 2 of the Specification.

5/19.12 Wire broom clean the edges of the pavement and paint with tack coat.

5/19.13 Lightly prime the compacted road base layer with prime coat as directed by the
Engineer.

5/19.14 Place and compact wearing course or base course as applicable in the
excavation in 50 mm layers to the same level as the adjacent surface. The lower
layer shall be compacted with a vibratory compactor and the top layer shall be
compacted with a steel wheel roller by first compacting the hot-mix bituminous
layer 150 mm from the two traffic edges and then by rolling in the direction of
traffic. The drive wheel of the roller shall be in a forward position. Use of asphalt
pavement finisher will depend on the size of the area being patched.

5/19.15 Check levels of the repair with a straight edge and make corrections as required.

REPAIR OF DEPRESSED PAVEMENT

In case where the pavement has depressed but the asphalt has not fractured and
the pavement appears stable, the Contractor shall:

5/19.16 Cold plane and remove the upper 5 cm of the pavement starting just back from
the depression. Cart away and dispose of the removed pavement at a location
designated by the Engineer.

5/19.17 Wire broom clean the surface and lightly tack the surface and the edges with tack
coat (do not exceed 0.23 liters per square meter of tack coat).

5/19.18 Fill the cut with bituminous base course or wearing course as applicable and
compact with a steel wheeled roller by first compacting the hot asphaltic concrete
150 mm from the two traffic edges and then by rolling in the direction of traffic.
The drive wheel of the roller shall be in the forward position.
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 12 SECTION 5 ANCILLARY WORKS

5/19.19 Check the level of the repair with a straight edge and make corrections as
required.

5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS

5/20.1 The Contractor shall barricade the immediate work site to protect workmen and
motorists without closing the entire carriageway width to traffic. A single lane
should be closed for such operations.

5/20.2 Cut and remove sufficient asphalt pavement, if any, and concrete from the
manhole to permit removal of the cover and frame without damaging the
reinforcing steel, cart away and dispose of the rubble at a site designated by the
Engineer. Raising or lowering of manhole cover will be executed as per details
shown on the drawings or as otherwise specified.

5/20.3 Before starting any adjustment activity the Contractor shall obtain approval from
the concerned Authority to which the manhole belongs.

5/20.4 The Contractor shall submit to the Engineer for approval shop drawings for each
manhole affected by the work showing existing and new levels and a statement
of the methodology that will be followed.

5/20.5 Payment will be made upon receipt by the Engineer of a certificate issued by the
concerned Authority stating their approval of the works.

5/21 METAL BEAM GUARD RAIL SAFETY FENCING

5/21.1 Safety fencing shall comprise untensioned corrugated rails, channel-section,

posts, blocking-out pieces, nuts, bolts and washers for fixings, and end
anchorages.

5/21.2 Steelwork shall be mild steel Grade 43A to BS 4360, and shall be hot-dip
galvanized after fabricating in accordance with BS 729 to the thickness shown on
the Drawings. Thickness of coating (galvanization) shall be tested as per BS EN
ISO 1461: 1999 at Dubai Central Laboratory.

5/21.3 Fencing shall be erected to the dimensions and tolerances shown on the
drawings to produce a flowing alignment. The Contractor shall adjust the
elevation of any rail as required.

5/21.4 The rail section shall be such that when freely supported over a 3 m clear span,
with the road face uppermost, and centrally loaded with a point load of 1000 Kg,
the deflection measured at the centre of the span shall not exceed 40 mm.

5/21.5 Adjacent rails shall be connected by bolted lap of joints made in the relevant
direction to prevent vehicles striking rail ends.

5/21.6 Guardrail posts may be driven into the ground as detailed on the drawings
provided that:-

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 13 SECTION 5 ANCILLARY WORKS

i. The accuracy of placing will permit the rail mounting to be erected to

present a flowing alignment.

ii. A representative sampling of driven posts selected by the Engineer shall

satisfactorily withstand a test load of 10 KN applied horizontally at the level
of the centre of the rail with a deflection at that level not exceeding 200 mm.
Where the previous cannot be met all posts shall be set into Class 25/20
concrete or as detailed on the drawings.

iii. Driven posts shall have a protective coating of bituminous paint over the
length which is to penetrate the ground and extend 75mm above the
finished ground level. The bituminous paint shall be of high quality with
excellent adhesion properties. A sample of the paint together with the
manufacturers specifications shall be submitted to the Engineer for approval
prior to use.

5/21.7 The ends of safety fences shall terminate with a mitred end rail and anchorage
flared away from the line of fence.

5/21.8 Site drilling or cutting of beams and posts shall not be permitted without approval.
Flame cutting shall not be permitted.

5/21.9 Minor surface damage to steel components shall be repaired by cleaning with a
wire brush to remove all corrosion products, the application of two coats of rust
inhibiting paint, and two coats of approved cold galvanising paint or similar over
the damaged area.

5/21.10 The horizontal alignment of fences shall not depart from the road alignment by
more than 30 mm overall, and the relative deviation shall not be more than 10mm
in any two successive rail lengths.

5/21.11 The height of the uppermost edge of the rail shall not depart from the dimensions
shown on the drawing by more than 30 mm, nor shall the relative deviation from
this line be more than 5 mm in any two successive rail lengths.

5/22 HEAVY DUTY CAT'S EYES (REFLECTIVE STUDS)

(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"
Chapter 5, All Clauses)

5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS

(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"
Chapter 5, All Clauses).

5/24 REFLECTIVE STUDS MINIMUM MECHANICAL

AND PHYSICAL PROPERTIES
(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"
Chapter 5, All Clauses).

5/25 REFLECTIVITY
(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"
Chapter 5, All Clauses)

5/26 INSTALLATION OF REFLECTIVE STUDS

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 14 SECTION 5 ANCILLARY WORKS

(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"

Chapter 5, All Clauses)

5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION

5/27.1 This work shall consist of the placement of stone pitching on mortar bedding on
slopes at the locations shown on the plans, or as ordered by the Engineer, in
accordance with these Specifications and in conformity with the lines, grades,
thickness and typical cross-section shown on the plans or established by the
Engineer.

5/28 MATERIALS FOR STONE PITCHING

5/28.1 Stone for pitching shall be hard, sound, durable, stones as approved by the
Engineer. Samples of the stone to be used shall be submitted to and approved
by the Engineer before any stone is placed.

5/28.2 Tests for specific gravity and absorption shall be determined in accordance with
ASTM C-127:2007. The minimum apparent specific gravity shall be two and sixty
five hundredths (2.65) and the maximum absorption shall be two (2) percent. The
stone shall not have an abrasion loss greater than thirty (30) percent when tested
in a Los Angeles Abrasion Machine in accordance with ASTM C-535:2009.

5/28.3 The size and shape of the stones shall be such to allow for proper placement.
The widths of the stone shall not be less than one and one-half (1-1/2) times their
respective thickness and lengths of not less than two (2) times their respective
widths. The minimum width shall be 100 mm.

5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING

5/29.1 The bed upon which the stones are to be placed shall be excavated to the
required grades and lines as shown on the plans or as directed and approved by
the Engineer. A footing trench shall be excavated along the toe of the slope as
shown on the plans or as directed by the Engineer. All footings trenches and
excavations shall be approved by the Engineer prior to placement of stones or
concrete. Subgrade or base should be firm and well compacted as approved by
the Engineer. Stones shall be placed on a mortar bed as detailed on the
Drawings.

5/29.2 Stones shall be arranged in such a way that the largest stones are at the bottom
of the slope. The surfaces of the stone shall be cleaned of adhering dirt and clay
and shall be moistened immediately prior to grouting.

5/29.3 The space between stones of stone pitching shall be filled with grout consisting of
one (1) part Portland cement and three (3) parts of fine aggregate, and one-fifth
(1/5) part of hydrated lime with sufficient water to produce a plastic mix as
approved by the Engineer. Immediately after pouring, the grout shall be spaded
and rodded into place with suitable spades, trowels or other approved method,
and broomed into the spaces until the voids are completely filled. The exposed
surface of the rocks shall project not less than 40mm and not more than 80 mm
above the grout surface. The grouted stone pitching shall be cured by an
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approved method for a minimum period of four (4) days. Immediately after the
expiration of the curing period, the exposed surfaces shall be cleared of all curing
mediums.

5/29.4 Joints as detailed on the drawings will be provided at a maximum interval of 12

meters.

5/30 GABIONS

DESCRIPTION

5/30.1 Gabions shall consist of furnishing and placing wire mesh boxes rectangular in
shape filled with clean and uniform rocks larger than the mesh openings in
accordance with the drawings, and these Specifications.

Gabions shall be of approved quality.

MATERIALS

5/30.2 Wire mesh shall consist of galvanised steel fabricated in double twist woven
hexagonal shape with the following requirements:-

WIRE DIAMETER MESH SIZE

Boxes 2.7 mm 8 cm x 10 cm

Mattresses 2.2 mm 6 cm x 8 cm

5/30.3 The rocks shall consist of clean solid rock non-friable and resistant to weathering
and frost action meeting the following requirements:-

Absorption (ASTM C128 : 2007a/C127: 2007) Max. 2.0%

Soundness by Magnesium Sulphate Max. 12%
(ASTM C88: 2005) 5 cycles

5/30.4 The rock shall be greater than 150 mm in size.

5/30.5 Excavation required for the placement of gabions shall be made in accordance
with the dimensions as shown on drawings or as directed. Gabions shall be
constructed in units to the dimensions indicated on the drawings.

5/30.6 The sides, ends, and diaphragms of the gabions shall be lifted into a vertical
position, and located together with binding wire to form the base.

5/30.7 The binding shall be carried out in a continuous lacing operation, the wire being
passed through each mesh and around both selvedges which must be tied
together with two round of turns after every second mesh.

5/30.8 Assembled gabions may be placed in position for filling singly, or wired together
in groups suitable for man-handling. The baskets shall be securely wired together
at all corners and edges in the same manner as described above.
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Where there are more than one course of gabions, the one in the upper course
must be laced to those below. Gabions shall be slightly over-filled to allow for
subsequent settlement.

5/31 CHAIN LINK FENCING

5/31.1 The chain link fencing shall be PVC coated and erected according to the lines
shown on the drawings or as otherwise directed by the Engineer. The fencing
components shall have a five year corrosion warranty from the manufacturer.

5/31.2 The Contractor shall supply shop drawings showing all fixing and erection details,
for approval prior to erection.

5/31.3 Steel posts, mesh, braces and struts shall conform to the requirements of BS
1722-1:2006 and they shall be hot-dipped galvanised in accordance with BS EN
ISO 1461:99 and then polyester coated to a minimum thickness of 60 microns.

5/31.4 Polyester coating shall conform to the requirements of BS 6496: 1984 and BS
EN 13438: 2005

Table 5- 3: Polyester coating requirements

MECHANICAL TESTS Limit
Flexibility (Conical Mandrel), BS EN Pass 3 mm
ISO 1519:2002 or ASTM D522:1993
Adhesion (2 mm Crosshatch) BS Pass GTO
3900-E6:1992
Erichsen Cupping, BS EN Pass > 7 mm
1520:1995
Hardness (400 gms) BS EN ISO Pass – No Penetration to substrate
1518:2001
Impact Resistance BS 6496 Clause Pass 2.3J direct (front) and reverse
16:1984

Table 5- 4: Chemical and durability tests for the Polyester coating

Chemical and durability Test Limit
Salt spray ASTM B117 @ 35 deg.C, Pass at 1000 hrs, no corrosion area
Acetic Acid/Salt spray BS6496, more than 2 mm from scribe
Clause 15:1984
Cyclic Humidity BS 3900-F2:1973 Pass at 1000 hrs, no blistering or loss
of gloss
Distilled Water Immersion- BS EN Pass - no blistering or loss of gloss
ISO 281251:1995 after 24 hours.
Sulphur Dioxide BS EN ISO Pass - no blistering, loss of gloss, or
3231:1999 discoloration after 240 hours.
Exterior Durability BS 6496, Clause Excellent performance, Slight even
4.10, 12 months Florida 40 deg. loss of gloss, no checking, Cracking
South or flaking.

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 17 SECTION 5 ANCILLARY WORKS

Chalking None in excess of minimum in ASTM

D 4214:07

5/32 STEEL AND METAL WORK

5/32.1 Steel for the fabrication of bridge parapets and sign gantries shall comply with the
requirements of BS 4, Part 1, BS 5400, BS 4360 and BS 4848 as appropriate.

5/32.2 Fixing bolts and accessories complying with BS 5400, BS 4190 and BS 4320 as
appropriate.

5/33 ALUMINIUM FOR PARAPETS

5/33.1 Extruded sections shall conform to the following requirements:-

Posts Alloy 6082 TE to BS 1474

Other Locations Alloy 6082 TF to BS 1474

5/33.2 Casting shall be in alloy LM6M to BS 1490.

5/34 FASTENINGS FOR ALUMINIUM PARAPETS

5/34.1 Holding down bolts shall be of stainless steel A4-80 to BS 6105.

5/34.2 Aluminium parapets in contact with concrete shall have bearing pads of
rubber/fabric, new and unvulcanised.

5/34.3 All other fastening shall be of stainless steel 315S16 quality to BS 970 Part 4.

5/35 PAINT AND OTHER PROTECTIVE COATINGS

5/35.1 All paints forming any one painting system shall be obtained from one
manufacturer and, unless otherwise agreed by the Engineer, the source of supply
shall not be changed after the Engineer's approval has been given. Paint shall be
supplied in sealed containers of not more than 5 litres capacity and these shall be
used in strict order of delivery.

5/35.2 The Contractor shall obtain from the paint manufacturer paint ready for the use
specified under the contract. The paints shall be adequate in all respects for the
purpose intended.

5/35.3 The system of protection for all non-galvanised steel work shall be as follows:-

- Prime Coat: Inter zinc QHA 027/028 (or equivalent) minimum dry film
thickness 65 microns.

- Second Coat: Intergard EBA 070/EBA 100 JB (or equivalent) natural M.I.O.
minimum dry filter thickness 100 microns.

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 18 SECTION 5 ANCILLARY WORKS

- Third Coat: Intergard EBA 070/EBA 100 JB (or equivalent) silver grey
M.I.O. minimum dry film thickness 100 microns.

- Fourth Coat: Intergard EFK 724 (or equivalent) epoxy finish grey minimum
dry film thickness 50 microns.

Total dry film thickness - 315 microns (minimum).

The coating shall have a minimum adherence to the steel work of 2.5 MPa
when tested with an adhesive tester.

- All coating thickness shall be verified at DCL

5/35.4 Prior to painting the steel work shall be grit blasted to SA 2-1/2 Swedish Standard
055900 or by other approved method to equivalent standard. Before the steel
surface shows signs of flash rusting the first coat of zinc primer shall be applied. If
the steel does flash rust then the cleaning process is to be repeated.

5/35.5 Steel work specified as galvanised shall be hot-dipped galvanised to the standard
required by BS EN ISO 1461:1999.

5/36 WATERPROOFING MEMBRANES FOR STRUCTURES

WATERPROOFING BRIDGE DECK SLAB - TYPE 1

GENERAL
TYPE 1

5/36.1 Deck waterproofing shall be composed of a proprietary membrane of a polyester

reinforced, SBS (Styrene-Butadiene Styrene) polymer modified bitumen sheet
sprayed or torched applied to primed concrete deck as detailed on the drawings.

MATERIALS

5/36.2 Membranes shall comply with the requirements of Technical Memorandum BE 27

(Bridges) Waterproofing and Surfacing of Bridge Decks and the system shall be
certified by the British Board of Agreement. Tensile properties of bitumen sheet
for waterproofing shall be tested in accordance with BS EN 12311: P1 2000 at
Dubai Central Laboratory. Materials shall have the following physical properties.

- Minimum thickness 1.5 mm

- Flexibility Over 20 mm dia Mandrel - 20 deg.C

- Longitudinal Elongation at Constant

temperature (20 deg.C, 100 mm/min) 54%

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 19 SECTION 5 ANCILLARY WORKS

- Longitudinal Elongation with Thermal

shock (20 deg. C., 100mm/min) 57%
(-10 deg.C., 10 mm/min) 42%
- Longitudinal Tear Resistance at
Constant Temperature (20 deg.C.,
100 mm/min) 180 N/mm

- Adhesion to Concrete at 20 deg.C > .40 MPa

- Puncture Resistance at 20 deg.C.,

500 mm/min. > 800 N

The following additional tests shall be checked at Dubai Central Laboratory:

1. Low temperature flexibility of modified bituminous sheet material (ASTM

D5417 C-11:2002)
2. Compound stability of modified bituminous sheet material (ASTM D5417 C-
15:2002)
3. Tensile tear strength of bituminous water proofing material (ASTM
D4073:2006).

PREPARATION OF SURFACE

5/36.3 All concrete surfaces to be waterproofed shall be smooth and free from
projections or holes which might cause puncture of the membrane. The surface
shall be dry and immediately before the application of primer or membrane, the
surface shall be thoroughly cleaned of dust and loose materials.

5/36.4 Immediately after cleaning and drying of surface, priming should be applied in
strict compliance with manufacturer's instructions. Primer coat shall be allowed to
cure completely before membrane application. Membrane shall be laid parallel to
traffic direction and tangent to the bridge curve in such a manner that overlaps
are never less than the specified width. In all cases, waterproofing shall begin at
the low point of the surface to be waterproofed.

End laps should be staggered one metre so that at no point are there more than
three thicknesses of membrane. It shall be installed with 100 mm side laps and
150 mm staggered endlaps.

APPLICATION DETAILS

5/36.5 At the edges of the membrane and at any point where it is punctured by
appurtenances such as drains or pipes, suitable provision shall be made to
prevent water from getting between the waterproofing and the waterproofed
surface, as recommended by the manufacturer.

5/36.6 Precautions must be taken to prevent injury to the finished membrane by any
cause.

5/36.7 The bituminous wearing course should be laid as soon as possible after a
minimum period of four hours has elapsed from completion of the membrane.

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 20 SECTION 5 ANCILLARY WORKS

WATERPROOFING BRIDGE DECK SLAB - TYPE 2

GENERAL

5/36.8 Type 2 deck waterproofing membrane shall consist of a two part rapid curing
liquid applied system based on methacrylate resins. The complete system shall
comprise of a primer to ensure good adhesion to the substrate; the membrane
and a tack coat to ensure good adhesion to the bituminous road surfacing. The
system must be suitable for use in Dubai. The temperature of the bituminous
surfacing at the time of laying onto the waterproofing membrane must be
according to Clause 3/33.

CERTIFICATION

5/36.9 The Type 2 waterproofing membrane system must hold a British Board of
Agreement Certificate.

APPLICATION

5/36.10 Application shall be strictly in accordance with the manufacturer's instructions.

WATERPROOFING OTHER SURFACES

5/36.11 Waterproofing membranes for structures other than top of bridge deck slab, shall
consist of an impervious laminate comprising a 0.3 mm PVC sheet and 1.5 mm of
flexible self adhesive rubber/bitumen compound. The laminate shall withstand
cracking of the substrate up to a crack width of 0.6 mm and shall have a tear
resistance (ASTM D1004: 2009) of 340 N/mm longitudinally and 310 N/mm
transversely, an elongation film (ASTM D638: 2008) of 210% longitudinally and
160% transversely and a backing sheet tensile strength (ASTM D638: 2008) of
4.2 N/mm2 longitudinally and 4.8 N/mm2 transversely. Rubberised mastic and
primer for use with waterproofing membranes shall be special compounds
provided by the manufacturer of the membrane and formulated for its intended
use. Refer to the Waterproofing membrane requirements given in Clause 9.2.2.1-
a in Volume 2. Part 2, Section 9 for more details.

5/36.12 Vertical and horizontal faces shall be made smooth, dry and free from nails or
concrete projections. It shall immediately be primed and allowed to completely
dry before installation of membrane. Installation procedures shall be strictly in
accordance with manufacturer's instructions.

5/36.13 Joints between sheets shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. If the work must be left partially complete temporarily,
the exposed edges of outside strips of the membrane shall be finished with a
trowelled bead of mastic.

5/36.14 Waterproofed surfaces to be backfilled or otherwise exposed to possible damage

by plant or other construction operations shall be protected by proprietary
protection boards specifically designed for this purpose and installed strictly in
accordance with the manufacturer recommendations. As an alternative to the
waterproof membrane plus protection boards a composite membrane consisting
of a rubberised bitumen compound and integral geotextile layer (min. 400g/sq.m)
shall be permitted. The protection boards shall be a minimum of 6 mm thick.

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 21 SECTION 5 ANCILLARY WORKS

5/37 RUBBERISED BITUMEN EMULSION

5/37.1 Rubberised bitumen for application to buried concrete surface as detailed on the
drawings shall comply with D.M. 500 and consist of a water bound emulsion
containing not less than 65% of bitumen with fine particles of rubber dispensed in
the bitumen, the consistency being such that it can be applied to the surface by
brush at normal air temperature. The rubber content of the dried film shall not be
less than 10%.

5/37.2 The Contractor shall submit to the Engineer for approval three samples in one
litre containers of the rubber bitumen emulsion. The Contractor shall also submit
to the Engineer certificates that the material complies with the requirements of the
Specification, and is suitable for the intended purpose.

5/38 WATERSTOPS

5/38.1 Alternatives from those indicated on the drawings will be accepted only if the
Engineer is satisfied that their material and their performance are not inferior. The
waterstop, used must be installed strictly in accordance with the manufacturer
instructions.
5/38.2 Waterstops shall be manufactured either from rubber or from polyvinyl-chloride
(PVC), at the discretion of the Contractor subject to the approval of the Engineer.
PVC waterstops when tested in accordance with BS 2571:1990, the PVC
compound shall exhibit the following properties:-

- Tensile Strength 13.78 N/sq.mm

- Elongation at Break 300%

- BS Softness 45

- Specific Gravity 1.3

For rubber waterstops the rubber compound shall comply with specifications and
standards (latest edition).

5/38.3 No splices will be permitted in straight strips. Strips and special connection pieces
shall be well cured in a manner such that cross section shall be dense,
homogeneous and free from all porosity. All junctions in the special connection
pieces shall be full moulded. During welding or vulcanising periods the joints shall
be securely held by suitable clamps. The materials at the splices shall be dense
and homogeneous throughout the cross section.

5/38.4 If, after placing concrete, waterstops are materially out of position or shape or if
voids are found, the surrounding concrete shall be removed, the waterstop reset,
and the concrete replaced, all at the Contractor's expense.

5/39 PREFORMED JOINT FILLERS

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 22 SECTION 5 ANCILLARY WORKS

5/39.1 Joint fillers in expansion joints for structures shall consist of a compressive
non-extruding board manufactured from bitumen impregnated fibres.

5/39.2 The physical properties of the materials shall conform to the requirement of
ASTM D-1751: 2008, except asphalt content shall not be less than 10% of the
weight of the finished product in order to get a material that is characterized by
the Low moisture absorption due to bitumen impregnation.

5/40 COLD APPLIED JOINT SEALANT

5/40.1 Cold applied joint sealant shall be a multi-component, gun applied material of a
grade suitable for the hot climate with a service temperature of up to 70 degrees
centigrade and high resistance to ultra-violet exposure.

5/40.2 The compound shall comply with BS EN ISO 11600:03.

5/40.3 The sealant must be suitable for the particular application whether the joint to be
sealed is horizontal or vertical and with the ability to accommodate any
movement at the joint without rupturing or losing adhesion.

5/40.4 The hardness of the joint sealant shall be no less than 20 on the "Shore A" scale.

5/40.5 The Contractor shall supply samples together with the manufacturers literature
relevant to any sealant for any application for the Engineer's approval prior to
use. Only high quality products with demonstrable resilience to the local climate
conditions shall be approved. If a polysulphide based sealant is proposed for
locations exposed to biological attack or wet conditions then it should have a
minimum 40% polymer content. All polysulphide based sealant must utilise a
manganese dioxide curing system.

5/40.6 The mixing, application and curing of the approved sealant shall be strictly in
accordance with the manufacturers recommendations.

5/40.7 The approved sealants shall be delivered to site in sealed containers showing
date of manufacture, batch number and shelf life.

5/41 BRIDGE DECK EXPANSION JOINT

5/41.1 GENERAL

Expansion joint assembly shall be as shown on the drawing.

Full details of the proposed suppliers with their technical specifications,

maintenance manual, design calculations, covering materials, dimensions and
sizes shall be submitted to the Engineer for approval before the Contractor places
an order.

All expansion joints shall be guaranteed by the manufacturer against any defect
in material and workmanship for a period of ten years.

The Contractor shall submit the detailed shop drawings and obtain the Engineer's
approval before manufacture is commenced.
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 23 SECTION 5 ANCILLARY WORKS

During placing and hardening of concrete or mortar under the expansion joint
components, relative movement between them and the supports to which they
are fixed shall be prevented.

Thorma-Joints shall comprise Thorma-Joint with BJ 200 binder as manufactured

by Prismo Ltd., of Crawley, West Sussex, United Kingdom, or equal approved.

Elastomeric expansion joints shall be waboflex SR Type as manufactured by

Servicised Ltd., or equal and approved.

Installation details shall be as shown on the drawings and as otherwise

recommended by the manufacturer and approved by the Engineer.

5/41.2 All anchoring steel plates, bolts and sockets shall be protected against corrosion.

5/41.3 Joint installation shall be carried out strictly in accordance with manufacturer's
recommendations and in the presence of the manufacturers representatives.

5/42 LOCKABLE MEDIAN BOLLARD

5/42.1 Lockable median bollards shall be as shown on the drawings.

5/42.2 Movable bollard and locking mechanism shall be galvanised steel to BS EN ISO
1461:99 standard and treated with anti-corrosion paint.

5/42.3 Post sleeve shall be 4 mm thick PVC pipe.

5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED

CONCRETE SURFACES

GENERAL

5/43.1 The coating system shall be an elastomeric system of single component

products, a weather resistant top coat used in conjunction with a penetrating
primer. The coating shall have the ability to provide in-depth protection for
reinforced concrete structures against corrosion associated with the ingress of
chloride and sulphate ions, carbon dioxide and other air-borne acid gases, and
shall have the ability to allow water vapour to escape from the structure. All dry
film thickness of coating shall be verified by DCL.

PRIMER

5/43.2 The primer shall be a low viscosity reactive silane-siloxane/acrylic blend

dissolved in a penetrating organic carrier. The primer shall have the capability to
penetrate and produce a chemically bound Hydrophobic barrier to prevent the
passage of chloride and sulphate ions. The primer should also be film forming to
condition and stabilise the substrate prior to the application of the topcoat. The
primer should be applied in full accordance with the manufacturers instructions.

TOPCOAT

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 24 SECTION 5 ANCILLARY WORKS

5/43.3 The top coat shall be a pure aliphatic acrylic resin, decorative, high performance
water based, pigmented coating. It shall have resistance to water, carbon dioxide
and other air-borne acids and have the ability to allow the passage of water
vapour from within the structure.

5/43.4 The top coat shall have elastomeric and flexural capabilities and should be
applied in strict accordance with the manufacturer's instructions.

5/43.5 The system will, during trials, display the following properties when applied in
accordance with the manufacturer's specification to samples obtained from
concrete made without additives.
Reduction in Water Absorption 82% minimum at 28
(measured against a control days
concrete sample in accordance
with ASTM C 642)

Reduction in Chloride Ion 90% minimum at 28

Penetration days.

Water Vapour Transmission > 13g/m2/day

Carbon Dioxide Diffusion Equivalent to 500mm

Resistance of 30 N/mm2 concrete
TRIAL PANELS

5/43.6 Prior to applying the system in the works, trial applications shall be carried out on
trial panels made by the Contractor under Clause 4/33. The trials will
demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating. Representatives of the
coating manufacturers shall be present at the trials and the surface preparation
and application of the coating shall be carried out under their direction. The
Contractor shall at his own expense surface coat as many panels as required by
the Engineer until a trial panel has been accepted by the Engineer as
satisfactory. The coated panel, when accepted will form the standard against
which the corresponding coating in the works will be judged. No application of
the coating in the works shall be undertaken until trials have been completed to
the Engineer's satisfaction.

INSPECTION OF CONCRETE

5/43.7 The Contractor shall not proceed with the surface finish or making good of
concrete surfaces until he has received the Engineer's Representative's
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck until
the concrete has been inspected and approved by the Engineer's Representative.

FAULTY CONCRETE WORK

5/43.8 The Contractor shall on the written instruction of the Engineer remove and
reconstruct any such portion of the work which in the opinion of the Engineer is
unsatisfactory as regards quality of concrete, incorrect dimension of the cast
portion, badly placed or insufficient reinforcement, honeycombing or other such
cause as shall render the construction not up to the standard required and which
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 25 SECTION 5 ANCILLARY WORKS

in the opinion of the Engineer may prejudicially affect the strength or durability of
the construction.

APPROVAL PRIOR TO COATING APPLICATION IN THE WORKS

5/43.9 The Engineer's approval must be obtained prior to applying the coating system in
the works. Before approval is given the Engineer will need to be satisfied as to
the following:-

a. All construction work in the immediate vicinity of the structure to be coated

has been completed.

b. The surface preparation of the structure has been completed.

c. The whole of the structure can be coated in a continuous operation.

d. Adequate measures have been taken to protect the property of third parties,
including vehicles, from coating splatters.

e. The weather conditions accord with the coating manufacturer's directions

for coating application.

5/44 BRIDGE BEARINGS

5/44.1 Bearings for concrete Works, including those that are to be furnished and
included as a part of the Concrete Work under Section 4, Clause 4/36, Post-
Tensioned Concrete Works, of these Specifications, shall be as indicated on the
Drawings, as specified herein and as directed by the Engineer.

5/44.2 Elastomeric Bearings

1. General-Elastomeric bearings shall consist of laminated Elastomeric pads or

assemblies of laminated Elastomeric pads with externally bonded structural
steel bearing plates, structural steel top bearing plate and required stainless
steel and PFC sheets, as indicated on the approved shop drawings and as
specified herein.

Well in advance of their scheduled inclusion in the Works, the Contractor

shall submit a method statement for the approval of the Engineer including
the specifications of all materials, bedding mortar, the corrosion protective
system, and method of handling, transportation, storage and installation. It
shall also include detailed design calculations in support of the sizes and
quality of each component of the bearing, shop drawings, maintenance
manual and replacement scheme for the bearings.

The manufacturer shall submit for approval prequalification of three accredit

independent test facility. Accordingly, the engineer shall nominate the
approved independent test facility, who shall certify the compliance statement
for each bearing. Compliance statement shall be inline with specification as
marked below.

The information supplied should include documentation from the bridge

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 26 SECTION 5 ANCILLARY WORKS

bearing manufacturer of successful usage in similar environmental conditions

to those experienced in Dubai. The bearings shall be guaranteed for 10
years and the Contractor shall provide the guarantee from the bearing
manufacturer.

Variation in thickness of an individual Elastomeric lamination shall not exceed

3 mm within the width or length of a bearing pad and the variation in
thickness of all elastomer laminations within a bearing pad shall be such that
each metal or fabric lamination will not vary by more than 3 mm from a plane
parallel to the top or bottom surface of the bearing pad.

The total out to out thickness of a bearing pad shall not be less than the
thickness indicated on the approved shop drawings nor more than 6 mm
greater than that thickness. Variation of total thickness within an individual
bearing pad shall not exceed 3 mm.

The length and width of a bearing pad shall not vary more than
3 mm from the dimensions indicated on the approved shop drawings.
The bond between the elastomer and the steel laminate shall be such that,
when a sample is tested for separation, failure shall occur within the
elastomer and not between the elastomer and the steel.

2. Materials - All material used in the manufacture of the bearing assemblies shall
be new and unused with no reclaimed material incorporated into the finished
assembly. All bonding of components shall be done under heat and pressure
during the vulcanizing process. The bond shall be continuous throughout the
plan area with no voids or air spaces greater than 0.25 mm within the bonding
material. The bearing assemblies shall be furnished as complete units from
one manufacturing source.

The materials for the Elastomeric bearings and assemblies shall comply with
the following requirements:

a) Elastomeric Materials - The Elastomeric materials of the compounds

shall be 100% virgin polychloroprene synthetic rubber meeting the
requirements of Table 5-5. The properties of the Elastomeric compounds
shall be determined from test specimens complying with ASTM D3182
through D3190 inclusive and D3192. A variation of ± 10% in tensile
strength and ultimate elongation under "physical properties" will be
permitted when test specimens are cut from the finished product.

b) Internal Steel Laminates - The internal steel laminates for the laminated
Elastomeric bearing pads shall be rolled carbon steel sheets complying
with ASTM A570 or AASHTO M183 (ASTM A36).

c) Laminated Elastomeric Bearing Pads - Laminated Elastomeric bearing

pads shall be individually molded to the required size. Corners and edges
may be rounded with a radius at the corners not exceeding 9 mm and a
radius at the edges not exceeding 6 mm. All edges of the steel
laminations shall be covered with not less than 4 mm and not more than 6
mm of elastomer. The dimensions of the Elastomeric bearing pads shall
be within the following listed tolerances (Table 5-5):

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 27 SECTION 5 ANCILLARY WORKS

Table 5- 5: Polychloroprene - Synthetic Rubber

ASTM
Standard Physical Properties Value Value

D2240:2005 Hardness, ASTM D2240 50 ± 5 60 ± 5

D412:2006 Tensile strength, min. kg/cm² 156 (2,250 156 (2,250
Ultimate elongation, min. % psi) 400 psi) 350

Heat Resistance
Change in durometer +15 +15
hardness, max. points

D573:2004 Change in tensile strength, -15 -15

70 hr. max. %
@ 100 C

Change in ultimate -40 -40

elongation, max. %

Compressive Set
D395:2003 (08) 22 hours @ 100C, max. % 35 35
Method B

Ozone
D1149:2007 100 pphm ozone in air by No No
o
volume, 20% strain, 37.7 C Cracks Cracks
± 1C, 100 hours mounting
Procedure D518, Procedure
A

Adhesion to Steel
Bond made during 80% R (Z1) 80% R
vulcanization (Z1)
D429, A:2008 Bond Strength 6.9 kn/m 6.9 kn/m
D429, B: 2008 Peel Strength 6.9 kn/m 6.9 kn/m
D746: 2007 Low Temperature Test -
Durometer Change
Bearing or sample to be
exposed for 96 hrs. @-28°C,
± 2°C. (The specimen shall
have a 24 hr. conditioning
period at room temperature
prior to low temperature
exposure). The durometer
test shall be made at 28°C on +15 (Z2)
an unbuffed surface.
Durometer hardness
increase, Max. ASTM D2240,
30 second reading.
Durometer to be placed in
freezer with test specimen.
Brittleness temp., 3 min., at - No cracks
40°C
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 28 SECTION 5 ANCILLARY WORKS

Procedure B Structural Steel. The internal

steel laminates for the
laminated elastomeric
bearings shall be rolled mild
steel sheets conforming to
SAE 1020 or AASHTO M183.
Laminated elastomeric
bearings shall be individually
molded to the required size.
Corners and edges may be
rounded with a radius at the
corners not exceeding 9 mm
and a radius at the edges not
exceeding 6 mm. All edges
of the steel laminations shall
be covered with not less than
3 mm and not more than 6
mm of elastomer. The
dimensions of the elastomeric
bearings shall be within the
following listed tolerances:
Fabrication Tolerances
a) Overall Vertical Rubber Dimension.
 Average total rubber thickness 32 mm or -0, + 3 mm
less -0, + 6 mm
 Average total rubber thickness over 32 mm
b) Overall Horizontal Rubber Dimension.
91.4 cm or 0, + 6 mm
less than 91.4 cm 0, + 12 mm

c) Thickness of individual layers of elastomer ± 20% of design value

(Laminated Bearings Only) but not more than ± 3
mm
d) Thickness of Top and Bottom Cover Layer - 0, the smaller of 1.5
(if required) mm and +20% of the
nominal cover layer
thickness

e) Parallelism with Opposite Face Top and .005 radians

Bottom Sides .02 radians

f) Position of exposed connection members ±3mm

holes, slots or inserts

g) Edge cover of embedded laminates or -0, + 3 mm

connection members

h) Size of holes, slots or inserts. ± 3 mm

The rubber laminates shall be of uniform integral units, capable of being

separated by mechanical means into separate, well-defined elastomeric
layers. The ultimate breakdown limit of the elastomeric bearing under
compressive loading shall be not less than 140 kgs/cm². In addition to the
requirements of Table A, the compressive stress-strain relationship of the
finished elastomeric bearings at room temperature shall not exceed the
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 29 SECTION 5 ANCILLARY WORKS

following limitations:

Stress 35 kgs/sq.cm 56 kgs./sq. cm

Strain* 5% 7%

* Percent of total thickness of all elastomer laminations.

In addition, shear resistance of the bearing shall not exceed 2.80 kgs/cm 2 (40
psi) for 60 durometer, Table A compounds at 25% strain of the total effective
rubber thickness after an extended four-day ambient temperature of -28°C.

The Contractor shall furnish to the Engineer a certification for each bearing by
the approved independent test facility that the elastomer, in the elastomeric
bearing pads to be furnished conforms to all of the above requirements. The
certification shall be supported by a certified copy of the results of tests
performed by the approved independent test facility upon samples of the
elastomer to be used in the pads.

3. Bearing Installation - The concrete bearing surfaces on which elastomeric

bearing pads are to be placed shall be wood float finished to a level plane
which shall not vary more than 3 mm from a straightedge placed in any
direction across the area. The finished bearing seat shall not vary more than 3
mm from the elevation shown on the approved shop Drawings.

Concrete or metal surfaces on which the bearing pads are to be set shall be
dry, clean and free from dirt, grease, latency, and contaminants. No bearing
pad shall be placed until the Engineer has inspected and approved the seat
conditions.

All elastomeric bearing pads shall be fixed in position on the bearing seat with
an approved epoxy and applied in accordance with the recommendations of the
manufacturer of the bearing pads.

For expansion bearings only, concrete bond to the top surface of the bearing
pad shall be prevented by the use of polyethylene sheeting or other removable
bond breaking material as approved by the Engineer.

5/44.3 Pot Type Bearings - Guided Expansion and Fixed Bearings

1. General - The Contractor shall furnish and install pot type, guided expansion
and fixed bridge bearings at the locations shown on the Drawings. The bearing
assemblies shall be complete and ready for installation. Expansion bearings
shall have sliding surfaces of polytetrafluorethylene (PTFE) and shall be subject
to the requirements of this specification and as shown on the Drawings.

Fixed bearings shall allow rotation but no longitudinal or transversal movement,

in the bearing plane.

Expansion and fixed bearings shall be capable of supporting the maximum total
vertical and horizontal loads as shown on the Drawings.

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 30 SECTION 5 ANCILLARY WORKS

The PTFE material consisting of filled or unfilled sheet, as shown on the

approved shop drawings, together with the adhesive materials, stainless steel
mating surface and manufacturing processes shall conform to the requirements
given in these specifications.

The Contractor shall furnish Certified Test Reports, Materials Certificates and a
Certificate of Compliance for each bearing in accordance with the Engineer’s
instructions.

Well in advance of their scheduled inclusion in the Works, the Contractor shall
submit a method statement for the approval of the Engineer including the
specifications of all materials, bedding mortar, the corrosion protective system,
method of handling, transportation, storage and installation. It shall also include
detailed design calculations in support of the sizes and quality of each
component of the bearing, detailed analysis for the stresses in the base element
and in concrete/bearing plinth immediately under the bearing will also be
required to check peak stresses. The Contractor shall provide shop drawings,
maintenance manual and replacement scheme for the bearings.

The information supplied should include documentation from the bridge bearing
manufacturer of successful usage in similar environmental conditions to those
experienced in Dubai. The bearings shall be guaranteed for 10 years and the
Contractor shall provide the guarantee from the bearing manufacturer.

2. Design - PTFE sliding surfaces are designed to translate or rotate by sliding of a

self-lubricating polytetrafluorethylene surface across a smooth hard mating
surface of stainless steel.

Expansion bearings having sliding surfaces of PTFE shall have provision for
rotation or equalization of the stress on the PTFE sliding surface. Rotation shall
be considered the sum of live load rotation, changes in camber during
construction and misalignment of the bearing seats due to construction
tolerances. Rotational capability shall not be less than 1:50. The design,
materials and construction of the means of equalizing the stress or provision for
rotation in the bearing shall be in accordance with these specifications and as
shown on the approved shop drawings.

PTFE sliding surfaces shall have the following minimum and maximum
thickness:

 Unfilled or filled PTFE 0.79 mm minimum, 2.38 mm maximum.

 The PTFE sliding surface must be bonded under factory controlled

conditions to a rigid back-up materials capable of resisting bending
stresses to which the sliding surfaces may be subjected. Alternatively,
PTFE material of twice the thickness specified above may be recessed
for half its thickness in the back-up material.

 The mating stainless steel surface to the PTFE should be an accurate

flat surface as required by the design and shall have a minimum Brinell
hardness of 125 and a surface finish of less than
5 x 10-4mm (20 micro inches) rms (root mean square). The mating
surface shall completely cover the PTFE surface in all operating
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 31 SECTION 5 ANCILLARY WORKS

positions of the bearing.

 The average bearing pressure on the PTFE sliding surface due to all
loads shall not exceed:

Filled PTFE 246 kg./cm² (3500 PSI)

Unfilled PTFE (Recessed) 246 kg./cm² (3500 PSI)
Unfilled PTFE (Not recessed) 140 kg./cm² (2000 PSI)

The design shall include means to positively locate all elements of the bearings.
Where a thin non-corrosive smooth facing materials is used as a mating
surface, it shall be structurally bonded by an approved adhesive system and
may also be mechanically fastened by means of either screws, or rivets to the
back-up materials or if the material permits, seal welded around the entire
perimeter of the facing material.

3. Description - PTFE Bearing Surfaces. Prefabricated fixed and expansion

bearings having a working surface of PTFE conforming to the design
requirements, shall conform to the following materials, manufacturing and test
requirements.

4. Materials

a) General -The virgin PTFE resin, filled or unfilled PTFE sheets, back-up
materials and all other parts of the fixed or expansion bearings shall have
the friction, mechanical, physical and weathering properties prescribed in
this specification.
b) PTFE Resin - PTFE resin shall be virgin material (not reprocessed)
meeting with requirements of ASTM designation D4894:2007. Specific
Gravity shall be 2.13-2.19. Melting point shall be 327°C (623°F±2).
c) Filler Material - Filler material when used, shall be milled glass fibers,
carbon or other approved inert filler materials.
d) Adhesive Material - Adhesive material shall be an epoxy resin meeting
the requirements of specification MIL-A-8623A or equal, as approved by
the Engineer.
e) Unfilled PTFE Sheet - Finished unfilled PTFE sheet shall be made from
virgin PTFE resin and shall conform to the following requirements:

Mechanical ASTM Method 25% Carbon

Tensile Strength (min) ASTM D4894:2007 197 kg/cm² (2800 PSI)
Elongation (min) ASTM D4895:2004 200%

f) Filled PTFE Sheet - Filled PTFE sheet shall be made from virgin PTFE
resin uniformly blended with inert filler material. Finish filled PTFE sheets
containing glass fiber or carbon shall conform to the following
requirements (Table 5-6 and 5-7).

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 32 SECTION 5 ANCILLARY WORKS

Table 5- 6: PTFE sheets mechanical requirements

Mechanical ASTM 15% 25% Carbon
Method Glass Fibers
Tensile Strength D4894:2007 140 kg/cm² 91 kg/cm²
(min) (2000 PSI) (1300 PSI)
Elongation (min) D4895:2004 150% 75%

Table 5- 7: PTFE sheets physical requirements

Physical ASTM 15% Glass 25% Carbon
Method Fibers
Specific Gravity (min) D792:2008 2.20 2.10
Melting Point D4894:2007 327°C±10°C 327°C±10°C

g. Surface Treatment - Where PTFE sheets are to be epoxy bonded, one

side of the PTFE sheet shall be factory treated by an approved
manufacturer by the sodium ammonia or sodium nepthalene process.
h. Stainless Steel Mating Surface - Stainless steel mating surfaces when
used shall be 20-gage minimum thickness and conform to ASTM A240:
2009C Type 304 with a surface finish of less than 20 micro inches rms.
Stainless steel mating surfaces shall be polished or rolled as necessary to
meet the friction requirements of this specification.
i) Structural Steel - All structural steel bearing components including
masonry plate, pot base, top plate, sole plate, piston and guide bars shall
conform to the requirements of ASTM A588: 2005.
Anchor studs, as shown on the approved shop drawings, shall be welded
to the sole plates in accordance with requirements of the AWS Welding
Specification.
High tensile strength guide bar bolts shall be as specified by the
manufacturer and shall develop full resistance to the lateral forces. The
friction between the bearing and substructure shall not be considered to
assist in resisting horizontal forces as shown on the Drawings.
All structural steel shall be given a 0.254 mm (10 mil) epoxy coal tar finish
after fabrication in accordance with the paint manufacturer’s specifications.

j. Anchor Bolts - Anchor bolts provided to anchor the masonry plate to the
concrete substructure shall conform to the requirements of ASTM A307:
2007 and shall be galvanized in accordance with the requirements of
ASTM A153.
k. Elastomeric Components - The elastomeric bearing disc, seal rings for
containing elastomer in expansion bearings and seal for fixed bearings
shall be made from neoprene of 50 Durometer A hardness in accordance
with the requirements specified herein for “Elastomeric Bearings.”

5. Manufacturing Requirements

a) General -The virgin PTFE resin, filled or unfilled PTFE sheets,

back-up materials and all other parts of the fixed or expansion
bearings shall have the friction, mechanical, physical and
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 33 SECTION 5 ANCILLARY WORKS

weathering properties prescribed in this specification.

PTFE material shall be factory bonded, mechanically connected,
or recessed into the back-up material as shown on the approved
shop drawings.
b) PTFE Sheets - The bonding shall be performed at the factory of
the bearing manufacturer of the expansion bearings under
controlled conditions and in accordance with the written
instructions of the manufacturer of the approved adhesive system.
After completion of the bonding operation, the PTFE surface shall
be smooth and free from bubbles. Filled PTFE surfaces shall then
be polished.
6. Testing and Acceptance

a) General - The manufacturer of the bearings shall furnish facilities

for the testing and inspection of materials and of the completed
bearings at an independent test facility approved by the Engineer,
the representative of independent test facility of shall be allowed
free access to the manufacturer’s plant to apply the approved
testing and inspection plan.
For each bearing, certificate from the approved independent test
facility shall be furnished for approval; testing and inspection plan
for each bearing shall be included.

b) PTFE Cold Flow Test - The manufacturer of the bearings shall

demonstrate to the Engineer, by approved methods of testing, that
the cold flow of the PTFE material proposed to be used, filled or
unfilled, will not deform laterally, by more than 1.6 mm radially
(i.e., diameter of the Teflon shall not increase by more than
3.2mm, under a uniform loading of 246kg/cm² (3500 PSI) imposed
continuously for a period of not less than one hundred (100) hours.
The dynamic loading shall include the sliding of the stainless
mating surface in a back and forth motion of 25.4mm.
c) Test Specimens - After the manufacture of all bridge bearings
one bearing from each load range will be selected at random by
the Engineer for testing in accordance with AASHTO Clause 18.7
(Division 2).

If all tests performed on the selected bearing in a given load range

meet specified requirements, all bearings within that load range
will be acceptable. In the event that any test on a bearing in a
given load range does not meet specified requirements, the tested
bearings and all other bearings in that same load range will be
rejected unless each individual bearing is satisfactorily tested and
approved by the Engineer.

d) Proof Load Test - A test bearing shall be loaded to 150 percent of

the bearing’s rated design capacity and simultaneously subjected
to a rotation range of 0.02 radian (1.146o) or design rotation,
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 34 SECTION 5 ANCILLARY WORKS

whichever is greater, for a period of one (1) hour.

The bearing will be visually examined both during the test and
upon disassembly after the test. Any resultant visual defects, such
as extruded or deformed elastomer, polyether urethan or TFE,
damaged seals or limited rings, or cracked steel, shall be cause
for rejection of the lot.

During the test, for pot bearings the steel bearing plate and steel
piston shall maintain continuous and uniform contact for the
duration of the test. Any observed lift-off will be cause for rejection
of the lot.

e) Testing for Coefficient of Friction - The test shall be arranged

so that the coefficient of friction on first movement, on the fifth and
fiftieth cycles and during sliding can be measured. The test
method and equipment shall be subject to the approval of the
Engineer.

The Static Coefficient of Friction shall be determined at breakaway

by dividing the horizontal force to start motion by the vertically
applied force which shall be equivalent to application pressure.
The Dynamic Coefficient of Friction shall be determined by the
same method.

The testing procedure shall be as follows:

i) The bearing shall be loaded with the Maximum Total Load

indicated for the load range and this load shall be applied
continuously for 12 hours immediately prior to measuring the
coefficient of friction.

ii) The bearing load shall be reduced to a Minimum Dead Load

indicated, and the first movement static and dynamic
coefficient of friction for the test bearing shall be determined
at a sliding speed not exceeding 25.4mm per minute.

iii) The bearing shall then be loaded with the Maximum Total
Load and be subjected to 100 movements of the full design
relative movement at a speed of less than 30cms per minute.
If the test facility does not permit the full design movement to
be used, the Engineer may permit a reduced movement to
be used, but this shall not be less than 25.4mm.
iv) The static and dynamic coefficients of friction shall then be
determined again with the bearing loaded with the Minimum
Dead Load.

v) The static and dynamic coefficients of friction between the

polished stainless steel sliding surface and the PTFE bearing
surface when tested as provided herein, at the Minimum
Dead Load, shall not exceed three (3) percent.

vi) In addition to the above requirements, to be acceptable, the

bearings shall show no appreciable sign of failure or other

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 35 SECTION 5 ANCILLARY WORKS

defects.
Bearings represented by the test specimens passing the
above requirements will be approved for use in the structures
subject to on-site inspection for visible defects.

7. Packaging and Identification Marking - Each bearing shall be

assembled at the plant, shall be marked for identification and shall be
delivered to the construction site as a complete unit. Packaging shall be
accomplished in such a manner so as to ensure that the bearings during
shipment and storage will be protected against damage from handling,
weather or any other hazard. Each completed bearing shall have its
components clearly identified, be securely taped or otherwise fastened
for shipment and marked on its top as to location in each structure in the
project in conformity with the Drawings.

8. Bearing Installation - The Contractor shall certify to the Engineer that a

skilled representative of the bearing manufacturer will be available to
the Contractor to give such aid and instruction in the installation of
bearings as is required to obtain satisfactory results.

The skilled representative shall be present during the initial installation

of the bearings. The representative shall remain on the job until, in the
opinion of the Engineer, the bearing installation is proceeding smoothly
and the workmen are familiar with the work required for each
installation. The Contractor shall also arrange to have the
representative present at such other times as the Engineer may
request.

Anchor bolts shall be cast monolithically with the substructure concrete

by the use of templates to the exact locations and with bolt projections
above bearing seat precisely as shown on the Drawings and approved
shop drawings.

Bearing grout pads shall be placed as shown on the Drawings and as

herein before specified for “Grout Pads” using an epoxy and quartz
sand grout as recommended by the bearing manufacturer. The top
surfaces of the epoxy grout pads shall be perfectly level and any
perceptible deviations from a straightedge shall be ground level or filled
with epoxy mortar and ground until a true level surface is obtained.

The bearings shall be placed at the time of superstructure form erection

and all temporary restraints shall be removed as directed by the bearing
manufacturer.

The bearings shall be set on the exact alignment as shown on the

Drawings for each location and shall be oriented in the proper direction.
Extreme care shall be exercised in aligning both the base and the upper
part of the guided expansion bearing parallel to the expansion axis of
the structure to avoid a wedging action in the bearing during movements
of the superstructure. The location of the upper part of the bearing shall
be adjusted relative to the base to allow for temperature at the time of
erection.

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 36 SECTION 5 ANCILLARY WORKS

If for any reason the bearings are disassembled, extreme care shall be
used to ensure that the rubber pads and piston rings are properly
seated in the recess with the piston ring gaps 180° apart.

5/44.4 Temporary Bearings at Integral Abutments

5/44.4.1 Temporary bearings shall consist of structural steel base plates, galvanized
anchor bolts, structural steel H-sections and teflon coated sliding plates.

5/44.4.2 The temporary bearing components shall be in accordance with Clause 5/45
Metal Works. The teflon coated sliding plate shall meet all the requirements
given in Clause PS 5/44 Bridge Bearings of the Particular Specifications. All
structural steel welding shall be in accordance with the requirements of the
AWS Welding Specifications. The Contractor shall submit detailed shop
drawings for the bearings assembly for the approval of the Engineer.

5/45 METAL WORKS

5/45.1 Structural Steel

All structural steel shall be new and shall comply with the following specifications
and requirements:

Structural carbon steel shall comply with the specification for steel for bridges and
buildings of ASM A36 and/or AS88, unless otherwise specified herein, indicated on
the Drawings or in the Particular Specifications.

High strength steel bolts and washers shall comply with ASTM A325. All high
strengths nuts shall be of such capacity to develop the bolt strength.

Steel anchor bolts, nuts and washers and assembly bolts, nuts and washers for
round tube post bases shall be ASTM A307.

Steel bolts, nuts and hardened washers shall be galvanized in accordance with
ASTM A153 unless otherwise indicated on the Drawings or in the Particular
Specifications.

5/45.2 Stainless Steel

All stainless steel shall be new and shall comply with the following specifications and
requirements: All members or parts called for on the Drawings to be stainless steel
shall be AISI Type 302, 303, 304 or 316 and complying with ASTM A276. Unless
otherwise indicated on the Drawings or in the Particular Specifications, stainless
steel shall be Type 316 with a mill finish. Unless otherwise indicated on the Drawings
or in the Particular Specifications, all bolts shall be of the same type of stainless steel
as the adjoining parts. Stainless steel pipe rails and posts shall be as indicated on
the Drawings and shall be of AISI Type 304 stainless steel tubing (except Type 312
can be used for curved corners) complying with ASTM A-54. The completed handrail
shall have a surface finish complying with ASTM Designation A480 No. 2B finish.
Unless otherwise indicated on the Drawings, all posts and railings shall be 38 mm
nominal (48 mm outside diameter) stainless steel with 16 gauge wall thickness.
Where possible, the minimum shop fabricated length of handrail shall be 6 meters.

5/45.3 Galvanizing

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 37 SECTION 5 ANCILLARY WORKS

Shall be by the hot dip process in accordance with ASTM A123 and A385. The
galvanizing coating shall be uniform and bright when the galvanized surface are not
to be painted. All fabrication shall be completed and ready for assembly before
galvanizing. No punching, drilling or cutting shall be permitted after galvanizing.
Precautions shall be taken against embrittlement, warpage and distortion in
accordance with ASTM A143, and in accordance with ASTM A384. All coating
thicknesses shall be specified in mm or microns and shall be verified at DCL.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 37

 Section 6
Works in Connection with
Services Authorities
 1 SECTION 6 WORKS IN CONNECTION WITH SERVICES

TABLE OF CONTENTS

6/1 GENERAL REQUIREMENTS .................................................................................... 2

6/2 EXCAVATION FOR EXISTING SERVICES .............................................................. 4
6/3 SERVICES DUCTS.................................................................................................... 5
6/4 EXCAVATION FOR DUCTS ...................................................................................... 5
6/5 BEDDING AND LAYING OF DUCTS ........................................................................ 6
6/6 BACKFILLING OF TRENCHES................................................................................. 7
6/7 TESTING DUCTS ...................................................................................................... 7
6/8 MARKING AND RECORDING OF DUCTS ............................................................... 8
6/9 DUBAI ELECTRICITY AND WATER AUTHORITY WORKS.................................... 8
6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES ................. 9
6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES ........................................ 10
6/12 WATER WORKS - GENERAL ................................................................................. 11
6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR .. 11
6/14 WATER WORKS - STANDARDS ............................................................................ 12
6/15 WATER WORKS - PIPES........................................................................................ 12
6/16 WATER WORKS - GRE FITTINGS ......................................................................... 14
6/17 WATER WORKS - PHYSICAL AND CHEMICAL REQUIREMENTS OF GRP
FITTINGS ............................................................................................................................ 15
6/18 WATER WORKS - VALVES .................................................................................... 18
6/19 WATER WORKS - MANHOLE COVERS AND FRAMES ....................................... 19
6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES .................................. 19
6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES ............... 20
6/22 WATER WORKS - PIPE ANCHOR AND THRUST BLOCKS................................. 22
6/23 WATER WORKS - CLEANING OF PIPELINES...................................................... 23
6/24 WATER WORKS - TESTING PIPELINES .............................................................. 23
6/25 WATER WORKS - FINAL CLEANING AND STERILISATION ............................... 24
6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE ............................. 24
6/27 WORKS FOR ETISALAT - GENERAL .................................................................... 24
6/28 MATERIAL SUPPLIED BY ETISALAT .................................................................... 25
6/29 INSTALLATION OF PVC DUCT-(DUCT NO. 54D) AS SUPPLIED BY ETISALAT25
6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPARTMENT (DMD) .......... 28

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 2 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/1 GENERAL REQUIREMENTS

6/1.1 This work consists of the provision of new services and/or the searching,
protection, diversion and relocation of the existing services for the following
authorities:

- Dubai Electricity and Water Authority

- Emirates Telecommunications Corporation Ltd.
- Dubai Municipality Roads Lighting Section
- Dubai Municipality Drainage & Irrigation Dept.
- Roads and Transport Authority Roads Department

6/1.2 The full scope of the new works required for the protection, diversion and
relocation of services cannot be determined at the tender stage and the
Contractor shall allow in his rates for any variation in quantities and for the non
continuous and interrupted nature of the work.

6/1.3 The Contractor's attention is particularly drawn to the procedures to be

followed concerning existing services and service diversions laid down in
section 1 of the specifications and all current Administrative orders.

6/1.4 The service ducts shown on the Drawings or as directed by the Engineer are
to be provided so that future services can pass through them without
disturbing the road construction.

6/1.5 Position, types of ducts, pipes, cables, manholes etc. and constructional
details are shown on the Drawings but final locations will be determined on
site by the Engineer after having consulted with the concerned authorities.

6/1.6 The Contractor shall verify the position of services by digging trial trenches
and pits and if ducts, pipes, cables and manholes which are not marked on the
Drawings are found, the Engineer and the concerned Authority will then
instruct on the action to be taken, if any.

6/1.7 All protected services, existing ducts found or newly laid ducts shall be marked
with approved markers (Sub-Section 6/8) of size and type shown on the
Drawings or as indicated by the Engineer. The Location of markers shall be
as shown on the Drawings. No asphalt course with be laid unless the ends of
the ducts or protected services have been exposed and marked with markers.

6/1.8 No work concerning services will be started without having first informed and
obtained approval of the Concerned Authorities. Services works shall be
executed in accordance with the relevant clauses of the Specifications.

6/1.9 The protection of the existing services shall be carried out before the earth
work starts in the vicinity of the services to be protected.

6/1/10 Where new cable/ducts are to be laid along side, over or under the existing,
the Contractor shall take care to interfere as little as possible with the existing
services and connections thereto and any damage shall be repaired by the

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 3 SECTION 6 WORKS IN CONNECTION WITH SERVICES

Contractor to the approval of the appropriate Authority or by appropriate

Authority at the cost of the Contractor.

6/1.11 If some services have already been protected by the various Departments no
protection will be carried out under this Contract, but such protection can be
extended and/or upgraded as instructed by the Engineer on Site after having
consulted with the Concerned Authority.

6/1.12 All concrete works shall conform to the requirements of Section 4 of the
Specification.

6/1.13 Road crossing ducts shall extend beyond the road line at each side of the road
as shown on the Drawings. When appropriate, the excavation for the road
crossing and laying of ducts, concreting etc., shall only be carried out on half
the width of the road at one time, the other half being left available for traffic.
In this case, the necessary traffic warning signs on self-supporting
tripods/cones shall be provided well ahead of the duct crossing work and all
care and attention exercised to avoid risk of traffic accidents during
preparation and execution of the work.

6/1.14 To prevent soil and/or sand blocking the ducts, the openings at both ends are
to be protected with appropriate blanking caps.

6/1.15 The Contractor shall be responsible for public safety during execution of work.
He will take all steps, including where necessary the provision of ropes, picket
fence, etc., on each side of the trenches and excavations with warning lights
and night watchman etc. to ensure the safety of the public. The Contractor will
be held responsible for any damage to property or injury to persons due to his
negligence. Any instruction from the Engineer concerning the safety aspects
of the work must be carried out immediately, but the Contractor shall remain
responsible for the adequacy of the safety measures.

6/1.16 The Contractor shall after completing each duct, make the necessary
arrangements with the Services Authorities for testing and acceptance of the
work.

6/1.17 The Contractor shall supply continuous warning tape for service Authorities
with the following requirements:

a) The Contractor shall install approved warning tapes during backfilling

work over buried pipes, cables, conduits and ducts, as required.
Warning tapes shall be coloured and inscribed for identification
according to the requirements of the relevant Authority.

b) Warning tape shall be approved high quality, acid and alkali-resistant

polyethylene film 250 mm wide, and with a minimum thickness of 150
microns. Tape shall have minimum tensile strength of 125 kg/sq.cm.
longitudinally and 105 kg/sq.cm. laterally with an elongation factor of
350% .

c) Tape shall be printed with 50 mm high black lettering, alternatively in

Arabic and English. The complete wordings shall be repeated every 2m

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 4 SECTION 6 WORKS IN CONNECTION WITH SERVICES

along the tape. The colours shall be vivid, glossy and permanent with a
life expectancy of 40 years.

d) Warning tapes shall be placed with the inscriptions facing upwards. The
level of the tape relating to the top of service shall be in accordance with
the requirements of the relevant Authority.

e) Warning tapes over non-metallic services shall be backed with Aluminum

foil to facilitate detection.

6/1.18 All trenches and other excavation shall be maintained in a dry condition and
the Contractor shall arrange a suitable dewatering system for any dewatering
involved, in agreement with the Engineer, to keep the working place clean
and dry. The Contractor shall be deemed to have included in his rates for all
costs associated with this work.

6/2 EXCAVATION FOR EXISTING SERVICES

6/2.1 The Contractor's attention is again drawn TO SECTION 1 of the Specification,

regarding existing services and diversions, which must be strictly adhered to.

6/2.2 The position of existing services as shown on the drawings are for
informational purposes only and do not necessarily show exact locations,
depths, spacings, and smaller services such as house connections which are
not normally indicated on such drawings. The Contractor shall excavate by
hand, take trial pits at regular distance and also at all road intersections to
locate existing services, their number, depth and route direction. As these
services are located the Contractor shall prepare shop drawings indicating the
aforementioned information.

6/2.3 After existing services, according to the Engineer's instruction, have been
exposed and if according to the opinion of the Engineer and after approval of
the concerned authorities it is found necessary to proceed with the lowering or
diversion, thereof, the Contractor shall proceed with the relevant excavation
in co-ordination with the said authorities.

6/2.4 The Contractor shall maintain records of such excavation in a form acceptable
to the Engineer. Two copies of such records shall be submitted to the
Engineer on a weekly basis or as agreed with by the Engineer.

6/2.5 The Contractor shall include all tools, labour, equipment and accessories as
required to complete the hand excavation. The Contractor shall include all
materials, labour and equipment necessary to protect the existing utilities, as
well as any shoring and protection during hand excavation.

6/2.6 All materials removed shall be disposed of by the Contractor in accordance

with the specifications or as directed by the Engineer.

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 5 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/2.7 When directed by the Engineer, all such excavation shall be backfilled with
suitable material, placed and compacted, all in accordance with the
requirements of the Specifications. The Contractor shall place fill material and
compact with care to avoid damage to the existing services. The Contractor
shall be responsible for any and all damages caused by his construction
operations.

6/2.8 The works relevant to the lowering of the existing service(s) will be started as
soon as, according to the Engineer, all the necessary precautions have been
taken to prevent any injury to person and/or property or services.

6/2.9 The excavation for lowering the existing service(s) shall be performed by hand
down to the elevation indicated by the Engineer and/or the concerned
authority.

6/2.10 At all times the Contractor shall provide and maintain, at his expense, access
to the adjoining properties to the satisfaction of the Engineer.

6/2.11 Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in
an approved manner and fenced on each side with post and rail stock proof
fences finished on top with one strand of galvanised barbed wire, or otherwise
protected as required by the owners or occupiers and the Engineer.

6/2.12 Where fences or walls are damaged or destroyed the whole shall be restored
and reinstated with like materials to the satisfaction of the owners or occupiers
and the Engineers.

6/2/13 The Contractor shall ensure that no trees are damaged or permanently
removed in carrying out the Contract except where directed due to the
presence of permanent works.

6/3 SERVICES DUCTS

6/3.1 The Contractor shall supply (unless otherwise specified) and install all the
necessary service ducts required by the Contract. The duct material shall be
as specified on the Drawings. A sample of the proposed duct shall be
submitted to the Engineer for his approval prior to their use. (For ducts for
works for Etisalat, refer to Sub-Section 6/28).

6/3.2 In general all ducts laying work is subject to the approval of the Engineer and
any particular requirements of the concerned Authority.

6/4 EXCAVATION FOR DUCTS

6/4.1 The trench shall be excavated with the width and to the depth shown on the
drawings or as indicated by the Engineer.

6/4.2 The sides of pits and trenches shall be vertical and adequately supported at all
times. The sides of pits and trenches shall be vertical and adequately

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 6 SECTION 6 WORKS IN CONNECTION WITH SERVICES

supported at all times. Excavation may be battered with a safe slope, if

considered necessary, but only with the Engineer’s written permission

6/4/3 The bottom of the trench shall be accurately graded. Care shall be taken not
to excavate below the depths indicated. Where rock is encountered, the rock
shall be excavated to the required depth. Uneven surfaces of the bottom of
trench shall be excavated 150 mm deeper. Such depth in rock shall be
backfilled with approved fill material and compacted as specified and/or as
directed by the Engineer.

6/4.4 Where ducts are laid in the line of the road construction, the bottom of the
excavation shall be compacted to not less than 95% of its M.D.D, as
determined by BS 1377 Part 4: 1990 (method 3.5, 3.6) or as otherwise
approved by the Engineer. Insitu density tests shall be carried out in
accordance with BS 1377: Part 9: 1990: Method 2.2.

6/4.5 Excavated material shall, if found unsuitable as defined in the Specification, be

disposed of to an approved tip and replaced with suitable material. All surplus
suitable excavated material shall be used in road construction or disposed of
in an approved manner.

6/4.6 Where split ducts are required for existing services crossing the works, hand
excavation shall be carefully undertaken until the position of apparatus to be
protected is fully exposed.

6/5 BEDDING AND LAYING OF DUCTS

6/5.1 As soon as possible after trench excavation, ducts of the required diameter
shall be jointed in accordance with the Drawings and manufacturer's
instructions.

6/5.2 Ducts shall be laid to the lines and levels indicated on the Drawings with the
required depth of cover. Where the specified minimum cover cannot be
achieved, or as otherwise directed by the Engineer, they shall be bedded and
surrounded with 150mm of concrete Class 15/20.

6/5.3 Unless surrounded in concrete, ducts shall be bedded on a layer of sand

150mm thick and fully surrounded with sand to a depth of 300mm above the
duct barrel, well packed and tamped. Filling with suitable material above this
level shall be free from large stones. For multiple ducts, the spaces between
ducts are to be filled with compacted sand and the ducts surrounded to a
depth of 300 mm above the uppermost layer. Trench backfill shall be
compacted to the requirements of the Specifications.

6/5.4 The line of ducts shall be maintained as straight as possible. Short length of
duct, but not less than 600mm, long may be used to achieve any required
deviation in the duct runs.

6/5.5 Ducts shall be cut by the Contractor as necessary only at right angles to their
length using a saw in a simple cutting guide. The inside cut edges shall be
thoroughly rounded off or dressed before installation to prevent damage to
cables drawn through the ducts.

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 7 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/5.6 Existing services shall be protected where necessary, unless otherwise

directed by the Engineer, using split uPVC ducts laid as described above, fully
surrounded with 150 mm of concrete Class 15/20. The Contractor shall
consult the Engineer prior to carrying out protection works to agree the exact
method.

6/5.7 The halves of the split ducts shall be wired together and wrapped twice with
polythene sheeting to prevent the ingress of concrete.

6/6 BACKFILLING OF TRENCHES

6/6.1 After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer
being well compacted by hand with iron rammers weighing not less than 5 kg,
until the trench has been filled to a height of 300 mm above the top of the
cable/duct.

6/6.2 The reminder of the trench shall then be refilled in compacted layers not
exceeding 200 mm in thickness, each layer being well compacted, with power
rammers, vibrating plate compactors or other mechanical means of a type to
be approved until the ground is thoroughly consolidated up to the required
level for surface reinstatement. Each layer shall be compacted to not less
than 95% of its maximum dry density as determined by BS1377 Part 4: 1990:
AMD 13925: 2002 (method 3.5, 3.6). Should the quantity of the excavated
material be not sufficient, due to unsuitability or otherwise, for the process of
backfill and fill, the Contractor shall obtain the quantity required of such backfill
and fill from approved borrow pits and transport same to the site of the work at
his own expense.

6/6.3 Trenches shall not be backfilled until all required tests are performed and until
the Engineer has verified that the cables/ducts have been installed in
accordance with the Specification and Drawings.

6/6.4 Lumps and clods shall be broken up before use. Materials shall not be
dropped from a height and where directed, water shall be added to assist in
adequate consolidation.

6/6.5 Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided
according to an approved drawing or as ordered by the Engineer.

6/7 TESTING DUCTS

6/7.1 On completion of all ducting, two mops of appropriate sizes connected to each
end of an iron mandrel shall be passed twice each way to clean the ducts and
to remove foreign matter. All proving tests shall be witnessed by the Engineer
and the service Authority. Should any obstruction or other defect be
discovered it shall be removed or rectified immediately to the Engineer's
satisfaction.

All testing is to be complete before commencement of asphalt works.

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 8 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/8 MARKING AND RECORDING OF DUCTS

6/8.1 Unless otherwise shown on the Drawings each cable duct of length greater
than 3m shall be provided with a drawcord of approved 15mm diameter nylon
rope. The length of each 15mm drawcord shall be such that at least 1m
extends from each end of the duct. As soon as each duct or set of ducts have
been proved and the draw cords installed the ends shall be plugged with a
wooden or other approved bung and a single coat of bituminous paint shall be
applied over the end of the duct and the bung. The free end of drawcords
shall be stored in an approved manner. The Contractor shall ensure that all
ducts are kept free from dirt, rubble, water and other obstructions.

6/8.2 In kerbless stretches of new roadway the Contractor shall provide suitable cast
aluminum stud duct markers (Type 2) to be fixed into the road surface over the
line of the respective duct or ducts at each end of the duct run, shown on the
Drawings. The head of the stud shall be suitably inscribed in Arabic and
English, with the approved abbreviation of the concerned Authority, such as,
D.E.C, E.T.C., etc. Should the markers not be placed immediately on
completion of duct runs, the Contractor shall expose the end of the duct to
satisfy the Engineer of its position when placing the marker. The stud to be
provided will be as per the products manufactured by approved manufacturers
based in U.A.E. In this regard the Contractor must submit his proposal with
samples for approval.

6/8.3 In kerbed areas of new roadway Type 1 and Type 2 duct markers shall be
used. Type 1 duct marker shall be of concrete construction, in situ or precast
depending on the location, as per the details shown in the Contract drawings,
complete with approved abbreviation cast thereon. The finished product shall
be solid in appearance, free of segregation, honey combing broken edges and
other defects. The cost of these particular markers will be subsidiary to the
relevant duct provision item.

6/8.4 The Contractor shall prepare and maintain up to date drawings for each
Service Authority giving details of each duct laid including precise location,
level, number and type, and these drawings to be submitted to the Engineer.

6/9 DUBAI ELECTRICITY AND WATER AUTHORITY WORKS

6/9.1 ELECTRICITY WORKS - GENERAL : The works relate to the following:

a) The installation, jointing and commissioning of low, medium and high

voltage power cable and pilot/telephone cable.

b) The relocation and protection of existing cables and pilot/telephone

cables.

c) The provision of duct crossing for future development use, all in

accordance with the relevant sections of the Specification and to the
satisfaction and approval of the Engineer and DEWA representative.

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 9 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/9.2 Where existing cables require extension of existing protection ducts of

concrete encasement or where shown on the drawings, the Contractor shall
provide such protection by means of split PVC ducts with concrete surround all
as per the relevant clauses of the Specification.

The longitudinal seam of the split duct shall be sealed with waterproof tape to
prevent the ingress of grout. The tape shall be denso or equivalent.

6/9.3 Elsewhere, following lowering as found necessary, additional duct(s) will be

furnished and installed alongside existing cables in accordance with the
requirements of the DEWA and relevant Contract Drawings.

6/9.4 If requested, and upon receipt of authorisation by DEWA Engineer, the

Contractor shall excavate, remove de-energised cable(s), transport to store or
dispose of as directed by DEWA Engineer, and backfill the excavation. The
cost of the excavation shall be paid under the relevant items of the Bill of
Quantities.

6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES

6/10.1 The cables, pilot cables and enclosures, straight through joints, splitter boxes,
jointing accessories, PVC tiles, marker tape and earthing strip required for
installation of cables shall be supplied from DEWA Stores at Aweer, as free
issue items.

6/10.2 The 6.6 KV power cable is 3 core, 300 sq.mm Copper or Aluminum
Conductors PLY/SWA/PVC according to BS6480 - 1988 in drum lengths of
250/400 Metres respectively.

6/10.3 The 33KV power cable is 3 core 400sq.mm. copper stranded CONDUCTOR
HSL type PLY/SWA/PVC and is in drums of 400 metre lengths.

6/10.4 The composite, 33 KV pilot/telephone cable comprises of 6 pilot cores of 2.5

sq. mm. each in two triple sleeves and 8 telephone pairs of 1/1.13 mm in four
quad formations wound on 1000 metre drum lengths.

6/10.5 132 KV pilot cables comprises of 14 pair 1/1.13 mm copper conductor,

polyethylene insulated, paired, polyethylene sheathed, galvanised single wire
armoured, PVC sheathed wound on 1000 metre drum length.

6/10.6 Cable tiles are made of high density PVC compound and are in 1 metre
lengths with provision of interlocking longitudinally. 20 and 15 cms. Wide tiles
shall be laid centrally as a physical cover over 6.6 KV, 33 KV power and
pilot/telephone cables respectively.

6/10.7 Upon taking delivery, if the Contractor feels that material given is of inferior
quality, he should immediately bring to the notice of the DEWA and the
Engineer.

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 10 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES

6/11.1 Trenching with mechanical aids shall be permitted at the discretion of the
Engineer where minimum of services exist, and where location of services is
already effected, otherwise only manual excavation shall be permitted.
6/11.2 The cables are to be laid in trenches to the dimensions shown on the
Drawings. All cables, screens and armouring will be solidly earthed at each
end of the route to the station earthing system. Separate cable tiles are
required for the main cables and for the pilot cables. The tiles for the 33 KV
cables shall be 1000mm long and 200mm wide. The tiles for the pilot and 6.6
KV cables shall be 1000mm long and 150mm wide. The tiles are to be placed
centrally over each cable and are to be laid with ends interlocked with adjacent
tiles. Plastic warning tape shall be installed at the specified level.

6/11.3 Pressure testing of the cables will be carried out by DEC for the whole of each
route. Any failure of the joint or cable due to its mishandling shall be rectified
by the Contractor at no extra charges. All additional material required for
making good the fault/damage shall be at the Contractor's cost. All work is to
be guaranteed for one year by the Contractor.

6/11.4 The Contractor shall remove within a period of 15 days after completion of
route, all the empty cable drums from the works and transport to DEC stores.

6/11.5 Contractor shall supply "As laid drawings" for the cable circuit to a scale of
1:1000 indicating the following:

- Layout of cable work

- Length size, type and grade of cables
- Location of each joint with respect to permanent landmarks available at
site.
- Name of the circuit, Contractor number, date of completion, Name of
Contractor with signature, DEWA's Senior Distribution Construction
Engineer's approval.

6/11.6 After a route/circuit is completed, the Contractor shall take full care to clear the
site completely and leave it neat and tidy. All the remains i.e. excess earth,
stones, tile pieces, rubbish or any unwanted solid waste should be removed to
tip.

6/11.7 Route markers as per the Drawing shall be provided along straight runs of
cable at locations approved by the Engineer and DEC and generally at
intervals not exceeding 100 metres. Markers shall also be provided to identify
the change of the cables route and also for location of every underground
joint.

6/11.8 Even though the circuit may be energised due to compelling reasons, the
taking over date for maintenance/guarantee period shall be the date on which
all the outstanding work pointed out to Contractor is completed satisfactorily
and official taking over certificate issued to the Contractor.

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 11 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/12 WATER WORKS - GENERAL

6/12.1 This section deals with the specification for works to be carried out in
connection with Water Service pipework to be ultimately taken over by the
Dubai Electricity and Water Authority. Works shall comply with the current
DEWA standard specification and this will take precedence over the following.

6/12.2 The works include for the supply, installation, testing and commissioning of the
Water Service installation, the layout for which is shown on the Drawings. The
Contractor shall include for all labour, materials, tools and tackle, complete
with all trenching and backfill.

6/12.3 The Contractor shall include for the preparation for all necessary working
Drawings. The Contractor shall be responsible for the location of other
services and the correct setting out of the installation.

6/12.4 The work also involves the exposing of existing water pipe lines for the
purpose of transferring existing house connections if any to the new
distribution system and for the connection of the new system thereto, and the
recovery and disposal of all abandoned existing connection lines, all as
indicated in the Drawings or otherwise directed by the Engineer.

6/12.5 The Contractor shall allow in his programme for the non continuous nature of
the work relating to the water services.

6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR

6/13.1 All materials shall be provided by the Contractor, unless otherwise specified,
including but not limited to pipes, collars, rubber rings, valves, hydrants and
fittings.

6/13.2 The materials provided by the Contractor shall include all materials for
temporary works, planking and strutting, excavations, shuttering and
formwork, staging and scaffolding, approved filling materials, approved road
surfacing and paving materials, all materials required for repairing the internal
coating of valves, etc., such as primer, coal tar enamel etc., all concrete of
each required class including reinforcing steel and mesh, all surface boxes
etc.

6/13.3 All materials supplied locally by the Contractor shall be of the best quality in
their class and of the respective kinds as described in the Contract and in
accordance with the Engineer's instructions and to the satisfaction of DWD.
They shall be inspected from time to time at the site during the progress of the
work.

6/13.4 Any materials arriving on site found unsuitable shall be rejected. The
Contractor shall replace the rejected material at his own expense.

6/13.5 The Contractor shall, before supplying any local material, prepare and submit,
at his expense, to the Engineer for approval samples of materials which he
proposes to use. Such samples shall be retained by the Engineer. The

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 12 SECTION 6 WORKS IN CONNECTION WITH SERVICES

materials represented shall not be used in the works unless and until the
samples have been approved in writing by the Engineer.

6/14 WATER WORKS - STANDARDS

6/14.1 All calculations, drawings and submissions shall be in SI (System

International) units. Material items shall be to the latest BS (British Standard)
or equivalent comparable internationally recognised standard of construction
and quality.

6/15 WATER WORKS - PIPES

GENERAL

6/15.1 Asbestos cement (AC) pressure pipe shall conform to the requirements of BS
EN 512:1995. Pipe shall be manufactured in the U.A.E. All pipe and joints
shall be supplied by one manufacturer and certified by DM/DCL.
CLASS

6/15.2 AC pipe shall meet the requirements for class 18 suitable for an operating
pressure of 9 bars.
Pipe wall thickness shall meet all design requirements for class 18 pipe as
follows (Table 6-1):-

Table 6- 1: Pipe wall thickness requirements

Nominal diameter Outside diameter

(mm) (mm) at the end

75 93
80 106
100 126
150 178
225 255
300 344
550 616
600 668
700 780
900 1000
1200 1320

CEMENT
6/15.3 All cement used in the manufacture of asbestos cement pipe and joints shall
be a high sulphate resisting cement conforming to BS 4027: 1996. Copies of
cement mill certificates shall be submitted with each consignment delivered to
site.

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 13 SECTION 6 WORKS IN CONNECTION WITH SERVICES

JOINTS
6/15.4 Asbestos cements pipe shall be provided with spigot ends to be joined with
'Reka' type couplings with two rubber rings. Rubber rings shall conform to the
requirements of BS 2494. Joints shall be capable of withstanding a test
pressure of 18 bars without any leaks even when deflected to the angle
specified below (Table 6-2):

Table 6- 2: Joints properties (maximum deflection angle)

Nominal diameter mm Max. Joint deflection angle degrees

up to 225 5
250 - 350 4
400 - 550 3
600 - 1000 2
1100 - 1500 1

Copies of test reports showing compliance to these requirements shall be

submitted to DEWA for approval. Joint lubricant shall be an approved
vegetable-based type and shall be supplied by the pipe manufacturer.

LENGTH

6/15.5 Asbestos cement pipe shall be manufactured in 3 metre lengths for diameters
225 (9") and smaller and in 5 meter nominal lengths for larger sizes.

6/15.6 TESTING

Asbestos cement pipes shall be factory tested in accordance, with the BS EN

512:1990 copies of test certificates shall be submitted for each consignment
manufactured, and delivered to site. Sampling and inspection shall be in
accordance with BS EN 512:1990. Witnessing of factory testing by DEWA
representative may be required before any consignment is delivered to site.
All compulsory and optional tests shall be carried out by the manufacturer.

DEWA shall have the right to return up to 1% of pipes and joints delivered to
site for factory testing by the DEWA representative. All pipes testing shall be
performed on immersed samples.

6/15.7 MARKINGS

Each pipe and all joints shall be legibly and indelibly marked with the
following:-

i. The manufacturing standard.

ii. The manufacturer's name.
iii. Manufacturing date.
iv. Nominal diameter (ND) in mm.
v. Pressure rating in bars (class).
vi. Inspection mark.

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 14 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/16 WATER WORKS - GRE FITTINGS

6/16.1 All the fittings (bends, adapters, tees, etc.) shall be GRP (Glass Fibre
Reinforced Pressure fitting) which comply with the following specifications:-

GENERAL

6/16.2 This section covers the design, manufacture and testing of glass fibre
reinforced (GRP) pressure fittings for use with Asbestos cement pipelines in
nominal sizes 80 mm and larger. GRP fittings shall be locally manufactured in
the U.A.E.

CONSTRUCTION

6/16.3 GRP fittings shall have the following principal construction:-

- A corrosion resistant, resin rich liner having a minimum thickness of 0.5

mm. The liner surface shall be reinforced with "c" glass mat impregnated
with vinylester or Epoxy Resin.

- A structural wall consisting of continuous glass filament windings and/or

woven rovings and chopped glass reinforcements and may include
fillers, all impregnated with Resin.

- A resin-rich exterior surface having a minimum thickness of 0.25 mm,

impregnated with resin.

6/16.4 No pigments shall be allowed in the GRP fittings.

DESIGN REQUIREMENTS

6/16.5 GRP fittings and flanges shall be designed for service at the following
conditions:-

Maximum Operating Pressure 10 Bars

Minimum Site Test Pressure 15 Bars
Maximum Allowable Vacuum -1 Bar
Minimum Depth of Cover 1.0 Metre
Maximum Depth of Cover 4.0 Metre
Truck Loading (Wheel Load) 100 KN
Maximum Service Temperature 50 Deg.C.

6/16.6 Flanged fittings shall be designed for installation above ground (in Chambers)
with no thrust blocks.

6/16.7 Flanged branches on Spigot Tees and puddle (Wall) flanges shall be designed
to resist End thrust from closed valves.

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 15 SECTION 6 WORKS IN CONNECTION WITH SERVICES

GRP JOINTS

6/16.8 SPIGOT JOINTS, where specified shall have the same outside diameter (O.D)
as Asbestos Cement (AC) pipe class 18 used by DEWA. The joint dimensions
and tolerances shall be equal to AC pipe spigots such that the joint remains
water tight under all normal operating conditions. The spigot ends shall be
clearly marked with a Home line indicating the proper insertion limit for the AC
couplings.

6/16.9 FLANGED JOINTS, where specified shall be GRP filament wound flanges
manufactured from Vinylester or Epoxy resin. Flanges shall be flat faced and
drilled to BS 5404 PN 10 drilling pattern. Full face rubber gaskets 3 mm
minimum thickness shall be provided by the fitting manufacturer.

6/16.10 LAMINATED OR ADHESIVE JOINTS, used in the fabrication of fittings shall

be equal or superior in strength to the sections they join. The thickness of
laminated joints shall not be less than the wall thickness of the adjoining pipe
section.

6/17 WATER WORKS - PHYSICAL AND CHEMICAL REQUIREMENTS OF GRP

FITTINGS

CHEMICAL REQUIREMENTS

6/17.1 GRP fittings shall not impart any taste, odour or colour to drinking water. All
resins used shall be suitable for use in drinking water systems.

DIMENSIONS

6/17.2 GRP fittings shall be produced in Metric sizes and shall be classified by their
nominal inside diameter (N.D). The actual fitting inside diameter shall not be
less than that shown in the table below (Table 6-3):-

Table 6- 3: GRP fittings dimensions

NOMINAL DIAMETER MINIMUM INSIDE DIAMETER mm

ND (mm)
80 78
100 98
150 148
200 198
225 223
250 248
300 298
550 546
600 595
700 695
750 744
900 892
1200 1190

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 16 SECTION 6 WORKS IN CONNECTION WITH SERVICES

ELBOWS

6/17.3 Elbows of nominal diameter 300 mm and smaller shall be of the smooth radius
type, having a turning radius of 1.5 times the elbow nominal diameter. Elbows
larger than 300 mm shall be smooth radius of 1.5 times the elbow nominal
diameter. All internal surfaces shall be finished smooth.
FLANGES

6/17.4 The minimum GRP flange wall thickness shall not be less than that shown in
the table below (Table 6-4):-

Table 6- 4: GRP flange wall thickness

NOMINAL DIAMETER MINIMUM INSIDE FLANGE

ND (mm) THICKNESS (mm)

80 32
100 32
150 32
200 37
225 42
300 48
550 68
600 68
700 73
750 77
900 82
1200 106

WALL THICKNESS

6/17.5 The wall thickness of GRP fittings shall be determined by the manufacturer to
meet the design requirements of these specifications but shall in no case be
less than the values shown in the table below (Table 6-5):-

Table 6- 5: Wall thickness of GRP fittings

NOMINAL DIAMETER ND (mm) MINIMUM WALL THICKNESS mm

80 3.2
100 3.2
150 3.2
200 3.2
225 3.4
300 3.6
550 4.4
600 5.7
700 6.3
750 7.3
900 9.5
1200 12.5
(Excluding inner and exterior layer).

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 17 SECTION 6 WORKS IN CONNECTION WITH SERVICES

MECHANICAL PROPERTIES

6/17.6 GRP fittings shall meet the following minimum strength requirements (Table 6-
6) :-

Table 6- 6: GPR fittings minimum strength requirements

PROPERTY TEST METHOD MINIMUM VALUE

Hoop Tensile Stress ASTM D2290 :04 180 MPa
Axial Tensile Stress for ASTM D 638 :03 40 MPa
spigot fittings
Axial Tensile Stress for ASTM D 638 :03 90 MPa
flanged fittings
Stiffness (EI/D) BS 5480 : 1990 5000 Pa

In addition to factory testing, the following tests shall be carried out at DCL.
1. Initial longitudinal unit tensile strength by tensile strip test in accordance
with BS 5480: Appendix “A”
2. Initial specific stiffness under Ring Deflection Test in accordance with BS
5480: Appendix H.
VISUAL REQUIREMENTS

6/17.7 GRP fittings shall be free from delamination, crazing, dry areas or cracks.
Spigot ends shall be free from end delamination, torn edges, gouges and shall
be finished smooth to ensure water tightness.

TESTING GRP FITTINGS

6/17.8 The following tests shall be carried out by the fitting manufacturer at the
intervals specified. Test results and certificates shall be submitted to DEWA
for each consignment delivered. Witnessing of factory testing by the DEWA
representative may be required.

TEST FREQUENCY

1. Visual Inspection Every Item

2. Dimensions Every Item
3. Hydraulic Pressure Once per 100 Flanged Items
4. Stiffness Once per 100 Equal Items
5. Longitudinal Tensile Stress Once per 100 Equal Items
6. Hoop Tensile Stress Once per 100 Equal Items

SUBMITTALS/DRAWINGS

6/17.9 Prior to start of production, the fittings manufacturer shall submit to DEWA
dimensional drawings of each fitting required for approval.

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 18 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/17.10 For flanged fittings, the manufacturer shall submit before delivery, the
bolt-torquing sequence and maximum recommended torque for each flange
size supplied.
MARKINGS

6/17.11 Each fitting shall be indelibly marked with the following:-

- Manufacturer's name or Trademark

- Nominal Diameter (N.D) in mm
- Pressure rating in Bars
- Manufacturing Date
- Inspection Mark

6/18 WATER WORKS - VALVES

6/18.1 Sluice valves supplied shall be suitable for use IN DUBAI, the valves shall be
supplied complete with gaskets and galvanised nuts and bolts. The sluice
valves shall be in accordance with BSI BS 5163-1: 2004, latest edition.
Manufacturer's test certificates are required the nominal pressure shall be 10
bar.

6/18.2 Double spigot valves with bevelled edges are required unless otherwise
indicated. The outside diameters of the machined ends shall fit with the
specified pipes.

6/18.3 Valves greater than 300 mm dia shall be butterfly type valves.

6/18.4 The maximum tolerance shall be + 0.6 mm. It is preferred that the
manufacturer makes an allowance for the 300 microns epoxy coating during
machining.

6/18.5 Valves shall be grey cast iron, metal seated as per BSI BS EN ISO 1452-4:
2010. With a wedge of grey cast iron and gun metal rings, the stem shall be of
high tensile brass with a grey cast iron stem cap. Toraidal sealing rings are
required for stem sealing for all valves of 300 mm dia or less.

6/18.6 Valves up to and including 300 mm dia shall be clockwise closing without hand
wheel.

6/18.7 Where flanges are required they shall be drilled to PN 10 in accordance with
BS 4504 unless stated otherwise.

6/18.8 Additional markings on the valves shall be the year of manufacture and an
individual number which relates directly to the manufacturer's test certificate.

6/18.9 The valves shall be coated externally and internally to 300 microns with an
epoxy coating suitable for use with drinking water, the primer shall be zinc rich
and the preferred colour of the coating is blue.

6/18.10 A certificate verifying the suitability of the epoxy paint for use with drinking
water is required from the manufacturer endorsed by DEWA.

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 19 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/18.11 The manufacturer shall supply the original test certificate for each valve
supplied, the certificate shall relate to the individual number cast on each
valve, the certificate shall give the date of test.

6/19 WATER WORKS - MANHOLE COVERS AND FRAMES

6/19.1 The manhole covers and frames shall be in accordance with BS EN 124:
1994: AMD 8589: 1995

6/19.2 The frame shall be square with a circular clear opening of 600 mm diameter
and be single sealed.

6/19.3 The cover shall be badged "DEWA" in English and Arabic and also with the
DEWA logo. The pattern shall have the prior approval of the Dubai Electricity
and Water Authority.

6/19.4 Two keys shall be provided for every 10 Nos. of covers supplied.

6/19.5 The cover and frame shall be coated with suitable heavy duty abrasion
resistant epoxy paint to a minimum DFT of 375 microns and shall be verified
by DCL.

6/19.6 DEWA reserves the right to request a manufacturer's certificate certifying

compliance with the specification.

6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES

6/20.1 Prior to undertaking any work, the Contractor shall submit to the Engineer for
approval, his proposal for the handling and storage of pipes and all fittings
thereto. Such proposals shall ensure that all pipes are properly handled and
stored both by his staff and sub-contractors staff.

6/20.2 The storage surface should be as level and as firm as possible and clear of
rocks or solid objects that might damage the pipes. Stockpiles should not
exceed a certain height. This height is limited for safety and practical reasons
as per the following (Table 6-7):-

Table 6- 7: Stockpiles height (storage of pipes and all fittings)

DN 80-400 450-600 700-1000 1000-1400 > 1500

Layers in 5 4 3 2 1
Stockpile
Height <2m < 2.9 m < 3.0 m < 2.8 m < 2.0m

6/20.3 Asbestos cement coupling rings shall be stored lying flat and particular care
shall be taken to prevent damage to the internal face of the ring or the turned
ends of the pipes which may affect the sealing of the coupling.

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 20 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/20.4 Rubber sealer rings and gaskets shall be stored in a cool, dry dark place away
from grease, oil and sunlight until required.

6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES

6/21.1 The trench depth shall be according to the approved shop drawings but never
less than 1.0 m between the ground level and the pipe crown level.
6/21.2 The Contractor shall excavate trenches to a sufficient depth and width
according to the following (Table 6-8):-

Where B: is the width of the trench at the crown pipe level.

Table 6- 8: dimensions of the trenches for pipes

DN (mm) B MIN. (mm) MAX. (mm)

80 - 200 600 700
250 700 800
300 800 900
350 - 2000 DN+600 DN+1000

6/21.3 The side of trenches shall be adequately supported at all times. Trench sides
must be vertical and no battering will be allowed without the express
permission, in writing, of the Engineer.

6/21.4 The Contractor shall thoroughly compact the bottom of the trench formation,
the trench shall be cleaned of all stones, soil and other debris that might have
fallen therein.

6/21.5 Immediately following a prepared trench, pipes shall be laid and jointed on
specified pipe bedding material. Bricks or hard material shall not be placed
under the pipes for temporary support.

6/21.6 Prior to laying, each pipe and fittings shall be carefully examined both inside
and outside for any damage, and all dust, dirt and foreign matter shall be
removed.

6/21.7 For assembling, the Contractor shall adhere to the following conditions:-

PREPARATION OF THE REKA COUPLING

6/21.8 In order to avoid its damage the sealing rubber ring must be fitted into reka
coupling just before laying starts. Ensure that the groove of the rubber ring is
carefully cleaned, the ring is then fitted according to the following:-

a. Lay the coupling horizontally.

b. Fit the ring into the groove.

c. Check that the ring is uniformly and fully seated into the groove all the
way round.

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 21 SECTION 6 WORKS IN CONNECTION WITH SERVICES

d. For large diameter (600 mm and above) two men are necessary to insert
the ring.

MOUNTING THE COUPLING IN THE PIPE

6/21.9 Clean coupling and pipe with a soft brush and insert them fully. Lubricate the
pipe end and the coupling ring by means of a dry clean piece of cloth or a
sponge. For lubricant use Eternit supplied products soap. In dusty conditions
lubricate generously the coupling only.

6/21.10 For small diameter pipes (DN < 300) the coupling can be mounted by hand.
Use a timber block to protect the coupling and force the coupling into the
correct position as indicated by a black line on the pipe.

6/21.11 For larger diameters and where this method does not work the pulling can be
achieved by means of suitable mechanical devices. The gap between the
pipes (15 mm) is achieved automatically because the coupling stop at the level
of the strap fixed to each end of the pipe. N.B. It is essential to push the
coupling to the home line and not beyond, otherwise the pipes in the coupling
will touch each other and consequently not allow any expansion.

6/21.12 Maximum deflection angles for curved pipelines shall be according to the
following schedule (Table 6-9):-

Table 6- 9: values of maximum deflection angles for curved pipelines

DN O (mm) R (m)
L=3 m L=5 m L=3 m L=5 m
80-250 5 290 963 38.18 57.33
300-350 4 232 399 97.71 71.25
400-600 3 175 262 63.6 95.5
700-1200 2 117 175 95.4 143.25
1300 1 59 88 190.8 286.50
Where: R: Radius of Curvature
O : Offset
L : length of the pipe

BACKFILLING

6/21.13 The Contractor shall backfill the pipes as follows:

The backfilling material shall be brought up on both sides of the pipe first to
the level of the centre of the pipe line and then to height of 30 cm above the
top of the pipe barrel. This backfill material shall be placed in layers each not
more than 15 cm thickness and shall be carefully compacted for the full width
of the trench with hand tools to the satisfaction of the Engineer.

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 22 SECTION 6 WORKS IN CONNECTION WITH SERVICES

UNDER THE ROAD, PARKING AREAS AND FOOTPATHS

6/21.14 Backfill shall be in layers of thickness not exceeding 150 mm. Backfill shall
have a minimum soaked CBR of 15% (BS 1377 Part 4 : 1990 Method 7, AMD
13925: 2002) and compacted to not less than 95% of the maximum dry
density as determined by BS 1377 Part 4 : 1990 (method 3.5 or 3.6, AMD
13925: 2002). Backfill within 30 cm of road subgrade level shall meet the
requirements of improved subgrade described in Section 2 of the
Specification. Insitu density tests shall be carried out in accordance with BS
1377: Part 9 : 1990: Method 2.2, AMD 17229: 2007.

OUTSIDE THE ROAD

6/21.15 Backfill shall be in layers of thickness not exceeding 250 mm compacted

carefully to a minimum of 90% maximum Dry Density to the finished ground
level. Insitu density tests shall be carried out in accordance with BS 1377:
Part 9 : 1990: Method 2.2, AMD 17229: 2007.

6/21.16 In order to prevent stones and soil from entering the pipe, a suitable cap and
or plug shall be provided with which the last pipe laid shall be closed when
pipe laying is not actually in progress. The plug shall be of the screw up
expanding type or of tapered wood.

6/21.17 Where the cover to pipes is less than 1.0 m or where ordered by the Engineer,
protection in the form of concrete slabs above the pipe shall be provided
according to an approved drawing by DEWA.

6/22 WATER WORKS - PIPE ANCHOR AND THRUST BLOCKS

6/22.1 Pipe anchor and thrust blocks, shall be constructed on pipelines at all bends,
slopes greater than 1/6 and stop ends, tees and as otherwise required by site
conditions.

6/22.2 The thrust blocks shall be designed by the Contractor in accordance with BS
8110. The Structural Use of Concrete. The Contractor shall show that soil
resistance is greater than or equal to 1.2 times the force exerted by the pipe
when tested to 9 bar pressure. The soil resistance shall be calculated as the
frictional resistance of the soil against the thrust block. In calculating the
passive resistance the co-efficient of passive pressure of the soil shall be
factored by 0.5.

6/22.3 The design of thrust blocks shall not be less than the dimensions given on the
drawings. This design is always subject to DEWA approval.

6/22.4 Before any internal pressure is applied to a pipeline, all the permanent
concrete thrust blocks shall have been cast in contact with the undisturbed
ground and cured for a minimum of 7 days.

6/22.5 Concrete Class 30 with Sulphate Resisting Cement shall be used for the
construction of thrust blocks.

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 23 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/23 WATER WORKS - CLEANING OF PIPELINES

6/23.1 On completion of construction, and before any sterilisation, internal surfaces of

pipelines shall be cleaned thoroughly by flushing in such a way as to remove
all oil, grit and other deleterious matter.

6/23.2 Flushing of the new pipeline may be carried out by temporary connections to
the existing water system if present in the working area. DEWA will charge for
giving the water to the Contractor as per normal rates. In the absence of
mains water supply tankers shall be used.

6/24 WATER WORKS - TESTING PIPELINES

6/24.1 The Contractor shall provide written notice to the Engineer of any tests two
days before the test is to be carried out. All tests must be witnessed by the
Engineer. The Contractor shall maintain written records of the tests and
provide copies of the records to DEWA prior to the completion of the project.

6/24.2 The Contractor shall provide all, water, fittings, pipe stoppers, test pump,
pressure gauges and the necessary equipment and tools for pipe work testing.
Hydraulic pumps, gauges and apparatus shall be equipped with locking
devices to prevent tampering during the test period.

6/24.3 Prior to hydraulically testing the pipelines the Contractor shall provide
adequate temporary thrust blocks only at the ends of uncompleted sections.
Pipes shall be partially backfilled to about 500 mm above the crown of the
pipe, in order to anchor the pipes during testing. Joints and fittings, however,
shall remain uncovered for inspection until the pipeline has been tested
satisfactorily.

6/24.4 The length of the section of pipeline to be tested may be determined by the
Engineer/Contractor but shall not exceed 500 metres. The levels of the length
of pipe under test shall be such that the minimum test pressure specified is
achieved at all points whilst the maximum test pressure specified is not
exceeded at any point.

6/24.5 Valves shall not be used to isolate sections forming the pipeline whilst testing
operation are in progress.

6/24.6 Before testing the line should be filled slowly and evenly with water through
any convenient top or valve from the lowest point. At every high point an
automatic air release valve must be installed. After expelling all the entrapped
air out of the test portion, all air release valves should be closed. If it is not
possible to fill the line from the lowest point an additional outlet should be
added at the inlet point to release air at that point and this line/section should
be kept filled for 24 hours before the pressure test.

6/24.7 The test pressure shall be 1.5 times the maximum working pressure or 9 bar
whichever is greater. The pressure shall be raised slowly to the specified test
pressure and maintained at that pressure for a period long enough for the
Engineer to examine the whole section under test. There after, for a period of
not less than 4 hours, the leakage of water as measured by the amount drawn
into the pumps to maintain the pressure shall not exceed 0.1 litre per

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 24 SECTION 6 WORKS IN CONNECTION WITH SERVICES

millimetre of pipe diameter per kilometer of pipeline per 24 hours for each 30
meters head of pressure applied at the lowest point. Expected losses due to
absorption shall be as specified by the pipe manufacturer.

6/24.8 The pipework, joints and connections shall be examined. Should leaks be
detected the pipework shall be repaired to the satisfaction of the Engineer and
the test repeated.

6/25 WATER WORKS - FINAL CLEANING AND STERILISATION

6/25.1 Upon completion of hydraulic tests the Contractor shall flush out the pipework
with chlorinated fresh water and a cleaning swab will be passed through the
pipework, this process will continue until the flushing water runs clear.

6/25.2 The Contractor shall prepare a solution of chlorinated dosing solution using
calcium hydrochloride at a rate of 77g/cu.m. of system water volume, or with
chlorinated water containing between 30 and 50 mg per litre of free chlorine.
The solution shall be slowly pumped into pipeline and a chloride level of 50
p.p.m. shall be maintained for a period of 8 hours. The pipework shall be
flushed out, until the chloride level drops below 0.2 p.p.m. per litre.

6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE

6/26.1 All final connections of new pipelines to existing pipelines will be carried out by
the Dubai Electricity & Water Authority. The Contractor is to provide one week
of notice to DEWA for this work and shall render all necessary assistance.

6/27 WORKS FOR ETISALAT - GENERAL

6/27.1 GENERAL

The works relate to the protection and diversion of existing telephone duct
lines, for major trunk communications services alterations, including demolition
and rebuilding where instructed, to existing telephone manholes and joint
boxes and the provision of duct crossings for future development purposes.
The layout of the works for Etisalat are shown in the Drawings.

6/27.2 Where applicable, all civil works essential to the relocation/replacement of the
existing major coaxial cable systems including duct installation, manhole and
joint box construction shall be carried out by the Contractor within the
stipulated Contract period for sectional completion.

6/27.3 Where applicable, the installation of new Etisalat cables shall be carried out by
Etisalat within the time stipulated in the Contract.

6/27.4 Civil works for Etisalat other than the above shall be carried out by the
Contractor according to his approved programme.

DUCTS

6/27.5 The installation of ducts of the required diameter shall be in accordance with
Etisalat Specifications as per Sub-Section 6/29.

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 25 SECTION 6 WORKS IN CONNECTION WITH SERVICES

MANHOLES AND JOINT BOXES

6/27.6 The existing manholes to be demolished and rebuilt and the new manholes to
be constructed, if shown on the Drawings, are for information purposes only
and do not necessarily show the exact locations thereof. Exact details and
locations of these manholes will be determined on site in accordance with the
Etisalat Engineer's instructions.

6/27.7 The construction of new manholes shall be performed in accordance with the
Drawings.

6/27.8 Manholes shall be as per types shown on the Drawings or as required by

Etisalat. The concrete mix shall be Class 30 according to the requirements of
Section 4 of this Specification.

6/28 MATERIAL SUPPLIED BY ETISALAT

6/28.1 PVC pipes, draw cord, manhole frames and covers, and all other fixtures and
fittings will be furnished by Etisalat. The Contractor shall make the necessary
arrangements for providing labour and all equipment for loading at the Etisalat
Stores, for transporting to site, unloading, storing and fixing in position the
above mentioned material. The Contractor's responsibility for material
furnished by Etisalat shall begin upon the Contractor's acceptance at the place
of delivery. All such materials can be examined and tested by the Contractor,
and all defective material shall be rejected by him at the time and place of
delivery.

6/28.2 All material found to be defective or damaged at this time will be replaced by
Etisalat. Once accepted by the Contractor at the place of delivery, he has no
right for any claim. All defective or damaged material discovered prior to final
acceptance of the work shall be removed by the Contractor and replaced by
new approved material at his own expense.

6/28.3 In that event, the Contractor shall be responsible for the safe storage of all
material furnished to or by him, accepted by him until it has been incorporated
in the Works and finally accepted by the Employer. Any material lost or stolen
from the site shall be replaced by the Contractor at his own expense.

6/29 INSTALLATION OF PVC DUCT-(DUCT NO. 54D) AS SUPPLIED BY ETISALAT

6/29.1 GENERAL. Duct No. 54D is manufactured from PVC. It is supplied in 6.0
metre effective lengths, has an internal diameter of 90mm and a nominal wall
thickness of 3.25 mm. Each duct length has a tapered socket at one end
which will accept the barrel of the duct. Couplings, Ducts 54A, 300 mm in
length are also available for use with short lengths of duct which have no
socket. Couplings Duct, 54A shall not be used for duct leading into buildings.

6/29.2 TRENCH. The trench shall be excavated to the required width and depth; the
trench bottom shall be free from stones, level and well tamped. The duct shall
be laid at standard depths unless otherwise specified.

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 26 SECTION 6 WORKS IN CONNECTION WITH SERVICES

6/29.3 FORMATIONS. Duct No. 54D may be laid as a single duct or in multiway
formation as follows:

(a) Up to and including 9 ways in rectangular formation.

(b) Over 9 ways rectangular formation with concrete surround.

(c) The duct bank must be properly secured to the ground before concreting
to avoid displacement due to flotation.

LAYING AND JOINTING

a) For Singleway

6/29.4 The open starting end of the trench shall be blanked off with a board or
boards, to act as an anvil against which the duct can be driven home. The
duct shall be recessed into the wall of jointing chambers 10 mm from the
inside surface. The surface of the duct shall be roughened with glass paper or
sand paper for its length in the jointing chamber wall.

6/29.5 The duct shall be laid on the trench bottom with the socket towards the duct
layer; the spigot end and the inside of the socket of the duct to be jointed shall
be thoroughly cleaned with dry rag.

6/29.6 The spigot end of the duct shall be offered to the socket initially pushed in by
hand and then to achieve proper engagement a suitable wooden batten is
placed across the remote socket and tapped with a hammer. Full engagement
should be ensured. Occasionally, due to variations in size, this cannot be
achieved, in which case, excessive force must not be exerted after a tight joint
has been effected.

6/29.7 When jointing short lengths of duct together with a Coupling, Duct No. 54A,
both spigot ends and the inside of the Coupling shall be thoroughly cleaned
with methylated spirits applied with a clean rag. The spigot ends should be
given a liberal coating of PVC Cement and then fitted into the coupling. This
operation involves using toxic and inflammable materials.

b) For Multiway Up to and Including 9 Ways

6/29.8 The preparatory work and jointing shall be as for singleway.

6/29.9 The first layer of ducts shall be laid on the prepared trench bottom so that their
outer surfaces touch each other and a minimum gap of 75mm remains
between the outside ducts and the sides of the trench timbering where used.
Wooden stakes or an approved alternative shall be driven into the ground at 3
metre intervals along the trench to keep the ducts in the correct position.
Suitable material shall be placed to fill the spaces between the ducts and the
next layer of duct when the latter is bedded down. The second and
subsequent layers of duct shall be laid between the wooden stakes so that
they are vertically above and then bedded down to touch the ducts in the layer
below, the spaces between the ducts being filled in the same way with suitable

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 27 SECTION 6 WORKS IN CONNECTION WITH SERVICES

fill material. The joints shall be staggered so that no joint touches any other
joint.

6/29.10 At approximately 5 metres from the jointing chamber at each end of the track,
the duct formation shall open to provide a gap between each duct, both
vertically and horizontally, of 25mm using, spacers. Over this 5 metres section
all spaces between the duct and the trench wall shall be filled with well
compacted fill.
c) For Multiway ducts over 9 ways

6/29.11 The preparatory work and jointing shall be as for single-way duct.

6/29.12 The first layer of duct shall be laid on the prepared trench bottom so that their
outer surfaces touch each other and a minimum gap of 75mm remains
between the outside ducts and the sides of the trench, or trench timbering
where used. Mild steel bars, 12 mm diameter and of the required length shall
be driven into the ground at 1.5 metre intervals along the trench to keep the
ducts in the correct position. The second and subsequent layer of duct shall
be laid between the mild steel bars so that they are vertically above and
touching the ducts in the layer below. The joints shall be staggered so that no
joint touches any other joint. On completion of the assembly of the duct nest,
6 mm diameter mild steel bars shall be placed horizontally across the
uppermost layer of ducts and tied to the vertical bars.

6/29.13 Where the total number of layers of duct in any one formation exceeds 8 and
the number of ducts in each layer exceeds 2 the following shall apply.
Between the two layers of duct midway, or approximately midway, from the top
and bottom of the duct nest an intermediate layer of reinforced concrete, 75
mm in depth and with 12 mm mild steel reinforcing bars conforming to the
layout of reinforcing in the top cover detailed on the Drawings shall be placed
across the duct nest. The additional reinforcing required by this
sub-paragraph shall not be required in the 5 metre sections detailed in
sub-paragraph 14 below.

6/29.14 At approximately 5 metres from the jointing chambers at each end of the track
the duct formation shall open out to provide a gap between each duct, both
vertically and horizontally of 25 mm. Banks of spacers shall be placed 325
mm and 1325 mm from the jointing chamber wall to provide this spacing.
Each spacer bank shall enclose all the ducts except those in the bottom layer
on which the spacer bank shall rest. Where sub-paragraph 13 applies, the 75
mm intermediate layer shall be reduced over 5 metre sections to provide the
required 25 mm spacing at the jointing chambers.

6/29.15 Where the total number of layers of duct exceeds three, concreting of spaced
formations shall be in stages such that the number of layers of duct laid and
concreted at each stage shall not exceed three. The concrete shall be brought
to a level which shall not interfere with laying of subsequent layers of ducts
and spacers.

6/29.16 Concrete class and workability as specified by Etisalat and approved by the
Engineer shall be used throughout. The concrete shall be evenly placed
around the duct to give a finished minimum thickness of 75 mm on both sides
and to a depth of 130 mm above the top layer of ducts. Care must be taken to

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 28 SECTION 6 WORKS IN CONNECTION WITH SERVICES

ensure that each batch, as it is placed, is properly compacted without creating

unbalanced side thrust against the ducts. Each batch shall be vibrated using a
vibrator having a maximum diameter of 51 mm, the vibrator shall be lowered
into the concrete between the wall of the trench and the outside of the duct
nest and shall not touch the duct. In spaced formation sections care must be
taken to ensure that the gaps between the ducts are properly filled with
concrete, the final layer of concrete shall be thoroughly trowelled.

6/29.17 With formations of four or more ducts wide, mild steel reinforcing bars
conforming to the Drawings shall be placed and wired in position before
placing concrete over the uppermost ducts of the completed nest.

6/29.18 In the case of column entry manholes, the duct formation shall open out to
enter the manhole as shown on the appropriate manhole drawing and at right
angles to the entry wall. The distance over which the transformation is made
shall be no greater than is necessary to satisfy the 5 metres minimum bedding
radius for duct No. 54D. The ducts shall be secured in position during
concreting with spacers, built up to the required centres or by reinforcing rods
which may be encased in the concrete. The volume between the separated
duct formations shall be excavated and filled with concrete of the same quality
as that surrounding the duct formations.

ALTERNATIVE METHOD OF JOINTING AND LAYING

6/29.19 Provided that space permits, duct No. 54D may be jointed above ground and
fed into the trench from one end. The leading end of each duct way being
guided into position using a suitable hooked tool made from 6 mm diameter
mild steel reinforcing bar.

6/29.20 BENDS. Normally bends are not supplied since the duct is sufficiently flexible
to provide a minimum bending radius of 5 metres. Tighter bends should not
be attempted otherwise kinking of the duct may result.

6/29.21 VARIATIONS. Any variation of duct formation and/or depth shall only be
carried out with the prior agreement of the Engineer or Etisalat Civil Works
Supervisor.

6/29.22 BACKFILL. (a) Backfilling of trenches where duct No. 54D has been laid
without concrete surround shall be carried out carefully in a manner that shall
not disturb the duct formation. Where duct No. 54D has been laid with
concrete surround the end shuttering and trench supporting timber, if used,
shall be removed not less than 12 hours after the concrete has been placed.
Backfilling of the trench, in accordance with the Specifications shall not be
carried out until a further 48 hours have elapsed.

6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPARTMENT (DMD)

6/30.1 All drainage and sewerage to be performed under this contract shall follow the
specifications given in Volume 2 – Part III and IV – Dubai Sewerage and
Drainage Master Plan standard specification. For all other works the
contractor shall refer to the applicable specifications as given in Volume 2 Part
I and II.

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 Section 7
Roadway Lighting
 1 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

TABLE OF CONTENT

7A/ ROAD LIGHTING ............................................................................................................ 3

7B/ TUNNEL AND UNDERPASS LIGHTING ...................................................................... 33
7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS.......................................................... 57

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 2 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

TABLE OF CONTENT

7A/ ROAD LIGHTING ............................................................................................................ 3

7A/1 SCOPE ..................................................................................................................... 3
7A/2 ELECTRICITY SUPPLY........................................................................................... 3
7A/3 REGULATIONS AND STANDARDS ....................................................................... 4
7A/4 CLIMATE .................................................................................................................. 7
7A/5 GENERAL ................................................................................................................ 8
7A/6 CONTRACTOR’S DRAWINGS AND DOCUMENTATION ..................................... 9
7A/7 INSPECTION, TESTING AND COMMISIONING .................................................. 10
7A/8 EARTHING ............................................................................................................. 12
7A/9 SWITCHBOARDS AND SWITCHGEAR ............................................................... 13
7A/10 CABLING ................................................................................................................ 18
7A/11 LUMINAIRES ......................................................................................................... 23
7A/12 LIGHT POLES ........................................................................................................ 25

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 3 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/ ROAD LIGHTING

7A/1 SCOPE

7A/1.1 The Works include the supply and installation of:

 Traffic management
 Cabling with conduiting and warning tape from DEWA
substation to switchboards
 Duct crossings for service cables
 Civil works of the roadway lighting system (except as otherwise
specified)
 Switchboards including feeder pillars
 Earthing
 Cabling with conduiting and warning tape from switchboards to
luminaires
 Light poles including service cut-outs and foundations with
holding down bolts, nuts and washers
 Luminaires with lamps and lamp control gear
 Road sign illumination
 Under-bridge lighting
 Pedestrian pathway lighting
 Underpass lighting
 Navigation lighting
 Façade lighting
 Tunnel lighting
 Interior lighting of switch rooms, etc.
 Inspection, testing and commissioning
 Manuals and “Record” Drawings
 Maintenance during the Defects Liability Period
 Sundries that is all minor and incidental work and materials,
specified or unspecified, which are required for proper
completion of the works to the true intent and meaning of the
Specification and to the satisfaction of the Engineer.

7A/1.2 Works excluded:

Dubai Electricity and Water Authority will install any new sub-stations required for
the system
The Lighting and Traffic Systems maintenance Section will be responsible for the
maintenance of above ground services.

7A/2 ELECTRICITY SUPPLY

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 4 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/2.1 MAIN POWER SUPPLY:

The Contractor shall contact the supply authority at an early stage of the Contract
to make all the necessary arrangements for the power supply.
The power supply for the light poles will be from new and/or from existing feeder
pillars located as shown on the Drawings. Power supply to new feeder pillars shall
be from new or existing DEWA substations as shown on the drawings.

7A/2.2 CHARACTERISTICS:

Arrangement 3 phase 4 wire

Nominal Voltage 415/240 V +/- 10%
Nominal Frequency 50 Hz +/- 5%

7A/3 REGULATIONS AND STANDARDS

7A/3.1 REGULATIONS

All equipment and workmanship shall comply with the most recent
requirements of:
 BS 7671 Requirements for Electrical Installations, IEE Wiring Regulations
 Occupational Health and Safety Act
 Dubai Electricity and Water Authority’s Safety Manual
 United Arab Emirates Electricity and Water Regulations and Guide
 Requirements of the local electricity supply authority

7A/3.2 STANDARDS

CIE
CIE S 016 Lighting of Work places
CIE 23 International recommendations for motorway lighting
CIE 27 Photometry of luminaires for street lighting
CIE 31 Glare and uniformity in road lighting installations
CIE 32 Lighting in situations requiring special treatment (in road lighting)
CIE 34 Road light luminaire and installation data: photometric,
classification and performance
CIE 37 Exterior lighting in the environment
CIE 66 Road surfaces and lighting
CIE 68 Guide to the Lighting of exterior working areas
CIE 77 Electric light sources
CIE Guide to the lighting of road tunnels and underpasses
88:2004
CIE 100 Fundamentals of the visual task of night driving
CIE 115 Recommendations for the lighting of roads for motor and
pedestrian traffic
CIE 122 Design methods for lighting of roads
CIE 126 Guide to the lighting of urban areas
CIE 140 Road lighting calculations
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 5 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

CIE 180 Road transport lighting for developing countries

CIE S008 Lighting of indoor work places

IEC

CISPR 15 Limits and methods of measurement of radio disturbance

characteristics of electric lighting and similar equipment.
60050-845 International electrotechnical vocabulary
60061 Lamp caps and holders together with gauges for control of
interchangeability and safety
60068 Environmental testing.
60073 Colours of indicating lights and push buttons
60188 High pressure mercury vapour lamps – performance specifications
60192 Low pressure sodium vapour lamps
60238 Edison screw lampholders
60364 Electrical installations in buildings
60439 Low voltage switchgear and control gear assemblies
60502-1 Power cables with extruded insulation and their accessories for
rated voltages from 1kV up to 30kV Part 1: Cables for rated
voltages of 1kV and 3kV.
60529 Degrees of protection provided by enclosures (IP Code).
60598 Luminaires
60898 Specification for circuit breakers for overcurrent protection for
household and similar installations
60923 Auxiliaries for lamps – ballasts for discharge lamps excluding
tubular fluorescent lamps) – Performance requirements
60927 Auxiliaries for lamps – starting devices(excluding tubular
fluorescent lamps) – Performance requirements
60947 Low voltage switchgear and control gear, general rules
60662 High pressure sodium vapour lamps
61000 EMC limits
61008 Residual current operated circuit breakers without integral
overcurrent protection for household and similar use
61009 Residual current operated circuit breakers with integral overcurrent
protection for household and similar use
61048 Auxiliaries for lamps. Capacitors for use in tubular fluorescent and
other discharge lamp circuits. General and safety requirements.
61439 Low voltage switchgear and control gear assemblies
61167 Metal halide lamps – Performance requirements
61247 Lamp control gear
61547 Equipment for general lighting purposes –EMC immunity
requirements
61643 Low-voltage surge protective devices
62035 Discharge lamp[s (excluding tubular fluorescent lamps)

ILE

TR 12 Lighting of pedestrian crossings

TR 23 Lighting of cycle tracks
TR 25 Lighting For traffic calming schemes

BS & EN

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 6 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

40 Lighting columns
88 Low voltage fuses
145 Specification for chromium-nickel-copper-molybdenum corrosion
resistant steel (precipitation hardening/billets, bars, forging, and
parts(1270 MPa to 1470 MPa)
485 Aluminium and aluminium alloys. Sheet, strip and plate.
10257-1 Zinc or zinc alloy coated non-alloy steel wire armouring for either
power cables or telecommunication cables... Land cables.
12373 Aluminium and aluminium alloys. Anodizing. Method for specifying
decorative and protective coatings on aluminium.
1261 Specification for cartridge fuses for a.c. circuits in domestic and
similar premises.
1263 13 A plugs, socket outlets, adaptors and connection units.
1461 Hot dip galvanized coatings on fabricated iron and steel articles
1990 Eurocode. Basis of structural design.
1991-1.4 Eurocode 1 Actions on structures. General actions. Wind actions.
1993.1 Eurocode 3. Design of steel structures. Towers, masts and
chimneys. Towers and masts.
3036 Specification. Semi-enclosed electric fuses (ratings up to 100
Amperes and 240 Volts to earth)
4727 Glossary of electrotechnical, power, telecommunication,
electronics, lighting and colour terms.
4607 Non-metallic conduits and fittings for electrical installations
5467 Electric cables. Thermosetting insulated armoured cables for
voltages of 600/1000 V and 1900/3300 V.
5489 Code of Practice for the design of road lighting
6004 Electric cables. PVC insulated non-armoured cables for voltages
up to and including 450/750 V for electric power, lighting and
internal wiring.
6007 Electric cables. Single core unsheathed heat resisting cables for
voltages up to and including 450/750 V, for internal wiring.
6121 Mechanical cable glands. Code of Practice for selection,
installation and inspection of cable glands and armour glands
60598 Luminaires
6231 Electric cables. Single core PVC insulated flexible cables of rated
voltage 600/1000 V for switchgear and controlgear wiring.
6234 Specification for polyethylene insulation and sheathing of electric
cables.
6346 Electric cables. PVC insulated armoured cables for voltages of
600/1000 V and 1900/3300 V.
6469 Insulating and sheathing materials of electric cables.
6500 Electric cables. Flexible cords rated up to 300/500 V for use with
appliances and equipment intended for domestic, office and similar
environments.
6910.2 Cold pour resin compound and heat shrink cable joints in the
voltage range up to 1000 V a.c. and 1500 V d.c. Code of Practice
for on-site installation.
7430 Code of Practice for earthing
7654 Specification for single-phase street lighting fuses (cut-outs) for
low-voltage public lighting electricity distribution systems. 25 A
rating for highway power supplies and street furniture.
7668 Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels. Specification
7889 Electric cables. Thermosetting insulated unarmoured cables for
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 7 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

voltage of 600.1000 V.
7919 Electric cables. Flexible cables rated up to 450/750 V for use with
appliances and equipment intended for industrial and similar
environments.
7933 Electric cables. Accessories.
9692 Welding and allied processes
1001 Durability of wood and wood based products. Terminology.
1011 Welding. Recommendations for welding of metallic materials
10020 Definition and classification of grades of steel
10025 Hot rolled products of structural steels.
10257 Zinc or zinc alloy coated steel wire for cables armouring either
power cables or telecommunications cables.
12032 Photometric data for luminaires
12373 Aluminium and aluminium alloys. Anodizing. Method for specifying
decorative and protective coatings on aluminium.
13201 Road lighting
13032 Light and lighting. Measurement and presentation of photometric
data of lamps and luminaires.
15614 Specification and qualification of welding procedures for metallic
materials.
50086 Specification for conduit systems for cable management
55011 Industrial, scientific and medical (ISM) radio-frequency equipment.
Electromagnetic disturbance characteristics. Limits and methods of
measurement
60155 Specification for starters for fluorescent lamps
60228 Conductors of insulated cables.

7A/4 CLIMATE

7A/4.1 SUITABILITY
All equipment and material shall be suitable for long term operation in Dubai.

7A/4.2 CONDITIONS
The average prevailing local conditions at Dubai City shall be assumed as follows:
Max. Ambient Temperature 550 C
Min. Ambient Temperature 10 C
Design Ambient Temperature, 500.C
incident light intensity (energy) 780 m/W/cm2
Light intensity (measured under the sun approximately 100,000 Lux
Max. metal temperature under sun 850 C
Min. Barometric Pressure 998 mbar
Max. Barometric Pressure 1030 mbar
Average Barometric Pressure 1015 mbar
Ambient Humidity 100%
Min. Ambient Humidity 20%
Design Ambient Humidity 80%
Max. Design Wind Velocity 160 km/h.
Wind gust factor 1.3
Average Yearly Rainfall 80 to 150mm

The climate of Dubai is relatively mild from November to April, and hot from May to
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 8 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

October with high relative humidity.

Distribution of rainfall is irregular, and the precipitation amounts are normally of no
significance, but attention should be paid to the fact that sudden heavy rainfalls in
a very short period of time can occur.
The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr. and sandstorms and dust
storms occur in the summer months

7A/4.3 RATINGS

In calculating the rating of electrical cables, switch-gear and all items of equipment,
the necessary derating factors shall be determined and applied to ensure that the
equipment will operate satisfactorily and meet its design criteria.

7A/4.4 CORROSION
Particular attention should be paid to the prevailing corrosion conditions. Materials
and equipment shall be suitable for use under the prevailing conditions of a harsh
marine environment.
A considerable amount of salt is contained in the atmosphere which together with
the extremely high ambient humidity can produce severe corrosion problems.
Under certain combinations of the climatic conditions considerable condensation
may take place.

7A/5 GENERAL

7A/5.1 OPERATIONAL LIFE

The road lighting system, apart from consumable items such as lamps, shall have
an economic operational life of at least twenty years.

7A/5.2 WARRANTIES

The following minimum warranty periods shall apply:

 Cables - 10 years
 Luminaires - 5 years (with the exception of lamps)
 Pole galvanizing – 10 years
 Poles - 15 years
 Switchboards and kiosks - 10 years
 Labelling – 10 years
 PLC and dimming control systems – 10 years
 Batteries - 5 years
 Cable ladders and trays - 15 years

7A/5.3 EXISTING ROAD LIGHTING SERVICES

Street lighting services which fall within the site of the works which are damaged

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 9 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

by the Contractor shall be repaired and rectified by the Contractor within 24 hours.
Failure to repair any underground fault within 24 hours can result in fines being
applied in accordance with Local Order No.84/93. The Contractor shall be
responsible for obtaining road closure permission where applicable and to provide
necessary material and manpower.

7A/5.4 CHECK OF EQUIPMENT SUPPLIED BY OTHERS

The Contractor shall ensure that any materials and equipment supplied by others
forming part of his installation shall be new and in accordance with the standards
required. Any defect must be reported in writing within seven days of receipt of the
equipment in order to allow changes to be made or replacements instructed by the
Engineer.

7A/5.5 LAYOUT
Survey and peg, or mark, the locations and routes of electrical equipment. While
the locations and routes are shown on drawings, the Contractor shall coordinate
with other services, liaise with the Roads and Transport Authority Street Lighting
Section Engineer and coordinate activities with the Dubai Electricity and Water
Authority.
The Contractor shall confirm the locations and routes on shop drawings and submit
the shop drawings to the Engineer for review prior to commencement of
construction.

7A/5.6 EXTENSION OF EXISTING DUCTS

Where roads are widened or will cover existing cables, extend existing cable ducts
clear of such roads

7A/5.7 FINAL LEVELS

Where levels will change, raise or lower existing light poles and switchboards, with
foundations, to suit the final levels.
Where there are existing cables and the depth of burial is rendered inadequate by
level changes, excavate and relay the cables to achieve adequate cover.

7A/5.8 SAFETY MEASURES

While working on road lighting services maintain the switchboard’s main switch in
the OFF position. Fit a safety tag inside the switchboard to warn against
energization by others.

7A/6 CONTRACTOR’S DRAWINGS AND DOCUMENTATION

7A/6.1 SHOP DRAWINGS

The contractor shall design and prepare shop drawings of equipment, layouts,
specialised components, switchboards, cut-outs, light poles, and pole foundations.
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 10 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Switchboard drawings shall include: equipment schedules with dimensions,

ratings, and manufacturer names and reference; and wire and terminal numbers.
Switchboard drawings shall include labelling schedules with wording, colour and
fixing information, dimensions, opening locations, gland plate and cable entries,
door hinges, ventilation design, louvres, and single line diagram.
Pole shop drawings shall include the anchor bolts and reinforcing mesh cage,
outreach arms and mounting brackets and their fixings, and shall be accompanied
with the following data:

 Material specifications,
 Design calculations assuming a wind design velocity of 160 km/h and stating
the mass and windage of the luminaires. Calculations shall include
deflection.
 Deflection at pole top at 160 km/h,
 Impact resistance at 1 m height to shear the flange from the pole
 A Certificate of Structural Adequacy for each type of pole.
 Any deviations from this specification,
 Concrete foundation drawings and calculations, and
 Assembly instructions. Submit shop drawings to the Engineer for review.

7A/6.2 RECORD DRAWINGS

Maintain a complete set of current drawings, with shop drawings, on the site and
mark any changes as works proceed to record the “as-constructed” status of the
works.
Ensure Record Drawings show the final location of equipment, cabling, conduits,
boxes, pits, switchboards, outlets, switches, etc., and any other information which
will assist in future maintenance, and alterations.
Submit the Record Drawings as AutoCAD .dwg files, or Microstation.dgn files, with
a set of paper prints, including shop drawings, to the Engineer for review.
Amend the Record Drawings after review by the Engineer.
Provide bond paper prints of the Record Drawings in each switchboard.

7A/6.3 TUITION AND MANUALS

Provide tuition to the Roads & Transport Authority Street Lighting Section in
operation and maintenance of all components.
Prepare and deliver a tuition program including:
 Course outline
 Course schedule with elements and element durations
 Course notes for each trainee (at least five trainees will participate)
Provide a training room and follow training room tuition with site demonstrations of
operations and maintenance procedures with simple instruction sheets.
Provide three copies of an Operations and Maintenance Manual. Submit a draft
copy to the Engineer for review.

7A/7 INSPECTION, TESTING AND COMMISIONING

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 11 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/7.1 STANDARDS
Test in accordance with BS 7671 Requirements for Electrical Installations, IEE
Wiring Regulations

7A/7.2 FACTORY ACCEPTANCE TESTING

Prepare test schedules and test record forms and submit to the Engineer before
testing.
Factory acceptance testing shall comprise testing by accredited test laboratories.
Test sheets shall be submitted to the Engineer for review before delivery.
For switchboards test in accordance with IEC 64319, including ingress protection.
For cables test in accordance with the relevant standard, including: insulation;
moisture resistance; and fire and smoke performance
For conduit and associated enclosures test in accordance with BS 4607
For luminaires test in accordance with IEC 60598, including: ingress protection;
impact resistance; thermal performance; photometric performance; and electro-
magnetic compliance
For poles and associated components, test to BS 40 (Lighting columns) and to BS
1461(hot dip galvanizing).
Submit completed test records to the Engineer for review.

7A/7.3 SITE ACCEPTANCE TESTING

Prepare test schedules and test record forms and submit to the Engineer before
testing.
Provide test apparatus and test as follows:

 Polarity
 Phase rotation.
 Load balancing of phases.
 Verification of phase, neutral and earth identifications.
 Verification of labelling, and wire & terminal numbering.
 Continuity.
 Earth loop impedance.
 Earth bonds.
 Insulation (Phase-phase; phase-neutral; phase-earth; neutral-earth with a
1000 V insulation tester). Insulation shall exceed 8 megohm per metre
cable length
 Effectiveness of individual earth electrodes. The resistance of any point in
the earth continuity system of the installation to the main earth electrode
shall not exceed 1 ohm, and the resistance to earth at the termination shall
not exceed 0.5 ohm.
 Checking of voltages at transformer, switchboards and each HID luminaire
and setting of appropriate tappings on control gear.
 Checking of RCD's.

Submit the manufacturer’s name and model of proposed test apparatus with
calibration certificates to the Engineer for review.
After cable installation, but before erection of poles, test the cabling.
Submit completed test records to the Engineer for review.

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 12 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/7.4 COMMISIONING

 Test each circuit of each switchboard before connecting electricity supply

 Verify the operation of control circuits and change over switchgear.
 Record and submit test results on printed test sheets.
 Advise of all inspections and tests in time to allow witnessing of such
inspections and tests
 Arrange for any inspection and test by the Dubai Electricity and Water
Authority and assist the Network Operator Inspector by providing access
tools, instruments and attendance
 Inspect the switchboards before they leave the manufacturer's works and
check suitability for application and compliance with specification
 Submit signed test sheets to the Engineer. These sheets shall be printed
and include the manufacturer’s name and model of the test apparatus and
the calibration certificate.

7A/7.5 LIGHTING VALIDATION TESTS

 After 100 hours of operation, replace any faulty components and conduct
lighting measurements in accordance with EN 13201-4 Road Lighting – Part
4: Methods of measuring the light performance of installations

7A/8 EARTHING

7A/8.1 SYSTEM

Comply with BS 60364, BS 7430, and the requirements of the Dubai Electricity &
Water Authority and the UAE Electricity and Water Regulations. Where the
requirements of the UAE Electricity and Water Regulations and Guide differ from
those of the British Standards, the former shall prevail.
The Contractor shall install an earthing system for the full length of each circuit. All
metallic parts of all equipment, other than current carrying conductors, shall be
bonded to form a continuous path by way earth conductors, and / or cable
armouring. The earthing conductors shall have a minimum current carrying
capacity in accordance with BS 60364 and BS 7430. All earth electrodes, earth
cables and earthing leads shall be of copper.

7A/8.2 EARTH ELECTRODES

Earth electrodes shall consist of 16 mm minimum diameter hard drawn copper rod
complete with hardened steel tip and driving cap. Rods shall be capable of being
extended in lengths, as necessary, by the provision of permanent screw
mechanisms. Owing to the highly corrosive nature of the sub-soil at certain
locations the Dubai Electricity and Water Authority shall be consulted regarding the
metal to be used for the earth termination.
Earth electrodes shall be driven vertically to a depth such that it penetrates the
summer water table by minimum of 2 metres and to a minimum depth of 3.0 m.
Provide an earth pit, approximately 300 mm x 300 mm x 300 mm, at each earth
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 13 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

electrode. After installation, fill the pit with sand and install a removable pit lid.
Earth electrode distance should not exceed 5 metres out of centre of foundation of
last pole, and at an agreed location adjacent to each switchboard.

7A/8.3 EARTH LEADS

Connect the earth electrode to the earth stud in the switchboard or light pole with a
70 mm2 copper conductor PVC insulated earth cable. Connect the cable to the
earth electrode with an earthing clamp. After testing wrap in petrolatum
impregnated tape

7A/9 SWITCHBOARDS AND SWITCHGEAR

7A/9.1 FEEDER PILLARS

7A/9.1.1 General

Feeder Pillars shall consist of a single compartment cabinet with one door opening.
All panels shall be suitable for permanent outdoor installation for the control of road
way lighting.
Double door feeder pillars shall measure 1400mm wide, 1300mm high and 300mm
deep.
Feeder pillars shall be of Rittal, or approved alternative, manufacture, rated at 63A,
100A, 160A, 185A, 200A, or as requested by DEWA and shown on approved load
schedules and drawings with IEC class gL/gG fuses.
On each Feeder Pillar, provide two single phase 40 A M.C.B.’s complying with IEC
60947 connected to the outgoing side of the kWh meter for feeding a traffic control
panel.)
For each Feeder Pillar of less than 210A rating, provide 3-phase direct metering.
Construct the Feeder Pillar to facilitate the installation of a 3-phase kWh direct
reading meter. The Dubai Electricity and Water Authority will supply each kWh
meter. Install the meter complete with meter fuses and all connections.
For each Feeder Pillar of 210A rating or above, provide 3-phase current
transformer metering. Supply and install the current transformer metering
complete with current transformers, current transformer links, meter and all
connections. Submit the meter and current transformers to the Dubai Electricity &
Water Authority for review and calibration. Submit a signed Dubai Electricity &
Water Authority test report to the Engineer.
Provide an insulating panel for the kWh Meter.
Provide a document pocket in the Feeder Pillar and insert the Record drawing and
the Dubai Electricity & Water Authority test report. The pocket shall be of marine
grade aluminium welded to the door.
Provide a name plate of marine grade aluminium painted red at least 150 m high
and 300 mm wide 2.5 mm thick, engraved with black paint filled lettering. The
lettering shall read:

“ROADS AND TRANSPORT AUTHORITY

LIGHTING PANEL **** ”

The labelling shall be in English and Arabic with the first row in 50 mm and the

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 14 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

second row in 25 mm high lettering. Secure the label to the door with at least four
4 mm rivets.

7A/9.1.2 Construction

Construction shall be totally enclosed, metal clad, dead front, air insulated, Form 1
of IEC 61439.
Construct the enclosure of marine grade aluminium of minimum thickness of 3 mm
with ingress protection to IP55 of IEC 60529. Provide a channel base frame hot
dip galvanized to BS 1461 with an insulating film between the aluminium and steel.
Secure the base frame to the concrete foundation with six M10 stainless steel
anchor bolts. Provide a stainless steel cover behind the feeder pillar to cover the
cabling, 3 mm thick for 750 mm feeder pillars and 5 mm thick for 1400 mm feeder
pillars.
Provide a sloped sun and rain canopy of marine grade aluminium. The canopy
shall extend 150 mm beyond the footprint of the Feeder Pillar and shall be spaced
150 mm from the top of the Feeder Pillar.
Provide at least four louvres to give diagonal ventilation. The louvres shall have
ingress protection of IP 55 to IEC 60529.
Provide a 10 mm thick Marguard meter reading window opposite the kWh meter.
Provide three stainless steel (Grade AISI 316) lift off pintle hinges per door.
Provide two flush stainless steel locks with a three point latching system. Door
opening shall be 1800 and shall be restrained with a door stay. Doors shall be
equipped with silicone rubber gaskets capable of withstanding the ambient
temperatures for at least ten years. All hinges and locks are to be easily
removable and replaceable.
Coat the enclosure with an epoxy/polyester powder coat, colour beige (RAL 7032).
Provide a fluorescent luminaire at the top of the Feeder Pillar inside the door
operated by a door switch. The luminaire shall have an acrylic diffuser.
Provide a removable gland plate of maximum 1 mm thickness at the base of the
enclosure for compression type brass glands with earth tags. Cable entry shall be
through the base. Provide six factory punched cable entries to suit the cable
number and sizes. Provide at least six cable entries. Any spare entries shall be
sealed.

7A/9.1.3 Dimensions

For small Feeder Pillars, the dimensions shall be::

 Height : 1000 mm (without canopy)
 Width : 750 mm
 Depth : 250 mm
For large Feeder Pillars, the dimensions shall be:
 Height : 1000mm (without canopy)
 Width : 1400mm

7A/9.1.4 Depth : 250mmDepth : 250mm Earthing

Provide a tin plated copper earth bar at least 40 mm x 4 mm shall be solidly bolted
with stainless steel (AISI 316) bolts to the enclosure. Bond the earth bar to the
earth electrode. Bond the enclosure door to the enclosure with 4 mm 2 copper
braid. Bond all circuits to the earth bar.

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 15 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/9.1.5 Contactors

Contactors shall comply with IEC 60947 Class AC3, 660 V, and Class II
intermittent duty. Contactors shall be non-latching and be controlled by an
astronomical time switch. Control circuits shall be connected to the Brown phase.

7A/9.1.6 Circuit breakers

Provide a three-phase and neutral (four-pole) moulded case circuit breaker to IEC
60947 as the Main Switch of each Feeder Pillar.
Each Main Switch shall be fault rated at 50 kA at the temperatures inside the
cabinet. Each Main Switch shall be able to accommodate two auxiliary contacts
and an under voltage release, a padlocking device, and shall be equipped with
insulated shrouds to the incoming terminals to provide finger protection. Provide
300 mm clearance between the Main Switch and the gland plate. Terminals shall
be capable of accommodating 185 mm 2 cables.

7A/9.1.7 Busbars

Provide tin-plated, phase colour insulated, copper busbars to BS 159. Busbars

shall be rated to match the load and fault ratings of the Main Switch. An earth or
ground bar not less than 40 mm x 4 mm shall be solidly bolted with stainless steel
bolts of grade AISI 316 to the main body of the control cabinet.

7A/9.1.8 Wiring and Cabling

All secondary internal wiring within the control cabinet shall be with heat resisting,
1000V hard grade PVC/XLPE Insulated copper cables of at least 2.5 mm² (7
strand) for control wiring, and 10 mm2 for power wiring, colour coded or sleeved for
easy phase identification, suitable for the circuit rating, arranged neatly and firmly
attached. All the wiring leads shall be so arranged to allow current reading with a
clip-on ammeter on each phase of main incoming and all outgoing circuits. All
wiring shall be housed in wiring trunking. Sufficient vacant area (250 mm x 300
mm minimum) shall be left for future installation of a kWh meter.
All wire terminals into connectors shall have wire ends or straight lugs. All the wires
selected should have the amperage rating at 600 ambient and sufficient allowances
for enclosure de-rating.
Terminals shall be able to accommodate:
 incoming cables (armoured, sector shaped, copper conductors, 4 core,
MDPE insulated and PVC over sheathed)
 outgoing cables (armoured, STET, stranded copper conductors, 4 core,
MDPE insulated and PVC over sheathed)
The outgoing terminals shall be suitable for two cables of 70 mm 2, 50 mm2, 35
mm2 and 25 mm2.
Cabling and wiring shall be colour coded as follows:
 Phases - Brown, Black & Grey.
 Neutral - Blue
 Earth - Green/Yellow

7A/9.1.9 Fuse and Fuse Base

There shall be a LV HRC system consisting of fuse bases, fuse cartridge and
accessories complying with BS 88.
Fuse cartridges shall be IEC class gL/gG and the base shall be of modular
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 16 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

construction suitable for DIN-rail mounting. The bases are to be made of thermo
setting, self extinguishing material rated for 100A. Metal parts, contacts and
springs are to be zinc plated and passivated for protection against corrosion. The
fuse bases shall have shielded terminals and be Legrand 21471 single pole, or
approved alternative. Cylindrical cartridge type fuse links suitable for the bases
are to be used. They shall conform to IEC 269-2 and BS 1261 (1986) or DIN 43620
and shall withstand a rupture capacity of 100 kA. Fuses shall be of a low internal
loss and low internal temperature rise. Each fuse shall be protected by an
insulating shield or approved alternative.
Each feeder pillar shall have one 4 A single phase HRC fuse with base for the
internal lighting circuit.
Each feeder pillar shall have one BS 1263 13 A 3 pin switch socket outlet
protected by a residual current device. The socket outlet shall be corrosion
resistant and mounted on a pattress inside the door of the Feeder Pillar.

7A/9.1.10 Cable Glands

Glands shall comply with BS 6121 and shall be the brass compression type with
earth rings and tags, and lock buds, for XLPE/SWE/PVC/MDPE 4 core cables.
Supply matching cable sleeves for each gland. Glands shall be fitted with PVC
shrouds filled with waterproof plastic compound and secured to the cable with PVC
tape.
Glands shall be weatherproof, with inner and outer seals suitable for steel wire
armoured cables.

7A/9.1.11 Control System

The switching of the lighting luminaires shall be through an automatic control

arrangement comprising of an astronomical time switch and selector switch. The
selector switch shall have three positions: ON/OFF/AUTOMATIC.

7A/9.1.12 Samples

Submit a sample Feeder Pillar, fully equipped to the Engineer for review.

7A/9.1.13 Testing

Submit type test certificates to IEC 61439. In addition submit routine test
certificates for each Feeder Pillar for review by the Engineer.
Inspect the switchboards before they leave the manufacturer's works and check
suitability for application and compliance with specification.
Test each circuit of each switchboard before connecting electricity supply.
Test the operation of all residual current devices.
Verify the operation of control circuits.
Record and submit test results on printed test sheets.
Advise of all inspections and tests in time to allow witnessing of such inspections
and tests by the Engineer.

7A/9.2 STREET LIGHT CUT-OUTS

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 17 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/9.2.1 Application

Install street light cut-outs in the base of each light pole. The cut-out serves as a
protective device for the luminaires and pole wiring

7A/9.2.2 Rating

The service cut-out shall be rated at 415V/240V, 50 Hz operation, at 500 C ambient

and 95% relative humidity.

7A/9.2.3 Standard

The street lighting service cut-out shall comply with BS 7654.

7A/9.2.4 Construction

The typical arrangement of street lighting services cut-out with dimensions and
materials of construction shall be submitted by the Contactor for review by the
Engineer.
The street lighting service cut-out shall consist of:
Housing with cover
Fuse bases of required numbers
4 Terminals: Brown; Black; Grey; and Blue
Outgoing cable glands
The fuse base shall be DIN rail mounted fully insulated and suitable for 10 mm
diameter X 38 mm cylindrical H.R.C. fuses.

7A/9.2.5 Terminals

4 cable terminals (3 phases and 1 neutral) shall be fixed to a high quality phenolic
fibre board, or glass fibre reinforced insulator. The dielectric strength of the
insulator shall not be less than 2 kV/mm. The flexural strength of the insulator shall
be not less than 1000 kg/cm2 the insulator material to be in accordance to DIN
7735 type 2081 or similar reviewed by the Engineer. Each terminal shall be
capable of accepting two sector shaped copper cables of not less than 35 mm 2
each.
Each incoming and outgoing terminal shall be bolted to an electrolytically tinned
H.C.H.D. copper bar of 40 mm Xx 5 mm cross section.
Each cable terminal shall have the provision to connect and to tap off a lugged 4
mm2 phase coloured wire of not less than 10 cm. long.
The wire shall be bolted on to the main terminal by using a M5 x 15 mm slit head
screw with spring washer.
All terminal parts to be made from materials which are not subject to corrosion
when used in combination with each other.
A flexible phase insulating barrier shall be provided between all terminals as well
as on both sides of the end terminals. The phase barrier shall protrude sufficiently
on all sides of the terminal to ensure electrically safety.
Brass cable glands shall be mounted together with a 1 mm thick tinned copper
plate, linking them together. The copper plate shall be bonded to an external earth
stud and to the earth bar.
Neutral and earth bars shall be of nickel plated brass, accepting 10 mm2 cable
sizes. The earth bar shall be solidly bounded to the metal housing.

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 18 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/9.2.6 Housing

The housing consists of a base plate, holding all components and glands, and a
removable cover. The material shall be electrogalvanized sheet steel, polyester
powder coated to a film thickness of min. 100 microns, against corrosion under
Dubai climatic conditions. The plate shall be 3 mm thick and the cover 1.25 mm
thick. Protection class shall be IP 44. The base plate shall have 2 Nos. rear fixing
holes of 7 mm diameter.
The cover fixing screws shall be captive.

7A/9.2.7 Testing

Submit type test certificates to IEC 61439 for review by the Engineer. In addition
submit routine test certificates for each type of cut-out for review by the Engineer.

7A/9.2.8 Samples

Submit a sample of each type of cut out fully equipped for review by the Engineer.
The samples shall be accompanied by the manufacturer’s operating instructions.

7A/10 CABLING

7A/10.1 GENERAL

7A/10.1.1 Insulation Colours

For all cabling insulation colours shall be:

 Phases - Brown, Black & Grey.
 Neutral - Blue
 Earth - Green/Yellow

7A/10.1.2 Manufacturer’s Data Sheets

Submit manufacturer’s data sheets and one metre sample lengths of each size to
the Engineer for review.
Submit test certificates of each size of cable to the Engineer for review.

7A/10.1.3 Earth Cable

Earth cables shall be single-core stranded plain annealed copper core PVC
insulated cable to BS 6004. Insulation colour shall be yellow-green.

7A/10.1.4 Sealing and Drumming

Before dispatch, seal cable ends against moisture ingress. Label cable drums with
a discrete reference number, manufacturer, year, and cable construction. Deliver
drums to site with seals and labelling intact. Submit seals and labels to the
Engineer for review. The drum reference number shall be reference on the test
sheets.

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 19 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/10.1.5 Installation

Install cables in accordance with the following documents: BS 7671; the United
Emirates Electricity Regulations and Guide; and the manufacturer's
recommendations.
Install cables in one length without joints from terminal point to terminal point.
Observe the bending radii requirements of the United Emirates Electricity
Regulations and Guide and the manufacturer’s recommendations

7A/10.2 UNDERGROUND CABLING

7A/10.2.1 Construction

Underground cables shall be 4-core stranded copper 600/1000 V

XLPE/SWA/MDPE armoured cables complying with BS 5467 and suitable for
direct burial in saline soil.

7A/10.2.2 Earth Cable

Earth cables shall be single-core stranded plain annealed copper core PVC
insulated cable to BS 6004. Insulation colour shall be yellow-green.
Submit manufacturer’s data sheets and one metre sample lengths of each size to
the Engineer for review.
Submit test certificates of each size of cable to the Engineer for review.

7A/10.2.3 Identification

Emboss the sheath with two lines of lettering:

First Line:
“ROADS & TRANSPORT AUTHORITY ROAD LIGHTING 600/1000 V”.
Lettering shall be upright block characters. The maximum size of the characters
shall be 12 mm and the minimum size 15% of the approximate overall diameter of
the cable or 5 mm whichever is greater. The gap between the end of one legend
and the beginning of the next shall not be greater than 150 mm.

Second Line:
“Manufacturer/year/country of origin/number of cores/cross-section/type/length”.
Lettering shall be equally spaced with the first line along the circumference marked
at regular intervals on the sheath. This shall not affect the spacing between
repetitions of the legend for the voltage designation.

7A/10.2.4 Installation

Lay in the cable trench an earth cable of not less than 16 mm 2 for 16, 25 and 35
mm2 4-core cables; 25 mm2 for 4-core 50 mm2 cable; and 35 mm 2 for 4-core 70
mm2 cables.
Install the earth cable all the way from the feeder pillar to the last pole of each
circuit, looping the earth cable inside each pole.
Runs shall be neat and free from kinks, care being taken in the routing to avoid risk
of damage to or interference with other equipment.

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 20 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/10.2.5 Direct Burial:

Excavate cable trenches along the cable routes, removing loose rock, stones and
other sharp materials. Supply and install clean sand that has been washed and
sieved along the cable routes. Before laying cables lay a 75 mm bed of level,
compacted, clean sand. After cable laying, backfill and compact with clean sand to
provide 75 mm of cover over the cable. Backfill the cable trench with selected
material and lay the PVC cable warning tape. At the entry and exit duct of each
foundation, allow a loop of 1 metre of cable for future use.

7A/10.2.6 Inspection:

Prior to backfilling and compaction, notify the Engineer to inspect the installation.
Any trenches backfilled and compacted without inspection will not be accepted and
shall be re-excavated at the contractor’s expense and risk for inspection by the
Engineer.

7A/10.2.7 Cables in Ducts

Where cables cross under roads and paved areas draw the cables through the
ducts and seal the ducts with tapered wooden plugs to prevent soil ingress.

7A/10.2.8 Cables In Concrete Trenches:

Install cables in concrete trenches with a cable management system. The cable
management system shall comprise:
Vertical hot dip galvanized steel channels (Unistrut P1000 or approved alternative)
secured with stainless steel (AISI 316) chemical anchors.
Hot dip galvanized cable clamps.

7A/10.2.9 Cables Fixed To Steel Work Or Concrete Walls:

Install XLPE insulated cables installed on steel work in moulded reinforced nylon
hooks and clamps spaced to avoid sagging of cables. Spacing of the cleats shall
not exceed 750 mm. Arrange cleats and cable routes in the neatest and least
obtrusive manner.
All steel work cable supports shall be hot dip galvanized and painted as specified
for Miscellaneous Metal work.

7A/10.2.10 Cables Saddles:

Cable saddles shall be fixed with stainless steel (AISI 316) anchors.

7A/10.2.11 Cable Support Spacing:

Spacing of cable supports shall be prescribed in the United Emirates Electricity

Regulations and Guide, BS 7671, and the manufacturer’s recommendations.

7A/10.2.12 Termination of Cables:

Jointing materials shall comply with BS 7933 and be installed in accordance with
BS 6910.2. Submit proposed termination equipment and material data sheets to
the Engineer for review.
Cable terminations shall be colour coded as follows:
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 21 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Phases - Brown, Black & Grey.

 Neutral – Blue
 Earth - Green/Yellow
Coloured tapes and sleeves will not be permitted.
For all cable ends allow at least 300 mm of cable to be cut off immediately before
the termination. Seal cable ends against the ingress of moisture and dirt.

7A/10.3 CABLING IN STRUCTURES

7A/10.3.1 Construction:

Cabling in structures shall comprise stranded copper conductor, PVC insulated,

non-armoured cables to BS 6004.
Cabling shall be sized to the circuit protective device, current load, voltage drop
(which shall not exceed 3% for lighting circuits), and earth loop impedance. For
lighting circuits, the minimum size shall be 4 mm² copper.
Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529.

7A/10.3.2 Installation:

The cabling shall be installed loop-in, draw in system, connecting conductors from
point to point without joints. Cabling may be looped into luminaire terminal blocks,
but shall not be looped through luminaires.
Conductors shall be terminated with crimp lugs.
Cabling shall be installed in compliance with manufacturer’s instructions and using
the manufacturer’s recommended accessories.

7A/10.3.3 Conduit

Conduits shall be uPVC and comply with BS 4607, be suitable for the climatic
conditions, and be at least 20 mm in diameter. Conduit joints shall be cemented.
During construction conduits shall be protected to prevent movement, ingress of
moisture and dirt, and damage. Any open ends shall be capped to keep out dirt
and moisture.
Conduits shall be installed in straight runs, level, and parallel or perpendicular to
the structure, and to avoid the spread of fire and ingress of moisture. Conduits
shall be installed with all requisite accessories. Internal burrs shall be removed
from the conduit ends.
Draw boxes shall be uPVC (or accepted alternative) with an Ingress Protection
rating of IP67. Draw boxes shall be installed in accessible locations at least every
50 m and between every two right angle bends. Gasketted lids shall be provided
where exposed to dust or moisture.
At structural expansion joints maintain continuity with flexible conduit within a
larger sleeve.
Provide conduit bends without deformation.
Provide draw-wires in conduits for future services and in conduit for services to be
installed by other parties.
Conduits installed in concrete shall be: located near the neutral axis; spaced at
least 25 mm apart; tied to the reinforcing steel with tie wire at a maximum spacing
of 600 mm; and be terminated in deep pattern conduit boxes.
Surface mounted conduit shall only be permitted where shown on drawings or
where accepted by the Engineer. Surface mounted conduit shall be installed to

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 22 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

avoid crossovers. Surface mounted conduit shall be saddled, or where in multiple

runs, fixed to pre-drilled stand-off brackets, at a maximum of 1000 mm intervals.

7A/10.4 LANDSCAPED AREAS

In landscaped areas, cabling may be installed by direct burial.

7A/10.5 POLE WIRING

Pole wiring between the cut-out and luminaires shall comprise 850 C rubber
insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to suit the
lamp load but shall be 3 core 2.5 mm 2 minimum for lamps circuits up to 250 W and
4 mm2 minimum for lamps circuits of 400 W.
The outer sheath shall be coloured black and be suitable for exposure to strong
sunlight and a marine environment.
Submit manufacturer’s test sheets submit test sheets to the Engineer for review.

7A/10.6 MID HINGED POLE WIRING

Pole wiring between the cut-out and luminaires shall comprise 850 C rubber
insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to suit the
lamp load but shall be 3 core 2.5 mm 2 minimum for lamps circuits up to 250 W and
4 mm2 minimum for lamps circuits of 400 W.
The outer sheath shall be coloured black and be suitable for exposure to strong
sunlight and a marine environment.
Submit manufacturer’s test sheets submit test sheets to the Engineer for review.

7A/10.7 CROWN POLE WIRING

Pole wiring between the cut-out and luminaires shall comprise 850 C rubber
insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to suit the
lamp load but shall be 3 core 2.5 mm 2 minimum for lamps circuits up to 250 W and
4 mm2 minimum for lamps circuits of 400 W.
The cable shall be capable of withstanding the mechanical stresses produced by
the anchoring and pulley system and rated for the maximum electrical loading.
The outer sheath shall be coloured black and be suitable for exposure to strong
sunlight and a marine environment.
Provide guides so that power cables and stainless steel wire ropes are separated
before passing over their respective pulleys. The guides shall to prevent ropes
and cables from leaving the pulley grooves.

7A/10.8 CABLING FOR ADVERTISING FACILITIES

Include cabling from substations to any feeder pillars serving advertising and
bridge banners.
Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529
Provide separate circuits from the feeder pillars to the advertising facilities.
In poles, provide a separate cut-out for the advertising facilities.
Pole wiring between the cut-out and the advertising facilities shall comprise 850 C
rubber insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to
suit the lamp load but shall be 3 core 2.5 mm 2 minimum for lamps circuits up to
250 W and 4 mm2 minimum for lamps circuits of 400 W.

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 23 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The outer sheath shall be coloured black and be suitable for exposure to strong
sunlight and a marine environment.
Submit manufacturer’s test sheets submit test sheets to the Engineer for review.
Refer to standard drawings.

7A/11 LUMINAIRES

7A/11.1 GENERAL

Luminaires shall comply with BS EN 60598.

The optical chamber shall be separate from the lamp control gear chamber.
For the optical chamber, Ingress protection shall be IP66 and for the control gear
chamber shall be IP54 of IEC 60529. Provide one-piece silicone rubber gaskets.
Gaskets shall not be exposed to sunlight or lamp flux.
The body shall be made of die-cast aluminium, grade LM6.
The reflector shall be of high purity aluminium, grade S1 with an anodic coating
grade AA10, “Alanod Miro” or approved alternative.
The lenses shall be of borosilicate glass.
Hinges and fastening clips shall be of stainless steel, grade SS316.
Lamp control gear shall be mounted on a gear tray with plug-in connectors. The
gear tray shall be easily removable without the use of tools.
Luminaires shall allow routine maintenance without the use of tools.
Luminaires shall include two adjustable cable entries, a terminal block and an eat
terminal welded to the body.
Luminaires shall be capable of withstanding the wind conditions including a gust
factor. Refer to sub-section on CLIMATE.
Luminaire mass shall not exceed 15 kg for road lighting luminaires up to 400W.
Mounting shall be suitable for post-top, or side entry, for 42 to 76 mm spigots, with
upcast adjustments between 0 and 200 in 50 increments. Mountings incorporate
vibration-resistant locking devices.
Lampholders shall comply with IEC 60061, shall be porcelain and E27 or E40 to
IEC 60238. Wiring to lampholders shall be heat-resistant silicone rubber or glass
fibre insulated cable.
Luminaires shall be labelled with lamp type and wattage next to the lampholder.
Wall mounting luminaires shall be installed at heights not exceeding 5m.

7A/11.2 LAMP CONTROL GEAR

Lamp control gear shall comply IEC 60923 and IEC 60927 and have:

 Efficiency not less than 90%

 Power factor not less than 85%
 Harmonic distortion less than 30%
 A suitability for ambient temperatures listed in 7A/4 CLIMATE
 Metal type capacitors rated for at least 900 C
 Taps for 240 V and 250 V operation
 Nominal arc tube voltage of approximately 100 V
 Ballasts shall incorporate thermal cut-out switches.
 For poles of 20 m in height and under, high pressure sodium vapour lamp
ballasts and ignitors shall suit the specific lamps; ignitors shall be external

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 24 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

bilateral multipulse superimposed ignitors which stop pulsing upon ignition of

the lamp; and shall incorporate electronic timers which stop pulsing after 120
seconds.
 For poles of 20 m in height and under, metal halide lamp ballasts and
ignitors shall suit the specific lamps; ignitors shall be external bilateral
multipulse superimposed ignitors which stop pulsing upon ignition of the
lamp; and shall incorporate electronic timers which stop pulsing after 11
minutes.
 For poles over 20 m in height, high pressure sodium vapour lamp ballasts
and ignitors shall suit the specific lamps; ballasts shall be semi-parallel with
external multi-pulse ignitors which stop pulsing upon ignition of the lamp; and
shall incorporate electronic timers which stop pulsing after 120 seconds.

For poles over 20 m in height, metal halide lamp ballasts and ignitors shall suit the
specific lamps; ballasts shall be semi-parallel with external multi-pulse ignitors
which stop pulsing upon ignition of the lamp; and shall incorporate electronic timers
which stop pulsing after 11 minutes.

7A/11.3 LAMPS

High pressure sodium vapour lamps shall comply with IEC 60662.
Metal halide lamps shall comply with IEC 61167.
Failure rate shall be less than 3% in the first 100 hours of operation.
High pressure sodium lamps shall have a life of 16 000 hours with less than 5%
failure.
Depreciation shall be less than 70% over service life.
Lamps shall comply with the following characteristics:

Flux (lumens) Life (h)

Type Wattage Lampholder
@100 h (50% survival)
High 70 E27 6,600 24,000
pressure 100 E40 10,700 24,000
sodium 150 E40 17,500 24,000
vapour 250 E40 33,200 24,000
400 E40 56,500 24,000
600 E40 90,000 24,000
1000 E40 130,000 24,000
Metal 70 E27 6,400 12,000
Halide 100 E27 8,500 16,000
150 E27 14,000 16,000
250 E40 22,500 16,000
400 E40 40,000 16,000
1000 E40 100,000 16,000
Fluorescent 36 G13 3,350 12,000
58 G13 5,200 12,000

Submit lamp data sheets with test certificates.

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 25 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/11.4 GANTRY SIGN LUMINAIRES

7A/11.4.1 Luminaires

Luminaires shall be metal halide floodlights.

7A/11.4.2 Wiring

Wiring to lighting luminaires shall be by means of PVC cables in a GI pipe. GI pipe

shall be securely fixed to structural steel work by distance saddles and a flexible
conduit from GI pipe to luminaire.
Final connections to lighting luminaires shall be carried out by short lengths of EPR
insulated, butyl sheathed flexible cable.
The interface between the PVC cable system and the flexible cable shall be a
weather-proof 3-pin socket outlet and plug. The control box for each gantry shall
be mounted on the steel structure and shall be complete with all electrical
accessories required. Main power supply shall be taken from the nearest feeder
pillar by XLPE/SWA/MDPE cabling as specified elsewhere.

7A/11.4.3 Control

Arrange control from the relevant Feeder Pillar.

7A/11.4.4 Lighting requirements

The gantry sign lighting shall be as per CIE No. 35 (TC-4.6) 1978, and shall have a
maintained average luminance of 180 candelas per square meter (for white letters)
and the ratio of the maximum luminance of one colour in a specified area to the
minimum luminance in the same area shall not exceed:
 2.5 for the inner zone of each area with a definite colour
 5 for the outer zone of each area with a definite colour
 8 over the total area of the sign face.
Whereas the inner area shall be that area bounded by a similar rectangle of length
and height equal to 70% of the overall length and height of the rectangular area
located symmetrically within the sign.
The maintained average luminance value is to be based upon the total of luminaire
dirt depreciation factor and a lamp lumen depreciation factor of 0.65.

7A/12 LIGHT POLES

7A/12.1 GENERAL

Poles and outreach arms and brackets shall comply with BS 80 and be hot dip
galvanized to BS 1461.
The height of amenity lighting poles shall not exceed 3.5m.
Fasteners shall be hot dip galvanized and threaded parts centrifugally spun to
remove any local excess of zinc. Test the galvanizing coating with suitable
electronic or magnetic measuring apparatus.
Steel shall comply with BS EN ISO 10025 and 10020.
Welding shall comply with BS EN ISO 9692 and 15614.
Poles shall have an octagonal or hexagonal cross section and have a continuous
longitudinal taper. Where poles are made in more than one section, the poles shall
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 26 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

be assembled on site with winches that pull the sections together. Overlap shall
be at least 1.5 times the across flats dimension. Poles shall have indelible
markings to indicate where sufficient overlap between sections has been achieved.
Poles shall be provided with outreach arms and brackets to suit the luminaires.
Poles shall be rated for winds of 160 km/h with gust factor.
Stress shall not exceed 50% of the yield strength of the pole at 160 km/h.
The pole shall be straight within 6 mm in 3 meters.
The pole surface shall be smooth, free of blemishes, protuberances, dents, cracks
or other imperfections. Protect the poles during transport and installation to
maintain the surface finish.
Provide a mounting flange at the base with cabled entry.
For roadways with speed limits in excess of 70 km/h, poles within 6 m of the kerb
or edge of shoulder shall be frangible with slip bases.
Provide a chamber for the cut-out with a flush access door. The door shall provide
easy access to the service cut-out for installation operation and maintenance.
Reinforce the door opening. Secure the door with a positive action stainless steel
(AISI grade 316) lock that forces the door open. All parts of the lock shall be
captive. Provide a 6 mm stainless steel (AISI grade 316) chain to hold the door
captive to the pole. The cut-out chamber shall have ingress protection of IP53 and
be provided with a one-piece silicone rubber gasket. Install warning labels in
English and Arabic inside of the door.
Provide a mounting plate for the cut-out with predrilled mounting holes for the cut-
out.
Provide a 30 mm M8 earth stud in the chamber. Provide hot dip galvanized anchor
bolts, each with two nuts and two washers, and with reinforcing steel cage.
Where poles are mounted to New Jersey Barriers, the gap in the barrier shall be
covered with a 14 mm thick hot dip galvanized steel cover, free of snags and
shaped to conform to the profile of the barrier, rebated at each end into the
concrete of the barrier to present no protrusions, and secured with hot dip
galvanized Allen key button head screws to the New Jersey Barrier.

7A/12.2 ADVERTISING FACILITY POLES

Advertising facility poles , their flanges, holding down nuts and bolts, and
foundations shall be designed to withstand the windage and the mass of the
advertising facilities under the conditions specified under 7A/4 CLIMATE.

7A/12.3 ALTERNATIVE MATERIALS

7A/12.3.1 General

Alternative pole materials such as aluminium and glass reinforced polyester may
be submitted to the Engineer for review.

7A/12.3.2 Glass Reinforced Polyester Poles

Glass reinforced polyester poles shall comply with EN 40-7 and be made of resin
impregnated glass filament mandrel wound with a high impact polyester gel coat
with UV inhibitors. The mass to ratio of glass to resin shall be 70:30. The gel coat
shall be at least 250 microns thick.
Poles shall be capable of withstanding the Max. Design Wind Velocity with a
deflection of less than 5% at the top.

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 27 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/12.3.3 Aluminium Poles

Aluminium Poles shall comply with “The Aluminium Design manual: Specifications
and guidelines for aluminium structures, Part 1 B: Specification for Aluminium
structures , Load and Resistance Factor Design of Buildings and similar type
structures” (issued by the U.S Aluminium Association) and shall be manufactured
of 6061 grade aluminium to T5 or T6 temper with grade 5083 rolled aluminium
plate base plates. The aluminium base shall be effectively insulated from the steel
holding down bolts and concrete foundation.

7A/12.4 MULTI -FUNCTION POLES

Multi-function poles shall comprise a hot dip galvanized steel core with a marine
grade anodised aluminium extrusion outer shell. The base of each pole core shall
have a hot dip galvanized flange for securing to the foundation. The poles shall be
ventilated. The poles shall be capable of supporting:
luminaires and outreach arms,
signage,
traffic signal luminaires and pedestrian push buttons
banner arms
These items shall be capable of being mounted at any height and at any
orientation.
Multi-function poles shall comply with the requirements for aluminium poles.

7A/12.5 POLE FOUNDATIONS (APPLIES TO ALL TYPES OF POLE)

Provide concrete pole foundations. The concrete shall be Class 30 in accordance

with Section 4 of these Specifications. Increase the cement content by 10% if any
part of the foundation is below the water table. Vibrate for at least two minutes.
Submit to the Engineer shop drawings with supporting design calculations for
review prior to construction of the foundations.
Protect the foundation with bituminous paint to ASTM D1187 – Standard
Specification for Asphalt-Base Emulsions for Use as Protective Coatings for Metal.
A sample foundation is to be reviewed by the Engineer and Roads & Transport
Authority Roads Lighting Section before commencement of the work and the same
standard is to be maintained throughout the contract.
No site welding will be permitted. Provide a precision made steel template to
ensure correct horizontal and vertical holding down bolt alignment.
All stainless steel components shall be of Grade AISI 316.
Holding down bolts and their nuts and washers shall be hot dip galvanized steel.
Wrap Denso Self Adhesive Tape on the exposed section of the threaded part of
the holding down bolts before casting the foundations. The tape shall consist of
PVC with a backing of rubber resin pressure sensitive adhesive.
Refer to standard drawings.

7A/12.6 POLE INSTALLATION (APPLIES TO ALL TYPES OF POLE)

Install poles within ± 10 mm of level and ± 100 mm of location.

Erect poles truly vertical within a tolerance of ± 10.
Orientation of outreach arms shall be at right angles to the kerb.
Do not use chain slings without adequate protection and take care so that the

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 28 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

galvanizing and any paint finish are not damaged.

After concreting, thoroughly clean and grease the bolts and check with a template
to ensure accurate placement.
Install the pole with a nut and washer under the pole flange, and a washer and nut
above the pole flange.
Grout the gap between the foundation and the pole flange.
Grout for gaps of less than 40 mm shall comprise 1 part of Portland cement, 2
parts of sand and no more than 0.45 water cement ration by mass.
Grout for gaps of more than 40 mm shall comprise 1 part of Portland cement, 1.5
parts of sand, 1.5 parts of coarse aggregate and no more than 0.45 water cement
ration by mass.
Cut any excess length of holding down bolts and coat with zinc rich paint.
Coat holding down bolts, nuts and washers with bituminous paint to ASTM D1187
– Standard Specification for Asphalt-Base Emulsions for Use as Protective
Coatings for Metal.
On completion of installation, exposed nuts and bolts heads of holding down bolts
shall be capped with grease filled uPVC caps.

7A/12.7 MID-HINGED POLES

The pole shall be hinged approximately midway above the base so that it may be
raised or lowered by means of externally operated lanyard and an internal counter-
weight. Provide a lanyard suitable for each type of mid-hinged pole.
Provide a compartment with access door to accommodate the cut-out and lamp
control gear.
Provide a hinge spindle of stainless steel (AISI grade 316). Ingress protection at
the hinging point shall be IP53 of IEC 60529.
Between the fixed and hinging sections, provide a copper brad earth bond.
Provide cable supports within the pole to avoid stress on the pole wiring.
Provide a means of securing the moved section to the fixed section when the pole
is lowered.
Provide tuition to the Roads & Transport Authority Street Lighting Section in the
operation and maintenance.
Shop drawings shall include calculations of forces encountered by the pole and
foundation during lowering and raising.

7A/12.8 CROWN POLES

7A/12.8.1 Poles

General: Poles shall be equipped with a mobile crown arrangement.

Structure and Construction:
The pole shall not be more than 3 sections, other than the luminaire carriage for 30
and 40 meters high poles respectively.
The pole shall be suitable for supporting the array of luminaires.
The pole shaft shall have a polygonal cross-section, continuously tapered and
longitudinally welded. The shaft shall be delivered in separate sections to be
assembled on site by slip-on joint system.
Pole with luminaire carriage and mobile ring and luminaire shall be able to
withstand the maximum Design Wind Velocity.
Provide a compartment with access door to accommodate the cut-out and lamp
control gear.
All the moving parts of the locking device shall be stainless steel (grade AISI 316).
Assemble the poles in accordance with the manufacturer’s recommendations.
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 29 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/12.8.2 Aviation Lights

Aviation lights shall be provided to the top of any pole exceeding 30 m in height.

The aviation light shall comply with the Civil Aviation requirements and shall be
permanently powered.

The aviation lights shall be fixed to the mobile ring and located to facilitate
maintenance and replacement.

Drawings and samples shall be submitted to the Engineer.

7A/12.8.3 Marine Navigation Lights

Marine navigation lights shall be provided to bridges across navigable waterways.

The marine navigation lights shall comply with the Dubai Ports Authority
requirements and shall be permanently powered.

Drawings and samples shall be submitted to the Engineer.

7A/12.8.4 Lowering and Raising Devices

The lowering raising device with latching mechanism allows for load to be removed
from hoisting unit when luminaires ring is latched in.
The lowering and raising system shall consist of, but not limited to:
 Driving Head
 Mobile Ring
 Hoisting Unit

Driving Head
The driving head shall be made of hot dip galvanised steel and be fixed to the top
of the plate by a flange secured to the most top by at least 6 bolts.
The driving head shall be pre-assembled and tested in the factory prior to shipment
and supplied complete with 3 stainless steel ropes (Grade AISI 316) and
associated double pulley assemblies and electrical power cable. Each steel rope
and power cable shall have its own separate arm, housing the pulleys made of
stainless steel (grade AISI 316) and mounted on self lubricating ball bearings and
seamless axles.
The housing cable, 3 units, shall be made of stainless steel (grade AISI 316). Each
cable shall have a safety factor of not less than 5 times the safe working load of
winch. The hoisting cables shall be of three connectors allowing regulation from
ground.
Provide three latching sleeves assuming correct positioning, entering and locking
of the mobile part of the crown when raised and locked in final position.
The locking system shall take up all horizontal and vertical loads of the mobile part
of the crown without vibration even when exposed under the most severe climatic
conditions.
The top of the driving head shall be covered with a canopy of 3 mm thickness
aluminium sheet.
The latching and unlatching operations shall be regulated by two limit switches
located at the base of the pole, easily accessible through the inspection door.
The mobile part is fastened in raised position to the fixed part of the head gear by

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 30 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

means of 3 positive latching system protected against corrosion, and the

suspension cables shall be tension free. Submit both the latching system and
suspension cables to the Engineer for review.
All bolts, nuts and washers of the pole assembly shall be stainless steel grade AISI
316.

Mobile Ring:
The mobile ring shall be fabricated and coated against corrosion according to the
pole specification. It shall be complete with luminaires and brackets to suit lighting
design requirements consisting of flood lights and control gear boxes.
During lowering and raising operations the mobile ring shall smoothly and without
any sideward movement/rotation slide along the shaft with 3 groups of plastic
rollers at 120 degrees.

Hoisting Unit:
Suitable numbers of drum winches, with base flanges for mounting on holding
down bolts shall be fitted in the bottom of pole for operation by hand and power
tool, for raising and lowering the mobile ring. The winch shall be fitted with a friction
winch clutch, ratchet and pawl, and the handle. Spindle plate shall have a safety
pin locking device. Winches shall be totally enclosed to exclude dust and blown
sand from gears and oil baths.
The mobile ring shall be raised and lowered by means of remote control push
button panel box 10M away. The control box shall conform to IP 55 of IEC 60529,
be of heavy duty construction, be corrosion resistant, be UV resistant and have
proper locking arrangements.
Winch power tools shall be portable, multi-speed, reversible, units incorporating
torque limiting. They shall be supplied with a flexible supply cable and a remote
control switch to allow winches to be operated from a distance of 10 meters. A
supporting system shall be provided to securely locate power tools during
operation. Power tools shall be rated to raise the crown from ground to pole top in
not more than 15 minutes.
One spare winch power tool set shall be handed over to the Engineer on
completion of the contract.

7A/12.8.5 Electrical Equipment

The driving head shall be designed to accommodate a round power cable. Plugs
and sockets shall comply with IEC304-1 and IEC 309-2.
Internal control panels within pole bases shall incorporate a moulded case circuit
breaker main switch, and outgoing MCBs for the pole wiring circuits. The control
panels shall have the facility for terminating incoming power cables and shall be
fitted with weatherproof plug and socket arrangement to allow connection of the
pole wiring rising multi-core cables. Control panels shall be complete with a 16A,
240V weatherproof socket and ELCB of appropriate rating to supply the winch
power tool. Control panels shall receive protective treatment as specified and shall
be sealed to IP 54 of IEC 60529.
On the mobile ring, provide an IP65 distribution enclosure made of 3 mm. thick
aluminium sheet, housing the terminal clamps and a powered socket with cable for
flood lights, ground test
The contractor shall supply and install 2.5 mm2, 3 core butyl rubber insulated and
sheathed flexible cords to be pulled through flexible conduits for the connections
between terminal boxes, control gear boxes and individual flood light fittings.
An earthing terminal shall be provided within the pole base, located so that easy
access for connection/disconnection of the copper earthing tape can be achieved.

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 31 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7A/12.8.6 Design Information

Prior to the fabrication of any part of the poles or brackets, submit to the Engineer
for review the following:
 Design parameters
 Calculations and data
 General dimensions of all components of the pole include mounting mobile
ring and multiple luminaires array.
 Detailed scale drawings of both pole and luminaires mounting brackets.
 Details of the fixing and locking system between the pole and the luminaires
mounting bracket.
 The total maximum load moments for each section under maximum stresses.
Computation of stresses in the base plate and anchor bolts under maximum
windload with maximum number of luminaires in place.
 Maximum deflection at the top of the pole, under conditions and wind velocity
mentioned earlier.
 Any new treatment method for extra protection against corrosion of the base
plate area and up to the height of 300 mm.
 Detail calculations of the necessary strength for anchor bolts to be used.
 Means of assembling of pole’s sections shall be indicated in details.
 Impact resistance calculations at a height of one meter above the base plate
of the pole.
 Maximum tolerable impact calculations to shear the plate from the pole and
from an impact point one meter above the flange plate
 Materials specification for each parts of the pole.

7A/12.8.7 Test Certificate

The Contractor to provide with each pole a detailed test certificate for:
 pole shaft materials and accessories;
 electrical power supply system;
 hoist system
 galvanizing; and
 Anchor bolts, nuts and washers for both material and galvanizing.

7A/12.8.8 Warranty

The Contractor shall submit to the Engineer a written warranty that the hoisting and
latching systems used in the pole shall work maintenance free for a period of at
least 20 years from date of commissioning.
The Engineer reserves the right to reclaim from Contractor any cost involved for
repair or replacement of any item related to the hoisting and latching system used
during the twenty years period.

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 32 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

TABLE OF CONTENT

7B/ TUNNEL AND UNDERPASS LIGHTING ...................................................................... 33

7B/1 GENERAL .............................................................................................................. 33
7B/2 SCOPE OF WORKS .............................................................................................. 33
7B/3 STANDARDS ......................................................................................................... 33
7B/4 TUNNEL AND UNDERBRIDGE LIGHTING DISTRIBUTION BOARD ................. 33
7B/5 TUNNEL AND UNDERBRIDGE LUMINAIRES - GENERAL ................................ 36
7B/6 TUNNEL AND UNDERBRIDGE LUMINAIRES - CONSTRUCTION .................... 36
7B/7 TUNNEL AND UNDERBRIDGE LUMINAIRES – MECHANICAL
REQUIREMENTS ................................................................................................................. 37
7B/8 TUNNEL AND UNDERBRIDGE LUMINAIRES – EMERGENCY LUMINAIRES .. 38
7B/9 TUNNEL AND UNDERBRIDGE LUMINAIRES – ELECTRICAL REQUIREMENTS
38
7B/10 TUNNEL AND UNDERBRIDGE LUMINAIRES – PHOTOMETRICAL
REQUIREMENTS ................................................................................................................. 39
7B/11 TUNNEL AND UNDERBRIDGE LUMINAIRES – PHOTOMETRICAL
PERFORMANCE REQUIREMENTS ................................................................................... 40
7B/12 TUNNEL AND UNDERBRIDGE LUMINAIRES – DOCUMENTATION
REQUIREMENTS ................................................................................................................. 40
7B/13 TUNNEL AND UNDERBRIDGE LIGHTING CLIMATE ......................................... 41
7B/14 TUNNEL AND UNDERBRIDGE LIGHTING CONTROL ....................................... 41
7B/15 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLS ................... 43
7B/16 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLLERS ............ 44
7B/17 TUNNEL AND UNDERBRIDGE MAIN CONTROL SYSTEM ............................... 44
7B/18 TUNNEL AND UNDERBRIDGE PROGRAMABLE LOGIC CONTROLLERS
(PLC’s) 45
7B/19 TUNNEL AND UNDERBRIDGE REMOTE SUPERVISION AND BACK UP
CONTROL SYSTEM ............................................................................................................ 47
7B/20 TUNNEL AND UNDERBRIDGE CABLING ........................................................... 48
7B/21 TUNNEL AND UNDERBRIDGE JUNCTION BOXES ........................................... 50
7B/22 TUNNEL AND UNDERBRIDGE CABLE TRAYS .................................................. 50
7B/23 TUNNEL AND UNDERBRIDGE INSPECTION TESTING AND COMMISSIONING
51

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 33 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7B/ TUNNEL AND UNDERPASS LIGHTING

7B/1 GENERAL
This Section specifies the requirements for design, manufacture, supply, factory
testing, packing, insurance, delivery to site, unloading, storage, protection, erection
and installation, wiring and cabling, site testing and commissioning of the complete
equipment for underpass lighting, and control.

7B/2 SCOPE OF WORKS

The Scope of Works shall involve the steps below:
Connect the utility cables to MDB.
Provide the Lighting Distribution Board (LDB) and placement as shown on the
drawings.
Supply and Installation of Lighting Equipment comprising:
 415 V Lighting Distribution Board.
 Lighting fixtures and associated brackets, supports, conduits, trunking, trays
and cabling/wiring for Underpass lighting.
 All the required sizes and lengths of service cables.
 Earthing and bonding of all electronic items and electrical equipment
including supply of earthing materials.
 All jointing and termination, lugs, fuses, lamps, keys, locks, labels and all
necessary material to complete the installation.
 All necessary civil works.
 All Junction boxes for loop-in, loop-out connections for groups of lights.
 All accessories for modular cabling along with cable system.

Provide all labor, plant and materials for the complete erection, adjustment, testing,
painting and putting to work all equipment supplied.
Supply and installation of any material which may not be expressly specified but
which is necessary for the completion of the project.
Reinstatement of the existing conditions of the services and properties that will be
affected during the construction.

7B/3 STANDARDS
All equipment and workmanship shall comply with the most recent documents
published by the CIE, IEC, British Standards, and European Norms. The following
Standards and Codes form part of this Specification:
NFPA 101 Life Safety Code
NFPA 101A Guide on Alternative Approaches to Life Safety
NFPA101B Code for Means of Egress from Buildings and Structures
NFPA 502 Standard for Road Tunnels, Bridges and other Limited Access
Highways

7B/4 TUNNEL AND UNDERBRIDGE LIGHTING DISTRIBUTION BOARD

Construction shall be in accordance with the following standards.

 Publication BS EN 60073: Colors of indicator lights and push buttons.

 Publication BS EN 60529: Degree of protection of enclosures.
 Publication BS EN 60947: Low-voltage switchgear and control-gear.

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 34 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Publication IEC 269: Low-voltage fuses.

 Various publications relevant to apparatus, devices and components.

The Contractor shall be responsible for the correct sizing of the electrical
equipment and for the proper selection of materials in accordance with the ambient
conditions. All materials used shall be able to operate normally, during high
temperature conditions.
The Contractor shall guarantee that the LDB supplied by him, inclusive of all
materials and installed equipment, are free from all defects or imperfections and
are capable of proper operation at rated load within the tolerance limits established
by governing construction codes.
The design and construction of electric LDB shall be such to ensure:

 Public safety and personnel under all operating and fault conditions;
 Construction and operating reliability;
 Possibility of future considerations.

Public safety shall be assured by the prevention of direct and indirect contacts with
live or moving parts under any operating and expected fault conditions or
otherwise under maintenance conditions or occasional handling on LDB.

General and partial protection shall ensure that the Public cannot come in to
contact with the live parts of the electric LDB.

The general external protection shall be achieved by means of permanent barriers

or enclosures, which prevent any contact with the live parts.

The spacing, insulation level and mechanical strength shall be consistent with the
stresses they may normally undergo.

The luminaires shall be fed by the LDB as indicated in the Drawings.

The LDB shall contain all the electrical components necessary for automatic
lighting of the luminaire in night hours and day hours.

The LDB foundation shall be made of concrete.

The foundation shall be all, excluding the top surface, bituminous painted.

The LDB cabinet shall be made by zinc plated sheet steel 1.6 mm thickness
minimum. The external side of the LDB shall be epoxy powder coated having the
color pigments as per RTA requirement. The cabinet shall be provided with IP 55
ventilation intakes on the lateral sides.

The LDB cabinet shall be housed inside air-conditioned double walled thermally
insulated Kiosk combined with the MDB and DPS (Drainage Pump Station) panel if
they are closed to each other. Separation shall be maintained between the LDB
and the MDB and DPS in two rooms with different doors and key locks. This is only
one BOQ item and shall not be included under any other scope of work.

The bottom of LDB shall be removable for gland installation.

The LDB shall be fixed to stainless steel grade 316 anchor bolts, with extra wide
washers, spring washers and stainless steel nuts.

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 35 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The degree of protection required is IP55 according to BS EN Publication No.

60529.

The LDB shall be certified to withstand 50 KA for 1 sec.

Two lugs of appropriate dimension shall be fixed on top of the LDB for easy
handling. The access inside the LDB shall be provided by one or two doors with
180-degree polyamide hinges and fitted with two vertical and one horizontal wedge
actuated by a rotating handle which can be pad locked with a Master lock with key.

Latching devices to fix the door open shall be provided. A danger notice in Arabic
and English languages shall be riveted on the front of the LDB.

The equipment inside the LDB shall be screwed, with easy unfastening access, to
one metallic structure of galvanized steel or equivalent.

Insulated set of busbars of hard drawn tinned copper shall be rigidly supported (air
insulated system will be adopted).

The phase and neutral bar shall be rated as indicated on drawings. The cross
section area of phase and earth bars shall be as per rated and short circuit
currents. The metallic structure of the LDB shall be connected to the earth bar
together with the external cable armoring earth and from this bar the earthing lead
will depart accordingly. All connections shall be obtained with copper tinned lugs
and phosphor bronze bolts, washer, spring washers and nuts.

The Circuit Breakers shall be TPN and 1PN rating as shown on drawings with
Breaking Capacity 50 KA rms. in "SERVICE" as per BS EN 60898 at 415 V, 50 Hz.

The branch circuit breakers shall have direct acting relays with differential current
relay operation at 100 mA of fault.

One door switch operated internal fluorescent lamp (minimum of 15 W) shall be

provided as well as one single-phase internal 13A - 240 V socket both protected by
circuit breaker.

Glands with moisture and humidity seal rings, entry thread seal under the lock nut,
earth tag, plastic shrouds covered, shall protect the incoming and outgoing cables.

Modular cables of determined size stranded and fire rated with sockets shall be
used for lighting circuits. Individual luminaire shall be supplied with 2.5 mm2
flexible and fire rated cables from the socket of modular cable.

Contactors shall be air magnetic type; they shall be compact anti-shock, or

assembled to result insensitive to shocks or vibrations according to BS EN 60947-
4. Contactors shall be suitable for continuous duty and capable of at least 150
duty cycles per hour. Contactors shall close positively with 85% of rated coil
voltage and shall be maintained positively with a voltage-drop up to 65% of the
rated voltage. Rated operational current and for mounting inside LDB shall not be
lower than 130% of the load rated current. Breaking/making capacity shall not be
lower than 8/10 times the rated current up to 100A and 6/8 times the rated current
over 100A. Contactors shall also be capable of withstanding, a current equal to
their breaking capacity for a duration of 5 seconds, with rated voltage of control
coil. Contactors shall be coordinated with the associated protections (thermal and
magnetic) in such a way that permanent damage shall be avoided, under fault

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 36 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

current of any value up to the specified short circuit current. Permanent damages
shall be avoided. No contact chattering and fusion shall occur under full load
current at coil supply voltage equal to 80% of the rated voltage. Each contactor
shall always have at least 2 auxiliary contacts (1NO 1NC) available and wired to
the auxiliary terminal strip.

7B/5 TUNNEL AND UNDERBRIDGE LUMINAIRES - GENERAL

Luminaires shall contain high pressure sodium lamps and operate on 240 Volts,
+/- 10%, 50 Hz

The Underpass lighting luminaires shall follow the latest versions of the following
standards:

 BS 4533: 1971
 BS 4533 Part 2 Section 2.7 : 1971
 BS 4533: Section 102.3: 1990
 BS 1615: 1987
 BS 1470: 1987
 BS EN 60922: 1991 and BS EN 60923: 1991
 BS 6500: 1990
 IEC 598 Part 1 and 2
 BS 4533: Part 103: Section 103.1: 1988
 BS 5489 Part 1, 2 & 3: 1992
 BS 5225: Part 1: 1985
 BS 5101 (Part 1) and (Part 2): 1986
 BS EN 60529: 1992
 BS 6193:1990
 BS 3772:1990

7B/6 TUNNEL AND UNDERBRIDGE LUMINAIRES – CONSTRUCTION

Luminaires shall meet the following minimum construction requirements.

Aluminium (Magnesium-silicon alloy) extruded or Die-cast Aluminium body in one

piece with an anodized finish and side covers in die cast aluminium alloy as per BS
4533 Section 102.3: 1990.

Super purity one-piece aluminium reflector of grade S1 of BS 1470: 1987 with an

anodic coating of not less than grade AA10 of BS 1615: 1987.

Strong, very high thermally resistant, hinged, front glass protector assembly
comprising clean toughened, heat tempered glass plate, fixed into aluminium
frame with rapid closing devices, sufficient to achieve IP65 degree of protection for
enclosure. In the open position, the glass remains suspended from the luminaire.

Front flat glass assembly is to be sealed using neoprene non-rotting type

gaskets/or high quality felt gaskets silicon. The glass shall be capable of opening
180 degrees.

Hinges, mounting clips and fastening bolts shall be of stainless steel grade SS316.
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 37 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Movable porcelain lamp holder with position markings and anti-vibration fixation
device.

Optical system, electrical control gear and lamp, mounted on "Plug-in" type
reflector gear tray with locating pins to ensure correct alignment when being fitted
into body. (As per BS EN 60922: 1991 and BS EN 60923: 1991).

The luminaire shall be provided with anti-glare grill and clear flat glass.

Two adjustable cable entries and a terminal block for the connection of incoming
supply cables shall be provided in luminaires incorporating auxiliaries. These shall
be situated as close as possible to the point of entry of the supply cable and shall
be readily accessible. Ground wire connection shall be taken through the plug and
socket connector to ensure that ground potential is maintained on the gear tray
when it is being removed from the luminaire for maintenance.

A means of clamping the electrical supply cables shall be provided in the luminaire
where necessary to relieve the termination of strain. The cable clamp arrangement
shall not damage the insulation of the cable.

Protective sheath for power supply cable, and expandable nylon cable grip for
wiring, conforming to BS 4533 Section 102.3: 1990.

Brass earth terminal set-in housing, according to BS 4533 Section 102.3.1990.

The lamp caps and the lamp holders shall meet the requirements of BS 5101:
1986 (Part 1) and BS 5101: 1986 (Part 2) respectively.

The luminaire shall be equipped with two brackets suitable for top/ corner
mounting and shall be of hot dipped galvanized steel. The brackets shall be
adjustable for continuous inclination from 0-180 degree.

Luminaires shall withstand prevailing ambient and lamp temperatures and shall
operate normally under such conditions.

7B/7 TUNNEL AND UNDERBRIDGE LUMINAIRES – MECHANICAL

REQUIREMENTS

Luminaires shall be provided with two separate compartments for the optical
system and for the control gear.

The tightness of the optical compartment shall be IP65, according to the BS EN

60529 standard. This tightness degree shall be achieved by the use of neoprene
gaskets or silicon gasket. The design of the luminaire shall be such that the sealing
gasket will never be exposed to sunlight or to the luminous flux emitted by the
lamp.

The tightness of the control gear compartment shall be IP65 or better, according to
the BS EN 60529 standard.

The opening of the control gear compartment shall allow a complete and easy
visual check of all electrical parts and to be suitable for easy access and easy
maintenance.
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 38 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The mechanical strength of the body and its accessories and the protector of the
luminaire shall be sufficient to withstand a mechanical shock having an impact
energy complying with BS 4533 Section 102.3: 1990, without any damage.

The luminaire shall be able to withstand a wind speed of 160 km/h without any
damage.

Fixing shall be of an effective locking means using stainless steel bolts grade AISI
316.

The luminaire in general shall comply with the requirements mentioned in BS

4533, Section 102.3: 1990.

All luminaires shall have overall protection against ingress of moisture of IP 65.

All fixings, which carry the weight of the luminaire and internal accessories, shall
be provided with suitable locking devices to prevent the dislodgment of any part of
the luminaire by vibration either in service or in maintenance. Compliance shall be
verified as per BS 4533 Section 102.3: 1990.

7B/8 TUNNEL AND UNDERBRIDGE LUMINAIRES – EMERGENCY

LUMINAIRES

Emergency luminaires shall comply with BS 5266 and EN 60598-2-22 and shall be
of the pictogram type.
Emergency luminaires shall be manufactured with polycarbonate diffusers and
have an ingress protection of IP55 to IEC 60529.
Thermal and photometric test reports shall be submitted. Emergency luminaires
shall be complete with nickel-cadmium batteries, inverter, dual-rate charger,
change-over equipment test switch, etc.
Emergency luminaires shall be wired with an Active, Neutral and Earth conductors
and an additional “unswitched active conductor”.
Refer to Particular Specifications

7B/9 TUNNEL AND UNDERBRIDGE LUMINAIRES – ELECTRICAL

REQUIREMENTS

The electrical accessories such as ballasts, igniters and capacitors shall be pre-
wired and pre-assembled on metallic supports that are fixed into the control gear
compartment for each lamp.

Special care shall be taken to allow easy maintenance and quick replacement of
the accessories. They shall be bolted (and not riveted) on the removable supports.
The supports shall be laid down in the compartment and in no case shall be
suspended by bolts, for security reasons and maintenance facilities.

All electrical accessories shall be able to withstand the temperature existing in the
control gear compartment in continuous operation and without any damage, at
ambient temperature of 50 degree C. Cable connections to the lamp holder within
the luminaire shall be of the heat resistant type with glass fiber or other approved
insulation. The arrangement shall comply with BS 4533 Section 102.3: 1990.

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 39 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The cable feed terminals and the earth screw shall be fixed inside the control gear
compartment. A cable holder shall be mounted near the terminals. An isolating
conduit shall be fitted to protect the incoming feeder cable. The arrangement in
general shall comply with BS 4533 Section 102.3: 1990.

A separate set of control gear shall be provided for the lamp comprising one
ballast associated with one capacitor and one igniter. The control gear should be
encapsulated in an approved enclosure conforming to IP 65 or better tightness.

Terminals of all ballasts, capacitors and igniters shall be shrouded. The ballast
shall be designed to operate the lamp and control it continuously in ambient
temperatures ranging from 0 degree C to 80 degree C. The igniter shall be
complete with timer no less than T15S (T fifteen seconds). Ballast should have
thermal protection built-in switch.

The capacitor shall be of the biphenyl impregnated type and shall be in a leak
proof metal container fitted with an internal discharge resistor. The permitted
operating temperature of the capacitor shall be marked on its case and shall be 90
Deg. C. The capacitors shall have value sufficient to raise the power factor of the
complete system to 0.85 or better. Each lamp shall operate using only one
capacitor. Any combination of two or more capacitors to have the equivalent value
of capacitance will not be accepted. Capacitors shall comply with the latest BS EN
60922: 1991 and BS EN 60923: 1991.

The control gear shall be supplied by the luminaire manufacturer and shall be
incorporated in a separate compartment in a way that heat emitted by lamp is not
conducted or transferred to the gear components.

The luminaire shall have a screw type lamp holder. The lead at the higher potential
above earth shall be connected to the center contact.

The operating temperature and thermal endurance characteristics shall conform to

Part 2 of BS 4533 Section 102.3: 1990.

7B/10 TUNNEL AND UNDERBRIDGE LUMINAIRES – PHOTOMETRICAL

REQUIREMENTS

The lamp fitting shall be adjustable to allow the luminous flux distribution to be
adapted to the geometrical installation conditions

The adjusting device of the lamp shall be sufficiently sturdy, and designed in a way
that cannot be disturbed, during its normal lifetime (vibrations) or during
maintenance operations (lamp replacement).

This device shall have permanent markings so that the lamp position
recommended by the manufacturer can be easily realized.

The photometrical classification of the luminaires, according to CIE Nr. 34

publication shall incorporate the following characteristics, depending on the lamp
position adjustment:

 Longitudinal flux control : Throw - intermediate or long

 Transverse flux control : Spread - Narrow or average
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 40 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Glare control : SLI - Greater than 3

7B/11 TUNNEL AND UNDERBRIDGE LUMINAIRES – PHOTOMETRICAL

PERFORMANCE REQUIREMENTS

Computer calculations relating to illuminance and luminance results detail shall be

submitted including the overall luminance uniformity ratio (UO) and longitudinal
luminance uniformity ratio (UI) which has to be achieved in the underpass, values
of glare control mark (G), threshold increment (TI) and specific Luminaire Index.

For the luminance calculation, the road surface to be considered is the R3 type
with QO = 0.07 according to CIE Standards.

The calculations shall be performed in accordance with the latest edition of CIE Nr.
30 publication and shall be based on the data given in the drawings. These
computer calculations shall achieve the requirements of Sub-Section P2/5 and as
shown on drawings.

These results are to be achieved taking into consideration a total maintenance

factor of 0.8 (dust depreciation factor x lamp lumen depreciation factor).
Computer calculations shall determine the maximum spacing of luminaires to be
adopted to achieve the above results.

7B/12 TUNNEL AND UNDERBRIDGE LUMINAIRES – DOCUMENTATION

REQUIREMENTS

The Contractor shall supply the following technical documentation and information
for each type of luminaires for the approval of the Engineer. The approval of the
Engineer does not absolve the Contractor of the contractual obligations regarding
the performance and compliance to the specification requirements.

 Catalogue sheet of the luminaire, ignitor, ballast, capacitor, and lamps.

 Detailed construction drawing of the luminaire, Polar diagram of luminous
intensity in roadway vertical plane and transverse vertical planes.
 Utilization factor curve for actual inclination of luminaire.
 Isolux diagram for actual inclination of luminaire.
 Intensity table, in the C-gamma co-ordinates recommended by CIE Nr. 27
Publication.
 Computer calculation printout showing the illumination and luminance levels.
Longitudinal Uniformity Ratio (UI), overall Uniformity Ratio (UO), specific
luminaire index (SLI), glare control mark (G) and threshold increment (TI).
These calculations shall also show the lighting curve as per CIE 88
recommendations.
 Tightness test certificate conforming to IP65 protection degree for the optical
compartment of the luminaires and the IP65 protection degree for the control
gear compartment. This test certificate shall be issued by an independent
official laboratory.
 Shock test certificate confirming the resistance of the body to impact energy
as per Clause 4.4 Section 1.4 of BS 4533, Part 1. This test certificate shall be
issued by an independent laboratory.

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 41 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Wind resistance certificate confirming that no damage will occur to the

luminaire at winds up to 160 Km/h for a short period. This certificate shall be
issued by an independent official laboratory.
 Total weight of the luminaire (with lamp and control gear).
 Power factor of one complete luminaire (under normal working conditions).
 Total electric consumption of the luminaire, including control gear losses
separately indicated.
 Rated lumen output of the lamp under nominal conditions.
 Depreciation curve of the luminous flux with burning hours.
 Luminous flux variation with the main voltage.
 Make and type of ballast and capacitors separately with their electrical
characteristics, e.g., Impedance, power factor, Temperature rise (t),
maximum temperature and power losses.

The contractor shall submit full details of areas using the same type of luminaires
in the Middle East and Gulf Area.
A computer program according to CIE standard on CD (compact disks) full IBM
compatible should be supplied and the matrix program for the offered luminaire.
The supplier shall submit for the Engineer's approval dimensioned drawings of the
control gear arrangements showing the exact positions of ballast, ignitor, lamps
and capacitors within the luminaire.
The contractor shall submit an assembled sample of the proposed luminaire for the
approval of the Engineer.
Single Line Diagrams, General Arrangement drawings for all Lighting Distribution
Boards and Panels.
System configuration diagram for the complete lighting control system.
Electronic (on CD) and hardcopy of the PLC Program shall be handed over to the
Client at the completion of contract. The PLC program printout shall have all the
information about all the computation elements like timing delays and counters,
logical instructions and inputs and outputs.
Contractor shall provide along with tender a recommended list of spare parts for
the complete lighting system including spares for Light fittings, PLCs, Dimming
controllers, etc. for 5 years of trouble-free operation. This list shall be complete
with unit rates.
Contractor to provide along with the tender a detailed description about the Mean
Time Between Failures (MTBF) of the proposed lighting system. This shall show
MTBF of all major parts of the system, such as Light fittings, PLCs, Dimming
controllers, L20 meters, Lighting controllers, etc.

7B/13 TUNNEL AND UNDERBRIDGE LIGHTING CLIMATE

Refer to 7A/4 CLIMATE in this specification

7B/14 TUNNEL AND UNDERBRIDGE LIGHTING CONTROL

The Underpass lighting system shall be controlled automatically by means of a
photometer system consisting of photometers, dimming controllers and a PLC.

Microprocessor based PLC/lighting controllers shall be provided in Underpass

LDB.

LDB shall contain sets of dimming controllers, HMI for Operator/programmer,

Interface for PC, photometer relays and lighting controllers and other items as
necessary.

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 42 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The lighting control shall be such as to continuously adjust by dimming control,

selected groups of luminaires in conformity with the increase and decrease of
external luminance at the entrance zone.

The photometers shall continuously monitor the external luminance and transmit
the signals to the lighting control unit, which shall process and convert the signals
received to determine the appropriate dimming level.

It is envisaged to have remote access for monitoring and controlling capability for
lighting control from a central SCADA system through operator workstations.
Hence the provision of such remote control SCADA connectivity is to be ensured
by installing all necessary devices, communication interfaces, etc. in the LDB
panels. The devices shall be ready for communication and shall be completely
configured. The actual remote SCADA communications will take place in future
and the communication devices should remain powered Off till such time.

Operator system entry shall be password protected with different levels of

accessibility depending on the level of Authority of the operator.

Lighting controller PLC shall support all functional requirements to achieve this
remote control.

Dimming / Lighting Control shall be generally in line with the Lighting control
schematic drawing included in the Tender drawings. However alternate schemes
with better functionality and with higher specifications may be acceptable subject to
Client/ Engineer’s approval during construction.

Photometers shall be provided for the purpose of sensing the adaptation

Underpass surrounding luminance. The photometers shall give a linear electrical
signal output proportional to the luminance measured. Adaptation of the level of
luminance detected by the photometer to the spectral sensitivity of the human eye
to be ensured. The photometer housing shall be corrosion proof and made of
high-grade stainless steel. The housing shall be equipped with a high-grade steel
swivel base, which can be swivelled +25 degree horizontally and vertically.

A self-limiting heating cable system shall be provided to ensure the absence of

moisture so that it would not affect the operation of the instrument.

Suitable shade shall be provided to prevent solar radiation to the casing.

Cable entry glands for power supply and signals to the photometer control unit
shall be absolutely dustproof and moisture-proof to IP67.

The signal cable interconnecting the photometers and the photometer control units
shall be multi-core armoured cable with shielding, compatible to the control system
proposed.

The photometers shall be mounted on hot dip galvanized steel column pointing in
the drivers' direction of vision, at a height of approximately 4.5m and at safe
stopping distance from the tunnel entrance, to meet the CIE standards
requirements and shall be approved by the Engineer/Client after site inspection.

Provide a suitable Industrial grade PC similar to Siemens PG type laptop,

equipped with all accessories related to MPI operations and software licenses to

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 43 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

interrogate the aforementioned data and to control the PLCs accordingly.

Empirical luminance measurement of all to be conducted on site as below.

 Luminance meters accepting a 20 deg. circular field of view shall be used for
luminance measurement in all zones.
 The luminance meter shall be mounted on a tripod in the centre or at a
suitable location of the eventual approach roads at a height of 1.5 m above
the road surface and with the 20 deg. field centered in that particular zone.
 The meter shall be positioned at the safe stopping distance from the
beginning of the measuring Zone.
 The measurements are to be repeated for each lighting stage for each Zone.
Collected readings are to be submitted to the Engineer/Client along with the
lighting design calculation for comparison and approval.

7B/15 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLS

The Underpass daytime lighting shall be dimmed in four steps and one night step.
The daytime lighting shall be continuously controlled in accordance with the
daylight outside the respective Underpass entrance.
Entrance shall have a photometer to measure the daylight at the respective
entrance. The lighting control system shall control the switching and dimming of
the entrance and exit zones.
The lighting control system shall work independently and shall have PLCs in the
LDB.
Dimming controller shall be controlled by the PLC as will be shown in the Lighting
Control Schematic diagram that will be prepared by the Contractor and submitted
to Engineer for approval. The PLC shall manage the switching of the HPSV lamps
in accordance to the outside light and determine the level of dimming for each
step.
The Lighting Controller PLC shall be located in the LDB as shown in the Lighting
Control Schematic drawings. All necessary cabling and interfaces between the
Lighting controller PLC and all the Dimming Controllers shall be provided.
The system shall be designed to have manual control at LDB level. For this
reason, LDB shall have a 3-position switches installed (AUTO – MANUAL – BY-
PASS). The manual operation shall permit to switch each step ON and OFF and to
adjust the dimming signal using potentiometers on the LDB. The 3- position switch
shall be adequate for ease of operation and manipulating logical groups of
dimming controllers. It shall be possible to remove any one of the dimming
controller out of service without affecting the rest of the lighting.
All data signal transmission in the field shall utilize Modbus or approved equal
protocol and to the future SCADA System by using Profibus or Industrial Ethernet
as applicable.

Dimming Controllers shall meet with following minimum functional specifications:

 Start-up: It shall provide Automatic programmable burn in cycle for the
lamps.
 Soft Start: Switching ON of lamps shall always take place at Zero crossing of
voltage waveform.
 Power: Rating to suit the load as a single unit without paralleling.
 Output Voltage: Stabilized + 1% of RMS value, independent of input voltage.
 Inputs/Outputs As necessary to meet the functional requirements of this
specification.
 Dimming Range: 100-30% of luminous output for HPS lamps

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 44 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Site Operation Temperature: 0°C / +60°C

 Humidity: 90% no condensing
 Efficiency: >98% at rated load
 EMC: EN 50081-1, EN 6055-2, EN 60555-3, EN 50082-2, CE conformity
 Harmonics: ≤ 1%
 Output Voltage Waveform: The dimming control shall be achieved using
trailing edge control. Peak voltage has to be maintained at each half-wave at
its maximum level.

7B/16 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLLERS

HPSV lamp circuits shall be designed to have minimum four switching steps to
avoid a large difference in the illumination levels while shifting from daytime to
nighttime. The steps shall be continuously stabilized, dimmed and monitored using
appropriate size of Dimming Controller.
A PLC, Dimming Controllers and communication port for use of Fiber optic cabling
for communication with the future central SCADA System, shall be provided for the
Underpass.
The PLC shall be programmed to communicate all instantaneous electrical values,
status of all lighting zones, L20 value, and percentage illumination levels achieved
in various zones inside Underpass, and alarms over an industrial type open
protocol to the future SCADA System. The communication protocol to be used is
subject to approval during construction and shall be compatible with the future
SCADA system of the Airport Tunnel Control Center which will monitor, control,
and receive alarm of this Underpass.

7B/17 TUNNEL AND UNDERBRIDGE MAIN CONTROL SYSTEM

The Underpass daytime lighting shall be dimmed in four steps and one night step.
The daytime lighting shall be continuously controlled in accordance with the
daylight outside the respective Underpass entrance.
Entrance shall have a photometer to measure the daylight at the respective
entrance. The lighting control system shall control the switching and dimming of
the entrance and exit zones.
The lighting control system shall work independently and shall have PLCs in the
LDB.
Dimming controller shall be controlled by the PLC as will be shown in the Lighting
Control Schematic diagram that will be prepared by the Contractor and submitted
to Engineer for approval. The PLC shall manage the switching of the HPSV
lamps in accordance to the outside light and determine the level of dimming for
each step.
The Lighting Controller PLC shall be located in the LDB as shown in the Lighting
Control Schematic drawings. All necessary cabling and interfaces between the
Lighting controller PLC and all the Dimming Controllers shall be provided.
The system shall be designed to have manual control at LDB level. For this
reason, LDB shall have a 3-position switches installed (AUTO – MANUAL – BY-
PASS). The manual operation shall permit to switch each step ON and OFF and
to adjust the dimming signal using potentiometers on the LDB. The 3- position
switch shall be adequate for ease of operation and manipulating logical groups of
dimming controllers. It shall be possible to remove any one of the dimming
controller out of service without affecting the rest of the lighting.

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 45 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

All data signal transmission in the field shall utilize Modbus or approved equal
protocol and to the future SCADA System by using Profibus or Industrial Ethernet
as applicable.
Dimming Controllers shall meet with following minimum functional specifications:
 Start-up: Automatic programmable burn in cycle for the lamps.
 Soft Start: Switching ON of lamps shall always take place at Zero crossing
of voltage waveform.
 Power: Rating to suit the load as a single unit without paralleling.
 Output Voltage: Stabilized + 1% of RMS value, independent of input
voltage.
 Inputs/Outputs As necessary to meet the functional requirements of this
specification.
 Dimming Range: 100-30% of luminous output for HPS lamps
 Efficiency: >98% at rated load
 EMC: EN 50081-1, EN 6055-2, EN 60555-3, EN 50082-2, CE conformity
 Harmonics: ≤ 1%
 Output Voltage Waveform: The dimming control shall be achieved using
trailing edge control. Peak voltage has to be maintained at each half-wave
at its maximum level.

7B/18 TUNNEL AND UNDERBRIDGE PROGRAMABLE LOGIC

CONTROLLERS (PLC’S)

General:
1. Each PLC System shall comprise of a Central Processing Unit (CPU),
Input/Output modules, serial interface module and programming units. PLC’s shall
be installed inside Local Control Panels or in separate cubicles. PLC shall be
suitable for ambient temperature of up to 65C and 95% relative humidity. Power
supply shall be 240 V a.c. 50 Hz. The system shall include at least 25 % spare
capacity for future expansion. Panel mounted display units shall be provided for
man machine interface where specified or shown in the Project Drawings. PLC
shall be of modular construction with plug in I/O cards and facility to install
expansion modules when necessary. The PLC shall have a real time clock with
battery backup.

PLC diagnostic indications shall include the following:

 Power OK
 Low battery
 Forced I/O
 CPU fault
 I/O status indicators

Central Processing Unit. The CPU shall perform the following function:

Scan all inputs, execute relay ladder logic programs and generate outputs for the
final control elements.
Monitor status of the system hardware and provide diagnostic information.
Process scan time shall be 8 milliseconds/kilobyte maximum.

Memory:

Random Access Memory (RAM) for real-time program execution with lithium
battery backup for data retention and EEPROM backup for permanent storage of
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 46 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

program shall be provided. The PLC memory shall be as required for the program
and future requirements subject to a minimum of [16] Mb.
Input/Output Module:Analogue input modules shall be for current, voltage, RTD Pt
100 or thermocouple input type, with a 16 bit resolution. Power supply for 2 wire
transmitters shall be provided where specified. Analogue outputs shall be isolated
4-20 mA d.c with 14 bit resolution, unless otherwise specified. Digital I/Os shall be
optically isolated. Contacts shall be rated 1A at 24 V d.c. The systems shall
support on-line replacement of I/O modules, in case of failure.

Programmer/Simulator:
Supply one programmer/simulator with PLC software for use by the Roads &
Transport Authority. Programming shall be through a lap-top programming unit.
Programming shall be user friendly, self-documenting type, with facility for
identification and comments. PLC programming shall be compliant with IEC
61131-3 standard on programming languages for PLC’s.

Serial Interface:
PLC shall be provided with serial interface ports for peer to peer communication,
MMI for operator interface, or Telemetry. Communication protocol shall conform to
the seven layer ISO Open Systems Interconnect (OSI) model, subject to approval
by the Engineer.

Programmer/Simulator:
 Programming shall be on relay ladder language.
 Password protected programming through hand held programmer or
personal computer.

A Panel mounted VDU shall be provided for the PLC when specified in the Project
Specification, as per the following specification.
 A panel mounted LCD (liquid crystal display) unit for graphic, numeric and
message display.
 Touch screen front glass with one million cycles minimum operational life.
 240 V a.c. 50Hz power supply.
 Enclosure protected to IP65.
 EEPROM for application program storage.
 Provide restricted access to the PLC database for simulating or forcing
inputs/outputs.
 This display unit shall be able to display the graphical trends of all analogue
values, status of all the dimming controllers, LDB power and luminance value
trends, failure alarms, communication status, Earth leakage relay operation
status, etc. This display unit shall also be programmed to show the savings
achieved due to use of dimming controllers. This shall also display the lamp
usage report with lamp replacement schedule.
 Size of display viewable area of the LCD unit shall minimum 17 inches.
 LCD shall be TFT type with high MTBF value. LCD shall have a resolution of
1400 x 900 minimum. LCD shall have horizontal Dot Pitch spacing of
0.22mm minimum and shall support all display requirements of the operation
and control as described above.
 There shall be a provision to connect keyboard to the PC at the local panel.
This PC shall have the Read/write CD, and 2 nos. USB ports.

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 47 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7B/19 TUNNEL AND UNDERBRIDGE REMOTE SUPERVISION AND BACK UP

CONTROL SYSTEM

The system shall provide remote access for monitoring and controlling the lighting
system from a central SCADA system (future) through operator workstations in the
Airport Tunnel Control Center.

Remote access and control for the lighting system shall be through the PLC
provided in the lighting control panel.

The communication between the lighting panel and the future central SCADA
system shall use Fiber Optic cables. The PLC shall be capable of supporting this
communication mode over a long distance to the Airport Tunnel control room.

Dimming controllers, the associated software, PLC and all other hardware shall
have open architecture and shall support communication interfacing on industrial
standard open protocols for communication with SCADA systems (future) of other
manufacturers.

It shall be possible to view the complete information and make necessary changes
with password protection based on authority level allocation from remote SCADA
station (future).

The future SCADA systems shall consist of PLC for overall lighting control and a
locally installed Industrial grade PC as operator /programming interface.

The PLC shall meet the requirements of specification section PS11, PS-7A/22.20
and as detailed below.

PLC shall control all dimming controllers of the appropriate Underpass section,
based on L20 measurement. The PLC shall also be programmed to compensate
for the Lumen maintenance factor and age of lamps. PLC shall be mounted in the
controls section of LDBs, as shown in the Lighting Control schematic diagram. For
the purpose, the K factor shall be available for changing locally and remotely,
through password authorization.

Should the Luminance meter (L20) fail or the signal is not available to the PLC,
then the PLC shall control the lighting with hourly historical peak luminance data
averaged over the last 7 days, or using its own astronomical clock.

In case a dimming controller fails during operation, the peak dimming controller
itself shall also be equipped with an automatic by-pass system. A failure shall be
communicated via a LED on the dimming controller PLC. Should the auto-by-pass
fail, each step in the LDB shall have a hard-wire by-pass activated with the Hand-
Auto-Bypass switch.

A Laptop PC with software installed, shall be capable of performing all the

necessary functions of the LDB. The operating environment shall be fully
multitasking, Microsoft / Windows 2000 or the latest operating system subject to
approval.

The Laptop PC shall have most recent processor and shall be similar to Siemens
PG or approved equal and shall be suitable for the purpose of programming and
maintenance of the system. The Laptop PC shall be supplied with pre-installed
operating system and programming software, licensed to RTA.
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 48 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The alarms that shall be communicated to remote SCADA system (future) on the
communication bus from lighting system shall include, but not be limited to the
following.

 Status of each LDB- Failed.

 Status of each dimming controller- Failed, Vin Fail, Vout Fail, etc.
 Status of each PLC/ Lighting controller- Failed.
 Power supply at each LDB- Fail.
 Each Dimming controller- failed alarm.
 Each circuit failure alarm.
 Mains supply failure alarm.
 Communications failure alarm between Dimming controller and the Lighting
controller PLC.
 Communications failure alarm between Lighting controller PLC and the
SCADA system (future).
 High temperature of dimming controller.
 Loss of L20 signal.
 Any other parameter critical for the monitoring of the Lighting system-
proposed by Manufacturer.

The List of parameters to be displayed and recorded on the SCADA system

(future) from the Lighting control system shall include as a minimum as listed
below. Each of the analog signals shall be provided with a trend indicating the
signal values for the time as necessary. At the end of desired period the values
shall be archived in an off-line storage location. It shall be possible to get a printout
of the desired parameters through PLC/SCADA system.

 Power consumption for each LDB, for every section of Underpass, and for
every dimming stage.
 Reduction in power achieved at each LDB due to dimming.
 Voltage, power and Current at each LDB.
 Input and Output voltage, Current and power of each dimming controller.
 Hours of operation of each stage for each Underpass.
 Circuit wise, Lamp usage report and lamp replacement schedule, with date.
 Current status of all dimming circuits at any given time.
 Status of all LDBs, Dimming controllers and PLCs used in lighting control
system.
 Current and historical L20 values at each entrance, in graphical and
numerical form for 12 last months.
 Dimming controller percentage applied.
 Auto/manual/bypass status of each dimming controller.
 Photometer status.
 Any other parameter as proposed by the lighting system supplier.

Redundancy to be ensured for the optical fibre cables and PLC communications to
the future Central SCADA system.

7B/20 TUNNEL AND UNDERBRIDGE CABLING

General

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 49 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The 600 Volt Grade Cable are for operating voltage 415/240 V and complying with
IEC Publication 502.
All cables and wires used for underpass lighting shall be FRLS type and meet fire
resistance requirements as per IEC331, IEC332-1, IEC332-3 and BS7864
Underpass lighting cables shall be multi-core, fire resistant modular construction
cabling system with quick connection socket and plug assembly installed on the
cable run at intervals as required for connection to luminaires.
Modular cable system shall comprise of fire resistant feeder cable and fire resistant
socket and plug assembly. Plug and socket assembly shall be 13A, 3 pin type.
Plug shall be sized for 2.5mm2 spur cable connection to the luminaires.
Ingress protection rating for the system shall be IP67 as per IEC standard.

Conductors
Cable conductors shall comprise class 2 stranded clean smooth annealed copper
wires having a conductivity not less than 100% international standard. The surface
of the individual strands shall be smooth and clean before the insulation is applied.
Cable sizes shall be selected based on de-rating factors, voltage drop
considerations (max 3%). The cable sizing calculations shall be submitted for
Engineer’s approval during construction.

Neutral
Cable of all sizes shall have full size neutral, i.e. same wire size as phase
conductor up to 25mm2 and about half size for cable size bigger than 25mm2.

Insulation
The insulation shall be XLPE with mineral ceramic fire resistant tape complying
with the following requirements:
 Normal operating temperature: 90 deg C.
 Chemical resistance: High
 Moisture resistance: High
 Thermal resistively: Low
 Fire resistance: Good
 Insulation thickness: in accordance with IEC publ. 502.1
 Phase identification: Cables shall be color coded. Red, yellow and blue for
phases and black for neutral and yellow / green for earth.
 Protection conductor identification: "YELLOW and GREEN"

Laying Up
The cores of cable shall be laid up and where necessary non-hygroscopic fillers
shall be used to form a compact and circular cable.

Sheath (Bedding)
The sheath shall consist of an extruded layer of low smoke, no halogen compound.

Armor
The armoring shall consist of galvanized round steel wire.

Over sheathing
The over sheathing shall be MDPE not PVC, whenever used outside the
underpass.

Serving
The serving shall be fire retardant and termite resistant and shall comprise of an
extruded black PVC sheath applied over the armor.
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 50 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Terminations
Terminations shall be by means of mechanical clamps which shall correspond to
the number and cross sectional area of the conductors.

Cable lengths
No joints shall be made in any of the cables. The cables shall be continuous
between termination points throughout the circuit.

Glands
All glands shall be fitted with moulded PVC shrouds to completely cover the
glands.
Earthing tag
Earthing tags shall be fitted to all glands.
Cable ends
The ends of all cables shall be sealed during laying.
Conduits used inside Underpass area shall be fire resistant epoxy coated GI/GRP
conduits.

7B/21 TUNNEL AND UNDERBRIDGE JUNCTION BOXES

Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529

7B/22 TUNNEL AND UNDERBRIDGE CABLE TRAYS

Cable tray material

Cable trays shall comply with NEMA Standard No VE 1
Install cable tray where noted on drawings, and where more than three large
cables follow the same route
Cable tray shall be manufactured of Grade 316 stainless steel with 90 mm sides
with double folded top edge and 40 mm min. wide folded rungs at max. 300
centres with mechanical couplings that provide earth continuity
Cable trays shall be at least 150 mm wide, unless otherwise noted. Cable trays
shall be wide enough to accommodate cabling in a single layer with 50% spare
width

Cable tray installation

Install cable trays as follows:

 Straight routing parallel, or perpendicular, to structure and coordinated with

other services
 With manufactured splices, bends, and intersections
 Joined with telescopic splice plates, secured to the cable tray using bolts,
washers and anti-vibration locking nuts, and shaped to provide a smooth
surface.
 With 40 mm min. air clearance to structure.
 On manufactured brackets spaced so that deflection is less than 1/360th of
the span when loaded and with at least two brackets per length at 1.5 m
max. spacing
 all lengths and accessories earthed
 Where cut, the edges of the tray shall be smoothed

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 51 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 In accordance with manufacturer’s recommendations using manufacturer’s

recommended accessories.
 Provide ventilated, peaked sun covers to all exterior cable trays.
 Label cable trays: ‘DANGER 415 VOLTS’ at 2 meter centres by means of
300mm x 40mm high white engraved plastic labels screw-fixed

Secure cables as follows:

 with GKN Type TC clamps for trefoil or quad groups of single core cables
 with GKN Type K clamps for large multi-core power or control cable (greater
than 120mm diameter)
 with UV resistant nylon wire ties for small cable.
 Refer to Particular Specifications.

7B/23 TUNNEL AND UNDERBRIDGE INSPECTION TESTING AND

COMMISSIONING

General
This Section covers particular requirements of Tests on Completion for the
inspection, testing and commissioning.

Equipment Inspection
As required, the Engineer's and Client’s Representative will attend the
manufacturer's works at the Contractors cost to inspect equipment prior to
shipment. Notify the Engineer at least 30 days prior to shipment, so that Factory
inspection can be arranged. Factory inspection shall be made only after the
Manufacturer has performed satisfactory checks, adjustments, tests and
operations on the complete system. Approval of equipment at the factory only
allows the manufacturer to ship the equipment to site, and does not constitute final
acceptance by the Engineer. The items to be inspected shall include all items for
the installation including but not limited to the following major equipment.

 LV and Control Cables

 Lighting Controllers and LDB
 Lighting fittings

The scope of inspection will include type tests, Document control & routine test
and inspections.

Factory Acceptance Tests

The Contractor shall be responsible for the completion of the following minimum
tests to provide assurance that the equipment/plant/material being supplied will
meet the performance requirements of this Specification and the relevant IEC
Standards. Where applicable, all tests shall be carried out in a manner as set down
in relevant IEC Standards. The List provided is an indicative minimum of the tests
required.

The Contractor shall develop full test schedules and sheets for the approval of the
Engineer's representative in accordance with the requirements of this
Specification.

Cables
 Continuity test
 Earth test

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 52 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Polarity test
 Dielectric test
 Conductor resistance test
 Insulation resistance test
 Tensile strength and elongation test
 Fire test
 Flame propagation test
 Temperature index test

Lighting Distribution Board

Inspection of the FBA (Factory Built Assemblies) (LDB) including wiring, electrical
and mechanical connections, Communication interfaces with SCADA (future) and
with other controllers, external and internal finish etc. Complete functionality of
photometer, Lighting controllers, and LDB shall be demonstrated during Factory
Acceptance tests on LDBs.

Mechanical tests including checking of all mechanical and electrical connections,

interlock etc.

Continuity and dielectric tests.

Ingress protection test.

Functional checks of all control circuit including the shunt trip operation of breaker
at 70% and 110% of the rated control supply voltage.

Calibration of metering instrument, CT, etc.

Training for RTA Personnel

Training shall be conducted by personnel employed by the Electrical
Subcontractor, familiar with the system supplied, experienced and trained in
developing and implementing instructional courses.

The Contractor shall submit information on the training program for approval prior
to shipment of the equipment. This submittal shall include a course outline, time
required, course schedule, sample workbook and instructor qualification
information, for each level.

The Contractor shall make a workbook on each course available to every person
taking the courses listed herein. The workbook shall be of sufficient detail so at a
later date a trainee could review in detail the major topics of the course.

One copy of each book shall be delivered to the RTA for its library.

The training times shall be scheduled by Employer in advance, so as not to disrupt

the RTA ability to operate the equipment.

Specialized training shall be provided for a minimum of five of the Employer’s

personnel in the operation and maintenance of the system at the manufacturer’s
facility or in Dubai. The training program shall be divided into two segments and
each shall consist of at least five, eight hour working days.

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 53 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The maintenance training program shall be developed for personnel who have
electronics maintenance and repair experience and a general knowledge of
computer systems, but shall not assume any familiarity with the specific hardware
furnished. As a minimum, the following subjects shall be covered:

 System architecture and layout.

 Hardware components.
 Module switch settings (configuration switches).
 I/O modules.
 Power supplies.
 Data highway.
 Programmer connection.
 Programming and diagnostic techniques.
 Battery replacement and recording.
 Troubleshooting.
 Disassembly.
 Cleaning.
 Component replacement.
 Reassembling.

The operation training program shall include the following topics:

 Power-up, bootstrapping and shutdown of all hardware devices.

 Interpretation of all standard displays.
 Appropriate actions for software and hardware error occurrences.
 Manual data entries.
 Loading of any required software into the system.

System Management:

The training in this area shall cover the following:

 Provide training for clients personnel and Maintenance Contractor for
programming, operation, maintenance & troubleshooting of all parts of
Lighting System including but not limited to following:
 Lighting Controllers
 Lighting Fixtures
 Photometers
 Communication Interfaces
 PLC’s
 The training shall involve classroom training and field demonstrations.

Site Inspection and Testing

The Engineer shall attend the inspection and tests before setting the equipment to
work. The Contractor shall notify the Engineer, in writing, one week before
commencing tests.

A Site Acceptance Test (SAT) shall be conducted as part of the Lighting system
validation and shall include all equipment and software within the Contractor’s
scope of supply. This test shall be conducted after the equipment has been
installed at the Site and the Client is satisfied of the correctness of the installation
and of the operation of the equipment.

Particular Test Requirements:

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 54 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

1. Communication test
The Contractor shall conduct a test to establish the correct functioning and
ability for transmission of data correctly over fiber optic cable to and from
each port on the system. In the event of any problem or deficiency being
identified in any equipment supplied by any party, this shall be reported fully,
in writing, by the Contractor to the Engineer.

2. Hardware test
Demonstrate correct operation of hardware using off-line diagnostics.

3. Functionality test
Demonstrate the system performance and functionality meets the
specification.

4. Test details

The SAT shall be carried out in accordance with a test specification produced
by the Contractor and approved by the Engineer

Test equipment and test software shall be provided by the Contractor to load
the system to the worst case scenario defined in the test specification.

The Contractor shall prepare a test report following the SAT.

5. Underpass Lighting

Illuminance measurements.
Luminance measurements.
Calibration of photometer control unit sensors and control devices.
Test to establish correct operation of Underpass lighting control from LDB
and through SCADA (future).

6. Redundancy Test of the FO “Fiber Optic” communication network and PLC.

System Commissioning:
Where required in the Project Specification, the Contractor shall provide staff to
work in conjunction with the RTA to ensure the satisfactory service operation of all
equipment in the system, to assist the RTA to adjust the configuration data and to
develop/modify application program.
The Lighting Subcontractor shall provide Performance verification test of the
complete Lighting system for a continuous period of 90 calendar days, for all items
under of Lighting system, for demonstration of reliability, repeatability and
operability. In the event of failures during this period, the demonstration shall be
extended for a further 90 days period. The list of parameters to be monitored
during the Performance Verification test shall be approved by the Engineer before
commencing the Test.

The supply system shall be tested in the sequence indicated:

 Continuity of protective conductors, including main and supplementary
equipment bonding.
 Earth electrode resistance.
 Insulation resistance.
 Protection by electrical separation.
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 55 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

 Polarity.
 Earth fault loop impedance.

System Takeover:
The criteria for takeover of the system shall be:
 Submission by the Contractor and approval of as-built drawings.
 Submission by the Contractor of all documentation.
 Submission of operational and maintenance manuals.
 Submission of all software design and support documentation and the
lodging of source codes in a place of secure safe-keeping and storage with a
Third Party.
 Provision of information and examples of each type of report and each item
of user-configurable functionality.
 Issue of all relevant test certificates.
 Successful completion of the SAT.
 System commissioning and issue of Final System Test Certificate by the
Contractor.
 Following satisfactory completion of the above, the Engineer will issue the
System Takeover Certificate.

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 56 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

TABLE OF CONTENT

7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS.......................................................... 57

7C/1 TRAFFIC SIGNAL SYSTEM GENERAL SPECIFICATIONS ................................ 57
7C/2 TRAFFIC CONTROLLER SPECIFICATIONS ....................................................... 63
7C/3 TRAFFIC SIGNAL HEADS AND LAMPS SPECIFICATIONS .............................. 87
7C/4 POWER AND SIGNAL CABLES ........................................................................... 93
7C/5 PEDESTRIAN PUSH BUTTON ............................................................................. 96
7C/6 TRAFFIC SIGNAL CANTILEVER POLES ............................................................. 98
7C/7 POLE FOUNDATIONS ........................................................................................ 102
7C/8 MANHOLES AND CHAMBERS ........................................................................... 102
7C/9 LOOP DETECTORS ............................................................................................ 102

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 57 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS

7C/1 TRAFFIC SIGNAL SYSTEM GENERAL SPECIFICATIONS

7C/1.1 SUMMARY

This section specifies the requirements in general for the design, procurement,
installation, testing, calibration and commission for the Traffic Signaling system.
The traffic signaling system refers to all the equipments such as signal heads,
lamps, gantries, supports, poles/posts, pedestrian push buttons, foundation for
gantries/poles, manholes and chambers, detector loops, signal and power cables,
communications, telephone leased lines, etc. as required to provide a fully
functional Traffic Signal System as per International standards and Dubai Local
Standards. All the necessary civil, electrical and mechanical works shall be
considered to be included in the scope of work for the Contractor.

7C/1.2 REFERENCES

(a) All supplies and services offered in response to this specification shall conform
to the latest International standards.
(b) The design, equipment and installation requirements shall comply with the
latest editions of standards and recommendations laid down by the following:

1. AASHTO Standard Specifications for Structural Supports for Highway Signs,

Luminaires and Traffic Signals.
2. AASHTO Standards for Traffic Signals.
3. RTA Standards on ITS and Traffic Signals
4. ISO1461:1999 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
5. BS 5649: Part 4:1978 or BS EN 40:2004 Lighting columns.
6. EN 12368: 2006, Traffic control equipment. Signal heads
7. MUTCD - Manual on Uniform Traffic Control Devices
8. BS-EN 60529, Specification for Degrees of Protection provided by Enclosures
(IP Code)
9. BS-EN 50293, Electromagnetic Compatibility Road Traffic Signal Systems
Product Standard
10. BS-EN 12675, Traffic Signal Controllers – Functional Safety Requirements
11. IEC 439, Low-voltage switchgear and controlgear assemblies
12. BS 1376, Specification for colours of light signals
13. BS 4300/4, Wrought aluminium and aluminium alloys for general engineering
purposes (supplementary series).
14. BS EN 12373-1, Aluminium and aluminium alloys. Anodizing. Method for
specifying decorative and protective anodic oxidation coatings on aluminium

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 58 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

15. BS 6346, Electric cables. PVC insulated, armoured cables for voltages of
600/1000 V and 1900/3300 V
16. BS-EN 60529:199, Specification for Degrees of Protection provided by
Enclosures (IP Code)
17. BS 729:1986, Specification for hot dip galvanized coating on iron and steel
articles
18. BS 5486 Part 1:1990 Low-voltage switchgear and control gear assemblies.
Requirements for type-tested and partially type-tested assemblies
19. BS EN 124 D400 Gully tops and manhole tops for vehicular and pedestrian
areas
20. BS EN 40-5, Lighting columns, Specification for steel lighting column
21. BS 5649-5, Lighting columns. Specification for base compartments and
cableways
22. BS EN 1011, Specification for Arc Welding of Carbon and Carbon Manganese
Steel
23. Regulations for Electrical Installations as issued by the Dubai Electricity and
Water Authority (DEWA).
24. Regulations for Electrical Installations as issued by the Institution of Electrical
Engineers (IEE), London (for points not included in DEWA Regulations).
25. Recommendations for Lighting Installations as issued by DEWA and the
Chartered Institute of Building Services, London, and CIE.
26. Standards relating to Electrical Installations and equipment as issued by
International Electro technical Commission (IEC) and British Standards
Institute (BSI).
27. Regulations for communications telephone leased lines system installation as
issued by local telecommunications authorities and RTA UTC/ITS.
28. National Electrical Code issued by National Fire Protection Association
(NFPA), USA.
29. NFPA-70-National Electrical Code issued by NFPA, USA.
30. IEC801-4 Susceptibility Of Electronic Equipment And Systems At Higher
Frequencies And Voltages.
31. IEC 60529 IP 65, Ingress Protection
32. IEC 60529 IP 66, Ingress Protection
33. DIN 67527, Traffic control equipment. Signal heads
34. BS EN 12368, Traffic control equipment. Signal heads

7C/1.3 CLIMATIC CONDITIONS

(a) The climate in Dubai in the summer months is hot and humid. A humidity of
100 percent at 50 degree Celsius has been recorded.
(b) Climate

1. Violent sand and dust storms of several hours duration occur and even on
comparatively still days, fine dust is carried in suspension in the atmosphere.

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 59 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

2. All apparatus and equipment shall, therefore, be so designed and constructed

that they operate satisfactorily and without any deleterious effect for prolonged
and continuous periods in the conditions stated above and at the following
ambient temperature conditions:

maximum sun radiation temperature in summer - 85 °C

maximum ambient temperature in summer - 55 °C
average max. ambient temperature in summer - 50 °C
minimum ambient temperature in winter - 10 °C
altitude of Dubai may be taken as - sea level

(c) The temperatures quoted above make no allowance for heat generated from
equipment itself or from any other equipment in the vicinity.
(d) The capacity and ratings of all electrical equipment and materials given are,
unless otherwise indicated, for Dubai climatic conditions as stated in Clause
(a) above. Provide the basis of the derating factors applied in each case.
(e) Where specific sizes are indicated e.g. cable sizes, due allowances shall be
made in the design for the climatic conditions of Dubai and derating shall be
applied.

Where no ratings or sizes are indicated for components and other

accessories, supply equipment, which will give trouble free service in the
ambient conditions stated above.

(f) Degree of Protection – For All outdoor equipment the degree of protection
shall be minimum IP 66 as per IEC 60529.

7C/1.3.1 Temperature

(a) The Traffic Controller in the enclosure shall be designed to operate in external
ambient temperatures of -25°C to +60°C.

(b) The Traffic controller will be subjected to high levels and long periods of solar
radiation. The design of all components of the Traffic Controller shall take into
account the effects of such exposure and must be able to operate satisfactorily
without any malfunctions or failures. Any Hardware restrictions must be clearly
identified in the technical submittal, which shall be subject to approval by RTA.

7C/1.3.2 Atmospheric Conditions

The Controller shall be protected against driving rain and sand, dust conditions and
industrial pollution. The Degree of Ingress Protection shall be minimum IP65 for
the complete enclosure. All openings and entries must be sealed to provide this
rating.

7C/1.3.3 Humidity

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 60 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The equipment shall withstand a temperature of 50°C with a relative humidity of

95%.

7C/1.4 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT

7C/1.4.1 Civil Works

The civil engineering contractor or the authority shall carry out civil works
associated with the installation of traffic signals, and supply necessary materials.
The work and material supply will include:

1. The construction of draw pits and channelizing islands.

2. Laying of cable conduits across the carriage-way
3. Moving kerbs and medians and reinstatement
4. Erection of poles, guardrailing and reinstatement to pavements and footways.

7C/1.4.2 Excavation

All excavations shall be in accordance with standards approved by the engineer

and shall have a firm level base and clean workmanlike sides. The exact location
of all signal equipment and channelizing islands and hence of the excavations,
shall be agreed on site by the engineer before excavation begins.

7C/1.4.3 Ducts

Cable ducts shall be 100mm PVC in footways

7C/1.4.4 Draw Pits

Draw pits will be constructed at changes of direction of ducts. Draw pits shall be
located off the carriage-way. The contractor will be responsible for excavation and
reinstatement of routes from draw pits to signal poles and controller cabinets.

7C/1.4.5 Cable Duct and Conduits

Cable ducts and conduits shall be laid with a minimum cover of 150mm under
footways and medians and a minimum of 600mm under carriage-ways. All ducts
and conduits shall be fitted with draw cords.

7C/1.4.6 Median and Kerb Construction

Medians and kerbs may be of two types, pre-cast or cast in place. They should be
constructed in accordance with the drawings.

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7C/1.4.7 Pavement Construction

Where new pavement or reinstated pavement is to be constructed, it shall be of the

same type and level as that surrounding. It shall be constructed in accordance with
the contract drawings.

7C/1.4.8 Footway Construction

The footway shall be reinstated or constructed as shown on the contract drawings,

and shall generally use the same materials as the surrounding surface.

7C/1.4.9 Signal Controller

Signal controllers shall be mounted on concrete plinths and secured by four bolts.
The design of the base shall allow the equipment case to be replaced readily when
required. The equipment case shall be sealed at the base and all ducts and
conduits entering the controller shall also be sealed.

7C/1.4.10 Site Clearance

1. Dismantle existing signal installation equipment.

2. It shall be the responsibility of the contractor to dismantle all existing traffic signal
installations at locations where new equipment is to be provided.

3. Return to store all dismantled traffic signal equipment shall be transported to the
store of the RTA.

4. The contractor shall take all necessary precautions in the handling of dismantled
equipment to ensure the delivery to store in a condition that will permit the RTA
to refurbish the equipment.

7C/1.4.11 Installation

1. The traffic signal contractor shall set out the positions of all signal poles and
controller cases in accordance with the contract drawings. If during the course of
setting out or after excavation he discovers any obstructions that will prevent the
placing of any pole or controller in its designated position he shall propose an
alternative position to the engineer and await his decision. If any variation in cable
quantity results from such repositioning he shall notify the engineer accordingly.

2. The traffic signal contractor shall supervise the installation of all signal poles and
controller bases, together with all excavations for cables from draw chambers to
signal poles and controllers.

3. After the signal poles and controller bases at each junction have been installed,
the traffic signal contractor shall assemble and install all the other requirements of
his supply, including the laying and terminating of all cables.

4. The ends of all cables that have been cut to length shall be properly sealed
immediately they are cut, unless they can be terminated the same day.

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 62 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

5. Cable terminations shall be mechanically and electrically sound, and able to

withstand all traffic induced vibration.

6. The armoring of all cables shall be electrically bonded together in the controller
case, and to controller cases and signal poles.

7. Cable ends shall be bound with PVC tape after termination of the conductors.

8. All cables shall be adequately supported on cable clamps or gland plates.

9. The traffic signal contractor shall adjust the direction of beam of all signal faces
as directed by the authority.

10. When each signal installation has been completed and has passed its tests ,
excess cable ducting space shall be sealed with epoxy resin to prevent ingress of
vermin. All damaged paint work on the enclosure shall be made good to the
satisfaction off the Engineer. (For the door seal, please refer to Clause 7C/2.6
(n)).

7C/1.4.12 Testing and Placing in Service

Traffic signal equipment and installation will only be accepted by the Engineer and
RTA/ RLTS following factory acceptance testing at the works depot and site
acceptance testing following installation. The Engineer and RTA/ RLTS may, at
his/her discretion, attend work/depot tests and inspect equipment and materials
before dispatch from the works.

1. Factory acceptance tests (FAT)

FAT shall be carried out at the traffic signal contractor’s works or on the premises
of the local depot. The Contractor shall demonstrate the correct operation of the
equipment. Suitable test facilities and assistance, including dummy loads, test
switches, etc. shall be provided for the tests by the Contractor. These facilities
shall allow the equipment to be tested over the whole of the specified voltage and
environmental ranges. Works tests of controllers shall demonstrate the correct
functioning of all standard functions of the controllers, in addition to those required
in the particular installation to which it is destined.

The traffic signal contractor shall furnish to the Engineer a manufacturer’s

certificate for each controller supplied certifying that it has satisfactorily passed the
appropriate tests and that it conforms with the individual specifications.

The Contractor shall give the Engineer and RTA/ RLTS every opportunity for
observing the FAT.

2. Site acceptance tests (SAT)

Tests after installation shall be carried out by the traffic signal contractor and
observed by the Engineer and RTA/ RLTS representative.

After installation and termination of all cables, but before the insertion of signal
lamps and controller logic units, all signal cables shall be connected together and

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 63 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

subjected to an insulation test. The tests shall be carried out at 500 V D.C. The
resistance to earth of the cable network shall be not less than 1 megaohm.

Provided the above test has been satisfactorily passed, signal lamps and controller
logic shall be inserted and the installation switched on. All timings and functions of
the whole installation shall be tested.

To assist in on-site testing, the traffic signal contractor shall provide and fit
temporary hoods to all signal heads of each installation under test. The hoods shall
prevent the signal aspects being seen by traffic, but shall allow illuminated aspects
to be checked by testing staff.

The entire installation shall be inspected by the Engineer for good workmanship.

When the installation has been inspected and tested and found to be satisfactory ,
a Take-Over Certificate will be issued. The installation will then be placed into
service by the contractor when requested and approved by the Engineer.

7C/1.4.13 Liaison
Provide liaison with Dubai Electricity and Water Authority or RTA Roads
Department/ Road Lighting and Traffic Signals Section in accordance with project
co-ordinations.

7C/2 TRAFFIC CONTROLLER SPECIFICATIONS

7C/2.1 SUMMARY

(a) This section specifies the requirements in general for the design, Procurement,
installation, testing, calibration, and commissioning for the Traffic Signal Controller.
The “traffic Controller” term refers to all the equipments associated with the Traffic
Signal Controls, including but not limited to the equipment such as Controller CPU,
Lamp Cards, Dimming Control transformers, Power Supply unit, Controller
Cabinet, Timers/ Telephone communication, etc. as required to provide a fully
functional Traffic Signal Controller System as per relevant International standards
and Dubai Local Standards. All the necessary Electrical and Mechanical
Equipment for the Traffic Controller, including Supply, installation, testing and
commissioning of the Controller and Electrical equipment, systems, items,
accessories etc. for a complete Traffic Signal Controller System part of the Project,
shall be considered to be included in the scope of work for the Contractor.
(b) The Contractor shall provide a minimum warranty period of 10 years from the
date of commissioning for all equipment, components and services supplied within
this Clause.

7C/2.2 STANDARDS AND REFERENCES

(a) All supplies and services offered in response to this specification shall conform
to the latest International standards.
(b) The design, equipment and installation requirements shall comply with the latest
editions of standards and recommendations laid down in Clause 7C1.2

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 64 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/2.3 CONTROLLER GENERAL REQUIREMENTS

(a) The operation of the controller shall be phase oriented. Timings and demands
shall be associated with phases and the control philosophy shall be designed
to give right-of-way to phases in an optimum manner.

(b) Phases shall be grouped into stages for Manual Control, operation in Urban
Traffic Control Schemes and in Cable less Linking Schemes. The traffic
requirements and safety constraints shall also condition the grouping of
phases into stages.

(c) The controller shall receive change requests for ROW from either/all of the
followings:
I. ‘On-street’ detection equipment and pedestrian push-buttons
II. The UTC computer
III. The Cable less Linking Facility
IV. Manual inputs
V. Special requests, e.g. Ambulance or Civil Defense hurry calls

(d) The controller shall based on the above requests, change the appearance of
phases in accordance with the controller strategy, the current mode operative
and the demand requests for ROW. The controller shall always change stage
cyclically when the stages are demanded.
(e) The Contractor shall submit to the Engineer the layout and construction of the
controller unit and the logic control module for approval.

7C/2.4 MAINS SUPPLY

(a) The Traffic Controller shall be usually provided with Single Phase power
supply from nearby Street Lighting Feeder Pillar. The following table shows the
supply voltages that will be available:

Table ‎C-1 Supply Voltage

Nominal Voltage Minimum Voltage Maximum Voltage

200V to 240V 184V 264V
110V to 120V 92V 132 V

The controller shall be capable of being operated using these values of supply
voltages. If required, Necessary selector switches shall be provided on the
controller.

(b) Frequency of Supply Voltage : 50Hz ±2Hz

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 65 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(c) In case of Mains Brownout, the Traffic controller shall continue to operate with
up to 50mS loss of mains, without any harmful effects.

(d) The Traffic Controller shall be capable of sustaining a prospective short circuit
current of value 16 KAmps from the supply.

(e) On resumption of supply following a mains failure, the traffic controller shall
restart without operator intervention.

(f) During power failures, the In-Built Primary cell Lithium battery shall provide
support for the following:

1. Clock Synchronization (programmable up to 31 days).

2. Timing Data (greater than one year)

3. A backup facility shall be provided to data integrity of 4 hours if the battery has
failed or is removed for replacement.

(g) Solar Cell Input: Solar cell input operating voltages shall be as follows:
 80V RMS indicates switch to Dim
 less than 40V RMS indicates switch to Bright

(h) The solar cell shall enable the controller to identify the light level and thus dim
the signals when it is dark. The switch shall be set to operate at 55 lux and release
at 110 lux. Time switch control of the change to and from Dim shall also be
provided.
(i) Obtain confirmation from the Supply Authority/ RTA Road Lighting section of
the size and number of cables from Feeder Pillars/ Main Switchboards. Allow for
adequate and appropriate cable glands, lugs and boxes.

7C/2.4.1 Electrical Noise

(a) Supply Transients

i.The Traffic Controller shall be designed to withstand the following transients

on its supply: ±1kV transients with a repetition frequency of 5 kHz applied
according to IEC801-4.

(b) Electrical Interference

i.The Traffic Controller shall be designed to create very little electrical

interference by the use of built in filters and solid state lamp switching control.
The lamp switches shall be switched at zero crossover of the mains’ supply to
reduce any switching transients.
ii.The switching of the signals from dim to bright (or vice versa) shall be
controlled carefully to ensure the switching does not cause interference.
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 66 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

iii.The Traffic Controller design shall also be extremely tolerant of externally

generated electrical interference. Care shall be taken to avoid earth loops
using a ‘Star’ point earthing system to which the cabinet, the cabinet doors,
the internal metal work, the junction cabling and the mains earth should be
connected.

7C/2.4.2 Controller Load

This Contract may accept quartz halogen lamps or LED lamps. The Contractor
shall provide detailed information on the type of lamps proposed.
If the Contractor proposes to use Extra Low Voltage (ELV) lamps such as quartz
halogen or light emitting diodes (LED), the submission shall provide all loading
requirements on the mains power supply.
The Contractor shall provide a detailed calculation on the total power consumption
of the completed controlled junction.

7C/2.4.3 Lamp Drive Capability

The lamp power circuits of each signal phase of the controller shall be capable of
providing the current for 6 signal heads each with 3 signal aspects as a minimum.

7C/2.4.4 Detector Power Supplies

The signal controller shall provide power for vehicle loop detectors. A maximum of
32 loop detectors shall be allowed for.

7C/2.4.5 Audible Supplies

(a) The Audible power supplies on the Traffic Controller shall be designed to
provide a DC voltage between 10V and 24V, and typically provide 50mA at 18V
DC. This shall be provided using a dedicated Audible Power Supply Kit.

(b) This kit shall also provide the controlling signal for ‘Tactile Power Supplies’.
The tactile power supply shall obtain its power directly from the pedestrian green
drive. The controlling signal shall allow the controller to switch off the tactile while
the green is flashing.

(c) Audible and tactile units used must operate correctly over the voltage range 10
to 24V DC. The Contractor shall liaise with the Engineer on the suitability of
audible and tactile units.

(d) The audible and tactile units shall provide 4 modes of operation.

i.Normal Audible
ii.Switched
iii.Muted Audible Output
iv.Pelican With Flashing Green Man
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 67 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(e) The Audible units shall only be used as directed by RTA / Engineer. However
the Traffic Controller shall have the capability to provide the required outputs as
described above.

7C/2.5 OPERATIONAL REQUIREMENTS

7C/2.5.1 General

The Controller shall be phase oriented. Each vehicular or pedestrian phase shall
have its own set of timings and timers. While operating in the vehicle actuated
mode, phases will be introduced by demands and/or programmable conditions.
Each phase shall be able to control three lantern aspects.

Each Controller shall have the capability to control up to 32 phases. Depending on

the configuration of each junction a Controller may not be fully equipped for 32
phases.

If a junction requires less than 32 “real” phases, the Controller shall have the
facility to utilize the remaining phases as “software” phases.

For traffic efficiency, non-conflicting phases could be grouped into stages. The
Controller shall have facility to support 32 phases. When demands are present for
all stages, the Controller shall cycle sequentially through all the stages as
programmed. Stages may be skipped if there is no demand for the stage.

7C/2.5.2 Vehicular Phase

Each vehicular phase shall have control of the following lantern displays at the
street level:
(a) RED
(b) GREEN
(c) AMBER
(d) Flashing AMBER (for Stand-alone Pedestrian Stream site)

A vehicular phase may control one, two or three lantern aspects

As a minimum requirement, each phase shall be divided into the following timing
intervals:
(e) Red,
(f) Minimum Green,
(g) Variable Initial Green (depending on vehicle detector placement),
(h) Rest Green,
(i) Extension Green,
(j) Amber (intergreen),
(k) Red (intergreen).

The display of the various lanterns shall be controlled by timing intervals

programmed within each phase. The Controller shall provide facilities to allow:

(a) The introduction of the green aspect to be delayed;

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(b) The termination of the GREEN to be delayed;

(c) A minimum safe green period to be maintained under all conditions;
(d) The green period to be extended by the associated vehicle detectors, if traffic
demand continues, to a set maximum period;
(e) The green period to be terminated conditionally even demand to extend the
GREEN display still exist;
(f) The rest green period to be held if there is no other conflicting traffic demand;
(g) The green period can be held conditionally or by an UTC System;
(h) Within a stage, any one selected phase or phases be able to be terminated
earlier to allow for conflicting pedestrian phase to be introduced;
(i) The intergreen period to be varied without compromising the safe minimum
intergreen period.

A demand for a vehicular phase shall be introduced by any of the following

conditions:

(a) An actuation of one of a selected group of vehicle detectors associated with

the phase;
(b) a demand for a parallel pedestrian phase;
(c) when a phase terminates due to maximum timer expired and demand on that
phase still exist, a revertive demand should be generated for that phase;
(d) a manual selection of the phase using the operator interface unit;
(e) an artificial demand generated by the UTC system.

Under normal operation, the demand for a phase is reset when the phase is
introduced. In other cases, the demand may also be reset when the demand is
fulfilled by another phase.

These demand conditions and phase termination conditions shall be

programmable in accordance with the junction layout and conditions.

When the Controller is controlled by an UTC system, the Controller shall execute
the system commands independent of local demands. The control system shall
not be able to override the safe minimum green time and intergreen time.

7C/2.5.3 Pedestrian Phase

A pedestrian phase shall control two lantern aspects – RED and GREEN. Each
pedestrian phase shall have control of the following lantern display at the street
level:

(a) RED (Don’t Walk )

(b) GREEN (Walk)
(c) Flashing GREEN Clearance (by flashing the GREEN Walk display)

A demand for a pedestrian phase shall be placed when the associated pedestrian
push button is actuated. The display of the GREEN walk shall cancel the
pedestrian demand.

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 69 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The Controller shall be capable of introducing a pedestrian phase automatically

when a selected vehicle phase is introduced based on time schedules stored in the
Controller.

When the Controller is controlled by an UTC system, the Controller shall execute
the system commands independent of local demands. The control system shall
not be able to override the pedestrian clearance period.

7C/2.5.4 Stages

A stage is a time period during which compatible phases are allowed to operate
simultaneously. The stages may include both vehicle and pedestrian phases.
Stages are provided to maximize the throughput and minimize delays to traffic at a
junction. A primary requirement is safety. The selected phases should have no
possible conflict with each other.

The Controller shall provide facilities to allow all the stages necessary to be
established. These facilities shall include processes and tools to define:

(a) the phases composition of each stage,

(b) the phases that could operate in two or more sequential stages without
interruption to the GREEN aspects,
(c) the total number of stages,
(d) conditions for the introduction of each stage,
(e) conditions for the termination of each stage,
(f) prohibitive stage transition sequences,
(g) a minimum of four different composition and sequence of stages that are
selectable conditionally.

The algorithms used for the transition of stages shall ensure conflicting displays do
not occur. The minimum GREEN settings and pedestrian clearance settings are
not violated by the transition.

Under vehicle actuated operation, the Controller shall ensure that all phases are
serviced if demands exist for these phases within each signal cycle.

7C/2.5.5 Detection System

The Controller shall provide a minimum of 64 input circuits for the processing of
detectors. The inputs may be assigned to vehicle phases, pedestrian phases or
special functions. The assignment shall depend on the individual junction layouts
and operation.

The input interface circuits shall generate the following status signal for the
Controller:

Open Circuit = Input Active

Closed Circuit = Input Inactive

Inductive loop detectors are used normally for vehicle detection. However, other
types of detectors, e.g. radar, infrared, video may also be used.

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 70 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Pedestrian push buttons are used for pedestrian detection.

The Controller shall monitor all vehicle detectors and pedestrian push buttons. An
alarm shall be generated by the Controller if a vehicle detector or pedestrian push
button is active or inactive for a predefined period. The predefined alarm period
shall be programmable for up to 4 hours in one minute increments. The alarm
shall not be reset until the input has changed state since the alarm was reported.

7C/2.5.6 Safety Requirements

The Controller shall perform internal software and hardware, and external
hardware checks regularly. The Controller shall be shut down automatically and
orderly when a fault or a malfunction has been detected. The Controller shall
adopt remedial actions to minimize the impact of such faults. The Contractor
should provide the methodology used for these self checking functions and the
remedial actions taken to ameliorate the operation.

The internal checks should include but not limit to software integrity (e.g.
checksum), memory and data communications channels. The Controller hardware
and software shall have built-in software-execution checks (watchdogs) to ensure
that the Controller integrity is maintained.

The external checks should include but not limit to the individual lamp circuits,
electromechanical aspects of the Controller such as:
 circuit cards are inserted properly
 cables are effectively terminated on connectors
 signal lamps are properly inserted into lamp holders.

The Controller shall log all detected faults and malfunctions. The log shall be
stored in non-volatile memory. The log shall have capacity to store up to 6 months
of data.

The Controller shall, as a minimum, continuously monitor and respond to the

following conditions.

(a) Lamp Circuit

The electric current and/or voltage of individual lamp circuits shall be

monitored at intervals no greater than 200 mS during the lamp active period.
The Controller shall take remedial action if the measured value varied from the
expected value.

(b) Red Lamps

The Controller shall monitor failures of vehicle phase RED lamps. When all
the RED lamps have failed Drivers and pedestrian frequently assume that the
phase is in GREEN. In this situation, the Controller shall change its operation
to ensure that dangerous signal displays of conflicting traffic movements and
conflicting vehicle/pedestrian phases cannot occur.

(c) Phase Display Integrity Check

The Controller shall carry out regular checks to ensure that the phase outputs
issued by the Controller Logic Module are identical to the phase displays

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 71 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

presented at the site. The system shall take remedial action if the two sets of
data differ.

(d) Lamp Failure

The Controller shall monitor individual lamps. Failure of one or more lamps
shall be reported and logged. If all lamps of one aspect of a phase have
failed, remedial action shall be taken.

(e) Conflicting Phase Displays

The Controller shall provide facilities to specify phases that create traffic
conflict if they were granted right-of-way simultaneously.

The Controller shall provide an effective conflict monitoring system to ensure

that the GREEN/GREEN (WALK), GREEN/AMBER, AMBER/AMBER lamps of
these conflicting phases will not be active simultaneously. The system shall
reliably detect lamp fault conditions affecting signal displays and take remedial
actions within less than 200 mS.

(f) Prohibited Stage Transition

The Controller shall monitor individual lamps. Failure of one or more lamps
shall be reported and logged. If all lamps of one aspect of a phase have
failed, remedial action shall be taken.

(g) Conflicting Phase Displays

The Controller shall provide facilities to specify phases that create traffic
conflict if they were granted right-of-way simultaneously.

The Controller shall provide an effective conflict monitoring system to ensure

that the GREEN/GREEN (WALK), GREEN/AMBER, AMBER/AMBER lamps of
these conflicting phases will not be active simultaneously. The system shall
reliably detect lamp fault conditions affecting signal displays and take remedial
actions within less than 200 mS.

If prohibited stages transitions has been specified for the junction, the
Controller shall enforce the prohibition effective under all operational modes.

The Contractor shall provide details of the methodologies on achieving these

requirements. The submission should highlight also all additional safety

features provided by the Controller.

7C/2.5.7 Timings

(a) All Controller timings shall be stored in EPROM at configuration time. These
timings shall be subsequently transferred to battery supported RAM during
controller initialization. Once transferred in RAM all the controller timings
should be possible to be varied by handset commands. It shall not be possible
to repeat the loading of Data from EPROM, after first loading the data from
EPROM without a complete controller initialization using a different EPROM.
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 72 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

This shall ensure that accidental overwriting of any configuration data that may
have been set up using the handset does not take place.

(b) Alternatively, the complete controller configuration, including its timings, shall
be loaded directly in the controller’s battery supported RAM from a PC. With
the PC connected to the controller’s handset port, the Traffic Signal controller
configuration utility shall load the configuration data into the controller,
eliminating the requirement for an EPROM.

(c) Certain timings considered to be fixed timings shall not be available for
changing using handset, such as the Amber and Red/Amber periods. These
timings shall, however, be specified as alterable at configuration time to suit
other signal sequences as required by RTA.

(d) Some controller timings are considered to be safety timings and shall only be
changed by an authorized person at the controller, e.g. minimum green, inter
greens and blackout timings. These require the operator to access the specific
higher level using allocated buttons before attempting to modify these timings.

(e) The signal controller shall provide time settings listed in Table C-2. The Table
also lists the maximium and minimum limits of each setting.. All timings are in
seconds unless otherwise marked.. The Contractor must provide the
availability of proposed Controller Timings for RTA and Engineer’s approval
prior to starting the procurement of traffic controller.

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 73 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Table ‎C-2 Timings Summary

Lower Upper
Resol’n Config’ble Config’ble
Limit Limit
(sec) Lower Limit Upper Limit
(sec) (sec)
General Timing Periods
Minimum green 1 per 1 per
0 255 1
phase phase
Minimum green (8 sets) 0 255 1 1 value 1 value
Green extension 0.0 31.8 0.2 1 value 1 value
Conflicting phase change intergreen 1 per
0 199 1 change 1 value
(32x32)
RLM 1st RED extra Intergreen 0 255 1 1 value 1 value
Starting Intergreen 0 255 1 1 value 1 value
Red/Amber time 0 255 1 1 value 1 value
Leaving amber time (8 sets) 0 31.8 0.2 1 value 1 value
All red extension 0 31.8 0.2 - -
All red maximum 0 255 1 - -
Phase delay 0 255 1 1 value 1 value
Pedestrian window 0 255 1 - -

Pedestrian Clearance Periods

Fixed Clearance Period 0 255 1 1 value 1 value
Extendable Clearance Period 0 255 1 1 value 1 value
Clearance Red Period 0 255 1 1 value 1 value

Hurry Call Timing Period

Hurry call delay 0 255 1 1 value 1 value
Hurry call hold 0 255 1 1 value 1 value
Prevent hurry call 0 255 1 1 value 1 value
Hurry call watchdog (Requires
0 500 2 1 per timer 1 per timer
Special Conditioning)
Hurry call request watchdog
0 255 1 1 per timer 1 per timer
(Requires Special Conditioning)

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 74 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Table ‎C-2 Timings Summary (continued)

Lower Upper Config’ble Config’ble

Resol’n
Limit Limit Lower Upper
(sec)
(sec) (sec) Limit Limit
Linking Timing Periods
Linked Pedestrian controller
0 255 1 1 per timer 1 per timer
release (conditioning timer)
C.L.F. group offset 0 255 1 1 value 1 value
Plan offsets 0 255 1 1 value 1 value

Detector Timing Period

Call delay period 0 255 1 - -
Cancel delay period 0 255 1 - -
Detector Fault Monitoring 1 254 1 1 value 1 value

Priority Timing Period

Monitor Time 0 2550 10 - -
Emergency gap 0 255 1 - -
Priority extension (4 sets) 0 31.8 0.2 - -
Priority maximum (4 sets) 0 255 1 - -
Priority inhibit (4 sets) 0 255 1 - -
Phase compensation (4 sets) 0 255 1 - -
Priority 1st delay time 0 255 1 1 value 1 value
nd
Priority 2 delay time 0 255 1 1 value 1 value

Speed Discrimination Period

SDE/SA extra clearance 0 50 1 - -

Conditioning Timers
For each timer, either: 0 255 1 1 per timer 1 per timer
Or: 0 31.6 0.2 1 per timer 1 per timer

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 75 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(f) All timings, except CLF and Master Time Clock, shall be derived from the crystal
frequency which shall have a tolerance of 35 ppm (parts per million). An additional
error due to random signals not being synchronized to the clock pulse may add up
to 200mS to the time. If the result of the above timings is required to change the
signal lamps, a further error may occur, which may be up to a maximum of 21mS.
The maximum tolerance values shall be submitted for approval by RTA / Engineer.

(g) The set-up accuracy of the real time clock and offsets calculated from it shall be
maximum 1 second.

7C/2.5.8 Master Time Clock and Cable Less Link Facility

The Controller Master Time clock shall have following features.

(a) Master Time Clock

i.Timing Sources – 50Hz Mains (automatically detected)
ii.Option for GPS (Global Positioning System) unit from which the controller
continually checks and updates its clock.
iii.Standby Timing – On board crystal and battery support programmable up to
31 days. Accuracy of standby crystal oscillator is 35 parts per million.
iv.Programmable changeover to mains synchronization.
v.Facilities for synchronizing the real time clock and group timer from existing
U.T.C.
vi.Number of time switch settings – 64
vii.Number of time switch functions – 3
viii.Isolate controller
ix.Introduce a CLF plan
x.Introduce events, such as alternative maximum greens

(b) Cable less Link Facility – The Traffic Controller shall have the following
features for the Cable less link facility.

i.Number of plans : 16
ii.Number of plan influence tables : 16
iii.Number of groups per plan : 32
iv.Number of group influences : 10 types

7C/2.5.9 Modes of Operation

The Controller shall have following modes of operation.

i.Vehicle actuated (Speed Detection Equipment/Speed Assessment should be

able to be added to V.A)
ii.Timetable selected fixed time plans either Cable less linked or in isolation.
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 76 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

iii.Central computer controlled in a traffic control system.

iv.Fixed time
v.Hurry call
vi.Manual
vii.Parallel stage streaming
viii.viii Priority
ix.Part time lamps off
x.Part time lamps flashing, e.g. flashing vehicle ambers
xi.Stand-alone pedestrian stream ‘VA’ (with pre-timed maximum option)
xii.Stand-alone pedestrian stream ‘Fixed Vehicle Period’

The Controller shall provide facilities for any of these modes to be introduced by:

 day-of-time and date as a schedule stored in the Controller;

 an operator manually using the operator interface unit;
 UTC system via the communications channel;
 the mode priority facilities.

The Controller shall provide switches on the Controller Front Panel for the manual
selection of various operating modes.

7C/2.5.9.1 Mode Priority

The Controller shall provide facilities to define the priorities of operating modes.

The operating modes shall be selected based on the prevailing traffic conditions,
current time and date, and the UTC system commands.

The Controller shall operate in the highest priority mode when all the conditions for
this mode are active. When the conditions of the current mode are disabled
partially or fully, the Controller shall search for next highest priority mode. This
new mode of operation shall be adopted when all the conditions for this mode are
active.

While operating in a lower priority mode, the Controller shall continuously monitor
the conditions that will allow the Controller to operate in a high priority mode. This
monitoring shall continue until the highest priority mode has been adopted. If more
than one higher priority mode has been detected, the Controller shall adopt the
mode with the highest priority without adopting the intermediate mode.

When no priority mode conditions can be found, the Controller shall fallback to the
Vehicle Actuated or Fixed Time mode.

The transition from one operating mode to another:

i.shall not affect the safety of the junction,
ii.shall not be violated any minimum safe settings,
iii.shall not skip any demanded phases (except when the Controller is
responding to EMERGENCY VEHICLE or HURRY CALL),

When two or more priority demands or Hurry Calls are activated, the Controller
shall provide a priority conflict resolution strategy to manage the conflicting

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 77 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

requirements. The Contractor shall provide the methodologies for the resolution of
these conflicts.

7C/2.5.9.2 Modes

i.Vehicle Actuated (VA)

This mode of operation allows the Controller to execute its functions autonomously
to achieve the control strategy designed by the traffic engineer. In VA mode, the
introduction and the duration of a phase shall be determined by the prevailing
traffic conditions as presented by the vehicle detectors and pedestrian push
buttons.

During periods of heavy traffic, the Controller shall introduce phases in sequence
as programmed cyclically. A phase shall be extended to its set maximum time.
When a stage has completed, the next stage and the associated phases shall be
introduced accordingly.

When traffic demand has eased, phases may be terminated in accordance with the
phase extension/termination rules. With the absence of demand, a phase or a
stage could be skipped.

The Controller shall provide facilities to allow Speed Discrimination Equipment

(SDE) and Speed Assessment (SA) functions to be incorporated. The SDE shall
allow the Green Extension of the phase to be altered when thresholds have been
reached. The SA shall allow the Gap to be varied to suit the junction geometry.

When the SDE or the SA alters the operation of a phase, facilities shall be
provided to allow the green extension and gap intervals and intergreen time
settings to be changed in accordance with the associated control algorithms.

ii. Time Selected Fixed Time Plans (Cableless Link)

The Controller shall provide a master clock timer. All time schedules and operating
traffic plans shall be synchronized to this master clock.

While operating in this mode, the Controller may be coordinated with other
adjacent junction controllers or operating in isolation.

The Controller shall provide facilities for 32 traffic plans. The maximum cycle time
shall be settable to 255 seconds in one second intervals. Each plan shall specify
the phase/stage sequence and the duration of each stage.

There shall be a minimum of 64 schedules set for the introduction of traffic plans
per week. Each schedule shall have:
A traffic plan
a day code specifying the day/days when this traffic plan is applied (a code may
allow multiple days to be selected)
time of day when the plan will be activated.

iii.Central Computer Controlled

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 78 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The Central Computer Control Mode is also known as the Urban Traffic Control
(UTC) mode.

While under the control of the UTC system, the Controller shall respond to the
force, release and hold commands of the UTC for the selection and termination of
the phases and stages. The UTC will communicate with the Controller on
operational status, alarms and statistics. The Controller shall respond accordingly.

The Controller shall communicate with the UTC using the Outstation Transmission
Unit (OTU). The OTU requirements are not part of this Specification. The
Controller shall provide a parallel input/output (I/O) port for communication with the
OTU. The specifications for the I/O requirement is included in Clause
PS11/2/12/2. If the Controller operates with an integral OTU, other I/O
arrangement may be acceptable. The Contractor shall provide details on the
operation of the integral OTU.

The operational and technical requirements of the UTC system is not part of this
Specification. The Contractor shall acquire the operational and technical
requirements of the UTC system from the Engineer and ensure that the Controller
complies with these requirements.

iv.Fixed time

The Fixed Time mode allows the Controller to operate with neither vehicle detector
nor pedestrian push button input. The Controller shall cycle through all
phases/stages as programmed.

v.Hurry call

The Hurry Call mode of operation allows emergency vehicles such as fire brigade
and ambulance to gain right of way from their respective base stations.

The Hurry Call mode of operation shall be activated by dedicated push buttons or
vehicle detectors that are strategically located. This mode of operation may also
be used to allow traffic queues to be cleared when queue detectors are triggered.

When a Hurry Call is activated, the Controller shall service this call promptly
providing that other higher priority mode is not in operation. A delay period may be
introduced before the Hurry Call is executed. A delay timer shall be provided. The
timer shall be settable to 255 seconds in one second increments.

The transition to the Hurry Call shall not violate the minimum green and intergreen
time settings.

vi.Manual

The Manual mode of operation allows the stages of the Controller to be executed
sequentially by a traffic officer or police using the controller front panel, a hand held
terminal or a police panel. An officer shall be able to step through the pre-selected
stages in a fixed sequence. Alternatively, an officer shall be able to select up to 8
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 79 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

stages, one at a time, for execution depending on traffic demand. One of the 8
stages shall be an All Red stage.

The Controller shall prevent transition from one stage to another until all minimum
phase green times have expired.

The Controller shall prevent stage transition if the transition is prohibited.

vii.Parallel Stage Streaming

Parallel Stage Streaming allows one controller to control several non-conflicting

groups of phases as if they were controlled by several controllers.

The Controller shall provide a minimum of 8 independent streams. Parallel

streaming shall be available to all modes of operation.

viii.Priority

The Priority mode of operation provides designated vehicles to gain right of way at
the junction expeditiously. The designated vehicles will require dedicated selective
vehicle detectors or transponders that interacts with the Controller. When an input
from these special detection systems is activated, the Controller shall generate a
priority demand. This demand shall initiate a phase/stage transition that will allow
the priority phase to be introduced with minimum delay.

If the Controller is already operating in the priority phase, additional priority

demands shall allow the GREEN time to be extended. A Priority Maximum
Running Period timer shall be provided. This maximum shall be settable up to 255
seconds in one second increments.

A Priority Inhibit Period timer shall be provided to prevent the execution of the
priority phase repeatedly. This timer shall be settable to 255 seconds in one
second increments.

When two or more priority demands are activated, the Controller shall provide a
priority conflict resolution strategy to manage the conflicting requirements.

The transition to the priority phase shall not violate the minimum green and
intergreen time settings.

The priority mode may be introduced for public transport vehicles, emergency
vehicles or special motorcades.

The selective vehicle detectors and transponders are not part of this Specification.

ix.Part Time Lamps Off

The Controller shall provide a Part Time Lamps Off mode. The mode is normally
selected by time of day. The transition from the prevailing mode to Part Time
Lamps Off mode shall not violate the minimum phase green times.

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 80 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

When exiting the Part Time Lamps Off mode, the Controller shall go through the All
Red Stage.

x.Part Time Lamps Flashing

The Controller shall provide a Part Time Flashing mode. The mode is normally
selected by time of day. The transition form the prevailing mode to Part Time
Flashing mode shall not violate the minimum phase green times.

When exiting the Part Time Flashing mode, the Controller shall go through the All
Red Stage.

Stand-alone Pedestrian Stream Vehicle Actuated

This mode of operation is normally set up for sites that have only one vehicle and
one pedestrian phase only.

The site normally rests in the vehicle GREEN. When a pedestrian demand is
registered and if the Controller has satisfied the vehicle termination conditions, the
Controller gives right of way to the pedestrian WALK signal. When the WALK and
CLEARANCE WALK is completed, the Controller reverts back to the vehicle
GREEN.

The Controller shall have the capability to flash the vehicle AMBER signal during
the pedestrian clearance period (The Flashing Green Walk period).

xi.Stand-alone Pedestrian Stream Fixed Time

This mode of operation is the same as (k) above except that, in this mode, the
transition between the vehicle and pedestrian phases are based on pre-
programmed times.

7C/2.6 ENCLOSURE

(a) Housing shall be to standards equivalent to BS EN 60529: 1991.

(b) The enclosure shall be fabricated from high-grade aluminium sheet with
thickness not less than 3mm. The sheet aluminium enclosure shall be
coated with a thermosetting powder of an epoxy resin base modified by
polyester resins. The enclosure shall be provided with a smooth finish and
excellent protection against corrosion for 10 years maintenance free
outdoor use. It should also have excellent chemical protection properties
against acid, salt, water and solvents. All other sheet metal should be hot
dip galvanized in accordance with BS 729:1986.

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 81 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(c) The panel enclosure shall be made suitable to withstand the dynamic
stresses in the event of a short-circuit. The doors shall be sealed by
Neoprene gaskets to protect against the ingress of moisture and dust in
accordance with IP55 of BS EN 60529. The gasket shall be adequate to
maintain this protection at 60 degree C. ambient.

(d) The panel is to be provided with removable mounting plate made of fiber
with thickness of not less than 5mm.

(e) A pre-fabricated sloped canopy of suitable dimensions to protect the

cabinet from water and direct vertical sunlight shall be provided. The
material shall comply with the requirements mentioned at (b) above. An air
gap not less than 1.5cm shall be present between the canopy and cabinet.

(f) The door shall have robust weatherproof hinges of polyamide type with
suitable and substantial lockable latching device. A metal pocket for the
schematic diagram and the ‘As-built’ diagram shall be provided in the
enclosure door. The enclosure door shall have two locks. One lock shall be
flush type with non-rusting triangular metal insert stainless steel. The other
lock shall have small wing handle with separate keys (two numbers) to
each panel. All keys shall have the same profile and design to match all
doors. Non-rusting materials shall mean stainless steel Grade AISI 316 or
gunmetal.

(g) The door opening shall attain a swing of 180 degree. An anodized
aluminium label, preferably dual colour, bearing ‘ ‘RTA’ in both Arabic and
English, 50mm size in first row, and 25mm size for the second row shall be
attached to the door in a proper location and firmly attached with rivets. All
hinges are to be gunmetal or stainless steel.

(h) The enclosure shall be provided with a door switch-operated internal

illumination lamp circuit complete with fluorescent lamps suitably protected
from accidental damage and located in the topside of the panel.

(i) The panel shall have full size neutral completely bonded to the main shell
and connected to the door by a braided copper wire. Provision shall be
made in the enclosure to terminate the earth copper plate with the earth
electrode outside the panel.

(j) Appropriate mounting openings on the bottom plate anchoring the feeder
pillar to the concrete foundation shall be provided. Dimension, location and
size of anchor bolts to be used are to be specified. A rubber insulation
sheet has to be included, separating the aluminium bottom from the
concrete base. The controller housing panel shall allow building up
equipment complying with IEC 439 and BS EN 60439-1.

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 82 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(k) Cable gland entry holes are to be factory punched and are to be the
knockout type or sealed with appropriate rubber cover. The number of
cable entry holes shall not be less than three.

(l) The complete pre-assembled panel shall be appropriately packed and

protected from damage during storage, shipment and handling. The panel
dimensions shall be within the range specified herein:

Height : 800mm (without canopy) : Dimensions +/- 5mm

Width : 600mm (without canopy) : Dimensions +/- 5mm
Depth : 300mm (without canopy) : Dimensions +/- 5mm, and consist of the
following.

(m) The enclosure for Traffic Controller shall be a single sided access cabinet
with the following typical dimensions. The dimensions of existing
controllers installed by the RTA are listed in Table C-3. The Contractor
may propose housings with alternative dimensions subject to approval by
the RTA.

Table ‎C-3 Size and Weight of Existing Controllers

Height (above ground level) 1210mm

Width 730mm
Depth 425mm
Approximate weight of bare enclosure 30Kg
Approximate weight with a 16 phase
75Kg
controller

(n) The enclosure door shall be provided with durable and resilient
weatherproof sealing gaskets. The sealing gaskets shall be made o an
ultra-violet stable, closed-cell material. The sealing gasket shall be
securely held in position and shall be readily replaceable while the
controller is in service.

(o) In addition to the screw-locks, the main controller door shall be fitted with a
S18 lock. The key lock must not be operated unless the screw locks are
tight. Therefore, it shall be necessary to unlock the door before undoing the
screw-locks and only lock the door after tightening the screw locks.

(p) The lock used on the Police manual panel shall be a small Yale lock with a
‘900 pattern’ barrel.

(q) There shall be a facility to change the S18 lock to a Yale with an RKA27C
pattern barrel.

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 83 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/2.7 GENERAL ARRANGEMENT HARDWARE

The layout of equipment, cable terminations, power switches and cable access
shall allow easy access to field maintenance and service staff. The Contractor
shall submit layout plans as part of the tender submission.

7C/2.8 HANDSET INTERFACE (RS 232 PORT)

(a) The Traffic Controller shall have the interface kit for interfacing using the
Handset for changing the Controller settings. The settings which are allowed
to be changed using the handset are as described in this specification. The
interface kit shall be based on RS232 protocol for communication. (RS232
CCCIT V24 and V28). One set of Handset with all the necessary hardware
such as connecting cables handset, connectors shall be supplied for each
Traffic Controller.

(b) Method of Connection

The method of connection with the controller and terminal device shall be as
follows.
i. Controller - Cannon DP 25-way female socket connector
ii. Terminal Device - Cannon DP 25-way male plug connector

(c) Pin Allocation

Typical pin allocation for the pins shall be as follows. This is for guidance only.
The actual pin allocation shall be as per Approved Manufacturer’s standard
and shall be subject to RTA and Engineer’s approval.

Pin 1 - Protective ground

Pin 2 - Transmit data fro terminal to controller
Pin 3 - Received data from controller to terminal
Pin 4 - Request to send
Pin 5 - Clear to send
Pin 6 - Data set ready
Pin 7 - Signal ground
Pin 9 - 5V supply (see below)
Pin 10 - 5V supply (see below)
Pin 18 - 5V supply return
Pin 19 - 5V supply return
Pin 20 - Data terminal ready

(d) Pins 9 and 10 shall be connected to the controller’s 5-Volt logic supply
(protected by a 500mA fuse) and can supply a maximum of 300mA (total).
(e) Bit Format

Bit Format shall be as detailed below.

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 84 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

START BIT 1 2 3 4 5 6 7 PARITY STOP BIT

(SINGEL BIT) (LSB     MSB) (EVEN) (SINGLE BIT)

(a) Baud Rate

Baud rate shall be 1200, 9600 or 19200 Baud – Auto-detected.

(b) Mode

Mode of communication shall be Full duplex.

(c) Character Set

The character set shall follow the ISO Alphabet No. 5 (ASCII)

7C/2.9 INTERFACE TO OUTSTATION TRANSMISSION UNIT (OTU)

While the Controller is operating in the UTC mode, the Controller communicates
with the UTC computer system via the OTU. The OTU may be an integral part of
the Controller or as a stand-alone unit.

This Clause specifies the interface requirements of the Controller when a stand-
alone OTU is installed.

The Controller shall provide a parallel data port for communication with the OTU.
The functions of each bit of the parallel port is described briefly in Table C-4
below.

Table ‎C-4 OTU Parallel Interface Port Bit Description

Bit Function Description

UTC Control Bits
F1…Fn Forces Commands to move to another stage
DX Demands: common Artificial demands to all phases
D1…Dn Demands: Stage Artificial demand to specific stages
PX Demands: Ped stream Artificial demand for a pedestrian
phase
PV Ped stream hold At stand-alone pedestrian stream,
vehicle hold vehicle stage at ROW
SF1, SF2 Switch facility Simulate facilities provided by the
time schedule
SO Solar override Command to override automatic
dimming
SG CLF group sync Reset CLF cycle time

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 85 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Bit Function Description

LO Lamps on/off Turn lamps off for Part Time mode
LL Lock link inhibit Override to Local Link to other
adjacent junctions
FM Fallback mode Disable CLF on fallback, run VA or
FT
TS RTC set Set RTC to stored value
TS1 RTC synchronization Synchronize RTC with preset values
TO Take over May be used in conjunction with the
F1…Fn bits
TC Transmission confirm Status bit indicating valid
communication with UTC is
maintained
Controller Reply Bits
G1...Gn Stage confirm Response when Controller reach next
stage
SD1…SD2 Stage Demand Confirm Current demands on stages
WI Wait indicator At stand-alone pedestrian stream, the
WAIT indicator is on (O/C when
WAIT is on)
GX Vehicle stream confirm At stand-alone pedestrian stream,
vehicle is at ROW (O/C when vehicle
is at right of way)
PC Ped stream confirm At stand-alone pedestrian stream,
pedestrian is at ROW (O/C when the
pedestrian is at right of way)
SC1, SC2 Switch facility confirm Switch facility is active
SC Solar override confirm Dimming has been overridden
CS CLF group sync confirm Confirm cycle time has been reset
LE Lamps off Lamps are off for Part Time mode
FR Signals flashing Lamps are flashing for Part Time
mode
LC Local link inhibited Local link is inhibited
FC Fallback confirm Fallback inhibit is active
CC RTC set confirm Stored value has been loaded
RT RTC at configured time RTC has reached preprogrammed
time
CC1 RTC sync confirmed RTC has been resynchronized
TOR UTC control is active, generated by
Take over confirm the OTU
Miscellaneous Controller Status Bits
CF A fault has been logged by the
Controller fault Controller
DF Detector fault A detector fault has been logged

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 86 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Bit Function Description

LF One or more lamp fault/s has been
Lamp fault logged
MC Manual control mode Manual mode is selected or operating
RR Remote reconnect Request UTC to takeover control
GR1 First group Indicates Group 1 of the current CLF
confirm plan is active
HC Hurry call confirm A Hurry Call is being activated
TF A handset has been plugged into the
Test facility Controller

The logic states of this parallel I/O port are as follow, unless stated otherwise:
Inputs to the Controller: open circuit when inactive (0)
Outputs from the Controller: closed circuit when inactive (1)

Please note that the descriptions of the communications bits provided by the Table
above are only a summary of their functions. The Contractor must refer to the
Technical and User Manuals of the UTC system for the detailed functional,
operational and technical specifications of the communications interface between
the Controller and the Outstation Transmission Unit.

7C/2.10 INSTALLATION TESTING AND COMMISSIONING

(a) The Traffic Controller installation shall be carried out only by approved
specialist Sub-Contractor having experience in the field of Traffic Signal Systems.
It is preferred that the Installation of Traffic Controller is carried out under direct
supervision of specialist manufacturer of the Traffic Controller.

(b) A set of shop drawings shall be provided as part of the tender. The information
presented on the shop drawings shall include:

i. a scaled junction plan

ii. positions and types of all hardware within the plan
iii. all line markings within the site
iv. phasing diagrams for the operation of the signals
v. positions and dimensions of detector loops
vi. positions of all pedestrian push buttons
vii. positions of all audible and tactile devices
viii. positions, types and alignment of all signal heads
ix. positions of cable pits
x. positions, quantities, dimensions and alignments of cable ducts
xi. property and building boundaries

(c) Prior to starting the installation necessary permits shall be obtained from the
RTA Traffic Signals section.

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 87 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(d) Installation must be carried out in strict compliance with the approved shop
drawings.

(e) The location of controller shall be as per the approved shop drawings which
shall indicate the exact co-ordinates of the controller and the distances from
the nearby curbstones, road edges, bridges, etc.

(f) The Traffic Controller shall not be powered ON unless a written permission
has been obtained from the RTA, RLTS, Department RTS ITS, IM, TMC(UTC)
as well as from the Dubai Traffic Police Department.

(g) At the time of commissioning of the Traffic Controller presence of Dubai Police
must be ensured at the site.

(h) Telephone communication leased line must be functional and tested prior to
starting the commissioning of Traffic Controller.

(i) Necessary communication with the RTA TMC (Traffic Management Center)
shall be established and all interfaces shall be completed and tested prior to
setting the controller to operation.

Prior to starting the operation of a Traffic Controller at any junction, at least one
week written notice shall be given to the RTA Traffic signal section and Dubai
Police.

7C/3 TRAFFIC SIGNAL HEADS AND LAMPS SPECIFICATIONS

7C/3.1 SUMMARY

(a) This section specifies the requirements in general for the supply, installation,
testing, and commissioning for the traffic signal lamps, signal heads and
associated hardware. The “traffic signal” term refers to all the equipment as
required to provide a fully functional Traffic Signal System.

(b) The Contractor shall submit during construction stage material submittals for
each Item such as traffic signal head, lamps, etc. as per the RTA/RTLS
standards and as per detailed drawings C6 – 1.3 to C6 – 3.3. All the materials
shall be subject to approval by the RTA /RTLS and Engineer during
construction.

(c) The Contractor shall provide a minimum warranty period of 10 years from the
date of commissioning for all equipment, components and services supplied
within this Clause.

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 88 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/3.2 STANDARDS AND REFERENCES.

All supplies and services offered in response to this specification shall conform to
the latest local and International standards as specified in Clause 7C/1.2

7C/3.3 TRAFFIC SIGNAL GENERAL REQUIREMENTS

(a) Construction

1. Signal heads shall have UV stabilized polycarbonate lenses. The color of the
lens shall be Green/ Red/ Amber (yellow) as indicated in the drawings.

2. Signal Head Diameters shall be 100mm, 200mm or 300mm as required as per

the approved drawings.

3. Housing for the signal heads shall be dark green (RAL Code 9005) in color.
Housing shall be manufactured using UV stabilized polycarbonate.

4. The signal heads shall be complete with Internal wiring and terminal blocks for
termination of external cables as well as internal wiring. The terminal blocks
shall be vibration resistant and shall be spring type to allow quick connection.

5. Signal heads shall be complete with visor. The visor shall be suitable for snap
fitting and quick removal / installation. The blades of the visor shall be painted
with black matt finish to ensure that the sunlight entering the signal does not
get reflected.

6. An anti phantom insert shall be provided to ensure sunlight does not reflected
from the reflector inside the signal head.

7.

8. The Signal head should have the possibilities of adding signs and symbols
such as pedestrian, green arrows, etc.

9. The signal lens shall be diffuser type avoiding excessive glare and providing
sufficient light during the day.

10. The front cover shall be attached with the base by use of hinges and shall be
locked in place using the quick release type latches to facilitate quick re-
lamping.

11. The signal head brackets shall be made of aluminium and all the hardware for
fixing the signal heads shall be Stainless Steel SS 316L. The signal heads
shall be attached to the poles using purpose made brackets, clamps, jubilee
clips as appropriate depending on the type of pole and the bracket. Whatever
the type of attachment provided, it shall be designed for quick mounting and
shall not necessitate drilling holes on the pole or mast.

12. Background screens shall be provided for the traffic signal heads to enhance
the visibility during daytime. These background screens shall be attached to

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 89 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

the signal head without drilling the signal head enclosure by using special
clamps.

13. For fixing the signal heads to the whip mast a special purpose made whip
mast attachment shall be provided which shall provide flexibility of installation
and height adjustment.

14. Signal head optical system shall consist of reflector with surface made of
specular aluminium, diffuser made from UV stabilized polycarbonate. The
diffuser shall have cobweb pattern inside to provide distribution of light.

15. The cable entries to the signal head shall also have ingress protection of IP55
minimum and shall ensure no seepage of water and or sand.

16. Number of units at a signal head shall be either 1,2, or 3 as indicated in the
approved drawings.

(b) Structural and Mounting

1. The signal heads shall be suitable for installation on stand posts, gantries or
on the whip posts.

2. All necessary brackets, clamps, caps, shall be provided to ensure that the
installation can be achieved completely without any additional hardware.

3. All hardware used for brackets, supports, shall be hot dip galvanized. Clamps
shall be of stainless steel SS 316 L grade.

4. The entire signal unit comprising of signal head, support brackets, poles,
masts, cantilever shall be capable of withstanding the wind speed of 160
Km/Hr minimum.

(c) Lamps and Lamp holders

1. The lamp used in the optical system shall be of the quartz halogen type and
shall be highly shock resistant. Lamp base shall be BA20s. For LED type
lamps special base shall be provided subject to approval from RTA and
Engineer. The lamp shall be designed for Traffic Signal usage, we shall not
accept general purpose lamps.

2. Lamps shall be rated at 10.5V, 50 Hz with power rating of 30W (at full voltage)
for vehicle aspect and 20 W for Pedestrian aspect
.
3. The lamps provided shall have high luminous efficiency and long service life.
For lamps rated for low voltage necessary transformer and accessories shall
be included within the signal head.

4. The lamp shall only be used in the horizontal position.

5. Luminous flux output of the lamps shall not decrease below 80% of the rated
flux output within six months. Luminous intensity shall be minimum 400 Cd.

6. The lamp holder shall be composed of porcelain and be suitable for the above
lamp type. The spring contact material shall be designed as to maintain
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 90 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

adequate electrical conductivity and to ensure that the lamp remains securely
located under traffic vibrations and under temperatures of 250oC.

7C/3.4 OPTICAL REQUIREMENTS

(a) Distribution of Light:

Each full and restrictive signal shall present a uniform appearance, free from
excessively bright spots or sectors, over the whole area of the lens when
viewed from any direction within the cone of directions for which the
intensities are specified TABLEC-5. The minimum luminance values for red
and green pedestrian signals shall be as set out in TABLE C-6.

Table ‎C-5 Distribution of Non-restrictive red, amber and green light for signals (Candelas

On Geometric 10º on side of 25º on side of

Horizontal/Vertical
axis geom. axis geom. Axis
On Geometric axis 950 450 60
10o below geom.
445 236 48
Axis

Table ‎C-6 Minimum values of luminance for red and green pedestrian signals (Candilas)
On Geometric 10º on side of 25º on side of
Horizontal/Vertical
axis geom. axis geom. Axis
On Geometric axis 570 270 36
10o below geom. 267 142 29
Axis

(b) Direction of Beam:

i.Light signals intended for traffic:

Light signals shall be directed at a point approximately 150 meters from the
primary signal face and approximately 1.5 meters above ground level at the
center line of the carriage-way allocated to approaching traffic.
ii. Light signals for Pedestrians:
The light signals shall be directed towards the center line of the part of the
carriage-way allocated to pedestrian movement.

(c) Limits of chromaticity of signals:

The colour of the light transmitted by the signals shall comply with the limits
set out
in British Standard 1376:1974, Table-1, or DIN 6163 or an equivalent
specification.

(d) Sun phantom effect:

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 91 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Phantom images which are caused by extraneous incident light reflected by

the
signal optical system shall comply to the limits specified in DIN 67527 (or
equivalent) Type-1 – “Sufficiently restricted”, but must be capable of being
improved to Type-2 “with low reflectivity” if required.

(e) Optical system arrangements

1. Light signals for Traffic (3 Aspect Head):

Each signal face shall contain three optical systems arranged vertically and
each having a diameter of between 295 and 305mm. The coloured lens of the
upper optical system shall be red, the middle amber and the lower one green.
Arrows or other masks may replace the full colour or be additional to the basic
arrangement.

2. Light Signals for Pedestrians (2 Aspect head)

Each signal face shall contain two optical systems arranged vertically each
having a diameter of between 200 and 215mm. Which shall incorporate
pedestrian symbols approved by the RTA. The upper optical system shall
illuminate a red symbol and the lower one a green symbol. The background for
the symbols shall be obtained by coating the lens or filter with heat resistance
black paint or enamel or by other suitable means.

7C/3.5 MOUNTING REQUIREMENTS

(a) Post-mounted traffic control signals for traffic

The height of the signals shall be such that when erected the center of the amber
optical system shall be between 2433 and 2484 millimeters above the top of tiling
or finished ground level as appropriate.

(b) Light signals for pedestrians:

The height of the signals shall be such that when erected the lower edge of the
housing enclosing the green signal shall be 2530 millimeters above the top tiling or
finished ground level as appropriate.

7C/3.6 SIGNAL HEAD

The signal head shall comply with IP55 and neither corrodible nor brittle over the
temperature ranges normally experienced in Dubai. It shall be of such form as to
resist deterioration over this temperature range and to resist substantial distortion
in wind velocities up to 160 Km/hr including gust factor. External wiring to the
signal head shall be protected by non-flexible conduit.

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 92 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Signal heads shall be secured to the pole by means of a clamp at the top of the
signal head and pole and by a ribbon clip at the bottom of the signal head. Fixing
requiring the drilling of holes in the pole are not permitted.

(a) Signal head assembly

The signal head, the fixing brackets and the necessary parts thereof shall be
designed such that they shall be capable of horizontal and vertical adjustment in
respect of all approach roads and pedestrian crossings to which the signals apply.
The adjustment shall be such that no signal shall obstruct the view of optical
systems of any other signal head within 25 degree of the axis of the beam. The
signal head assembly shall be capable of being locked securely after adjustment.
A backing board shall be provided with each signal face for the benefit of vehicle
drivers. The signal face shall be centrally located within the backing board and it
shall not exceed a width of 650mm and a height of 1370mm. The backing board
shall have a white border of a width between 70 and 80mm.

(b) All parts of the signal head assembly shall be composed of dark green
coloured ultraviolet-stabilized polycarbonate material, in accordance with RAL
6001, DIN 6163 and the recommendations of C.I.E. The backing board shall have
a white border with a black strip all around on the front face of the board only. All
screws and fixings shall be non-corrodible.

(c) Optical systems:

The optical system shall be in accordance with IP55 and shall be rain proof, and
manufactured from materials which are neither corrodible nor brittle over the
temperature ranges normally experienced in Dubai. It shall be of such form as to
resist deterioration over this temperature range. Means shall be provided so that
when mounted the optical system cannot be rotated from its normal position. The
lenses shall be made of glass. The permanence of the colour of lenses shall be of
the best for the purpose, durable on the prolonged exposure to weather conditions.
Each lens shall have pressed on its flange the word “TOP” if applicable to indicate
the proper positioning of the lens in the door for obtaining the light distribution
required.

(d) Reflector:

The reflector shall be of either thermoplastic polyester with vacuum evaporated

reflective film or aluminium alloy to BS 4300/4:1973 with an anodic coating of not
less than AA5 grade to BS EN 12373-1or an equivalent specification. The reflector
shall be of sufficient thickness to retain its shape during assembly, relamping or
cleaning operations.

(e) Visor:

A visor shall be fitted to each optical system and shall be manufactured from
material which is neither corrodible nor brittle over the temperature range normally
experienced in Dubai. It shall be of such form as to resist deterioration over this
temperature range, to resist substantial distortion in winds at up to 160 Km/hr and
to prevent permanent deformation from the same cause. The visor shall be fully
cylindrical with a length of 428mm while only 5cm space is allowed at the button
side of the visor.

(f) Top pole cap:

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 93 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The top pole cap shall be composed of green coloured ultraviolet-resistant

polycarbonate material and be to the dimensions shown on the drawings.

7C/3.7 MAINS SUPPLY

The traffic signal heads and lamps shall operate within the same supply conditions
as specified in Clause 7C/2.4.

7C/3.8 ELECTRICAL NOISE

The traffic signal heads and lamps shall operate within the same supply conditions
as specified in Clause 7C/2.4.

7C/3.9 ENVIRONMENTAL CONDITIONS

The traffic signal heads and lamps shall operate in accordance with the climatic
conditions specified in Clause 7C/1.3

7C/3.10 DOCUMENTS TO BE SUBMITTED:

The tenderer shall supply the following technical documentation and information for
each item:

 Catalogue sheets
 Detailed construction drawing
 Tightness test certificate: This certificate shall be issued by an independent
official laboratory.
 Tenderer shall submit with his tender all details of known areas using the
same type of item.

7C/3.11 IMPORTANT NOTES

Each signal head to be packed in a single carton with 3 or 2 visors to be included

in the same carton.

Mounting parts (cantilever type) to be packed separately in nylon bags. Each bag
shall contain the required jubilee clips, stainless steel Grade 316, size 140mm
diameter full thread.

7C/4 POWER AND SIGNAL CABLES

7C/4.1 GENERAL

The Contractor shall provide cabling for the interconnection of all components at
the site to form an operational signal controller junction. These cabling shall
include power supply feeds, signal drive circuits, link with outstation transmission
units and ancillary equipment required to form the controlled junction.

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 94 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.

7C/4.2 POWER CABLE CHARACTERISTICS

Junction power cables shall be as follows:

a) Multicore
b) Not smaller than 1.5 mm2 solid copper conductors
c) PVC/Polythene insulated
d) PVC/Polythene bedded
e) PVC/Polythene sheathed
Cables shall be in accordance with B.S.I. specification No. 6346 (metric equivalent
No.
3346) or an equivalent specification.
Note: Each cable shall have a separate earth conductor of adequate size

7C/4.3 CABLING PRACTICE

7C/4.3.1 Jointless Runs

Cables shall be run between the controller and a termination point on the signal
poles
without intermediate jointing during initial installation.

7C/4.3.2 Cabling Use

A separate cable shall be provided between each signal aspect and the controller.
The
right hand primary signal on each approach shall be provided with a separate
cable link
to the controller. All approaches shall be cabled separately as if controlled by
separate
phases.

7C/4.3.3 Mains Supply at Poles

A permanently energized fused mains supply core shall be provided to each signal
pole. The fuse used shall be located in the controller cabinet and be of 13 amps
maximum rating.

7C/4.3.4 Spare Capacity

At least 4 spare cores shall be provided in each cable at the time of installation.
Spare
cores shall be identified on the installation drawing supplied by the Contractor

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 95 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Each signal cable shall have 2m of spare cable coiled in the draw pit at the
controller base and 3m of spare cable coiled in the draw pit by the pole..

7C/4.3.5 Extra Low Voltage Cables

All cores carrying extra low voltages (e.g. Push-buttons) shall be in separate
cables.

7C/4.3.6 Labelling

A separate 7-Core cable is to be used for each traffic signal phase. Cable cores
shall be identified by number labels as shown in table C-7. All cores shall also be
clearly labelled at the controller as to their function and destination.

Table ‎C-7 Junction Signals Cable Core Allocation

Core No Label Function Allocation

1 Red Signal Lamp
2 Yellow Signal Lamp
3 Green Signal Lamp
4 Neutral
5 Spare
6 Spare
7 Earth

7C/4.3.7 Earth Continuity

To provide earth continuity at each end of the cable, the earth core/conductor wire
shall be clamped to a ring or cable gland which is bonded to earth.

7C/4.3.8 Markings

All signal cables shall be marked at each end to indicate their function and
connection. They shall also be marked in each draw pit they pass through.

Cable marking shall be to the approval of the Engineer and shall be designed to
last the life of the cable.

7C/4.3.9 Installation on Other Properties

Where signal heads are to be installed on existing structures or on the walls of

buildings, their cables shall be installed in galvanised steel conduit (supplied by the
Contractor) up to a height of at least 2m. Above that height they may be in solid or
flexible conduit, at the Contractor’s discretion. The Contractor shall securely fix the
signal head brackets and conduit to the wall or structure.

7C/4.3.10 Linking Cables

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 96 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Linking cables (if used) shall be to the same specification. No voltage in excess of
42V (D.C.) or RMS (A.C.) shall applied to linking cables.

7C/4.4 CABLE LAYING

7C/4.4.1 Ducting

Cable shall be drawn into ducts, pavement boxes and pole boxes provided under
the main civil engineering contract.

7C/4.4.2 Excavation by Contractor

Where cables pass through excavations made by the Contractor to approach the
base
controllers or poles, where pole boxes are not provided, the following requirements
shall be met:

(a) Before bending upwards, cables shall have a minimum of 750mm of cover.

(b) Trenches shall not be excavated appreciably deeper than the ducts or bases,
except to allow for a 100mm thickness of fines which shall be applied to surround
the
cable.

(c) Backfill shall be free from flint and large stones, and shall be compacted in
layers of 200 mm.

7C/5 PEDESTRIAN PUSH BUTTON

7C/5.1 GENERAL

The pedestrian Push Button shall operate in accordance with BS50293:2001. The
front panel of which is modified for use in Arabic speaking countries. The housing
shall be made of die-cast aluminium.

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.

The tenderer shall submit the mechanical, electrical and operational details of the
push button to the Engineer for approval.

7C/5.2 OPERATION

The operation of the pedestrian push button at any time shall result in a demand of
the pedestrian stage and the immediate illumination of WAIT indicator which shall
be written in Arabic, and English languages
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 97 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

The push button shall provide audible signals to assist visually impaired
pedestrians to locate the push button and to indicate to them when it is safe to
cross the road. The unit shall provide a tactile indicator in the form of an arrow to
indicate the direction of the crossing on the front of the unit.

The ‘locating’ audible signal shall have a tone of approximately 1 KHz and with a
repetition rate of 0.5 Hz. The volume of this signal shall be adjustable on site
allowing compensations to ambient noises to be made.

The ‘safe to walk’ crossing audible signal shall have a tone of approximately 50 Hz
at a repetition rate of 8 Hz. The volume of this signal shall be adjustable on site
allowing compensations to ambient noises to be made.

7C/5.3 FRONT PANEL DETAILS

The front panel shall be made up of

 Acrylic sign plate (dimension: 23.2 x 16mm x 6mm thick)
 Screen printed – 5 colour printing: Black Blue Red White Green
 Reverse printing on clear acrylic sheet (3mm thick).
 Printed matter to be provided with a protective 3mm clear acrylic sheet at the
back, i.e. printed matter shall be sandwiched to form a 6mm thickness plate.
 A tactile indicator arrow of approximately 80mm long, 8 mm wide, an arrow
head of 16 mm wide and raised 1.5 mm above the base plate.

7C/5.4 WORKING TEMPERATURES

The following describes the allowable working temperatures for the push button
assembly. The front panel shall withstand to the following temperature ranges.
 Door panel: Maximum working temperature 125oC.
 PVC Wire: 70-85oC.
 Terminal Block (Melamine): 100oC.

7C/5.5 MOUNTING

The push button back side shall be capable for mounting (no flat back surface
mounting is accepted) on a 100mm diameter pole by means of brackets and
screws.

The push button shall be mounted in a position such that the tactile arrow indicator
is pointed at the direction of the crossing.

7C/5.6 COLOUR

The external surface of the push button box carrying the front panel shall be
yellow, colour BS 381C No. 355. This colour shall not be visible in front elevation.
The black of the front panel shall be continued around the front edge of the case,
this boarder shall not be more than 25mm deep.

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 98 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/5.7 INDICATING LIGHT

The push button shall be provided with an internal heavy duty traffic signal lamp
E27 base. The lamp shall be rated 75W. (LED is optional.)

7C/5.8 PUSH BUTTON

The push button shall be aluminium material designed against vandalism.

7C/6 TRAFFIC SIGNAL CANTILEVER POLES

7C/6.1 GENERAL

The Cantilever poles are intended to hold six traffic signal heads and traffic signs
as detailed in the RTA Drawing C6-2.3.

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.

7C/6.2 SPECIFIC

The cantilever shall consist of pole and single arm or double arm, each shall be of
one solid piece other than the attachment parts and brackets.

The pole shaft shall have a circular cross section continuously tapered and
longitudinally welded. The welding of the cantilever pole shall be metal-arc-welding
complying with BS EN 1011. No circumferential weld shall be accepted

All pole shafts shall be provided with substantial rigid flange plate, thickness as per
drawing, with an opening for cable entry. The plate shall be welded with the shaft
with 2 butt welds from inside and outside. The weld shall be metal-arc-welding
complying with BS EN 1011 .

The cantilever pole shall be fabricated from a high strength structural steel
complying with the requirements of standards mentioned in the drawing or
equivalent

Poles, flange plates/base plates, doors, brackets, anchor bolts, nuts and washers
shall be protected against corrosion from inside and outside in compliance with the
requirements of BS 729:1971 (the minimum average zinc coating weight on one
side should not be less than 714 g/sq. meter. Minimum 100 microns DFT) and BS
EN 40-5.

All component parts or fasteners shall also receive the same hot-dip galvanized
treatment, threaded components centrifugally spun to remove local excess of zinc.

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 99 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Coating weight shall be determined by a suitable magnetic or electronic measuring

device. However, in cases of dispute, the Engineer may direct that a stripping test
in accordance with BS 729 be carried out.

Cantilever pole shall be able to withstand a wind-speed of 160 km/hr. including

gust factor.

The single arm rube shall have a minimum rotation of 90 degree at the arm joint
with pole tube where the double arm tube shall have no rotation angle at the arm
joint with pole tube.

The pole tube and arm tube shall be constructed straight. The exterior and interior
surfaces of the poles shall be free from protuberances, dents, cracks or other
imperfections. Appropriate wrapping and packing is to be done before shipping to
maintain this quality and to preserve the finish during shipping and storing.
Wrapping with tape is not acceptable. Anchor bolts shall be packed in wooden
boxes.

The pole to be adequately reinforced and strengthened at the location of the

inspection compartment opening to compensate for loss in section of the post at
this point

A 30mm long threaded stud of corrosion resistant steel carrying 2 nuts and 2
washers to be provided for earth connection. The stud to be located in an easy
accessible place near the inspection cover inside the pole (stud diameter to be of
M8 size) in compliance with Clause 5 of BS 5649: Part 5: 1982 .

The door shall be flush and secured by a positive action lock which forces the door
out when opening. All loose parts of the locking device shall be so arranged that
they are held captive on the door when it is in the open position. All the moving
parts of the locking device shall be stainless steel of Class 316 - material. There
shall be a stainless steel chain (6mm), Class 316 - material strength, between the
pole and the door to ensure the door cannot be lost if incorrectly secured.

100mm thick rubber protector cover to be fixed at the bottom of the pole shaft to
observe the impact of the hit during accidents made by vehicles.

Electrical junction box to be supplied as per drawing and proper arrangement to be

made inside the pole to fix this box.

All bolts, nuts, locking screws and door chain shall be stainless steel Grade
AISI31G.

Tenderer may submit alternative design that shall suit the requirement of the
specification.

7C/6.3 MISCELLANEOUS REQUIREMENTS

Specification compliance statement shall be submitted.

Offered material shall be supplied exactly as indicated on specifications and

drawings.

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 100 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

Shipment will be allowed only after the approval of the free sample given by the
supplier at our RTA Stores at Rashidiya.

All material shall be delivered to Contractor’s Stores on Project Sites and/or RTA
Stores at Rashidiya. The off-loading in the Store yard shall be arranged by the
supplier at no cost to Roads and Transport Authority.

A test certificate from an independent laboratory shall be submitted confirming the

galvanization coating weight and component composition.

7C/6.4 DESIGN INFORMATION

The supplier shall submit for approval the design calculations and data prior to the
fabrication of any part of the cantilever poles.

> General dimensions of all components of the pole.

> Detailed scaled drawings of the pole.

> Details of the fixing and locking system between the pole tube and arm tube.

> The total maximum load moments for each section under maximum stresses.

> Computation of stresses in the base plate and anchor bolts, under maximum
wind-load with maximum loads indicated in the drawing.

> Maximum deflection at the end of the arm tube, under climatic conditions and
wind velocities specified in Section ‎7C/1.3 CLIMATIC CONDITIONS

Supplier may submit any new treatment method for extra protection against
corrosion of the base plate area and up to the height of 300mm.

Detailed calculations of the necessary strength for anchor bolts to be used should
be submitted for different heights of pole.

Means of assembling the cantilever poles shall be indicated in detail. If special

tools are required, supplier is to include one complete set and the price shall be
included in the tender.

Impact resistance calculations at a height of one meter above the base plate of the
column.

Maximum tolerable impact calculations to shear the plate from the pole from an
impact point one meter above the flange plate.

Material specification for each part of the column.

Tenderer shall provide along with the samples, table showing all data and all test
results mentioned under Clause 7C/6.3 above and indicate deviations from
contract specifications, if any.

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 101 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/6.5 MATERIALS TO BE SUBMITTED WITH THE OFFER

Each tenderer shall submit one number sample cantilever pole tendered for.

The materials to be accompanied by manufacturers assembling and erection

instruction.

The sample materials shall be delivered to Roads and Transport Authority Stores
at Rashidiya soon after the tender opening.

The delivered pole(s), bracket(s) and anchor bolt(s) shall be subject to

nondestructive performance test conducted by Roads and Transport Authority.

The outcome of the performance test shall be considered in the tender evaluation.

7C/6.6 COLLECTION OF TENDER MATERIALS

In case of tender award, the materials for testing supplied by the awarded tenderer
shall be returned to tenderers after completion of delivery.

In all other cases the non-selected materials supplied by tenderers who are not
awarded the contract shall be returned to the same.

Roads and Transport Authority will notify those tenders for collection of their
belongings within ten days after the contract has been awarded

The non-selected sample materials shall be collected from RTA Stores by the
suppliers within one month of notification. Failure to collect within this period will
render the materials to become property of Roads and Transport Authority.

7C/6.7 MISCELLANEOUS REQUIREMENTS

The below mentioned points are to be added to the specification.

 All caps shall be made out of Aluminium.

 Junction box shall be provided with European made terminals.

 Expanding type PVC gland for cables entry.

 Cantilever door to have gasket.

 Red marine ply wood for mounting junction box to be fixed inside the pole.

 All hardware to be stainless steel grade 316.

 Rubber to be one piece as shown on RTA/ RLTS standard drawing C-6-3-3 and
screwed together. Rubber to be impact resistant, non-aging, non-fading, non-
corrosive and reusable and easily replaceable.

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 102 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/6.8 SPECIFICATIONS FOR CANTILEVER POLE BRACKETS

 The brackets material shall be completely stainless steel - Grade 316, or cast
aluminum.
 To securely attach signal heads on high mast arms (cantilever poles) using
stainless steel clips (Grade 316).
 The above clips shall be of 250 mm diameter and shall be of all threaded type. All
attachments (Screws, nuts) to be resistant to corrosion.
 Brackets shall be capable to suit a 3 unit, 300 mm, signal head with a back plate.
All attachments provide stability against wind speed of up to 160 Km./hr.
 The attachment is characterized by swiveling to any required angle by means of a
ball head and height adjustment (or anything else similar) after mounting.
 The brackets shall enable the head to rotate to minimum of 90 degrees.

7C/7 POLE FOUNDATIONS

7C/7.1 FOUNDATION FOR CANTILEVER POLE

The Contractor shall refer to RTA Drawing C6-1.3 for cantilever pole foundation
details.

7C/8 MANHOLES AND CHAMBERS

7C/8.1 MANHOLES

The Contractor shall refer to RTA Drawing C6-3.3 for details of manholes for traffic
signal applications.

7C/8.2 MANHOLE COVER

The Contractor shall supply and install manhole covers comply with BS EN 124
D400 specifications.

7C/9 VEHICLE DETECTORS

7C/9.1 GENERAL

This Clause specifies the supply, installation and testing of vehicle detector loops
for permanent works and temporary works. The following specifications and
installation instructions have to be followed carefully. The loops shall be installed
at positions as presented on the approved shop drawings and RTA/ RTLS
standard details drawing (C6-3 of 3)

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 103 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

It should be noted that reliability of detector loops is of paramount concern to the

RTA/ RLTS. The Contractor must make every effort to ensure that the required
warranty is met and not less than 10 years.

Before commissioning of these loops, the Contractor shall conduct leakage,

continuity, loop characteristic test to the satisfaction of the Engineer and RTA/
RLTS.

The Contractor shall provide feeder cables between each loop and the traffic
signal controller. All feeder cable shall be terminated onto the controller
termination block to complete the detection circuit.

For both types of installation mentioned above, the Contractor shall adhere to the
following procedures.
1) The Contractor shall advise the Engineer and RTA/ RLTS that the loops have
been received and checked. The Contractor may commence installation of the
loops upon approval by the Engineer and RTA/ RLTS.
2) The Contractor shall test the installed loops to the satisfaction of the Engineer.
3) The loop lead-in cables to be kept safely in the nearest bypass chamber
constructed especially for the loop detectors.
4) The Contractor has to ensure that the loops are not damaged at any stage until
the site is handed over to the Engineer.

7C/9.2 LOOPS

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.

7C/9.2.1 Specifications
(a) Loops shall be constructed from polypropylene conduit with 3/8" I.D. (9.5 mm)
5/8" O.D. (16mm).
(b) Conduit shall be filled with hot rubberized asphalt which allows the loop to
remain flexible once cooled, prevent incursion of moisture and set the turns of
wire firmly in place.
(c) Loops shall have 130mm expansion/contraction joints at intervals along the
loop to allow for movement of the pavement and to prevent breakage of the
wire and/or conduit due to this movement. Each expansion/contraction joint
shall have a 230mm long schedule 80 polypropylene cover slide to be placed
over the joint.
(d) The encapsulated copper loop wire shall be 20 gauge, stranded, teflon coated,
single conductor. (Military-MIL-W-16878/4 Type E. 200C, 600V) Loop shall
have 4 turns.
(e) Loop shall be one continuous wire through the loop lead-in to prevent loop
malfunctions due to splicing.
(f) Lead-in wires shall be encased in a non conductive 2250 psi flex hose
constructed with a seamless extruded polyester fiber braid reinforcement and

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 104 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

a non-conductive, seamless extruded urethane non-perforated jacket. Fill

lead-in hose completely with hot rubberized asphalt. Twist wires in all lead-ins
a minimum of three turns per foot for the entire length of the lead-in. Attach
lead-ins to loop heads with a schedule 80 CPVC tee.
(g) All loops shall be tested three ways prior to shipment: resistance to ground
(measured in megaohms), resistance (measured in ohms), inductance
(measured in microhenries). All test results (readings) to be sent to Dubai
identified per loop.
(h) Loops shall be shipped fully tested, and documented and ready for installation.

7C/9.2.2 Installation

Loops are installed in a grove on the surface of WET-MIX or AGGREGATE

ROADBASE (according to Road Design).
(a) Remove loop from container and unfold 24 hours before installation. Verify
dimensions and test.
(b) Mark on the ground location of loops in accordance to design STOP LINE.
(c) Open loop on the ground and mark the place.
(d) Excavate trench 30 x 30 mm by hand tools.
(e) Slide sleeve over the expansion/contraction joint and tape ends of sleeve
directly to conduit.
(f) Piece Loop in the trench.
(g) Cover Loop with Fine Asphalt mix (remove big size stones.)
(h) Compact asphalt with hand compactors.
(i) Lead cable from curbstone to manhole protect in a 2.54 cm (1”) PVC conduit.
(j) Protect exposed lead wires during construction.

7C/9.3 FEEDER CABLE

A feeder cable is the cable connecting a vehicle detector loop and its associated detector
unit.
The Contractor shall provide a minimum warranty period of 10 years from the date of
commissioning for all equipment, components and services supplied within this Clause.

7C/9.3.1 Cable Specifications

The feeder cable shall be to the following specification:

(a) Core conductors shall

 be of annealed copper
 (at least 7 strands)
 have a nominal cross-section area of 1.5 sq. mm (7/0.5 mm.)
 Comply with the appropriate requirements of AS 1125 or equivalent.

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 105 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(b) Drain Conductor shall

 ensure electrical continuity of a tape metallic screen throughout the length of
the cable.
 comprise at least 7 strands of 0.25 mm tinned annealed copper conductor.

(c) Insulation:Material: Insulation shall be low density polyethylene, type 03, in

accordance with the requirements of AS 1049 or equivalent. Thickness:
The average thickness of insulation shall be not less than 0.4mm and the
thickness at any point shall not be less than 0.3 mm.

(d) Inner Sheath Materials: Inner sheath material shall be low density
polyethylene, type 03, in accordance with the requirements of AS 1049 or
equivalent.

(e) Thickness: The average thickness of the inner sheath shall be not less than
0.5 mm and the thickness at any point shall not be less than 0.3 mm.

(f) Metallic Screen: The laid-up cores shall be collectively screened with OR
overlapped metallic tape (tape screen). The tape screen shall have
minimum metallic thickness of 0.02 mm and it shall include a drain
conductor. The drain conductor shall comprise at least 7 strands of 0.25
mm tinned annealed copper conductor.

(g) Outer Sheath: Materials: The sheath shall be of V-75 PVC complying with
the requirements of AS 3147 or equivalent. Thickness: The average
thickness of sheath shall be not less than 0.8 mm and the thickness at any
point shall be not less than 0.62 mm.

(h) Overall diameter: The overall diameter over the PVC sheath shall not
exceed 9.0 mm, weight 97 kg/km.

7C/9.3.2 Installation

(a) All armoured feeder cables shall be terminated in the equipment housing
using compression type cable connectors approved by the authority, and
each connector shall be bonded to the earth point using 4.5mm2 flexible
earthing cable terminated with crimped connection tags. The contractor
shall ensure that no other earth connection exists along the length of the
cable.

(b) Cables shall not be bent to a radius of less than 12 times their diameter or
less than a radius recommended by the manufacturer whichever is the
greater.

(c) Feeder cables shall be installed in a high impact resistance PVC duct to BS
3506 (Class 6 or 7) The duct shall be level with the base of the slot from
which the feeder cable emerges. The excavated area shall be backfilled
with fine aggregate concrete to this level. The cables shall then be
backfilled with compacted fine cold asphalt and hot oxidized bitumen
R85/40. The kerb stone shall be reinstated. The contractor shall ensure that
cables entering the footway are adequately protected from any abrasive
action.

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 106 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

7C/9.4 LOOP DETECTORS

7C/9.4.1 General

Vehicle detectors are required where specified, to provide count and occupancy
information at selected sites and to register demands in traffic signal controllers for
demand dependent or vehicle actuated stages.

The detector shall be of the auto re-tuning type. Each detector module shall make
up of no less than four independent detector channels.

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.

7C/9.4.2 Drift Compensation

The vehicle detecting equipment shall incorporate adequate automatic

compensation against the effects of changes in environmental conditions and
changes in loop dimensions and shall be fully self-tuning. Detectors employing
potentiometers for tuning or sensitivity adjustment will not be acceptable. The
vehicle detecting equipment shall operate correctly as required by this specification
when the loop is installed in the vicinity of electrically and mechanically stable
metallic bodies including materials for road reinforcement. After installation the
vehicle detecting equipment shall continue to operate correctly without the need for
any subsequent manual adjustment for warranty period.

7C/9.4.3 Recovery Time

The vehicle detecting equipment shall regain its specified performance as quickly
as possible after a moving vehicle leaves the loop. For the purposes of
measurement, the recovery time is taken as the time from when the rearmost part
of a vehicle vertically clears the loop to when the detector output restores to the
non indicating state, shall be not more than 100 milliseconds for a passenger car
crossing the loop at a speed of 50 km/hr.

7C/9.4.4 External and Mutual Interference

Adequate precautions shall be taken in the design of the vehicle detecting

equipment to prevent mutual interference between equipments of the same type
when connected to adjacent loops. These precautions shall be at least sufficient to
avoid any interaction between equipments connected to a pair of loops each 3
meters square, with adjacent sides parallel to each other and spaced 0.5 meter
apart throughout their lengths.

7C/9.4.5 Failure Conditions

(a) A disconnection of the loop or feeder connected to vehicle detecting

equipment shall automatically produce an output signal from the equipment
for so long as the disconnection persists.
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 107 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(b) An interruption of the power supply to the vehicle detecting equipment shall
after an interval not exceeding 5 seconds automatically produce an output
signal from the equipment which shall regain its specified operation within 1
minute of the restoration of the power supply.

7C/9.4.6 Equipment Housing

Vehicle detectors shall preferably be mounted in traffic signal controller cabinets.

Where this is not possible, POLE MOUNTED HOUSINGS MAY BE USED. The
design of the pole mounted housings is subject to approval by the Engineer.

7C/9.4.7 Maximum Loop Configurations

The manufacturer shall specify (and, if required, shall also demonstrate) the upper
limits of the loop and feeder configuration (in terms of number of loops, loop
dimensions, length of feeder, etc.) which when connected to a single vehicle
detector will satisfy the performance requirements of this specification.

Performance Requirements

(a) The zone of detection for a passenger car for the vehicle detection
equipments shall be not less than the physical area of the loop and not
greater than an area whose sides are parallel to the physical sides of the
loop and not further than 200mm from these sides.

The detector shall operate satisfactorily with a feeder up to 60 meters in

length. The feeder is defined as the cable between the loop and the
detector housing.

(b) The equipment shall respond to any type of motor-driven vehicle normally
encountered on public roads travelling at any speed between 5Km/h and
120 Km/h. The associated equipment shall give a single unbroken output
for all motor-driven vehicles with 2 or more road wheels. An exception can
be made for special classes of vehicles such as those having a ground
clearance greater than 0.8 metres. For the purpose of a single unbroken
output signal the vehicle shall traverse the loop in such a way that at least
25% of the loop area is covered by the vehicle.

(c) The presence time shall be:

 For counting applications: Between 2.5 mins. And 20 mins.
 For demand dependent stages or vehicle actuated: Between 30 seconds and
4 minutes.

7C/9.4.8 Output and Fault Conditions

(a) The output from all types of vehicle detecting, equipment shall be an
isolated contact, or the solid state equivalent. This output shall have DC
isolation from earth and from the supply to the detecting equipment. If the
output is polarity conscious, a means shall be provided to protect the output
device against an accidental reversal of current flow. The correct direction
of current flow shall be clearly marked on the relevant output terminals.
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 108 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS

(b) While no vehicle is being detected by the detecting equipment, the output
shall continuously allow a current of up to 50 mA to pass with a voltage
drop of no more than 2.5V. The connection of up to 50V DC to the output
terminals for one second shall not damage the output.

(c) While a vehicle is being detected by the detecting equipments, the output
shall continuously present a resistance of at least 100K ohms. The output
must be able to withstand a continuous voltage across it of 50V DC and
must not be damaged by transients of up to 650V peak amplitude for one
millisecond duration.

(d) An interruption of the power supply to the vehicle detecting equipment shall
after an interval not exceeding five seconds automatically produce an
output signal for so long as the interruption persists. The equipment shall
regain its specified operation within twenty seconds of the restoration of the
power supply.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 108

 Section 8
Concrete Pile Foundations
 1 SECTION 8 CONCRETE PILE FOUNDATIONS

TABLE OF CONTENT

8/1 DESCRIPTION ...................................................................................................... 1

8/2 MATERIALS .......................................................................................................... 1
8/3 GROUND CONDITIONS ....................................................................................... 2
8/4 TOLERANCES ...................................................................................................... 2
8/5 PILING METHOD AND PROGRAMME.................................................................. 2
8/6 PILING RECORDS ................................................................................................ 3
8/8 CONCRETE FOR PILES ....................................................................................... 4
8/9 REINFORCEMENT FOR PILES ............................................................................ 5
8/10 BORING FOR PILES ............................................................................................. 5
8/11 DRILLING FLUID ................................................................................................... 7
8/12 PLACING CONCRETE .......................................................................................... 9
8/13 EXTRACTION OF CASING ................................................................................. 11
8/14 TEMPORARY BACKFILLING .............................................................................. 13
8/15 DISPOSAL OF EXCAVATED MATERIAL ............................................................ 13
8/16 CUTTING OFF PILE HEADS ............................................................................... 13
8/17 INTEGRITY TESTING OF PILES ........................................................................ 13
8/18 LOADING TESTS ................................................................................................ 14
8/19 FAILURE OF PILE ............................................................................................... 15
8/20 RECTIFICATION OF FAILURE ........................................................................... 15
8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK ..................................... 16
8/22 CLEARANCE OF WORKS................................................................................... 16

8/1 DESCRIPTION

8/1.1 All pile foundations shall be bored cast-in-place concrete piles and shall be
constructed as indicated on the Drawings and in compliance with these
specifications.

8/2 MATERIALS

8/2.1 The materials for the manufacture of the reinforced concrete shall be in
accordance with Section 4 - "Concrete Works".

8/2.2 The temporary steel casings and the permanent casings or liners shall be
cylindrical, of the diameter indicated on the Drawings and shall be of sufficient
strength to maintain shape and location during boring and placement of
concrete. The casings shall be sufficiently watertight to exclude ground water
during placing of concrete.

8/2.3 In case drilling, bentonite, as supplied to the site and prior to mixing shall be in
accordance with Specification DFCP 4 of the Oil Companies Materials
Association.

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 2 SECTION 8 CONCRETE PILE FOUNDATIONS

8/3 GROUND CONDITIONS

8/3.1 Factual information and reports on site investigation for the Works will be
provided to tenderers. However, in the event that a full report is given,
including interpretations, opinions or conclusions, no responsibility is accepted
by the Employer.

8/3.2 The Contractor shall report immediately to the Engineer any circumstances
which indicates that in the Contractor's opinion the ground conditions differ
from those reported in or which could have been inferred from the site
investigation reports or trial pile results.

8/4 TOLERANCES

8/4.1 SETTING OUT

Setting out of the main grid line shall be carried out by the Contractor. The
installation of marker pins at pile positions as required by the Engineer shall be
accurate to 75 mm in any direction. An additional tolerance for a pile head cut
off below ground level will be permitted in accordance with Sub-Section 8/13.8
and/or 8/16.

8/4.2 VERTICALITY

At the commencement of installation, the equipment governing the alignment

of the bored pile shall be made vertical to a tolerance of within 1 to 100. The
maximum permitted deviation of the finished pile from the vertical is 1 in 75.

8/4.3 RAKE

The equipment governing the direction and angle of rake shall be set to give
the correct alignment of the pile within a tolerance of 1 in 50. The piling rig
shall be set and maintained to attain the required rake. The maximum
permitted deviation of the finished pile from the specified rake is 1 in 25 for
piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.

8/4.4 FORCIBLE CORRECTIONS TO PILES

Forcible corrections to concrete piles to overcome errors of position or

alignment shall not be made. Forcible corrections may be made to other piles
only if approved and where the pile shaft is not fully embedded in the soil.

8/5 PILING METHOD AND PROGRAMME

8/5.1 The Contractor shall supply for approval all relevant details of the method of
piling and the plant he proposes to use. Any alternative method to that
specified shall be subject to approval.

8/5.2 The Contractor shall inform the Engineer each day of the intended programme
of piling for the following day and shall give adequate notice of his intention to
work outside normal hours and Public Holidays.

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 3 SECTION 8 CONCRETE PILE FOUNDATIONS

8/5.3 The Contractor shall submit to the Engineer his proposed sequence and timing
for boring piles, having regard to the avoidance of damage to adjacent piles.

8/5.4 Any proposals by the Contractor for ground treatment of any nature or for
temporary lowering of the water table by well pointing or any other method
shall be subject to the approval of the Engineer. The Contractor shall however
remain fully responsible for any effects of such ground treatment or control of
the level of water tables upon the existing roads, building and structures in the
vicinity of works.

8/5.5 Any proposals by the Contractor for underpinning, needling and shoring of
existing structures in the vicinity of the works shall be carefully designed by the
Contractor and be subject to approval of the Engineer.

8/6 PILING RECORDS

8/6.1 The Contractor shall keep records as follows for the installation of each pile
and shall submit two signed copies of these records to the Engineer not later
than noon of the next working day after the pile was installed. The signed
records will form a record of the work.

Any unexpected boring conditions shall be noted in the records.

Data to be recorded

a. Contract
b. Pile reference number (location)
c. Pile type
d. Nominal cross-sectional dimensions or diameter.
e. Nominal diameter of under ream/base.
f. Standing groundwater level from direct observation or given site
investigation data.
g. Date and time of boring.
h. Date of concreting
i. Ground level at pile position at commencement of installation of pile
(commencing surface).
j. Working level on which piling base machine stands
k. Depth from ground level at pile position to pile to
l. Toe level.
m. Pile head level as constructed.
n. Pile Cut-off level.
o. Length of temporary casing
p. Length of permanent casing.
q. Soil samples taken and in situ tests carried out during pile formation or
adjacent to pile position.

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 4 SECTION 8 CONCRETE PILE FOUNDATIONS

r Surrounding soil condition of toe to be recorded”. Condition recording

includes, but not limited, to:

- Presence of rock at toe (either local or overall),

- Soft or strong soil or any abnormality in soil profile at the vicinity of
the pile toe.
s Length and details of reinforcement.
t. Concrete mix.
u. Volume of concrete supplied to pile where this can be measured in
practice.
v. All information regarding obstruction delays and other interruptions to the
sequence of work.

8/7 DAMAGE TO ADJACENT SERVICES AND STRUCTURES

8/7.1 If damage will be, or is likely to be, caused to mains, services or adjacent
structures, the Contractor shall submit to the Engineer his proposals for
making surveys, monitoring movements or vibrations, and minimising or
avoiding such damage.

8/7.2 The Contractor shall carry out the work in such a manner and at such times so
as to minimise noise and disturbance.

8/8 CONCRETE FOR PILES

8/8.1 Concrete for piles shall be Class 30 or as shown on the drawings and shall be
in accordance with Section 4 of the Specification and the following
requirements:

8/8.2 When a designed mix is specified the Contractor shall be responsible for
selecting the mix proportions to achieve the required strength and workability,
but the Engineer will be responsible for specifying the minimum cement
content and any other properties required to ensure durability.

8/8.3 The Concrete shall have sufficient workability to enable it to be placed and
compacted by the methods used in forming the piles.

8/8.4 For piles exposed to potentially aggressive ground or groundwater, approved

measures shall be taken to ensure durability. Reference should be made to
Building Research Establishment Design 363 published in the U.K. relating to
sulphate attack.

8/8.5 The cement content in any mix shall not be less than 360 kg/Cu.m. Where
concrete is to be placed under water or drilling mud by tremmie the cement
content shall be not less than 380 kg/Cu.m., or where the pile will be exposed
to sea water 400 kg/Cu.m.

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 5 SECTION 8 CONCRETE PILE FOUNDATIONS

8/8.6 All concrete aggregates, cement and water shall be sampled and tested as
frequently as deemed necessary by the Engineer as detailed under the
relevant clauses in section 4 concrete work. All test samples shall be supplied
by the Contractor at his own expense.

8/8.7 Trial mixes shall be prepared for concrete in accordance with BS 5328,
showing that the proposed mix proportions and manufacture will produce a
concrete of the strength and quality required, having adequate workability for
compaction by the method to be used in placing.

8/8.8 The Contractor shall keep a detailed record of the results of all tests on
concrete and concrete materials. Each test shall be clearly identified with the
piles to which it relates.

8/9 REINFORCEMENT FOR PILES

8/9.1 The reinforcement for the piles shall conform to the requirement of SECTION
4 of the specification.

8/9.2 Reinforcement in the form of a cage shall be assembled with additional

support, such as spreader forks and lacings, necessary to form a cage which
can be lifted and placed without permanent distortion. Intersecting bars shall
be fixed together by approved means. Hoops, links or helical reinforcement
shall fit closely around the main longitudinal bars and be bound to them by
approved wire, the ends of which shall be turned into the interior of the pile.
Reinforcement shall be placed and maintained in position to provide the
specified projection of reinforcement above the final cut-off level.

8/9.3 The cover to all reinforcement in cast-in-place piles shall be not less than
75mm unless otherwise approved by the Engineer. Spacers shall be designed
and manufactured using durable materials which will not lead to corrosion of
the reinforcement or spalling of the concrete cover.

8/9.4 The number of laps in longitudinal steel bars shall be kept to a minimum.
Joints in reinforcement shall be such that the full strength of each bar is
effective across the joint and shall be made so that there is no detrimental
displacement of the reinforcement during the construction of the pile.

8/10 BORING FOR PILES

8/10.1 Prior to boring the Contractor shall check the casing position for each pile
during and immediately after placing the casing, and agree it with the
Engineer.

8/10.2 Where the open bore is unstable, temporary casing, or bentonite suspension
may be used to support the wall of the bore prior to concreting.

8/10.3 Piles shall not be bored so close to other piles which have recently been cast
and which contain workable or unset concrete that a flow of concrete could be
induced from or damage caused to any of the piles.

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 6 SECTION 8 CONCRETE PILE FOUNDATIONS

8/10.4 The Contractor shall carry out the work in such a manner and at such times as
to minimise noise and disturbance.

8/10.5 Any proposals by the Contractor for ground treatment of any nature or for
temporary lowering of the water table by well pointing or any other method
shall be subject to the approval of the Engineer. The Contractor shall however
remain fully responsible for any effects of such ground treatment or control of
the level of water tables upon the existing roads, buildings and structures in
the vicinity of the Works.

8/10.6 Any proposals by the Contractor for underpinning, needling, and shoring
structures in the vicinity of the works shall be carefully designed by the
Contractor and be subject to the approval of the Engineer.

8/10.7 Temporary casings shall be free from significant distortion. They shall be of
uniform cross-section throughout each continuous length. During concreting
they shall be free from internal projections and encrusted concrete which
might adversely affect the proper formation of piles.

8/10.8 Where piles are bored under water or bentonite suspension in an unlined
state, the insertion of a full-length loosely fitting casing to the bottom of the
bore prior to placing concrete will not be permitted.

8/10.9 Where boring takes place through unstable water bearing strata, the process
of excavation and the depth of temporary casing employed shall be such that
soil from outside the area of the pile is not drawn into the pile section and
cavities are not created outside the temporary casing as it is advanced.

8/10.10 Where the use of drilling fluid is specified or approved for maintaining the
stability of a bore, an adequate temporary casing shall be used in conjunction
with the method so as to ensure stability of the strata near ground level until
concrete has been placed. During construction the level of drilling fluid in the
pile excavation shall be maintained within the cased or stable bore so that it is
not less than 1.0 m above the level of external standing groundwater at all
times.

In the event of rapid loss of drilling fluid from a pile excavation, the bore shall
be backfilled without delay and the instruction of the Engineer shall be
obtained before boring at that location is resumed.

8/10.11 All reasonable steps shall be taken to prevent the spillage of bentonite
suspension on the Site in areas outside the immediate vicinity of boring.
Discarded bentonite shall be removed from the Site without undue delay. Any
disposal of the bentonite shall comply with the regulations of the Dubai
Municipality.

8/10.12 Pumping from pile bores shall not be permitted unless the bore has been
sealed against further water entry by casing or unless the soil is stable and will
allow pumping to take place without ground disturbance below or around the
pile.

8/10.13 For a pile constructed in a stable cohesive soil without the use of temporary
casing or other form of support, the pile shall be bored and concrete shall be

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 7 SECTION 8 CONCRETE PILE FOUNDATIONS

placed without such delay as would lead to significant impairment of the soil
strength.

8/10.14 Each pile bore which does not contain standing water or drilling fluid shall be
inspected directly or indirectly prior to concrete being placed in it. This
inspection shall be carried out from the ground surface in the case of piles of
less than 750mm diameter. Torches or other approved means of lighting,
measuring tapes, and a means of measuring verticality shall be provided. For
piles of 750mm diameter or larger, equipment shall be provided by the
Contractor to enable his representative and the Engineer to descend into the
bore for the purpose of inspection. Any method of descent and the equipment
used shall comply with the requirements of BS 8008: 1996+A1, AMD 1: 2008.

8/10.15 On completion of boring and where inspection of a dry pile bore indicates the
necessity, loose disturbed or softened soil shall be removed from the bore.
Where pile bores contain water or drilling fluid, a cleaning process shall be
employed before concrete is placed. Large debris/or accumulated sediment
shall be removed using appropriate approved methods, which shall be
designed to clean while at the same time minimising ground disturbance below
the pile bases.

Water or drilling fluid shall be maintained at such levels throughout and

following the cleaning operation that stability of the bore is preserved.

8/11 DRILLING FLUID

8/11.1 Bentonite, as supplied to the Site and prior to mixing, shall be in accordance
with Specification DFCP 4 of the Oil Companies Materials Association.

8/11.2 A certificate shall be obtained by the Contractor from the manufacture of the
bentonite powder, showing the properties of each consignment delivered to
the Site. This certificate shall be made available to the Engineer on request.

The properties to be given by the manufacturer are the apparent viscosity

range (in centipoises) and the gel strength range (in Newton per square metre)
for solids in water.

8/11.3 Bentonite shall be mixed thoroughly with clean fresh water to make a
suspension which will maintain the stability of the pile bore for the period
necessary to place concrete and complete construction. The temperature of
the water used in mixing the bentonite suspension, and of the suspension
when supplied to the borehole, shall be not lower than 5 deg. C.

8/11.4 Where saline or chemically contaminated groundwater occurs, special

precautions shall be taken to modify the bentonite suspension or pre-hydrate
the bentonite in fresh water so as to render it suitable in all respects for the
construction of piles.

8/11.5 The frequency of testing drilling fluid and the method and procedure of
sampling shall be proposed by the Contractor for approval prior to the

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 8 SECTION 8 CONCRETE PILE FOUNDATIONS

commencement of the work. The frequency may subsequently be varied as

required, depending on the consistency of the results obtained, subject to
approval.

Control tests shall be carried out on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be
measured daily as a check on the quality of suspension being formed. The
measuring device shall be calibrated to read to within 5g/L.

Tests to determine density, viscosity, shear strength and pH value shall be

applied to bentonite supplied to the pile bore. For average soil conditions the
results shall generally be within the ranges in Table 1.

The tests shall be carried out until consistent working pattern has been
established, account being taken of the mixing process, any blending of
freshly mixed bentonite suspension and previously used bentonite suspension.
When the results show consistent behaviour, the tests for shear strength and
pH value may be discontinued, and tests to determine density and viscosity
shall be carried out as agreed with the Engineer.

In the event of a change in the established working pattern, tests for shear
strength and pH value shall be reintroduced for a period if required.

Table 8- 1: Average soil conditions ranges

Property to be Range of results Test Method

measured at 20 deg. C

Density Less than 1.10g/ml Mud density balance

Viscosity 30-90s Marsh cone method

or
less than 20 cP Fann Viscometer

Shear strength 1.4-10N/Sq.m. Rehometer

or
4-40N/Sq.m. Fann Viscometer

pH 9.5 - 12 pH indicator paper

strips
or electrical pH meter

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 9 SECTION 8 CONCRETE PILE FOUNDATIONS

The testing methods pertaining to the above table should confirm to API –
RP13B (standard procedure for testing drilling fluids).

* Where the Fann Viscometer is specified, the fluid sample should be

screened by a number 52 sieve (300 u) prior to testing.

8/12 PLACING CONCRETE

8/12.1 The method of placing and workability of the concrete shall be such that a
continuous monolithic concrete shaft of the full cross-section is formed.

8/12.2 The concrete shall be placed without such interruption as would allow the
previously placed batch to have hardened. The method of placing shall be
approved.

8/12.3 The Contractor shall take all precautions in the design of the mix and placing
of concrete to avoid arching of the concrete in temporary casing. No soil,
liquid or other foreign matter which would adversely affect the performance of
the piles shall be permitted to contaminate the concrete.

8/12.4 Slump measured at the time of discharge into the pile bore shall be in
accordance with the standards shown in Table 2.

The concrete shall be of the workability approved when in its final position and
shall remain sufficiently workable for all pile construction procedures to be
safely completed.

Table 8- 2: concrete Slump for pile foundation

Piling Mix Slump Typical conditions of Use

Workability Minimum Range
mm mm

A 75 75-150 Placed into water free

permanently lined bore of
600mm dia. or over, or where
casing level lies below
temporary casing;
reinforcement widely spaced,
leaving ample room for free
movement of concrete between
bars.

B 100 100-200 Where reinforcement is not

spaced widely; where cut-off
level of concrete is within
temporary casing; where pile
bore is water-free and the
diameter is less than 600mm.

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 10 SECTION 8 CONCRETE PILE FOUNDATIONS

C 150 150 or Where concrete is to be placed

more by tremie under water or drilling
mud or by pumping.

8/12.5 Internal Vibrators shall not be used to compact concrete.

8/12.6 Approved measures shall be taken to ensure that the structural strength of
concrete placed in all piles is not impaired through grout loss, segregation or
bleeding. Concrete shall be directed vertically into the centre of each vertical
pile so that grout is not lost from the initial discharge.

8/12.7 Before placing concrete, measures shall be taken to ensure that there is no
accumulation of silt or other material at the base of the boring, and the
Contractor shall ensure that heavily contaminated bentonite suspension, which
could impair the free flow of concrete from the tremie pipe, has not
accumulated in the bottom of the hole.

8/12.8 Concrete to be placed under water or drilling fluid shall be placed by tremie
and shall not be discharged freely into the water or drilling fluid. Pumping of
concrete may be approved where appropriate.

8/12.9 A sample of the bentonite suspension shall be taken from the base of the
boring using an approved sampling device. If the specific gravity of the
suspension exceeds 1.20 the placing of concrete shall not proceed. In this
event the Contractor shall modify or replace the bentonite as approved to meet
the Specification.

8/12.10 The concrete shall be a rich coherent mix of high workability and cement in
accordance with Subsection 8/8.5 and mix C, Table 2. The concrete shall be
placed in such a manner that segregation does not occur.

8/12.11 The hopper and pipe of the tremie shall be clean and watertight throughout.
The pipe shall extend to the base of the bore and a sliding plug or barrier shall
be placed in the pipe to prevent direct contact between the first charge of
concrete in the tremie and the water or drilling fluid. The pipe shall at all times
penetrate the concrete which has previously been placed and shall not be
withdrawn from the concrete until completion of concreting. A sufficient
quantity of concrete shall be maintained within the pipe to ensure that the
pressure from it exceeds that from the water drilling fluid. The internal
diameter of the pipe of the tremie shall be not less than 150 mm for concrete
made with 20mm aggregate. It shall be so designed that external projections
are minimised, allowing the tremie to pass within reinforcing cages without
causing damage. The internal face of the pipe of the tremie shall be free from
projections.

8/12.12 No concrete shall be placed until all driving within a radius of 4.5 meters has
been completed, nor until all the shells for any one cluster have been
completely driven. If this cannot be done, all driving within above limits shall
be discontinued until the concrete in the last pile cast, has been set for at least
seven days.

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 11 SECTION 8 CONCRETE PILE FOUNDATIONS

8/12.13 Unless designated as basement piles all piles shall be placed with their tops at
least 1 metre above pile cut-off level in their respective pile caps. All
boreholes, except for basement piles or unless otherwise specified, shall be
filled with concrete to the top of the hole so that the Engineer can be assured
that all the bentonite has been displaced by the concrete.

8/13 EXTRACTION OF CASING

8/13.1 Temporary casings shall be extracted while the concrete within them remains
sufficiently workable to ensure that the concrete is not lifted. During extraction
the motion of the casing shall be maintained in an axial direction relative to the
pile.

8/13.2 When the casing is being extracted, a sufficient quantity of concrete shall be
maintained within it to ensure that pressure from external water, drilling fluid or
soil is exceeded and that the pile is neither reduced in section nor
contaminated.
8/13.3 The concrete level within a temporary casing shall be topped up where
necessary during the course of casing extraction in such a way that the base
of the casing is always below the concrete surface until the casting of the pile
has been completed.

8/13.4 Adequate precautions shall be taken in all cases where excess heads of water
or drilling fluid could occur as the casing is withdrawn because of the
displacement of water or fluid by the concrete as it flows into its final position
against the walls of the pile bore. Where two or more discontinuous lengths of
casing (double casing) are used in the construction the proposed method of
working shall be approved by the Engineer.

8/13.5 For piles cast in dry bores using temporary casing and without the use of a
permanent lining, pile heads shall be cast to a level above the specified cut-off
so that, after trimming, a sound concrete connection with the pile can be
made. The casing level shall be within the tolerance above the cut-off level
shown in Table 3 but shall not be above the commencing surface level.

No pile shall be cast with its head below standing water level unless approved
measures are taken to prevent inflow of water causing segregation of the
concrete as temporary casing is extracted; and where applicable, the standing
water level for each pile shall be agreed with the Engineer, and this level is to
be treated as the cut-off level for the purpose of calculating tolerance.

8/13.6 For piles cast in dry bores within the permanent lining tubes or permanent
casings, or where their cut-off levels are in stable ground below the base of
any casing used, pile heads shall be cast to a level above the specified cut-off
so that, after trimming, a sound concrete connection with the pile can be
made. The casting level shall be within the tolerance above the cut-off level
shown in Table 4, but shall not be above the commencing surface level.

8/13.7 For piles cast under water or drilling fluid, the pile heads shall be cast to a
level above the specified cut-off so that, after trimming to remove all debris
and contaminated concrete, a sound concrete connection with the pile can be
made. The casing level shall be within the tolerance above the cut-off level

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 11

 12 SECTION 8 CONCRETE PILE FOUNDATIONS

shown in Table 5, but shall not be above the commencing surface level.
Cut-off levels may be specified below the standing groundwater level, and
where this condition applies the borehole fluid level shall not be reduced below
the standing groundwater level until the concrete has set.

8/13.8 Where the cut-off level of piles lies at depths greater than 10m below the
commencing surface, than the tolerances given in Tables 3 - 5 will be varied
after discussion with the Contractor and before commencement of the piling to
take account of the special conditions which apply.

8/13.9 During extraction of temporary casings, where circumstances are such that
newly placed unset concrete is brought into contact with external groundwater,
precautions shall be taken to ensure that the internal concrete pressure at all
levels within the pile exceeds the external groundwater pressure.

Table 8- 3: Casting tolerance above cut-off level for piles cast in dry bores using
temporary casing and without the use of a permanent lining

Cut-off distance below Casting tolerance above

commencing surface Cut-off Level m
H(m)
0.3+H/12+C/8
0.15 - 10.00 Where C=length of
temporary casing below
the commencing surface *

 If H is greater than C this tolerance is no longer applicable and the tolerances in Table 4 will
apply.

Table 8- 4: Casting tolerance above cut-off level for piles cast in dry bores within
permanent lining tubes or permanent casings, or where their cut-off levels are in
stable ground below the base of any casing used.

Cut-off distance below Casting tolerance above

commencing surface H(m) Cut-off Level m

0.15 - 10.00 0.3+H/10

Table 8- 5: Casting tolerance above Cut-off level for piles cast under water or drilling fluid*.

Cut-off distance below commencing Casting tolerance above Cut-off

surface H,m Level m

0.15 - 10.00 1.0+H/12+C/8

Where C=length of temporary
casing below
the commencing surface
* In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
tolerance is given by deletion of the casing term C/8 in the table.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 12

 13 SECTION 8 CONCRETE PILE FOUNDATIONS

8/14 TEMPORARY BACKFILLING

8/14.1 After each pile has been cast, any empty bore remaining shall be protected
and shall be carefully backfilled as soon as possible with the approved
materials.

8/15 DISPOSAL OF EXCAVATED MATERIAL

8/15.1 Disposal of excavated material shall be carried out by the Contractor as

necessary to facilitate the works and to the satisfaction of the Engineer.

8/16 CUTTING OFF PILE HEADS

8/16.1 When cutting off and trimming piles to the specified cut-off level, the
Contractor shall take care to avoid shattering or otherwise damaging the rest
of the pile. Any cracked or defective concrete shall be cut away and the pile
repaired in an approved manner to provide a full and sound section at the
cut-off level.

8/17 INTEGRITY TESTING OF PILES

All testing shall be carried out as per Laboratory Testing Clause.

8/17.1 Where integrity-testing is called for but the method is not specified, the method
to be adopted shall be approved by the Engineer and shall be one of the
following:

a. Sonic Method - ASTM – D 5882: 2007

b. Vibration Method - ASTM – D 4945: 2000
c. Sonic Logging - ICE – Section9: 1996

8/17.2 Other methods may be adapted to the approval of the Engineer and subject to
satisfactory evidence of performance.

8/17.3 In the cast-in-place concrete piles, integrity tests shall not be carried out until 7
days or more have elapsed since pile-casting unless otherwise approved.

8/17.4 Where the method of testing requires the positioning of sensing equipment on
the pile head, the head shall be clean, free from water, laitance, loose
concrete, over spilled concrete and blinding concrete, and readily accessible
for the purpose of testing.

8/17.5 The testing shall be carried out by an approved specialist firm in accordance
with the DM Administrative Decision No.(160) for year 2000.

8/17.6 The interpretation of tests shall be carried out by competent persons and the
full test results and findings shall normally be given to the engineer within 10
days of the completion of each phase of testing. Full details of the ground
conditions and construction method shall be made available to the specialist
firm when required in order to facilitate interpretation of the tests.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 13

 14 SECTION 8 CONCRETE PILE FOUNDATIONS

8/18 LOADING TESTS

All testing shall be carried out as per Laboratory Testing Clause.

8/8.1 Each test pile and working pile to be tested shall be loaded axially to 2.0 times
and 15 times the working load respectively as specified on the Drawings. The
tests shall not be commenced until the concrete has reached 90% of its design
strength and shall be maintained on the pile as aforementioned or for such
further period as the engineer may direct.

8/18.2 Loading tests shall be carried out (according to BS 8004 Clause 7.5.5) at the
date ordered on individual piles selected by the Engineer.

8/18.3 Piles selected by the Engineer shall be tested as follows:

a. The test load shall be applied by a method approved by the Engineer

and shall be measured within an accuracy of 2 percent. Settlements
shall be measured within an accuracy of 0.25mm.

b. The test load and unloading shall be applied in suitable increments and
as smoothly and expeditiously as possible.
c. The load after each increment shall be kept constant until the rate of
settlement does not exceed 0.25 mm per hour.

d. The amount of settlement shall be recorded before the next load

increment.

e. The full test load shall be maintained for 48 hours and the total
settlement recorded.

f. The load after each reduction shall be kept constant until the rate of
recovery does not exceed 0.25 mm per hour.

g. The amount of recovery shall be recorded before the next load reduction.

h. The Contractor shall, within 24 hours of the completion of the test, submit
to the engineer for each pile tested graphs showing:

- Load and settlement plotted above and below a common base line
of time

- Settlement and recovery plotted vertically against a base line of

time.

i. The settlement of the pile under the test load and the recovery of the pile
after its subsequent removal shall be within the limits agreed with the
Engineer.

8/18.4 The temporary caps will be cut away and the debris removed by the
Contractor.

8/18.5 The Contractor shall keep detailed records in collaboration with the Engineer
of the settlement and recovery of the pile as the increment of load are applied
and removed respectively.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 14

 15 SECTION 8 CONCRETE PILE FOUNDATIONS

8/18.6 The Contractor shall provide the Engineer with two copies of his records of
each test.

8/18.7 If the tests indicate that, in the opinion of the Engineer, the piles are
unsatisfactory for the working load, the Contractor shall at his own expense
replace the tested pile in a suitable position and if necessary support to be
given to the structure to be carried.

8/18.8 The Contractor shall bear the cost of any additional work made necessary as a
result of the unsatisfactory pile or piles. The Contractor shall also satisfy the
Engineer that any piles constructed prior and subsequent to the results of the
tests being known are capable of carrying the specified working load. Further
tests shall be carried out, if required by the engineer, and any piles deemed to
be unsatisfactory by the Engineer shall be replaced or augmented by further
piles. No extra cost will be accepted or extension of time granted in
connection with the foregoing work.

8/18.9 The Contractor shall state in his proposals the measures he intends to take if
the ultimate load of any pile fails to reach the required value under the loading
test, with regard to lengthening, re-driving and retesting of the test pile, and
also to the provision of additional piling to augment or replace the tested pile.
No extra cost will be accepted or extension of time granted in connection with
the foregoing work.

8/19 FAILURE OF PILE

8/19.1 A pile shall be considered to have failed when any of the following conditions
apply:

- On completion of a load test, the residual settlement after rebound

exceeds 6 mm.

- The test load as specified in the contract shall not have been achieved.

- The maximum settlement exceeds 1 % of the least lateral dimension of

the pile under ultimate load.

8/20 RECTIFICATION OF FAILURE

8/20.1 In the event of a pile failing a load test, notwithstanding any contrary proposals
by the Contractor, the Engineer may insist on the following methods of
rectification (as a minimum):

- When a trial pile - an additional trial pile shall be driven as directed by the
Engineer and tested. If this second trial pile fails, the Engineer shall
order such changes in the design of the pile as he considers necessary.

- When part of the main piling operation - a further pile in the same group
shall be tested. If this second test pile fails, the Engineer shall order
such changes in the design of the pile/pile group as he considers
necessary.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 15

 16 SECTION 8 CONCRETE PILE FOUNDATIONS

8/20.2 In the case of the first pile of the main piling operation failing a test load, but
subsequent piles passing the load test, a new pile shall be driven to replace
the defective pile in a position agreed by the Engineer at the expense of the
Contractor.

8/20.3 In the event of additional works being carried out as a result of new piles being
required under this Clause, the cost of this additional work will be at the
expense of the Contractor.

8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK

8/21.1 All Piles shall have protective sleeve for a minimum depth of 3 m below the
cut-off level of the pile. This sleeve shall be plastic or metal bedded in mastic
to form a fully water-proofed seal to the concrete.

8/22 CLEARANCE OF WORKS

8/22.1 Upon the completion of the works the Contractor shall clear away and remove
from the Site all constructional plant, equipment, surplus materials, rubbish,
etc. and leave the whole of the Site and Works clean and in perfect condition
to the satisfaction of the Engineer.

Volume 2, Part 1, General Specifications-Road Works March 2017 Page 16

Appendix A
General Specifications Volume 2 - Part 1

APPENDIX “A”

LABORATORY TESTING

Testing of all materials and completed work shall be carried out in accordance with DM
Administrative Decision No. 160/2000:

1. Dubai Municipality — Dubai Central Laboratory (D.C.L) in accordance with

Appendix “Al”.

2. Independent Laboratory in accordance with Appendix “A2”.

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 Appendix A1
Laboratory Testing Schedule
Applicable to the Dubai Municipality
Dubai Central Laboratory Department
General Specifications Volume 2 - Part 1

APPENDIX “Al”

(1) TESTING AT DUBAI MUNICIPALITY -Dubai Central Laboratory Department

(DCLD)

1.1 All transportation of personnel and materials on site and to/from the DCL shall be
borne by the contractor. Suitable approved transport with driver shall be
maintained for this specific use by the Contractor.

1.2 The contractor shall pay for all the tests carried out by the DCL.

1.3 Any testing which is required under the contract which cannot be carried out by
the DCL shall be carried out at Contractor’s expense at an Independent
Laboratory in accordance with Appendix “A2”. Copy of such sampling and testing
reports shall be forwarded to the DCL and to the DM Department concerned for
information not later than a week from the date of the issuance of the reports.

1.4 The testing of the works by the DCL shall in no way absolve the contractor from
his responsibilities to carry out his own job control testing of the quality of his
work and the materials used.

1.5 Representatives of the Consultant and the Contractor shall be permitted to witness
the testing carried out by DCL.

1.6 DCL will not be held liable for interpreting test data, since this will be the
responsibility of the Consultant.

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General Specifications Volume 2 - Part 1

CONTINUATION OF APPENDIX “Al”

1.7 All sampling for such tests shall be earned out by the Consultant’s Representative
and labeled as per relevant standard sampling requirements and submitted by the
Consultant to DCL along with the sampling reports.

1.8 The Contractor shall submit to DCL Monthly Laboratory Testing Program. The
program shall detail the specific test requirements for the coming month which
includes the type, number and approximate date that testing will be required.

1.9 Minimum twenty-four (24) hours notice shall be given to DCL before any tests are
scheduled to be carried out.

1.10 The Consultant shall inform DCL and RTA/DM Department concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.

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 Appendix A2
Testing at an
Independent Laboratory
General Specifications Volume 2 - Part 1

APPENDIX “A2”

(2) TESTING AT AN INDEPENDENT LABORATORY.

2.1 Any testing which is required under the contract and as detailed in DM
Administrative Decision No. (160) for year 2000 may be carried out at the
Contractor’s expense at an approved Independent Laboratory, provided this
laboratory meets the following requirements.

2.1.1 Independent laboratories that operate in Dubai Emirate shall meet all the
requirements of DM rules and regulations including DCL accreditation
requirements.

2.12 Independent laboratories that operate outside Dubai Emirate shall be accredited to
one of the National Accreditation Systems for laboratories such as UKAS, NATA,
etc. The Contractor shall forward a copy of the accreditation certificate to DCL for
approval prior to approaching such laboratories for testing services.

2.2 All sampling for such tests shall be carried out by the Consultant’s Representative
and labeled as per relevant standard sampling requirements and submitted by the
Consultant to the independent laboratory along with sampling reports.

2.3 Representatives of the Consultant and the Contractor shall be permitted to witness
the testing carried out by the independent laboratory.

2.4 The testing of the works by the independent laboratory shall in no way absolve the
Contractor from his responsibilities to carry out his own job control testing of the
quality of his work and the materials used according to the contract specifications.

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General Specifications Volume 2 - Part 1

CONTINUATION OF APPENDIX “A2”

2.5 The Consultant shall inform D.C.L and RTA/DM Department concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.

2.6 The independent laboratory shall give original copies of the sampling and testing
reports to the Consultant and copies to:

2.6.1 RTA / DM Department concerned

2.6.2 DCL

2.6.3 Contractor

2.7 The independent laboratory shall divide non - destructive samples into four
representative sub-samples:

Part “A” : to be tested by the independent laboratory;

Part “B” : for RTA / DM Department concerned/Consultant Recheck;

Part “C” : for independent laboratory internal quality control;

Part “D” : for DCL Cross-check.

2.8 Contractor shall enter into an agreement with an independent laboratory. This
agreement shall include all conditions as detailed in appendix “A2”

2.9 Any material requiring certification as per DM regulation shall not be used unless
certified by DCL.

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Appendix B
General Specifications Volume 2 - Part 1

APPENDIX B

Schedule of Surveying Equipment to be Supplied

by the Contractor for the Use of the Engineer

The Contractor shall supply and maintain in full working order during the progress of the
Works, Surveying Equipment and other items, and the supply of expendable surveying
material as required from time to time in connection with the Works. All equipment
specified shall be new, approved by the Engineer, and for the exclusive use of the
Engineer, but shall remain the property of the Contractor.

ITEM DESCRIPTION NO.

a. LEIRA TC1202 or 1205 Total Station and Tripod. 1

b. Wild NAK Universal Automatic Level with tripod 2
(or approved equal).
c. Sectional leveling staves with leveling bubble, 5m long. 2
d. Ranging rods, painted, 2.5m long. 4
e. 30m steel measuring tape graduated in meters and mm, 2
Rabon Permaline or approval equal.
f. 30m long non-metallic measuring tape graduated in 2
meters and mm, Rabon Permaline or approved similar.
g. 5m steel pocket tape graduated in mm Stanley or 4
approved equal.
h. Universal straight edge 3m with edge gauge. 2
I. Aluminum spirit level 1m long with four plumb and two 2
level tubes.
j. Safety helmets, reflective jackets and other safety As required*
equipments as required.
k. Rolling Straight Edge when required. As required*
l. One copy of all standards referred to in the Specifications. As required*
m. Target reflection with 3km range. 2
n. Plumbing pole to target and reflector. 1
o. Tripod and Tribarch. 3
p. Weather proof rubber-cased torches. 2
q. Surveying umbrellas, level books etc. As required*
r. Digital thermometer for asphalt and concrete 2
s. Manhole lifting keys for
i) heavy duty covers 1
ii) medium duty covers 1
iii) light duty covers 1

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General Specifications Volume 2 - Part 1

ITEM DESCRIPTION NO.

t. GPS receivers and ancillaries As required*

u. Other miscellaneous equipment and tools necessary for As required*
the carrying out of the Engineer's duties.
v. Laser road surface testing machine for testing rideability. As required*
w. Travelling beam for testing surface evenness/levels As required*

* As required by the Engineer

Detailed Design Page B/2

Appendix C
General Specifications Volume 2 - Part 1

APPENDIX C

SCHEDULE OF ENGINEER'S OFFICE AND EQUIPMENT

General Preambles

The Contractor shall provide, maintain and keep clean, the new temporary site offices with
all associated new equipment, new fittings and services for the exclusive use of the
Engineer's Representative and his staff, from commencement until one month after the
completion of the whole of the Works.

The temporary site offices shall be either newly prefabricated portable unit/s or alternatively
of some other form of weatherproof design and construction to the approval of the
Engineer.

The Employer will not provide free of charge any area of land for the location of the
Engineer’s office and compound; this should be the contractor responsibility to provide at
his own cost. The contractor’s own offices also be located on the land but no workshops,
stores, fabrication or manufacturing facilities will be permitted therein.

The offices shall have full partitions and room sizes shall be as shown in the attached
Schedule of offices. All rooms shall have individual entrance doors.

Corridor and entrance areas shall be additional to the office sizes.

The offices shall be air-conditioned with the exception of the Toilet, Shower and Kitchen
areas.

All rooms shall have glazed windows complete with fly screens.

Adequate fitted hardware, electrical switches, sockets, lighting and plumbing fittings,
sanitary ware and fittings and fixtures etc., shall be provided as necessary for the different
areas.

The electrical installation shall provide for simultaneous use of all electrical appliances.

The Contractor may either arrange for a temporary power supply to the offices or
alternatively provide and maintain adequate diesel generator sets. All electricity bills shall
be paid by the Contractor.

The Contractor may either arrange for a temporary mains water supply or alternatively
provide tanker water supply. All water bills shall be paid by the Contractor.

Independent telecommunication lines (3) with extensions to all rooms shall be provided for
the offices as shown in the Schedule of Fittings and the Contractor shall pay all installation
and rental charges and call charges within the U.A.E. An Independent Fax line including
equipment and Internet / E-mail connection shall be provided.

The Contractor shall submit any necessary drawings and calculations for the construction
of the offices for the Engineer’s approval before commencing construction and shall be
responsible for ensuring that the offices are structurally sound. The Engineer may request

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General Specifications Volume 2 - Part 1

alterations at this stage. The drawings shall be approved in writing by the Engineer before
installation / construction shall commence.
The offices shall be completed and all the equipment provided by the end of the
Mobilisation Period.

The Contractor shall provide all items listed in the attached Schedules.

Throughout the duration of the Contract, the Contractor shall ensure an uninterrupted
supply of gas, water, refreshments and electricity to the offices.

The office requirements on this contract are as follows:

Room No. Description Size No.

1 Resident Engineer 6m x 4m 1
2 Conference Room 8m x 4m 1
3 Assistant Resident Engineer / 4m x 4m 10
Civil Engineer / Landscape
Engineer / Materials Engineer /
Safety Engineer / Electro
Mechanical Engineer / Quantity
Surveyor/ Senior Quantity
Surveyor/ Senior structural
Engineer/ Structural Engineer
4 Materials Inspector 8m x 4m 1
5 Land Surveyor 8m x 4m 1
6 Inspectors Civil /Landscape 6m x 4m 2
7 Typist / Clerk / Filing 6m x 4m 1
8 Toilet 4m x 2m 4
9 Shower 2m x 2m 1
10 Kitchen / Store 4m x 2m 1
11 Store 4m x 2m 1
12 RTA Liaison Engineer 4m x 4m 1
13 Structural Inspectors 8m x 4m 1

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 General Specifications Volume 2 - Part 1

Schedule of Fittings

The new fittings required under this Contract for the site offices indicated in the schedule of
offices, shall be to the Engineer's approval and are as follows:

Room No. and Quantity

Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13

a. Executive desk with two No. 1 - - - - - - - - - - 1

locking drawers & revolving
chair
b. Conference table to No. - 1 - - - - - - - - - -
accommodate 12 people
with revolving chairs
c. Desk with two locking - - - 10 - - - - - - - - -
drawers, side table and
revolving chair
d. Desk with two locking No. - - - 3 3 4 - - - - - - 3
drawers and revolving chair
e. Visitor's chair - steel frame No. 2 - 20 3 3 4 2 - - 1 - 2 3
f. Typist desk and revolving No. - - - - - - 1 - - - - -
chair
g. Side table for drawings No. 1 - 10 3 3 2 - - - - - - 3
h. Samples cupboard No. - - 1 - - - - - - - - -
i. Four drawers steel filing No. 1 - 10 1 1 3 2 - - - - 1 3
cabinet
j. Shelving and pin boards AS REQUIRED ON SITE
k. In/Out Tray No. AS REQUIRED ON SITE
l. Waste paper basket No. AS REQUIRED ON SITE
m. Telephone hand set No. 1 1 10 1 1 2 1 - - - - 1 1
(6 land lines + 3 Mobile
(including Sim Card
Charges for phone)
n. Portable dry powder fire No. - - - - - - 1 - - 1 1 -
extinguisher
p. Maximum-minimum No. 1 - 1 - - - - - - - - -
thermometer
q. Refrigerator 10 cubic feet No. - - - - - - - - - 1 - -
r. Water filter No. - - - - - - - - - 1 - -
s. Sink Unit No. - - - - - - - - - 1 - -
t. Electric Kettle No. - - - - - - - - - 1 - -
u. Photocopier with paper No. - - - - - - 1 - - - - -
sorter.

1 2 3 4 5 6 7 8 9 10 11 12

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 General Specifications Volume 2 - Part 1

Schedule of Fittings (Cont’d..)

Room No. and Quantity

Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13
v. P.C: No. 1* - 6* - 3 2 - - - - - 1 2
Processor: Quad core
Xecon Proc ES410, 2.33
GHz, 2x6MB L2 Cache
Front Side Bus (FSB) 1333
MHz,
O/S: Windows 7, RAM: 46B,
DDR2 ECC SDRAM
Memory 667 MHz (4
DIMMS). Hard Disk: 2-806B
SATA 3.0 Gb/s, 7200 RPM
NCQ Hard Drivers with 8
MB DataDurst Cache.
Video: 256MB Pcle x 16
nVidia NVS 290, Dual
Monitor DVI capable (via
cable). Optical Drive:
16xDVD+/-RW DL. Sound:
Integrated HD Audio
MS Keyboard, Mouse and
Mouse Pad, 17” LCD
Monitor, latest PC Microsoft
office software with
licences. Microstation
software and license. Latest
Primarera software and
latest license. Arc GIS
version 10.1 (or approved)
w. P.C. No. - - 4* 1* - - 1* - - - -- -
Processor: Intel Core 2 Duo
E8400/3.0 GHz, 6M. Front
Side Bus (FSB): 1333 MHz
O/S: Windows 7. RAM: 46B,
Non-ECC, 800 MHz DDRz2
(4 DIMH). Hard Disk: 806B
SATA 3.0 6b/s and 8 MB
DataBrust Cache. Video:
Integrated Intel 6MA 4500
w/DVI adaptor cord.
Network Interface: Intel
8256/LM Gigabit. Optical
drive: 16xDVD=/- RW DL
SATA. Sound: Integrated.
MS Keyboard, Mouse and
Mouse Pad, 17” LCD
Monitor, Latest Microsoft
office software with licenses
x. A4 Laser printer 8PPM No. - - - - - - 1 - - - - -
(or equivalent) networked
y. A4 Colour printer networked - - 1 - - - - - - - - -
z A3 Colour printer networked 1 - - - - - - - - - - -

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 General Specifications Volume 2 - Part 1

Schedule of Fittings (Cont’d..)

Room No. and Quantity

Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13
aa. High definition Digital - - - 1 - - - - - - - -
camera with zooming &
printing of dates facilities
(min 10 mega pixels)
ab. Refreshments and other AS REQUIRED ON SITE
consumables including
stationery, photocopy paper
etc.
ac. Site Office cleaning & AS REQUIRED ON SITE
Maintenance
ad. Laser Facsimile machine No. - - - - - - 1 - - - - -
with separate phone line
ae. A4 High resolution colour No - - - - - - 1 - - - - -
Scanner.

af. Installing Software No. 1 - 2 - - - - - - - - -

Primavera
ag. Installing Micro Station No. - - 1 - 1 - - - - - - -
Software
1 2 3 4 5 6 7 8 9 10 11 12 13

* with email / internet connections. Computer shall be provided with Web Facilities for on-line
submission of test requests and on-line receiving of test reports.

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General Specifications Volume 2 - Part 1

VEHICLES

The Contractor shall provide and maintain the following three vehicles for the Engineer.

4-wheel Drive Double Cabin AC Pick-up with experienced Driver possessing valid
UAE License

Year of Manufacture : As per Engineer’s approval

Engine Capacity : 2700 cc onwards
Transmission : Manual

The above Vehicles supplied shall be approved by the Engineer, and for consultant’s use
exclusively for material testing, but shall remain the property of the Contractor.

Detailed Design Page C/6

 ROADS & TRANSPORT
AUTHORITY

‫ ﺗطوﯾر وﺻﻠﺔ اﻷﺻﺎﯾل‬- ‫ ﺗﺣﺳﯾﻧﺎت ﻣﺣور اﻟﺷﯾﺦ راﺷد‬- 1060/2‫ط‬

PROJECT: R1060/2
– IMPROVEMENT OF SHEIKH RASHED
DEVELOPMENT OF AL ASAYEL LINK

TENDER DOCUMENT

VOLUME 2 – PART I – BOOK 2

RTA SPECIFICATIONS (SERVICES WORKS & APPENDICES)

EMPLOYER: CONSULTANT:

Roads & Transport Authority AECOM Middle East Ltd.

Roads Department P.O. Box 51028
P.O. Box 118899 Dubai – U.A.E.
Dubai – U.A.E.

RTA MAY 2024

 R1060/2 - Improvement of Sheikh Rashed – Development of Al Asayel link
Tenderer & Contract Conditions

PROJECT R1060/2:
IMPROVEMENT OF SHEIKH RASHED –
DEVELOPMENT OF AL ASAYEL LINK

GENERAL INDEX

VOLUME 1 - TENDERER & CONTRACT CONDITIONS

VOLUME 2 - SPECIFICATIONS

 PART I - RTA SPECIFICATIONS

o BOOK 1 – ROAD WORKS

o BOOK 2 – SERVICE WORKS & APPENDICES

 PART II - DM SPECIFICATIONS

o BOOK 1 - DM GENERAL SPECIFICATIONS, PART-1

o BOOK 2 - DM GENERAL SPECIFICATIONS, PART-2

& APPENDICES

Volume 3 - BILL OF QUANTITIES

Volume 4 - DRAWINGS

Volume 5 - GEOTECHNICAL INVESTIGATION REPORT

May 2024 Tender Document 1

 VOLUME 2

Part 2: Services Works

TABLE OF CONTENTS

Section Description

1 GENERAL

2 EARTHWORKS

3 CONCRETE WORK

4 PIPES, PIPEWORKS, MANHOLES AND CHAMBERS

5 BRICWORKS AND BLOCKWORKS

6 INSPECTION AND TESTING OF PIPELINES AND STRUCTURE

7 WORKS IN CONNECTION WITH SERVICES OTHER THAN STORM

WATER DRAINAGE SANITARY SEWERS AND WATER SUPPLY

8 SPECIFICATIONS IN CONNECTION WITH DUBAI WATER

DEPARTMENT WORKS

9 CORROSION PROTECTION AND ODOUR CONTROL

10 BUILDING SPECIFICATIONS

11 REINSTATEMENT OF ROADS PAVEMENTS AND TILED

SIDEWALKS

12 SAFETY PROCEDURES

13 SEWER CLEANING AND CCTV SURVEY

14 PIPELINES RENOVATION, REPLACEMENT AND ABANDONMENT

15 MANHOLE RENOVATION AND ABANDONMENT AND PUMP

STATION AND RISING MAIN ABANDONMENT

16 MICRO TUNNELING AND PIPE JACKING

17 ELECTRICAL AND MECHANICAL SPECIFICATIONS

18 INSPECTION, TESTING AND COMMISSIONING OF MECHANICAL

AND ELECTRICAL ITEMS

19 MISCELLANEOUS METALS AND PLASTICS

20 MISCELLANEOUS ELECTRICAL AND MECHANICAL

21 AUTOMATIC IRRIGATION

A APPENDICES
 1 SECTION 1 GENERAL

TABLE OF CONTENTS

1/1 GENERAL INFORMATION ............................................................................. 2

1/2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE .................................. 4
1/3 GENERAL REQUIREMENTS ......................................................................... 4

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 2 SECTION 1 GENERAL

1/1 GENERAL INFORMATION

1/1.1 PREAMBLE

These Specifications shall be read in conjunction with the other documents of

the Tender and Contract Documents and Drawings. The Contractor shall
comply with all the provisions contained within these Documents. The
Contractor shall take note of the Appendices contained in Part 3 of 3 of these
Specifications. Where items in Part 1 of 3 of the Specifications are also
covered in the Appendices the requirements of the Appendices shall take
precedence.

Any clause in these Specifications which relates to work or materials not

required by the Contract shall be deemed not to apply.

In order to avoid needless repetition of such phrases as "to the Engineer" and
"by the Engineer" or "the Engineer's Representative" throughout these
Specifications it shall be understood that when an order, instruction, decision,
exercise of judgment or other similar act is indicated, such order, instruction,
decision, exercise of judgment or other similar action will be issued, given,
made or referred to the Engineer or the Engineer's Representative.

1/1.2 ABBREVIATIONS

In this Contract the following abbreviations have the meanings hereby assigned
to them:

"AASHTO" means the specification issued by the American Association of

State Highway and Transportation Officials.

"ACI" means the specification issued by the American Concrete Institute.

"ASA" means the specification issued by the American Standard Association.

"ASTM" means the specification by the American Society for Testing and
Materials.

"ANSI" means American National Standards Institute.

"BS" means the specification issued by the British Standards Institution.

"BS. EN" means European Standards adopted as a British Standard.

"CP" means the Code of Practice issued by the BS.

"ISO" means International Standards Organisation.

"mm" means millimetre.

"cm" means centimetre.

"sq. cm, or cm2" means square centimetre.

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 3 SECTION 1 GENERAL

"lin. m" means linear metre.

"sq. m, or m2" means square metre.

"cu. m, or m3" means cubic metre.

"km" means kilometre.

"kg" means kilogrammes.

"t" means tonne.

"gal" means U.S. gallon.

"ml" means millilitre.

"l" means litre.

"U S G" means U.S. gauge.

"No." means Number.

Where no units are quoted for a figure the relevant "System International" (SI)
unit should be assumed.

1/1.3 DATUM

The levels shown on the Drawings are referred to a series of bench-marks,

located throughout the area of the project, and whose positions and values are
shown on the Drawings. In the event of any such bench-mark having become
obliterated, the Contractor shall make his own arrangements to ensure that the
Works are

constructed to the levels shown on the Drawings or as amended by the

Engineer, and if it is found necessary to cover or destroy any of such indicated
bench-marks the Contractor shall transfer the level of such bench-marks to
other approved fixed points, which shall then be surveyed and marked on the
Drawings. The survey station details obtained by the Contractor from the Dubai
Municipality Survey Section shall be at Contractor’s cost.

1/1.4 RIGHT OF WAY

The Contractor shall make all the necessary arrangements for any land
required for working areas outside the right of way, including payment when
necessary, and the Employer does not accept any liability in connection with
such land. This includes land for compounds, temporary roads, detours,
diversions and stock piling materials.

1/1.5 GEOTECHNICAL INFORMATION

Any soils and materials test results and information provided for the Contractor
with the Contract Documents at Tender stage is for information only. The
Contractor shall be deemed to have studied this information during the

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 4 SECTION 1 GENERAL

preparation of his Tender and to have carried out any further tests as he may
consider necessary. No claims for additional payment will be considered from
the Contractor on the grounds that the information is insufficient, incorrect, or
misleading.

1/1.6 INTERPRETATION OF DRAWINGS

The Employer and the Engineer accept no responsibility for any omissions from
or for correctness of the representation of existing features on the Drawings.

1/1.7 RESPONSIBILITY OF CONTRACTOR

Where the approval of the Engineer is required under these Specifications such
approval shall not relieve the Contractor of his duties, responsibilities or
liabilities under the Contract.

1/1.8 GOVERNING STANDARDS

For all materials where no governing standard is quoted in the Specification

then a suitable national standard approved by the Engineer (BS, BS EN,
AASHTO or ANSI/ASTM) shall be used.

The most recent edition of any standard shall always be adopted unless
otherwise stated in the Specification or directed by the Engineer.
The equivalence between AASHTO and ANSI/ASTM will only be accepted
when directed by the Engineer. The Engineer may consider other national
standards (BS, BS EN, AASHTO, ANSI/ASTM) in place of those stated in the
Specifications.

1/1.9 GROUNDWATER LEVELS IN DUBAI

The Contractor will be deemed to have carried out his own investigations at the
time of Tender to ascertain for himself the nature of the soil conditions and in
particular the groundwater levels that will be encountered.

Method statements for dealing with groundwater shall be submitted within three
weeks of the signing of the Contract.

1/1.10 POLLUTION OF KHOR DUBAI OR ARABIAN GULF

The Contractor shall ensure that no extraneous matter, rubbish or polluting

liquid is deposited or discharged to the Khor Dubai (Creek) or to the foreshore
or sea of the Arabian Gulf.

1/2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE

(REFER to Volume 1, Appendix C)

1/3 GENERAL REQUIREMENTS

1/3.1 MATERIALS

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 5 SECTION 1 GENERAL

All material and products shall have an approved certificate issued by DCL.
Any material required certification as per RTA regulation shall not be used
unless certified by DM-Dubai Central Laboratory or any other independent
laboratory accredited by RTA and /or DCL.

Such Certification shall state that the materials specifications and test results
are in compliance with the specified requirement of the pertinent designations
of the most recent edition of ASTM, BS or any other approved equivalent
National Standard unless otherwise directed.

Falsification of such Certificates, Materials, Specifications or Test Results shall

be just cause for the rejection of the materials.

1/3.2 SETTING-OUT THE WORK

The Contractor shall stake-out the work as to lines and grade in accordance
with the Drawings and secures the approval of the Engineer's Representative
before constructing the work. The Engineer's Representative will, if he deems it
necessary revise the lines or grades and will require the Contractor to adjust
and to stake-out accordingly. The Contractor shall give the Engineer's
Representative not less than 24 hours notice of his intention to set out or give
levels for any parts of the Works, in order that arrangements may be made for
checking. The Contractor shall be responsible for obtaining any setting-out
data he may require from Dubai Municipality Survey Section. The Contractor
shall also be responsible for obtaining Dubai Municipality Survey Section’s
approval on right-of-way. Any costs incurred in this shall be borne by the
Contractor.

The Contractor shall, as a requirement of the Contract and without extra

charge, provide all necessary instruments, appliances, surveyor personnel and
labour, and any other material or staging, which the Engineer's Representative
may require for checking the setting out or for any relevant work to be done.
Any marks made by the Engineer's Representative or Contractor shall be
carefully preserved and, if destroyed, shall be replaced by the Contractor at his
own expense and to the approval of the Engineer. Work shall be suspended for
the time necessary for checking the lines and levels on any part of the work,
and shall proceed only after approval of measurements.

In the case of any variation from the approved works, the Contractor shall give
the Engineer three copies of cross-sections and profiles of the graphical record
or notes and computations of his stake-out as required by the Engineer. At his
option he may submit cross-mark on one copy with his approval of the
proposed lines of the work or his revisions thereof and return it to the
Contractor. The Contractor shall resubmit for approval any cross-sections the
Engineer may amend.

1/3.3 NOTICE OF OPERATIONS

The Contractor shall, when required, supply in writing full information regarding
the localities in which the materials are being obtained and in which the work is
being prepared.

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 6 SECTION 1 GENERAL

No permanent work shall be carried out without the consent in writing of the
Engineer's Representative. Full and complete notice, in writing, shall be given
24 hours in advance of the time of the operation in order to make such
arrangements as deemed necessary for inspection.

1/3.4 TRAFFIC SAFETY AND CONTROL

1. The Contractor shall provide, erect and maintain such traffic signs, lamps
barriers and traffic control signals as may be necessitated by the
construction of the Works in accordance with Dubai Municipality and
Dubai Traffic Police requirements. The Contractor shall submit proposals
for dealing with such situations to the Engineer Dubai Municipality and
Dubai Traffic Police for consent. Compliance with this Clause shall not
relieve the Contractor of any of his other obligations and liabilities under
the Contract.

2. The Contractor shall, after consultation with any statutory or other

authority concerned, submit to the Engineer for his approval a
programme based on such consultation showing the scheme of traffic
management he proposes for carrying out the Works before
commencing any work which affects the use of the public highway rights
of way or parking areas and thereafter furnish such further details and
information as necessitated by the Works or as the Engineer may
require.

3. The Contractor shall not commence any work which affects the public
highway until all traffic safety measures necessitated by the work are
fully operational.

4. The traffic diversion and signs, lamps, barriers and traffic control signals
shall be in accordance with the requirements of Dubai Municipality (also
refer to Clause 1/1.5).

5. Traffic signs shall comply with the requirements of Dubai Municipality. The
flashing rate for flashing lamps shall be within the range 120-150 flashes
per minute. The minimum luminous intensity of the lamps shall be 0.5
candela for steady lamps, 1.0 candela for ripple lamps at their peak, and
1.5 candela for flashing lamps at their peak.

6. The Contractor shall keep clean and legible at all times all traffic signs,
lamps, barriers and traffic control signals and he shall position,
re-position, cover or remove them as necessitated by the progress of the
Works.

7. Where road diversions roads are approved these must be maintained at

frequencies to suit the traffic volume using them. A good running surface
must be maintained and must at all times be free from ruts and potholes.

1/3.5 ACCESS TO PRIVATE LAND

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 7 SECTION 1 GENERAL

The Contractor shall give three weeks notice to the owner/occupier before
entering private lands and the Contractor shall not enter on to those lands until
given permission by the Engineer.

1/3.6 ROADS AND SITE TO BE KEPT CLEAN

The Contractor shall take great care and all reasonable precautions to ensure
that roads and thoroughfares used by him either for the construction of the
Works or for the transport of plant, labour and materials are kept clean during
of such construction or transport and in the event of their requiring cleaning in
the opinion of the Engineer the Contractor shall take all necessary and
immediate steps to clean them.

On completion of dewatering the Contractor shall immediately dismantle and

remove from the Site disused discharge pipes and dewatering points.

Each individual site of work must be clean during the work and must be
thoroughly cleaned up on completion.

1/3.7 COMPENSATION FOR DAMAGE TO PROPERTY

The Contractor shall reinstate all properties whether public or private affected
by the Works, Temporary Works, constructional plant, labour materials or
transport to a condition at least equal to that existing before his first entry on to
them.

If in the opinion of the Engineer the Contractor shall have failed to take
reasonable and prompt action to discharge his obligations in the matter of site
clearance or reinstatements the Engineer will inform the Contractor in writing of
his opinion in which circumstances the Employer reserves the right to carry out
the reinstatement himself or to arrange for it to be carried out by others or to
make payments to the owners and occupiers in respect of such matters for
which the Contractor is responsible. All such costs incurred and payments
made will be deducted from any monies due or which shall become due from
the Employer to the Contractor.

1/3.8 EXISTING SERVICES

Drains, pipes, cables and similar existing services encountered in the course of
the Works shall be guarded from injury or damage by the Contractor at his own
cost so that they may continue to function uninterruptedly to the satisfaction of
the owners thereof and the Contractor shall not store materials or otherwise
occupy any part of the site in any manner likely to hinder the operations of such
owners.

1. The Contractor shall protect and support, during the progress of the
Works, all pipe mains, cable wires and other apparatus which might be
endangered by his operations. The approximate positions and alignments
of known services are indicated on the Drawings, but no guarantee of
exact location can be given, and the Contractor must communicate with
the authorities and/or proprietors concerned to locate them exactly, and he
shall then prepare shop drawings 1/500 scale for each Utility as directed
by the Engineer. When approaching each indicated position, the

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 8 SECTION 1 GENERAL

Contractor shall search, by safe methods which will not endanger the
service, to determine its precise position.

2. The Contractor shall make his own arrangement with the owners of the
services and with other persons interested, for any diversions, temporary
stoppages and reinstatements, and he shall allow in his programme for all
such arrangements.

3. If any underground service is encountered unexpectedly, excavation shall

cease, and the Engineer's Representative shall be notified immediately.
Emergency work, as necessary, should be put in hand without delay and
without prejudice to the indemnity of the Employer.

4. The Contractor shall give notice, in writing, to the Engineer and to the
appropriate service company of all damages to existing services caused by
him or by any Sub-Contractor in the course of the Works. He shall be held
responsible for any such damage and shall immediately have such
damage made good at his own expense and shall relieve the Employer of
all claims in respect of any loss or interruption involved.

5. If in the opinion of the Engineer, it is necessary or expedient that any pipe,

drain, ditch, cable or overhead wire (including supports) should be broken
out, stopped up, diverted, taken down, or altered, the cost of doing so shall
be the responsibility of the Contractor. Such work shall be executed only
on the written instruction of the Engineer.

6. All existing sewers, culverts, water courses and drains of every kind and
condition that have been altered, extended or otherwise interfered with
either directly or indirectly by the work, or that may by leakage, silting,
stopping of free flow or otherwise interfere with or delay the execution of
the work, shall be made good, cleaned, placed in working order,
supported, maintained, and protected and the Contractor shall provide
everything necessary for efficiently dealing with, protecting, pumping or
removing, as the case may be, all water, sewage, or spoil there from.

1/3.9 CONTINUOUS WORKING

If in the opinion of the Engineer it is necessary for the safety of the Works or for
any other reason, the Contractor shall, when so ordered, carry out the Works,
or any portion thereof continuously by day and night. The Contractor will be
reimbursed the agreed extra costs, provided the necessity for the order is not a
result of the Contractor's negligence.

1/3.10 TEMPORARY STAGING FOR STRUCTURES

Temporary staging shall be provided by the Contractor to enable the

construction operations to be performed in the required sequence. The staging
shall be properly designed and constructed for the loads which it will be
required to support, and complete details of the arrangements proposed shall
be submitted to the Engineer for approval.

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 9 SECTION 1 GENERAL

Such approval, however, will not relieve the Contractor of his responsibility for
the adequacy of the staging. The cost of such staging is to be included in the
tendered rates and prices entered in the Bills of Quantities.

1/3.11 WATER SUPPLY

The Contractor shall carry out an investigation prior to submitting his Tender as
to the availability of water for the purpose of the Works and shall consult and
arrange with the appropriate authorities and consider all legal aspects. The
Contractor shall be entirely responsible for the supply of sufficient water of the
specified quality at all times throughout the Contract, and the costs shall be
deemed to be covered in the Contract rates and prices.

1/3.12 FILLING IN HOLES AND TRENCHES

The Contractor, immediately on completion of any part of the work, shall, at his
own expense, fill up all holes and trenches which have been made or dug by
him and are not part of the Works. Holes, cavities, trenches or depressions
shall be backfilled with suitable materials and compacted to the grade required
or as directed by the Engineer. The Contractor shall clear away all rubbish and
materials that is no longer required for the execution of the work, whether his
own or any other party to the satisfaction of the Engineer.

1/3.13 PROTECTION OF WORKS FROM WEATHER

The Contractor, at his own expense, shall protect all works and materials from
injury by weather. All damage caused by adverse weather conditions, whether
by flooding or intense heat or any other weather conditions shall be rectified by
the Contractor at his own expense. Abnormal weather conditions shall not be
considered any reason for a claim by the Contractor for compensation for
damage.

1/3.14 KEEPING THE WORKS FREE FROM WATER

The Contractor shall at his own expense keep the works at all times well
drained and excavations whether above or below the normal water level of the
water table free from storm or percolating water which may accumulate on the
Site and which may interfere with progress of construction or has or is likely to
have deleterious effect on the work in progress or the use thereof, by provision
of temporary open drains and sub-soil drains, diversion of ditches and other
surface water channel or by pumping or other means as required.

1/3.15 SIGN BOARDS

The Contractor shall provide and erect signboards as detailed in the BOQ, at
the Site and at the Offices of the Engineer and the Contractor. Normally
signboards will be required on all major road approaches to the Site.

The layout and lettering size and location of all signboards shall be subject to
the approval of Dubai Municipality.

The signboards shall give, in English and Arabic, the name of the Project and
the names, Post Office Box numbers and contact telephone numbers of the

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 10 SECTION 1 GENERAL

Employer, the Engineer and the Contractor. The boards shall be of dimensions
as shown on the drawings and shall be of durable construction capable of
withstanding the effects of the climate for at least the period of the construction
and the Defects Liability Period. The boards shall be mounted on substantial
frames.

The signboards shall be periodically cleaned, remain legible and be maintained

in a structurally safe condition throughout the period of construction and
Defects Liability Period. Upon issue of the Defects Liability Certificate they shall
be removed from the Site within two weeks.

1/3.16 TEMPLATES

When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of certain
work. The templates will be in accordance with the Specifications and Drawings
where such are provided.

All templates must be approved and shall be maintained in good order to

provide the section required for the entire works. Templates may be checked
from time to time and any deficiencies noted shall be rectified immediately.

The Contractor shall also supply straight edges and lines when required to
control the work.

1/3.17 ASSISTANCE TO THE ENGINEER

1. The Contractor shall provide and maintain for the use of the Engineer such
surveying and engineering instruments as the Engineer may require for his
duties as detailed in (Clause 1/3.18). The Contractor shall provide the
Engineer with all necessary assistance in checking the setting out of the
Works and interpreting any information used by the Contractor for this
purpose including the sole use of a minimum of three (3) chainmen.

2. The Contractor shall provide the Engineer with all assistance, equipment
and material required to document and record progress of the Works.

3. The Contractor shall provide all assistance, equipment and material

required by the Engineer for all the measurement of the Works for monthly
valuation and for the final certificate payment.

4. The Contractor shall be responsible for all follow up and co-ordination with
all the service departments. (Electricity, Water, Drainage, Street Lighting,
Telephone, Horticultural, etc.).

5. The Contractor shall provide all unskilled labour and necessary tools as
directed by the Engineer.

6. If at any time before the commencement or during the progress of the work
it appears to the Contractor that for the proper execution of a specified part
of the Works, shop drawings are necessary, these drawings shall be
established by the Contractor and submitted to the Engineers'

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 11 SECTION 1 GENERAL

Representative for approval. The Engineer's Representative shall have

authority to order at any time and the Contractor shall agree to provide any
number of shop drawings which, in the opinion of the Engineer's
Representative are necessary for the proper execution of a specified work.

The Contractor shall not proceed with the above mentioned work until these
shop drawings are approved by the Engineer's Representative. The
Contractor shall not be entitled to any extra compensation or extension of
time for the preparation of the above mentioned drawings.

These details shall be dimensioned in the metric system and shall describe
accurately the method of fabrication, applied finish and sizes of all members
and fixings and shall indicate methods of marking of components for site
erection.

7. The Engineer shall furnish the Contractor transparencies and AutoCAD

ver.12 diskettes of the original drawings to be corrected as the Works
proceed. The Contractor shall correct where required, prepare and supply
the Engineer’s Representative the updated transparencies and diskettes for
his approval. The diskette copies shall be in Micro-station DGN format of a
standard and detail acceptable to the Dubai Municipality Drainage and
Irrigation Department.

Such record Drawings produced by the Contractor shall include but not be
limited to the following information:

- Offsets from permanent references such as road edge, road centreline,

kerb line, building line, etc., at suitable intervals as directed by the
Engineer, for all services encountered during the Works and during trial
trenches including description of offsets..

- Level profiles for all sewerage, drainage, rising mains.

- House connection layout and details to be completed as separate

drawings and included on main sewer layout drawings.

8. The Contractor shall not be entitled to any extra payment or extension of

time for the preparation of the above mentioned record drawings.

The Contractor shall at the commencement of works, provide the

Engineer's Representative for his full and exclusive use sufficient number of
water, soil, concrete, asphalt, and room thermometers as required by the
Engineer.

1/3.18 SURVEYING EQUIPMENT

The equipment required on Site under this Contract shall be to the Engineer's
approval.

1/3.18.1 Expendable Materials

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 12 SECTION 1 GENERAL

The Contractor shall provide adequate supplies of expendable materials such

as stationary, pencils, inks, drawing paper, pens, pegs, brushes, paint and
other similar items required for the satisfactory completion of survey and as
required by the Engineer's Representative.

1/3.19 LABORATORY (SEE APPENDIX, PART 3 OF 3):

1/3.19.1 General

All testing shall be in accordance with DM Administrative Decision No. 160 for
2000.

1/3.20 MINIMUM TEST REQUIREMENTS

The following is the schedule of minimum requirements governing tests of

materials which shall be carried out during the execution of the Works. Should
the Engineer's Representative deem it necessary to increase or reduce the
number of the following mentioned tests, he shall issue his written instructions
to the Contractor as and when required, following due consultation with the
Employer.

All materials shall be tested as per the relevant BS and ASTM Standards
referred to in the DM DCL test schedules.

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 13 SECTION 1 GENERAL

Table 1- 1 Minimum test requirements of materials and frequencies of quality control tests
Serial Product/ Test Name Test Standard Sampling Sampling Split Results
No. Material Frequency Method Sample Reporting
Time
1. Subgrade Classification BS 1377-Part1 & 1 per soil type or Source of Yes when Before using
and/or Part 2, 1990 AMD Max 1 per 5,000m3 Material requested in work
Embankment 9027:96
Gradation BS 1377-Part 1 per 5,000m3 Source of Yes when Before using
2,Test 9.2, 1990 Material requested in work
AMD 9027:96
Liquid Limit BS 1377-Part 2 1 per 5,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Plastic Limit BS 1377-Part 2 1 per 5,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Linear Shrinkage BS 1377-Part 2 1 per 5,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Dry BS 1377-Part 4 1 per 5,000m3 Source of Yes when Before using
Density/Moisture 1990 AMD Material requested in work
Content 8259:1995 & AMD
13925:2002
3
CBR at 95% MDD BS 1377-Part 4 1 per 5,000m Source of - Before using
1990 AMD Material in work
8259:1995 & AMD
13925:2002
Compaction BS 1377-Part 9 1 per 5,000m3 In Place - Before
1990 AMD placing next
17229:2007 & AMD layer
8264:1995
2
Field Density BS 1377-Part 9 3 No./ per 2,250m After laying Yes when Before
1990 AMD on site requested placing next
17229:2007 & AMD &Compaction layer
8264:1995

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 14 SECTION 1 GENERAL

2
Moisture content BS 1377-Part 2 1 / per 1,000m After laying Yes when Before
1990 AMD 9027:96 on site requested placing next
&Compaction layer
3
Field CBR with BS 1377-Part 9 1 / per 5,000m After laying Yes when Before
speedy estimate 1990 AMD on site requested placing next
for Moisture 17229:1997 & AMD &Compaction layer
content and dry 8264:1995
unit weight
(Provisional as
directed by the
Engineer)

Improved Classification BS 1377-Part1 & 1 No./ per 3,000m3 Source of Yes when Before using
Subgrade Part 2, 1990 AMD Material requested in work
9027:96
Dry BS 1377-Part 4 1 No./ per 3,000m3 Source of Yes when Before using
Density/Moisture 1990 AMD Material requested in work
Content 8259:1995 & AMD
13925:2002
CBR at 95% MDD BS 1377-Part 4 1 No./ per 3,000m3 Source of Before using
1990 AMD Material in work
8259:1995 & AMD
13925:2002
2
Field Density BS 1377-Part 9 3 No./ per 1,500m After laying Yes when Before
1990 AMD 17229: on site requested placing next
2007 & AMD &Compaction layer
8264:1995
Compaction BS 1377-Part 9 3 No./ per 1,500m2 In Place Before
1990 AMD 17229: On shoulder placing next
2007 & AMD layer
8264:1995

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 15 SECTION 1 GENERAL

3
2. Aggregate Gradation BS 1377-Part 1 No./ per 3,000m Source of Yes when Before using
Subbase 2,Test 9.2, 1990 Material requested in work
AMD 9027:96
3
Liquid Limit BS 1377-Part 2 1 No./ per 3,000m Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
3
Plastic Limit BS 1377-Part 2 1 No./ per 3,000m Source of Before using
1990 AMD 9027:96 Material in work
Linear Shrinkage BS 1377-Part 2 1 No./ per 3,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
3
Sand Equivalent ASTM D2419:2009 1 No./ per 3,000m Source of Yes when Before using
Material requested in work
Compaction by BS 1377-Part 4 1 No./ per 3,000m3 Source of Before
modified proctor 1990 AMD Material placing next
method with 8259:1995 & AMD layer
compaction curve. 13925:2002
3
CBR at 95% of the BS 1377-Part 4 1 No./ per 3,000m Source of Yes when Before using
modified Field 1990 AMD Material requested in work
Proctor Density 8259:1995 & AMD
13925:2002
3
Loss Angeles ASTM C-131:06 or 1 No./ per 3,000m Source of Yes when Before using
Abrasion Loss ASTM C-535:09 Material requested in work
2
Field Density BS 1377-Part 9 4No./ per 1,500m After laying Yes when Before
1990 AMD 17229: on site requested placing next
2007 & AMD &Compaction layer
8264:1995

3. Aggregate Gradation BS 1377-Part 1 No./ per 1,000m3 Source of Yes when

Base 2,Test 9.2, AMD Material requested
9027:96
Liquid Limit BS 1377-Part 2 1 No./ per 1,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Plastic Limit BS 1377-Part 2 1 No./ per 1,000m3 Source of Before using
1990 AMD 9027:96 Material in work

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 16 SECTION 1 GENERAL

3
Linear Shrinkage BS 1377-Part 2 1 No./ per 1,000m Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Sand Equivalent ASTM D2419:2009 1 No./ per 1,000m3 Source of Yes when Before using
Material requested in work
Compaction by BS 1377-Part 4 1 No./ per 1,000m3 Source of Before
modified proctor 1990 AMD Material placing next
method with 8259:1995 & AMD layer
compaction curve. 13925:2002
3
CBR at 98 % BS 1377-Part 4 1 No./ per 1,000m Source of Yes when Before using
(Base) of the 1990 AMD Material requested in work
modified Field 8259:1995 & AMD
Proctor Density 13925:2002
3
Loss Angeles ASTM C-131:06 or 1 No./ per 1,000m Source of Yes when Before using
Abrasion Loss ASTM C-535:09 Material requested in work
Field Density BS 1377-Part 9 4 No./ per 900m2 After laying Yes when Before
1990 AMD 17229: on site requested placing next
2007 & AMD &Compaction layer
8264:1995
2
4. Wet Mix Field Density BS 1377-Part 9 3 No./ per 750m Source of Yes when Before using
Macadam 1990 AMD 17229: max Material requested in work
2007 & AMD
8264:1995
Liquid Limit BS 1377-Part 2 1 No./ per 1,000m3 Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Plastic Limit BS 1377-Part 2 1 No./ per 1,000m3 Source of Before using
1990 AMD 9027:96 Material in work
3
Linear Shrinkage BS 1377-Part 2 1 No./ per 1,000m Source of Yes when Before using
1990 AMD 9027:96 Material requested in work
Sand Equivalent ASTM D2419:2009 1 No./ per 1,000m3 Source of Yes when Before using
Material requested in work

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 17 SECTION 1 GENERAL

3
Compaction by BS 1377-Part 4 1 No./ per 1,000m Source of Before
modified proctor 1990 AMD Material placing next
method with 8259:1995 & AMD layer
compaction curve. 13925:2002
CBR at 100 % of BS 1377-Part 4 1 No./ per 1,000m3 Source of Yes when Before using
the modified Field 1990 AMD Material requested in work
Proctor Density 8259:1995 & AMD
13925:2002
Loss Angeles ASTM C-131:06 or 1 No./ per 1,000m3 Source of Yes when Before using
Abrasion Loss ASTM C-535:09 Material requested in work
Field Density BS 1377-Part 9 4 No./ per 750m2 After laying Yes when Before
1990 AMD 17229: (Carriageway) on site requested placing next
2007 & AMD 4 No./ per 450 &Compaction layer
8264:1995 linear.m (shoulder)

5. Water for Mixing Water for BS EN 1008:2002 One test for each Source of Before using
Concrete Concrete source Material in work
(Specification for
Sampling, Testing
and Assessing the
Suitability of
Water, Including
Water Recovered
from Processes in
the Concrete
Industry, as Mixing
Water for
Concrete)

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 18 SECTION 1 GENERAL

6. Portland Composition, BS 12 OPC One bag of cement Source of Before using

Cement specifications and (withdrawn and shall be taken from Material in work
conformity criteria superseded by BS each 250 tons or
for common EN197-1:2000) fraction thereof for
cements BS 4027-SRC each source or
(Sulfate Resistance manufacturer.
Portland Cement) Testing certificate
Active/Current may be accepted in
BS 4550 – Part1 lieu of this by the
(withdrawn no engineer.
replacement),
7. Coarse All tests BS 812 One sample shall be Source of Before using
Aggregate for (General taken from each Material in work and
Concrete Specification- designated source. when the
Part1) After approval, one material is in
sample shall be use
taken from each
1000m3. On each
sample, 2 sets of the
required tests should
be carried out.
Except sieve analysis
which shall be 3 in
number.

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 19 SECTION 1 GENERAL

8. Fine All tests BS 812 One sample shall be Source of Before using
Aggregate for (General taken from each Material in work and
Concrete Specification- designated source. when the
Part1) After approval, one material is in
sample shall be use
taken from each
1000m3. On each
sample, 2 sets of the
required tests should
be carried out.
Except Sieve
Analysis which shall
be 3 in number.
9. Bituminous All tests See list One sample of Source of Before using
Material (General bituminous material Material in work and
Specification- shall be taken from when the
Part1) each designated material is in
source or delivery use
from the
manufacturer.
Subsequent testing
shall be as directed
by the engineer but
not less than one
sample for each 80
tons or equivalent.
10. Aggregate for All tests See list One sample shall be Source of Before using
Bituminous (General taken from each Material in work and
Material Specification- designated source. when the
Part1) After approval, one material is in
sample shall be use
taken from each
1000m3.

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 20 SECTION 1 GENERAL

11. Mineral Filler All tests See list One sample shall be Source of Before using
for (General taken from each 50 Material in work and
Bituminous Specification- tones or fraction when the
Mixture Part1) thereof. material is in
use
12. Bituminous All tests See list 1- One sample Source of Before using
Mixture (General of each day Material in work and
Specification- production or each when the
Part1) 200 tones laid or material is in
part thereof use
whichever is
greater, shall be
taken. The
sample should be
taken from the
paving machine
after
approximately half
of any one load
has been laid from
the plant.
2- One Core
sample for specific
gravity testing
shall be taken for
each 300 linear
meter of traffic
lane or 2000m2 or
parts thereof for
each completed
layer of pavement.

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 21 SECTION 1 GENERAL

13. Reinforcing All tests See list Reinforcing steel Before using
Steel (General shall be supplied to in work and
Specification-Part site with a when the
1) manufacturer’s test material is in
certificate for each use
load. Where directed,
testing on any
sample of
reinforcement for the
following types may
be required.
1. Steel fabric
reinforcement.
2. Mild steel and
high yield (hot
rolled) bars.
3. Cold worked steel
bars
Chemical analysis of
steel for carbon
content as directed
by the engineer.

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 22 SECTION 1 GENERAL

14. Concrete All tests See list  One set of at least Before using
(General 6 cubes (or 4 in work and
Specification-Part cylinders) shall be when the
1) obtained from material is in
3
each 75m . or use
fraction thereof
placed in each day
or class of
concrete.
 Slump tests and
compaction factors
tests shall be
carried out at site
of the actual
placing of concrete
as directed by the
engineer.
 Preparation of
concrete
specimens and
curing of
specimens.
 Minimum cement
content of
hardened concrete
as directed by the
engineer.

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 23 SECTION 1 GENERAL

15. Precast All tests See list Flexural / Transverse Before using
Concrete (General Strength and Water in work and
Specification-Part Absorption for each when the
1) supplier of precast material is in
kerbs and slabs (2 use
no. of samples).
Subsequently, on
approval of a source
or supplier, 2
samples will be
tested every 2000
linear meter. For
kerbs and every
2
2000m for slab tiles.

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 24 SECTION 1 GENERAL

1/3.21 Sources of Materials

The Contractor shall be responsible for obtaining the Approval of the local
Authorities for the sources of materials and he shall have no right to claim for
any compensation if he is to pay for the material at its source.

1/3.22 Programming the Progress of the Works

A detailed computer-based programme using critical path methods shall be

produced by the Contractor as set out in the Conditions of Contract. This shall
include full details of resources and rates of progress. The Engineer may
require the Contractor to modify the programme on occasions during the
course of the Contract. The Contractor shall work to the latest approved
programme at all times.

In planning his programme the Contractor shall allow reasonable time for the
Engineer to confirm setting out details as the Works proceed in accordance
with the programme.

The Contractor shall indicate on his programme whether the work is to be

carried out during normal site hours or whether overtime or a shift system is
necessary to execute the Works.

The Contractor shall present a weekly summary to the Engineer detailing

personnel, plant materials and equipment orders and shipping movements of
same.

Before the close of Site on each working day the Contractor shall submit a
brief programme for the following working day stating in which area of the site
work will be carried out and the location of plant and labour. The format of the
programme shall be agreed with the Engineer. The Contractor shall also
submit for the Engineer’s approval a daily record of manpower and plant
resources.

1/3.23 Progress Reports

The Contractor shall be required to submit to the Engineer weekly and monthly
progress reports on the first day of the week following and the first day of the
month following respectively.

Weekly Report

The report shall include: the meteorological data; Contractor's plant and labour
returns; a brief summary of work completed.

Monthly Report

The report shall include: a description of the month's work; details of any
problems relating to the Works; quantities; records of test results; charts
illustrating progress in terms of work done against programmed work and the

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 25 SECTION 1 GENERAL

financial status of the Contract including value of works completed, certified

and monies received; progress photographs.

1/3.24 PROGRESS PHOTOGRAPHS

The Contractor shall arrange to take monthly record photographs of the Works
in progress. These photographs shall cover such extent of the Works as the
Engineer shall direct. The days upon which the photographs are to be taken
shall be decided by the Engineer.

The Contractor shall provide the Engineer on the last day of each month, one
copy of progress digital photos of high resolution on a CD with dates imprinted
on it.

The copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of
exposure.

1/3.25 FLOWS IN PIPELINES AND AT PUMPING STATIONS

During the execution of the Works the Contractor shall maintain flows in
pipelines and at pumping stations or alternatively provide adequate means of
diverting the flows or over pumping of the flows to the satisfaction of the
Engineer.

The Contractor should note that the Employer may decide to carry out over
pumping utilising his own plant and resources and the Contractor shall make
due allowance for the necessary coordination with the Employer with respect to
the Contract programme. Such arrangements will not relieve the Contractor of
his obligations for the maintenance of flows and the safety of the Works,
personnel and the general public. No claim for delay or additional work arising
from this requirement will be considered by the Employer.

1/3.26 SUPPRESSION OF NOISE

The Contractor shall make every reasonable endeavour both by means of

temporary works and by the use of appropriate plant or silencing devices to
ensure that the level of noise resulting from the execution of the Works does
not constitute a nuisance.

1/3.27 CLOSING OF ROADS

The Contractor shall give four weeks notice in writing to the Engineer of his
intention to commence work on any public road (which shall include un-made
rights-of-way).

The closure of public roads will not be permitted without the written permission
of the Dubai Municipality Roads Department, the Dubai Traffic Police and the
Engineer. The Contractor shall submit five (5) copies of his proposals for
diverting traffic indicating positions of all signs, cones, lights and anything else
which may be necessary. The Contractor shall comply with any Specification
for traffic diversion, including surfacing requirements, safety and control laid

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 26 SECTION 1 GENERAL

down by the Authorities in Dubai and shall be responsible for continuous

maintenance.

A period of up to 30 days may be required by the Dubai Municipality to process

permits authorising the cutting of existing carriageways. In the event of such
permission being refused the Contractor shall have no claim for any additional
payment.

No work will be permitted on a public road verge, central reservation or garden

without the SIGNED approval of the respective Authorities copies of which
must be submitted to the Engineer before work commences.

The Contractor’s work shall be so arranged that use of the roads affected by
the work shall be restored to the public with the minimum of delay. Laying of
the pipelines, backfilling, testing of the pipeline, temporary reinstatement and
clearance of the Site shall follow closely behind excavation and the Engineer
may limit the length of excavation when necessary.

1/3.28 NOC FROM RELEVANT AUTHORITIES

Not withstanding the requirements of clause 48 of "Conditions of Contract for

Works of Civil Engineering Construction, (Part 1 - General Conditions)" it shall
be the Contractor's responsibility to obtain all required No Objection
Certificates (NOC) from the relevant Authorities and submit them to the
Engineer prior to the Engineer issuing a Taking Over Certificate.

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 1 SECTION 2 EARTHWORKS

TABLE OF CONTENTS

2/1 CLEARING & GRUBBING ........................................................................................ 2

2/2 REMOVAL OF STRUCTURES AND OBSTRUCTIONS ............................................ 2
2/3 STRUCTURAL EXCAVATION .................................................................................. 3
2/4 BACKFILLING EXCAVATIONS............................................................................... 13
2.5 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT ....................... 17

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 2 SECTION 2 EARTHWORKS

2/1 CLEARING & GRUBBING

Unless otherwise specified, the areas designated for clearing and grubbing shall
be cleared of all trees, stumps, bushes, roots, rubbish, debris, and other
objectionable matters.

Before removal of any trees or shrubs the Contractor shall obtain written RTA
Horticultural Section unless otherwise instructed by RTA at least two weeks in
advance of the planned removal. The Engineer's approval of any removal of trees
and undergrowth must be obtained before commence-ment of work.

Trees and plants designated for preservation shall be protected from injury or
damage which could result from the Contractor's operations including dewatering.
The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.

The Contractor shall avoid, as far as practicable, injury to shrubbery, vines,

plants, grasses and other vegetation growing outside of the clearing limits. The
dragging, piling and burning of debris, the piling of materials of various kinds and
the performing of other work which may be injurious to vegetation shall, in so far
as practicable, be confined to areas which have no vegetation or which will be
disturbed by excavation.

For the full width to be cleared, all objectionable materials and any other
obstructions shall be grubbed from areas to be excavated, to the satisfaction of
the Engineer.

The topsoil should be scarified to a depth of at least 15 centimetres and

investigated if any unsuitable materials exist (as defined in PART 1 “Roadworks”
2/13.3. The unsuitable materials, if any, shall be removed to the depth required by
the Engineer's Representative and replaced by approved suitable material.

Cavities left below subgrade elevation by the removal of stumps or roots shall be
carefully backfilled and the backfill material compacted to the Engineer's
satisfaction.

All tree trunks, stumps, bush, limbs, roots, vegetation, and other debris removed
in clearing and grubbing shall be either burned or removed to approved location
outside the right-of-way or otherwise disposed of so as to leave the roadway and
adjacent areas free from unsightly debris. Burning shall be done at such time and
in such manner as to prevent any damage to areas adjoining the right-of-way.

2/2 REMOVAL OF STRUCTURES AND OBSTRUCTIONS

2/2.1 GENERAL

Removal of structures and obstructions shall consist of the removal, wholly or in

part, and satisfactory disposal of all structures and obstructions within the
right-of-way which have not been designated to remain. Salvaging designated
materials shall be included.

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 3 SECTION 2 EARTHWORKS

Prior to starting the removal of structures and obstructions, the Contractor shall
carry out a thorough survey of structures, fences, trees, etc., that are to be
removed. The Engineer shall be fully informed of the results of this survey and
the amount and extent of the planned removal and the plan shall then be agreed
by the Engineer.

Indications on the Drawings that existing structures, pavements sidewalks, curbs,

gutters and other existing improvements are to become an integral part of the
planned improvements shall be considered to mean that such designated
improvements are to remain even though not specifically noted to remain.
Existing highways, improvements, facilities, adjacent property and services
designated for preservation shall be protected from injury or damage which could
result from the Contractor's operations.

The Contractor shall raze, remove and dispose of all structures and obstructions
as required including, but not limited to, the following: buildings, sheds, walls,
slabs, foundations, inlets, catch basins, culverts, headwalls, trash racks, irrigation
structures, standpipes, manholes, valves, ditch lining, pipelines, tanks, pool lining,
posts, poles, columns, signs, fences, gates, planters, curbs, gutters, sidewalks,
driveways, trees, stumps, shrubs and plants.

Holes, cavities, trenches or depressions left by the removal of structures or

obstructions shall be backfilled with suitable materials and compacted to the
grade required or as directed by the Engineer.

2/2.2 REMOVAL OF PIPES

Where required, the Contractor shall be responsible, prior to removal of pipes, for
the disconnection of all services and clearance from the Dubai Municipality and all
Service Authorities.

All pipes to be removed and either salvaged or relaid shall be carefully removed
and every precaution taken to avoid breaking or damaging the pipe. The pipes
shall be stored when necessary so that there will be no loss or damage before
relaying. The Contractor will be required to replace sections lost from storage or
damage by negligence or by the use of improper methods in their removal.

2/3 STRUCTURAL EXCAVATION

2/3.1 GENERAL

Structural excavation shall consist of the excavation and removal of all materials
necessary for the construction of structures, pipelines and cables/ducts, including
foundations and substructures, in accordance with the details shown on the
Drawings and these Specifications and/or as directed.

The Contractor shall notify the Engineer a sufficient time in advance of the
beginning of excavation to allow pre-construction measurements and records to
be made of the undisturbed ground (refer to Clause 2/3.2). The required
excavation shall then be performed in reasonably close conformity to the lines,
grades and cross sections established or shown on the Drawings.

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 4 SECTION 2 EARTHWORKS

The sides of excavation may be sloped as required by soil conditions to stabilize

the sides for safe working conditions. Such excavation shall be limited to the
amount considered necessary for safety.
The Contractor shall take all necessary steps by means of shoring, timbering, or
otherwise (also refer to Clause 2/3.7) to avoid slips and falls of the sides of the
excavation but if any should occur the Contractor shall remove at his own
expense all such fallen or disturbed material from the excavation and shall
replace with backfilling as described elsewhere.

The Engineer may direct the Contractor to protect his excavation with timbering
where, in his opinion, such timbering is necessary to ensure the safety of the
workmen, adjoining structures and work generally. Any action taken by the
Engineer in this regard will in no way relieve the Contractor of any responsibility or
liability under the Contract.

Where a firm bearing material is not encountered at the elevation established for
bearing, due to soft, spongy or otherwise unstable soil, all such unsuitable
material shall be removed to the extent directed (see Clause 2/3.15).

No back throwing shall be allowed and all materials must be brought to the
surface and placed clear of the trench side.

The Contractor shall keep the trench excavation free from water at all times.

The Engineer reserves the right to direct the Contractor as to the lengths of
trench or portions of bulk excavations which shall remain open at any one time.

The use of explosives for any purpose whatsoever during the Contract is
prohibited.

2/3.2 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS

Before an excavation is started:-

(1) Ground levels shall be agreed at suitable intervals with the Engineer's
Representative.

(2) Surface materials and conditions will be recorded in collaboration with the
Engineer's Representative and where appropriate the owners or occupiers of
the land.

(3) The Contractor shall take photographs to illustrate existing damage or

conditions which may prove contentious at the time of reinstatement.

This information shall be neatly presented in bound volumes and submitted to the
Engineer. To this shall be added details of any existing natural or piped subsoil
drainage or other underground features as work proceeds.

Trial excavations may be ordered by hand or other methods to reveal sub-surface

conditions of any kind. The Contractor shall submit a written report or sketch
drawings of data so obtained and the excavations shall not be backfilled without
approval.

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 5 SECTION 2 EARTHWORKS

2/3.3 SETTING OUT

Before any structural excavation is commenced the Contractor shall define the
centre line or other agreed reference line of the Works and erect the necessary
profiles throughout their full length if so required by the Engineer. The Contractor
shall be responsible for obtaining all verifications from the Dubai Municipality
Survey Section and the Contractor shall bear all associated costs.

2/3.4 TOPSOIL AND SURFACING MATERIALS

Before commencing excavations or filling to an area, topsoil and other surfacing

materials shall be stripped and stored separately from the subsoil (refer to Clause
2/1). Subsequent spreading of topsoil shall be as directed on site.

2/3.5 LAND DRAINS

Where pipelines are to be laid in agricultural land the surface and subsoil
drainage shall be maintained whether natural or artificial. Before commencing
work the Contractor shall ascertain from the owner or occupier of the land the
location of any existing land drains or mole drains.

2/3.6 HAND EXCAVATION

Where instructed or necessary for reasons of limited access or any other reason,
excavation shall be carried out by hand at no additional cost.

2/3.7 SUPPORT TO EXCAVATIONS

The sides and/or the bottom of excavations in excess of 1.2 metres shall be
adequately supported.

The Contractor shall provide the necessary support for excavations and shall
submit to the Engineer his proposals for the supporting of excavations by trench
sheeting or other approved means at least seven days prior to the
commencement of any excavation works. His proposals shall take into account
the nature of the ground to be excavated, the level of the water table at the site
and the proximity of buildings and roads.

If in the opinion of the Engineer the support proposed for the excavations by the
Contractor is insufficient then the Engineer will order the provision of stronger
support than that provided by the Contractor and in this event the Contractor shall
adopt the methods so ordered by the Engineer and shall have no claim against
the Employer for any costs incurred in adopting the additional measures.

Trench supports shall be so arranged to permit withdrawal during the placing of

the pipe bedding and backfilling so as to prevent voids.

The Contractor shall not remove temporary works supporting the excavations until
in the opinion of the Engineer the permanent work is sufficiently advanced to
permit such removal which shall be executed under the personal supervision of a
competent foreman.

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 6 SECTION 2 EARTHWORKS

All temporary works supporting the excavation shall be removed during backfilling
unless previous approval has been obtained from the Engineer. Where
temporary supports have been used in the excavation any such supports left in
because it is impracticable to remove them shall be left in at the expense of the
Contractor.

Should temporary supports need to be left in any excavation carried out in open
cut owing to the Engineer deciding that their permanent installation is necessary
for the stability of an adjacent structure or service the Contractor shall be
reimbursed in accordance with the provisions of the Contract.

Any advice, permission, approval or instruction given by the Engineer relative to

such support or the removal thereof shall not relieve the Contractor from his
responsibilities or liabilities under the Contract.

Timbering steel sheeting strutting and sheet piling for the support of excavations
where provided shall be fixed in accordance with BS 6031:1981, AMD 4251:83

Battered sides to trenches or other excavations will only be permitted if they can
be constructed within the limits of the site, without damage or interference to
existing services, properties or structures, without undue interference with
pedestrians and traffic and to slopes which are sufficiently flat to ensure stability
of the ground.

2/3.8 DEWATERING

A high water table is expected and the Contractor must do all necessary
measures to ensure proper dry conditions are maintained at all times during
construction. The Contractor shall provide and maintain ample means and
devices (including spare units kept ready for immediate use in case of
breakdowns) with which to intercept and/or remove promptly and dispose properly
of all water entering trenches and other excavations. Such excavations shall be
kept dry until the structures, pipes, and appurtenances to be built therein have
been completed. In addition precautions shall be taken to prevent floatation of
partially built structures, completed structures to be filled on commissioning of the
Works and pipelines awaiting backfilling.

Dewatering methods proposed in the Contractor’s method statements may

include temporary drains, intercepting ditches, cut-off drains, sub-drains, sumps,
wells, pumps, well-points or other dewatering equipment and shall include all
other things necessary to keep water out of the excavations or to lower
groundwater around structures liable to floatation.

All necessary precautions shall be taken to prevent any adjacent ground from
being adversely affected by loss of fines through any dewatering process.

Method statements shall include proposals for disposal of the water arising from
dewatering systems.

All water pumped or drained from the work shall be disposed of in a suitable
manner without undue interference with other work, damage to pavements, other
surfaces, or property. Suitable temporary pipes, flumes, or channels shall be
provided for water that may flow along or across the site of the work. No such

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 7 SECTION 2 EARTHWORKS

water is to be disposed of into the existing sewer systems of the town or

otherwise without prior written approval of the Dubai Municipality Drainage and
Irrigation Department.

If permission is given to use new or existing pipes or culverts which are not part of
the live sewerage system, they shall be thoroughly cleaned of all silt and any
resulting damage made good after use.

When the Contractor proposes to make use of existing dewatering pipelines,

ducts, etc., he shall satisfy himself as to their condition prior to his use of them. If
any of these items is found to be in an unsatisfactory condition then, before use,
the Contractor shall notify the Engineer who may give instructions for the item to
be replaced or repaired. Time taken to carry out such work will not be considered
as delay to the Contractor's operations.

During use the Contractor shall be responsible for the condition of the pipeline,
duct, etc., and any defect or failure shall be made good at the Contractor's
expense. Any delay to the Contractor's works caused by such defect or failure
shall be deemed as the Contractor's responsibility.

After use by the Contractor such pipeline, duct, etc., shall be handed back to the
Municipality in a condition not less than that at the commencement of use. Any
repairs or replacement required shall be at the Contractor's expense.

It cannot be guaranteed that permission will be given to use existing ducts and
pipelines.

All temporary works for control of water shall be sited clear of the Works, except
where temporary sub-drains under the Works are approved in which case the
pipes shall be laid with a 75 mm surround of gravel, and the top surface of the
surround shall be covered with tarred felt cloth or other approved material.

Unless otherwise directed all temporary drains and sub-drains shall be finally
sealed with concrete at approved intervals and all temporary ditches, sumps,
wells, etc., shall be refilled and reinstated as specified elsewhere.

In the exceptional event that lagoons for the storage of groundwater are
permitted, they must be suitably protected with fencing and attended by day and
night to prevent access by the general public and will not be sited adjacent to
buildings. Approved means of preventing the formation of mosquito larvae on the
surface of the lagoons will be employed.

All necessary precautions shall be taken to prevent any groundwater from

entering mains to be used for the conveyance of potable water.

A. Temporary Underdrains

Temporary underdrains, if used, shall be laid in trenches, beneath the grade

of the structure. Trenches shall be of suitable dimensions to provide room for
the chosen size of underdrain and its surrounding gravel.

Underdrains, if used, shall be laid at an approved distance below the bottom

of the normal excavation and with open joints wrapped in geotextile, and

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 8 SECTION 2 EARTHWORKS

entirely surrounded by graded gravel, or crushed stone to prevent the

admission of sand or other soil into the underdrains. The distance between
the bottom of the pipe or structure and the top of the bell of the underdrain
pipe shall be at least 8 cm. unless otherwise permitted. The space between
the underdrain and the pipe or structure shall be filled with screened gravel or
crushed stone which shall be rammed if necessary and left with a surface
suitable for laying the pipe or building the structure.

B. Wellpoint Drainage System

Where the nature of the Works necessitates, the Contractor shall dewater the
excavations by means of an efficient wellpoint drainage system which will
drain the soil and prevent saturated soil from flowing into the excavation. The
wellpoints shall be designed especially for this type of service. The pumping
unit shall be designed for use with the wellpoints, and shall be capable of
maintaining a high vacuum and of handling large volumes of air and water at
the same time.

If required by the nature of the Works, the installation of the wellpoints,

pumps, surge tanks, settlement tanks, geotextile and other such
requirements shall be done under the supervision of the competent
representative of the manufacturer. The Contractor shall do all special work
such as surrounding the wellpoints with sand or gravel or other work which is
necessary for the wellpoint system to operate for the successful dewatering
of the excavations.

Material to be used in the wellpoint system is to be corrosion resistant where

possible.

2/3.9 FORMATION

Damage to the formation shall be prevented by bottoming-up with hand

excavation immediately before placing concrete or pipelaying. Any damaged
formation shall be excavated and refilled with concrete or selected material as
instructed.

The formation of excavations for pipelines shall be dry, even and free of stones
and other protrusions.

No permanent works of any kind shall be constructed on an excavated surface

until the formation has been approved by the Engineer’s Representative.

2/3.10 EXCAVATION AT OR NEAR ROADS

A. Safety

When excavating at or near roads, to protect persons from injury and to

avoid interference with traffic, adequate barricades, construction signs,
torches, guards, flashing lights, etc., as required by the Engineer shall be
provided and maintained during the progress of the construction work (refer
to Appendix 1 for Road Diversions and Road Signs). All materials,
stockpiles and equipment shall be placed in such a way that no obstruction

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 9 SECTION 2 EARTHWORKS

or interference to traffic is made and that these are enclosed by fences or

barricades and protected by lights.

All excavations shall be protected on all sides by an approved temporary

yellow plastic safety fencing, barricades and lights. The yellow plastic
safety fencing shall be manufactured of durable HDP polymer with Ultra
Violet stabilizers. The safety fencing shall be a minimum of 1.0 metre high.

B. Description

The Contractor shall make excavations in such a manner and to such

minimum widths as will give adequate room for building the structures or
laying and jointing the piping; shall furnish and place all sheeting, bracing,
and supports; shall carry out all cofferdamming, pumping, and draining, and
shall render the bottom of the excavations firm and dry and acceptable in all
respects.

In no case, except with the approval of the Engineer, shall the earth be
plowed, scraped, or dug by machinery so near to the finished subgrade as
to result in the disturbance of material below said subgrade, the last of the
material to be excavated shall be removed by hand immediately before the
placing of the pipe, masonry, or other structure.

C. Extent of Open Excavation

The extent of open excavation at any one time will be controlled by the
conditions, but shall always be confined to the limits prescribed by the
Engineer.

D. Separation of Surface Materials

The Contractor shall remove only as much of any existing pavement as is

necessary for the work. The Engineer may require that the pavement be cut
with pneumatic tools, cold planer, milling machine or the like without extra
compensation to the Contractor, when in the opinion of the Engineer it is
necessary to prevent damage to the remaining road surface. Where
pavement is removed in large pieces, it shall be disposed of before
proceeding with the excavation.

From areas within which excavations are to be made, loam and topsoil shall
be carefully removed and separately stored to be used again as directed, or
if the Contractor prefers not to separate surface materials, he shall furnish,
as directed, loam and topsoil at least equal in quantity and quality to that
excavated at no cost to the Works.

E. Sheeting and Bracing

In addition to the general requirements of Clause 2/3.7 the Contractor shall

furnish, put in place, and maintain such sheeting, bracing, etc., as may be
necessary to support the sides of the excavation and to prevent any
movement of earth from beneath the adjacent road surface which could in
any way diminish the width of the excavation to less than that necessary for
proper construction, or could otherwise injure or delay the work, or

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endanger adjacent road and structures. If the Engineer is of the opinion that
at any point sufficient proper supports have not been provided, he may
order additional supports placed at the Contractor's expense.

For any excavations in or adjacent to roads all trenches must be supported

by an approved method to ensure no settlement of roads either during
construction, when withdrawing supports or thereafter.

F. Bridging Trenches

The Contractor shall, at his own expense, provide suitable and safe bridges
and other crossings where required for the accommodation of travel, and to
provide access to private property during construction, and shall remove
said structures thereafter.

G. Road Signs

All existing road signs, street name plates and the like affected by the
Works are to be carefully taken down and stored. Signs to be re-erected
shall be cleaned, provided with new fixings where necessary and the posts
re-painted as required. Redundant signs shall be transported to the stores
or depots of relevant Authorities. Any sign, street name plate or the like
damaged by the Contractor during his operation shall be repaired or
replaced at the Contractor's cost.

2/3.11 EXCAVATION FOR STRUCTURES

Where concrete is to be placed on an excavated surface other than rock, special

care shall be taken not to disturb the bottom of the excavation. When the nature
or condition of the bearing material upon which concrete is to be placed is
determined to be such that the use of heavy excavating equipment will reduce the
stability of the soil, the final half meter of excavation to grade shall be performed
either by means of light equipment or by hand labour methods.

Should the Contractor excavate to a depth greater than that required for the
construction of the foundations or pile caps, such excavation shall be filled with
Class C concrete at his own expense. Should the material forming the bottom of
any excavation, while acceptable at the time of excavation, become puddled soft
or loose during the progress of the Works, the Contractor shall at his own
expense, remove all such softened or loosened material and replace with Class C
concrete as directed by the Engineer's Representative.

Where rock, in either ledge or boulder formation or other unyielding material, is

encountered in one portion of structural excavation for a box culvert and yielding
material (with bearing capacity less than 1000 kN/m² determined by appropriate
tests) is encountered in an adjacent area of the structural excavation for the same
box culvert, such unyielding material shall be removed for a minimum depth of
half meter below grade and replaced with special backfill.

Where such unyielding material is encountered in excavation other than for box
culverts or where an entire excavation for a box culvert bears on such materials,
the rock or other unyielding material shall be cleared of all loose fragments and
cut to a firm surface as directed.

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The placing of concrete shall follow as closely as practicable the structural

excavation.

2/3.12 EXCAVATION FOR PIPELINES

Trenches for pipes shall be excavated to a sufficient depth and width to enable
the pipe and any specified or agreed joint, bedding, hauncing and surrounding to
be accommodated. Trenches shall be of width as specified and as shown on the
drawing.

Where rock, in either ledge or boulder formation or other unyielding material is

encountered, such unyielding material shall be removed for a minimum depth of
half meter below grade and replaced with special backfill (see Clause 2/4.3).

2/3.13 EXCAVATION FOR CABLES/DUCTS

The Contractor in carrying out excavation for cables/ducts shall, where required,
erect and maintain an approved type of temporary yellow plastic safety fencing
(refer to Clause 2/3.10) around any work and shall provide fenced access ways
across the trenches.

The bottom of the trench shall be accurately graded. Care shall be taken not to
excavate below the depths indicated. Where rock is encountered, the rock shall
be excavated to the required depth. Uneven surfaces of the bottom of trench shall
be excavated 150 mm deeper. Such depth in rock shall be backfilled with
approved fill material and compacted as specified and/or as directed by the
Engineer.

Whenever unsuitable soil is encountered, which in the opinion of the Engineer is

to be removed, it shall be removed to the depth required and the trench backfilled
to the proper grade with approved fill material and compacted.

The width and depth of the trenches for electrical and telephone cables/ducts
shall be as specified in the relative drawings or as ordered by the Engineer.
Banks may be sloped or widened to facilitate placement of cables, but not the
extent that will cause interference with other utilities and structures. No battering
of trenches shall be allowed under existing carriageways, unless otherwise
agreed by the Engineer.

2/3.14 EXCAVATED MATERIAL

All excavated material will remain the property of the Employer unless designated
as surplus to the Contract requirements in which case it will be removed from site
immediately. The Contractor shall dispose of such surplus material as per Clause
2/3.16.

All excavated material shall be deposited so that it will cause as little damage and
inconvenience as possible.

Excavated material for use as backfill shall be as approved. Different classes of

material shall be handled and deposited separately.

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The excavated material, if found unsuitable as backfill, shall be removed from site
and shall be replaced with suitable imported backfill to the approval of the
Engineer.

Unsuitable material shall include the following:

- Peat, organic soil and other similar materials.

- Materials from swamps, marshes and bogs.
- Materials susceptible to spontaneous combustion.
- Stumps, roots and perishable material.
- Excessively wet materials.
- All materials producing bearing capacity lower than the assumed design value.
- Clays of liquid limit exceeding 40% and/or plasticity index exceeding 6%.

All surplus and unsuitable excavated material and rubble shall be transported to
the approved tip.

Where (natural) subsoil drainage depends on the relative positions of pervious or

impervious strata, special care shall be taken to separate those materials and
replace them in their natural positions.

2/3.15 REPLACEMENT OF UNSUITABLE MATERIAL

Where exceptionally poor ground conditions and unsuitable materials are

encountered at the limits (formation level) shown for structural excavation, the
Contractor shall, at the direction of the Engineer, excavate down to firm ground or
300 mm below formation, whichever is less. The extra excavation shall be
backfilled with either Class C concrete or special backfill in accordance with
Clause 2/4.3.

2/3.16 DISPOSAL OF MATERIAL

The Contractor shall seek approval for all the proposed disposal sites from the
Dubai Municipality before work commences and disposal at such sites shall be at
no extra cost to the Employer.

No excavated material shall be wasted without written permission from the

Engineer, and when such material is to be wasted, it shall be hauled to the
approved tip or as otherwise directed by the Engineer. Excavated materials
wasted by the Contractor without written permission of the Engineer shall be
replaced by the Contractor at his own expense.

The Contractor shall adhere rigidly to the requirements of Dubai Municipality

Circulars on the temporary storage and disposal of excavation material. These
include but are not limited to :-

- All material shall be stockpiled at an approved location and surrounded with

approved barricades. The Contractor shall also display his name and contact
telephone number.

- Certain separate areas will be designated for the disposal of hard debris such
as building rubble, broken concrete, kerbing, road pavement and the like.

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The Contractor shall use only these designated areas and shall keep these
disposal areas neat and tidy at all times.

2/3.17 COFFERDAMS

Suitable and practically watertight cofferdams shall be used wherever

waterbearing strata are encountered above the elevation of the bottom of the
excavation.

The Contractor shall, on request, submit detailed drawings for approval showing
his proposed method of cofferdam construction and other pertinent features not
shown in detail on the Drawings. No construction shall be started until such
Drawings are approved, however, such approval shall not relieve the Contractor
of any responsibility for the successful completion of the construction.

No timber or bracing which will extend into the concrete shall be left in cofferdams
or cribs.

Any pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of any portion of the concrete material being
carried away. No pumping will be permitted during the placing of concrete or for a
period of at least 12 hours thereafter, unless it is done from a suitable sump
separated from the concrete work by a watertight wall. Pumping to remove water
from a sealed cofferdam shall not begin until the seal has set sufficiently to
withstand the hydrostatic pressure.

When no longer required, all cofferdam material down to the natural bed of the
waterway shall be removed. Cofferdam material outside the waterway to a
minimum of 0.5 m below the surface of the finished ground shall also be
removed.

2/4 BACKFILLING EXCAVATIONS

2/4.1 GENERAL

Backfilling around structures and in pipe trenches shall be carried out as detailed
below except where otherwise designated/directed.

The Contractor shall backfill all excavations in an expeditious manner to minimize

disruption to the general public.

Backfilling of trenches other than in roads and paved/ tiled areas shall normally be
carried out using selected excavated materials similar to the in-situ materials in
which the trench or structure is being constructed.

Special backfill shall be used for backfilling trenches in roads, paved/tiled areas,
and where designated or directed.

Where the excavation is near an existing structure liable to subsidence, where

part of the Works may later be constructed over or near it or in emergencies the
Contractor may be instructed to backfill with concrete.

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2.4.2 SELECTED BACKFILL

Material for backfilling may be selected from any part of the site and methods of
selection may include sieving to remove large particles or methods of hand or
machine sorting together with soil classification and soil property testing.

Backfilling with selected material shall be carried out as defined below.

A. Cohesive Soils

Cohesive soils shall be placed in layers not greater than 150 mm thick
(compacted thickness) and compacted such that throughout each layer placed
the dry density is not less than 95% of the MDD of the soil or the air voids content
(volume of air divided by total volume of soil) is not greater than 10% which ever
gives the higher state of compaction.

If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill in
layers of greater thickness, but not exceeding 200 mm, providing the plant utilised
is that used for the trials.

The placement moisture of the soil shall be within the range +/-2% of O.M.C of
the soil before excavation.

B. Granular Soils

Granular soils shall be placed in layers not greater than 150 mm thick (compacted
thickness) and compacted such that throughout each layer placed the dry density
is not less than 95% of the maximum dry density as determined by BS 1377 on
the same soil at the same moisture content.

If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill in
layers of greater thickness, but not exceeding 200 mm, providing the plant utilised
is that used for the trials.

Unless otherwise directed the moisture content shall be maintained and if

necessary adjusted by approved means to fall within the range +/-1.5% of
optimum moisture content.

For free draining granular soils that have no clearly defined optimum moisture
content, compaction shall be carried out to achieve a relative density of not less
than 95%. During compaction the soil shall be made as wet as practicable.

C. Testing of Backfill

Tests to determine the optimum dry density of the backfill material shall be carried
out as directed, the frequency depending on consistency of material and test
results.

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 15 SECTION 2 EARTHWORKS

Unless directed otherwise on site testing for density and moisture content of
in-situ soils shall be at the minimum rate of: -

(1) One test per backfill layer for each structure.

(2) One test per backfill layer for every 30 linear metres of pipeline trench backfill
laid in one operation.

D. Backfill for a Replacement Land Drain

Where a land drain passes through an excavation the backfill shall first be taken
up to form a bed for replacement pipes. The severed drains shall then be
exposed at each side of the trench to allow for connection and laying of a new
drain across the excavation. This new drain shall be of similar pipes of the same
diameter as those in the existing drain. Before any further backfilling is done the
Contractor shall notify the owner or occupier to enable him to inspect the
reinstated land drain. The replacement drain shall be surrounded with pipe
bedding to a minimum thickness 150 mm before further backfilling.

2.4.3 SPECIAL BACKFILL

The material used for special backfill shall be obtained from designated and
approved sources.

Special backfill complying with the properties of Aggregate Roadbase Material

specified in Clause 3/8 of Appendix 4, Part 3 of 3 of the Specifications shall be
placed as fill or backfill in the areas required and in reasonably close conformity
to the lines, grades and dimensions shown on the Drawings. Special care shall be
taken to keep rocks away from structures.

The materials shall be placed in layers of not more than 20cm in depth before
compaction, and each layer shall be compacted by means of mechanical or
pneumatic tamping devices or other suitable equipment to density of at least 95
percent of the maximum dry density as determined in accordance with the latest
BS 1377: Part 4: 1990 (Method 3.5 or 3.6, AMD 8259: 1995 & AMD 13925: 2002)
and the correction shall be made according to BS 1377.

Water shall be added to the material, by prewetting or by applying uniformly to

each layer, when required for compaction, but only of sufficient quantity to ensure
proper compaction.

The layers of material placed around structures shall be placed on opposite sides
to approximately the same elevation at the same time.

Special care shall be taken in placing and compacting material under haunches of
all pipe to prevent moving or raising the pipe from its bedding.

Material shall not be placed against any concrete abutment, wing wall, retaining
wall, box culvert or similar structure until the concrete has been in place at least
14 days, unless otherwise authorised.

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2.4.4 FILTER MATERIAL

When required, filter material shall be placed in backfilling structures in

accordance with the details shown on the Drawings. Filter material shall conform
to the specified requirements for Fine Aggregate.

2.4.5 STRUCTURAL AND NON-STRUCTURAL FILLING

Structural filling is required within road corridors and/or wherever a structure is to

be supported on the fill and where settlement is required to be minimal.
Non-Structural filling will normally be carried out to embankments and other fill
areas. Embankments shall normally be overfilled and subsequently trimmed to
the required profiles.

A. Structural Filling

Structural filling shall be carried out using approved well graded natural sands
and gravel or special backfill in accordance with Clause 2/4.3.

B. Non-Structural Filling

The material and the procedure for Non-Structural filling shall be same as
outlined in Clause 2/4.2.

2.4.6 BACKFILLING OF TRENCHES FOR CABLES/DUCTS

After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer being
well compacted by hand with iron rammers weighing not less than 5 kg, until the
trench has been filled to a height of 300 mm above the top of the cable/duct.

The remainder of the trench shall then be refilled in compacted layers not exceed
150mm in thickness, each layer being well compacted with power rammers,
vibrating plate compactors or other mechanical means of a type to be approved
until the ground is thoroughly consolidated up to the required level for surface
reinstatement. Each layer shall be compacted to 95% of its maximum dry density.
Should the quantity of the excavated materials be not sufficient, due to
unsuitability or otherwise, for the process of backfill and fill, the Contractor shall
obtain the quantity required of such backfill and fill from approved borrow pits and
transport same to the site of work at his own expense.

Trenches shall not be backfilled until all required tests are performed and until the
Engineer has verified that the cables, etc., have been installed in accordance with
the Specifications and Drawings.

Lumps and clods shall be broken up before use. Materials shall not be dropped
from a height and where directed water shall be added to assist in adequate
consolidation.

Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided according
to an approved drawing or as ordered by the Engineer.

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2.5 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT

2.5.1 GENERAL

Where new pipes, mains, cables/ducts, etc., are to be laid alongside, over or
under the existing, the Contractor shall take care to interfere as little as possible
with the existing services and connections thereto and any damage shall be
repaired by the Contractor to the approval of the appropriate Authority or by
appropriate Authority at the cost of the Contractor.

The Contractor shall make all arrangements for protecting existing services and
for temporarily diverting them to maintain the services without interruption.

Existing services, pipes, mains, ducts, etc., exposed in trenches for new work
shall be protected in accordance with the requirements of the relevant Authority
before trenches are refilled.

The Contractor shall lay cables, fittings, specials, etc., under hedges, fences,
walls, etc., as necessary.

Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in an
approved manner and fenced on each side with post and rail stock proof fences
finished on top with one strand of galvanised barbed wire, or otherwise protected
as required by the owners or occupiers and the Engineer.

Where fences or walls are damaged or destroyed the whole shall be restored and
reinstated with like materials to the satisfaction of the owners or occupiers and
the Engineer.

The Contractor shall ensure that no trees are damaged or permanently removed
in carrying out the Contract except where directed due to the presence of
permanent works.

2.5.2 REINSTATEMENT OF UNPAVED LAND

In general the reinstatement of stripped areas of unpaved land shall restore the
ground to a condition not inferior to that which existed before the site was
occupied.

The compacted backfill shall be taken up to a level which allows for settlement. In
arable, grassed and similar areas the surface to be topsoiled shall then be
loosened to a depth of 200 mm and topsoil replaced on it to the specified depth
without compaction using approved topsoil of comparable quality to make up any
deficiency.

Areas where grass is to be sown shall be worked to a fine tilth, levelled, graded
and rolled with a light roller. The seed shall be sown evenly at the specified rate
of application in the proper season and in suitable weather conditions, and the
areas again rolled. Restoration and re-seeding of any areas where the new grass
is inadequate shall be carried out as instructed.

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As an alternative to seeding the 'dibbing in' at 200 mm centres of 'Bugunda' or

similar tropical grass tufts may be required.

The grass shall be well watered four times a day and the Contractor will be
required to keep the grass cut short until the Defects Liability Certificate has been
issued.

2.5.3 REINSTATEMENT WITHIN ROAD CORRIDORS

Trenches and other excavations within road corridors may be opened in four
types of ground:-

(1) in paved carriageways

(2) in footpaths and other paved areas (other than carriageways)

(3) in grassed verges and planted areas

(4) in unmade ground which does not fall into any of the above three categories.

In addition there are four classes of carriageway construction as follow:-

(1) Estate roads: single carriageway

(2) Main access: single/dual carriageway

(3) Primary distributors

(4) Main arterials/highways, etc.

All reinstatement works falling into the above categories/classes shall be carried
out either in compliance with the current Local Order and any subsequent revision
thereof issued by Dubai Municipality or in compliance with the details shown on
the Contract Drawings, whichever is the greater in either construction depth or
asphalt thickness.

2.5.4 REINSTATEMENT OF OTHER SURFACED AREAS

Surfaced areas not in road corridors shall be reinstated using materials similar to
and not inferior to those existing prior to commencement of the Works.

2.5.5 EXCAVATION AND REINSTATEMENT IN DEVELOPED RESERVATIONS

The Dubai Municipality Horticulture Section will remove any trees, bushes and
plants from developed reservations that they wish to preserve prior to the
commencement of work by the Contractor. The Contractor must allow in his rates
for the removal and disposal of any remaining trees, bushes and plants necessary
for the execution of the Works and to keep sweet soil separate in accordance
with the current Local Order.

The reinstatement of the developed reservation shall be in accordance with

Clause 2/5.3.

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 1 SECTION 3 CONCRETE WORKS

TABLE OF CONTENTS

3/1 GENERAL ....................................................................................................................................... 2

3/2 MATERIALS ................................................................................................................................... 2
3/3 MIX DESIGN. ............................................................................................................................... 10
3/4 TRANSPORTING AND PLACING CONCRETE .............................................................. 13
3/5 COMPACTING CONCRETE .................................................................................................... 15
3/6 CURING OF CONCRETE ......................................................................................................... 16
3/7 JOINTS IN CONCRETE ............................................................................................................ 17
3/8 INSPECTION OF CONCRETE ............................................................................................... 19
3/9 FAULTY CONCRETE WORK ................................................................................................. 19
3/10 REPAIRS TO CONCRETE ....................................................................................................... 19
3/11 SUPERVISION OF CONCRETE WORK ............................................................................. 19
3/12 FINISHING OF CONCRETE .................................................................................................... 20
3/13 DESIGN AND CONSTRUCTION OF FORMWORK ........................................................ 20
3/14 READY MIXED CONCRETE ................................................................................................... 23
3/15 REINFORCEMENT STEEL ...................................................................................................... 23
3/16 PRECAST CONCRETE KERBS, EDGINGS & QUADRANTS ..................................... 26
3/17 IN-SITU CONCRETE EDGING ............................................................................................... 27

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 2 SECTION 3 CONCRETE WORKS

3/1 GENERAL

The prevailing standard for all concrete work shall be BSI BS EN 206-1: AMD
15571: 2006, and such amendments as shall be approved by the Engineer in
accordance with the CIRIA Guide to Concrete Construction in the Gulf Region.

Concrete work shall consist of furnishing all materials and constructing

structures of the forms, shapes and dimensions shown on the Drawings or as
directed, using Portland Cement concrete, in accordance with the details shown
on the Drawings and these Specifications.

Portland Cement concrete shall consist of a mixture of Portland Cement, fine

aggregate, coarse aggregate, water and additives when required. The mixture
shall be proportioned, mixed, placed and cured in accordance with the
requirements of BSI BS EN 206-1: AMD 15571: 2006. Where an additional
clause conflicts or is inconsistent with the requirements of BSI BS EN 206-1:
AMD 15571: 2006, the additional clause shall always prevail. The concrete
mixes shall be designed mixes for special or ordinary concrete as defined in BSI
BS EN 206-1: AMD 15571: 2006, the design requirements of which are laid
down in this Specification.

3/2 MATERIALS

3/2.1 CEMENT

3/2.1.1 General

Only Sulphate Resisting Cement as specified in Clause 3/2.1.3 shall be used

unless otherwise directed.

Unless otherwise approved by the Engineer all cements shall comply with the
following requirements:-

- The acid soluble alkali level measured as Na2O + 0.658 K2O shall not
exceed 0.6% by weight determined by the test method described in BS
EN196: P2: 2005 .

- The specific surface (fineness) shall not be greater than 325 m 2/Kg and not
less than 225 m2/Kg when tested as described in BS EN196-6:1996.

The cement shall be of approved manufacture and shall be delivered in bags

with seals unbroken, or delivered in bulk in approved containers which shall bear
the manufacturer’s name, cement type and the date of manufacture. Test
certificates from the manufacturers or suppliers shall be submitted for each
consignment and shall indicate the results of the tests for compressive strength,
setting time, soundness and fineness carried out in accordance with the
requirements of the relevant BS or ASTM standards.

Further tests may be required by the Engineer after the cement is delivered and
stored on the site. The failure of any sample to satisfy the BS or ASTM
requirements shall entitle the Engineer to reject the entire consignment from
which it was taken.

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 3 SECTION 3 CONCRETE WORKS

Cement shall be stored immediately upon receipt at site in such a way to keep it
away from water and moisture at all times. The Contractor shall provide a
method statement for the storage of cement which shall be approved and
implemented before any cement is delivered to site.

Consignments shall be used in the order in which they were delivered. Any
consignment not used within 2 months from the date of manufacture will not be
allowed to be used in the Works.

No cement from any consignment shall be used in Permanent Works without

the approval of the Engineer. Cement which the Engineer considers to have
deteriorated in any way shall not be used and shall be removed from site without
delay.

One brand only of cement as approved by the Engineer shall be used

throughout the Works unless otherwise authorised by the Engineer in writing.
Differing types of brands shall not be mixed together for use in the Works.

3/2.1.2 Ordinary Portland Cement

Ordinary Portland Cement (OPC) strength generally shall be Class 42.5N and
shall comply with BS EN 197-1: 2000: AMD 15209: 2004 & AMD 17325: 2007 or
ASTM C150/C150M-2009, Type 1. Ordinary Portland cement shall contain not
less than 4% and not more than 13% of Tricalcium Aluminate by weight content.

3/2.1.3 Sulphate Resisting Cement

Sulphate resisting cement (SRC) strength shall be Class 42.5N and shall comply
with BS 4027 or ASTM C150: 2009 Type 5. The limit for heat of hydration shall
be 290 Kj/Kg when tested as per BS 4550: Part 3: test 3.8. The maximum limit
for Tricalcium Aluminate Content is 3.5% when tested according to BS EN 196:
Part 2: 2005.

3/2.1.4 Moderate Sulphate Resisting Cement

Moderate sulphate resisting cement (MSRC) strength generally shall be 42.5N

and shall comply with ASTM C150/C150M-2009, Type 2. In either case the
cement shall not contain more than 2.5% proportion by weight of sulphur trioxide.

All other requirements shall be as specified in sub-clause 4/1.3 of Volume 2: Part

I. Moderate Sulphate Resisting Cement shall contain not less than 4% and not
more than 8% of Tricalcium Aluminate by weight.

3/2.2 FINE AGGREGATE FOR CONCRETE AND MORTAR

Fine aggregate for concrete shall consist of natural screened and washed sand
or crushed sand having hard and durable particles, or of other inert materials with
similar characteristics.

It shall not contain harmful material such as salts, clay lumps, tree roots, shale,
iron pyrites, coal, mica, organic matter or any deleterious matter which may

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attack the reinforcement, in such a form or in sufficient quantity to affect

adversely the strength and durability of the concrete.

If necessary, the aggregate shall be washed and sieved to remove the

deleterious substances.

The fine aggregate shall comply in all respects with the requirements of BS EN
12620:2002, AMD 15333: 2004 and the fine Aggregate shall also comply with
Dubai Municipality Administrative Order No. 143/91. In addition to the above, fine
aggregate for concrete shall meet the requirements in Table 3-1.

Table 3- 1: Limits for Properties of Fine Aggregates for Concrete

Type Test Method Permissible
Limits

1. Magnesium Sulphate ASTM C88:2005 Max. 12%

Soundness
(5 Cycles)

2. Clay Lumps and Friable ASTM Max. 1% by

Particles C142:1997(2004) weight
3. Organic Impurities ASTM C40:2004 Lighter than
standard
4. Material Finer than ASTM C117:2004 Max. 3%
0.075 mm
5. Acid Soluble Chlorides (Cl) BS 812: Part 117:1988
For reinforced concrete Max. 0.03%
made with SRC
For reinforced concrete Max. 0.03%
made with OPC & MSRC
For mass concrete made Max. 0.03%
with:
SRC
For mass concrete made Max. 0.03%
with: OPC & MSRC
For prestressed concrete Max. 0.03%
and
heat-cured reinforced
concrete
6. Acid Soluble Sulphates (SO3) BS EN 1744-P1:1998 Max. 0.3% by
weight of fine
aggregate
7. Water Absorption ASTM C128:2007a Max. 2.3%
8. Specific Gravity (apparent) ASTM C128:2007a Min. 2.6
9. Sand Equivalent (when ASTM D2419:2009 Min. 75
aggregate other than natural
sand is approved)

Fine aggregate of fine grading (BS EN 12620:2002, AMD 15333: 2004) shall not
be used. Fine aggregate shall conform to one of the gradings given in Table 3-2
(reproduced from BS 882: 1992).

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Table 3-2: Grading of Fine Aggregate for Concrete

BS 410 Percentage by Weight Passing BS Sieve
Test Sieve
(mm) Coarse Medium

10 100 100
5 100 100
2.36 60 - 100 65 - 100
1.18 30 - 90 45 - 100
0.60 15 - 54 25 - 80
0.30 5 - 40 5 - 48
0.15 0 - 15 0 - 15

3/2.3 COARSE AGGREGATE FOR CONCRETE

Coarse aggregate for concrete shall consist of natural gravel, crushed gravel, or
crushed stone, free from coating of clay or other deleterious substances. It shall
not contain harmful materials such as salts, iron pyrites, coal, mica, laminated
materials, tree roots, shale, or any materials which may attack the reinforcement,
in such a form or in sufficient quantity to affect adversely the strength and
durability of the concrete. If necessary, coarse aggregate shall be washed to
remove deleterious substances.

The coarse aggregate shall comply in all respect with the requirements of BS
882. The coarse aggregate shall also fulfill the requirements in Table 3-3.

Table 3-3: Limits for Properties of Coarse Aggregate for Concrete

Type Test Method Permissible
Limits
Particle Shape (Note 1)
1. Flakiness Index for 10mm BS EN 933, Max. 25
&20mm CA Part3:1997:AMD 14866:
2004
2. Elongation Index for 10mm BS 812: 1990-Part 105 Max. 25
&20mm CA
3. Ten Percent Fines Value or BS 812: Part 111: 1990, Min. 100KN
Impact Value BS 812: Part 112:1990, Max. 30%
AMD 8772: 1995
4. Los Angeles Abrasion ASTM C131:2006 Max. 30%
ASTM C535: 2009
5. Soft Fragments and Shell BS EN 933-Part7:1998 Max. 3% by
Content weight
6. Magnesium Sulphate ASTM C88:2005 Max. 12%
Soundness (5 Cycles)
7. Clay Lumps and Friable ASTM C142:1997 (2004) Max. 1% by
Particles weight
8. Material Finer than 0.075 ASTM C117:2004 Max. 1%

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mm
9. Acid Soluble Chlorides (Cl) BS 812: Part 117:1988

For reinforced concrete

made
with : Max. 0.01%
- SRC Max. 0.02%
- OPC & MSRC

For mass concrete made Max. 0.02%

with: Max. 0.04%
- SRC
- OPC & MSRC
Max. 0.01%
For prestressed concrete
and
heat-cured reinforced
concrete
10. Acid Soluble Sulphates BS EN 1744, Part1:1998
Max. 0.3%
(SO3) by weight of
coarse
Aggregate
11. Water Absorption ASTM C127:2007 Max. 2%
12. Specific Gravity (apparent) ASTM C127:2007 Min. 2.6
13. Drying Shrinkage BS EN 1367-4:1998 Max. 0.05%
Note 1): The index shall be max 25 for combined aggregate but should
not exceed more than 30 for individual sizes.

The coarse aggregate shall conform to the gradings given in Table 3-4 in
accordance with the nominal size of aggregate specified (reproduced from BS
EN 12620: 2002: AMD 15338: 2004).

Table 3-4. Gradings of Single Size for Coarse Aggregate

Sieve Size Percentage by Weight Passing BS Sieve for Nominal Sizes
(mm) 40 mm 20 mm 14 mm 10 mm
50 100 - - -
37.5 85 - 100 100 - -
20.0 0 - 25 85 - 100 100 -
14.0 - - 85 – 100 100
10.0 0-5 0 - 25 0 – 50 85 - 100
5.0 - 0-5 0 – 10 0 - 25
2.36 - - - 0-5

3/2.4 COMBINED AGGREGATE

Approved coarse aggregate and fine aggregate in each batch of concrete shall
be combined in proportions as specified in BS 882: 1992 and as approved by

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the Engineer. However, in no case shall materials passing the 0.075 mm sieve
exceed three (3) percent by weight of the combined aggregate.

The combined concrete aggregate gradation used in the work shall be as

specified, except when otherwise approved or directed by the Engineer.
Changes from one gradation to another shall not be made during the progress
of the work unless approved by the Engineer.

Naturally occuring sand/gravel mixtures (all in aggregates) shall not be used

unless otherwise directed by the Engineer.

3/2.5 WATER

3/2.5.1 General

Water for washing aggregate and for mixing or curing of concrete shall be
fresh, clean and substantially free from oil, acids, alkali, sewage, deleterious
mineral or organic matter. Water shall comply in all respects with BS 3148:
1980.

It shall not contain impurities in sufficient amounts to cause discoloration of the

concrete.

All sources of water for use with cement shall be approved by the Engineer.
Sources of water shall be maintained at such depth and the water shall be
withdrawn in such a manner as to exclude silt, mud, grass and other foreign
matter.

If at any time during construction the water from an approved source becomes
unsatisfactory, the Contractor will be required to provide satisfactory water
from some other source.

3/2.5.2 Specific Requirements

Water for washing aggregate and for mixing or curing of concrete shall be
tested in accordance with BS and ASTM standards and shall meet the
following requirements:

Table 3-5. Chemical Limitations for Mixing Water

Parameter Maximum Test Method
Concentration
Limit
1. Chlorides as C1 250 mg/l ASTM D512: 2004 or
BS EN 1008:2002
2. Sulphates as SO3 350 mg/l ASTM D516: 2007 or
BS EN 1008:2002
3. Alkali carbonates and ASTM D513: 2003 or
Bicarbonates 500 mg/l BS EN 1008:2002
4. Total dissolved solids, BS 1377: Part 3 or
including 1, 2 & 3 2,000 mg/l BS EN 1008:2002
above

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5. pH Min. 7/max. 9 ASTM D1293: 1999

(2005) or BS EN
1008:2002

The temperature of water for concrete should not be less than 5 C nor more
than 25C. Water may be cooled to not less than 5C by the gradual addition of
chilled water or ice but on mixing, no ice particles should be present in the mix.
Alternatively, flaked ice may be used. The ice to be used should be crushed
and should be the product of frozen water which complies with the above
requirements.

3/2.6 ADMIXTURES

Unless agreed by the Engineer neither admixtures nor cements containing

additives shall be used.

Where the use of admixture had been agreed by the Engineer, they shall
conform to the requirements of Type A, Type D, Type F or Type G as specified
in ASTM C494 / C494M: 2010 and shall be used in strict accordance with the
manufacturer’s instructions. The Contractor shall be entirely responsible for
the use of any approved admixtures. Samples of proposed admixtures shall, if
required, be submitted to an approved testing authority by the Contractor in
order to ascertain its suitability for use in the Works.

Approved methods and equipment shall be used for dispensing and

incorporating the admixture into the concrete. The dispensing unit shall be
designed so that the discharge of the admixture is visible.

The cost of such admixtures shall be included in the cost of concrete and no
extra payment shall be made if they are used. The proportions of cement, fine
aggregate and water shall be determined by the Contractor before concreting
commences and submitted together with such test results as may be required
to the Engineer for approval and the Contractor shall not commence concreting
before such approval is given nor shall he alter or vary in any way the
proportion of mix unless he submits fresh test results and mix proportions to
the Engineer for approval.

The approval by the Engineer of such mix designs does not in any way absolve
the Contractor of any of the requirements of the Specifications.

3/2.7 CONCRETE MIX SPECIFICATION

The classes of concrete and their respective minimum cement content,

consistencies and the minimum required compressive strengths shall be as
shown:

Table 3-6. Concrete Classification and Mixes

Comp. Strength Slump Min.Cemen Max. Free
(N/mm2) (mm) t Content Water/Cement
Class of (kg/m3) Ratio
Concrete
7 28

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days days
A 20 30 100+ 310 0.55
(30/20/SRC) 25
B 16 25 100+ 275 0.60
(25/20/SRC) 25
C 10 15 100+ 250 0.65
(15/20/SRC) 25

The chloride and sulphate levels in the concrete mix shall comply with the
requirements of Table 3-7.

Table 3-7. Maximum Limits of Chloride & Sulphate in Concrete Mix

Chlorides as Sulphate as SO3*
Type of Concrete C1* (According (According to BS
to BS 1881:Part 124:1988)
1881:Part
124:1988)
a. For reinforced concrete
if made with OPC/MSRC 0.30% 3.70%
if made with SRC 0.06% 3.70%
b. For mass concrete
if made with OPC/MSRC 0.60% 3.70%
if made with SRC 0.12% 3.70%
c. For prestressed concrete and 0.10% 3.70%
heat-cured reinforced
concrete
*Maximum limits of chloride and sulphate content as a percentage by weight of
cement in the mix.

The OPC and MSRC cements can also contain chlorides, the relevant standard
BS 12 allows up to 0.1% C1. Therefore any chloride content present in the
cement has to be taken into account while computing total C1 in the mix. In
case the cement contains the maximum limit of 0.1% Cl, then the aggregates,
water and admixtures used for prestressed concrete or heat-cured reinforced
concrete should be absolutely free of chlorides.

3/2.8 CEMENT MORTAR AND GROUT

Unless otherwise specified, mortars and grouts shall be composed of Ordinary

Portland Cement (satisfying Clause 3/2.1) and sand (satisfying Clause 3/2.2) in
the following proportions:-

NOMINAL PROPORTIONS

Quality Portland Cement Sand

G1 1 1
G2 1 2
G3 1 3

The amount of water (satisfying Clause 3/2.5) added shall just be sufficient to
make the mortar or grout workable consistent with its purpose.

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3/3 MIX DESIGN.

3/3.1 SAMPLES OF AGGREGATES

Before any material from a particular source is used, the Contractor shall
obtain representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the Works, the grading and chemical
characteristics may be checked at frequent intervals. Sampling of aggregates
shall be carried out in accordance with BS EN 932-6:1999 & BS EN 932-1
19997.

The results of these tests shall be submitted to the Engineer and his approval
shall be obtained before any of the material is used in the Works. Part of each
sample will be required for concrete trial mixes and part shall be retained for
comparison with subsequent deliveries.

No deliveries in bulk are to be commenced until such samples are approved by

the Engineer as complying with this Specification.

3/3.2 TRIAL MIXES FOR CONCRETE

Following the Engineer's approval of the materials for each class of concrete,
the Contractor shall prepare trial mix of each grade of concrete in the presence
of the Engineer's Representative. Each trial mix shall comprise not less than
1/3 of a cubic metre of concrete and shall be mixed in an approved type of
concrete mixer similar to that which the Contractor propose to employ on the
Works. The quantities of all ingredients of trial mix including water shall be
carefully determined by weight according to the approved mix design. Each
trial mix shall show no tendency to segregate when handled and compacted by
the methods by which the Contractor proposes to handle and compact the
grade of concrete in the Works and it shall be capable of adequate compaction
by such methods.

3/3.3 WATER/CEMENT RATIO

The quantity of water to be added to the cement and aggregates during mixing
shall be just sufficient to produce a workable mix to enable it to be well
compacted and worked into corners of formwork and around reinforcement. All
mixes shall be designed in respect of the proportioning of water so that the
Slump Test as carried out according to BS EN 12350-2:2009 shall be in
accordance with the requirements laid out in Clause 3/2.7. Measurement of
water on the Site shall take into account the moisture present in the
aggregates, and Slump Tests shall be taken frequently to ensure that
variations in the moisture content of the aggregate are fully taken into account
in determining the amount of water to be added. If slump exceeded the
specification limits, Flow test is recommended in this case. Flow test shall be
performed according to BS EN 12350-5:2009.

3/3.4 MEASUREMENT OF INGREDIENTS

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The aggregates for the concrete shall be measured by weight but

measurement by volume may be allowed in special circumstances with the
approval of the Engineer.

When the aggregates are to be measured by weight the weight batching

machines shall be of a type approved by the Engineer's Representative. They
shall be kept clean and in good condition and adjustment. At intervals as the
Engineer's Representative may require, the Contractor shall check the
accuracy of each weight-batching machine.

When the aggregates are to be measured by volume, the proportions of fine

and coarse aggregates shall be measured in well constructed gauge boxes, of
dimensions approved by the Engineer's Representative to guarantee that
whole multiples of such gauge boxes will ensure the use of one more whole
bags or containers of cement and the capacity of the concrete mixer shall be
such as to ensure that no splitting of cement bags or containers is required.
Gauge boxes shall be properly filled and struck off level, addition of fine
aggregates to allow for bulking due to moisture content being made as
required.

An efficient water measuring device shall be fitted to each concrete mixer.

Any cement container shall be such as to contain an accurately weighed

amount of cement.

3/3.5 MIXING CONCRETE

The concrete shall be mixed in a power driven machine of the batch type, no
hand mixing being allowed. The mixer shall be large enough to admit the use
of 1 cement bag or container or whole multiples of bags or containers at a time.
The mixing shall continue until there is a thorough distribution of the materials
and the mass is uniform in consistency and colour. The period of mixing,
judged from the time that all the ingredients including water are in the mixing
drum shall be as ordered by the Engineer's Representative but shall not be
less than 2 minutes or 20 revolutions of the drum whichever is the longer.
Should there be for any reason a stoppage of greater than 30 minutes, the
drum or other containers of the mixer shall be thoroughly washed and cleaned
before mixing is resumed. On completion of the mixing the concrete shall be
discharged onto clean boards or into clean barrows. The method of discharge
from the mixer shall be such as to cause no segregation whether partial or
otherwise of the concrete materials.

3/3.6 RE-MIXING CONCRETE

Concrete which has commenced to set shall not be remixed either with or
without additional water and in no case shall such concrete be used in the
Works.

3/3.7 CONCRETE TESTING

3/3.7.1 General

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The compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS1881: Part 116: 1983, AMD 6720: 1991 & AMD 6097: 1989.
Sampling, making test cubes and curing of cubes shall be in accordance with
BS 1881: Parts 101, 1983, AMD 6728: 1991 & AMD 6091: 1989, 108 and 111
respectively.

The following methods of testing shall apply to standard concrete cubes.

3/3.7.2 Preliminary Testing

After the materials have been approved and at least 10 days before any
concrete is poured, the Contractor shall make preliminary sets of test cubes.
Each set of test cubes shall comprise of three cubes made from a single
sample of concrete taken from the point of final discharge of the wet concrete.
Each cube shall be made under the Engineer's Representative supervision.
Cubes shall be tested as follows: one cube shall be tested 7 days after the date
of manufacture and one cube 28 days after the date of manufacture. The third
cube will only be tested if the Engineer's Representative wishes to check the
results of the tests on either of the other two cubes and shall otherwise be
preserved by the Contractor until the end of the Period of Maintenance.
Preliminary test cubes shall be made and tested for all grades of concrete and
for all proposed variations of quality, quantity or origin of the aggregates and
cement.

Should either the test cube crushed at 7 days or that crushed at 28 days fall
below the specified requirements and the failure is confirmed by the testing of
the third cube, the Contractor shall, on the Engineer's Representative's
instructions alter the mix design and/or the source of aggregates, cement or
water and/or the method of mixing including alteration of the type of mixer. The
compressive strength of the concrete cube at 7 days shall be equal to or more
than two thirds the required compressive strength at 28 days.

3/3.7.3 Works Testing

During the course of the construction of the Works, the Contractor shall make
test cubes as required by the Engineer's Representative. One set of six cubes
will normally be taken from each individual concrete member, e.g. culvert
invert, Irish crossings, but additional cubes shall be taken as directed by the
Engineer's Representative. Three cubes will be tested at 7 days and three
cubes at 28 days as the Engineer's Representative directs. Where the strength
of the concrete is shown to be below that specified, the Contractor shall
remove and replace at his own expense all concrete from the concerned pour.
The Engineer may require the Contractor to cut out defective concrete from the
Works at his own expense even though test cubes made from that concrete
have not failed.

3/3.7.4 Workability Testing

The Contractor shall carry out slump test in accordance with BS EN 12350-
2:2009 and/or compacting factor test in accordance with BS EN 12350-4:2009
at such frequency as the Engineer's Representative considers necessary to
ensure that the workability and consistency of the concrete is maintained in

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accordance with the specified mix or accepted mix design and the trial mix. In
any case workability tests shall be carried out at least once every two hours
during which concrete is being mixed at plant.

3/3.8 FREQUENCY OF TESTING AGGREGATE AND CONCRETE

During the mixing and casting of concrete the frequency of testing for control
purposes shall be as indicated in Table 3-8 or as directed by the Engineer's
Representative. No direct payment is made for testing. The price of this work is
to be included in the bid prices of concrete.

Table 3-8. Required Frequency of Testing Aggregates & Concrete

Type of Test Frequency
Grading of Fine and Coarse Once for each source prior to approval
Aggregate; Flakiness and and once prior to casting of each lift for
Elongation Index; Aggregate any major concrete structure or as
directed by the Engineer
Crushing Value
Concrete Cube One set (Min. 6 Cubes) from each mixer
for each individual pour or every 2 hours
for large pours or as directed by the
Engineer.
Compacting Factor Test As directed by the Engineer.
Flexural Loading (1) (as per As directed by the Engineer.
BS 7263 : Part 1: 2001)
(2)
Absorption Requirement As directed by the Engineer.
(as per BS 1881: Part 122,
1983, AMD 6108: 1989)
Slump Test From each mixer or as directed by the
Engineer.
Mix Design Once for each source of aggregate or
every combination of sources or as
directed by the Engineer.
Notes: (1) Minimum requirement is 22.24 KN at 28 days
(2) Maximum 2% after 30 minutes

3/4 TRANSPORTING AND PLACING CONCRETE

3/4.1 GENERAL REQUIREMENTS

Concrete shall be taken from the place of mixing to the place of depositing by
approved methods which will prevent the segregation or loss of the ingredients
and which are sufficiently rapid to ensure that the concrete does not
commence to set before it is compacted in position. The concrete shall be
deposited as near as possible to its final position in the Works and shall not be
allowed to flow into position. Deposition of the concrete through chutes shall
not be permitted and neither shall the concrete be dropped freely from a height
exceeding 2.0 m. Pumping concrete through delivery pipes may be permitted
but only with the prior approval of the Engineer's Representative.

No concrete shall be placed in a foundation until the extent of excavation and

the character of bearing material have been approved and no concrete shall be

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placed in any structure until the placement of reinforcing steel and the
adequacy of the forms and flasework have been approved.

The concrete shall be placed in its final positions as soon as possible after it
has been mixed, and in any case before the initial set has taken place. The
Contractor shall ensure that concrete which has already been placed in
position and commenced to set is not disturbed by the placing or compaction of
further concrete nearby. All concrete shall be carefully worked around and
between reinforcement and all other embedded fittings without such
reinforcement or fittings being disturbed. Concrete is to be worked well up
against whatever surface it joints.

No concrete shall be mixed or placed when the light is insufficient, unless an

adequate and approved artificial lighting system is operated and such night
work is approved by the Engineer.

3/4.2 PLACING CONCRETE IN HOT WEATHER

Concrete shall only be placed where the general requirements in regard to

ambient and mix temperatures laid down in the CIRIA Guide to Concrete
Construction in the Gulf Region are met. The parameters laid down therein
shall only be exceeded with the prior written consent of the Engineer.

Concrete shall not be placed when the shade air temperature exceeds 40 C
or during periods of windblown dust or rain.

The temperature of batched concrete at time of placing shall not exceed 32C
unless otherwise specified.

Measures shall be taken to provide cool concrete and cool concreting

conditions in order to reduce workability loss, premature drying of concrete and
the development of high temperatures and temperature gradients in placed
concrete.

Proposed measures must be described in method statements and may

include:-
(a) Painting white or silver all storage vessels, hoppers, pipes, walls or roofs
which contain or convey aggregates, cement or mixing water.
(b) Dampening the forms.
(c) Reducing the concrete temperature to the lowest practical level by
procedures such as :-
- Shading the aggregate.
- Cooling the mixing water before use.
- Screening the mixing plant and transporting vehicles from wind, rain
and sun.
(d) Erecting wind breaks and sunshades at the concrete placing location.
(e) Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.

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 15 SECTION 3 CONCRETE WORKS

(f) Minimizing evaporation (particularly during the first few hours subsequent
to placing the concrete) by suitable means such as applying moisture by
fog spraying.

These measures are in addition to those specified for the curing of concrete.

In contracts which small structures spread over a large site, such as sewerage
contracts, where transportation times could be large, dry mixing of concrete
with addition of water immediately prior to placing may be proposed. Method
statements for such a proposal must describe methods for accurate batching
of water.

3/4.3 PLACING CONCRETE IN WATER (TREMIE CONCRETE)

Tremie concrete shall be deposited in water only if specified on the Drawings

and/or directed by the Engineer and under the Engineer's supervision.
Concrete to be deposited in water shall have the cement content increased by
25% at the Contractor's expense. Concrete shall be carefully placed in a
compact mass in the space in which it is to remain by means of a tremie
bottom dump bucket or other approved method that does not permit the
concrete to fall through the water without adequate protection. The concrete
shall not be disturbed after being deposited. No concrete shall be placed in
flowing water and forms which are not reasonably watertight shall not be used
for holding concrete deposited under water.

3/4.4 BLINDING CONCRETE

Prior to placing any concrete on natural surfaces a blinding layer of Class C

concrete shall be laid to a minimum of 75 mm thickness. This blinding shall be
suitably curved prior to subsequent concrete placement. The blinding shall be
clean and free from any dust or impurities prior to subsequent concrete
placement.

3/5 COMPACTING CONCRETE

3/5.1 TAMPING

All concrete shall be thoroughly compacted to the maximum with approved

rammers without any segregation in its final position before it commences to
set. Care shall be taken to ensure that the use of spade type rammers does
not cause segregation of the aggregates and water. Initial compaction of slabs
shall be with approved rammers and compaction by a screed board shall be
limited to that required for the final shape and finish. During the placing and
compaction of reinforced concrete, a competent steel mixer shall be in
attendance to adjust and correct if necessary the position of the reinforcement.

3/5.2 VIBRATING

Concrete shall be compacted by vibrating with an approved vibrator. The

vibrators shall not be attached to any reinforcement or embedded fitting and
where vibrators of the immersion type are used, care shall be taken to ensure
that they do not come into contact with the reinforcement or embedded fittings.
Freshly placed concrete shall not be vibrated in a manner likely to cause

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 16 SECTION 3 CONCRETE WORKS

damage to concrete in other parts of the Works which has already taken its
initial set. Concrete shall not be vibrated in such a manner and to such an
extent as to cause segregation of the constituent materials. If shutter type
vibrators are used they shall be augmented by immersion type vibrators if the
thickness of the concrete member is more than 15 centimetres.

3/6 CURING OF CONCRETE

All concrete shall be protected from the harmful effects of sunshine, drying
winds, rain, flowing water, or other adverse effect. For at least 7 days after
placing, the concrete shall be prevented from drying out by being sprayed with
fresh clean water and covered with hessian, clean sand or other approved
material which shall be kept wet.

Whenever approved by the Engineer, membrane curing of concrete with an

approved liquid may be used as an alternative to curing with water except that
membrane curing liquid shall not be applied to surfaces of concrete from which
the shuttering has been struck, until the concrete has been inspected and
approved by the Engineer's Representative.

The concrete curing compound shall comply with the following requirements:

1) Only products which have been proved to be effective through extensive

use shall be proposed and manufacturers’ literature shall include recent
test certificates illustrating effective quality control and high curing
efficiencies.

2) All materials shall be supplied in the containers marked by the

manufacturer with his name, date of manufacture, shelf life, pot life and
instructions for handling and application.

3) The liquid shall contain a white or silver colour pigment in sufficient

quantity to give a uniform colour when applied to the concrete surface.

4) The liquid shall be of such chemical composition and consistency that it

can be applied by an approved mechanical sprayer in fine spray to
produce an even, uniform, impervious, continuous film within one hour of
application which will not crack, peel or disintegrate within three weeks of
application.

The compound shall not be poisonous, odorous or explosive and shall not
react chemically with cement.

5) Curing compounds shall not be applied to surfaces to which further

concrete or a surface finish is subsequently to be bonded unless the
approval of the Engineer is obtained to the use of a water soluble type.

The Contractor shall ensure that all concrete is adequately protected against
inclement weather until properly set and shall if necessary provide additional
protection to that specified above.

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 17 SECTION 3 CONCRETE WORKS

3/7 JOINTS IN CONCRETE

3/7.1 INTERVALS DURING CONCRETING

The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc., and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organized to ensure that the above mentioned interval shall not be exceeded.

3/7.2 CONSTRUCTION JOINTS

Construction joints shall be as shown on the Drawings or as directed by the

Engineer's Representative. If the Contractor wishes to make additional
construction joints he shall obtain the prior approval of the Engineer's
Representative. Such approval may include the provision and placing of
additional reinforcement at the Contractor's expense.
Construction joints shall be formed by inserting temporary vertical stopping-off
boards to form tongue and groove joint with the concrete placed subsequently
except if separately detailed on the Drawings. Unless otherwise shown on the
Drawings construction joints shall be located as near as possible to the position
of minimum shear and tensile stress in the concrete.

3/7.3 JOINTING FRESH TO SET CONCRETE

At a construction joint, the face of the previously placed concrete shall be

cleaned of any skin or latance or loose material by brushing with a wire brush
or other approved method and washing with clean water. Insecurely held
aggregate shall be removed. Excess water shall be removed and the surface
while still wet shall be covered with 1:2 cement mortar which must be
vigorously stippled into the surface by means of a suitable stiff brush, the
depositing of the fresh concrete following closely.

3/7.4 EXPANSION JOINTS

Expansion joints shall be constructed at positions shown on the Drawings or as

directed by the Engineer and shall be formed according to the instruction and
dimensions shown on the Drawings.

Filled expansion joints shall be provided at every 6 m or as shown in the

drawings and/or directed by the Engineer for the kerb and concrete backing.
Any excavated surface for the concrete bedding should be watered and
compacted to a minimum 95% of optimum density.

3/7.5 EXPANSION JOINT FILLER

Expansion joint filler shall be composed of approved durable non-extruding

fibrous material suitably impregnated to prevent deterioration. Sheet bitumen
fillers will not be accepted. Preformed strips of expansion joint filler shall be of
such a nature as not to be permanently deformed or broken by twisting,
bending or other normal handling on site. Samples shall be submitted for

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 18 SECTION 3 CONCRETE WORKS

approval before ordering. The vertical expansion joints in kerbs and parapets
shall be formed with approved vertical seal. Such vertical seal shall adhere to
the vertical face sealed and shall not flow under maximum local sun
temperature nor shall it be sticky to the touch.

1) Expansion joints for precast upstand kerbs shall be at 6 m.

2) For flush kerbs cast in-situ, at 2 m max.
3) For precast slabs, every 4 m min.

3/7.6 EXPANSION JOINT SEALING COMPOUND

The sealing compound shall be of an approved polysulphide compound, non-

pouring grade for vertical application and pouring grade for horizontal
application, as specified in Clause 9/2.1.2 (1) or it may be a rubber-bitumen
compound.

The rubber-bitumen compound shall be a flexible weather resistant seal, slump

resistant unaffected by permanent immersion in water, or by alkalis or
sulphates. The material shall have a minimum storage life of 12 months in
original containers stored in cool dry conditions and a density of 1.30 kg/litre.

The sealing compound shall adhere firmly to the concrete in all weather
conditions. The sealing compound shall not flow either along or down the joint
during hot weather. The sealing compound shall be durable and shall not
weather beyond the forming of a thin surface skin.

Samples shall be submitted for approval before ordering. Vertical sealer shall
be used with an approved priming compound. Application of the sealing
compound shall be strictly in accordance with the Manufacturer's instructions.

3/7.7 WATERSTOP ACROSS JOINTS IN CONCRETE STRUCTURES

Seepage of water through any joints in a water retaining or water excluding

concrete structure shall be prevented by the use of PVC Waterstop or other
material as directed and approved by the Engineer. They shall be placed
centrally as a water barrier across the designated joint in in-situ concrete
structures and cast centrally into the edges of adjacent concrete components.

Waterstop shall be used at all Expansion and Contraction Joints in concrete

structures below water table. For a Construction Joint, requirement of a
Waterstop shall be indicated in the drawing. The Engineer may also require the
Contractor to provide Waterstop at any additional Construction Joint approved
at his request.

Waterstop shall be extruded from high grade grey PVC Compound. Flat
Dumbell plain web Waterstop shall be used for a Construction Joint while for
an Expansion Joint or a Contraction Joint, a centre bulb Waterstop shall be
used. The width of the Waterstop shall depend upon the concrete thickness,
the aggregate size and the position of reinforcement. In general, the following
shall be taken as a guide to select the width, w, of a Waterstop:-

w < t, but w > (6a+j)

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 19 SECTION 3 CONCRETE WORKS

where, t = concrete thickness

a = largest aggregate size
j = width of Expansion Joint

The following Technical Data shall apply :

Hardness : 42 - 52 BS Softness degrees at 25 C.

Tensile strength : 13.8 N/mm2 minimum at 25 C.

Elongation at break : 285 % minimum at 25 C.

3/8 INSPECTION OF CONCRETE

The Contractor shall not proceed with the surface finish or making good of
concrete surfaces until he has received the Engineer's Representative's
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck
until the concrete has been inspected and approved by the Engineer's
Representative.

3/9 FAULTY CONCRETE WORK

The Contractor shall on the written instruction of the Engineer's Representative

remove and reconstruct any such portion of the work which in the opinion of
the Engineer's Representative is unsatisfactory as regards quality of concrete,
incorrect dimension of the cast portion, badly placed or insufficient
reinforcement, honeycombing or other such cause as shall render the
construction not up to the standard required and which in the opinion of the
Engineer may affect the strength or durability of the construction.

3/10 REPAIRS TO CONCRETE

The method of repairing and replacing defective concrete which the Contractor
proposes to adopt shall be submitted to the Engineer's Representative for prior
approval and the repair shall be carried out in such manner as the Engineer
may direct or approve.

3/11 SUPERVISION OF CONCRETE WORK

Throughout the progress of the concrete work the Contractor shall employ and
provide such supervision as is necessary to ensure

(a) the day to day control of the quality of the concrete and

(b) the mixing, transporting, placing, compacting, curing and protection of

the concrete, and
(c) the carrying out of all testing as specified herein and any further testing
which the Engineer's Representative may require, and

(d) the conducting of investigations as the Engineer's Representative may

require, and

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 20 SECTION 3 CONCRETE WORKS

(e) the preparation of reports and the keeping of such records as the
Engineer's Representative may require.

3/12 FINISHING OF CONCRETE

All concrete surfaces (except top faces of culvert decks) not requiring
shuttering shall be trowelled to a smooth dense surface with the minimum of
cement and fine particles being brought to the surface and shall be free from
irregularities. Top faces of culvert decks shall be carefully screeded and
tamped to the required shape and to a dense surface with the minimum
amount of cement and fine particles being brought to the surface and should
be free from irregularities greater than 3 mm in height or depth.

Shuttered surfaces of concrete which will always be in contact with the ground
may be cast against sawn timber. All other exposed shuttered surfaces
including precast concrete shall be cast against steel, plywood or planed
timber formwork and shall be carefully rubbed down with carborundum to
remove all imperfections and irregularities. Surfaces which are honeycombed,
porous or irregular and which in the opinion of the Engineer's Representative
do not comply with the Specification shall be cut out and replaced with sound
concrete as directed by the Engineer's Representative. The cost of all normal
surface finishes and making good shall be deemed to be included in the
tendered rate for the concrete.

3/13 DESIGN AND CONSTRUCTION OF FORMWORK

3/13.1 GENERAL

Formwork shall in every respect be adapted to the structure and the required
surface finish of the concrete. It shall include all temporary moulds for forming
the concrete to the required shape and finish and for the support of such
moulds. It shall be fixed in perfect alignment and securely ledged and braced
so as to be able to withstand, without displacement deflection or movement of
any kind, the weight of the construction and the movement of persons
materials and plant. Joints shall be close enough to prevent the leakage of
liquid and fine materials from the concrete.

The Engineer's Representative may at any time require the prior submission
for approval of the Contractor's proposals for design and construction of
formwork including supports. The formwork shall be constructed so as to
permit its removal without damage to the concrete.

3/13.2 SPACING BLOCKS AND TEMPORARY CONSTRUCTION TIES

Internal spacing blocks and construction ties shall be avoided as far as, in the
Engineer's Representative opinion, possible and practicable. Where it is
intended that the spacing blocks or construction ties shall be removed whether
before or after the concrete has set, the making good of the concrete shall be
subject to the Engineer's Representative's approval. The removal of the blocks
or ties must not jeopardise the stability of the construction. If, with the approval
of the Engineer's Representative, the spacing blocks and construction ties are
allowed to remain in the concrete then they shall be of such material and of

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 21 SECTION 3 CONCRETE WORKS

such quality that they do not prejudice the strength of the work. Concrete
spacing blocks shall be made of concrete at least equal in quality to the main
concrete. Metal ties shall be positioned such that they do not come into contact
with any of the reinforcement or fittings and no part of the tie shall be
permanently embedded in the concrete nearer than 5 cm to the exterior
surface of the concrete.

All holes shall be filled with 1:2 cement mortar.

3/13.3 SLAB FORMS

Where timber is used for the soffits of slabs, the boards shall be placed and
laid perfectly true with close joints to prevent the percolation of liquid or fines
from the concrete. Tongue and groove planks shall be used if specified. All
requisite bearer and struts shall be adjusted in position and placed where
necessary on bearers as specified in the case of beam forms.

3/13.4 TYPE OF FORMWORK

3/13.4.1 Exposed Concrete Faces for Bridges

All concrete faces shall be left as struck with a fair face, true to line finish.

In order to have the finish as it will be formed, approved by the Engineer, test
pieces of 1 sq.m vertical panel 25 cm thick shall be cast. After approval they
shall be retained in position until the concrete works have been completed then
they shall be demolished and removed from the Works.

After careful inspection, all superfluous fines and similar projections shall be
carefully removed. No render or other applied finish shall be used to obtain a
fair face to the concrete. All concrete faces to be exposed in the finished works
shall be adequately protected against damage and surface staining during the
execution of the Works.

3/13.4.2 Sawn Formwork

Shall be used for all culverts.

3/13.5 PREPARATION OF FORMWORK FOR CONCRETING

Immediately before the concrete is deposited, the formwork shall be thoroughly

cleaned out and freed from sawdust, shavings, wire cuttings, dust, sand, clay
and all other deleterious and extraneous materials. Temporary openings shall
be provided in the formwork to facilitate this work. The inside surfaces of the
formwork shall, immediately prior to final erection, be coated with mould oil.
The mould oil shall be of approved type and shall be applied uniformly and the
quantities used shall be the minimum consistent with its purposes. The
Contractor shall ensure that all steel reinforcement and adjoining concrete
surfaces are kept free of mould oil.

All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.

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 22 SECTION 3 CONCRETE WORKS

3/13.6 APPROVAL OF FORMWORK BEFORE CONCRETING

The Contractor shall in all cases request the approval of the formwork by the
Engineer's Representative in sufficient time to allow an inspection to be made
and shall not commence concreting until such approval is obtained. The period
between the Contractor's request for approval and his intention to commence
concreting shall be not less than one clear normal working day and the
Engineer's Representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.

Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

3/13.7 REMOVAL OF FORMWORK

All formworks shall be struck without jarring the concrete or subjecting the
same to sudden shock.

Before striking any formwork, the Contractor shall satisfy himself that the
concrete is sufficiently hardened to bear its own load and any other loads that
may be placed on it.

No formwork is to be removed, if in the opinion of the Engineer's

Representative, the concrete has not set sufficiently. approval of the Engineer's
Representative shall not absolve the Contractor of his responsibilities under the
Contract.

Subject to the above and the concrete test cube results, the minimum periods
for the removal of formwork generally are as follows:

Sides of beams, walls and columns - 2 days

Soffits of beams and slabs (props left in) - 7 days
Removal of props (beams and slabs) - 14 days
Soffits of precast beams - 7 days

(These times may be reduced only with the written approval of the Engineer)

In the case of the special types of formwork, striking times are to be approved
by the Engineer.

If a beam slab is required to support a construction load in excess of its design

load, the beam or slab is to be propped until the supported construction has
reached the age when the propping may be removed.

No supports for the shuttering may be left in the finished concrete without the
written permission of the Engineer.

3/13.8 CONCRETE BELOW GROUND

All concrete placed below ground level shall have a minimum protection to its
outside faces with a bituminous membrane as per Clause 9/2.1.2 of this
Specification.

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 23 SECTION 3 CONCRETE WORKS

3/14 READY MIXED CONCRETE

3/14.1 COMPLIANCE WITH SPECIFICATION

The use of concrete delivered to the Site in a plastic condition and ready for
placing in its final position shall be permitted subject to the following
conditions:-

(a) The constituent materials and the concrete mix shall comply with the
requirements of this Specification.

(b) The concrete shall be produced in accordance with the standards laid
down in the current edition of the "Authorisation Scheme for Ready Mixed
Concrete", published by the British Ready Mixed Concrete Association
(B.R.M.C.A.), except that
(i) Para. 11.1 (i) of the above publication shall be replaced by item (d)
below.
(ii) Water shall be added to the mix under the control of the central
batching plant.
(iii) Dry batching with water added on site will not be permitted.

(c) The concrete shall be supplied by a depot approved by the Engineer and
Dubai Municipality.

(d) The concrete shall be placed in its final position and left undisturbed
within 1-1/2 hours maximum of the time when the cement first comes into
contact with wetted aggregates, ie. the time when hydration of the
cement commences. If the temperature is less than 4C or if the
temperature is above 21C, this period shall be reduced to one hour.

3/14.2 DOCUMENTATION

The Engineer shall receive copies of the delivery tickets for each batch of
concrete, and have access to a site record book maintained by the Contractor
in which the following information is recorded for each batch of concrete
delivered:-

(i) Delivery ticket number.

(ii) Slump of the concrete, testing on site immediately prior to placing.
(iii) Time when concrete is placed in position and left undisturbed.
(iv) Location that the concrete is placed.
(v) Works test cube reference.

3/15 REINFORCEMENT STEEL

3/15.1 GENERAL

This work shall consist of furnishing, fabricating and placing steel

reinforcement bars of the grade, type, quality, size, shape and quantity

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 24 SECTION 3 CONCRETE WORKS

designated, all in accordance with these Specifications and the details shown
on the Drawings.

The Contractor shall be responsible for furnishing reinforcing steel in sufficient

quantity and of the proper sizes, lengths and shapes shown on the Drawings
for any given structure.

3/15.2 MATERIAL SPECIFICATIONS

All reinforcement bars shall be of a deformed type in accordance with BS 4449,

except that plain bars may be used where specifically indicated on the
Drawings. Plain bars shall be in accordance with BS 4449.

All steel reinforcement shall conform to the requirements of the Specifications

for Deformed High Yield Steel Bars, Grade 460 Type 2, unless otherwise
shown on the Drawings or specified by the Engineer and shall be tested as per
BS 4449 : 1997.

Mild steel where specified or called for shall be either deformed or plain bars
complying with ASTM A615 structural grade or BS 4449 or any equivalent
National Standard as directed and approved by the Engineer.

Tying wire shall be No.16 gauge soft annealed iron wire or No. 18 gauge
stainless steel wire or the equivalent AASHTO specification for tying wire.

Welded wire fabric shall be used as reinforcement for concrete where shown
on the Drawings and as directed. Welded wire fabric shall conform to the
requirements of AASHTO M55 or to BS 4483.

All reinforcement shall be protected against corrosion with a fusion-bonded

epoxy coating in accordance with the requirements of ASTM A775/A775M and
BS 7295.

The Contractor shall be responsible for obtaining the Engineer’s approval to the
steel bars prior to coating commencing. Such approval will in no way relieve
the Contractor of his responsibilities under the Contract.

The Contractor shall furnish to the Engineer a certificate of compliance for each
shipment of coated steel bars. The certificate of compliance shall state that
representative samples of the coated bars have been tested and that the test
results comply with the requirements of the Specifications.

3/15.3 CONSTRUCTION OF REINFORCEMENT

Steel reinforcing shall be stored on timber packing clear of the ground. The
steel bars shall be free from sharp deformations, rolled-in silvers, deep
recesses or surface faults/blemishes which could result in inefficient or
inadequate coating. When fixed in the work and immediately prior to
concreting, steel reinforcing shall be entirely free from loose mill scale, loose
rust, oil, grease, paint, mould oil, and all other deleterious and extraneous
material. All hooks, bends, etc., unless otherwise shown on the Drawings shall
be to BS 4466.

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 25 SECTION 3 CONCRETE WORKS

Before ordering reinforcing steel, the Contractor shall prepare bar bending
schedules at his own cost and submit them to the Engineer for his approval.
Bar schedules shall show the weight of each bar, the total weight of each bar
size and the total weight of bars, and bending diagrams for bars in accordance
with BS 4466. The length of each bar shall be calculated in accordance with
BS 4466 except that the minimum internal bending radius shall be four times
the bar diameter.

The Contractor shall also provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of bar bending schedules or for the completion of
the Works.

The Engineer’s approval of the Contractor’s working drawings and bar bending
schedules shall in no way relieve the Contractor of responsibility for the
correctness of such drawings or schedules.

Steel reinforcement shall be bent accurately to the shapes and dimensions

shown on the approved bar bending lists or drawings. Bars shall be bent round
mandrels of the requisite diameter.

Steel reinforcement shall be cut and bent in accordance with BS 4466. Cutting
or bending by the application of heat is not permitted. Welding of
reinforcement shall only be permitted when approved in writing by the
Engineer. If such approval is given then the workmanship shall be in
accordance with BS 5135. The Contractor shall submit full technical details of
his proposed procedures prior to seeking approval.

Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.

Links, hoops, stirrups are generally to be bent round pins of the same diameter
as the bars they are to embrace. Where however, such bars are less in
diameter than twice the diameter of the link, the radius of the bend shall be
equal to the diameter of the link.

3/15.3.1 Placing Reinforcement

The number, size, form and position of all reinforcement shall, unless
otherwise directed or authorized by the Engineer, be strictly in accordance with
the Drawings. Nothing shall be allowed to interfere with the disposition of the
reinforcing bars. Bars generally must be of the required lengths. Welding of the
bars will not be permitted. Lapping of the bars other than the lap splices shown
on the Drawings should be avoided. The Engineer may approve certain
lappings under special conditions. All lappings should comply strictly with the
AASHTO specifications, namely Article 1/5.6. Clause "c".

The steel reinforcement shall be firmly held in position by wire ties and
concrete blocks or other approved spacers designed to maintain the correct
clear cover of concrete over steel reinforcement. They shall be as small as

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 26 SECTION 3 CONCRETE WORKS

possible consistent with their purpose, and of a shape acceptable to the

Engineer. Minimum cover to reinforcement shall be 50 mm unless otherwise
detailed. The position of spacers and their method of use shall be approved by
the Engineer. The steel reinforcement shall be so connected as to form a rigid
cage.

All intersecting bars shall be bound together with No.16 gauge soft iron wire
with the ends of the wire turned into the main body of the concrete.

3/15.3.2 Maintaining Reinforcement in Position

Concrete distance blocks shall, unless otherwise directed, be used between

the reinforcement and the bottom and sides of the forms to ensure correct
placing and cover of the bars. The strength of such concrete distance blocks
shall be not less than that of the main concrete. The greatest care shall be
taken to prevent any displacement or bending of the members of the
reinforcement adjusted and temporarily fixed in position before commencement
of the concreting. Reinforcement temporarily left projecting from the concrete
at construction of other joints shall be adequately protected against
displacement both during concreting and afterwards and shall not be bent out
of position unless agreed by the Engineer's Representative. During the
concreting competent steel fixer shall be in attendance to re-set any
reinforcement inadvertently displaced.

3/15.3.3 Approval of Reinforcement Before Concreting

The Contractor shall in all cases request the approval of the Steelwork by the
Engineer's Representative in sufficient time to allow an inspection to be made
and shall not commence concreting until such approval is obtained. The period
between the Contractor's request for approval and his intention to commence
concreting shall not be less than one clear normal working day and the
Engineer's Representative may require a longer period if, in his opinion, the
reinforcement is of such complexity as to require it.

Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

3/16 PRECAST CONCRETE KERBS, EDGINGS & QUADRANTS

Precast concrete kerbs and edgings shall be hydraulically pressed and they
and precast concrete quadrants shall comply with the requirements of BS
7263: Part 1 and to the dimensions and shapes shown on the Drawings and/or
as directed by the Engineer. They shall be Class B concrete with sulphate
resisting cement as indicated in Clause 3/2.7 of this Specification. They shall
be uniform in colour free from cracks, flaws or other defects with well defined
arises.

The kerbstones shall be 900 mm long or as directed by the Engineer's

Representative. Samples of kerbstones proposed to be used shall be
submitted to the Engineer for his approval prior to order or manufacture.
Kerbstones shall not be used before they have been inspected and approved
by the Engineer. They shall be fully cured when delivered to site (28 days
min.).

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 27 SECTION 3 CONCRETE WORKS

Kerbstones shall be laid on concrete Class C bedded on 1:3 sand cement

mortar as specified and/or as directed by the Engineer. All kerbstones shall be
well bedded and settled in place true to line and level with a suitable wooden
mould. Before kerbstones shall be approved it should be ensured that their top
surfaces are in a uniform plane and their front faces are in correct alignment.
Any kerbstones not satisfying these requirements or having cracked or broken
arises or faces shall be removed and replaced or reset as instructed by the
Engineer.

Joints between kerbstones shall be not less than 3 mm nor greater than 5 mm
in width and shall be uniform from top to bottom. Joints shall be left open.

Where precast kerbs of straight section are laid to form radii, joints should be
filled with non-shrinkage mortar, and expansion joints (using flexel or similar
joint filler) shall be provided at 3 m centres. For radii of 10 m or less quadrants
shall be used. Kerbs of a reduced size shall only be used for this condition
where approved by the Engineer.

Tolerance in top level of kerbstones and horizontal alignment shall be  3 mm.

All kerbstones shall be painted alternately black and white. The paint shall be
an approved concrete paint giving a nominal thickness 100 microns in two
applied coats.

Transverse strength and Water Absorption shall be in accordance with BS

7263: Part 1.

3/17 IN-SITU CONCRETE EDGING

In-Situ concrete edge strips shall be to the cross section shown on the
drawings and the class of concrete made with sulphate resisting cement
indicated thereon in accordance with Clause 3/2 of this Specification.

The edge strip shall be formed in as long lengths as possible and the form
work shall be set on the top surface of the sub-base, set to produce the line
and level in accordance with the requirements of this Specification. Care must
be taken to ensure that the top surface is carefully finished to achieve these
requirements and to provide the control of the wearing course. Expansion joints
will be provided with an approved joint filler at maximum 3 m centres as shown
on the drawing and/or as directed by the Engineer. The kerb shall be protected
against covering or splashing by bitumen or cement.

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 1
SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

TABLE OF CONTENTS

4/1 PIPE MATERIALS ........................................................................................................................ 2

4/2 STORAGE AND HANDLING OF PIPES ............................................................................. 11
4/3 GRANULAR MATERIAL FOR PIPE BEDDING ................................................................ 12
4/4 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION .......................... 14
4/5 PIPEWORK WITHIN STRUCTURES .................................................................................. 26
4/6 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES ........................................ 27
4/7 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS ................ 31

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 2
SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

4/1 PIPE MATERIALS

4/1.1 PIPE CLASSIFICATIONS AND PRESSURE RATINGS

For structural purposes, pipes shall be classified into two groups:-

Group A: Rigid pipes which do not depend on lateral support from the bedding
and trench sides for structural strength.

Pipe materials include:-

o Concrete
o Clayware
o Pitch Fibre
o Grey Iron

Under no circumstances shall pipes containing asbestos fibres be

incorporated into any works.

Group B: Flexible pipes which depend on lateral support from the bedding and
trench sides for structural strength and to prevent distortion.

o Pipe materials include :-

o uPVC (unplasticised Polyvinyl Chloride)
o HDPE (High Density Polyethylene)
o PP (Polypropylene)

Pressure pipes shall be supplied to the following rated pressure

classifications:-

uPV 12 bar (12 bar rated uPVC pipes used to allow for temperature
derating).

4/1.2 JOINT REQUIREMENTS AND LIMITATIONS

Unless pipes are detailed with rigid joints or are specified differently all
pipelines shall be jointed with approved mechanical, flexible joints with
elastomeric joint rings. The whole joint assembly shall be compatible with the
pipe construction, the surrounding environment, specified performance of the
completed pipeline and the specified performance of the completed pipeline.

4/1.2.1 Flexible Joints

Flexible joints shall be as a separate sleeve coupling and double spigot

assembly with two sealing rings.

Elastomeric joint sealing rings shall be manufactured to EN-681-1 from

ethylene propylene rubber (EPDM) and shall have a hardness measured in
International Rubber Hardness Degrees (IRHD) compatible with the pipe
material.

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 3
SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

NOTE: The standard EN-681-1 “Elastomeric seals. Materials requirements for pipe
joint seals used in water and drainage applications-Part 1: vulcanized rubber”
Modified by:

NF EN 681-1/A1:199903 (T47-305-1/A1),

NF EN 681-1/A2:200302 (T47-305-1/A2),
NF EN 681-1/A3:200512 (T47-305-1/A3'

Deflection: The completed joint shall be capable of accepting the

following ranges of deformation (Table 4-1) when subjected to
internal pressure without losing its seal at the specified test
pressure, without direct contact between spigot and
socket/coupling and without inducing stresses or strains in the
pipe material beyond the safe working limits.

Table 4 - 1 Minimum allowable angular deflection for flexible joints

Pipe Material Pipe Diameter (mm) Angular Deflection
(Degrees)

All materials up to 200 3

(except concrete Over 200 to 500 1.75
and clay pipes) Over 500 to 1350 1
Over 1350 0.5

Straight draw: Not less than 10 mm or the following proportions of the

length of the longest pipe/unit at any joint:

1% for polyethylene pipes

0.5% for polypropylene, polybutylene or ABS pipes.

0.3% for GRP and uPVC pipes

Shear: Pipe materials which are listed in structural Group A shall be

loaded to 10 times DN (mm) in newtons in accordance with
BS EN-512. Pipe materials which are listed in structural
Group B shall be subjected to a load of 17.5 N/mm of pipe
diameter in accordance with ASTM D-4161.

If the approved standard for a pipe material does not include

a shear test for the jointing system, this test shall be carried
out in accordance with test procedure of another appropriate
pipe material standard.

4/1.2.2 Flanged Joints

Flanged pipes shall incorporate an annular gasket at the Joints and these
gaskets shall be manufactured to BS EN 1514-1, 2, 3 and 4: 1997 from
ethylene propylene rubber (EPDM) 3.0 mm thick and shall be dimensioned to
full face of the pipe flange and to suit the flange drillings. The hardness of the
rubber (IRHD) shall be to the manufacturer's recommendations to suit the
pipe material but for pipe materials in Group A shall be in the range 66 to 75.

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4/1.2.3 Flange Adaptors

The adaptors shall be manufactured from rolled steel or approved material

with an approved coating and be capable of withstanding the pressure tests
of the pipeline in which they are incorporated. The adaptors shall
accommodate a deflection at least 3o between adjacent pipes in any direction
and they shall be capable of accommodating a movement of 10 mm between
the ends of pipes they connect.

The adaptors shall be protected as stated in Clause 4/4.12.2. The adaptors

shall be jointed as instructed by the manufacturer.

4/1.2.4 Bolted Couplings

Bolted couplings shall be flexible couplings and shall be capable of

withstanding the pressure tests of the pipeline in which they are installed.
They shall also be capable of accommodating the deflections and movements
specified for flange adaptors.

4/1.2.5 Nuts and Bolts

All bolts, nuts and washers shall be of stainless steel grade 320S17 to DIN
17440:1.4571 and shall remain unpainted. PTFE washers shall be fitted
beneath stainless steel washers for both bolthead and nut.

4/1.2.6 Shipping and Handling

All elastomeric joint sealing rings and gaskets for flanged pipes shall be
supplied and transported in light proof packaging so as to prevent damage
due to ultra violet radiation. The Contractor shall provide suitable storage
facilities to prevent ultra violet exposure until use.

4/1.3 REMOVED

4/1.4 UNPLASTICISED POLYVINYL CHLORIDE PIPES AND FITTINGS (UPVC)

uPVC non-pressure pipes and fittings shall be manufactured and tested to BS

4660 for pipes upto and including 160 mm diameter and BS 5481 for pipes
greater than 160 mm diameter; and to BS 3505 for pressure pipes.

uPVC pipes and fittings shall be installed in accordance with the

manufacturer's guidelines. Pipes shall be BS kite marked.

uPVC pipes shall be capable of withstanding ultraviolet degradation. A rodent

inhibitor shall be incorporated in the material of the pipe. Pipes shall be
manufactured with integral flexible rubber ring joints.

uPVC pipes for gravity pipelines shall have a standard dimension ratio, D:t
(diameter to thickness), of between 35 and 45.

The Contractor shall advise the manufacturer of the climatic and transporting
conditions at the site of the works and shall seek his advice on the storage of
uPVC materials on site. Subject to the Engineer's approval this advice shall
be followed at all times.

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Any pipes exhibiting cracks, notches or deep scratches or other damage will
be condemned and shall not be incorporated into the permanent work under
any circumstances.

4/1.5 UPVC PIPES FOR LAND DRAINS

Pipes for slotted land drains/slotted carrier drains shall be uPVC pipes. Prior
to perforation, the basic pipe shall be manufactured to BS 4660 and BS 5481,
kite marked, and shall comply with the requirements of Clause 4/1.4 of this
specification relating to uPVC pipes for non-pressure application. The slots
shall be designed to give at least the minimum infiltration rates laid down in
BS 5911: Part 114. The final configuration of the slots shall be subject to
approval by the Engineer.

The slots shall be cleanly machine cut and be not less than 3 mm or greater
than 4 mm in width. The slots shall be in one 180 segment of the barrel in
one or more longitudinal rows, the slots in each row being spaced
equidistantly. Where more than one row of perforations are provided the slots
shall be staggered. No slots shall be nearer to the ends of the barrel than the
spacing between two adjacent slots. The spacing between slots in any row
may vary up to  20 mm.

The minimum cross-sectional area of the perforations, at the inside surface of

2
the pipe barrel, shall be 2700 mm per metre run of pipe but shall not affect
the structural integrity of the pipe. Care must be exercised to prevent impact
damage when placing stone surround and during backfilling operations over
the pipes.

4/1.6 GLASS REINFORCED PLASTIC PIPES AND FITTINGS (GRP)

4/1.6.1 General

Pipe manufacturers must be members of, or affiliated with, a quality control or

certification authority relevant to the pipes or fittings proposed for
incorporation in the Works. ISO 9001 certification is required for pipe
manufacturers.

GRP pipe and fittings shall be manufactured in accordance with BS 5480.

Resins shall comply with BS 3532: 1990 or ASTM D1763: 2000 (2005). GRP
pipe and fittings shall be at least adequate to achieve a minimum working life
of 50 years under all applicable loading, environmental and installation
conditions. The pipes and fittings shall be designed to withstand up to 5%
long term deflection in their installed conditions.

GRP pipe and fittings shall be supplied with a rated pressure of 6 bar for
o
gravity pipes and shall be suitable for service temperatures at least 50 C.

GRP pipe and fittings shall be composite laminate consisting of a corrosion

resistant inner liner, a structural layer and an exterior layer as follows:

1. The resin-rich inner liner shall have a minimum thickness of 1.5 mm,
consisting of ‘C’ glass veil backed with chopped strand ‘ECR/ADVANTEX’
glass fibreall impregnated with vinylester resin.

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2. The structural layer shall be reinforced with ‘ECR/ADVANTEX’ glass

impregnated with isophthalic resin but a vinylester resin may be used
throughout. Silica sand may be included as a stiffener agent.

3. The exterior resin-rich layer shall have a minimum thickness of 1.0 mm

consisting of ‘C’ glass veil impregnated with isophthalic or vinylester
resin.

Silica sand aggregates as defined in BS EN 14364+A1: 2006: AMD, 2009 &

BS EN 1796: 2006+A1: AMD, 2009, shall contain no impurities. Fillers as
defined in BS 5480: 1990 shall not be used. The silica sand content of the
pipe material shall not exceed 50% in accordance with the test type submitted
for approval.

The resin shall be cured to reach a hardness not less than 90% of the resin
manufacturer's recommended hardness using a prescribed test.

A manufacturer's tolerance of ± 1.00% shall be allowed on the nominal

diameter of the pipe. The pipes shall be supplied in standard lengths of 3, 6
or 12 metres with a tolerance of ± 25.00 mm. The deviation from straightness
of the bore of the pipe shall not exceed 0.30% of the effective length or 15.00
mm whichever is smaller and shall apply when measured on site. Up to 10%
of the pipes will be allowed in random lengths.

The ellipticity of any pipe when measured resting freely on the ground shall
not be more than 2% of the mean diameter at any point. No pipe known to
have undergone a deflection greater than 7% shall be incorporated into the
Works.
2
Stiffness shall be minimum 5000 N/m for all pipes but for pipes to be used in
pumping stations and valve chambers the stiffness shall be minimum 10,000
2
N/m and pipes for use in microtunnelling or similar jacking operations the
2
stiffness shall be minimum 50,000 N/m unless enclosed in concrete.

The hoop flexural modulus shall be demonstrated by application of the

following equation:

Stiffness of the pipe = EI/D3

Where: E = bending modulus of pipe wall

Circumferentially (in N/m2).

I = moment of inertia of pipe wall per

unit length (in m4.m)

D = nominal pipe diameter in metres

Calculations shall be provided to show that the proposed form of pipe

manufacture will give the specified physical properties identified in this
specification.

Pipes shall have a resistance to longitudinal tensile force per unit of

circumference as under (Table 4-2):-

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Table 4 - 2 Resistance to longitudinal tensile force

Nominal Diameter (mm) Initial Ultimate Resistance (N/mm)
up to 700 100
700 to 1,000 120
1,000 to 1,600 160
1,600 to 2,400 250
2,400 to 4,000 300

When subjected to a parallel plate loading test no evidence of crazing or

cracking shall be evident with a deflection of 10% and no structural failure
with a deflection of 20%.

Evidence from the manufacturer shall be provided of the satisfactory

completion of the "strain corrosion test" on a sample of pipe representative of
those to be supplied together with an assurance that such tests are
continuing. Testing shall be in accordance with BS 5480 or ASTM D-3681.
The appearance of blisters, delamination, wicking or any other structural
degradation of the test sample will constitute failure of the test
notwithstanding the wording of the standard test procedure.

The jointing system shall be an approved coupling system. Where the system
involves separate reinforced plastic couplings of sockets formed by a lay-up
process subsequent to pipe production, the resins used shall be clear and
non-pigmented to permit visual examination within the laminate.

Where GRP laminate is cut, exposed ends shall be sealed with a suitable
resin and approved prior to incorporation into the Works. Where such cutting
and sealing takes place at site the resins used and the methods of storage,
mixing, application and curing shall be strictly to the manufacturer's
recommendation. Before any such work takes place the manufacturer's
representative shall visit the site to demonstrate and give clear procedural
advice to the Contractor in the presence of the Engineer.

GRP pipe and fittings shall be as uniform as commercially practicable in

colour, opacity, density, and other physical properties.

GRP pipe and fittings shall be smooth and both the internal and external
surfaces shall be clean and free from delaminations, cracks, bubbles,
pinholes, pits, blisters, foreign inclusions and resin-starved areas that due to
their nature, degree or extent detrimentally affect the strength and
serviceability of the pipe.

Unless authorized by the Engineer, repair will not be permitted on any pipes
with defects as listed below and such pipes shall not be incorporated into the
works:-

(1) A scratch of greater depth than 0.30 mm.

(2) Cracks of any type on the inside of the pipe.
(3) Cracks on the outside, longer than 200 mm circumferentially or 6
mm longitudinally.
(4) Delaminations.

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(5) Damaged ends including bubbles, cracks, voids, exposed

reinforcement or extraneous matter.
(6) Internal protruding fibres.
(7) More than 25% of the external area with protrusions of any sort.
(8) Air voids and blisters exceeding 5 mm diameter or 1 mm in depth,
greater in area than 0.50% of internal or 1.00% of external surfaces.
(9) Pitting to more than 5% of the internal or 10% of the external surface
area and individual pits more than 1 mm diameter or 0.5 mm in
depth.

(10) Wrinkles over than 3% of the surface area and individual wrinkles
more than 2 mm deep.

4/1.6.2 GRP Pipes and Fittings for Pumping Stations and Valve Chambers

The design of GRP pipe and fittings for pumping stations and valve chambers
shall incorporate all the requirements of these specifications except for the
following over-riding or supplemental stipulations.

GRP pipe and fittings inside pumping stations and chambers shall be
designed for use above ground with no thrust blocks and shall have sufficient
axial strength to resist end thrust, temperature and bending stresses.
2
GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m and
a minimum wall thickness of 10 mm.

The design working pressure for pipes and fittings shall be 10 bar and the
service temperature shall be 70°C. A minimum surge allowance of 40%
above the working pressure shall be included in the design of pipes and
fittings. Copies of the design calculations shall be submitted to the Engineer
for approval. The basis of design shall be checked by conducting 'type' tests
on representative sample(s) of manufactured materials, in accordance with
the requirements in BS EN 14364+A1: 2006: AMD, 2009 & BS EN 1796:
2006+A1: AMD, 2009 or ASTM D-2992: 2006.

The wall of the pipes and fittings shall be made up of:

1. A resin-rich inner liner of 1.5 mm minimum thickness, consisting of ‘C’

glass veil, and 'ECR/ADVANTEX' glass and impregnated with vinylester
or epoxy resin.

2. The structural layer consisting of ‘ECR/ADVANTEX’ glass reinforcements

impregnated with vinylester or epoxy resin. Silica sand shall not be used.

3. An exterior resin-rich layer of 1.0 mm minimum thickness reinforced with

a ‘C’ glass veil and impregnated with vinylester or epoxy resin.

No dark pigments, sand or aggregate fillers shall be used for pipes and
fittings. Ultra Violet stabilizers shall be incorporated in the pipe and fitting
construction.

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GRP pipe and fittings for pumping station and valve chamber pipework shall
have a suitably designed restrained joint capable of withstanding the design
operating pressure with no leaks and without the use of thrust blocks.

The acceptable jointing system shall be GRP flanges. GRP flanges shall be
machine filament wound using 'E' or 'ECR/ADVANTEX' glass fibre
reinforcements and vinylester or epoxy resin. Hand layed up flanges shall not
be permitted. Flanges shall be drilled to BS 4504: 1989 (metric units) type PN
10.

4/1.6.3 Factory Testing

The following tests shall be carried out on manufactured GRP pipe and fittings
at the intervals specified. Test methods shall be in accordance with BS EN
14364+A1: 2006: AMD, 2009 & BS EN 1796: 2006+A1: AMD, 2009 or ASTM
equivalent. Witnessing of factory testing by the Engineer's Representative will
be required prior to delivery of the material. Copies of the Manufacturer's test
reports shall be submitted to the Engineer after each consignment of pipe or
fittings delivered to the site.

All GRP standard pipe and pipe used for fitting fabrication shall be factory
pressure tested to 20 bar for pressure pipes and 12 bar for non-pressure
pipes.

The following tests shall be conducted on all GRP pipe and fittings:

- Dimension measurements (Wall thickness, Diameter, Length)

- Visual inspection

- Barcol Hardness (Resin Cure)

Mechanical property testing shall be conducted on 1% of GRP pipe and

fittings produced.

Other tests for quality assurance shall be carried out on representative

sample(s) as required by BS EN 14364+A1: 2006: AMD, 2009 & BS EN 1796:
2006+A1: AMD, 2009 or ASTM equivalent.

4/1.6.4 Installation

GRP pipe and fittings shall be installed in accordance with the manufacturer's
written instruction. A field representative of the manufacturer shall be made
available as and when required during the installation of the GRP pipe and
fittings. All flanges shall be tightened in accordance with the Manufacturer's
written instructions using a torque wrench.

4/1.7 POLYETHYLENE PIPES (HDPE OR HPPE)

4/1.7.1 General

Polyethylene (PE) pipe, either high density polyethylene (HDPE) or high

performance polyethylene (HPPE) pipe shall be manufactured to conform to
the requirements of CP 312 Part 1 and 3, and BS 6437: 1984 or DIN 8075:
2009. Where pipes are used for renovation work, pipes shall be of short lengths
or short length conforming to the requirements of the method selected and the

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available working space in the manholes or drive shafts. Longer lengths may be
used for new installation where conventional open trench methods of
construction are employed.

The base polymer shall be polyethylene with a derived density greater than 930
kg/m3 when determined in accordance with the method required by BS 3412.
The base polymer shall be blended with additives that are necessary for the
manufacture, storage and use of PE pipes for sewer lines, including
antioxidants, carbon black and UV stabilizers.

The material in pipe form shall have a thermal stability of at least 15 minutes
when tested in accordance with the isothermal method for differential thermal
analysis.

The ovality of pipes up to and including nominal size 250 mm shall not exceed
0.02 the nominal size (mm). The ovality of pipes greater than nominal size 250
mm shall not exceed 0.035 the nominal size (mm). The ends of the pipe shall
be cut, cleanly and squarely, to within the following tolerances (Table 4-3):

Table 4 - 3 Pipe end cut tolerances

Nominal Size (mm) Maximum Out of squareness
180 - 225 4 mm
250 - 315 5 mm

The calculated 24 hour and 50 year creep modulus shall be not less than the
values given below in Table 4-4 when tested in accordance with either the
pipe ring in tension or the three point bend method.

Table 4 - 4 Short & long term creep modulus

Property Minimum Mean
Requirement
Short term flexural creep modulus (24hr) Es 350MPa
Long term flexural creep modulus (50yr) El 130MPa

The jointing system for polyethylene pipes and fittings shall be in accordance
with the pipe manufacturer’s recommendations subject to approval by the
Engineer.

4/1.7.2 Wall Thickness

The polyethylene (HDPE or HPPE) pipe shall be Type 50 i.e. shall be designed
to sustain a maximum working stress of 50 bar at 20°C. The wall thickness shall
be based on a nominal pressure rating (PN) of 10 bar.

When manufactured in conformity with BS 6437, the wall thickness of HDPE

pipe shall be as follows (Table 4-5):-

Table 4 - 5 Required wall thickness of HDPE pipes

Nominal Mean outside Wall thickness (mm)
Size diameter (mm) Individual values Av.values
(mm)
min. max. min. max. max.
180 180.0 181.2 16.4 18.9 18.3

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225 225.0 226.4 20.5 23.6 22.8

250 250.0 251.5 22.8 26.3 25.3
280 280.0 281.6 25.5 29.4 28.3
315 315.0 316.8 28.7 33.0 31.8

4/2 STORAGE AND HANDLING OF PIPES

4/2.1 GENERAL

Method Statements must be approved for the transportation, handling and

storage of pipes before any pipes are delivered to site.

All pipes shall be handled and stored in compliance with the manufacturer's
recommendations subject to the following limitations:-

Pipes shall be transported, handled and stored with such packing and in such
a manner that damage does not occur and that contact is avoided with sharp
edges which may cause damage. During transit, pipes and fittings shall be
well secured and adequately supported along their length.

At every point of loading or unloading, all pipes or castings must be handled

by approved lifting tackle unless specified elsewhere. Unloading by rolling
down planks or any other form of inclined ramp will not be allowed. Pipes
shall not be tipped or dropped.

Pliable straps, slings or rope shall be used to lift pipes, and steel cables or
chains will not be used without written permission.

Nesting of pipes for transportation shall be permitted provided method

statements demonstrate that effective precautions shall be taken to protect
inner surfaces from damage.

All pipes and fittings shall be thoroughly inspected on arrival at site after off-
loading and prior to installation for detection of any damages.

Damages to coatings, if any, shall be made good in an approved manner. For

other damages, proposals for repairs shall be submitted in writing for the
Engineer's approval. If in the Engineer's opinion the nature of any damage is
such that the condition of a pipe has been impaired and cannot be repaired,
the pipe concerned shall not be incorporated in the Works.

Suitably smooth and level storage areas shall be provided at or near the site
and made secure to prevent unauthorised access.

Pipes of different sizes and thickness shall be stocked separately.

4/2.2 GLASS REINFORCED PLASTIC PIPES (GRP)

When pipes are transported or stacked they shall be supported on cradles at

least 100 mm wide, conforming to the shape of the pipe placed at not more
than 3 metres centres. Pipes must on no account be stacked directly on the
ground but if individual pipes are placed on the ground prior to laying care
shall be taken to remove all rocks and any potentially damaging debris.

The number of layers in a stack shall not exceed the following (Table 4-6):

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Table 4 - 6 Maximum layers in stacked GRP pipes

Internal diameter of pipe Maximum number of layers
(mm)
Up to 500 5
500 to 700 3

The end pipes in each row shall be strapped to the battens. Pipes shall not
rest on their sockets.

4/2.3 THERMOPLASTIC PIPES

Pipes and fittings of plastic materials smaller than 300 mm diameter may be
handled manually and those equal or larger than 300 mm diameter shall be
lifted using a single fabric or large diameter rope sling. There shall be
enough slack in the sling to keep the hook at least 600 mm over the pipe.
Use of wire rope chains and fork lifts shall not be permitted.

Care shall be taken to prevent distortion of the pipes during transportation,

handling and storage. They shall be stacked either on bearing timbers on a
level surface staked to prevent movement, or in suitable racks. Not more
than two layers shall rest on the bottom layer, and for spigot and socket
pipes, sockets shall be at alternate ends so that no pressure comes on a
socket. Bearing timbers shall be spaced at not more than 1 metre and shall
be wide enough to prevent denting of the pipe wall. Sharp edges (e.g. of
metal) shall be avoided. Similar care shall be taken with pipes in transit.

Where shaped battens are used, they shall be at least 100 mm wide and
not more than 1.5 meters apart. The end pipes in each row shall be
strapped to the battens. The pipe shall not be stacked any higher than five
(5) layers.

All thermoplastic pipes shall be shaded/protected from direct sunlight during

handling, transportation, storage and laying.

The Contractor shall ensure that thermoplastic pipes do not come into
contact with bituminous or other hydrocarbon based materials.

4/3 GRANULAR MATERIAL FOR PIPE BEDDING

Granular material for pipe bedding shall be free-draining, hard, clean,

chemically stable gravel or crushed stone to BS 882: 1992 or approved glass
cullet which shall be graded in accordance with BS EN 12620: 2002 /A1,
2008 as shown in Table 4-7 below:-

Table 4 - 7 Grading of granular material for pipe bedding

Test Sieve Percentage by Weight Passing Sieve
( mm) For Pipe For Pipe Diameters
Diameters upto 600 400 mm and above
mm
63 - -
37.5 - -

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20 - 100
14 100 85 - 100
10 85 - 100 0 - 50
5 0 - 25 0 - 10
2.36 0- 5 -

Notes:

1) For pipes 400 mm to 600 mm diameter, either grading is acceptable

(BS 1377 Part 3:1990 AMD 9028:1996).

2) Total acid soluble content of the material when tested in accordance

with BS1377: Part 3: 1990 AMD 9028: 1996 shall not exceed 0.3
percent by weight of sulphate expressed as SO3 (sulphur trioxide).

3) The material shall have a Compaction Fraction value not exceeding

0.15.

4) For uPVC pipes only rounded aggregates will be permitted but for all
other pipe materials crushed aggregates may also be used.

4/3.1 STONE FOR LAND DRAINS

Stone for land drains shall be nominal single size 20 mm in accordance with
the limits listed in Table 4-8 or the manufacturer’s recommendations if
different, and placed as shown on the drawings. The stone shall also comply
with the general requirements of Clause 4/3.

Table 4 - 8 Grading of stone for land drains

Test Sieve Percentage by Weight Passing Sieve
(mm)
75 -
63 -
37.5 100
20 85-100
14 -
10 0 - 25
5 0- 5
2.36 -

4/3.2 Compaction Fraction Test

For testing pipe bedding material, a representative sample of about 40 kg shall

be heaped onto a clean surface and quartered to obtain approximately 10 kg.
The moisture content of the sample should not differ materially from that of the
main body of material, at the time of use in the trench.

A 150 mm internal diameter open ended cylinder 250 mm high, shall be placed
on a firm flat surface and loosely filled, without tamping, from the 10 kg sample.
Any surplus material shall be struck off level with the top of the cylinder. The

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area around the filled cylinder shall be cleared of all surplus material and the
cylinder then lifted clear of its contents and placed alongside the material.

Approximately one quarter of the material shall then be replaced into the
cylinder and compacted by tamping vigorously with a 40 mm diameter metal
rammer weighing about 1 kg until no further compaction can be obtained. This
operation shall then be repeated for each of the remaining quarters, tamping
the final surface as level as possible.

The distance from the top of the cylinder to the surface of final layer shall then
be measured and this value, divided by the height of the cylinder, shall be
taken as the Compaction Fraction.

4/4 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION

4/4.1 GENERAL

This section applies to conventional open-trench pipe works. Non-

conventional pipeworks have been detailed in Sections 14 and 16.

4/4.2 NOMINAL TRENCH WIDTHS

Nominal trench widths for single pipelines shall be defined as 1.50 times the
diameter plus 500 mm, subject to a minimum trench width of 750 mm.

Nominal trench widths for two or more pipes in the same trench (laid in
parallel with similar invert levels) shall be defined as the sum of the internal
diameters plus 450 mm between the pipes, plus 750 mm.

Any excavation from the bottom of the trench to 300 mm above the level of
the crown of the pipe which exceeds the nominal widths defined above shall
be filled with concrete or the specified bedding materials as directed on site.

A detailed method statement shall be submitted by the Contractor for

agreement by the Engineer to demonstrate an understanding of the correct
method of laying GRP and other pipes.

4/4.2.1 Pipelines in Wide Trenches

No wide unsupported trenches shall be permitted, in general, within the area

of the Works and therefore all trenches should conform to the minimum
trench widths stated above and shall be supported with the use of approved
trench sheeting or sheet piles. However in exceptional circumstances wide
trenches may be approved by the Engineer in which cases the following shall
apply:-

- Wide trenches shall be constructed to not less than the defined widths for
those categories of Group B flexible pipelines in granular bedding defined
below.

- Prior to commencing trench excavation in an area an assessment of the

Modulus of Deformation (E's) shall be made of the soils likely to be
encountered at springing level of the pipes. In non-cohesive soils,
approved static cone penetrometer tests shall be carried out prior to
excavation. In cohesive soils other approved methods shall be used to

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determine E's. Alternatively, standard penetration tests may be required

by the Engineer prior to excavation to suite pipe manufacturer’s standard
method of deflection and trench widths. Tests shall be carried out at
intervals to be determined on site which in variable ground conditions
may be to every pipe length.

- If the value of E’s determined from the results of such tests is greater than
2.5 MN/m2 then trench width is not critical. If less than 2.5 MN/m2 then
trench widths shall be constructed to the widths defined in Table 4-9
below unless alternative means of increasing the passive resistance of the
trench sides are detailed or are proposed in method statements where
economic or environmental restrictions make wide trenches undesirable.

Table 4 - 9 Wide trench widths for non-cohesive soils

Static Cone Modulus of Wide
TrenchWidths
Penetrometer
2
Test Deformation 2
(mm)
(Kg/cm ) E's (MN/m )
8.5 - 7.7 2.50 - 2.25 2.5 x dia.
7.7 - 6.1 2.25 - 1.80 3.0 x dia.
6.1 - 3.1 1.80 - 0.90 4.0 xdia.
<3.1 0.90 5.0 x dia.

Alternative solutions to wide trench conditions may be adopted including

increasing stiffness of the pipes used or encasing with concrete as agreed by
the Engineer.

4/4.3 PIPELAYING AND JOINTING

Pipes and fittings shall be laid and jointed in accordance with all relevant
recommendations of the manufacturer. Any variations between the
manufacturer’s recommendations and this specification shall be highlighted in
the Contractor’s Method Statements and a ruling will be given with the
Engineer’s agreement.

Pipes and fittings shall be checked for soundness and be thoroughly cleaned
out immediately prior to laying and jointing.

The setting of the pipeline to the required levels and alignment shall be
carried out by approved procedure such as boning between sight rails or the
use of laser systems. Sight rails, if used, shall be at a suitable height
vertically above the line of pipes or immediately adjacent thereto, and there
shall, at no time, be less than three sight rails in position on each length of
pipelines under construction to any one gradient. Large diameter pipes, 1000
mm diameter or greater, shall be individually set to level and line by
instrument.

For pipelines laid in trenches and headings the permissible tolerances in line
and level unless otherwise specified shall be ± 3 mm in level and ± 12 mm
from centreline between manholes or access points. Also where a gravity
pipeline or sewer is shown as a straight line between manholes it will not be
accepted as having passed the final test unless a full circular light can be
sighted through the bore of the pipe for the length concerned.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

For pipeline jointing systems incorporating flexible jointing rings pipes shall be
laid with a gap between the end of the spigot and the base of the socket, or
between spigots. This gap shall be not less than 6 mm or greater than one
third of the straight draw test dimension specified for the pipe joint or as
recommended by the pipe manufacturer, and it shall be achieved by approved
means, such as marking the outside of the pipe or using removable metal or
hardwood feelers.

The annular space between the pipe and the socket at a flexible joint shall be
sealed with an approved joint sealant to prevent the ingress of loose material
or concrete. Sealing shall be done on completion of a satisfactory preliminary
testing prior to concreting or backfilling, but not prior to the test.

For uPVC pipes solvent welded joints with parallel sockets shall not be
permitted unless made in the manufacturer's workshop.

Where flexible jointed pipes are laid to curves the angular displacement at any
joint as laid shall not exceed three quarters of the maximum recommended by
the manufacturer.

Flanged pipes shall incorporate an annular gasket at the joints. The gaskets
shall cover the full face of the flange and shall have holes cut in them
corresponding to the bolt holes in the flanges. However, in pipes fixed
vertically a plain ring covering the flange between the bolt circle and the bore
of the pipe may be used. Gaskets shall be manufactured as specified in
Clause 4/1.2.2.

When flanged joints are to be made the Contractor shall follow manufacturer’s
guidelines for the tightening of nuts and bolts.

The Contractor shall make sure that all joints are made strictly in accordance
with the manufacturer's instructions.

Pressure pipelines shall be secured at all changes in direction by concrete

anchor blocks or other means of restraint approved in advance by the
Engineer.

After laying a length of pipeline but before preliminary testing (specified in

Section 6) is carried out, the pipeline shall be checked for level and gradient
on top of the pipes. If a pipe is not at the correct level, it shall be unjointed and
removed, the bed shall be adjusted and the pipe shall be relaid and rechecked
for line and level. After the joint has been made and the preliminary testing
completed the annular gap at a socket or collar outside the flexible jointing ring
shall be closed with fine grained clayey soil or cotton waste to prevent the
entry of granular material.

Pipelines shall be temporarily capped when pipe laying ceases to prevent the
ingress of foreign matter. The Contractor shall ensure that the pipes remain
clean and free from obstructions, and if required by the Engineer, the pipelines
shall be cleaned out using approved methods and equipment which do not
damage the internal lining of the pipes and manholes.

4/4.4 PIPELINES IN CONCRETE CRADLES AND SURROUNDS

Where pipes are to be laid with a concrete cradle or surround they shall be
supported initially above the trench bottom on concrete setting blocks. The

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

blocks shall either be laid accurately to level and covered with damp-proof
sheeting beneath the pipe barrel or shall be provided with two hardwood
wedges each to an approved pattern to enable the pipe level to be adjusted.

The blocks and wedges shall be of sufficient size and strength to prevent
settlement of the pipes during laying and at least two concrete blocks shall be
provided for each pipe.

Concrete cradles and surrounds shall be of Class A. The concrete shall be

poured on one side of the pipe until it can be worked under the pipe along its
full length to ensure that no voids develop. The concrete shall then be brought
up equally on both sides of the pipe until the required level is reached.

The length of pipeline laid in any one operation before concreting the pipeline
shall be that which in the opinion of the Engineer permits accurate laying of the
pipeline and concreting in an efficient and proper manner.

Approved measures appropriate to the pipe material shall be provided to

prevent flotation or other movement during placement or curing of the
concrete.

Concrete cradles to pipes of all diameters and surrounds to pipes of one metre
diameter or less shall be poured in a single lift. Concrete surrounds to pipes
over one metre diameter shall normally be poured in two lifts, with a horizontal
joint not more than 100 mm below the crown of the pipe.

Concrete cradles and surrounds shall be interrupted over their full cross
sectional area at each pipe joint, by shaped expansion joint filler. The
thickness of filler shall be 18 mm for pipe diameter less than 450, 36 mm for
pipe diameter 450 to 1200 and 54 mm for pipe diameters greater than 1200.

In spigot and socket pipelines the joints in the bed shall be at the face of each
socket.

In all flexible joints the annulus of the pipe socket shall be sealed with an
approved sealant to prevent the concrete from entering the pipe joint.

When support to excavations is provided, building paper or an approved

material shall be placed against that support before concreting to facilititate
withdrawal of the support.

4/4.5 PIPELINES ON GRANULAR BEDS

Where granular beddings to pipelines are detailed the minimum thickness of

bedding material beneath the pipe shall be:-

 150 mm (minimum 100 mm under sockets) for pipes not exceeding

300 mm internal diameter.

 200 mm (minimum 100 mm under sockets) for pipes exceeding 300

mm internal diameter.

The time interval between placing bedding material on the trench formation
and commencing pipelaying shall be as short as is practicable.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

The bedding material shall extend to the full width of the trench and shall be
compacted in layers not exceeding 200 mm. The bedding material shall be
carefully compacted using a plate vibrator or other approved equivalent
mechanical method. Sufficient passes of a plate vibrator or other approved
mechanical method are required to achieve positive deflection of flexible pipes
to ensure that final deflections are within the specified limits. Hand tamping or
punning will only be permitted where insufficient space is available to allow the
use of mechanical plant.

Recesses shall be formed in the bedding to accommodate pipe joints while

ensuring continuous even support along the pipe length. Bedding material
shall be prevented form entering pipe joints. After the joint has been made
bedding material shall be carefully placed and hand compacted beneath the
joint barrel to close any void left by the recess.

Where the formation of the trench is of silt or soft clay and is below the natural
water table a 75 mm blinding layer of sand shall be substituted for the
specified bedding material directly above formation and carefully compacted if
directed on site.

4/4.6 PLACING SURROUNDS TO PIPELINES

In narrow trenches and where the Contractor's method of working involves the
use of trench sheets or other forms of trench support it is imperative that the
trench supports are carefully withdrawn to a point above the crown of the pipe
as the backfill material is placed to ensure that voids between surround and
trench side will be eliminated. Where the Contractor is instructed to leave
trench supports in place, the tops shall be burned or cut off.

4/4.6.1 Group A Pipe Materials

Except where concrete surrounds are specified or shown on the drawings,

either granular bedding material or approved selected excavated granular
material shall be introduced at both sides of the pipe and compacted until it
has been brought up to at least 150 mm above the crown of the pipe. The
methods of selecting excavated materials may include sieving either in bulk or
above the trench.

Wherever practicable the placing and compaction of the surround material

shall be carried out in sequence with the removal of the trench supports. In
particular trench sheets or boards shall be raised clear of each layer prior to its
compaction.

4/4.6.2 Group B Pipe Materials

Except where concrete surrounds are detailed Group B flexible pipelines shall
be laid with granular bedding and surround, as specified, to at least 300 mm
above the crown of the pipe.

4/4.6.3 Compaction of Pipe Surrounds

The granular material shall be carefully laid and compacted at the sides of
pipes according to one of the following methods listed in Table 4-10 for
alternative types of compaction plant as agreed with or directed by the
Engineer.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Table 4 - 10 Alternative methods for compaction of pipe surrounds

Surround Max.Layer Alternative Methods (Minimum Number
Material Thickness of Passes of Compaction Plant)
(mm)
Hand Vibrating 100 kg Power
Rammer Plate Rammer
Gravel 200 2 2 2
Sand 150 3 4 4

The Contractor must demonstrate that alternative methods of compaction will

provide positive deflection of flexible pipes during installation.

4/4.6.4 Pipelines below Permanent Groundwater Level

For Group A and B pipelines located beneath the permanent groundwater level
and for all slotted pipes any granular bedding material or approved selected
excavated granular material forming granular bedding and surround shall be
laid on and enclosed within a geotextile filter fabric membrane.

4/4.7 BACKFILLING OF TRENCHES - PIPELINES/STRUCTURES

After completion of placement and compaction of the surrounds to the

pipelines backfilling of trenches for pipelines shall proceed using selected
excavated materials in accordance with the specifications for earthworks.

The use of power rammers will not be permitted over any pipe until the depth
of fill above the crown of the pipe is at least 300 mm.

Services warning tapes shall be placed over the pipelines as specified in

Clause 4/4.15.

The backfill requirements for trenches around structures shall be the same as
that for pipeline except that compaction by mechanical means shall commence
from the formation level (to the specified densities).

4/4.8 DEFLECTION MEASUREMENTS ON GROUP B PIPELINES

4/4.8.1 General

All Group B pipelines will be subjected to in-situ deflection measurements. Any

section of pipe failing to meet the deflection criteria shall have its surround
material recompacted, such procedure being repeated until the in-situ
deflection is found to be satisfactory.

In the above paragraph deflection shall be considered as the maximum

difference between the measured in-situ diameter and the stated non-
deflected diameter on any axis divided by the non-deflected diameter.

For all pipes the horizontal and vertical deflections shall be measured at each
end at points 100 mm and 1.5 m away from the joint and at 3.0 m intervals
thereafter, or as directed by the Engineer. For pipe lengths of less than 3.0 m
these deflections shall be measured at each end at a point 100 mm away from
the joint and at the mid-point.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

For pipelines smaller than 600 mm diameter deflections shall be checked by

pulling through an approved cylindrical plug dimensioned to suit the
permissible minimum deflected diameter of the pipe.

Alternately, a deflectometer of a form that can be drawn through the pipeline

and be capable of measuring diametric dimensions both vertically and
horizontally may be used for deflection measurement of pipes of diameter less
than 600 mm. The deflectometer shall be calibrated for each diameter
regularly in the presence of the Engineer to maintain the accuracy of the
instrument. The device shall also provide a means of identifying where each
deflection measurement was taken along the length of a pipeline. This shall be
in the form of either a continuos printout or a visual display on a remote
monitor.

For pipes of 600 mm diameter and greater the device shall be in the form of a
telescopic spring loaded rod graduated for each diameter to show percentage
deflections.

The Contractor shall tabulate the results of the measurements and copies shall
be submitted to the Engineer immediately after each set of measurements has
been take

4/4.8.2 Deflection Measurements - GRP Pipes

The measurement shall be taken on at least three separate occasions:

1. After the pipe surround material has been placed and compacted to 300
mm above the pipe crown.

2. On completion of all backfill material up to final ground level but before the
dewatering is removed. This measurement shall be taken within one day of
completion of backfilling.

3. Immediately prior to the issue of a Certificate of Completion.

Pipes exhibiting any negative deflection in the vertical in (1) above and/or
pipes exhibiting a deflection in excess of 2% in (2) above or 4% in (3) above
shall be exposed and the surround replaced and recompacted. Should any
deflection exceed 7% that pipe shall be replaced. Any pipe removed for this
reason shall be taken from site and not incorporated in the permanent works.

All pipes exposed for recompaction and pipes replaced for any reason shall
subsequently be subject to the three deflection checks listed above.
Deflection checks shall also be carried out on adjacent pipes for 50 m either
side of the recompacted or removed pipes.

4/4.8.3 Deflection Measurements - uPVC and other Plastic Pipes

The measurement shall be taken on at least two separate occasions:

1. As soon as a pipeline has been installed, tested and the trench backfilled,
but before the dewatering is removed.

2. Immediately prior to the issue of a Certificate of Completion.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

If any of these tests indicate that the deflection may exceed the permitted
values the pipe or pipes shall be replaced. Any pipe removed for this reason
shall be taken from site and not incorporated in the permanent works.

All pipes replaced for any reason shall subsequently be subject to deflection
checks as described above. Deflection checks shall also be carried out on
adjacent pipes for 20 m either side of the removed pipes.

The permissible positive or negative deflections on the pipelines shall be as

follows (a reduction in the diameter is considered to be a negative deflection):-

 After Initial Installation 3%

 Long Term 5%

4/4.9 Stanks to Pipelines in Granular Bedding

Where pipes are laid on a granular bed or with a granular backfill, a stank, i.e.
an impermeable barrier, shall be provided across the full width of the trench
and for the complete depth of the bedding at intervals not exceeding 50 m,
and generally mid-way between manholes or chambers.

Stanks shall consist of:-

i. Either a 300 mm long plug of fine grained clayey soil or a 300 mm

long plug of a mixture of sand and bitumen consolidated in an
approved manner.

ii. Or a mixture of sand and clay or the local material known as sabkha
compacted to form an impermeable barrier at least one metre in
length.

iii. Or a layer of thick polyethylene cut to fit around the pipe across the
full width of the trench and laid on the granular bedding material at
its natural repose angle.

All methods must form an impermeable barrier. Bitumen shall not be used for
thermoplastic pipes.

4/4.10 Thrust and Anchor Blocks to Pressure Pipelines

Underground pressure pipelines shall be provided with concrete blocks as

follows:-

Thrust/anchor blocks shall be provided at every installed bend, tee or angle

branch.

Anchor/thrust blocks shall be provided on pipelines laid to gradients steeper

than 1:20, up to 1:15 every third pipe shall be anchored, up to 1:10 every
second pipe and at 1:5 every pipe shall be anchored.

Concrete shall extend to undisturbed ground on thrust faces of thrust blocks

and on both faces of anchor blocks.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Where details are not shown on the drawings the Contractor shall prepare
proposals for thrust and anchor blocks including calculations and submit them
to the Engineer's Representative for approval. Such approval shall not relieve
the Contractor of his responsibility for the adequacy of his proposals. Special
details shall be shown on the drawings or instructed at site where
environmental or ground conditions dictate.

4/4.11 Pipes Protruding from Structures,

Concrete Surrounds and Anchor Blocks

Unless otherwise detailed a pipeline at or below ground level protruding from a

structure shall have two flexible joints adjacent to the structure. A band of an
approved concrete encasement rubber shall wrap around the pipe prior to
placement of any concrete such that the rubber protrudes 25 mm from the
concrete.

The pipe shall be layed so the distance to first exposed flexible joint and the
distance between first and second joint are as follows (Table 4-11):-

Table 4 - 11 requirements for flexible joints for protuding pipes

Pipe Diameter Maximum distance Distance between
(mm) to first joint (mm) first and second joint (mm)
Min. Max.
Up to 300 150 450 2.5 * dia.
300 to 1000 300 1.5 * dia. 2.5 * dia.
above 1000 450 1.5 * dia. 2.5 * dia.

In the case of Group B pipe materials, particular attention will be placed on

elliptical deflection conditions.

These joints will be required at surrounds and anchor blocks unless directed
otherwise on site.

4/4.11.1 Group A Pipe Materials

Between the structure and the first joint any disturbed ground below the pipe
shall be removed and replaced with Class B concrete in the form of a cradle,
all to the direction of the Engineer. The cradle shall not extend beyond the first
joint.

Beyond the first flexible joint within the excavated working space of the
structure the concrete fill shall be brought up 300 mm below the pipe invert
only. Specified bedding materials will then be used.

4/4.11.2 Group B Pipe Materials

Within the excavated working space for the structure disturbed ground below
the pipe shall be removed and replaced with Class B concrete to within 300
mm of the underside of the pipe. Specified bedding materials will then be used
to support the pipe.

The width of the concrete backfill shall not be less than the nominal trench
widths except for any permanent shuttering against temporary trench supports
to facilitate removal of such trench supports after concreting.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Where a flexible pipe passes through a rigid concrete face to a structure or

surround the pipe shall be protected from stress concentration and possible
fracture of the pipe at the concrete face. A 10 mm thick neoprene or other
approved synthetic rubber strip shall be wrapped around and cemented to the
pipe unless special wall protection units are used.

The neoprene will normally extend through the width of a wall to a dry chamber
or structure but will be limited to 150 mm or 100 mm is exposed to liquid
(groundwater or liquid inside the structure) a sealant groove shall be formed if
detailed and filled with an appropriate, approved, joint sealant.

Care shall be taken to ensure that the rubber strip is not displaced during
concreting.

Where a pipeline protrudes from a concrete surround, no protection from

stress concentration will be required if the surround ends at a flexible joint
leaving the next pipe free. If the surround ends on a pipe barrel the specified
protection will be provided and, for pressure pipes only, the protruding pipe will
be wrapped from the edge of the neoprene strip along to the next flexible joint
at which the concrete surround is interrupted with an approved compressible
material such as damp-proof sheeting or building felt of minimum thickness
2 mm.

4/4.2 Protection of Pipelines and Pipeline Component

4/4.12.1 Pipelines

Protection of pipelines shall be in accordance with the manufacturer’s

recommendations which shall be included with submission details for
agreement by the Engineer. The minimum requirements are shown below:

Class A concrete protection slabs as detailed on the drawing shall be provided

over the uPVC pipelines under roads when cover to pipe is equal or less than
1.2 m for a gravity line; and for pressure line at any depth. In case of GRP pipe
concrete surround shall be provided as per drawing if the depth of cover is less
than 1.5 m and the pipeline lies within a strip of 20 m each side of the
centreline of the Road Corridor.

4/4.12.2 Pipeline Components

All buried valves, couplings, flange adaptors, and other metal components
shall be encased to guard against corrosion. Other pipe joints, valves and
similar items on both buried and exposed pipelines shall be encased where
specified or shown on the drawings.

The encasing shall be by one of the following methods, as detailed.

(1) Surrounding with Class B concrete.

(2) Enclosed by an approved hot-poured bitumen compound.

(3) Wrapped with tape.

Method (2) shall not be used with plastic pipes.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

The item to be encased shall first be cleaned and its original surface
treatment made good. The surface shall be dry before encasing is carried out,
which shall not be done before the pipeline has been tested.

The bitumen compound shall be cast in purpose-built moulds in accordance

with instructions issued by the supplier.

The protective wrapping tape shall be open-weave cotton or synthetic fibre or

woven glass fibre coated on both sides with an even coat of petrolatum
(petroleum jelly) containing a filler. The tape and paste shall be suitable for
use in the prevailing climatic soils pumped liquid and ground water conditions.

Before wrapping with tape the item to be encased shall be enclosed with an
approved mastic or inert putty-like filler which shall be moulded by hand so as
to provide a smooth surface for the tape. The tape shall be tightly spirally
wrapped with 25 mm overlaps so as to enclose the whole of the item and a
minimum of 150 mm of pipe length on each side. The enclosure shall be firmly
pressed out to prevent air being trapped under the wrapping.

4/4.13 INDICATOR POSTS TO PRESSURE MAINS

Where pressure mains pass through open ground, not adjacent to roads, or
where the danger of accidental breakage by excavation is evident, the
Engineer may instruct the erection of indicator posts of an approved design.
Details of the indicator post construction and spacing shall be shown on the
drawings or be directed by the Engineer.

The depth, location and size of the pressure main shall be detailed in Arabic
and English, to an approved design, on an engraved plastic or non-corrodible
plate attached to the post.

In addition at all air valve chambers, the Contractor shall erect indicator signs
on posts, to an approved design, at locations described to him by the
Engineer.

4/4.14 ENCLOSING GRANULAR OR STONE SURROUND WITH GEOTEXTILE

FILTER FABRIC

For all slotted pipes and pipes laid beneath the permanent groundwater level
the granular bedding material shall be laid on and enclosed within a geotextile
filter fabric.

Filter fabric used for subsurface drainage works shall consist of long-chain
synthetic polymer fibers composed of at least 85 percent by mass polyolefins,
polyesters, or polyamids. They shall be formed into a network such that the
filaments or yarns retain dimensional stability relative to each other, including
selvedges.

The fabric shall be stabilised against ultra-violet light, inert to commonly

encountered chemicals and chemical properties of the in-situ soil and water,
and it shall conform to the following minimum requirements (Table 4-12):

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Table 4 - 12 Requirements for geotextile fabric for subsurface drainage

Property Test Method Min.Requirements
Grab Strength (N) 800
ASTM D 4632:2008
Puncture Strength (N) ASTM D 4833:2007 355
Burst Strength (kPa) ASTM D 3786:2009 2000
Trapezoid Tear (N) ASTM D 4533:2004 220
Permeability (m/s) ASTM D 4491:2004 10-4
Apparent Opening Size 0.6
ASTM D 4751:2004
(mm)
Ultraviolet Degradation ASTM D 4355:2007 70 @ 150 h
(Percent Retained
Strength)

Where filter fabric is used to enclose granular or stone pipe surrounds, the
fabric will be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with
surround to the correct level the filter fabric shall be closed over the top of the
surround by forming a 'lap' of minimum width 500 mm. All membrane joints
shall be overlapped a minimum of 500 mm.

Care shall be taken not to puncture or damage the membrane in any way
during installation or during backfilling of the trench. Fabric damaged or
displaced before or during installation or during placement of overlaying
aggregate material shall be replaced or repaired to the satisfaction of the
Engineer at the Contractor's expense.

During periods of shipment and storage, the fabric shall be maintained

wrapped in a heavy-duty protective covering and protected from direct sunlight
and ultra-violet rays.

4/4.15 UNDERGROUND SERVICES WARNING TAPES

Service protection tapes shall be installed above all sewage, drainage and
irrigation pipelines and pressure mains constructed or exposed under this
contract excluding individual service connections.

For pipelines with the top of the pipe barrel more than 900 mm below finished
surface level the tape shall be placed over the centreline of the pipeline at 600
mm below finished surface level during backfilling and compaction operations.
For pipelines with less than 900 mm cover to the top of the pipe barrel the tape
shall be placed over the centreline of the pipe at 300 mm above the top of the
pipe barrel during backfilling, compaction and reinstatement operations.

The tape shall be continuous over pipelines and at joints between tapes from
separate rolls the joint shall be lapped a minimum of one metre.

Tapes shall be durable and detectable by electro-magnetic means using low

output generator equipment. They shall remain legible and colour-fast in all
soil conditions at pH values of 2.5 to 11.0 inclusive.

The tapes shall be flexible with a minimum width of 150 mm and thickness of
150 microns and shall be subject to the Engineer's approval.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Site tests to confirm detectability of the warning tapes after installation and
backfill shall be performed when ordered by the Engineer.

Text in Arabic and English indicating the protected services lying below the
tape shall be permanent ink bonded to resist prolonged chemical attack by
corrosive acids and alkalis with the message repeated at a maximum interval
of two metres. Tapes shall be colour coded as follows, with black text as
indicated. The sign and styles of the text shall be approved by the Engineer.

Sewers : Yellow

CAUTION : Sewer below

Sewage pressure mains : Yellow

CAUTION : Sewage pressure main below

Drains : Yellow

CAUTION : Drain below

Drainage pressure main : Yellow

CAUTION : : Drainage pressure main below

Irrigation pressure mains : Orange

CAUTION : : Irrigation pressure main below

4/5 PIPEWORK WITHIN STRUCTURES

(1) Pipework shall be supplied to the general arrangements and limits

indicated on the Contract drawings and shall be supplied complete with all
joint rings, gaskets, washers to each side of a bolted joint, nuts, bolts,
grease and any other components necessary for the complete installation.

(2) The layout and design of the pipework shall be such as to facilitate its
erection and the dismantling of any section for maintenance of associated
plant by inclusion of approved mechanical coupling or flange adaptors.

(3) Where a common delivery pipe is used, individual pump delivery branches
unless otherwise shown on the drawings shall be jointed to it in a
horizontal plane and angled to prevent sharp changes of flow direction.

(4) Adequate supporting and anchoring arrangements for all pipes shall be
included which may take the form of straps, stays, tie bars or concrete
cradles. All pipe hangers and supports inside pumping stations and valve
chambers or other structures shall be of 320S17 stainless steel. All fixing
bolts shall be stainless steel grade 320S17.

(5) GRP pipes shall be provided with puddle flanges where they pass through
the walls of underground or water retaining structures.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
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(6) Small bore pipework for sump pumps, vents, etc., may be an approved
plastic material.

(7) All pipes connected to pressure vessels, pumps, etc., shall have flanged
connections.

(8) All pipes shall be checked for alignment and mating of flanges and
connections before secured. Pipes shall not be sprung into position.

4/6 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES

4/6.1 GENERAL

The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the drawings
and herein specified.

Manholes, chambers, and special structures shall conform in shape, size,

dimensions, materials, and other respects to the details indicated on the
drawings or as ordered by the Engineer.

4/6.2 CONSTRUCTION OF MANHOLES, CHAMBERS, AND SPECIAL

STRUCTURES

All manholes, chambers, and special structures shall have reinforced-concrete

bases as detailed on the drawings. Manhole bases for storm-sewers less than
600 mm and bases for chambers may be precast or cast in place at the
Contractor's option and as approved by the Engineer. For precast reinforced-
concrete manhole bases, openings for pipes shall be cast in the base at the
required location during its manufacture. Field cut openings will not be
permitted. All other manhole and special structure bases shall be cast in place
as indicated on the drawings.

Manhole and chamber cover slabs shall be cast in place reinforced-concrete as

marked on the drawings. The ductile iron frames and covers for manholes and
chambers shall be brought to grade by the number of courses of concrete
blocks shown on the drawings or as instructed by the Engineer and a reinforced
concrete frame into which the ductile iron frame is embedded.

Class B concrete shall be cast to a minimum thickness of 150 mm around the

concrete blocks for rigidity or as detailed on the drawings.

The inverts shall conform accurately to the size of the adjoining pipes. Side
inverts shall be curved and main inverts (where direction changes) shall be laid
out in smooth curves of the longest possible radius which is tangential, within
the manhole, to the centerlines of adjoining pipelines all as indicated on the
drawings and instructed by the Engineer.

The ductile iron frames, grates and covers shall be to the Dubai Municipality
standard frame, grate and cover as indicated on the drawings and hereinafter
specified in Clause 4/7.

All benching and channel shall be formed with Class A concrete unless shown
otherwise in the drawing. 7 mm minimum GRP laminate shall be applied to
benching and channel.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
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Manhole walls shall be plain Class A concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to give
a fair faced finish.

Internal surfaces of manholes and structures shall be protected with a

reinforced plastic liner in accordance with Clause 9/2.3 or with an approved
coating in accordance with Clause 9/2.2(2)(a) as and where shown on the
drawing and the external (buried) surfaces shall be protected in accordance with
Clause 9/2.2 (1) either with water-proof membrane with protection board or with
a brush-applied bituminous emulsion as indicated in the drawing.

Pipes entering and leaving manholes, chambers and special structures shall be
laid soffit to soffit unless otherwise shown on the drawings. Details of pipelines
entering and leaving manholes, chambers, etc., shall be as specified for pipes
protruding from structures in accordance with Clause 4/4.11.

All construction joints to manholes, chambers and special structures shall be

perfectly watertight. Waterstop across joints in structures as specified in Clause
3/7.7 shall be provided where detailed in the drawings or as directed. Joints
shall be fully scabbled.

Manholes and chambers shall be completely constructed as the Works progress

and as each one is reached by the pipework. Frames and covers shall be
placed immediately after the completion of the manhole and chamber.

4/6.2.1 Road Gullies

Gullies shall comprise the gully grating and frame and the polypropylene gully
pot, all as shown on the drawing.

The gully pots shall be supplied with a fibre glass sand bucket with lifting
handle, as detailed in the drawing. The sand bucket shall have perforations in its
upper part and small holes 3 mm in diameter in its bottom part. The total area of
perforations shall not be less than 20,000 sq. mm and the minimum diameter of
each hole shall be 50 mm. The depth of the bucket shall not be less than 750
mm.

The gully pot shall be surrounded by a minimum of 150 mm of concrete as

shown on the drawing.

The connecting pipe between the gully pot and the drain/manhole shall be 160
mm dia. uPVC.

The connection into the drain pipe shall be made by means of an oblique
junction which may be of uPVC.

4/6.3 ACCESS COVERS, FRAMES, AND GRATES

4/6.3.1 General

The Contractor shall furnish all ductile iron frames, grates, and covers
conforming to the details shown on the drawings, and as specified in Clause 4/7
to Dubai Municipality Standards.

The Contractor shall submit for approval detailed shop and working drawings of
all castings before fabrication. Such drawings shall be obtained from the

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

supplier(s) he chooses to select from the approved list of Dubai Municipality

(see Clause 4/7.1).

The castings shall be of good quality, strong, tough, even-grained ductile iron,
smooth, free from scale, lumps, blisters, sandholes, and defects of every nature
which would render them unfit for the service for which they are intended.
Covers and frames contact surfaces shall be machined and the compatible
frames and cover carefully marked to ensure correct covers and frames are
matched on site.

If required by the Engineer, the Contractor shall obtain from the supplier/
manufacturer a guarantee that replacement component parts will be available
for a minimum period of 10 years from the issue date of the Completion
Certificate.

All covers, frames and grates shall be delivered to Dubai with a transit protective
packaging or wrapping. Any damage occuring to the approved coating system
shall be made good prior to installation.

One set of prising and lifting keys of approved design shall be supplied by the
Contractor with each twenty manhole covers and frames supplied.

4/6.3.2 Access Covers and Frames

All access covers and frames shall be of heavy duty construction complying
with BS EN124 and the requirements of the Dubai Municipality Standards
(Clause 4/7). With the exception of those for sewerage manholes, access
covers and frames shall be sand tight with seatings designed to be non-
rocking unless detailed otherwise.

Double triangular covers must be loosely coupled by stainless steel bolts with
nuts provided with an approved method to render the nuts incapable of both
undue tightening or loosening.

Holes provided in non-ventilating covers for lifting keys shall be appropriately

shaped pockets which shall not penetrate through and there may be no
projections above cover level.

Both sides of covers and frames shall be protected with an approved epoxy
coating system appropriate to the Dubai environment. The coating system may
be applied at the place of manufacture or in Dubai under controlled application
conditions approved by the Engineer.

Covers for sewerage manholes and chambers shall also be provided with a
reinforced plastic sealing plate. The design of cover, frame and sealing plate
shall be such that no load can be transferred from the cover to the sealing plate.

Access covers shall be as follows :-

(1) Sewerage

(a) Manhole covers shall be 600 mm x 600 mm square clear opening

double triangular heavy duty, embossed with the word 'Sewerage' in
Arabic and English.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

(b) Inspection chamber covers shall be single seal 600 mm x 600 mm

square clear opening heavy or medium duty, embossed with the word
'Sewerage' in Arabic and English. Alternatively, 600 mm x 600 mm
square clear opening double triangular covers may be used subject to
approval by the Engineer.

(2) Storm/Land drainage

Manhole covers shall be non-ventilated, 600 mm diameter clear opening

double semi-circular heavy duty with sealing plate, embossed with the
word 'Storm' in Arabic and English.

(3) Pumping Stations, Associated Chambers and Where Specified

They shall be rectangular 600 mm x 750 mm or 600 mm x 900 mm or

multiples of these sizes, as detailed on the drawings with concrete infill,
and shall be heavy duty.

Where ventilated covers are detailed the total area of ventilation shall not be
less than 5 % of the minimum clear opening area and the covers shall be
provided with suitable protective sand traps which shall seat in the access
cover frame.

4/6.3.3 Reinforced Plastic Sealing Plates to Access Covers

Reinforced plastic sealing plates to access covers shall be designed to

provide a push-fit, gas-tight seal with the cover frame. The sealing plate shall
be in the form of a plug with a flange to prevent the plate passing into the
manhole. The seal shall be achieved by means of an approved integral
synthetic rubber gasket mechanically locked into the periphery of the plate.
The gasket shall be suitable for the service temperature range 0oC to 60oC
and possess good weathering and H2S resistance. Any lubricant used on the
seal shall be silicon based. The underside of the plate shall have a resin-rich
finish and there shall be no exposed fibres. Cut and/or drilled faces shall be
sealed with resin.

The plate shall have a minimum thickness of 5 mm and be capable of

withstanding a static load of 150 kg applied centrally over a 150 cm square
surface area with a deflection, measured at the centre of the plate, not
exceeding 25 mm.

A minimum of two number reinforced plastic lifting handles shall be provided

per plate. They shall be of the same materials as the plate and securely
laminated to the plate or fixed by stainless steel blind rivets.

The complete sealing plate including gasket shall be resistant to 10%

sulphuric acid at 50oC for 100 days.

4/6.3.4 Road Gully Gratings and Frames

Road gully gratings and frames shall be of ductile iron construction to BS

EN124: 1994, AMD 8587:1995 badged to Dubai Municipality Standard
(Clause 4/7) as detailed in the drawing, and having a minimum waterway of
900 sq. cm. The grating and frame shall be of a non-rocking construction and
shall be dimensioned as detailed in the drawing.

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Gully gratings shall be of the raised kerb type complete with sand seal, road
retaining bar and a removable GRP debris bucket. The weir depth shall be a
minimum of 165 mm and the frame and cover are to be protected with an
approved epoxy coating system appropriate at the place of manufacture or in
Dubai under controlled application conditions approved by the Engineer. The
clear opening size shall permit removal of the GRP grit sand bucket.

4/7 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS

(Tables 4-13 & 4-14)

Table 4 - 13 Standards for covers and gratings for storm and land drainage
MANHOLE GULLY
GRATINGS PUMPIN
G STN.
REQUIREME IN ROAD OUT FLUSH UPSTAN ACCESS
NT OF ED D COVER
ROAD KERB KERB

Double Double
Shape Semi- Semi- -
Circular Circular Square Rectangu
lar

Size of clear 600 dia. 600 width weir dpt 600 x

opening dia. Nom.45 165 750
0 600 x
900

Standard BS EN BS EN BS EN BS EN BS
124 124 124 124 EN124

Strength D400 C250 D400 150 KN D400

(A 350) (B 150) (A 350) (B 150)

Material Ductile Ductile Ductile Ductile Ductile

Iron Iron Iron Iron Iron

Protective Epoxy Epoxy Epoxy Epoxy Epoxy

Coating

Ventilation No No - - No
Construction Solid Solid - - Concrete
Infill
Sealing Plate Yes Yes - - -
Inscriptions Storm Storm Storm Storm Storm
Tightness Yes Yes - - -
Rocking No No No - No
Locking No No No - No

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

Interchangeabi Yes Yes Yes Yes Yes

lity
Other - - - GRP Special
GRID Keys
Suppliers 1-5 1-5 1-5 1-5 1, 2

Table 4-14 Standards for Covers and Gratings for Sewerage

HOUSE PUMPING
CONNECTI STN.
REQUIREMENT MANHOLE
ON ACCESS
CHAMBER COVER
OUT OF
IN ROAD
ROAD

Shape Double Double Square Rectangular

Triangular
Triangular
Size of clear 600 x 600 600 x 600 x 600 600 x 750
opening 600 600 x 900
Standard BS EN BS EN BS EN BS EN
124:1994 124:1994 124:1994 124:1994
AMD AMD AMD AMD
8587:1995 8587:1995 8587:1995 8587:1995
Strength D 400 C 250 C 250 D 400
(A 350) (B (B 150)
150)
Material Ductile Ductile Ductile Ductile
Iron Iron Iron Iron
Protective Epoxy Epoxy Epoxy Epoxy
Coating
Ventilation No No No No
Construction Solid Solid Solid Concrete
Infill
Sealing Plate Yes Yes Yes -
Inscriptions Sewerage Sewerage -
Sewerage
Tightness Yes Yes Yes -
Rocking No No No No
Locking No No No -
Interchangeabili Yes Yes Yes Yes
ty
Other - - - Special
Keys
Suppliers 1-5 1-5 1-5 1, 2

4/7.1 APPROVED LIST OF SUPPLIERS

1. ELKINGTON

2. PASSAVANT

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SECTION 4 PIPES, PIPEWORKS, MANHOLES AND
CHAMBERS

3. STANTON

4. SELFOCK

5. GLYNWED BRICKHOUSE

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 1 SECTION 5 BRICKWORKS AND BLOCKWORKS

TABLE OF CONTENTS

5/1 MATERIALS...................................................................................................................................... 2
5/2 CONSTRUCTION ........................................................................................................................... 3

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 2 SECTION 5 BRICKWORKS AND BLOCKWORKS

5/1 MATERIALS
This section shall be read in conjunction with PART 1 “Roadworks” Section 5
“Ancillary Works”

5/1.1 CONCRETE BRICKS AND BLOCKS

Concrete bricks and blocks shall be constructed from Class B (Blended

cement as described in Part 1 Roadworks Section 4) concrete but the coarse
aggregate shall be 10 mm to 5 mm. The blocks shall be cast in clean oiled
moulds.

They shall be free from cracks, uniform in size, true to shape, free from
deleterious matter, clean, hard, impervious with smooth faces in appearance
similar to normal Class B concrete and with well defined arises. Paving blocks
shall comply with BS 6717: 2001 or BS EN 1338 2003

Bricks and blocks shall not be incorporated into the Works until they have
matured under suitable conditions for 28 days.

5/1.2 BRICKS

Engineering bricks and special purpose bricks such as radial bricks, weir
bricks, copings and bull nosed bricks shall have an average compressive
strength of at least 69 N/mm2 and an average absorption not exceeding 4.5
percent by weight measured by a standard boiling or vacuum method.

Faces of engineering bricks to be exposed to the weather or liquids shall not

be wire cut.

Bricks for arches and circular work of 1.5 metres and less in diameter shall be
purpose made radial bricks.

5/1.3 SAND FOR MORTAR

When tested in accordance with BS EN 13139:2002, sand for mortar shall

comply with the following table:-

Table 5 - 1Gradation of sand for mortar

Percentage by mass passing sieve
Sieve Size
Rendering Brickwork/General Purposes
5.00 mm 100 100
2.36 mm 90 - 100 90 - 100
1.18 mm 70 - 100 70 - 100
600 microns 40 - 80 40 - 100
300 microns 5 - 40 5 - 70
150 microns 0 - 10 0 - 15

5/1.4 LIME FOR MORTAR

Lime for cement-lime and lime-sand mortar shall be the hydrated type to the
approved standard.

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 3 SECTION 5 BRICKWORKS AND BLOCKWORKS

5/2 CONSTRUCTION

5/2.1 GENERAL

Bricks and blocks shall be properly stacked on level hard stand. Broken blocks
shall be removed from the site.

Bricks shall be adequately protected from inclement weather. During hot and
dry weather bricks and blocks shall be wetted as necessary and the tops of
walls shall be wetted before a course is laid

All faces of brickwork or blockwork will be kept clean and no rubbing down of
exposed faces will be permitted.

Brickwork and blockwork should be built in a uniform manner. Corners and

other advanced work should be raked back and not raised above the general
level more than 1.0 m at one lift.

All blocks shall be laid on even full beds of mortar; vertical faces of all blocks
shall be well buttered before being laid and the whole well grouted at each
course.

The overall dimensions of four blocks laid in mortar shall not exceed by more
than 25 mm the overall dimensions of the same blocks laid dry.

5/2.2 ENGINEERING BRICKWORK

Unless otherwise specified or ordered all engineering brickwork shall be built in

English bond.

When concrete is to be faced with brickwork, header bricks shall be built into
every fourth course and at intervals of 2 bricks horizontally so as to project 1/2
brick into the concrete. Headers in successive courses shall be staggered.

5/2.3 BLOCKWORK

All blockwork shall be built level, plumb and true to line with all perpends in line
vertically. Blockwork shall be built in stretcher bond and alternate courses
shall be bonded in at all junctions. All blockwork shall be set in gauged mortar
as described to the lengths, heights and thicknesses shown on the drawings.
Fair and fair-faced work shall be kept perfectly clean and no rubbing down of
blockwork will be allowed. Blockwork to be plastered shall have joints struck
off flush and left rough.

5/2.4 CEMENT MORTAR

Mortar for precast concrete units, brickwork and blockwork shall be gauged in
the proportions of one part of cement to three parts of sand. Lime shall only be
added if specifically ordered.

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 4 SECTION 5 BRICKWORKS AND BLOCKWORKS

Cement mortar shall be mixed on a clean surface in small quantities sufficient

only for 30 minutes work and shall not be remixed or worked up again after
setting or hardening; any mortar that has become set or hard shall be rejected
and removed from the site.

Ingredients shall be measured in proper boxes and shall be turned over and
thoroughly mixed on a wooden platform.

5/2.5 CEMENT LIME MORTAR

Cement lime (gauged) mortar shall consist of one part Portland Cement, one
part of lime and six parts of sand by volume (1:1:6). All materials shall be
accurately gauged using gauge boxes and shall be thoroughly mechanically
mixed. Mortar that has begun to set shall not be revived or re-used.

5/2.6 CEMENT MORTAR RENDERING

Cement mortar rendering shall consist of two or more coats; the undercoat
shall be 13 mm thickness and scored to form a key for the final coat which
shall be not less than 6 mm in thickness. The finished coat shall be worked
with proper metal floats, and the face left with an even and polished surface.
The mortar for the undercoat of the rendering shall be gauged in the propor-
tion of one part of cement to three parts of sand (by volume), and the finished
coat shall be in the proportion of one part of cement to two parts of sand (by
volume) unless shrinkage cracking occurs whereby the mix proportions should
be altered to increase the sand volume.

For at least 24 hours before rendering is applied the concrete or brickwork

face or previous coat of rendering shall be thoroughly soaked with water, and
the finished rendering shall be watered at least four times a day or at a
suitable interval dependent upon daily weather (wind and temperature) to
retain suitable curing dampness for a period of at least fourteen days after
completion. Not more than three days shall elapse between the application of
one coat and its being covered up with a second or finishing coat. All arises
shall be sharp and linear.

When rendering is to be applied to brickwork, the joints shall be raked and

cleaned out to a depth of 13 mm.

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 1
SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

TABLE OF CONTENTS

6/1 CLEANING AND INSPECTION OF PIPELINES ...................................................... 2

6/2 TESTING OF PIPELINES ........................................................................................ 2
6/3 TESTING OF VALVES ............................................................................................. 7
6/4 TESTING OF RENOVATED AND REPLACED PIPELINES ..................................... 7
6/5 TESTING OF WATER RETAINING STRUCTURES ................................................ 7

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

6/1 CLEANING AND INSPECTION OF PIPELINES

The Contractor shall ensure during and after construction that the interior of pipes
remain clean and free of all silt, mortar, debris and other obstructions, and if
required by the Engineer, the pipelines shall be cleaned out using approved
methods and equipment which do not damage the internal lining of the pipes and
manholes. When work is not in progress the open ends of the pipeline shall be
securely plugged with an approved watertight plug or stopper to prevent the ingress
of deleterious matter into pipelines.

After backfilling pipe trenches and completing chambers, hatch boxes, etc., and
before the trench surfaces are reinstated, the interior of pipelines shall be cleaned
of silt and debris by approved methods for inspection by the Engineer's
Representative as follows:-

All newly constructed pipelines of 600 mm (nom.) internal diameter and smaller
shall have a loose plug passed through them to show that they are clear of
obstruction and free from deflection. The loose plug shall be dimensioned to suit
the permissible minimum deflected diameter of the pipe. Alternately, a
deflectometer capable of measuring diametric dimensions both vertically and
horizontally may be used as specified in Clause 4/4.8.

All newly constructed pipelines greater than 600 mm (nom.) internal diameter will
after cleaning be inspected from the inside and the Contractor shall provide a
suitable trolley for this purpose.

All renovated or replaced pipeline shall after cleaning, be inspected from the inside
using CCTV inspection as specified in Section 13.

In addition gravity pipelines or sewers shown as straight lines between manholes

on the drawings shall be subjected to a light sighting test as detailed in the pipe
laying specification Clause 4/4.3.

Pipelines, manholes, chambers/structures will be inspected again before being put

in service or taking over (whichever is sooner) and if required by the Engineer's
Representative shall be cleaned again in whole or in part by suitable means which
may include, if directed, flushing with clean water.

6/2 TESTING OF PIPELINES

6/2.1 GENERAL

The Contractor shall make his own arrangements for the supply of water used for
testing and cleaning of pipelines which shall be obtained from a source approved
by the Engineer. All water required for testing and cleaning shall be provided by the
Contractor at his cost.

Prior to commencement of flushing or testing, approval shall be obtained to the

methods and programme for testing and to the method of disposal of all fluids used
for flushing or testing purposes. Under no circumstances will permission be given
for the discharge of such fluids until approval has been granted and discharge into
the existing sewerage system is not permitted.

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

If permission is given to use new or existing pipes or culverts which are not part of a
live system, they shall be thoroughly cleaned of all silt and any resulting damage
made good after use.

If lagoons for the storage of such fluids are permitted, they must be suitably
protected with fencing and attended by day and night to prevent access by the
general public and will not be sited adjacent to buildings. Approved means of
preventing the formation of mosquito larvae on the surface of the lagoons will be
employed.

Testing of pipelines shall in all cases be applied in the presence of the Engineer's
Representative. The Contractor shall notify the Engineer at least 48 hours prior to
of his intention to test a section of pipeline. The Contractor, at his own expense,
shall provide complete plant and all struts, thrust blocks, etc., as may be necessary
for effectively testing the pipelines to the specified pressures.

Pipelines shall be properly completed and supported before being put under test.
No testing will be permitted until seven days after thrust blocks and other holding
down works have been completed.

For both gravity and pressure pipelines only testing of new, renovated, or replaced
sections of pipelines and fittings will be required under the Contract, in accordance
with this Specification, unless detailed otherwise. Such testing will be carried out
before making final connections to the existing network. However where tees or
other fittings are inserted into existing pipelines and where lengths of pipeline are
replaced no backfilling will be allowed at the tees or fittings or at the joints between
new and existing pipe work until the pipeline has been returned to service and a
visual inspection of all such fittings and joints made at the network pressure.

Should any inspection be unsatisfactory or any test fail the Contractor shall replace
defective pipes, leaking joints or otherwise re-execute defective work as instructed
following which cleaning and testing will be repeated until the Engineer's
Representative certifies the pipeline to be satisfactory.

6/2.2 TESTING OF NON-PRESSURE PIPELINES

All non-pressure pipelines of 600 mm nominal diameter or smaller shall be given a

preliminary air test when the pipeline is bedded and jointed before backfilling and a
final water test after backfilling in the presence and to the satisfaction of the
Engineer.

Unless otherwise instructed non-pressure pipelines shall be tested in sections

between manholes.

Preliminary and final air and water tests will not normally be applied to pipelines
greater than 600 mm (nom.) internal diameter and acceptance of these pipelines
will be dependent on satisfactory visual inspection of the pipes and joints.

Air Test (Preliminary Test)

After a length of pipeline is bedded and jointed, and before backfilling, it shall be
given a preliminary test as detailed below:

1. The Contractor shall plug all pipe outlets with suitable plugs, and brace each
plug securely where needed.

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

2. Air shall be pumped slowly into the pipe until a pressure of 100 mm head of
water is indicated on a manometer connected to the system.

3. After the internal pressure of 100 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.

4. Air may be added to restore the pressure to 100 mm.

5. During a further period of 5 minutes (without further pumping of air) the

pressure should not fall below 75 mm.

6. Release of the air pressure shall be carried out by removal of the stopper at
the end of the pipeline away from the manometer which will remain
connected. Failure to carry out the air pressure release in this manner shall
render the test invalid.

7. The Contractor will not be permitted to commence testing later than 4 hours
after sunrise or earlier than 4 hours before sunset during the summer period
unless otherwise directed by the Engineer.

Water Test (Final Test)

After backfilling the length of pipeline under test, it shall be given the following final
test:

1. All branches and open ends shall be closed with suitable stoppers, secured
with longitudinal braces before testing commences.

2. Water shall be filled from the lowest point and air allowed to escape. No
entrapped air shall remain in the pipeline while testing.

3. An internal pressure equivalent to a head of water of depth to invert of the

pipeline plus 1.25 m, or 4 m head whichever is greater shall be maintained for
one hour to allow for initial absorption of water.

4. After that, the test pressure shall be maintained for 60 minutes and water
added shall be measured.

5. Pipeline shall be treated as passed if water consumption in 60 minutes does

not exceed 7.5 litres per metre of diameter per 30 m of length of pipeline
under test.

Where in the opinion of the Engineer's Representative the above test is not
sufficiently indicative of water tightness by reason of high ground water levels the
test will not be applied. Acceptance of the pipelines will then depend on satisfactory
inspection or testing for infiltration as referred to below, and air test of the pipeline
in manhole lengths.

The Engineer may require any length of pipe suspected of being damaged to be
retested by the water test at any time during the contract period.

Infiltration Test

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

After completion of backfilling and restoration of normal subsoil conditions, all

gravity pipelines and manholes shall be examined for infiltration as follows:

1. All inlets to the system shall be closed sufficiently to prevent the entrance of water.

2. Groundwater pumping shall be discontinued for at least 3 days prior to the

test for infiltration.

3. The section of the pipeline under test, including manholes, shall be

accepted as satisfactory if the infiltration does not exceed 1.00 litre per hour
per metre of pipe line per metre of nominal internal diameter.

Notwithstanding the satisfactory completion of the infiltration test, if there is any

discernible flow of water entering the pipeline at a point which can be located either
by visual or closed circuit television inspection, appropriate measures shall be taken
to stop such infiltration.

6/2.3 TESTING OF PRESSURE PIPELINES

All pressure pipelines of 675 mm or more internal diameter shall have each joint
individually tested by means of an approved joint testing apparatus.

Pipelines of less than 675 mm shall be subjected to a preliminary air test as soon
as a length of pipe has been laid and before backfilling. Pressure pipelines shall
then be given a final test using water after they have been backfilled, cleaned and
inspected.

Preliminary pressure testing of pipelines may be carried out if so required by the

Engineer with partial backfill only and exposed joints, but the stability and safety of
the Works must be ensured at all times.

Each test shall be restricted to pipes of one class. Pipelines shall be tested in
sections not exceeding 500 metres or between valve positions. In addition the
whole pipeline shall be tested upon completion. Particular care must be taken to
isolate air valves, etc., not to apply higher pressure than specified at any point on
the pipelines and to ensure that the pipelines are adequately anchored before any
test is carried out.

Gauges used for testing pressure pipelines shall be capable of reading increments
of 0.1 metre head. Before any pressure gauge is used, the Contractor shall arrange
for it to be checked independently and a dated certificate of its accuracy shall be
provided to the Engineer. Calibration of pressure gauges shall be carried out at
regular intervals as required by the Engineer

Air Test (Preliminary Test)

As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary test:

1. The Contractor shall plug all pipe outlets with suitable plugs, and brace each
plug securely where needed.

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

2. Air shall be pumped in slowly to the pipe until a pressure of 300 mm head of
water is indicated on a manometer connected to the system.

3. After the internal pressure of 300 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.

4. Air may be added to restore the pressure to 300 mm.

5. The test will not be satisfactory if the air pressure falls to less than 275 mm
during a period of 5 minutes without further pumping of air.

Water Test (Final Test)

Pressure pipelines shall be given the following final test using water after they
have been backfilled, cleaned and inspected:

1. All the joints of the pipeline shall be left open for the purpose of inspection for
leakage if any, where practicable or instructed by the Engineer.

2. Pipe ends shall be closed with suitable stoppers, secured with longitudinal
braces/thrust block, before testing commences.

3. Water shall be filled slowly (to prevent possible water hammer) from the
lowest points and air allowed to escape through an air vent fixed for the
purpose at the highest points of the pipeline section under test. No entrapped
air shall remain in the pipeline while testing.

4. Pressure in the pipeline shall then be raised steadily upto and maintained at
the rated pressure for a period of 30 minutes to allow for absorption and
achieve conditions as stable as possible for testing.

5. If no leakage has been observed, pumping shall then be resumed and the
pressure slowly raised to the specified test pressure.

6. Unless specified elsewhere or directed otherwise by the Engineer, the test

pressure shall be 900 KN per square metre (91.8 m head of water).

7. Test pressure shall be continuously maintained by the use of the pump for a
period of 60 minutes and the amount of makeup water required to maintain
the pressure shall be accurately measured (to the nearest 1/8 litre).

8. Pipeline shall be deemed to have passed the test if all the following conditions
are satisfied:

a. No water is visible coming out of the pipe or joints at any point;

b. Amount of make-up water required does not exceed 1 litre per hour
per 100 mm diameter per kilometer of pipeline under test;

c. The loss of the pressure during the test period does not exceed 70KN
per square metre.

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SECTION 6 INSPECTION AND TESTING OF PIPELINES
AND STRUCTURE

6/3 TESTING OF VALVES

Valves and all pipelines appurtenances shall be hydraulically tested together with
the pipeline in which they are installed. Valves shall be tested for operation under
working pressure and shall be adjusted so that they operate smoothly, seat
properly and are installed to tolerances recommended by the manufacturer.

6/4 TESTING OF RENOVATED AND REPLACED PIPELINES

All non-pressure pipelines renovated or replaced by slip lining, soft lining, or pipe
bursting methods shall be given an air test or water test per Clause 6/2.2 in the
presence and to the satisfaction of the Engineer.

6/5 TESTING OF WATER RETAINING STRUCTURES

All water retaining structures shall be visually inspected to confirm that there is no
infiltration. Where it is required by the Engineer, water retaining structures shall be
tested for water tightness. The structure shall be filled with water and shall stand for
a period of three days, to allow for absorption. The structure shall be considered
satisfactory if, subsequent to this period, there shall be no fall in level over a period
of 24 hours (after making the allowance for rainfall and evaporation) and there shall
be no visible leaks, or damp surface areas.

This shall be carried out before any backfilling and before the application of any
external concrete protection has taken place. Any damages revealed as a result of
such tests shall be made good to the satisfaction of the Engineer.

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 SECTION 7 WORKS IN CONNECTION WITH SERVICES OTHER
1 THAN STORM WATER DRAINAGE SANITARY SEWERS AND
WATER SUPPLY

(Not Used)

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SECTION 8 SPECIFICATIONS IN CONNECTION WITH
DUBAI WATER DEPARTMENT WORKS

(Not Used)

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 SECTION 9 CORROSION PROTECTION AND ODOUR
1
CONTROL

TABLE OF CONTENTS

9/1 MATERIALS............................................................................................................. 2
9/2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE ..... 7
9/3 ODOR CONTROL FACILITIES ...............................................................................10

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SECTION 9 CORROSION PROTECTION AND ODOUR
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9/1 MATERIALS

9/1.1 CORROSIVE ENVIRONMENTS

Corrosion protection systems and surface coatings shall in all cases be suitable
for exposure to their contact with environmental conditions which may include
any or all of the following :-

(1) The climatic conditions prevailing in the project area with particular
emphasis on temperature variations, high surface temperatures and high
humidities.

(2) Septic sewage with a pH value of less than 7

(3) Sulfuric acid solution in sewage slimes in concentrations up to 15 % by

weight.

(4) Hydrogen sulfide and other gases emanating from sewage, septic sewage
and sewage sludges.

(5) Saline groundwater with high chloride or sulphate contents both below the
water table and in soil zones above the water table where capillary action
and the presence of oxygen may cause extremely severe conditions.

(6) Wind blown chlorides.

(7) Wind blown abrasive sands.

9/1.2 PAINT

Protective and decorative paint systems including primers and undercoats shall
be obtained ready mixed for use. All containers of paints and other coating
systems shall show date of manufacture, shelf life and pot life where applicable.
Paint shall be applied as per Clause 9/2.2 (refer to Clause 19/2 for schedules of
protective coatings and surface preparations).

The Contractor shall only be allowed to use paints which are delivered to the site
in sealed cans or drums bearing the name of the manufacturer and properly
labeled.

Tints and shades of final coats shall be advised by the Engineer or his
Representative.

9/1.3 IMPERVIOUS TANKING MEMBRANE

Membrane used for tanking to concrete structures shall be impervious, self-

adhesive and covered with a release agent.

Rubber bitumen/PVC membrane shall have a minimum bitumen thickness of 2.0

mm and PVC thickness of 0.3 mm.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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9/1.4 PVC SHEET LINING MATERIALS

PVC sheet materials to be used for lining concrete structures and pipelines
internally shall be manufactured from polyvinyl chloride, plasticisers and
pigments to make permanently flexible sheets.

The colour of the sheet shall be approved on site.

The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed
by extrusion to have on one side locking keys or ribs of either ‘T’ or diamond
section at centers not greater than 75 mm. It shall be capable of forming a
continuous 100% effective seal with the use of welding strips or other approved
method and shall be supplied with all materials and tools for making the joints.

The tensile strength of the material shall be not less than 17000 kN/m2.

All weld strips, patches and other sheets used in the permanent fixing of the
ribbed sheet shall be of a material having the same composition as the ribbed
sheet.

9/1.5 REINFORCED PLASTIC LINERS

Reinforced plastic liners to be used for lining pumping stations and manholes
shall be manufactured (as per Clause 9/1.4) to the dimensions given on the
Drawings, within the following tolerances :-

(1) The work size, which is defined as the internal diameter as specified by the
manufacturer, shall be declared and shall not differ from the normal
diameter by more than + 1%.

A manufacturing tolerance on the work size of 10 mm will be allowed

provided that a tight fit is achieved between the liner and the slab liner.

(2) Liners shall be supplied in lengths to suit requirements with a resin-rich

finish to internal surfaces.
(3) Minimum thickness shall be 7 mm for sewerage work and 5 mm where
approved for drainage work.

(4) The out of squareness shall not be greater than 10 mm.

(5) The deviation from straightness of the bore of the liner shall not exceed 20
mm.

Although the liners are not designed to be structural, they shall have a sufficient
stiffness to withstand :-

(1) Buckling or distortion in transit or storage.

(2) A hydrostatic head of 8 metres without distortion damage, leakage or

permeation.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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(3) Grouting pressures.

Prior to grouting of the manhole liner at least 24 hours shall be allowed for
temperature equalization between the manhole structure and the reinforced
plastic liner.

The manufacturer shall provide shop drawings of the proposed top slab liners
prior to manufacture for approval.

The manufacturer shall stipulate the maximum deflection of the slab liner
permitted without causing surface cracking to the gel coat. The Contractor must
take care not to exceed this limit, and any surface cracking that occurs will be
repaired.

9/1.6 IN-SITU LAMINATIONS

The Contractor shall apply either of the following systems of laminations to

renovate the manholes:

(1) Epoxy resin mortars and laminating systems.

(2) Lamination using Glass Fibre Reinforcedpolymer (GFRP) (viz glass

chopped strand mats) impregnated with isophthalic resin and with
vinylester resin.

(3) Bisphenol polyester resin with heavy duty glass cloth inclusion.

Epoxy Resin System

A mortar consisting of an epoxy resin and hardener shall be mixed with a filler
material to produce a thixotropic dense trowelable mix.

The mortar shall be manually applied to all internal surfaces and left at least
15 minutes.

A minimum of 7 mm of GRP laminate shall then be applied in two layers. The

benching laminate shall be sealed on to the in-situ channel liner with an
approved compatible material. The top surface of the benching shall be treated
to produce a non-slip finish.

Isophthalic and Vinylester Resin System

Firstly the surface of the manhole walls and the surface of the cover slab soffit or
inside of the cover slab, benching and channel (concrete) shall be coated with
isophthalic resin.

Three layers of 600 g/m2 isopthalic resin-impregnated “GFRP” sheets shall then
be applied and impregnated with isophthalic resin to provide an approximate
thickness of 5 mm.

Next one layer of 600 gm/m2 and one layer of 300 gm/m2 glass chopped strand
mat shall be applied and impregnated with vinylester resin.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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Following this two layers of glass veil shall be applied and impregnated with
vinylester resin.

Finally a coating of vinylester resin with paraffin wax shall be applied to provide a
total minimum thickness of 7 mm.

Bisphenol Polyester Resin with Heavy Duty Glass Cloth Inclusion System

All cleaned surfaces shall be primed with a polyester based primer to seal the
surface and aid the application of the lining.

The base coat of resin reinforced with filler shall be trowel applied to
approximately 1.5 mm thick. The reinforcing cloth shall be consolidated into the
first trowel coat with particular attention being paid to ensure that the cloth is fully
wetted out. This application shall be allowed to cure overnight before applying
the top coat of resin. This resin reinforced with the same filler shall be troweled
on and dressed with a rolling aid.

9/1.7 EPOXY MORTAR

Where indicated on the drawings or specified to use epoxy mortar for benching
and channels in any manhole or any other structure such as chambers, pump
station wet-well, etc., they shall be formed to have a min. of 10 mm thickness of
an approved epoxy-resin mortar system.

The epoxy mortar system shall be a trowellable, two component epoxy resin
system consisting of a prefilled base and unfilled reactor which when mixed shall
produce a high strength, impermeable and chemically resistant mortar.

The epoxy mortar system shall have excellent chemical resistance to sodium
chloride and sulphuric acid (shall pass the relevant chemical resistence test),
and shall have high impact resistance. Typical properties are given in Table 9-1
below:

Table 9 - 1 Properties of two component epoxy mortar

Property Test Method Limit

Sag at 10 mm - None
thickness
Working Time ASTM C308:2000 > 90 min. at 25C
(2005)
Full Cure at 25C ASTM C308:2000 3 to 7 days
(2005)
Setting Time at 25C ASTM C308:2000 30 to 45 min.
(2005)
Water Absorption ASTM C413:2001 < 0.07 %
(2006)

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SECTION 9 CORROSION PROTECTION AND ODOUR
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Compressive Strength BS 6319:Part 2:1990 > 40 N/mm2 at 25C,

7 days cure
Flexural Strength BS 6319:Part 3:1983 > 3 N/mm2 at 25C,7 days
cure
Tensile Strength BS 6319:Part 7:1985 > 8 N/mm2
Bond Strength BS EN 12615:1999 > 30 N/mm2
Density BS 6319:Part 1:1983 1750 kg/m3

When placed on a concrete substrate, the epoxy mortar system shall have a
bond strength not less than the flexural strength of concrete.

To achieve the necessary adhesion to the substrate an epoxy primer compatible

for use with the mortar and the substrate shall be applied.

The epoxy mortar, or the primer where required, shall be suitable for application
onto a substrate with a moisture content of 4% or less as measured by the
"wet-check" Moisture Meter or other instruments approved by the Engineer.

The pot-life of the mixed mortar shall not be less than one hour at the temperature
at the place of application at the time of mixing. The Engineer may restrict
application to such time as the ambient temperature is sufficiently low for the
specified pot-life to be ensured.

There shall be strict control of surface cleanliness between primer and epoxy
mortar and between coats of the same. Vacuum removal of dust and sand shall
be employed and water soluble contamination shall be removed as specified
above. Where dirt or dust has become trapped in the primed surface it shall be
removed with suitable abrasive paper. The surface being primed shall be free of
visible moisture throughout these operations.

The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a
maximum tolerance of +4 hours. Where this is exceeded the surfaces to be
re-coated shall be suitably abraded to remove gloss and cleaned of loose
particles.

Mixing of the components shall be strictly in accordance with the Manufacturer's

recommendations and care shall be taken to avoid the entrainment of air in the
mixes.

Wet thickness gauge shall be used by the mortar applicators continually to check
that sufficient mortar is being applied to achieve the required dry thickness.

9/1.8 BITUMINOUS EMULSION

Bituminous emulsion shall be to the approved standard and shall not contain
less than 53 % of bitumen.

9/1.9 WATERPROOF PAPER

Waterproof building paper shall be to the approved standard. For roadworks it

shall be Class B.

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9/1.10 PROTECTIVE MATERIALS FOR WRAPPING PIPELINE COMPONENTS

The protective materials for wrapping pipeline components shall comprise a rust
inhibiting compound for the bolts, a mastic or comparable filler which will not
harden for moulding over the assembly, and a waterproof tape for wrapping.

9/1.11 APPROVED PAINT SUPPLIERS

The following paint systems have been successfully used in sewage

environments in Dubai. Reference to these systems in no way precludes the use
of similar or superior systems by other suppliers.

Supplier Paint System

1. Colebrand Limited Epoxy Prefabrication Primer: CXL 100.

Colebrand House Epoxy Resin Solvent Free Coating : CXL 115.
20 Warwick Street High Build Epoxy Airless Spray Coatings.
Regent Street CXL 141 for temperate climates applications.
London WIR 6BE CXL 140 for hot climates applications.
England

2. Corroless International Limited Corroless T.

Berk House, Basings View Corroless Epoxy.
Basingstoke
Hampshire RG 21 2HW
England

9/2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE

9/2.1 GENERAL

Concrete structures shall be protected both internally and externally where

indicated on the Drawings and by the methods detailed.

9/2.2 PROTECTIVE COATINGS/PVC LINERS

All protection systems shall be applied strictly in accordance with the

manufacturer's instructions, two copies of which shall be included with the
Contractor's application for the approval of the material, and when approved will
be deemed to be part of this specification unless stated otherwise.

The permissible rate of permeation of all protection systems shall not exceed
0.0027 per inch of water per hour per square foot (0.0929 m2) per mil (0.0254
mm) of thickness for a 1 inch (25.4 mm) difference in Hg vapour pressure on
each side of a membrane. ASTM F1735-02 e1 “Standard Specification for Poly
(Vinyl Chloride) (PVC) Profile Strip for PVC Liners for Rehabilitation of Existing
Man-Entry Sewers and Conduits”

Coatings shall not be applied at expansion, contraction or construction joints

which incorporate a sealant.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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(1) External Buried Surfaces

The external surfaces of concrete substructures shall be protected or "tanked"

by one of the following methods which will be indicated on the Drawings.

a) An approved impervious bituminous waterproof membrane:

The membrane shall be tropical grade, cross laminated to have high tear
strength; and puncture and impact resistance and shall be chemically
resistant for protection against aggressive soils and contaminated
groundwater. The membrane shall comply with the following (Table 0-2) :-

Table 9 - 2 Membrane properties

Property Test Method Typical Results

Tape Strength ASTM D638: 2008 Long 4.2 N/mm²

Trans 4.8 N/mm²
Tensile Strength ASTM D638: 2008 Long 42 N/mm2
Trans 48 N/mm2
Elongation Film ASTM D638: 2008 Long 210 %
Trans 160 %
Tear Resistance ASTM D1004: Long 340 N/mm²
Trans 310 N/mm²
Adhesion to Self ASTM D1000: 2004 1.8 N/mm2
Concrete
Puncture Resistance ASTM E154: 2008 220 N 65mm²
Water Resistance : ASTM D570: 2005
- After 24 hours 0.14 %
- After 35 days 0.95 %
Environmental Resistance ASTM D543: 2006 Conforms
Moisture Vapour ASTM E96: 2005 0.3 g/m² / 24 hrs.
Transmission Rate

The membrane shall be laid on to smooth concrete blinding surface free from
sharp edges and projections and on to walls primed with an approved primer
and applying the prerformed membrane, sticky side downwards, laid strictly
in accordance with the manufacturer's instructions. The minimum overlaps
shall be 50 mm side and end.
During the backfilling operation around all tanked structures, the waterproof
membrane shall be protected from damage by the use of an approved
protection board.

The board shall be manufactured from graded and selected kork granules
bound with modified bitumen and encased between two layers of tough
asphalt paper. The board shall be light weight and capable of providing
protection against abrasive backfilling. The board may be stored outside, but
shall be kept flat on original pallets.

b) A brush applied bituminous emulsion:

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SECTION 9 CORROSION PROTECTION AND ODOUR
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The surface shall first be wire brushed and all dust and loose scale
removed. Three coats of bituminous rubber emulsion paint shall then be
applied. The second coat shall not be the same colour as either the 1st or
3rd.

Both methods of protection shall totally enclose the substructure within a

waterproof membrane to the limits shown on the Drawings.

(2) Internal and External Exposed Surfaces

Where exposed surfaces of concrete structures are not protected by reinforced

plastic liners one of the following systems will be indicated on the Drawings
where required.

a) An epoxy resin, acrylic, polyester or latex paint system:

The surface shall first be wire brushed and all dust and loose scale
removed (refer to Clause 19/4 for schedule of surface preparations). An
epoxy resin or other primer/sealer (for concrete and allied substrates) shall
then be applied followed by coats of high build epoxy airless spray or other
coatings to give a minimum dry film thickness (dft) of 300 microns.

Freedom from pinholes shall be established by use of a spark tester. The

approved paint system must have adequate flexibility to suit the thermal
movements of the concrete without cracking whilst maintaining an effective
bond.

b) A PVC sheet lining system :

The PVC sheet lining shall be fixed such that the keys or ribs are cast into
the concrete surface. The lining shall be capable of taking up the same
profile as the concrete substrate as indicated on the Drawings.

Site operatives for employment on this work shall be certified by the

manufacturer as trained to a satisfactory standard in fixing and welding
techniques.

After completion of either of the linings or systems as described in sub-clauses

(a) and (b) above they shall be offered for inspection and testing. Two sets of
testing equipment, e.g. feeler probes and spark testing, shall be provided and
be maintained and available at all times for the sole use of the Engineer's
Representatives.

Only linings or systems completely free from pinholes will be accepted.

9/2.3 REINFORCED PLASTIC LINERS

The construction methods employed shall be so as to ensure that a completely

water and gastight seal is made preventing any exposure of the concrete
surround to the corrosive liquids and gases present as detailed herein.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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In particular:-

Reinforced plastic liners shall be handled in the same manner as reinforced

plastic pipes. In addition, extra care shall be taken to avoid damage to the
liners which are not designed to carry loads.

The manufacturer shall visit the site to demonstrate to the Contractor in the
presence of the Engineer's Representative the methods of handling and lifting,
including formation of the joints between the chamber liner.

The Contractor is reminded that these liners are not designed to withstand
pressure exerted by the concrete during construction.

9/2.4 CUTTING AND SEALING OF REINFORCED LINERS

Where the Contractor is required for any reason to cut reinforced plastic liners,
he shall seal the exposed ends with an approved resin before incorporating the
cut reinforced plastic in the work. No cut reinforced plastic shall be used until
the resin has cured.

The resin shall be as recommended by the manufacturer of the reinforced

plastic item and shall be pigmented so that the areas where it has been applied
are easily identifiable.

It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labelled as to its content and shelf life.

9/3 ODOR CONTROL FACILITIES

9/3.1 GENERAL

The Contractor shall provide the labor, materials and equipment necessary to
install and test the odor control facilities as shown on the Contract Drawings
and as specified herein. The odor control units shall be either of the activated
carbon filter types or of the natural soil filter bed types as indicated in the
Drawings.

Masks equipped with suitable filters shall be provided for use by workers
handling adhesives and paints

9/3.2 SOIL MOISTURE AND PH PROBES

Moisture and pH probes shall be able to continuously measure percent

moisture and pH in the soil. All components shall be highly resistant to
corrosion due to sewage and very high concentration of hydrogen sulfide and
other gases. Soil moisture probes shall measure moisture on a percentage
basis in the full range of soil moisture (0-100 percent). pH probes shall at a

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SECTION 9 CORROSION PROTECTION AND ODOUR
CONTROL

minimum be accurate within the 4-10 standard unit range. All probes shall be
designed for maintenance and replacement with minimum soil disturbance.

9/3.3 ACTIVATED CARBON ODOR CONTROL FILTER

The activated carbon odor control filter shall be furnished and installed in
accordance with Section 17. The air blowers for the odor control unit shall be
as specified in Section 17 and 19.

9/3.4 NATURAL SOIL ODOR CONTROL FILTER

9/3.4.1 Materials

HDPE (High Density Polyethylene) Liner

The HDPE liner shall be furnished and installed in accordance with Clause 9.1
and section 19 and as shown on the Contract Drawings.

Washed Stone

Stone for the air plenum shall be washed, rounded, uncrushed, well graded in
size from 5 mm to 25 mm and consisting of clean, and durable particles free
from dirt, vegetation or other objectionable matter and free from an excess of
soft, thin elongated, laminated or disintegrated pieces. The Contractor shall
submit a sample of the stone to the Engineer for approval prior to placement.

Wood Chips

Wood chips shall be obtained from hardwood and shall be of 10 mm to 50 mm

diameter. Not more than 2 percent shall consist of leaves, twigs or shavings.
They shall be free of extraneous materials, stone and debris. The Contractor
shall submit a wood chip sample to the Engineer for approval prior to
placement.

Soil Filter

The soil filter shall be a mixture of approved natural sand or sandy loam and
treated compost. The compacted soil/compost mix shall have a 50 percent
porosity. The compost shall be a product of thermophilic aerobic stabilization. It
shall be adequately stabilized, so as to be completely free of any odors. The
compost shall be friable, pass through a 13 mm mesh screen, and be free of
stones, stocks and all objectionable debris. Compost shall have a pH of 5.5 to
8.0 and no less than 25 percent volatile solids. The compost source is subject
to the review of the Engineer. All compost shall be "cured" to the point that it is
no longer self heating.

9/3.4.2 Installation

The Contractor shall place the stone, wood chips, soil and compost in layers of
uniform thickness as indicated on the Contract Drawing(s) or as directed by the
Engineer. The stone, wood ships, soil and compost shall be placed so as not to
damage the aeration piping. Damaged piping is to be replaced by the
Contractor at no additional cost to the owner.

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SECTION 9 CORROSION PROTECTION AND ODOUR
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9/3.4.3 Monitoring

The Contractor shall perform the following selected soil and atmospheric
analyses at the direction of the Engineer, but not more than once per week with
the exception of soil moisture and pH, for the length of the natural soil filter
maintenance period. The results of the analyses shall be recorded and
presented to the Engineer at the end of each month. Soil samples must be
taken so as not to disrupt the even distribution of air through the odor control
filter.

Atmospheric Hydrogen Sulfide

Hydrogen sulfide (H2S) gas concentrations shall be measured in the

atmosphere directly over the filter bed with a probe placed immediately above
the surface of the natural soil filter. The H2S levels shall be monitored and
recorded continuously.

Soil Moisture and pH

Soil moisture and pH shall be monitored and recorded continuously at a depth

of 0.75 and 0.25m metres if vegetation is to be grown over the area from the
natural soil filter surface using the soil moisture and pH probes as specified in
Clause 9/3.2.

Chlorides, Sulfides and Biological Analysis

Chloride and sulfide concentration shall be measured from soil sample

collected at a depth of approximately 0.75 and 0.25m metres if vegetation is to
be grown over the area from the natural soil filter surface. A biological
analysis shall be performed on the same soil samples to identify biological
organism in the filter media. The samples for these analyses shall be taken
once per month unless otherwise directed by the Engineer.

9/3.4.4 Maintenance

Where excessive settling or discontinuities have occurred in the soil filter

media, the Contractor shall replace the entire soil/compost media or add
additional soil/compost mixture at the direction of the Engineer.

9/3.4.5 Acceptance Test

The Contractor shall test the porosity of the compacted soil/compost mixture
before placement and provide the results of the test to the Engineer.

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 1 SECTION 10 BUILDING SPECIFICATIONS

TABLE OF CONTENTS

10/1 CONCRETE ....................................................................................................................................... 2

10/2 BRICKWORK AND BLOCKWORK ............................................................................................ 2
10/3 ROOFING ........................................................................................................................................... 4
10/4 JOINERY ............................................................................................................................................ 5
10/5 METALWORK ................................................................................................................................... 7
10/6 PLUMBING ........................................................................................................................................ 8
10/7 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES.............................. 9
10/8 GLAZING .......................................................................................................................................... 13
10/9 PAINTING AND DECORATING ................................................................................................ 14

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 2 SECTION 10 BUILDING SPECIFICATIONS

10/1 CONCRETE

10/1.1 TOLERANCE

Floor and roof slabs shall be level to a point within  5 mm of the level shown on
the drawings. Columns and beams shall have no irregularities exceeding 3 mm
in a 3m length. The position of the face of columns, beams and walls at any
point shall be within 5 mm of its position derived from the drawings.

10/1.2 CONCRETE FINISH

All exposed concrete beams, columns and slab surface described as fair-faced
shall be Type f.f. as follows: -

Type f.f. shall be an as struck finish entirely free from honeycombing, stains,
pins, clippings, lining joint marks, nail and screw marks, raised grain marks, air
holes and surface defects and shall be uniform in colour tone and surface
texture with clean true faces and arises.

10/1.3 CONSTRUCTION BAYS

The Contractor shall submit to the Engineer for his approval prior to concreting
his proposals for the sequence of placing concrete and the position of horizontal
and vertical construction joints.

10/1.4 SMALL PRECAST ITEMS

Small precast items such as lintels, sills and pad stones shall be built in as the
work proceeds and have a fair-faced Type f.f. finish where exposed to view and
hacked surfaces where plastered.

Lintels shall have a minimum bearing of 100 mm or larger if indicated on the

drawings and shall have inserts for fixing windows and/or doors cast-in.

Sills shall be weathered and have a throat as described, if projecting, and shall
have inserts for fixing windows and/or doors cast-in.

10/1.5 CAST-IN FIXINGS

Cast-in fixings shall be securely fixed to formwork ready for casting and shall be
true to line in the positions shown on the drawings.

10/1.6 TIMBER CAST-IN FIXINGS

Timber cast-in fixings shall be made from 38 mm x 38 mm dovetailed shaped

softwood battens pressure impregnated with preservative.

10/2 BRICKWORK AND BLOCKWORK

10/2.1 DAMP-PROOF COURSE

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 3 SECTION 10 BUILDING SPECIFICATIONS

Horizontal and vertical damp-proof courses shall be hessian based lead cored
bituminous damp-proof course weighing not less than 4.4 kg/m2 to accepted
standards and approved by the Engineer.

Horizontal damp-proof courses shall be laid on an even level bed of fresh

mortar and shall be lapped for the full width of the sheet at corners and
junctions. Stepped damp-proof courses shall be wide enough to be built in to
both skins of the wall and to cross the cavity in one piece.

Vertical damp-proof courses shall be continuous and shall be the width of the
block closing the reveal.

Damp-proof courses shall not be bridged with mortar.

10/2.2 WALL TIES

Wall ties shall be 18/8 stainless steel vertical twist type 200 mm long.

Wall ties shall be built in the mortar beds as the work proceeds and shall be
spaced at a maximum of 900 mm horizontally and 450 mm vertically and shall
be staggered. Each door and window opening shall have wall ties at each joint
at 225 mm centres vertically.

10/2.3 DOOR AND WINDOW FRAME TIES

As described for Joinery Fixing Accessories. Door and window frame ties shall
be fixed as described under Joinery Work.

10/2.4 MASTIC

Mastic for pointing door and window frames shall be one part gun-grade
polysulphide mastic to accepted standards and approved by the Engineer.

Mastic seals to windows or door frames shall be neatly gun applied to clean,
solid and dry backgrounds in one operation. The mastic shall be a triangular
seal across the whole joint and any surplus shall be cleaned off when set.

10/2.5 BRICKWORK AND BLOCKWORK

Brickwork and blockwork shall be as specified in Section 5.

10/2.6 CEMENT MORTAR

Cement Mortar shall be as specified in Section 5.

10/2.7 POINTING

All pointing shall be done as the work proceeds and shall be flush with face of
blockwork.

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 4 SECTION 10 BUILDING SPECIFICATIONS

10/2.8 HOLLOW WALLS

Hollow walls shall be constructed with an outer skin of blockwork and an inner
skin of blockwork leaving a cavity of the widths shown. The two walls shall be
tied together with wall ties as described and the cavity shall be kept and left
clear of all droppings. Openings shall be left at intervals in the blockwork at the
bottom of the cavities and all debris shall be cleared out and the openings
bricked up on completion. Cavities shall be closed at opening reveals with either
brick or block to match the surrounding material and a continuous vertical
damp-proof course shall be built in.

10/3 ROOFING

10/3.1 ROOF SCREED

Roof screed shall be laid to fall over the concrete roof slab and have a minimum
thickness of 35 mm and maximum thickness of 75 mm. The screed shall be
thoroughly mixed 1:4 cement/sharp sand mix with very little water added. The
screed shall be laid and compacted and shall be levelled off and finished with a
steel trowel. Precautions must be taken to prevent rapid or excessive drying
out.

10/3.2 ROOF PRIMER

Primer for concrete shall be suitable for use with the waterproofing membrane
and shall be applied in accordance with the manufacturer's instructions.

10/3.3 WATERPROOFING MEMBRANE

Flexible waterproofing membrane for roofing shall be bitumen based to

accepted standards and approved by the Engineer.

Surfaces to receive the membrane shall be smooth, dry and free from dust. The
membrane shall be laid on a primed surface and in accordance with the
manufacturer's recommendations.

10/3.4 ROOF INSULATION

Roof insulation shall be 75 mm thick closed cell non-absorbent rigid polystyrene

insulation board. The insulation boards shall be placed immediately after the
membrane has been laid.

10/3.5 ROOF SURFACE

Roof surface shall be 50 mm thick 450 mm x 450 mm precast concrete paving

slabs laid dry.

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 5 SECTION 10 BUILDING SPECIFICATIONS

10/3.6 ROOF DECKING

The roof decking shall be aluminium profiled sandwich sheeting fixed to Metsec
‘Z’ section purlins all in accordance with the manufacturer’s instructions. The
Contractor shall provide working drawings and manufacturer’s literature for
approval before ordering the same.

10/3.7 FASCIA CLADDING

The fascia cladding shall be of single skin construction formed from profiled
aluminium sheeting with matching aluminium profiled flashings. The Contractor
shall provide working drawings and manufacturer’s literature for approval before
ordering the same.

10/4 JOINERY

10/4.1 TIMBER-GENERAL

Timber for joinery shall be air dried and the moisture content be allowed to
reduce until it reaches a level in equilibrium with local conditions. It will be
deemed to have reached equilibrium when the moisture content is 12% + 2%.

10/4.2 TIMBER SIZES

Timber shall be 3 mm less per wrought or finished face than the sawn size.

10/4.3 HARDWOOD

Hardwood for joinery shall be sound, well conditioned

3
and seasoned Mahogany
or Meranti with an average density of 529 Kg/m and a moisture content of 12%
+ 2%. Exposed surfaces of joinery shall comply with the following requirements.

Knots : Pin knots up to 6 mm diameter will be

permitted.

Checks & Shakes : Checks up to 3 mm width and 300 mm long will

be permitted.

Pitch Pockets : Not permitted unless cut out and filled.

Plugs and Inserts : Not permitted.

Joints and Lamination

Glue Lines : Not permitted.

Rate of Growth : Not fewer that 8 growth rings per 25

mm at any point on any cross section.

Slope of Grain : Not greater than 1 in 8.

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 6 SECTION 10 BUILDING SPECIFICATIONS

Species & Character : Same on all surfaces and matched as far as

possible.

Pinholes : Permitted if filled.

A sample of each representative section for use in the work shall be previously
submitted for approval by the Engineer's Representative.

10/4.4 TIMBER FIXING ACCESSORIES

Nails for fixing joinery shall be aluminium or sheradised mild steel.

Screws for fixing joinery shall be sheradised mild steel.

Bolts shall be stainless steel.

Adhesives for exterior use shall be synthetic resin types, weather and boil-proof,
complying with the approved standard. Adhesives for interior use shall be
synthetic resin types, moisture resistant and moderately weather resistant,
complying with the approved standard.

Door frame and lining fixing cramps shall be of 25 mm wide x 14 swg thick x
250 mm girth stainless steel, one end turned up 50 mm and twice drilled and
the end fishtailed for building-in.

Dowels for fixing door frames shall be 10 mm dia. x 100 mm long stainless
steel.

10/4.5 TIMBER PRESERVATIVE

Timber preservative shall be water repellent and protect the timber from all
wood destroying fungi and insects particularly termites. The preservative shall
be applied in accordance with the manufacturer's instructions including
treatment to all ends, notches and joints in treated timber out on site.

10/4.6 IRONMONGERY

Ironmongery shall be as shown on the drawings.

10/4.7 WORKMANSHIP

All exposed faces of joiners work shall have wrought faces.

All arises shall be rounded to a 1.5 mm minimum radius unless specified or

drawn to a greater radius.

Where the term 'framing or framed' is used it shall mean all halvings, dovetails,
tenons and hardwood pins and the best known means of putting this work
together.

10/4.8 STORAGE

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 7 SECTION 10 BUILDING SPECIFICATIONS

All joinery shall be protected from the weather during transit and shall be stored
under cover, clear of the ground in clean, dry ventilated conditions so as to
maintain the specified moisture content.

All framework shall be put together loosely and stored as described and shall
not be wedged and glued together until required for fixing.

10/4.9 DOOR FRAMES

External door frames shall be built-in as work proceeds with fixing cramps as
described. The fixing cramps shall be screwed to the back of the frames at 450
mm maximum centres with two sheradised screws 25 mm long. The fishtail
ends shall be built-in to the brickwork or blockwork mortar joints as the work
proceeds.

10/4.10 DOORS

External doors shall be hung on one and a half pairs of hinges unless otherwise
detailed, to give a maximum tolerance all round of 2 mm.

10/5 METALWORK

10/5.1 ALUMINIUM

Aluminium alloy sections for aluminium shall be type H59 TF box sections.

10/5.2 ALUMINIUM LOUVERS

Aluminium louvers shall be made from NS 4 H3 aluminium and have a natural

or bronze anodised finish with sizes to match the dimensions shown on the
drawings.

10/5.3 ALUMINIUM WINDOWS

Aluminium windows shall be manufactured by an approved specialist window

manufacturer from extruded aluminium sections mechanically cleated and
sealed. Glazing to be fixed into opening with clip on aluminium beads and
gasket sealed.

Finish to windows to be natural anodised 25 microns in thickness. Windows are

to be fixed into openings with stainless steel screws and sealed all round in
mastic bedding.

10/5.4 IRONMONGERY

Rates for supplying and fixing ironmongery shall include for all boring, cutting,
mortising, sinking, making good, replacing damaged screws, oiling, adjusting,
leaving in good working order and mastering all locks.

Screws shall be of suitable gauge and material for the purpose and shall match
the item to be fixed.

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 8 SECTION 10 BUILDING SPECIFICATIONS

10/6 PLUMBING

10/6.1 COPPER TUBES

Copper tubes shall be half hard copper tube of accepted standard approved by
the Engineer.

10/6.2 COPPER FITTINGS, WASTE PIPES, BALL VALVES ETC.

All fittings shall be of an accepted standard approved by the Engineer and as

described on the drawings.

10/6.3 UPVC PRESSURE PIPES AND FITTINGS

uPVC pressure pipes and fittings for water supply shall be of an accepted
standard approved by the Engineer.

10/6.4 WORKMANSHIP

The plumbing installation shall be carried out to the satisfaction and in

accordance with the Acts and By-laws of the Dubai Electricity and Water
Authority.

10/6.5 PIPEWORK

All pipework shall be neatly executed in long lengths to avoid unnecessary

jointing. Horizontal pipes shall be fixed with a slight fall to prevent airlocks and
to enable the system to be easily drained down.

10/6.6 COPPER TUBE FIXING

Copper tube shall be fixed clear of walls and ceilings with two piece copper
spacing clips or with proprietary plastic pipe clips. Clips shall be at 1.20m
horizontally and 1.50m vertically for 15mm diameter pipes and at 1.80m and
2.40m respectively for 22mm and 28mm diameter pipes. Capillary joints shall
be neatly made with all surplus solder removed.

Screw threads on compression joints shall be wrapped with PTFE tape prior to
tightening.

10/6.7 WASTE PIPES

uPVC waste pipes for sinks and urinals shall be fixed and jointed in accordance
with the manufacturer's instructions. Fixing clips shall be at 0.50m horizontally
and 1.20 m vertically and joints shall be by 'O' rings, seals or solvent cement.
Care shall be taken to allow for expansion in accordance with manufacturer's
instructions.

10/6.8 SLEEVES

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 9 SECTION 10 BUILDING SPECIFICATIONS

uPVC sleeves shall be provided through walls and ceilings for pipes and shall
be internally 3 mm minimum larger than the pipes.

10/6.9 TESTING

Soil and waste pipes shall be air tested for leaks to a pressure of 38 mm water
gauge, constant for three minutes.

Rainwater pipes shall be tested for leaks as above and gutters shall be tested
by filling with water to overflow level.

Testing shall be undertaken to hidden sections of pipework before they are

built-in.

All leaks found shall be rectified and retested.

10/6.10 STORAGE TANKS

GRP cold water storage tanks shall be placed on 2 nos. galvanised mild steel
brackets bolted to the wall.

10/7 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES

10/7.1 CEMENT

Cement shall be Portland Cement as described in Section 3.

10/7.2 LIME

Lime shall be the hydrated type to the approved standard.

10/7.3 SAND

Sand for plasterwork with gypsum plasters shall be suitable for use with the
brand of gypsum plaster used. Sand for rendering, internally and externally, and
floor screeds shall comply with Clause 5/1.3.

10/7.4 GYPSUM PLASTERS

Gypsum plaster shall be of an accepted standard approved by the Engineer.

10/7.5 PLASTER TRIMS

Metal angle beads and plaster stops for plasterwork and plasterboard shall be
manufactured from galvanised mild steel.

10/7.6 METAL LATHING

Metal lathing shall be manufactured from galvanised mild steel having a

minimum short-way aperture of 6 mm.

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 10 SECTION 10 BUILDING SPECIFICATIONS

10/7.7 PLASTICIZERS

Plasticizers shall be an approved vinyl resin type and used in the manner and
proportions recommended by the manufacturer.

10/7.8 BONDING AGENTS

Bonding agents generally shall be an approved polyvinyl acetate (PVA) type

and used in the manner and proportions recommended by the manufacturer.

10/7.9 STORAGE

Plaster shall be stored in a building in dry condition on timber platforms and

shall be used within two months of manufacture.

Plasterboards shall be stored in a building in dry condition and shall be laid flat
and stacked on a sheet of polythene.

10/7.10 FLOOR TILES

Vitrified and fully vitrified floor tiles shall be as detailed on the drawings.

Floor tiling shall be laid with a proprietary tile adhesive (approved by the
Engineer) either directly onto a clean, dry and level concrete sub-floor, or on a
cement/sand screed laid over the sub-floor.

The sub-floor surface shall be scabbled to remove all surface laitance prior to
tiling or screeding. The screed shall be mixed semi-dry by hand or in a pan
mixer and shall be a 1:4 cement/sharp sand mix with just enough water to
enable it to hold together when squeezed in the hand. The sub-floor shall be
kept damp for 24 hours and the screed shall be laid and well compacted to a
thickness of 56mm and brought to the required levels using a draw float. The
finished floor screed shall be kept damp for a period of 7 days prior to
commencement of tiling.

The tile adhesive shall be spread evenly by steel trowel to a thickness of 3mm
onto which the clean, dry tiles shall be laid to give a 3mm minimum joint width.
The tiles shall be grouted with a proprietary and approved tile grout within a
minimum period of 24 hours after laying.

10/7.11 WALL TILES (INTERNAL)

Coloured wall tiles shall be 152 x 152 x 5.5mm thick glazed tiles approved by
the Engineer.

10/7.12 WALL TILES (EXTERNAL)

External wall tiles shall be as detailed on the drawings.

The concrete surface to receive tiling shall be prepared as follows :-

1) Concrete surface to be 100% keyed by either bush hammering, hacking or

water scabbling of smooth surface.

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 11 SECTION 10 BUILDING SPECIFICATIONS

2) Concrete surface shall be thoroughly moistened and a concrete slurry mix of

one part cement to two parts of medium sharp sand applied as splatter-dash
thrown onto concrete surface.

3) While the surface is wet apply 1:3.5 mix sand/cement render to a thickness
of 12mm in two coats to a plumb and level finish and with wood float finish.

The completed rendering is to be protected and allowed to dry slowly with

damping as necessary. After curing, the surface is to be allowed to dry
completely before the fixing of tiles.

Tiles shall be fixed with proprietary tile adhesive (approved by the Engineer).
The tiles are to be bedded strictly in accordance with the manufacturer's
instructions with 10mm joints between tiles.

At least 24 hours after fixing tiles are to be jointed using approved mortar.

Movement joints are to be formed between tiles in positions shown on the

drawings to the full depth of the tiles, bedding and render. Joints are to be
10mm wide and are to be filled to within 8mm of surface with inert filler and
finished with 2 part polysulphide pointing in colour to match tile jointing.

10/7.13 TILE ADHESIVE

Tile adhesive for floor and wall tiling shall be as recommended by the Tile
Manufacturer and used in accordance with the adhesive manufacturer's
instructions.

10/7.14 TILE GROUT

Tile grout for floor or wall tiles shall be as recommended by the manufacturers
of the ceramic tiles and used in accordance with the manufacturer's
instructions.

10/7.15 EXPANSION JOINTS

Expansion joints in floor and wall tiling shall be 6.5 mm wide Polyethylene
backing strip with 6.5 mm wide approved silicone sealant, gun applied on the
face in accordance with the manufacturer's instructions.

Expansion joints in floor tiling shall be at 6 m maximum centres in both

directions and around the perimeter of rooms, over structural joints and around
machine bases and holes in the floor. The joints shall be the full depth of the
floor tiles, bedding and screed x 6.5 mm minimum width. The joints shall be
primed with two coats of approved primer and when dry, filled up to within 6 mm
of the tile finish with polyethylene compressible foam strip. An approved joint
sealant shall then be gun applied and tooled to a slightly concave smooth even
finish.

10/7.16 BACKGROUNDS

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 12 SECTION 10 BUILDING SPECIFICATIONS

All backgrounds shall be clean, dry, free from efflorescence, paint, oil and dust
and adequately prepared to provide a good key. All loose, flaking and unsound
material shall be completely removed and all mortar joints shall be raked out, if
required, to a minimum depth of 10 mm. Concrete surfaces shall be well wetted
five minutes prior to plastering or rendering.

10/7.17 DISSIMILAR MATERIALS

Joints between dissimilar materials such as blockwork and concrete shall be

covered with a 300 mm wide continuous strip of expanded metal lathing fixed to
both sides with masonry nails or plugs and screws at 200 mm centres.

10/7.18 HACKING

Concrete surfaces shall be well hacked to expose the aggregate thus providing
a firm coarse textured background.

10/7.19 DUBBING OUT

Dubbing out of all areas to receive plaster or render shall be in the same mix as
the subsequent coat, not exceeding 10 mm thickness in one application, and
shall be allowed to harden.

10/7.20 SPLATTER-DASH OR STIPPLE COAT

Splatter-dash or stipple coats shall consist of 1:1.5 cement/sharp sand mixed

with 50% water/50% PVA bonding agent to form a thick slurry. The mixture
shall be vigorously brushed onto the background and stippled to give a close
textured key. The resulting finish shall be kept damp to prevent rapid drying out
and allowed to harden for seven days minimum before subsequent coats are
applied.

10/7.21 INTERNAL FINISHES-GENERAL

All internal finishes shall not commence until the building is watertight, including
glazing, and reasonably dried out.

10/7.22 INTERNAL RENDER

Internal render shall be applied to concrete blocks as follows: -

The render shall be two coat work comprising a stipple coat as described
previously and a finishing coat giving a maximum thickness of 12 mm. The mix
shall be in the proportion 1:1:6 cement/lime/sand. The render shall be kept
damp for a minimum of three days. All window and door openings must be
closed to prevent through draughts causing rapid drying out.

10/7.23 STUCCO

A PVA copolymer based putty for concrete and plaster shall be applied, in
accordance with the manufacturer's instructions, to the surface of the internal
render after curing has taken place. The stucco shall only be applied in

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 13 SECTION 10 BUILDING SPECIFICATIONS

sufficient thickness to seal the surface of the render and remove minor surface
irregularities to give a smooth surface ready to receive the decorative finish.

10/7.24 EXTERNAL RENDER

External render shall be applied to concrete, concrete blocks and clay bricks as
follows :-

The render shall be three coat work comprising a stipple coat as described
previously, an undercoat and a finish coat giving a maximum thickness of 16
mm. The mixes shall be in the proportions shown on the schedule of mixes
(Table 10-1). The undercoat shall be level, true and of sufficient thickness to
prevent the background joints showing through and shall be kept damp for
three days before applying the final coat.

Where shown on the drawings the final coat shall be approximately 5 mm thick
coloured Tyrolean open honeycombed texture machine applied render.

A key for the final coat shall be provided by combing the undercoat prior to
setting with wavy lines 20 mm apart and 5 mm deep. The final coat shall be 6
mm minimum thickness and worked to a level and smooth finish with a wooden
float with clean, true and level arises. The whole shall be protected from rapid
drying out in hot, dry and windy weather.

Table 10-1: Schedule of Mixes for External Render

Concrete, Concrete Aerated Concrete
Mix Type Blocks or Engineering Blocks of Soft Clay
Bricks Bricks
Undercoat Finish Undercoat Finis
h

Cement: Lime: Sand 1:1.5:4 1:1:5 1:2:8 1:2:8

to 4.5 to 6 to 9 to 9
Cement: Ready-Mixed 1:4 1:5 1:8 1:8
Lime / Sand to 4.5 to 6 to 9 to 9
Cement: Sand with 1:3 1:5 1:7 1:7
Plasticizers to 4 to 6 to 8 to 8

10/8 GLAZING

10/8.1 GLASS

Glass for glazing shall be the best of its respective kind and free from
blemishes and imperfections. Glass shall be as shown on the drawings.

10/8.2 BEDDING COMPOUND

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 14 SECTION 10 BUILDING SPECIFICATIONS

The bedding compound for external glazing shall be an approved non-setting

butyl rubber based proprietary compound and sufficiently elastic to allow for
thermal or other movement of the glass and timber, compatible with the
approved decorative wood stain.

The bedding compound shall show no sign of separation after bedding.

10/9 PAINTING AND DECORATING

10/9.1 PAINTING-GENERAL

All primers, oil bound undercoats and finishes, emulsions and polyurethane
interior varnishes shall be used in strict accordance with the manufacturer's
recommendations and shall be obtained from an approved manufacturer.

Only fresh paint delivered to site in original sealed containers shall be used.
Each container shall be labelled with the manufacturer's name, contents, colour,
quantity, batch number and date and instruction on method of application.

10/9.2 EXTERIOR STAIN

Pigmented stain shall be PX 65 as manufactured by Sadolin's Ltd., and used in

accordance with their recommendations, or other equal and approved, two
coats before fixing and one coat after fixing.

10/9.3 WORKMANSHIP

All painting shall be carefully executed with clean brushes and in the best
manner and applied strictly in accordance with the manufacturer's instructions.

All paints, stains and varnishes shall be well stirred before use and thinned only
in accordance with the manufacturer's recommendations.

Painting of exterior work shall not be carried out in wet, dusty or foggy weather
and interior work shall not proceed in dusty conditions.

All woodwork shall be prepared to a fine clean finish by scraping or sanding all
made dust free immediately before painting and coating.

10/9.4 STOPPING TO PLASTER

Plaster shall be clean and dry and free from loose material. Holes and cracks
shall be cut back and solidly filled, allowed to dry and rubbed down smooth.

10/9.5 STEEL PRIMING

Mild steel shall be blast cleaned and primed with two coats of primer within four
hours of cleaning.

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 15 SECTION 10 BUILDING SPECIFICATIONS

Galvanised mild steel shall be degreased with white spirit and primed with two
coats of primer.

10/9.6 OIL-BASED PAINT

Interior primed softwood and all primed mild steel shall be painted with two
undercoats and one gloss or semi-matt finish coat of oil-based paint to give a
smooth, even and solid finish, all as instructed. Each coat shall dry overnight
before applying further coats.

10/9.7 INTERNAL FINISH TO WALLS

The paint finish to internal walls shall be PVA copolymer matt emulsion paint or
as detailed on the drawings.

10/9.8 IRONMONGERY

All fixed ironmongery except hinges shall be removed before painting and re-
fixed on completion.

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 1
SECTION 11 REINSTATEMENT OF ROADS PAVEMENTS
AND TILED SIDEWALKS

(Not Used)

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 1 SECTION 12 SAFETY PROCEDURES

TABLE OF CONTENTS

12/1 GENERAL .................................................................................................................... 2

12/2 FAMILIARISATION WITH SAFETY PROBLEMS ......................................................... 2
12/3 SAFETY OFFICER ....................................................................................................... 2
12/4 SAFE WORKING CONDITIONS AT THE SITE ........................................................... 2
12/5 SAFETY EQUIPMENT ................................................................................................. 3
12/6 SAFETY PROCEDURES ............................................................................................. 4
12/7 TRAFFIC CONTROL .................................................................................................... 6

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 2 SECTION 12 SAFETY PROCEDURES

12/1 GENERAL

The Contractor shall be responsible for the safety of personnel and the public during
the contract period and compliance with safety requirements stated herein shall not
relieve the Contractor of his responsibility or liability under the Contract.

Prior to the commencement of the Works, the Contractor shall submit a safety policy
for the Contract detailing all proposed specific safety arrangements for the
agreement of the Engineer. This shall include but not be limited to the requirements
set out in this section.

If at any time safety requirements are not being met by the Contractor, the Engineer
shall have the right to instruct the Contractor on the necessary safety provisions and
the Contractor shall comply with such instructions forthwith.

The Contractor shall notify the Engineer immediately of any accident that occurs
whether on or off site in which the Contractor is directly involved which results in any
injury to any person whether directly concerned with the site or whether a third party.
Such initial notification may be verbal and shall be followed by a written
comprehensive report within 24 hours of the accident.

12/2 FAMILIARISATION WITH SAFETY PROBLEMS

The Contractor shall make himself familiar with the condition of the site before
tendering in order to assess the nature of safety problems he is likely to encounter
and the safety requirements.

12/3 SAFETY OFFICER

The Contractor shall appoint a Safety Officer who shall be responsible for all aspects
of safety. He shall be conversant with and experienced in all general civil
engineering construction and sewer safety techniques and emergency procedures,
and shall be on site at all times operatives are working. He shall enforce and
supervise the safety procedures at all places of works and make sure that adequate
safety equipment, required under Clause 12/5, is available in good working condition
and at all places of works at the time works are on-going.

The Safety Officer shall also be responsible for organizing, implementing and
maintaining any road closures, traffic diversions, removal of parked cars causing an
obstruction, etc., in adequate time to ensure compliance with the Contract
programme.

12/4 SAFE WORKING CONDITIONS AT THE SITE

The Contractor shall provide Method Statements detailing proposed safe methods
of work with the Tender. The methods should generally follow the recommendations
of the following publications :

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 3 SECTION 12 SAFETY PROCEDURES

1) Code of Construction Safety Practice as published by the Dubai Municipality.

2) Administrative Order No. 330 in connection with Safety Manual of Dubai

Municipality.

3) Health and Safety Guideline No. 2, Safe Working in Sewers and at Sewage
Works as published in the United Kingdom.

Accident procedures and emergency procedures shall be fully detailed.

No persons shall be allowed to enter a confined space until the safe methods of
work have been agreed upon and fully implemented to the satisfaction of the
Engineer.

12/5 SAFETY EQUIPMENT

The Contractor shall make sure, prior to commencement of works on site, that
adequate safety equipment, apparatus and devices are available, and that as a
minimum the following equipment and devices are available at each entry point to a
confined space:-

Type of Equipment No. Required

a. Safety harness and ropes 2

b. Lifting frame and tackle for safety harness 1
c. Gas detector (suitable for H2S) 2
d. Approved mechanical air blower and power supply 1
e. Emergency breathing apparatus 2
f. Atmosphere monitoring device, capable
of monitoring oxygen levels, and levels
of toxic and flammable gas 1
g. Washing facilities with disinfectants,
toiletries As Required
h. Communication facilities As Required
i. Lighting (explosion proof) As Required

All personnel working on, visiting or inspecting any part of the Works shall be
provided with and be required to wear appropriate protective clothing or apparatus.

This may include:-

Safety helmets, coats, gloves, footwear, goggles, ear muffs, breathing apparatus
and any other protective apparel or any other equipment deemed necessary by the
Engineer.

Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle, used in
the Works shall be thoroughly examined by a competent person at least once every
6 months and shall be test loaded to 150% of the safe working load and shall then
be tagged with the safe working load and the date of successful testing by an
authorised testing authority.

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 4 SECTION 12 SAFETY PROCEDURES

All parts and working gear whether fixed or movable, including the anchoring and
fixing appliances of every crane and lifting machine shall be of good construction,
sound material, adequate strength and shall be properly maintained. All parts and
gear shall be examined at least once every twelve months.

A register of all such equipment and examinations shall be kept up to date by the
Contractor and be available for inspection by the Engineer.

12/6 SAFETY PROCEDURES

12/6.1 GENERAL

All excavation shall be adequately supported against collapse and provided with
protective safety barriers and appropriate warning signs and bunting. Suitable and
sufficient scaffolds shall be provided and properly maintained for all work that cannot
safely be carried out from the ground or from part of the structure or from a ladder.
Every scaffold shall be of good construction, of suitable and sound material and of
adequate strength for the purpose for which it is used. Unless designed as an
independent structure, every scaffold shall be rigidly connected to a part of the
structure which is of sufficent strength to afford safe support. Protective headgear
shall always be worn.

All manufacturer’s instructions and recommendations for the use, application,

erection or construction of any material or item of equipment or plant shall be
followed precisely.

Special care shall be taken to protect all employees when using power tools or
materials which will produce a fine dust and in particular all asbestos based
products. The operator should stand upwind of the operation and wear an approved
respirator and goggles. Wherever possible overalls should be worn and should
consist of 60% polyester fibre and 40% cotton.
Transportation of any material by the Contractor shall be in suitable vehicles which
when loaded do not cause spillage and all loads shall be suitably secured. The
Engineer shall have the right to instruct the withdrawal from the site of any vehicle
which does not comply with these requirements or any of the Dubai or UAE traffic
regulations and laws.

The Contractor shall adopt the safety procedures as proposed by him as per Clause
12/4 for entry into a manhole or other confined space. However, the following safety
procedures are outlined as a guide only. The Contractor shall, where appropriate,
use these procedures in addition to his proposed procedures while entering into a
manhole or a confined space. Also included are additional information on safety
procedures for manhole entry in Appendix 3 contained in Part 3 of 3 of these
Specifications for his guidance and use where appropriate.

It shall be explicitly understood that safety is the responsibility of the Contractor and
use of any of these procedures as outlined under this clause or in Appendix 3 shall
not relieve him of any of his contractual responsibilities.

a) The manhole or confined space shall be thoroughly vented by mechanical air

blower prior to entry.

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 5 SECTION 12 SAFETY PROCEDURES

b) A full gas check is to be undertaken prior to entry. If the level of toxic or

explosive gases is above the safe level (maximum acceptable for hydrogen
sulphide is 10 ppm) or the level of oxygen is below a safe level (18%) then entry
is not permitted without the use of full breathing apparatus.

c) All persons entering a manhole or a confined space shall wear a safety harness
properly rigged to the lifting frame.

d) The mechanical air blower shall be kept close by the manhole or confined space
which has been entered.

e) The hydrogen sulphide level in the manhole or confined space shall be

continuously monitored. If the level rises above 10 ppm then the manhole or
confined space shall be evacuated immediately.

f) At least two people shall be available close to the point of entry to operate the
air blower and lifting tackle in the event of an emergency and who shall note the
location of the nearest telephone in working order and the telephone number of
the nearest hospital before entry is permitted.

g) No smoking shall be permitted and ‘no spark’ tools shall be used.

12/6.2 ATMOSPHERE MONITORING

When any person is in a confined space, the atmosphere at the work place and at
the base of the access manhole or pit shall be continuously monitored by a
Monitoring Device to detect oxygen deficiency, flammable gas and toxic gases. The
monitoring equipment shall be designed to be lowered into the work place or access
manhole and shall not depend on a sample draw tube from the surface. The
monitoring equipment shall be the first piece of equipment to be lowered into the
place of work and shall be the last piece of equipment removed.

The Contractor shall provide, maintain and calibrate the approved monitoring
equipment in accordance with the manufacturer's instructions. The Contractor shall
provide adequate numbers of monitoring devices to fully cover all proposed work
places and open manholes or access pits with adequate spare devices, parts and
batteries as needed to ensure complete monitoring of all sites of work at all times
throughout the construction period. No entry into a confined space shall be allowed
until the monitoring devices have been properly placed at the work place or access
site and the readings indicate that the atmosphere is safe. Operatives are to be fully
trained in the use of the monitoring equipment and in the necessary response to
alarm conditions.

12/6.3 ATMOSPHERE VENTILATION

Before any person is allowed to enter a confined space, the atmosphere shall be
adequately ventilated. As a minimum, both ends of the sewer section or work place
shall be opened to the atmosphere either by removing the manhole covers or
through open access pits. Positive ventilation shall be provided at all times when a
person is in a confined space, even if the atmosphere monitoring equipment
indicates that the atmosphere is safe for access.

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 6 SECTION 12 SAFETY PROCEDURES

12/6.4 SAFETY HARNESS

Each person entering a confined space shall wear a harness at all times. The
harness shall be designed such that it will enable an unconscious person to be lifted
to the surface in a vertical posture.

12/6.5 EMERGENCY BREATHING APPARATUS

Each person in a confined space shall have emergency breathing apparatus

available and ready for use within the confined space. The breathing apparatus
shall have a minimum capacity of 2 litres and a working pressure of 200 bar and
shall be tested daily, prior to starting work.

12/6.6 ACTIVE CONFINED SPACE ENTRY

Before any person is allowed to enter a confined space that is in active service, the
Contractor shall ascertain the schedule of sewage flows which can be anticipated
over the duration of the work. This shall include average and peak gravity sewage
flows and the discharge flows from all upstream pumping stations. Should the
combined gravity and pumped flows exceed safe working conditions at the work
place, then the Contractor shall prepare a plan for the control and diversion of flows
around or away from the work place. The method of flow diversion shall be as
approved by the Engineer and by the Dubai Municipality. A "permit to work" system
shall be employed for work on sewers where incoming flows (from pumping or
diversion) are controlled by people remote from the work site.

12/6.7 WASHING FACILITIES

Every work place where persons are entering a confined space, shall be provided
with facilities for washing.

12/6.8 COMMUNICATION

The Contractor shall provide a means of communication, appropriate to the safe

system of work, between ground level and any work place within the confined space.

12/6.9 LIGHTING

When permanent works are being constructed or inspected, the confined space
shall be adequately lit. The lighting apparatus shall operate at a voltage not
exceeding 50 Volts. The circuit shall be protected against overload. No
transformers, switches, fuses, contact breakers, etc., shall be taken into the
confined space. Bulbs shall be protected against damage.

12/7 TRAFFIC CONTROL

Prior to initiating any work at a site, the Contractor shall prepare, for the approval of
the Engineer, a plan for the diversion and control of traffic around the work site. The
approved traffic control plan shall be submitted to the Dubai Municipality Roads

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 7 SECTION 12 SAFETY PROCEDURES

Department and Dubai Traffic Police for review. Work at the Site may not
commence until the traffic control plan has been approved by the Dubai Municipality
Roads Department and Dubai Traffic Police.

The traffic control plan shall include a street plan of the work site showing all traffic
lanes and building access drives that will be affected by the work. The proposed
system of traffic diversions and the manner of control shall be clearly illustrated,
including the location and types of traffic cones, warning signs and warning lights to
be used. The plan should indicate the anticipated schedule of works for which traffic
must be diverted. Road diversions and road signs shall conform to Clause 1/3.4 and
to Appendix 1 contained in Part 3 of 3 of the Specifications.

The traffic control plan shall take into consideration the requirements of the work
crew for access to the work site, for positioning and parking of vehicles needed for
the work and for the temporary storage of equipment and materials.

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 1 SECTION 13 SEWER CLEANING AND CCTV SURVEY

(Not Used)

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 1

 1
SECTION 14 PIPELINES RENOVATION, REPLACEMENT
AND ABANDONMENT

(Not Used)

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 SECTION 15 MANHOLE RENOVATION AND ABANDONMENT
1 AND PUMP STATION AND RISING MAIN
ABANDONMENT

(Not Used)

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 1 SECTION 16 MICRO TUNNELING AND PIPE JACKING

TABLE OF CONTENTS

16/1 GENERAL................................................................................................................. 2
16/2 SURVEY CONTROL ................................................................................................. 6
16/3 GEOTECHNICAL INSTRUMENTATION................................................................... 7
16/4 DEWATERING ........................................................................................................ 9
16/5 SITE INVESTIGATION ........................................................................................... 10
16/6 QUALITY CONTROL .............................................................................................. 10
16/7 EQUIPMENT .......................................................................................................... 11
16/8 EXECUTION ........................................................................................................... 11
16/9 TESTING ................................................................................................................ 12
16/10 SAFETY .................................................................................................................. 12

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 2 SECTION 16 MICRO TUNNELING AND PIPE JACKING

16/1 GENERAL

The Contractor shall furnish all labour, tools, materials and equipment required to
design and complete the installation of pipelines using micro-tunnelling and pipe
jacking, or any other non destructive trenchless techniques, as and where
indicated on the Drawings and as specified, including surveying, instrumentation
and dewatering.

The Contractor may also elect to use micro-tunnelling methods to install those
pipelines where the installation method has been left to the option of the
Contractor.

The method selected by the Contractor shall be capable of maintaining the stability
of the tunnels when accounting for soil and groundwater conditions and shall take
into account the types of soil likely to be encountered during construction and the
likelihood of encountering caprock or cobbles.

The options available to the Contractor can include the following non destructive
techniques used for trenchless works:

a) Micro Tunnelling Method

This is steerable remote control pipe jacking used primarily to install pipes of
internal diameter less than that permissible for man-entry. The Contractor
may select either the auger type system or the slurry type system depending
on his evaluation of the tunnelling conditions based on the site investigations.

b) Pipe Jacking Method

A system of directly installing pipes behind a shield machine by hydraulic

jacking from a drive shaft such that the pipes form a continuous string in the
ground. The pipeline can be installed either by jacking the tunnel shield or by
jacking the entire tunnel shield and pipe string. The selection of jacking
method is dependent on the type of micro tunnelling system to be used.

c) Thrust Boring

A method of forming a pilot bore by driving a closed pipe or head from a

thrust pit into the soil which is displaced. Some small diameter models have
steering capability achieved by a slanted pilot-head face and electronic
monitoring, generally in conjunction with a locator. Back reaming may be
used to enlarge the pilot bore.

d) Bursting

It is a technique for breaking the existing pipe by brittle fracture using a

mechanically applied force. The pipe remains are usually forced into the
surrounding ground. At the same time, a new pipe of the same or larger
diameter is drawn in behind the bursting tool. The pipe bursting device can be
a pneumatic impact moling tool used to exert diverted forward thrust to the
radial bursting effect required, or by using a hydraulic device inserted into the
pipe and expanded to exert direct radial force.
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 3 SECTION 16 MICRO TUNNELING AND PIPE JACKING

e) Ramming

A non steerable system of forming a bore by driving a steel casing, usually

open-ended, using a percussive hammer from a drive pit. The soil may be
removed from an open-ended casing by augering, jetting or by compressed
air. In appropriate ground conditions, a closed casing may be used.

f) Auger Boring

A technique used for forming a bore from a drive pit to a reception pit, by
means of a rotating cutting head. Spoil is removed back to the drive shaft by
helically wound auger flights rotating in a steel casing. The equipment may
have limited steering capability.

g) Directional Drilling

A steerable system for the installation of pipes, conduits and cables in a

shallow arc using a surface launched drilling rig. This term applies mainly to
large scale crossings in which a fluid filled pilot bore is drilled without rotating
the drill string, and this is then enlarged by a washover pipe and back reamer
to the size required for the product pipe. The required deviation during pilot
boring is provided by the positioning of a bent sub. Tracking of the drill string
is achieved by the use of a downhole survey tool.

During the bidding stage, the contractor shall submit a detailed and clear method
statement for the execution of the trenchless conduit installation. This
methodology shall be included in the CONTRACTOR’S TENDER SUBMISSION as
a METHOD STATEMENT and shall be considered as an original part of his
submission. The following items shall be adequately addressed by the contractor’s
the Method Statement as a minimum requirement:

(a) General description of the recommended micro tunnelling method

(b) Sequence of operations of the recommended method.
(c) The name and the address of the sub-contractors or specialised firms
to carry out the trenchless works of the project. The firm shall be
selected from the list approved by RTA.
(d) Conduit type and specification, including compliance with relevant RTA
or the concerned services authority standard.
(e) Direction of installation of conduit.
(f) Detailed mechanical description of any motorized pumping, jacking,
horizontal boring, directional drilling or mining equipment intended for
use.
(g) Jointing type and specification
(h) Identifying the Grout type, if required, methodology and equipment for
grout injection.
(i) Specifying the existing underground utility services:-Treatment at
conflict locations Protection of services in work zone of influence.
(j) Dewatering
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 4 SECTION 16 MICRO TUNNELING AND PIPE JACKING

(k) Survey equipment and methods

(l) Detailed information about the position, size, depth of temporary
access pits required.
(m) Location of temporary spoil site if required and nature of haulage
equipment
(n) Programmed daily working hours and duration for the operation
(o) Strategy for dealing with noise pollution problems if the work is to be
carried out in an urban area.
(p) Detailed traffic management plan at work zone approved by RTA or
any other concerned authority.

The Contractor shall decide the excavated dimensions of the drive and reception
shafts at the locations shown on the Drawings and as required for the
micro-tunnelling method selected. Minimum shaft dimensions shall be used at all
locations.

The thrust and receiving pits excavations shall be levelled and compacted as
required to provide firm and soild foundation to guiding tracks and for proper
alighnment.

The contractor shall ensure that Concrete thrust blocks are firmly fixed in the
excavated trench.

Caisson-type manholes may be used where possible to minimize drive and

reception shaft dimension and traffic disruption.

The Contractor shall also determine the necessary horizontal alignment of the
tunnel and the locations of any additional shafts that his approved construction
method may require.

The Contractor's work shall at all times remain within the road right-of-way and the
selection of shaft locations shall be such as to minimize disruption of normal traffic
and inconvenience to the public.

The Contractor's design shall include for all dewatering or other groundwater and
soil support systems, necessary to prevent any adjacent ground from being
adversely affected by shrinkage movement or loss of fines during and after the
construction of shaft and tunnels.

The Contractor's design shall include for all ground stabilization measures either in
advance or during micro-tunnelling operations.

The Contractor's design shall include formulation of construction procedures to

minimize ground movement and prediction of movement during shaft and tunnel
construction.

The settlements arising from the construction of the works shall be limited to the
following:

a. Ground or roadway surface above the pipe center line: 5 mm.

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 5 SECTION 16 MICRO TUNNELING AND PIPE JACKING

b. Front face of adjacent structures: 5 mm.

Safety measures are of paramount importance. All necessary safety measures

shall be taken into consideration prior to the commnecment of the excavations and
to satisfaction of the Engineer.Tunnelling through sands below the water table is a
potentially dangerous situation. A comprehensive statement of safety policy
related to these micro-tunnelling works shall be submitted and approved by the
RTA concerned deoartment or any other services authority prior to commencement
of works.

It is emphasized that in general no open trenching shall be allowed due to the

congested nature of the area and that sheeting shall have to be provided for all
open excavations when such open excavation is unavoidable. However, the
number and size of all proposed shafts shall be kept at a minimum.

The proximity of buildings is such that the driving of steel sheet piles to shafts is
not permissible, nor is any construction noise greater than 70 dB. All constructional
plant forming part of the micro-tunnelling system is to be electrically driven, either
by mains supply or on-site generation.

Before commencing on site, the Contractor shall submit a full Method Statement
indicating how all the measures required in this Specification are to be
accommodated including details of the sizes and type of micro-tunnelling
equipment proposed and the disposal of waste materials including any slurry.

This method statement shall be in addition to, and in conformity with any other
method statement(s) the Contractor is required to submit for micro-tunnelling at the
time of tendering.

The pipes and joints proposed for use in micro-tunnelling item(s) shall, as a
minimum, comply with the appropriate standards set for pipes and joints (refer to
sub-section 4.1) used in conventional (open-trench) pipeline construction in all
respects including materials of manufacture, tolerances, minimum strengths, etc.
In particular, the pipes and joints must comply with the details of Clause 4/1.6 for
use in micro-tunnelling or similar jacking operations.

The Contractor shall satisfy the Engineer that the proposed pipes and joints shall
adequately withstand the temporary loads applied during installation.

If the Contractor elects to propose GRP pipes with concrete surround for micro-
tunnelling, he shall submit along with his Tender, comprehensive material
standards and complete specifications for these pipes for review and consideration
of the Engineer.

The contractor shall also provide evidence of successful use of such materials
elsewhere in a similar construction method and in areas of similar soil conditions
including the highly saline nature of the groundwater as in Dubai.

16/1.1 LIST OF APPROVED SPECIALIST FIRMS/SUB-CONTRACTORS

Included below is the list of specialist Firms/ Sub-Contractors who are approved to
work for Micro-tunnelling on this project.

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 6 SECTION 16 MICRO TUNNELING AND PIPE JACKING

The Contractor shall be required to select and engage specialist

Firm(s)/Sub-Contractors(s) from the approved list to carry out all the
Micro-tunnelling works of this project (except where the Contractor himself is
included in the approved list Table 16-1):-

Table 16- 1: Approved Firm(s)/Sub-Contractors(s) entitled to carry out all the Micro-tunnelling
works
1. Euro-Iseki Ltd. (U.K.) 2. Foundation Engineering (U.A.E.)/
Avonbrook House, Masons Rd. Laserbore (U.K.)
Stratford-Upon-Avon C/O Foundation Engineering
Warwickshire CV37 9LQ P.O. Box 2526
United Kingdom Dubai, U.A.E.
Tel. : 44(0) 789 292227 Tel. : 04-450247
Fax : 44(0) 789 268350 Fax : 04-457641
Telex : 312440 PBSSPAG
3. M.C. Clancy (U.K.) 4. Dutco (U.A.E.)/
Clare House Coppermill Lane Brochier (Germany)
Harefiled, Middlesex UB96HZ P.O. Box 233
United Kingdom Dubai, U.A.E.
Tel. : 0044 5825263 Tel. : 04-851445
Fax : 0895 825263 Fax : 04-852103

16/1.2 COORDINATION WITH SEVICES AUTHORITIES

During the preparation of the microtunneling Method Statement, Services

authorities shall be contacted to obtain locations of water, electricity and telephone
services, sewer, storm water and gas piplines and other lines of services.

16/2 SURVEY CONTROL

16/2.1 GENERAL

The Contractor shall set out the works and establish the laser guidance system for
the micro-tunnelling machine using survey stations given on the Drawings or
indicated by the Engineer on site. Any temporary control points are to be recorded
and notified to the Engineer for checking.

16/2.2 SURVEY REFERENCES

The laser guidance system for the micro-tunnelling machine shall be such that the
machines position can be continuously monitored. Any deviations from line or level
shall be recorded as each new pipe is inserted.

16/2.3 STRUCTURAL SURVEY

A pre-construction survey of all structures within 4 times the depth of micro-tunnel

on each side of the tunnel centerline shall be completed within 30 days before the

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 7 SECTION 16 MICRO TUNNELING AND PIPE JACKING

start of the micro-tunnelling activities. The Contractor shall submit a report

containing photographs and descriptions of the structures.

Concurrently, a level survey on these structures and the surfaces of the roadway
within the above mentioned envelope shall be completed. All these survey data
shall be submitted to the Engineer prior to any construction.

16/2.4 SITE INVESTIGATIONS

The Contractor shall engage a competent geotechnical firm to design and conduct
a comprehensive soil investigation program along the route of all lines to be
constructed using micro-tunnelling methods.

Boreholes shall be sunk adjacent to all proposed shaft locations. Due to the
variability of soil, rock and groundwater conditions, boreholes should also be sunk
at intermediate locations.

It is recommended that boreholes be sunk at a maximum intermediate spacing

between shafts of 50 meters. In any case, it shall be the responsibility of the
Contractor to adequately familiarize himself with the ground conditions along the
pipeline routes and to assure himself that the selected construction method is
appropriate and safe. This data is also vital to the proper selection of cutting head
for the tunnelling machine.

The boreholes shall be sunk at least 2.0 meters below the level of the proposed
works or at least 50 percent deeper than the proposed works, whichever is deeper
and shall be sited at least 2 metres off the proposed tunnel line to avoid creating
areas of weakened ground.

The following parameters shall be determined from undisturbed samples taken at

different depths, particularly at the tunnel depth:

- Standard penetration tests,

- Liquid and Plastic limits (Atterberg limits),
- Particle Size distribution,
- Shear strength,
- Moisture content,
- Height of water table, and
- Chemical composition of the groundwater

The boring logs, results of the laboratory tests and a discussion of the results as
they pertain to the selection of micro-tunnelling method and the selection of cutting
head shall be compiled in a "Soils Investigation Report" and submitted to the
Engineer prior to commencing micro-tunnelling work on any section.

16/3 GEOTECHNICAL INSTRUMENTATION

The Contractor shall engage a geotechnical firm to design, install and operate a
geotechnical monitoring program. The monitoring program shall include:

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 8 SECTION 16 MICRO TUNNELING AND PIPE JACKING

- Optical survey for layout and verification of all instrument locations and
elevations.

- Borehole drilling for installation of settlement anchors, observation wells and, if

requested by the Engineer, inclinometer casings.

- Furnish, install and grout observation wells and, if requested by the Engineer,
inclinometer casings including sensor and readout unit, and furnish and install
settlement anchors and settlement markers.

- Furnish and install surface settlement points on existing structures.

The observation wells, settlement anchors, settlement points and inclinometer

casings (if requested) shall be installed and monitored for 14 days prior to advance
of the tunnel heading to the station of the instrumentation, or to the start of shaft
excavation or to the start-up of a dewatering system.

The geotechnical firm shall read and record data in accordance with the schedule
below and report data from the geotechnical instrumentation within 24 hours to
the Engineer during the course of the work for micro-tunnelling or shaft
excavations.

Table 16- 2: Micro-tunnelling Monitoring Schedule

Monitoring Schedule

Activity Instrument Reading Frequency

Tunnelling Piezometer and Daily while heading is within 100 feet of

Observation instrument. Weekly while heading is 100 to
Wells 500 feet from instrument.

Inclinometer, Daily while heading is within 50 to 500 feet

Settlement of instrument. After each advance of 5 feet,
anchors and when heading is within 50 feet of
settlement points instruments.

Excavations Observation Daily from start of dewatering to system

Wells shutdown.

Inclinometer Daily from start to completion of

excavation.

Weekly until backfill completed within 50%

of final grade.
Monthly until backfill completed.

16/3.1 SETTLEMENT POINTS

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 9 SECTION 16 MICRO TUNNELING AND PIPE JACKING

The geotechnical firm shall determine optimum location of settlement points to

monitor existing structures as acceptable to the Engineer.

He shall provide settlement points on the road surface and within existing
structures. Settlement points in the vicinity of the shafts will be agreed with or at
the direction of the Engineer.

He shall monitor all settlement points with reference to benchmarks located outside
the area of influence of the works. Monitoring shall demonstrate repeatability to
0.01 foot.

16/3.2 SETTLEMENT ANCHORS

The geotechnical firm shall install settlement anchors and reference head in drill
hole in accordance with manufacturer’s instructions. Anchors shall be grouted in
place with cement/bentonite grout mix. Proportions by weight shall be 1 part of
cement to 3 parts of bentonite to 3 parts of water, (1:3:3).

16/3.3 INCLINOMETERS (IF REQUIRED)

The Contractor (or his specialist sub-contractor as per Clause 16/3.4) shall install
inclinometer casings at locations as directed by or agreed with the Engineer. The
geotechnical firm shall supervise installation and testing of all devices and provide
qualified personnel for the proper operation and maintenance of the installation
and shall take field measurements for lateral deformation both perpendicular and
parallel to adjacent structure.

16/3.4 GROUNDWATER OBSERVATION WELLS

Prior to the installation works of the Groundwater Observation Wells, the

Contractor shall submit a detailed method statement for the installation works to
the Engineer for approval. The Contractor may engage a specialist sub-contractor
with the approval of the Engineer for the installation of Groundwater Observation
Wells. In any case the Contractor shall hire the services of a Geotechnical firm who
shall inspect the installation and shall monitor the wells at a set frequency and
prepare reports on the impact of dewatering and ground movements. Such data
and reports shall be submitted to the Engineer on a regular basis.

16/3.5 OPTICAL SURVEYS

The geotechnical firm shall reference all instrument locations and elevations to
existing benchmarks and line monumentation. He shall establish elevations on all
instrument reference points to a minimum accuracy of 0.01 foot.
He shall locate all instruments by coordinate and survey ties to permanent
topographic features to minimum accuracy of 0.10 foot.

16/4 DEWATERING

The Contractor shall submit to the Engineer a method statement for dewatering
along with necessary sketches indicating any dewatering route, etc., and shall

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 10 SECTION 16 MICRO TUNNELING AND PIPE JACKING

proceed with installation of dewatering system only with the approval of the
Engineer of the method statement and the dewatering route(s).

The Contractor shall supply all equipment, tools, materials and labour for
dewatering and control of groundwater using dewatering systems consisting of well
points and/or deep wells. The system shall include any system required to
recharge the groundwater so that adjacent structures are not affected with any
additional piezometers and observation wells.

Once dewatering has begun, it shall continue 24 hours per day for extent of time
shaft excavations are open. Water levels shall be maintained at least 0.6 meter
below shaft excavations and as required by the approved tunnelling method. In
event of disturbance of foundation soils or movement of existing structures in
excess of limits stated in Clause 16/1, or movements of embankments, roadway or
sheeting towards open excavation caused by an inadequate or interrupted
dewatering system, the Contractor shall immediately notify the Engineer and take
all corrective measures necessary at no additional compensation.

The corrective measures shall include modification to the dewatering system to

correct the deficiency and repair of any associated damage at no additional
compensation. If the corrective measures prove unsatisfactory to the Engineer and
results in damage to an existing structure, all expenses incurred in any redesign of
foundation or remedial measures to repair damage to structure and in any related
construction shall be reimbursed by the Contractor. The Contractor shall take out
adequate insurance for this risk and produce evidence of it to the Engineer upon
request.

16/4.1 SUBMITTALS

The Contractor shall submit detailed dewatering plans to indicate proposed type,
depths, installation locations and method of water disposal from the work sites,
including locations of piezometers, observation wells and reinjection wells, if
required.

16/5 SITE INVESTIGATION

The Contractor shall avail himself of all available information concerning ground
conditions to determine the appropriate cutting head compatible with the expected
conditions.

The position of drive and reception shafts should be checked on site by the
Contractor to ensure that the design has provided sufficient working space which
will cause the least disruption to the flow of traffic.

Any alterations to the designed position of shafts must be approved by the

Engineer.

16/6 QUALITY CONTROL

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 11 SECTION 16 MICRO TUNNELING AND PIPE JACKING

The Contractor shall retain the services of a qualified specialist to supervise the
assembly, operation and maintenance of the equipment required for the selected
method of micro-tunnelling.
The finished micro-tunnelled pipe centerline shall have the following tolerances:

a. Horizontal : ±50 mm per 100 m sewer length

b. Vertical : ±25 mm per 100 m sewer length

16/7 EQUIPMENT

The equipment utilized to perform this work shall be designed and provided so as
to carry out the micro-tunnelling work efficiently. It shall be able to handle the
ranges of ground conditions indicated by the boreholes and groundwater level
information, with excess capacity. The equipment shall be able to maintain stability
of the tunnel when taking into account the soil and hydrostatic loads as well as any
surcharges imposed by vehicular traffic.

The Contractor shall be capable of lubricating the pipe as it is advanced. The

equipment shall include a system for handling and transporting the excavated
material from the tunnel face, through the tunnel and via the drive shaft to the
ground surface. The excavated material, and the bentonite or similar slurry, if
used, shall be properly disposed of by the Contractor.

The equipment shall include a laser guidance system to permit continuous

controlling, monitoring and adjustment of the alignment and grade. The laser shall
be mounted independently of the thrust block. The tunnelling machine shall be
fitted with a calibrated laser target, robustly constructed and rigidly secured to the
tunnelling machine.

16/8 EXECUTION

Prior to the start of work on any pipe section, assemble all material, equipment and
tools necessary to conduct tunnelling work continuously until that section is
completed.

Institute approved traffic control and diversion program including required traffic
barriers, lights and signs. The traffic control program for each work area is to be
submitted to the Dubai Municipality and to the Dubai Traffic Police for approval
prior to mobilizing to the site.

Excavate the required shafts to complete the micro-tunnelling operations in

accordance with the approved schedule. The pipeline will be driven using the
method proposed by the Contractor and as agreed by the Engineer. While the
tunnel is being advanced, the Contractor shall monitor the ground and building
levels and geotechnical instrumentation as required.

The sewer lines are located such that manmade obstructions should not be
encountered. However, the Contractor should have contingency methods available
to remove natural or manmade obstructions should they be encountered including
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 12 SECTION 16 MICRO TUNNELING AND PIPE JACKING

the facility to withdraw the micro-tunnelling machine along the line of the tunnel
drive if obstructions or changes in ground conditions are encountered within 30
metres, to allow a different micro-tunnelling machine to be used.

The tunnel shall be excavated to a size such that the overbreak is kept to a
minimum. The overbreak occuring shall be filled with a suitable slurry to keep
ground movements within the tolerances given in Clause 16/1. Slurry pressure or
mechanical earth pressure shall be maintained to ensure a positive pressure on
the working face at all times.

At all times when the tunnel is being advanced, a field supervisor with extensive
experience in the operation of the equipment being used shall be present.

The setting of the laser and target and the alignment of the tunnel relative to the
laser beam shall be continuously monitored (refer to Clause 16/2.2) to ensure
compliance with the horizontal and vertical tolerances as specified in Clause 16/6.

16/9 TESTING

All pipelines constructed by micro-tunnelling shall be inspected and tested in

accordance with Clauses 6/1 and 6/2 for new pipes.

16/10 SAFETY

The Contractor is responsible for the safety of all personnel as well as for the
safety of the public during the performance of the work and is responsible for
maintaining safe conditions in and around the work area. This is specified in more
detail in Section 12.

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 SECTION 17 ELECTRICAL AND MECHANICAL
1
SPECIFICATIONS

TABLE OF CONTENTS

17/1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED ............................... 2

17/2 DRAWINGS AND INFORMATION REQUIRED FOR ELECTRICAL AND
MECHANICAL PLANT ............................................................................................ 2
17/3 WORKMANSHIP AND DESIGN OF PLANT .......................................................... 5
17/4 LUBRICATION OF PLANT ...................................................................................... 6
17/5 INITIAL CHARGES OF OILS AND OTHER CONSUMABLES................................. 7
17/6 SPARES.................................................................................................................. 7
17/7 TOOLS AND LUBRICANTS .................................................................................... 7
17/8 DELIVERY OF SPARES, TOOLS AND LUBRICANTS ........................................... 8
17/9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE ................................. 8
17/10 AUTOMATIC CONTROL OF PLANT ...................................................................... 9
17/11 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF ................................. 9
17/12 MAINTENANCE OF PLANT .................................................................................... 9
17/13 RETURN TO SITE ................................................................................................ 10
17/14 OPERATING AND MAINTENANCE MANUALS .................................................... 10
17/15 WORKS TESTING AND INSPECTION OF MANUFACTURED ITEMS ................. 14
17/16 TESTING AND CERTIFICATION OF MOTORS ................................................... 15
17/17 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL
PLANT .................................................................................................................. 16
17/18 PLANT SUPPLIERS FOR THIS CONTRACT ....................................................... 19
17/19 CLIMATE............................................................................................................... 21
17/20 ELECTRICITY SUPPLY ........................................................................................ 21
17/21 DERATING DUE TO THE CLIMATIC CONDITIONS ............................................ 22
17/22 TROPICALISATION .............................................................................................. 22
17/23 WORK IN DANGEROUS AREAS ......................................................................... 23
17/24 CLASSIFICATION OF HAZARDOUS AREAS ....................................................... 23
17/25 HEALTH AND SAFETY AT WORK, ETC. ACT 1974 ............................................ 23
17/26 PROGRESS REPORTS......................................................................................... 23
17/27 QUALITY ASSURANCE AND STANDARDS ......................................................... 23
17/28 ADAPTATION OF EQUIPMENT ........................................................................... 24
17/29 GUARANTEE ........................................................................................................ 24
17/30 CO-ORDINATION ................................................................................................. 24
17/31 TESTING AND COMMISSIONING PROCEDURES AND DOCUMENTS .............. 25
17/32 SITE RELIABILITY TRIALS .................................................................................. 26

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17/1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED

Electrical and Mechanical plant shall be supplied and installed as detailed and in
accordance with sections 17 through 20 of the specification.

Specification section 17 through 20 shall also be applicable to temporary plant

required throughout the duration of the contract.

Particular care shall be taken to ensure that all components are suitable for the
corrosive climatic and environmental conditions prevailing in Dubai.

17/2 DRAWINGS AND INFORMATION REQUIRED FOR ELECTRICAL AND

MECHANICAL PLANT

As well as complying with the specified procedures for approval the following
documentation shall be supplied and procedures followed for all items of electrical
and mechanical plant in the Contract.

17/2.1 AT THE START OF THE CONTRACT

Within 30 days of the Engineer’s order to Commence the Works the Contractor
shall submit the specified request for approval which shall include :-

(a) Detailed drawings (6 No.) of the general arrangements and specifications of

all electrical and mechanical plant showing all apertures, holes, chases,
trenches and ducts required in associated structures.

(b) Drawings (6 No.) of electrical and electronic equipment and specifications

giving details, dimensions, circuitry, component details and schematic
diagrams with a legend of symbols used and a written description of the
operation of the circuits marked thereon.

(c) Any additional drawings of particular items, called for by the Engineer.

The manufacture of items of Plant, shall not be commenced until written approval of
all relevant drawings and specifications have been obtained.

If the drawings are not approved one copy will be returned to the Contractor marked
to indicate the alterations required.

Upon final approval one copy will be marked ôApproved¤ and returned.

After approval of drawings a further six copies shall be provided to the Engineer.

17/2.2 AS BUILT RECORD DRAWING

During the course of the Works the Contractor shall maintain a detailed record of all
changes in order to facilitate accurate preparation of “As Built Record” drawings and
to ensure that these drawings are in all respects true record of the installation.

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The Contractor is at liberty to apply for copies of the Engineer’s drawings which he
considers will assist him in the production of the ‘As Built Record drawings required
to be supplied by him, providing the Engineer is satisfied the request is reasonable,
copies will be provided by the Engineer at cost. The Contractor shall treat the copies
of the Engineer’s drawings as confidential matter and shall not use them other than
for the purpose for which they are provided.

The final record drawings shall be prepared by the Contractor and shall show the
complete Works including the sizes and routes of all ducts, pipework and cables.
The scales used shall be such that all details are legible when reduced for inclusion
in the Operation and Maintenance manuals. All drawings shall show scale bars as
appropriate.

The drawings shall clearly show the names of the plant manufacturers, giving model
and type numbers, and all details of plant and machinery duty ratings, sizes, current
settings, fuse ratings, etc. of all items of plant including electrical distribution cabling
and wiring installations.

The Contractor shall provide three prints of all drawings and schedules correctly
modified as final record drawings. These shall be submitted to the Engineer for
approval before the issue of a Taking Over Certificate and shall be a complete
record of the Mechanical and Electrical installation.

If the drawings are not approved, one copy shall be returned to the Contractor with
marked indications of the alterations required.

Upon final approval, one copy of the drawings or document shall be stamped
“Approved” and returned to the Contractor.

One set of the approved record drawings on paper shall be included in each of the
Operation and Maintenance manuals. These may be full size drawings folded and
inserted into clear plastic sleeves bound directly into the document. Reduced size
drawings shall be legible in all respects, and the actual reduced scale clearly marked
on the drawings.

1 No. copy on magnetic disc or tape, digital drawings in AutoCAD release 13,
intergraph or DXF file as appropriate and three full size sets of approved record
drawings on polyester film or other approved reproducible film shall be handed to the
Engineer. The Engineer will not issue a Taking Over Certificate for the Works until all
approved record drawings have been received.

17/2.3 PRIOR TO DELIVERY OF THE PLANT

Before plant is delivered the Contractor shall provide for the use of the Employer and
the Engineer :-

(a) Copies of all Test Certificates demonstrating compliance with the

specifications.

(b) Two copies of Draft Instructions for the Operation of the Plant which shall
describe the installation as a whole and shall give step by step procedures for
every operation in the running of the Plant. All necessary drawings and
sketches shall be included.

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(c) Two copies of Draft Instructions for the Maintenance of the Plant. These
instructions shall include charts showing lubrication, checking, testing and
replacement procedures to ensure trouble free operation.

A separate section of these Instructions shall be devoted to a complete parts

list based on sectional arrangement drawings of the Plant. The maker’s
name, address and catalogue/serial numbers shall be given for each
component of the Plant supplied.

Recommendations for consumable supplies, e.g. lubricants, packings etc.

shall be included.

The Contractor shall obtain the Draft Instructions from the suppliers, check them for
accuracy and shall bind each Instruction Book in Uniform bindings, the cover of
which shall be finished with a black and greaseproof material and the title printed on
the front and the spine including the word ‘Draft’.

The Instructions shall be specific to this Contract, a collection of manufacturer’s

descriptive leaflets will not be acceptable.

The Plant shall not be considered to be completed for purposes of delivery until the
above information has been provided.

17/2.4 PRIOR TO THE ISSUE OF THE TAKING-OVER CERTIFICATE

Before the Taking-Over Certificate is issued the Contractor shall provide for the use
of the Employer and the Engineer :-

(a) Three copies of Approved Instructions for the Operation of the Plant which
shall describe installation as a whole and shall give step by step procedures
for every operation in the running of the Plant. Copies of the ôas built record
drawings¤ and sketches shall be bound in the document.

(b) Three copies of Approved Instructions for the Maintenance of the Plant.
These instructions shall include charts showing lubrication, checking, testing
and replacement procedures to ensure trouble free operation.

(c) 1 No. copy on magnetic disc & tape on digital drawings in AutoCAD release
13, intergraph or DXF file as appropriate and two hard copies of the following
ôAs Built Record drawings¤ for approval :-

(a) Drawings showing the internal construction of the major items, with
parts list and reference numbers for ordering spares.

(b) Complete assembly drawings of machinery and ancillary plant showing

all pipe connections and fittings.

(c) General arrangement drawings showing all equipment, cabling,

traywork, etc.

(d) Detailed arrangement of any conduit work buried in floors, walls or

ceilings, in any structure.

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(e) Detailed wiring diagrams of the main circuits.

(f) Diagrams of connections between all items of equipment (e.g. main and
auxiliary switchboards, generators, control boards, motors, starters,
batteries, meters, instruments, relays, and allied equipment, etc. with
component values

(g) Three copies of detailed revised Specifications and Schedules of the

Plant as actually installed.

When (a), (b), (c), (d), (e) and (f) have been approved by the Engineer, the
Contractor shall provide two prints of each drawing or detail on thick paper for the
use of the Purchases, and one 35 mm photographic negative of each drawing or
detail mounted in a card frame 187 mm x 83 mm for the use of the Engineer.

A separate section of these Instructions shall be devoted to a complete parts list

based on sectional arrangement drawing of the Plant. The maker’s name, address
and catalogue/serial numbers shall be given for each component of the Plant
supplied.

Recommendations for consumable supplies, e.g. lubricants, packings etc. shall be

included.

The Contractor shall bind each Approved Instruction Book in uniform bindings, the
cover of which shall be finished with a black and greaseproof material and the title
printed on the front and the spine including the word ‘Approved’.

The Contract shall not be considered to be completed for purposes of the issue of
the Taking-Over Certificate until the above information has been provided.

17/2.5 DURING THE MAINTENANCE PERIOD

The Contractor shall be responsible for the complete maintenance (preventive and
corrective) of the plant for one year and shall supply at his own cost all spare parts
required during this period (The maintenance period). The maintenance period
starts from the successful inspection and commissioning of the plant and acceptance
by the Employer. The plant shall be reinspected by the Employer at the end of the
maintenance period and any item found defective during the maintenance period
shall be replaced by the Contractor free of cost. The Contractor shall submit to the
Engineer a copy of the approved preventative maintenance schedule proposed for
the installed equipment.

17/3 WORKMANSHIP AND DESIGN OF PLANT

(1) The Plant shall be new, of sound workmanship and of robust design.

(2) The general electrical and mechanical design of the Plant and particularly
that of the bearings, contacts, and other wearing parts, shall be governed by
the need for long period of service without frequent maintenance and
attention being necessary.

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(3) Unless otherwise specified, all items of Plant shall be rated for continous
service at the specified duties under the prevailing atmospheric and
operational conditions on site.

(4) All component parts of the Plant shall be manufactured to a strict system of
limits and complete inter-changeability of similar parts is required.

(5) All items of Plant for which spare parts may be required shall have attached
to them untarnishable serial numbers and basic information as to rating, etc.
in sufficient detail to allow the unit or assembly to be identified in
correspondence and when ordering parts.

(6) All parts subject to wear shall be readily accessible.

(7) Provision shall be made for taking up wear in all bearings and other wearing
parts or for easy replacement if adjustment is not practicable.

(8) If any moving parts show, in the opinion of the Engineer, signs of undue wear
or unsuitability for the purpose for which they were installed, they shall be
deemed to be defective materials, workmanship or design and shall be
replaced.

(9) Suitable packers and/or shims shall be fitted for ease of adjustment and re-
alignment of all machinery units. Particular attention shall be given to
combined sets.

(10) Where fitted bolts, spigots or other means for precise location are not
employed in the assembly of the Plant, locating dowels shall be fitted, on
completion of erection, to the satisfaction of the Engineer.

(11) The equivalent control panel reference shall be prominently inscribed on each
item of plant in a manner to be approved by the Engineer.

17/4 LUBRICATION OF PLANT

(1) Adequate and, as far as is practicable, automatic means of lubrication shall

be provided for all moving parts.

(2) The positions of all greasing and oiling points shall be arranged so as to be
readily accessible for routine servicing. Where necessary, to achieve this,
suitable extension pipes shall be fitted.

(3) Lubrication grease points shall comprise hexagon headed nipples except
where the lubrication required is of a special nature. In such event they shall
be fitted with metal labels to indicate the special lubricant required.

(4) Where continual grease or oil feeding is required the capacity of the reservoir
shall be sufficient for not less than seven days continuous services.

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17/5 INITIAL CHARGES OF OILS AND OTHER CONSUMABLES

The Contractor shall supply the initial charges of oil, grease electrolyte and similar
materials necessary for the correct setting to work and operation of the Plant.

17/6 SPARES

(1) Spares shall be readily interchangeable with the parts they replace, and shall
comply with the specification.

(2) Schedules shall be included for all spares recommended by the

manufacturers to cover periods of 2 and 5 years operation of the Plant. The
Engineer will determine the actual spares to be provided.

(3) Spares shall be packed and protected for storage to the appropriate
standard. Electrical equipment shall be sealed in polythene or similar bags
with a liberal supply of desiccant. Other items shall be protected so as to
avoid corrosion and spoilage for a minimum of twelve months after handover
to the Client. Machined surfaces of all mechanical components shall be
further protected by the application of a protective coating which may be
easily removed at the time of installation. Each package shall have attached
to it an untarnishable metal plate giving information for identification. This
shall include the maker’s name and reference description as shown on the
marked-up drawings supplied.

(4) The packages of items of spares shall be collected together by the

Contractor into consignments of reasonable size and then packed in secure
cases each of which shall contain a contents list. Where electrical items are
involved the cases shall be of tongue and groove boarding. Each case shall
be durably marked with the Contract number and site address, and shall be
sent to site after detailed instructions have been received. Each package
shall be clearly identified as to its contents in both English and Arabic.

(5) The Contractor shall provide the detailed agreed schedule in duplicate of the
spares supplied one copy to be retained by the Engineer after checking the
goods.

17/7 TOOLS AND LUBRICANTS

(1) A schedule is included to cover all special tools necessary for the proper
maintenance of the Plant. The Engineer will notify the Contractor which tools
shall be included in the Contract. These tools shall not be used for the
purpose of erecting the works.

(2) The Engineer may require to inspect the tools and packaging before dispatch
and the Contractor shall hold them at his works and not allow them to be sent
by suppliers direct to site.

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17/8 DELIVERY OF SPARES, TOOLS AND LUBRICANTS

Spares and tools shall only be dispatched to site after instructions for their reception
have been applied for and obtained from the Engineer.

The Contractor shall provide a lockable metal tool box to contain two sets of tools as
required by (1) above together with two sets of steel combination spanners to fit
every nut/bolt size on the plant including the holding down bolts and unions, plus
other tools of a special nature necessary for general maintenance.

A supply of the recommended lubricants sufficient for a period of two year's running
shall be supplied for the plant. This does not relieve the Contractor of the
responsibility of ensuring that all grease lubricants have been filled and the grease-
gun applied to all nipples before starting up the plant.

Lubricants or their equivalents shall be those obtainable in the Dubai markets.

The Contractor shall provide a detailed schedule in duplicate of the tools and
lubricants supplied one copy to be retained by the Engineer after checking the
goods.

17/9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE

(1) All Plant shall be adequately protected and packed in accordance with the
approved standard. In addition the Plant shall be so protected as to be safe
from spoilage and corrosion until installation or in the case of spare parts for
a period not less than 12 months from its date of handover to the Client.

(2) Items of plant which are finished painted at the manufacturer’s works such as
switchboards, shall be suitably encased in wood (such as hardboard secured
by screws to a wood framework) for their protection before dispatch.

(3) Particular care shall be taken in the packing of electrical apparatus. It shall
be packed separately in sealed polythene or similar approved bags (including
a liberal supply of desiccant) taking all precautions to exclude moisture.

(4) Packing cases shall be strongly constructed using tongued and grooved
boards with internal and external battens. Each packing case shall be
durably marked with the Contract number and site address and such other
marking as may be directed.

(5) The Contractor shall make good to the satisfaction of the Engineer any
deterioration of the protective coatings, paintwork, etc., which may occur
during transportation.

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17/10 AUTOMATIC CONTROL OF PLANT

(1) The system of control and protection for unmanned automatically controlled
Plant shall be such that the Plant is protected against further damage should
any piece of apparatus fail and shall be capable, should the electricity supply
fail, of re-starting correctly on resumption of supply.

(2) Each starter shall be provided with an individual fuse for the control circuit
deriving its control supply from the live and neutral in its associated cubicle
unless otherwise specified. Indicating lamps shall be controlled by separate
auxiliary contacts.

(3) In multi-unit installations the control arrangements shall provide staggered

starting and stopping of the Plant, so that not more than one unit starts or
stops at a time, to minimise electrical and hydraulic surges on the systems.

(4) The duty change to stand-by pump shall be signaled by a suitable lamp
labeled ôSTAND-BY PUMP IN USE¤ and unless otherwise specified an
alarm relay with a minimum of four contacts shall be provided to initiate such
alarms as may be specified or required to be fitted at a later date.

(5) Each pump level float switch shall be separately provided with its own low
voltage supply transformer to avoid all pumps being cut out should one
transformer fail.

17/11 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF

The Contractor shall provide qualified engineer(s) to instruct and train the Employer’s
staff in the operation and maintenance of the plant.

After the equipment has been installed, tested, adjusted and placed in the
satisfactory operation the Contractor shall provide the services of the manufacture's
representatives to instruct the Employer's operating personnel in the use and
maintenance of the equipment. An instruction and training programme shall be
conducted for up to 6 operators designated by the Employer. The Contractor shall
give the Employer at least two month's written notice of the proposed instruction and
training programme. Instruction and training covering basic system operation theory,
routine maintenance and repair, and "hands on" operation of equipment shall be
included. The duration of the instruction and training period shall be based on the
complexity of equipment involved and the equipment manufacturers
recommendations. The Engineer's/ Employers acceptance of the adequacy of
training received must be obtained before terminating the programme.

17/12 MAINTENANCE OF PLANT

The Contractor shall be responsible for the maintenance of the plant for one year
from the date of Taking Over and shall supply at his own cost all spares required
during this period.

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The Contractor shall carryout weekly, monthly, quarterly and yearly inspection and
preventive maintenance schedules of the plant and any other maintenance
schedules of the plant as recommended by the supplier of the plant. The Contractor
shall respond immediately to all plant alarms which take place during the
maintenance period. The Contractor shall make all arrangements for the complete
reinspection of the plant by the Employer/Engineer at the end of the maintenance
period and any item found defective during maintenance period shall be replaced by
the Contractor at his own cost. The warranty period for any component/item found
defective and/or repaired/ replaced during maintenance period shall be agreed by
the Engineer/Employer.

Plant keys shall be handed-over to the Sewerage System Section of the Dubai
Municipality Drainage & Irrigation Department at the end of the one year
maintenance period.

17/13 RETURN TO SITE

Eleven months after the Plant has been in operation, a visit to site shall be made by
an experienced fitter, of the Contractor or the Manufacturer, who shall service all the
Plant. The service shall comprise tracing and correction of all faults and
replacement of any item of plant found to be defective which the Engineer considers
to be the Contractor’s liability.

17/14 OPERATING AND MAINTENANCE MANUALS

17/14.1 INTRODUCTION

The Operating instructions shall be prepared in English in such a way as to provide a

step by step description of the preparation and setting to work of the whole of the
Plant and its shutting down.

The Maintenance Instructions shall be in English and include the following :-

a) Schedules of routine maintenance to be carried out for each item of Plant

installed. 1 copy of the appropriate schedules and instructions shall be
mounted on neatly finished plywood boards suitably protected by clear
varnish or other approved material. and fixed on the wall adjacent to the item
of plant to which they refer.

b) Schedule of equipment supplied giving manufacturer's name and appropriate

Make/Model No./Cat. No.

c) Schedule of spares supplied.

d) Schedule of tools supplied.

e) Sectional arrangement drawings of major items of Plant i.e. pumps valves

etc. with dismantling instructions.

f) Plant layout drawings showing the "as erected" installation.

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g) General arrangement and schematic diagrams of the "as installed" control

panel.

h) "As wired" diagrams of all electrical connections between the control panel
and installed loads.

i) Full and comprehensive instructions for the maintenance of all items of

equipment installed.

j) Test certificates for motors, pumps, compressors, pressure vessels, lifting

equipment, transformers, electrical installation and other items where
appropriate.

k) Pump performance curves as tested.

l) System curves.

m) Schedule of recommended lubricants and their equivalents.

17/14.2 GENERAL REQUIREMENTS AND CONTENTS

i) General

a) The Contractor shall provide 3 No. fully detailed manuals including all
mechanical, electrical and electronic equipment.

b) Two copies of the draft manuals shall be submitted to the Engineer for review
and approval as required by Clause 17/2.3, before delivery of the equipment.

c) The final copies of the manuals shall be provided to the Engineer within 60
days of the commencement of the maintenance period. They shall include all
revisions and comments made be the Engineer and any revisions or
corrections necessitated by changes made during installation and testing.

d) Manuals shall be contract specific, and be fully indexed and sectioned, for
allocation and distribution to the specialist staff involved on the particular
plant and equipment.

e) Where several sub-contractors and manufacturers have supplied equipment

the Contractor shall provide a complete integrated manual which clearly
demonstrates the inter-relation of the equipment.

f) Manuals shall be provided in durable hard backed A4 sized loose-leaf four

ring binders. Lever arch binders are not acceptable

g) The manuals shall enable the client to safely operate, maintain, dismantle,
reassemble and adjust all part of the works.

h) Original copies of leaflets and instructions provided by the specialist

manufacturers shall be provided. Superfluous information shall be clearly
deleted and relevant information referred to separately in the text.

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i) All instructions and manuals shall be written in accordance with appropriate

National Standards and other recognised guidelines on technical manual
writing.

ii) Contents

a) These shall comprise a number of volumes, dependent on the amount and

technical content of the equipment installed. The operating instructions shall
always form a separate volume. Manuals shall include sections containing
information as described in the following paragraphs.

b) Introduction. the name, address, telephone and fax numbers of the Site, the
Engineer, the Consultant, the Contractor, Sub-contractors, Manufacturers
and their Agents. The date the Contract commenced, and the date of the
Taking Over certificate. A brief description of the plant provided and the
contractual scope of the work, with descriptions of any work subcontracted.

c) General description of equipment

i) General process description. This shall provide information on
treatment standards, flows and a general description of the treatment
processes provided, process P&I drawings shall be included with the
manual.
ii) Process design parameters. This shall provide information on the
performance of the individual processes.
iii) General description of the mechanical equipment. This shall provide
a brief description of all mechanical plant provided.
iv) General description of the electrical equipment. This shall provide a
brief description of the equipment provided, listing individual control
panel compartments and the remote controls.

d) Detailed description of the mechanical equipment. This shall provide details

of all the mechanical equipment including manufacturer type, rating, duties,
characteristic performance curves and schedules for all components stating
serial numbers.

e) Detailed description of the electrical equipment. This shall provide details of

all electrical equipment and cables including information on the control
panel(s), listing the display and controls available for each compartment and
stating the rating, manufacturer and supplier of main components, and full
component schedules with serial numbers, calibration procedures a schedule
of input and output signals, detailed number, signal type, polarity, digital open
or closed state and analogue range.

f) Operating instructions. These shall provide details of how each piece of plant
is controlled and operated in both automatic and hand modes, including the
control philosophy and its interrelationship with other interdependent plant.
Details of plant operation under non-routine conditions and details of start-up
and shut-down procedures with any associated safety checks shall be
provided.

g) Inspection and maintenance instructions. These shall provide schedules

recording the time interval for routine inspection, maintenance and lubrication

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tasks, with reference to individual manufacturer's instruction manuals for full

details. They shall describe briefly the more complex tasks that must be
under taken at irregular intervals. In addition to the routine operating and
maintenance task this section should identify the following:

i) more complex tasks, involved with plant shut-downs, fault rectification

to components level, fault diagnostics, overhauls, etc.
ii) specific hazards associated with operating and maintaining the plant
,e.g. auto starting, high voltage, noise levels.
iii) highlight any particular complex or critical tasks over the above
normal requirements.
iv) measurements and guidance on limits of acceptable wear for all items
subject to wear.

h) Fault finding and correction. This shall provide a guide to first line checks
that can be undertaken in the event of plant failure without the need for
reference to the detailed instructions. A detailed guide of more complex
checks shall be provided in Section (g).

i) Inventory of installed plant. A schedule of this shall be provided.

j) Drawings list. A list of the ‘As-Built’ drawings shall be provided.

k) ‘As Built drawings’. Approved copies of all "As-Built" drawings shall be

included for the following:-

i) process and instrumentation diagram

ii) site layout showing main works operational features
iii) equipment and machinery layout
iv) mechanical and electrical details
v) electrical power circuit diagrams
vi) control schematic diagrams
vii) HV and LV distribution single line diagrams
viii) HV and LV cable routes
ix) PLC programmes or computer programmes
x) one master copy of the proprietary software package shall be
provided to the Engineer within one week of Contract completion. All
software licenses and/or registration requirement must be forwarded
promptly to the Engineer for subsequent registration with the
manufacturer. Sole rights to all software developed and written on all
schemes financed by the Engineer shall be retained by the Engineer.
xi) assembly drawings shall clearly show the construction details and be
in sufficient detail to facilitate re-assembly.
xii) cable schedules shall include cable reference numbers and core
reference numbers relating to power circuit diagrams.

l) The above are to be supplied to the satisfaction of the Engineer. The

Contractor shall provide the Engineer black and white prints of each on thick
paper and one ISO size A2 (594 x 420) negative of each. All drawings shall
be prepared on a CAD system and printed on ISO standard sized paper A1
unless specifically requested otherwise. Each drawing shall be marked with
the Engineers Consultant's, Contractor's and manufacturers names and
references, drawing number, title, scales, date of completion and a full

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description and date of all amendments, and shall be certified 'As-built'. The
project title shall be included in a box at the bottom right had corner of each
drawing.

17/15 WORKS TESTING AND INSPECTION OF MANUFACTURED ITEMS

All manufactured items for incorporation in the Works shall be offered for inspection,
examination and witness testing and shall be supported by certificates to
demonstrate compliance with this specification and with the approved manufacturing
and testing standards specifications.

Where manufactured items are to be shipped the packaging shall also be offered for
inspection before dispatch.

Inspections when required shall be carried out by the Engineer or his appointed
Inspecting Engineer. A schedule of proposed equipment to be witness tested is
included in the Contract Documentation.

The Contractor shall give to the Engineer and the Inspecting Engineer reasonable
notice, which shall normally be of two weeks, of the date and place at which plant will
be ready for prescribed testing.

If the tests are beyond the resource of the manufacturer he shall make
arrangements for these to be carried out elsewhere. Any variation of this
requirement shall be agreed and confirmation in writing shall be obtained from the
Engineer.

The Contractor shall supply four unpriced copies of all sub-orders for manufactured
items. Two copies of each of these sub-orders shall be forwarded to the Engineer
and two to the appointed Inspecting Engineer at the time the sub-orders are placed.
The sub-order shall indicate the Works for which the item is required, state in detail
the inspection and test requirements, give sufficient information for ready
identification and shall state that these items will be subject to witness testing and
inspection.

Four copies of all test certificates and, where relevant, curves shall be supplied to the
Inspecting Engineer within two weeks of completion of any witnessed tests.

Where witness tests are not required or instructions to waive witness tests have
been issued, the test certificates and curves shall be forwarded to the Inspecting
Engineer within two weeks of the date of testing.

On each test certificate sufficient information including the Contract Number and
details shall be given for ready identification of the material or equipment to which
the certificate refers.

No inspection or passing by the Engineer, of plant or materials covered by this

Contract, whether carried out or supplied by the Contractor, shall release him from
any of his obligations under the Contract.

The Contractor shall be entirely responsible for complying with the above testing and
inspection requirements, including the provision of test certificates, curves and any

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other information required by the Engineer and shall ensure that due care is taken by
himself and his Sub-Contractors or suppliers before presenting the Plant for
inspection or test. If unauthorised delivery has taken place the Contractor may be
required to arrange for the Plant to be returned to the manufacturer for inspection
and/or witness testing by the Inspecting Engineer.

All apparatus, instruments and connections required for the tests shall have been
tested for accuracy within the preceding 12 months.

Any equipment used in the testing of the Plant shall in all respects comply with the
appropriate safety regulations and/or requirements regarding electrical apparatus for
the safety of the Plant and the men working therein.

The Contractor shall carry out tests as stated in the approved standard; performance
tests and such other tests as are necessary, in the opinion of the Engineer, the
Engineer’s Representative or his Inspecting Engineer, to determine that the Plant
complies with the Specification either under test conditions in the manufacturer’s
works, on site or elsewhere or in the ordinary working.

Where pumps are included in the Contract, at least one unit of each size shall be
tested with the suction rigged to conform to site conditions.

All cast metal components designed for the retention of liquids, e.g. pump casings,
gear boxes, engine crank cases, etc., shall be checked for soundness after
machining etc., but before assembly or painting by treating with paraffin or similar
method.

Where tests and inspection have been completed to the Engineer’s satisfaction, and
when the test certificates, curves etc., have been checked, the Engineer will confirm
acceptance in writing. Plant shall not be incorporated in the work or delivered until
this acceptance has been received.

17/16 TESTING AND CERTIFICATION OF MOTORS

Witness testing may be waived on standard types of small motors from recognised
manufacturers and on small components used in the manufacture of units of plant.

Motors of 15kW and above shall be witness tested for performance to the approved
standard.

Type test certificates shall be provided and shall include the following information for
all motors :-

(1) Approved standard of manufacture

(2) Class of insulation

(3) Size and type of cable fittings

(4) Type of bearings, sizes and lubricant

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(5) Type and rating of heaters

(6) Brush sizes and maker (if fitted)

(7) Line current all phases

(8) Phase current balance

(9) Efficiency and P.F. at 100%, 75% and 50% of Full load

After initial witness testing each motor shall be combined with its driven units and
witness tested to demonstrate satisfactory performance, correctness of assembly
and ease of re-assembly at site. The assembled units shall be adequately marked
and dowelled.

17/17 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL

PLANT

(1) Cables laid underground shall be tested in accordance with the appropriate
standard specification and to Dubai Electricity & Water Authority - Electricity
Division's requirements for insulation resistance, and continuity of earth
circuit in the presence of the Engineers’ Representative before the cable
trenches are back-filled. All joints made during the installation of cables
which prove faulty when tested shall be remade and re-tested to the
satisfaction of the Engineer.

(2) The connections of all electrical circuits shall be proved to be correct and the
whole installation shall be tested for insulation resistance and earth loop
resistance in the presence of the Engineer or the Engineer’s Representative
and Dubai Electricity & Water Authority - Electricity Division Representative
with instruments provided by the Contractor.

Any faults or defects shall be remedied at the Contractor’s expense.

Certificates in accordance with approved standard regulations of all service
authorities shall be issued to the Engineer.

(3) On completion of erection all pipelines shall be tested to ensure tightness of

joints and connections to a pressure agreed between the Contractor and the
Engineer. Test pressures will not exceed standard specification requirements
unless otherwise specified.

(4) Lubricating and fuel lines, sumps, tanks, etc., shall be adequately flushed to
remove any foreign matter before being put to use.

(5) On completion of erection of each item of Plant the Contractor shall test and
check it and as far as is possible proving it under working conditions.

(6) As soon as is practicable after erection the Contractor will be required to co-
operate under the supervision of the Engineer in test running the completed
installation (of which the Plant may form the whole or a part) and, as far as is
possible, proving it under working conditions.

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(7) Following successful initial testing the installation shall be operated

continuously by the Contractor(s) for 24 hours, or such time as the Engineer
may specify, following the requirements of subclauses (8) thru (13) during
which time the Contractor will check that the installation is in safe working
order and fulfills the function for which it is intended.

(8) Operational demonstrations and system validation tests are required for all
mechanical and electrical equipment, Telemetry and SCADA systems
specified including all associated and related electrical systems and control
devices specified.

All costs for this shall be included in the Contract Price.

Materials, water, chemicals and electrical power for testing and

commissioning and validation shall be supplied by the Contractor.
Temporary facilities, storage, and similar facilities necessary for these shall
be supplied by the Contractor. Testing and commissioning shall be
performed under continuous inspection by the Engineer. The Contractor
shall provide sufficient experienced skilled staff to carry out the testing and
commissioning. The various equipment manufacturers shall be present, if
specified.

All defects and malfunctions found by testing and commissioning shall be

corrected immediately, using approved method and new materials for repairs
as required. Interruption time necessary for corrective work may, at the
Engineer's discretion, be added to the specified testing and commissioning
period.

Satisfactory completion and approval of required commissioning and testing

is one of the conditions precedent to the Engineer's acceptance of the work,
but does not constitute final acceptance.

Testing and commissioning shall be in accordance with the Project

Specification, the relevant International Standards, DEWA requirements,
industry norms and to the Engineer's approval.

(9) Test Procedures

Testing shall be carried out in stages as follows :-

i) primary tests and checks

ii) unit testing
iii) system validation tests
iv) commissioning and setting to work

The Contractor shall not proceed from one stage to the next without the
Engineer's approval.

Consolidation of demonstration, testing and instruction requirements. Unit

and system validation testing, commissioning and instruction of the
Employer's personnel may be performed simultaneously but requires the

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written agreement of the Engineer where this is at variance with requirements

specified elsewhere.

(10) Primary Tests and Checks

All component unit and complete systems shall conform to the Specification,
Drawing and the approved working drawings, samples, construction manuals,
materials lists, and other approved submittals.

All specified components and complete systems shall have been installed
satisfactorily and are operable.

All installation shall be safe to use. Temporary access, covers etc., will only
be permitted if approved by the Engineer.

All cleaning work shall be completed.

Equipment shall be free from physical damage due to mechanical force,

exposure to the elements, incorrect connection etc.

(11) Unit Testing

Unit testing is defined as tests on individual equipment items such as pumps,

compressors, deodorisers, blowers, fans, conveyors and all similar
equipment item. Tests may be performed simultaneously on groups of
identical equipment, items, and groups of items supplied by one
manufacturer, if practicable.

Clean water shall be used to fill tanks, wells piping and systems that contain
water, sewage or sludge in normal operation. Where necessary specified
chemical shall be used for chemical systems but shall not exceed in-service
concentrations.

Tests shall show that all component units operate with the quantities,
efficiency, repeatability, and accuracy specified.

Tests shall be carried out continuously for a minimum period of 24 hours.

(12) System validation tests

System validation tests shall not commence until tests have been
satisfactorily completed.

This is defined as testing of complete systems that perform a discrete

process function such as autodesludging, pumping systems, emergency
power systems, Telemetry SCADA and similar systems. Each system shall
include associated structures tanks, piping, utilities, instrumentation and
controls, and like related items. Two or more separate systems shall be
validation tested simultaneously when necessary to validate an entire specific
function.

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Clean water shall be used for system validation tests if it is possible to carry
them out satisfactorily with this medium. If the tests require use of the
medium used in service, then this shall be used.

Each system validation tests shall be carried out for minimum of 24 hours,
unless longer is needed to prove the performance of the system.

(13) Commissioning and Setting to Work

Commissioning is defined as testing all the equipment and system together

under actual operating conditions using all the mediums used in actual
operating conditions. Setting to work follows consecutively from this. Once
the equipment and systems are operating satisfactorily they are left to work.

Each system shall be tested including standby equipment by continuous

operation under the "in-service" condition for not less than 14 consecutive
days, with no interruptions except for normal maintenance or corrective work.
Where the in-service condition is an automatically controlled repair cycle with
on/off intervals it shall be so operated.

Systems shall be operated continuously under constant inspection of trained

operators. System operation shall be cycled from full load to light load and
back to full load each 24 h. Variable speed equipment shall cycle through the
applicable speed range at a steady rate of change. Simulated alarm and
failure operating conditions shall be induced. Test controls and protective
devise shall be tested for correct operation in adjusting system functions or
causing system shutdown.

Subject to Contractor's request and Engineer's approval in each case, the

Contractor may simulate certain operating conditions relating to flow rates,
water levels, and malfunctions. Permission for simulations will be granted
only where it is unwise or impossible to obtain the conditions covered by the
capability of ranges or equipment. The simulation method shall reflect
reasonable anticipated operating conditions.

17/18 PLANT SUPPLIERS FOR THIS CONTRACT

In order to limit the number of manufacturers of electrical and mechanical equipment

used by Dubai Municipality and to simplify related maintenance, the following
suppliers have been selected for this Contract :-

Submersible Pumps: Stenberg Flygt AB

Suetsarevagen
S - 171 20 SOLNA 1
Sweden

OR ABS Pumpen GmbH

Postfach 1220
D5204 Lohmar 1
Scheiderhohe
West Germany

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SPECIFICATIONS

OR DAE Pumpen AS
Tolderlundsveg 3
DK - 5100
Odense C
Denmark

Klein, Schanzlin & Becker (KSB)

Aktiengesellschoft,
6710 Frankenthal (Pfalz)
Germany

HV Switchgear: South Wales Switchgear Ltd

Blackwood
Gwent NP 2XH
United Kingdom

OR ASEA Brown Boveri

P. O. Box 351 or P. O. Box 11070
D - 6800 Manneheim 1 Dubai, UAE
W. Germany

OR Groupe Schneider
P. O. Box 43103
Abu Dhabi
UAE

Electrical Control Panels and LV Switchgear:

Binghalib Engineering
P.O. Box 6969
Sharjah
United Arab Emirates

OR Siemens Aktiengesellschaft
Werrer-von-Siemens-Strasse 50
Power Engineering Group
E5 Division
D8520 Erlangen
Federal Republic of Germany

OR Blackburn Starling Ltd.

Queens Drive
Nottingham
United Kingdom

The Contractor shall be responsible for liaising with the suppliers, obtaining,
checking for accuracy and issuing all drawings and other documents and for co-
ordination of supply and installation.

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17/19 CLIMATE

All plant and materials used shall be suitable for the climatic conditions described
below.

Meteorological and Ambient Conditions Prevailing in Dubai:

Maximum Ambient Temperature 52oC

Minimum Ambient Temperature 1oC

Design Ambient Temperature 55oC

Maximum Surface Temperature

(recorded under direct sunlight) 85oC

Minimum Barometric Pressure 998 mb

Average Barometric Pressure 1015 mb

Maximum Ambient Humidity 100%

Minimum Ambient Humidity 20%

Design Ambient Humidity 100%

Maximum Design Wind Velocity 160 km/hr

Average Yearly Rainfall 80 mm - 150 mm

The climate in Dubai is relatively mild from November to April, and hot from May to
October with high relative humidity.

Under certain combinations of the above climatic conditions, considerable

condensation may take place.

Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with the
extremely high ambient humidity can produce severe corrosion.

Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance. However, sudden heavy rainfall can occur in a very short period of
time.

The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr and sand storms occur in the
summer months.

17/20 ELECTRICITY SUPPLY

The electricity supply available from the Dubai Electricity & Water Authority -
Electricity Division network is 3 phase 220/380 volts, 50 Hz 4 wire.

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17/21 DERATING DUE TO THE CLIMATIC CONDITIONS

The minimum derating for all electrical equipment including cables shall be in
accordance with the relevant Electrical Standards appertaining to the climatic
conditions referred to in Clause 17/19.

Switchboards, motor control centres, and electrical equipment shall be suitable for
continuous operation in an ambient temperature of 55oC. The fact that switch gear,
control rooms, pump rooms may be air conditioned shall not be taken into account
when rating equipment.

17/22 TROPICALISATION

17/22.1 GENERAL

In choosing materials and their finishes due regard shall be given to the conditions
under which equipment is to work. Tropical duty materials shall be used wherever
possible.

17/22.2 METALS

Ferrous metals shall be prepared and coated in accordance with the painting
specification. Small iron and steel parts (other than stainless steel) of all instruments
and electrical equipment the cores of electromagnets and the metal parts of relays
and mechanisms shall be treated in an approved manner to prevent rusting.

Cores etc. which are built up of laminations or cannot for any other reason be anti-
rust treated shall have all exposed parts cleaned and heavily enamelled or
lacquered.

When it is necessary to use dissimilar metals in contact these shall be selected such
that the electro-chemical potential difference is not greater than 250 mV and if
practicable the two metals shall be insulated from each other by an approved
insulating material or by a coating of approved varnish compound.

17/22.3 SCREWS, NUTS, SPRINGS, PIVOTS ETC.

The use of iron and steel shall be avoided in instruments and electrical relays
wherever possible. Steel screws when used shall be zinc, cadmium or chromium
plated or when plating is not possible owing to tolerance limitations shall be of
corrosion resisting steel. Springs shall be of bronze or non-rusting material. Pivots
for which non-ferrous material is unsuitable shall be of an approved rustless steel
where possible.

17/22.4 WOOD

The use of wood shall be avoided as far as possible. When used it shall be of an
approved type to resist termite attack and fungal decay.

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17/22.5 ELECTRICAL INSULATING MATERIALS

The use of hygroscopic insulating materials shall not be permitted except where
immersed in oil or suitably sealed to prevent ingress of moisture.

17/23 WORK IN DANGEROUS AREAS

The Contractor shall comply with any safety precautions called for by the Engineer
such as a "Permit to Work" system for access to designated high risk areas including
wet wells, sumps, valve chambers sewers and buildings in addition to Electrical
Danger Areas.

A minimum of 21 days notice in writing shall be given when requesting Permits to

Work. No unauthorised interruptions to the plant operations will be tolerated. The
applications for permits to work/plant shutdowns shall be accompanied by approved
method statements addressing all working practices, operational implications, safety
procedures, hazards and risks.

The "Permit to work" system will be administered by the Engineer.

17/24 CLASSIFICATION OF HAZARDOUS AREAS

The wet wells of pumping stations and raw sewage open channels to a height of one
metre above coping level shall be classified as Zone 2; in accordance with BS 5345.

17/25 HEALTH AND SAFETY AT WORK, ETC. ACT 1974

The entire installation and apparatus shall comply with the Health and Safety at
Work, etc. Act 1974 (incorporating provisions of the UK Factories Act) which lays
down standards of safety and shall also be in accordance with the current Institution
of Electrical Engineers (UK) Regulations for the Electrical Equipment of Buildings.

Copies may be obtained from the Government Bookshop, P.O. Box 569, London
SE1 9NH, UK.

17/26 PROGRESS REPORTS

The Contractor shall furnish a progress report for the ME&I Works at the end of each
month utilising software generated CPM planning and reporting methods The
Contractor shall in his report state the details with dates of the submission, approval,
manufacture, works testing, shipment, installation, site testing & commissioning of
the proposed equipment.

17/27 QUALITY ASSURANCE AND STANDARDS

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All equipment furnished under this specification shall be new, and wherever possible,
shall be a standard product of an approved or experienced manufacturer, assembled
from standard components readily available in the market.

Equipment shall conform to the applicable requirements of the particular and general
project specifications and reference standards.

Manufacturer's, manufacturing premises, sub-contractors and suppliers shall operate

on an internationally recognised and approved quality system, or an equivalent in-
house quality system approved by the Engineer. The Contractor shall, if required
supply full details of the quality system to the Engineer for his review and approval.

17/28 ADAPTATION OF EQUIPMENT

No responsibility for alteration of a planned structure to accommodate substitute

equipment shall be taken by the Engineer. Equipment which requires alteration of
the structures will be considered only if the Contractor assumes all responsibility for
making and co-ordinating all necessary alterations, at no additional cost to the
Employer. All modifications to structures, mechanical, electrical, or other work made
necessary by such substitution shall require the approval of the Engineer. The cost
of this work shall be made at the Contractor's expense.

After approval of the mechanical and electrical drawings the Contractor shall prepare
and submit to the Engineer revised drawings showing any necessary revisions to the
proposed building and civil structures. The location, size and details of box-outs and
fixings for mechanical and electrical and other equipment shall be shown on the
revised drawings and the Contractor shall be responsible for providing in the civil
structures the correct location and size of the box-outs and fixings shown on the
approved mechanical and electrical drawings. The Contractor shall prepare at his
own cost the necessary revised civil drawings and detailed structural and other
design calculations and submit them to the Engineer for approval. The Contractor
shall not be entitled to an extension of time for completion for any delays from the
preparation of such revised drawings. The Contract price shall not be increased as a
result of any changes in the civil structure from that designated unless such changes
are the result of variation properly ordered by the Engineer.

17/29 GUARANTEE

The Contractor shall provide a guarantee for the maintenance period for all
equipment in accordance with the General Conditions of Contract. In addition to the
general guarantee requirements, equipment warranty shall cover:

a) faulty or inadequate design

b) improper assembly or erection
c) defective workmanship or materials

17/30 CO-ORDINATION

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The Contract Drawings show in a general arrangement form the layout desired for
the principal equipment, piping, and similar appurtenances, and shall be followed as
closely as possible. Proper judgment shall be exercised in carrying out the work to
secure the best possible headroom and space conditions throughout, to secure neat
arrangement of all equipment and accessories, to overcome local difficulties and
interference with structural conditions wherever encountered.

The Contractor shall take all measurements for his work at the installation site, verify
all dimensions and conditions at the place of installation verify the sub-contractor's
drawings and be responsible for the proposed installation, of the equipment within
the available space specified and shown on the Drawings. Proposed deviations from
the Drawings and Specification shall be submitted to the Engineer in writing giving
full details and reasons for the requests. The Engineer’s approval must be obtained
for any modification of the original works.

17/31 TESTING AND COMMISSIONING PROCEDURES AND DOCUMENTS

This clause is supplemental to Clause 17/17 Site Testing and Commissioning of

Electrical and Mechanical Plant.

a) Test procedures Method Statement. At least 45 days before testing and

commissioning is to be performed, a detailed and comprehensive method
statement shall be submitted for the performance of each separate test.
Each method statement shall describe and itemise the involved system
including associated electrical equipment, instrumentation and control
system. Evidence of an organised step-by-step procedure, properly co-
ordinating the efforts of the various trades and manufacturers representative
involved, and of the operations of the facilities should be provided. Method
Statements shall include an estimated duration and commencement date for
each procedure and a schedule of personnel and equipment required.

b) Method Statement information. Each method statement shall include the

following information, as applicable :

i) description of temporary procedure facilities, including drawings and

sketches as necessary to fully illustrate the requirements.
ii) list of test materials and estimated quantities
iii) list of instruments, measuring and recording devices, and other test
equipment, whether a part of the equipment or furnished separately
for temporary use. Copies of calibration certificates shall be
submitted for any test equipment.
iv) names of supervisor and participating personnel
v) recording intervals.

c) Record materials. Samples shall be submitted of the forms, charts, and other
materials to be used when recording demonstration and validation test
results. Wherever possible, standard forms shall be used.

d) Test recording. Neat and comprehensive records of each test shall be

maintained by the Contractor. Each portion of the test procedure shall be
described with all components itemised. Records shall be prepared on forms

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in a step-by-step fashion paralleling the approved method statement. Forms

shall list for each test or check the following :

i) check/list taken
ii) result anticipated
iii) result obtained
iv) if incorrect, corrective action taken
v) re-test/check result
vi) steps (iv) and (v) shall be repeated until all systems operate as
required. Instruments, gauges, and other sensors and display
devices forming a part of the various systems shall be employed for
data acquisition where applicable. The Contractor shall furnish all
other instruments, gauges, recorders and test devices as required,
types conforming to the approved method statements.
vii) The names of the personnel conducting the tests and the serial
numbers of any measurement equipment employed.

All applicable data such as, but not limited to, water and other liquid levels,
flows, pressures, head differentials, duration of runs, instrument readings,
voltage settings, drive speeds, motor running currents, torque, voltages and
related information, as applicable, and in accordance with approved test
procedures shall be recorded at the start and finish of each operational
demonstration and at 30 minute intervals during system validation tests,
unless other intervals are specified.

e) When a repeat of the same demonstration or validation test is required to

verify the results the repeat procedure shall be indicated on the recorded data
by numerical indication, data and time.

f) Test and commissioning reports including results, final settings and

adjustments made shall be provided in a separately bound volume of the
Operations and Maintenance Instruction Manuals.

17/32 SITE RELIABILITY TRIALS

This Clause is supplementary to Clauses 17/17 and 17/31

The Site Reliability Trials shall be carried out as follows under the control of the
Contractor's staff and the supervision of the Engineer. The purpose of these trials
shall be as follows:-

(i) To confirm the results of the Works Tests.

(ii) To confirm the performance guarantee figures.

(iii) To provide a comprehensive record of machinery performance, bearing

temperatures and alignment at the time of commissioning.

The Contractor will be responsible for the following:-

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a) To provide all necessary measuring instruments, indicators, temporary

pipework, temporary pumping plant and all other apparatus necessary to
carry out tests as detailed herein. The Contractor shall provide all necessary
skilled personnel and testing water and fuel for the Site Reliability Trials.

b) To liaise with his sub-contractors associated with the completion of any part
of the Works to ensure that all parties concerned are present during any tests
to carry out their responsibilities within the defined limits of their individual
sub-contracts.

c) To provide Test Certificates in quadruplicate giving a detailed record of all

electrical and mechanical tests carried out on the plant and cabling under the
Contract both in the manufacturers works and at site. Test certificates for the
cable installation shall be issued with the Record Drawings.

The Site Trials shall be carried out under the control of the Contractor's staff and the
supervision of the Engineer. The Contractor shall provide all of the necessary labour
and instrumentation to conduct the test.

Failure of one of the elements during the test run shall invalidate the test run, and
test runs shall be repeated until a continuous uninterrupted test run of all equipment
has been obtained.

The Site Reliability Trials, as applicable shall include the following:-

(i) A record of bearing, coupling clearances, protective device settings and

alignments shall be tabulated to show the "as-built" condition of each pump
set and drainage equipment machinery.

(ii) A record of all limit switches, overloads, relay and protective settings etc.
shall be tabulated to show the "as-built" condition of each applicable part of
FBA’s and other electrical switchgear and include a discrimination chart.

(iii) All cables shall have an insulation test to confirm the integrity of the
insulation. A tabulated record of results shall be made. Every cable shall be
subject to the following tests after installation:-

Witnessed high voltage pressure tests shall not be carried out on

P.V.C/S.W.A/P.V.C. control cables, but it shall remain the responsibility of the
Contractor to test the insulation of these cables both between cores and
between cores and earth during installation with a 500 volt insulation tester.

The Contractor shall test all cables after installation to ensure phasing out of
cores and continuity of cores sheath and armour over the whole length of the
cable.

(iv) All earthing systems shall be tested to demonstrate the resistance of the
electrodes to earth and the earth conductor continuity is in accordance with
the Specification. The tests shall be made on completion of the installation.

Tests shall also be performed to prove earth loop impedance for all circuits.
Calculations shall be produced in accordance with the IEE regulations to
support the relevance of the impedance measured.

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(v) The control centres, control panels and instrumentation shall be statically
tested with motors disconnected to confirm the correct sequence and
functional operation.

(vi) Each pump shall be operated individually over the range from closed valve
to maximum emergency top water level on a recirculation basis using fresh
water. During this test the following parameters will be recorded:-

a) Motor current and voltage.

b) Pump and sewage treatment machinery outputs.
c) Ambient and Test Water temperatures.
d) Rotational and linear speeds, noise generated
e) Process product composition.
f) Sampling, Process and Dynamic Instrumentation settings.

(vi) All equipment subject to water pressure shall be hydraulically tested to at

least 8 bar, 1.5 times the maximum working pressure, twice the closed valve
pressure or 1.5 times the surge pressure whichever is the greater.

The hydraulic tests shall also be applied to the above ground pipework at Site
after erection. The Contractor shall provide the necessary equipment
including any temporary blank flanges which may be required to isolate
equipment.

(vii) All cranes shall be tested at works with a load 25% in excess of the rated
load.
The tests shall be repeated at site when erection is complete using test
weights to be provided under the Contract.

Certificates shall be provided for both tests and these shall include details of
centre span deflections recorded during the test procedure.

After all the deficiencies apparent during the site reliability trials have been
rectified to the Engineer's satisfaction, apart from necessary retesting, the
following test shall be carried out:-

(viii) Circuit Breakers and Control Gear:

Routine tests including H.V. pressure tests, and mechanical tests.

(ix) Protection and Control Circuits:

(x) All inter-tripping circuits in conjunction with other items of plant supplied
under separate contracts and controlled by others under the supervision of
the Engineer.

All testing and commissioning records shall be bound into a separate volume
of the Operations and Maintenance Manual.

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TABLE OF CONTENTS

18/1 HV AND LV FACTORY BUILT ASSEMBLIES (F.B.A.'s) ............................................ 2

18/2 CIRCUIT BREAKERS................................................................................................ 7
18/3 EARTH LEAKAGE CIRCUIT BREAKERS AND SWITCH DISCONNECTORS .......... 9
18/4 FUSE-SWITCHES AND FUSE-SWITCH DISCONNECTORS................................... 9
18/5 FUSES ...................................................................................................................... 9
18/6 CURRENT TRANSFORMERS .................................................................................. 9
18/7 INSTRUMENT VOLTAGE TRANSFORMERS ......................................................... 10
18/8 ISOLATING TRANSFORMERS ............................................................................... 10
18/9 SELECTOR SWITCHES ......................................................................................... 10
18/10 EARTHING .............................................................................................................. 10
18/11 AC MOTORS ........................................................................................................... 10
18/12 MOTOR STARTERS ............................................................................................... 12
18/13 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S) ............................................. 16
18/14 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S) ............................................. 17
18/15 TELEMETRY SYSTEM ........................................................................................... 17
18/16 BATTERY UNITS .................................................................................................... 18
18/17 TRANSFORMERS................................................................................................... 19
18/18 INSTRUMENTS, INDICATORS AND TRANSMITTERS .......................................... 21
18/19 FLOW MEASURING EQUIPMENT ......................................................................... 25
18/20 LEVEL MEASURING & CONTROL EQUIPMENT ................................................... 27
18/21 GENERAL DESCRIPTION OF LIGHTING AND SMALL POWER INSTALLATIONS
28
18/22 PORTABLE PLANT ................................................................................................. 31
18/23 WIRING & CABLING ACCESSORIES .................................................................... 31
18/24 CABLES .................................................................................................................. 34
18/25 CABLING METHODS .............................................................................................. 37
18/27 ELECTRIC ACTUATORS ........................................................................................ 44
18/28 PLC’s and Microprocessor Equipment ..................................................................... 46

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18/1 HV AND LV FACTORY BUILT ASSEMBLIES (F.B.A.'s)

HV FBA's shall comply fully with the requirements of an approved International

Standard for metalclad switchgear and control gear.

LV FBA's shall comply with the requirements of an approved International

Standard for Type Tested Multi-cubicle-type Assemblies in order to provide fully
segregated self contained compartments.

18/1.1 CONSTRUCTION

Switch and control boards shall be factory built assemblies (FBA) and be
constructed and certified by an approved short-circuit testing authority. They shall
normally be of steel, flush fronted cubicle type, and of rigid construction, the sheet
steel being not less than 2 mm. Each FBA shall be multi-cubicle or multi-box type
form 4 with a separate compartment for the busbars and for each functional unit
or group. The protective conductor shall not be exposed. Unless otherwise
detailed they shall be self standing and have front access. Each enclosure shall
be suitably protected to an approved International Standard against dust, damp &
vermin . Removable back and other plates, where fitted shall be provided with
suitable gaskets or inserts.

Each door shall be :

(a) hung on substantial stainless steel hinges secured with SS bolts.

(b) secured with a corrosion resistant, lockable handle, operating at a sufficient

number of points to ensure firm pressure on the gaskets around the whole
periphery. Lock and handle shall be heavy duty and approved by the
Engineer and shall have common keys, and be compatible with existing
Dubai Municipality lock types.

(c) interlocked with a fuse-switch disconnector, moulded case circuit breaker

so that, unless otherwise detailed, it cannot be opened unless all the
equipment contained in the cubicle is completely isolated from all supplies.

A circuit diagram and diagram of connections of permanent nature shall be

mounted inside the termination enclosure.

Steel used for the construction of boards shall be zinc sprayed or equally
protected. Bolts, nuts, washers, etc. shall be of stainless steel. Small fixing
screws and other similar items shall be of non-ferrous metal. Screws, bolts etc.
on the face of boards shall be of stainless steel. Painting shall be to final coat of
stove enameled grey gloss finish for external surfaces, unless otherwise detailed,
and stove enameled white gloss finish for internal surfaces. Each coat to be
individually stoved on. All paints shall be applied to the directions of the paint
manufacturer. Surfaces of boards which will be in contact with or close to
structures shall, in addition, be coated with bituminous paint or equal.

18/1.2 EARTHING BAR

Boards shall be properly earth bonded and provided with a tinned and sleeved
2
copper earthing bar of minimum size 300 mm running the full length of the board

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and supplied with terminals of adequate size for connection to the station earthing
system.

18/1.3 TERMINALS

All internal connections, terminals, and metal supports for equipment and cables
shall be included.

Cables, unless otherwise detailed, shall enter through the underside of the board
via approved cable glands secured to a blank steel glanding plate. Space shall be
provided to accommodate cable glands of appropriate size for incoming and
outgoing circuits. Direct termination on equipment such as distribution board fuses
or miniature circuit breakers is not acceptable. Undrilled non-ferrous gland plates
bolted into position shall be provided where single core cables are terminated.

All gland plates and trays shall be earthed.

Termination blocks shall not be more than 400 mm from the gland plates. They
shall be referenced, readily accessible, of adequate size and suitable for
accommodating surge diverters.

18/1.4 BUSBARS

Bus bars and connections shall be identified by phase colour marking and
adequately supported by suitable insulators the whole to be mechanically and
electrically designed to withstand the full fault capacity as specified herein.

Busbars shall be rated at 50 kA for 1 sec as minimum of solid rectangular section

copper, rigidly supported and extending for the full length of the board. They shall
be of uniform cross sectional area throughout. They shall be separately housed,
arc protection shields being provided at each cubicle division. Access covers
shall carry warning labels. Connections to the busbars shall take the form of
rigidly supported copper strip and the mechanical and dielectric strength of
busbars and supports shall be capable of withstanding the worst conditions of
electrical surge which can occur in the installation. All bare copper shall be
tinned. Busbars and connections to busbars shall be protected by flame retarded
cold shrink or heat shrinkable tubing.

18/1.5 ANTI-CONDENSATION HEATERS

Anti-condensation heaters shall be provided unless otherwise detailed. They shall

normally be of enclosed tubular pattern each served from a service fuse by a front
of board rotary switch and shall be controlled via a humidistat.

The capacity of the anti-condensation heaters shall be considered at 10 watts per

square metre of cubical surface area, excluding the base with a minimum of 20
watts and shall be of available standard range of watts as follows Table 18-1 :-

Table 18- 1: Anti-condensation heaters Cpacity

STANDARD RANGE OF WATTS STANDARD VOLTAGES
20, 30, 40, 60, 80, 100, 120 110, 220V, 380 Volts

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18/1.6 INDICATING LAMPS

Indicating lamps shall be housed in flush mounted, square or circular lamp units,
measuring not less than 25 mm across the smallest dimension. Bezels shall be of
the non-metallic rustproof type. All indicating lamps shall be low voltage with self
contained transformer. Bulbs shall be voltage rated higher than the transformer
secondary to ensure long life.

Indicating lamps shall be supplied from individually fused circuits.

Lamps shall be well ventilated and the design shall permit removal of lamp glass
and bulbs from the front of the unit.

All pilot lamp bulbs shall be of the same voltage regardless of transformer primary
voltage.

18/1.7 INDICATING INSTRUMENTS

Indicating instruments shall be as Clause 18/18

18/1.8 MOTOR STARTER ISOLATION

Each motor starter shall be provided with its own MCCB or fused switch, which
shall be suitable for padlocking in the "off" position.

18/1.9 CONTROL CIRCUIT PROTECTION

Separate short circuit protection devices shall be provided for each circuit and
shall be clearly marked to show the circuit that is protected.

8.1.10 ROTOR RESISTANCES

Rotor resistances shall normally be contained in separate enclosures adequately

ventilated to dissipate heat generated and arranged so that the grids are
accessible. If resistance is installed in the starter section, then a thermostat shall
regulate the temperature of the starter section.

18/1.11 SOCKET OUTLETS

Socket outlets where detailed, shall be of low voltage not exceeding 220 V fed
from a suitable double wound and fused transformer with earth leakage
protection. They shall be 3 pin 16 ampere flush socket outlets with flaps.

18/1.12 METERING

When provision for the Dubai Electricity Water Authority (Electric Division)
metering equipment is specified the Contractor shall obtain details of the
equipment and shall submit drawings of the arrangements to be provided for
approval. The approved arrangements shall be incorporated and annotated in the
drawings submitted to the Engineer. When the KWH meter is supplied by the
Control Panel Manufacturer, the meter shall be forwarded to the Dubai Electricity

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Water Authority (Electric Division) for calibration tests prior to installation. The
calibration certificates shall be included with the documentation.

18/1.13 LABELING

Labels shall be colourless transparent plastic material not less than 3mm thick
with beveled edges to half the thickness. Each shall be reverse engraved in
Arabic and English the engraving being filled white and the reverse side painted
blue unless otherwise detailed. Main labels shall be provided as detailed and
subsidiary labels be provided for each item on the face of the board, stating what
it indicates or controls. Any item which is not isolated at the board shall, in
addition, be provided with a warning label "Danger Live Terminals Isolate Before
Maintenance" with flash and voltage in red letters on white background in Arabic
and English.

A drawing giving label sizes and a list of inscriptions shall be submitted to the
Engineer for approval before manufacture. All labels shall be fixed before taking-
over tests are carried out.

All external labels shall be affixed with chrome plated nuts and bolts with slotted
holes to allow for expansion of the label. All internal labels shall be engraved
multi-layered plastic to an approved design affixed with chrome plated nuts and
bolts or a permanent adhesive.

18/1.14 SPARES

The spare parts list for the FBA’S shall be as approved by the Dubai Municipality.

A complete spare set of all fuses and indicating lamp bulbs in each cubicle shall
be provided suitably marked and clipped in readily accessible positions, preferably
inside the door; in each cubicle.

18/1.15 FUTURE EQUIPMENT

Where provision for future equipment is detailed the arrangement shall be such
that equipment can be installed safely without interfering with the operation of the
existing plant. Cubicles provided for future equipment shall be complete with
busbars and isolators.

18/1.16 STANDBY GENERATOR CONNECTION

Each panel shall have provision for standby generator incoming supply as an
alternative to the main supply as follows:-

(a) For a load of 125 Amps or less, a suitably rated three position change over
switch with indicator lights shall be provided.

One No. 3 phase, weatherproof neutral and earth, 5 pole male socket for
the connection of a standby power generator supply shall be flush mounted
on the L.H. bottom section of the panel. Where the panel is located inside of
a weather proof kiosk. A lockable door shall be provided to afford direct
access to the socket. Each socket shall be complete with a female plug for
the termination of the generator supply cable. The socket shall incorporate

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a mechanically interlocked mechanism to ensure that the plug is

fully/correctly inserted into the socket prior to switching on the supply. The
fitting shall be rated at 125 A, 600 V and shall be compatible with the
existing fittings. Each socket shall be complete with a secured cover
which may be placed in position when the plug is removed, and as detailed
on the single line diagram.

(b) For a load higher than 125 Amps appropriate termination and change over
arrangements shall be provided, and as detailed on the single line diagram.

18/1.17 WEATHERPROOF SWITCHBOARDS

Panels for use in locations exposed to the weather shall be installed within Fibre
Glass Kiosks.

(a) All fixing screws, bolts, etc. shall be of stainless steel.

(b) Each push button shall operate through a suitable shroud covering the
whole of the button and forming a barrier between the button and the
interior. All operating spindles on isolators, etc. shall enter their enclosures
through packed glands or similar, to exclude moisture.

(c) Each board shall be protected by an outer shell.

Hinges for kiosks shall be of an approved grade of Stainless Steel and robust in
design. Lock and handle shall be heavy duty and approved by the Employer and
all locks shall have common keys. Door restrainers shall be of an approved grade
of Stainless Steel and of adequate cross section (min. 6 mm x 35 mm). The clear
space between the front of the control panel and the kiosk shall not be less than
650 mm, clearance to the rear and sides shall be a minimum 300 mm and a
maximum of 500 mm for enclosures with front access only. For enclosures with
front and rear access the minimum clearance to the rear and sides shall be 600
mm.

A generator plug and socket enclosure shall also be provided on the L.H.S. of the
kiosk. The enclosure shall be fitted inside the kiosk, mounted flush with
appropriate opening and lockable doors.

18/1.18 PANEL WIRING

Joints of main or control wiring between the components are not permitted. All
control panel wiring, motor starters, control gear and the like shall be carried out in
a neat and systematic manner with cables supported clear of the panels and other
surfaces at all points to obtain free circulation of air. Claw washers shall be used
to terminate all small wiring. Insulating bushes shall be provided where necessary
to prevent chafing of wiring. Neoprene will not be used with PVC wiring. All panel
wiring shall be in PVC sheathed cable or fire-resisting cable of approved type.

All control panel wiring, motor starters, control gear and the like shall be carried
out in a neat and systematic manner with cables supported clear of the panels
and other surfaces at all points to obtain free circulation of air. Claw washers
shall be used to terminate all small wiring. Insulating bushes shall be provided
where necessary to prevent chafing of wiring.

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All circuits above 200 Volts shall be wired in 450 / 750 Volt grade cable but circuits
at 200 Volt and below in 300 / 500 Volt grade cable. The conductors shall be of
copper and shall have a minimum cross sectional area of 1 mm2.

All wire ends shall be tinned before termination and all terminals shall be
protected by PVC sleeves or flame retarded cold shrink or heat shrinkable tubing.
All wires shall be fitted with numbered ferrules of approved type at each
termination.

Crimped lugs shall be fitted to all wires and cables for termination.

18/1.19 THERMAL OVERLOAD RELAYS

Thermal overload relays shall be temperature compensated (-10oC/80oC)

sensitive to phase failure, adjustable and be calibrated in terms of motor full load
current. Auxiliary volt free contacts shall be fitted for remote indication circuits.

Relays shall be manually reset by means of integral push-buttons or levers. A

testing facility shall also be provided. Terminals shall be of the pinch screw
pattern.

18/2 CIRCUIT BREAKERS

18/2.1 H.V. CIRCUIT BREAKERS

Circuit breakers for use in AC circuits of rated voltage above 1 kV shall be of

either the SF6 insulated, vacuum type or air break type. They shall comply with
an approved International Standard and be suitable for use with the voltages and
fault levels anticipated.

18/2.2 AIR BREAK CIRCUIT BREAKERS

Circuit breakers of rated voltage below 1 kV shall be of the air break type and
shall be suitable for controlling loads as indicated in the schedules. They shall
comply with an approved International Standard and be suitable for use on
systems with voltages and faults levels anticipated.

18/2.3 GENERAL

The circuit breakers should be horizontally isolated, horizontal drawout pattern air
break type. The closing and tripping mechanism shall be as detailed in the
relevant Clauses or schedules.

The operating mechanism shall have a mechanical ON/OFF indicator and a

manual trip device fitted with means for locking test terminal blocks healthy trip
lamp (coloured white) and associated push-buttons set of auxiliary switches
SUPPLY AVAILABLE lamps (blue) (on incoming units only) and cable boxes
complete with glands of suitable size for the accommodation of the incoming and
outgoing cables entering from below.

Each circuit breaker shall be provided with an operations counter.

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Closing solenoids shall be suitable for operation at 80% of the nominal supply
voltage.

Closing and tripping batteries shall comply with Clause 18/16.

Auxiliary contacts for the indication of breaker state for use at 24V DC shall be
provided.

Circuit breakers shall be designed and constructed such that inspection

maintenance and replacement of the main fixed and moving contacts shall be
easily possible on site. Detailed manufacturer’s instructions shall be incorporated
in the maintenance manuals. Breakers requiring their complete return to the
manufacturers for service will not be acceptable.

All circuit breakers shall be provided with interlocks to ensure that:-

Circuit breakers cannot be plugged in or isolated when it is closed.

The circuit breaker cannot be closed until it is fully plugged in or completely

isolated.

The circuit breaker cannot be closed in the service position without

completing the auxiliary circuits between the fixed and moving positions.

Facilities shall be provided for testing the circuit breaker operation when in
the isolated and withdrawn position. Auxiliary jumper connections if
necessary shall be included.

The incoming circuit breakers should be fitted with over current tripping and
earth fault relays with auxiliary relay for instantaneous remote trip and
indication.

If transformer protection relays are to be located on the LV breakers an intertrip

relay shall be provided to trip the HV breaker on operation of transformer
protection device.

All incoming circuit breakers shall be fitted with a voltmeter with a selector switch
to read voltage of the line and line to neutral.

Ammeters shall be fitted on the bus bar side voltmeters on the line side of the
incoming circuit breaker trips.

The LV circuit breaker shall trip every time its associated HV circuit breaker trips.

Any other interlocking shall be provided as necessary to ensure the safe operation
and maintenance of all electrical equipment provided under the Contract.

All components of the switchgear including bus bars and cable boxes shall be
capable of withstanding the tests outlined in the approved International
Standards.

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18/3 EARTH LEAKAGE CIRCUIT BREAKERS AND SWITCH DISCONNECTORS

Earth Leakage circuit breakers and fuse-switch disconnectors or switch

disconnectors shall, unless otherwise specified, be of front access type. They
shall be of the horizontal draw-out triple pole type, provided with a detachable
neutral link suitable for the system voltage and capable of withstanding the fault
current of the system.

Contacts shall be of robust design, of adequate cross sectional area, capable of

carrying the full load current for an indefinite period and shall be readily
renewable. The fixed contacts shall be shrouded.

The switching mechanism shall be of a well proven type, interlocked to prevent

access under energised conditions and shall incorporate a mechanical switch
position indicator labeled "ON" and "OFF".

18/4 FUSE-SWITCHES AND FUSE-SWITCH DISCONNECTORS

(1) All fuse-switches and fuse-switch disconnectors shall be capable of

withstanding the fault level of the system.

(2) Unless otherwise called for in the detailed specification the following
standards sizes shall be employed throughout :-

60, 100, 150, 200, 300, 400, 500, 600 and 800 A.

60 A units shall be suitable for adapting carriers to accept 30 A fuses.

(3) The switch action shall be parallel, giving a simultaneous make and break
action on all contacts.

(4) Moving contacts shall be provided with suitable fillets between phases with
fixed contacts fully shrouded.

(5) The construction of fuse-switches and fuse-disconnectors shall be suitable

for easy removal of contacts and all moving parts under site conditions.

18/5 FUSES

Fuses for systems of up to and including 1,000 Volt pressure, shall be of the HRC
cartridge type to approved International Standards.

Control circuit fuses, alarm indicator fuses, semi-enclosed fuses, domestic

consumer unit fuses and high voltage fuses shall be manufactured to an approved
International Standard.

18/6 CURRENT TRANSFORMERS

Current transformers shall be manufactured to an approved International

Standard.

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18/7 INSTRUMENT VOLTAGE TRANSFORMERS

Voltage transformers shall be manufactured to an approved International

Standard.

18/8 ISOLATING TRANSFORMERS

Isolating transformers shall be manufactured to an approved International

Standard.

18/9 SELECTOR SWITCHES

(1) Selector switches shall be of robust design and construction and rotary in
operation. Bezels shall be of non-metallic rust-proof type.

(2) Switches for voltmeters shall be capable of selecting :-

R-B, B-Y, Y-R, R-N, B-N, Y-N and OFF

(3) Switches for ammeter

18/10 EARTHING

All switchboards and control boards shall be provided with a proper system of
earthing, suitable for connection to all protective conductors and metallic
sheathing of all associated cables, so as to be effectively connected to the
general mass of earth at the sub-station from which the installation is supplied, in
accordance with approved regulations and codes of practice as required by the
supply authority and to the approval of the Engineer.

18/11 AC MOTORS

(1) AC motors shall be continuously rated to S1 duty and performance and be

suitable for 15 starts per hour.

(2) Conditions of operation and type of protection shall be as given in the

detailed specification.

(3) Frame sizes shall be in accordance with an approved International

Standard.

(4) Commutator segments shall be constructed from hard drawn copper or

equal approved and of ample cross-section with sufficient depth to permit
"skimming".

(5) Brushes where applicable shall be of standard sizes. They shall be

mounted in holders with springs such that the correct pressure is applied
and no portion of the load current is carried by the springs. An alternative

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device which ensures constant pressure at the brushes throughout their life
may be offered. The whole brush assembly shall be continuously rated for
the duty and so constructed that it can be conveniently removed.

(6) Windings shall be designed to give an even temperature distribution, free

from hot spots.

(7) Temperature sensitive thermistor devices shall be embedded in each phase

winding for motors of 7.5 kW and above unless otherwise specified.

(8) The rotor assembly shall be statically and dynamically balanced, vibration
shall not exceed the limits set out in the approved International Standard or
such finer limits as defined in the detailed specification. Bearings shall
have lubricators suitable for ensuring an adequate supply of lubricant at all
times. For motors of 37 kW and above the bearings shall have plugged
pockets suitable for insertion of thermometers or temperature probes.

(9) Moving parts of the motor shall be provided with guards and where
appropriate hinged doors shall be provided for easy access to commutator
and brush gear.

(10) Unless otherwise specified, heaters shall be incorporated to prevent

moisture condensation when the motors are stationary. Where heaters are
not fitted the motor shall have a suitable drain hole in the casing.

(11) Terminal boxes shall be conveniently located and of adequate size to

accommodate all connection requirements. The heater and thermistor
connections may be located in the starter box provided they are isolated
from other connections, shrouded, and clearly marked. Alternatively
separate boxes with non-interchangeable covers may be provided for the
heater and thermistor connections. Terminal boxes shall be provided with
removable plates suitable for drilling and tapping by others unless details of
the required drillings are given in the detailed specification.

(12) Each motor shall be provided with a suitable external earthing terminal.

(13) Each motor shall have a rating plate with the following information:-

(a) Manufacturing standard reference.

(b) Maker’s name and motor type number.
(c) Frame size.
(d) Rating.
(e) Class of insulation.

and, where significant

(f) Ambient working temperature.

(g) Type of coolant.
(h) The permissible overspeed.

In addition motors of 7.5 kW and above shall have individual identification

numbers.

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18/12 MOTOR STARTERS

18/12.1 GENERAL

The starter cubicles as required are to form part of the FBA and as such circuit
connections protection devices and the like shall comply with the approved
International Standards appertaining to the FBA’s . The cubicles shall be easily
accessible for maintenance purposes and shall be damp-proof and dust-proof.
The motor starter shall comply with an approved International Standard and shall
be suitable to carry the full load current of its rated duty at its most severe load
conditions. All starters shall be capable of at least 20 starts per hour at 100% full
load torque. Motor starters shall be dust-proof. Motors up to and including 11 kW
shall be started direct on line. Motors above 11 kW shall be started in accordance
with applicable clauses detailed herein.

18/12.2 L.V. STARTERS

Each starter shall be housed in a separate compartment which shall contain the
following:-

a) 1 No. triple pole MCCB or fuse switch externally operated and

interlocked with the cubicle door. There shall be provision for
padlocking in the OFF position.

b) Contactors selected from one of the following types:-

i. 1 No. TP contactor for switching direct-on-line (DOL) in

accordance with an approved International Standard and fitted
with auxiliary contacts.

ii. Closed transition star-delta starting

iii. For auto-transformer starting there shall be provided

magnetically operated starting, accelerating and running
contactors operating under mechanical or pneumatic timing
devices. The auto-transformer shall limit the starting current to
4 times full load current (FLC) with 60%, 70% and 80%
tappings.

iv. For slip ring rotor resistance starting there shall be provided
magnetically operated starting, accelerating and running
contactors operating under mechanical or pneumatic timing
devices.

v. Contactors shall be selected for AC4 duty.

vi. For Solid State Reduced voltage Starting there shall be

provided a micro-processor based electronic logic module and
a 3 pole, 6 thyristor (SCR) full wave power section together
with the following features:-

(1) Turn on current adjustment - 100 to 400% FLC.

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(2) Pulse start adjustment - 0 to 2 seconds.

(3) Adjustable current ramp time - 2 to 30 seconds.
(4) Starting current limit adjustment - 100 to 400% FLC
(5) Over temperature protection.
(6) Fan assisted cooling above 11 kW.

c) 1 No. Electronic Motor Protection Relay with the following features:-

Protection Against:

overcurrent unbalance
single phase
earth fault

Digital Indication of:

relay settings
% of FLC that the motor is taking
continuous monitoring of thermal capacity of motor
thermal capacity used during start of motor
if tripped, how much time before restart to take place
stall or short circuit trip
earth fault trip
starting

Documentary evidence must be produced showing the current/time

characteristic of each overload at its setting (hot/cold for the thermal
overload) overlaid on the motor manufacturers thermal stability
time/current characteristic for comparison. Consideration must be
given as to the requested method of starting (DOL, auto transformer
etc.).

d) 1 Set of auxiliary relays and timers required to provide the necessary

indication and control sequence.

e) Motor starter TEST switch to allow operation of the starter with no

supply to the associated motor.

f) 1 Set of main motor terminals and auxiliary terminals for remote

controls and indicators all complying with clause 18/1.3.

g) 1 Set terminals for remote lock-off stop push buttons.

h) 1 No. 220/110V 50 Hz double wound single phase transformer with

earth screen and of suitable capacity to supply all pilot lamp
requirements. The control and pilot lamp circuits shall be fuse
protected on both sides. The transformer secondary shall be centre
tapped and earthed via a removable bolted earth link. The
transformer primary shall be supplied through a suitably rated fuse
and neutral link via auxiliary contacts of the main fuse switch with a
suitably wired switch marked "TEST" for the purpose of conducting
functional tests to the control circuit whilst the main fuse switch is
isolated.

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The switch shall be interlocked so as to prevent the closing of the

cubicle door with the said switch in the "ON" position.

i) 1 No. anti-condensation heater (off when starter contactor is closed).

The heater shall be separately fused.

j) 1 Set of power factor correction capacitors with fuses for all corrected
drives.

k) 1 Adjustable thermostat to be mounted in the starting resistance

cubicle and protecting the resistance from overheating by tripping the
main contactors. (Resistance and auto-transformer starting).

The following equipment shall be mounted on the door of the starter cubicle:-

l) 1 No. ammeter fitted with suppressed scale to read motor running and
starting current.

m) 2 No. pilot lamps to indicate "SUPPLY ON" (green) and "MOTOR

RUNNING” (Red).

n) 1 No. pilot lamp to indicate "MOTOR FAILED" (Amber).

o) 1 No. Blue pilot lamp to show automatic operation has been selected.

p) Pilot lamps shall comply with Clause 18/1.6.

q) 1 No. "HAND/OFF/AUTO" selector switch.

r) 1 Local/remote selector switch as required.

s) 1 set "START/STOP" push button.

t) 1 No. externally operated overload reset push button.

u) 1 No. motor and cubicle heater "OFF/AUTO" control switch.

v) 1 No. hour counter reading to 9999 hours.

w) 1 duty label.

x) 1 No. digital display unit.

Volt-free N/O and N/C auxillary contacts wired to terminals for remote
indication of motor running, motor stopped, hand and automatic
selected, shall be provided for all starters.

18/12.3 H.V. STARTERS

All H.V. starters shall be generally equipped as L.V. starters except as

detailed below.

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i) 1 No. TP externally operated load isolating switch mechanically

interlocked with the cubicle doors and electrically interlocked with the
main contactor. The isolator shall have three positions: closed, open
and earthed position. There shall be provision to lock the isolating
switch in the OFF & Earth position.

ii) 1 No. Externally hand operated shrouded control isolator with the
above unit to provide a contactor test facility.

iii) 3 No. bolt on type HRC fuses suitably fault rated.

iv) 1 No. Triple pole H.V. vacuum contactor which shall comply with
requirements of an approved International Standard and be designed
to minimise the mean currents chopped and transient over voltages to
those which could occur with an equivalent air contactor. Continuous
vacuum monitoring facilities shall be provided and interlocked with the
contactor coil.

The contactors shall be suitable for mechanical duty in accordance with an

approved International Standard.

18/12.4 SLIP RING ROTOR RESISTANCE MOTOR STARTERS

18/12.4.1 General

Where slip ring rotor resistance motor starters are employed the rotor
resistance shall be of the metal grid type and shall limit the starting current to
that specified for the size of drive.

Rotor resistance shall be mounted in floor standing units, panel top units or
integral panel units.

18/12.4.2 Floor Standing units

The rotor resistance may be mounted within floor standing cubicles

constructed of 2mm (minimum) thick sheet steel of welded construction. The
cubicles shall be provided with adequate ventilation louvers and access to the
resistance units shall be by means of a lockable, hinged front door. The
cubicle shall be arranged for cabling from below.
Both the exterior and interior of the cubicle shall be stove enameled to in
Grey to an approved International Standard. Warning notices to indicate
electrical hazard within shall be fixed to all access panels.

Each cubicle shall be equipped with a heater which shall be continuously "on"
while the associated resistance bank is de-energised.

18/12.4.3 Panel Top Units

The rotor resistance may be mounted within separate cubicles mounted on

top of the control panel. These cubicles shall be identical in construction to
the control panel and dummy cubicles shall be provided as necessary to
ensure uniform height of the entire control panel.

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The cubicles shall be provided with adequate ventilation louvres and access
to the resistance units shall be by means of a lockable, hinged front door.
Cable connections to the main control panel shall be via suitable cable glands
to maintain the integrity of the control panel enclosure.

Each cubicle shall be equipped with a heater which shall be continuously "on"
while the associated resistance bank is de-energised.

18/12.4.4 Integral Panel Units

The rotor resistance may be mounted within a cubicle within the control panel
itself provided that:-

(a) The resistance cubicle is adequately ventilated front and rear.

(b) The resistance cubicle is provided with suitable cable gland entries to
maintain the integrity of the control panel enclosure.

(c) The resistance cubicle is located so that no electrical components are

mounted above it.

(d) The motor starter equipment is located in a separate, totally enclosed

cubicle within the control panel.

(e) 1 No. TP wound magnetic overload relay fully adjustable but set at the
actual current setting required to trip under a stalled motor condition
within the maximum time that the motor characteristic permits this
condition to exist.

18/13 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S)

(1) M.C.C.B's shall withstand the system short circuit current of not less than
30 KA.

(2) M.C.C.B's shall accommodate the maximum number of poles available.

(3) The rated voltage insulation shall not be less than 600 V AC and the rated
operation voltage shall not be less than 380 V AC.

(4) The rated operational current for uninterrupted duty shall meet loading
requirements.

(5) The switching mechanism shall be fully interlocked with the compartment
door to prevent entry by personnel while the M.C.C.B is in the energised
position.

(6) All contacts shall be shrouded to prevent accidental contact by operations

and maintenance personnel.

(7) Thermal and magnetic settings shall be adjustable.

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(8) Volt free contacts shall be provided for ON/OFF indication, contacts shall
be wired to case mounted terminals.

18/14 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S)

The control unit shall be suitable for operation on 220 V AC supply and in the
ambient conditions prevailing in Dubai. It shall contain a built -in battery with a
minimum life of 2 years. Stored data shall be protected from being lost in the
event of a power failure. The unit shall record the time taken to empty the sump
and calculate the idle time to continuously adapt the operation of the pump(s) to
the station inflow to achieve the most economical operation. The current sensors
for use in conjunction with the computer logic system shall be either a current
transformer or a low level sensor and shall be installed in the control panel.

The current transformer primary current shall be as close to the pump's operating
current as possible.

The control system shall have the following facilities:-

(1) The pumps shall be controlled automatically by a computer logic system

installed in the control panel using signals received from float level
switches on a 1st duty, 2nd duty/standby (2 pumps only) and 3rd
duty/standby (3 pumps) to chamber of pumps basis with a common stop.
The duties shall alternate automatically.

(2) Each pump shall be capable of selection for manual/auto duty.

(3) The automatic duty shall be selected by an auto/hand selector switch.

(4) Each pump in manual shall be controlled by start/stop push button.

(5) Individual pump start delay to reduce starting current surges.

(6) The emergency stop (low level) float shall be in circuit for both manual and
auto modes of operation and shall stop all the pumps.

(7) A high level in the pump shall be indicated in the panel through a float
switch and a continuously rated flasher light mounted on top of the
kiosk marked 'HIGH LEVEL IN SUMP'.

(8) Reset button to erase all stored operating data from the memory.

18/15 TELEMETRY SYSTEM

The objectives and key features of the telemetry system will be as follows:

(1) The monitoring and remote control of automatically operating plant from a
central point.

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(2) To provide operational data for both normal and fault conditions including
the initiation of alarms in order to minimise the frequency of visits and to
provide a prompt response to faults.

(3) To collect, store and process operational data for management purposes.

The system shall make use of the public telephone network.

Sufficient space shall be provided in the control panel for the telemetry system.
The Contractor will be provided with outline requirements for the system and will
be required to then offer detailed proposals and specifications for the plant and
equipment to be supplied.

The specifications, plant and equipment etc. shall be subject to the approval of
both the Employer and the Engineer.

During the commissioning/start up period of the system it will be necessary to

provide appropriate training and instruction in the operation and maintenance of
the system for the Employer's operations staff.

18/16 BATTERY UNITS

The battery and charger shall be housed in a single sheet steel floor mounted
ventilated cabinet with batteries housed in the lower part of the cubicle.

The unit shall be complete with a self adjusting constant potential trickle charger
suitable for operating from a 220V single phase AC supply. The charger shall be
rated to continuously energise relay coils and lamps as applicable. The charger
shall be designed to maintain a constant voltage within 3% irrespective of mains
voltage or frequency variation. Booster charge facilities shall be included.

The unit shall be fitted with the following:-

1 No. Supply ON indicating lamp

1 No. ON/OFF switch
1 No. Charger ammeter
1 No. OFF/FLOAT/BOOST switch
1 No. Charger failure alarm relay and lamp
1 Set of cable terminals and fuses.

All battery cells shall be either nickel iron or nickel cadmium structure with an
alkaline electrolyte and be provided with a suitable drip tray to protect the cabinet
from corrosion caused by accidental spillage of the battery medium.

Batteries shall be 30V or 110V DC and of suitable ampere hour capacity to

operate the closing and tripping coils motor of the circuit breakers. Dual duty
batteries (i.e. for engine starting and for tripping circuit breakers) will not be
acceptable.

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18/17 TRANSFORMERS

18/17.1 STANDARDS

Transformers shall be manufactured to an approved International standard and

be of the Naturally Air Cooled Oil Filled Hermetically Sealed type. Transformer oil
shall be as recommended by the manufacturer for the local conditions.

18/17.2. WINDINGS

The windings shall be connected delta-star with group 4 phase displacement

primary to secondary vector group reference DY11 (plus 30o) with the star point
of the secondary winding brought out through the tank and suitably terminated in
a separate housing for solid earthing in addition to the neutral connection.
Provision shall be made for current transformers for fault protection to be mounted
on both neutral and earth connections.

The percentage value of the equivalent impedance of each transformer shall not
be less than that required to restrain the secondary voltage fault level to the
maximum permitted by the switchgear.

Solid insulation material for immersed type transformers shall be as defined in an

approved International Standard modified as necessary for service in an ambient
temperature of 50oC.

The high voltage windings shall be provided with tapping at +5%, +2.5%, -2.5%, -
5% with constant flux voltage variation as defined in an approved International
Standard.

Tap selection shall be by means of an externally operated manual control off-

circuit tapping selector. A mechanical tap position indicator shall be provided and
the selector shall be capable of being padlocked in any position.

The tap changing selector shall be located below the oil level inside the tank and
the selector operating rod shall extend outside the tank.

18/17.3 CONSTRUCTION

The core shall be constructed from cold rolled steel laminations manufactured to
an approved International Standard. The laminations shall be insulated from
each other by means of a suitable temperature resistant oil proof coating.

The windings design and construction shall provide adequately designed and
located coolant flow ducts so that possible hot spots are eliminated. Windings
shall be braced to withstand dynamic stresses due to short circuit conditions.
Full details shall be provided of arrangements for taking up or eliminating coil
shrinkage during service. The core and winding shall be designed so that the
iron loss is at a minimum but the ratio of copper loss to iron loss shall be in
accordance with an economic design and the manufacturer shall state the ratio
used.

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The arrangement of internal connections shall be such that the transformer core
and winding may be lifted bodily from the tank without disturbing the cable boxes
or insulators.

The transformer tanks shall be constructed from high grade steel with electrically
welded seams. The structure of the tank shall enable it to be handled whilst filled
with oil and shall be pressure tested to 70 kN/m2.

Tank shall be fitted with skids and four removable rollers and lifting eyes suitable
for the mass of the transformer and oil.

The tanks shall be provided with external cooling tubes to provide natural cooling
under the climatic conditions.

All terminals shall be brought out through oil tight insulating glands into
respective disconnecting terminal chambers to facilitate cable testing.

The tanks shall be non-breathing hermetically sealed type.

The tank covers shall be of such construction as will prevent the accumulation of
moisture and shall be bolted to a flange on the tank top to form a weather-proof
seal. All gaskets shall be of synthetic rubber and cork compositions. The tank
tubes and all steelwork shall be shot blasted internally and externally before
painting and a rust inhibiting paint shall be applied to both external and internal
surfaces before applying a final finish. The exterior shall be given an additional
coat on Site of a durable oil and weather resisting paint of an approved colour.

The design and construction of the transformer core winding and tank shall
ensure that the noise level at full load is kept to the minimum consistent with
economic design. The tank shall be reinforced or braced where necessary to
reduce the noise level.

The complete transformer arranged for service shall be capable of withstanding

the specified impulse voltage on the H.V windings.

All windings, winding terminals and connections shall be fully immersed in oil
under all operating conditions and materials shall be suitable for this duty and not
be subject to deterioration from contact with oil.

The windings shall be thoroughly dried out under vacuum at the manufacturer's
works and shall be delivered to Site filled with oil to the normal level and ready for
service.

18/17.4 FITTINGS

The following fittings are required:-

(a) Thermometer pockets, one for oil and one for winding temperature.
(b) 200 mm diameter dial type oil and winding temperature indicators each
fitting with 2 No. sets of adjustable contacts for alarm and trip functions.

(c) Rating and diagram plate complying with an approved International

Standard and of a durable and non-corrodable material.

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(d) Oil gauge clearly visible from ground levels.

(e) Pressure relief valve with alarm contacts.

(f) Separate neutral earthing terminal with independent access cover

enclosed with a weather-proof housing for the restricted earth fault
current transformer.

(g) Earthing terminal.

(h) Marshalling box for overtemperature, pressure alarm and trip contacts.

(i) Large identity labels shall be affixed to each transformer identifying their
primary circuit breaker.

(j) H.V and MV disconnecting chambers where compound filled cable boxes
are provided.

All joints shall be arranged so that they may be tightened externally.

A H.V compound filled cable sealing box complying with an approved

International Standard shall be provided. Large filling orifices and adequate
expansion space shall be provided. The necessary compound shall be included.

The cable boxes shall be completely detachable from the transformer without
breaking the cable termination. Suitably drilled cable sockets shall be provided.

18/18 INSTRUMENTS, INDICATORS AND TRANSMITTERS

Where not specified elsewhere, the following shall apply:-

18/18.1 GENERAL

All instruments, gauges and control equipment shall be to approval, and those
which perform similar duties shall be of uniform type and manufacture throughout
the scheme in order to facilitate maintenance and the stocking of spare parts.
Moving parts and contacts shall be adequately protected from the ingress of dust,
and all instruments shall be protected by moisture and dustproof cases including
those mounted in panels. All equipment shall be suitable for its environment and of
industrial quality.

Panel mounted receiving instruments shall be of the electrically operated miniature

flush mounting type unless otherwise stated.

Where applicable each instrument chassis shall be easily withdrawable from its
housing for maintenance without interrupting its signal.

All instrument bezels shall be finished in black

Main indicating instruments shall be of 140 mm minimum diameter. Secondary

indicating instruments shall be of 75 mm minimum diameter. Scales shall be clearly

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marked with black lettering and graduations on a white background. Instruments of

the same type and range have identical scales. Ranges shall be selected to show
normal plant operation between 50% and 75% of the instruments range.

18/18.2 INSTRUMENT RANGES

Indicating instruments shall be selected to operate using the following units:-

Flow l/s Litres per second

Level m Metres
Pressure m.hd Metres head of water
o
Temperature C Degree Centigrade
Concentration p.p.m Parts per million
Mg/l Milligram per litre
Current A Amperes
Voltage V Volts
Power W Watts
Electrical Energy Whr Watt-hours
Frequency Hz Hertz
Speed r.p.m. Revolutions per minute

Standard S.I. multipliers shall be used (kilo-, milli- etc.).

18/18.3 FIELD MOUNTED INSTRUMENTS

Field mounted instruments shall, where possible be hermetically sealed. If this is not
possible they shall be of weatherproof construction with heavy cast metal cases.

Transmitters and similar equipment shall be further enclosed in purpose made

weatherproof, glass reinforced fire-retardant polyester resin cabinets.

Particular regard shall be paid to the ease of access to all instruments. Serial
number/calibration plates shall be visible when the instrument is in its cabinet.

Locally mounted indicating instruments shall be mounted in viewable positions.

Field mounted instruments shall be complete with all mounting brackets, pillars, sun
shades, fittings and fixings to complete the installation.

18/18.4 PANEL MOUNTED INSTRUMENTS

Panel mounted instruments shall where possible be hermetically sealed. If this is not
possible they shall be enclosed in moisture and dust proof cases.

18/18.5 INDICATORS

All indication instruments shall have performances and scale markings in line with an
approved International Standard.

Level indicators shall be scaled vertically, alarm levels being indicated by red areas.

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Motor current ammeters shall have red lines or adjustable movable pointers to
indicate motor full load current.

18/18.6 DIGITAL INDICATORS

Digital flow indicators shall be three figure electronic digital display type. Precaution
shall be taken to ensure that fluctuation in the signal, however caused, does not
render the last figure to unstable and unreadable during normal running when
updating of readings at three second intervals.

Indicators shall read zero at “no flow” condition.

Direct readings shall be displayed without use of conversion factors other than
multiples of ten, which shall be clearly indicated. Display figures shall be 14 mm gas
discharge and visible from 12 metres distance.

18/18.7 INTEGRATORS

Flow integrators shall be six figure non-resettable mechanical impulse counters with a
minimum figure size of 9 mm x 4.5 mm.

Electronic counters may be employed providing precautions are taken to maintain the
count during power failure.

Integrators must not record under “no flow” condition.

Direct readings shall be displayed without use of conversion factors other than
multiples of ten which shall be clearly indicated.

18/18.8 CHART RECORDERS

All chart recorders for use in control and instrument panels, desks, consoles, etc.,
shall comply with the following unless specified elsewhere.

Maintain accuracy of quantity and time measurement to an approved International

Standard.

Have a separate scale plate for each signal channel.

Have a linear scale not less than 100 mm long with clear graduations and markings.

Have the units of the measured variable and any multiplying factor clearly marked on
the scale plate.

Be flush mounting with black bezel.

Be designed so that the chart may be withdrawn from the front and replaced without
interrupting the indicating section.

Have a plug-in chassis which may be withdrawn from the front leaving the housing in
position, without interrupting its signal.

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Have a minimum chart speed of 20mm per hour and a minimum chart duration of 4
weeks.

Have charts with printed calibration of 0-100% and 24 hr. time marks.

Have a window of anti-glare or low reflectivity glass in a hinged, lockable door which
opens a full 180o, with adequate window and door sealing to prevent the ingress of
dust and reduce the ingress of moisture to an absolute minimum.

Match all other meters and instruments (including indicating meters, meter relays,
integrators etc.) on the same panel, and on similar panels in the same room, as
regards style, finish and appearance.

The Contractor shall ensure that all meters intended for installation on inclined
surfaces are suitable for that application, and that when so mounted the accuracy will
be maintained over the whole range.

Sufficient charts shall be provided for two year operation at the time of take-over.

18/18.9 TRANSMITTERS

Transmitters shall provide 4 mA to 20 mA output signals proportional to the measured

conditions. They shall operate on a 2 wire system receiving their power from the
residual 4 mA in the transmission signal. They shall be fitted with output meters to
give an approximate indication of transmitter output scaled 0 - 100%.

Differential pressure transmitters which shall have capacitance or inductive type

sensing elements shall be fitted with direct mounted, stainless steel, 3 valve
manifolds. Pressure and level transmitters shall be fitted with two valve manifolds.

Transmitters shall be manufactured from materials suitable for use with the process
medium and for the site ambient conditions and this shall be approved by the
Engineer.

Pipework shall be run in copper or stainless steel pipe as appropriate with a minimum
gradient of 1 in 12 after an initial rise (gas) or fall (liquid) of 300 mm.

Transmitter equipment should be supplied and installed complete in all detail including
pipework, stop cocks, drain cocks and any similar ancillary items of equipment.

Process data, calibrated span, range, output, protection, accuracy and connection
details shall be as necessary to satisfy the particular specification requirements.

The transmitter shall have non-interacting external zero and span adjustment and
shall have facility for an optional external damping adjustment.

Each transmitter shall be equipped with a stainless steel nameplate, permanently

attached, indicating the following specified data as a minimum:-

1. Transmitter tag no.

2. Purchase order no.
3. Name and address of manufacturer
4. Type/Model no.

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5. Serial no.
6. Calibrated range
7. Range and maximum working pressure, temperature, speed, vibration level etc.
8. Materials of construction
9. Electrical protection classification.

18/19 FLOW MEASURING EQUIPMENT

18/19.1 ELECTRO MAGNETIC FLOW METERS

Magnetic flow meters shall be provided in accordance with the following:-

a. Meters shall be of the short form, having a modulated, direct current excitation
and inherent total zero stability.

b. The power consumption shall not exceed 16 watts per 100 mm of diameter.

c. The output shall be 4-20 mA and the system accuracy shall be within 0.75% of
the flow rate. Test Certificates shall be provided.

d. The field coils shall be fully encapsulated.

e. The equipment shall be guaranteed suitable for the ambient and process liquid
temperatures and the atmospheric environment.

f. Each flow-meter primary element shall be supplied with a Teflon liner and
electrodes of material best suited to the particular process fluid.

g. Primary units shall be as follows:-

Suitable for accidental submergence to a depth of 3 metres.

Have flanges in accordance with the relevant mechanical clauses relating to

pipes, flanges, fittings etc.,

Rated well in excess of the maximum possible fluid pressure, including possible
surge pressures.

Be supplied and installed complete with Flange Adaptor coupling or similar

approved arrangement to permit removal for repair or inspection.

Incorporate electrodes to detect when the pipe is not full. The detectors output
shall control circuits within the converter to short out the analogue signal and
initiate an indication of the "pipe not full" condition.

h. Complete with amplifier (converter), drive unit (if applicable) and all cable for
connecting between the components. Where this equipment is exposed to the
environment it shall be housed in a GRP enclosure.

The amplifier/converter shall be:-

Fully screened to prevent interference from adjacent equipment.

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Incorporate voltage stabilisation to ensure maintenance of system accuracy with

a supply variation of +10%.

i. Each installation shall be provided with Ultrasonic electrode cleaning equipment

or inherent protection against sludge build up. This facility shall include
equipment for hand and automatic operation, and shall be installed complete with
the necessary switches, push-buttons, timers etc.

j. Where the flow-meter is exposed to the environment provision shall be made to

protect the detector head from direct sunlight. The protective device shall be
secure with ease of removal for maintenance purposes.

18/19.2 ULTRASONIC IN-LINE FLOW METER

Ultra-sonic flow measuring equipment for "in-pipe" applications shall operate on the
phase difference technique employing 2 No. ultra-sonic probes displaced
longitudinally and mounted on opposite sides of the pipe to detect the difference
between the upstream and downstream flight times. The equipment shall include
acoustic transducers and a transmitter, and shall be installed complete with all
necessary fittings, cables and connectors.

The acoustic transducers shall be non-intrusive and arranged so that they may be
removed without shutting down the process line.

All materials in contact with the process liquid shall be approved for use in the
specified application.

All items of equipment attached to the pipe and/or pipe insert shall be of non-
corrosive material, designed to withstand continuous submergence to a pressure of
3m head and guaranteed suitable for the temperature and process pressures,
including maximum possible surge pressures.

The transmitter shall process the signals from the acoustic transducers and shall:-

(i) provide an output of 4 - 20 mA proportional flow,

(ii) be suitable for direct or wall mounting with up to 30m of cable,

(iii) incorporate contacts to initiate an alarm in the event of mal-function,

(iv) include facilities for field checking and zero adjustment.

The complete system shall operate with a minimum accuracy of ±1.5% of full scale
deflection over the full ambient temperature range. A test certificate shall be
provided for each set of equipment.

18/19.3 ULTRASONIC OPEN CHANNEL FLOW MEASURING EQUIPMENT

Where ultra-sonic equipment is specified for measuring flow in open channels, the
equipment shall be supplied and installed in accordance with the above Clause
18/20.1, except that in this application the control unit shall be micro-processor

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based incorporating algorithms for converting level to flow, as appropriate and shall
provide a 4-20 mA output proportional to flow. The system accuracy shall be within
±1.0% of the instrument span over the range 5% to 100% flow.

18/19.4 INSTALLATION OF ULTRASONIC SENSORS

Each ultra-sonic sensor shall be installed on a robust, rigid structure provided for
the purpose under this Contract. The structure shall include a means of leveling the
sensor so that the transmitted beam is perpendicular to the liquid surface and shall
provide a safe and easy access to the sensor for servicing and maintenance.

The Contractor shall, where applicable, provide a canopy around and/or above the
sensor and/or the control unit to provide a protection from direct sunlight.

18/20 LEVEL MEASURING & CONTROL EQUIPMENT

18/20.1 ULTRASONIC LEVEL MEASURING EQUIPMENT

Where ultra-sonic level measuring equipment is specified , level measurement shall

be accomplished by the use of non-contact, echo-time measuring equipment
operating at ultra-sonic frequency. The equipment shall transmit pulses which are
reflected back to the sensor from the surface of the liquid whose level is being
measured.

The equipment shall consist of a hermetically sealed sensor incorporating both

transmitter and receiver, together with a separate control unit.

The equipment shall be provided with automatic temperature compensation, shall

be suitable for operation in the designated application under the prevailing climatic
and environmental conditions.

The sensor shall be suitable for mounting in the open, or within an enclosed tank,
and shall be totally enclosed and hoseproof with environmental protection
appropriate for the installed location.

The control units shall incorporate facilities for adjusting independently both zero
and span, and shall have an output of 4-20 mA proportional to level.

The overall accuracy of the level measurements shall be within ±1.0% of the
instrument span.

The connection between the sensor and control unit shall be via a single length of
commercially available screened cable, and the equipment shall operate with up to
150 metres of such cable. Cable connections / joints will not be permitted above
the processing liquor.

The Contractor shall ensure that all equipment is suitable for the application,
particularly with regard to the blocking distance and transmitted beam angle / cone.

18/20.2 PRESSURE LEVEL MEASURING EQUIPMENT

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Where pressure level measuring equipment is specified in the relevant application

clause, level measurement shall be accomplished by the use of a chemically inert
high density fine ceramic transducer.

The equipment shall be provided with automatic temperature compensation, shall

be suitable for operation in the designated application under the prevailing climatic
and environmental conditions.

The sensor shall be hermetically sealed and suitable for mounting in sewage. It
shall be readily removable.

The control units shall incorporate facilities for adjusting independently both zero
and span, and shall have an output of 4-20 mA proportional to level.

The overall accuracy of the level measurements shall be within ±1.0% of the
instrument span. The connection between the sensor and control unit shall be via a
single length of commercially available screened cable, and the equipment shall
operate with up to 150 metres of such cable. Cable connections / joints will not be
permitted above the process liquor.

18/20.3 FLOAT LEVEL CONTROL EQUIPMENT

Where float level equipment is specified, level control shall be accomplished by the
use of a plastic encapsulated float switch. The float switch shall operate at 24V AC
for irrigation installations and 48V AC for sewerage installations. The Float casing
shall be manufactured of polypropylene supported by a Stainless steel suspension
chain.

18/21 GENERAL DESCRIPTION OF LIGHTING AND SMALL POWER

INSTALLATIONS

The Contractor shall provide and install all the necessary fittings, sub-distribution
boards, contactors, etc. for the complete small power and lighting installations as
follows:-

18/21.1 SMALL POWER INSTALLATIONS

General
Low voltage supplies required for illumination and power supplies etc. shall be as
follows:-

Socket outlets shall be manufactured from polycarbonate and protected from the
ingress of dust and moisture to an approved standard. All socket outlets shall be
colour coded in compliance with an approved International Standard. Each socket
shall be provided with a plug.

All handlamps shall be 25V and the socket outlets colour coded violet.

220V socket outlets colour coded blue.

380V socket outlets colour coded red.

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Installation

Small Power Installations shall be provided so that the following facilities are
available in each area.

a) Motor Room

16 amp 250 V 3 pin un-switched socket outlets (sufficient quantities to ensure

that any extension cable used does not exceed 3m).

16 amp 25 V socket outlets (sufficient quantities to ensure that any extension

cable used does not exceed 3m).

32 amp 380 V TP&N socket, switched and mechanically interlocked.

b) Control Rooms

A minimum of 4 No. twin 13 amp 220 V switched socket outlets; final

numbers and arrangement are subject to approval.

c) Exterior to Wet Well

32 amp TP&N socket, switched and mechanically interlocked

d) Pump Chamber Dry Well

As motor room.

e) GRP Kiosks (for control panels)

As motor room with sockets at each panel end.

f) Accommodation

A minimum of 2 No. Twin 13 amp 220 V switched socket outlets to an

approved International Standard to each habitable room and kitchen.

18/21.2 LIGHTING INSTALLATIONS

General

Lighting installations shall be provided to give minimum illumination levels as

detailed below. Lighting levels will be measured at a plane 1000 mm above ground/
floor/ access level. Two way switching will be included for areas where access may
be gained via two physically separate points.

The Contractor shall prepare lighting layout drawings of sufficient detail to enable
duct requirements to be ascertained prior to the casting of roof beams and columns.
Lighting conduits shall be surface mounted on ceilings and walls except in tiled
areas where the conduits shall be concealed beneath the tiles.

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The lighting shall be located in easily accessible positions for the purpose of
maintenance. If this is not possible the Contractor shall advise the method for
undertaking maintenance and if this requires special equipment such as scaffolding,
hoists or access tower, this shall be provided by the Contractor at no extra cost.

The Contractor shall submit his proposed scheme together with details of the fittings
he proposes to use and his calculations of illumination levels for the Engineer’s
approval.

The following lighting levels shall apply:

a) Motor Room

350 lux using energy efficient anti-corrosive fluorescent fitting with

polycarbonate diffuser;

b) Dry Well

350 lux using energy efficient watt anti-corrosive fluorescent fitting with
polycarbonate diffuser;

c) Control Rooms

400 lux using energy efficient fluorescent fittings with easy clean antiglare
diffusers.

d) Wet Well

As dry well, all fittings to be approved for Zone 1 environment.

e) External Lighting

Over each external entrance door there shall be installed 1 No. 250 watt high
pressure sodium floodlights controlled by an external weather-proof switch.

On the exterior of building mounted on each corner shall be polycarbonate

vandal proof light fittings controlled by a light sensitive cell with manual
override. This system shall be fully automatic and be mounted in the FBA.

f) Access/Car Park Areas

An average illumination of 20 lux shall be achieved.

g) Miscellaneous

GRP Kiosks (for control panels)

As motor room to provide sufficient lighting to be able to maintain the FBA at

night.

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External Maintenance Areas

Sodium weather-proof floodlighting to provide 50 lux at the working height.

Final locations of these units to be agreed at site.

Accommodation

Each room to contain sufficient 100 Watt light fittings with opaque white
glass to achieve the illumination level defined in an approved International
Standard as appropriate for the intended use of the room.

18/21.3 EMERGENCY LIGHTS

Emergency lights shall be wall-mounted, twin lamp units arranged to give at least 3
hours illumination in the event of main power supply failure. The units shall include
integral battery, battery charger and battery status indicator. A lamp test facility
shall be included. Emergency light units shall be connected to a dedicated
electrical circuit separate from all other lighting or small power supplies.

Lamps shall be provided as follows:

Motor Room - 1 No. unit adjacent to each access door;

Dry Well - 1 No. unit at each stairway landing plus 1 No. unit at pump level.

Control Room - 1 No. unit adjacent to each access door.

Accommodation - 1 No. unit adjacent to each access door.

18/22 PORTABLE PLANT

The Contractor shall supply for each pumping station:

1 No. Gripper Type handlamp with wire cage and 25 V, 40 watt B.C. rough service
lamp complete with 30 metres of 3 core tough rubber sheathed cable and plug
suitable for low voltage socket outlets;

1 No. 500 watt, 220 V, 50 Hz weather-proof portable floodlight complete with stand,
30 metres of 3 core T.R.S. cable with plug suitable for 220 V volt socket outlet;

18/23 WIRING & CABLING ACCESSORIES

Generally for all small power and lighting installations the following Clauses shall
apply:-

18/23.1 WIRING

Wiring shall be carried out in PVC cable enclosed in conduit. The minimum copper
conductor size used shall not be less than 1.5mm2. The use of junction boxes
between fittings shall be kept to a minimum and where practicable all connections

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shall be made at the fitting. Where used junction boxes shall be rectangular pattern
and where possible their position shall be hidden from immediate view but not made
inaccessible. Circuit wiring shall not be connected directly onto the terminals of
lighting fittings but shall be made off in point boxes consisting of a standard box
containing porcelain shrouded pinch screw connectors to which connections shall
be made to the light fitting by heat resistant flexible cables.

18/23.2 DISTRIBUTION BOARDS

All distribution boards shall be of the totally enclosed metal clad pattern (500 V
rating) manufactured in accordance with an approved International Standard.

The enclosure shall be made from zinc coated mild steel formed to a clean line and
complete with a lockable hinged cover with gasket. Removable plates with conduit
knockouts shall be provided at top and bottom.

All distribution boards shall be complete with a Residual Current Circuit Breaker.
The circuit breaker shall be rated and have the same number of phases as the
circuit from which it is fed.

Doors shall be fitted with gaskets and shall be easily removable to preserve the
finish and simplify installation. Each distribution board shall be arranged for top and
bottom cable entry and shall be provided with an ample cable termination plate and
chamber to enable cables to be neatly glanded with tails grouped and terminated
onto appropriate internal termination's. Distribution boards shall be wall or floor
mounted and shall when specified incorporate on-load isolators which shall be front
of panel operated with ON/OFF indicator and capable of being padlocked in the
OFF position. Distribution boards shall incorporate HBC cartridge fuses or
combinations of single pole and neutral and triple pole miniature pole circuit
breakers (MCB's) as specified.

Each bank of MCB's/fuses shall be clearly identified with its appropriate phase
colour code and the mounting framework for the banks of MCB's/fuses shall be
easily removable to simplify installation. Adequate phase barriers and shields shall
be fitted to ensure that after installation and wiring all bare terminals and wires are
covered to prevent accidental contact with live conductors during the normal
procedure of fuse changing and resetting of MCB's.

All distribution boards shall have a fusing factor of 1.5 to afford "close" overcurrent
protection to circuits.

All neutral bars shall have a separate terminal for each fuseway within the
distribution boards.

The termination of the circuit cables at distribution boards shall be neat and slack
left at each fusebank or neutral bar to enable the complete assembly to be removed
for inspection without disconnection. Neutral conductors shall be connected to the
bar in the same order as the phase conductor to the fuseway.

Each distribution board shall be complete with a permanent circuit identification

chart preferably mounted within the front door. This chart shall be permanently and
legibly filled in as circuits are completed with the circuit description including the
fuse rating.

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Painting of distribution boards shall be in approved colours.

18/23.3 SOCKET OUTLETS

Socket outlets shall be connected to a ring circuit with each 30 amp circuit feeding a
maximum floor space of 50m2. All socket outlets shall be switched and of the
shuttered type. They shall accept 13 amp. square plugs and comply with an
approved International Standard. They shall be selected from one of the following
types.

(a) Surface and externally mounted socket outlets shall be manufactured from
polycarbonate and protected from the ingress of dust and moisture to an
approved International Standard.

(b) Flush mounted socket outlets shall be of the grid switch pattern with matt
chrome heat cured powder lacquer finish covers.

18/23.4 SWITCHES

Switches shall be of the "multiple phase" type incorporating phase barriers with the
switches arranged in multigang boxes. They shall be one of the following types:-

a) Surface and externally mounted switches shall be manufactured from

polycarbonate and protected from the ingress of dust and moisture to an
approved International Standard.

b) Flush mounted switches shall be of the grid switch pattern with matt chrome
heat cured powder lacquer finish covers.

Special care shall be taken to ensure that all switches are securely fixed truly
vertical and that flush mounted switches are flush with the wall finish so that the
overlapping cover plates seat onto the rims of the boxes.

18/23.5 LIGHTING FITTINGS

Lighting fittings shall be complete with all supports, suspensions, flexible cables,
pendants and plugs. They shall be connected to the main circuit wiring with heat
resisting flexible cables of a minimum conductor size of 1.5m2 insulated with silicon
rubber.

Break joint rings shall be used in conjunction with batten holders, ceiling roses or
back plates mounted onto a flush installation.

The earthing of all pendant or semi-pendant fittings shall be by a separate core in

the connecting flex or cable securely bonding the earth terminal on the fitting to the
glanded joint of interconnecting cables. In no case shall pendant chains or conduit
support tube be used as a means of earthing.

Standard fluorescent lighting fittings shall have two suspension or fixing points.

Lampholders for flexible pendants, batten or wall mounting shall be of the all
insulated skirted pattern with cord grips. All lampholders shall be of the bayonet
cap pattern.

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The point box suspensions and other parts of the lighting fittings shall be erected at
times to suit the building programme for decoration.

The glassware, diffusers, shades, lamps and tubes shall not be fitted until all
building work is complete.

All fittings shall be left clean inside and outside ready for use. All fluorescent fittings
shall be suitable for instant start.

All fluorescent tubes shall be of an approved manufacture and standard white in

colour. They shall be suitable for the lighting fittings in which they are installed and
of the correct voltage. Diffusers on fluorescent fittings shall be polycarbonate.

All incandescent lamps shall be of an approved manufacture with metal coil

filaments gas filled pearl in standard sizes with standard caps to suit the fittings in
which they are installed.

The Contractor shall supply and install all lamps for the entire lighting installation
and shall replace all burned out lamps up to the time that the Employer takes final
acceptance of the works.

18/24 CABLES

18/24.1 GENERAL

All multi-cored cables on low voltage installations shall be 600/1000V grade.

Manufacturer's test certificates shall be submitted to the Engineer for approval of
the material before commencing cable installation.

Where a neutral conductor is required this conductor shall be in the form of a core
of the same section as the other cores.

The Contractor shall ensure that each cable is of sufficient rating for its normal and
fault conditions. To assess the rating and cross section required for each cable the
following factors shall be considered:-

(a) Fault level.

(b) Conditions of ambient temperature relevant to method of laying.

(c) voltage drop.

(d) Voltage drop in motor circuits due to starting.

(e) Overcurrent settings of circuit breakers.

(f) Disposition of cabling whether in air, ducts or ground.

Cable ratings shall be calculated in accordance with an approved procedure.

The Contractor shall submit details of the cable sizes for the Engineer's approval
before ordering.

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The Contractor shall be responsible for measuring the length of cable required.

Each cable shall be supplied in a suitable length, continuous through its run.
Through joints will not be permitted without the written permission of the Engineer.

The earthing conductor shall be of adequate cross sectional area and shall either
be one core of a multicore cable or a separately run single core cable.

The use of conduit, water or other service pipes in any part of the earth continuity
conductor is strictly prohibited.

The Contractor shall supply and install all necessary cable glands and sealing
boxes required to complete the installation.

The cores of each cable shall be taken direct to the terminals of the equipment to
be connected. Cable ends shall be sealed in suitable chambers bolted to terminal
boxes.

The general routing of cables is indicated on the Drawings but the final routes shall
be agreed with the Engineer before any work in connection with the cable
installation is commenced.

All cables shall be installed in strict accordance with the requirements of this
Specification.

Cables with a conductor size of less than 1.5mm2 section shall not be used in the
installation.

All cables used shall bear the manufacturer's original guarantee and all cables shall
be delivered to Site in their original wrappings. The Contractor shall obtain the
permission of the Engineer before removing wrappings and commencing
installation.

The Contractor shall ensure that the installation is installed so that no more than
one phase will occur at switch lighting or power outlets where these outlets are less
than 2.5m apart unless guarded by a wall partition or other barrier. If this is
impracticable the Contractor shall obtain the advice of the Engineer before
proceeding.

The scheme of wiring shall conform to the colour code requirements of an approved
International Standard.

A minimum tail length of 250mm shall be left on all cables at outlet positions for
connection of the apparatus fed by the outlet.

The installation of multi-core and single core cables or bunching of cables in conduit
is to be carried out on the assumption that such cables will carry alternating current.

The excessive bunching of small cables in large conduits will not be permitted.

The Contractor shall include for terminating each cable in excess of 30 amp current
carrying capacity in a pressure operated mechanically crimped leg terminal or
terminal socket.

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18/24.2 PLYSW & PVC OVERSHEATH CABLES

PVC insulated and sheathed galvanised steel wire armour cable with an overall
PVC sheath (PVCSWA PVC) shall conform to an approved International Standard.
They shall be of approved manufacture of 600V or 1000V grade with copper
conductors.

All such cables shall be terminated with mechanical glands in accordance with an
International Standard and shall be of a type to provide adequate mechanical
support by locking on the armour, with outer seal, shroud and earthtag.

18/24.3 PVC SWA PVC CABLES

PVC insulated and sheathed galvanised steel wire armour cable with an overall
PVC sheath (PVC SWA PVC) shall conform to an approved International Standard.
They shall be of 600V/1000V grade with copper conductors from an approved
manufacturer.

All such cables shall be terminated with mechanical glands in accordance with an
approved International Standard.

The gland shall be of a type to provide adequate mechanical support by locking on

the armour, with outer seal, shroud and earthtag

18/24.4 XLPE PVC SWA PVC CABLES

XLPE insulated and PVC sheathed galvanised steel wire armour cable with an
overall PVC sheath (XLPE PVC SWA PVC) shall conform to an approved
International Standard. They shall be of 600/1000V grade with copper conductors
from an approved manufacturer.

All such cables shall be terminated with mechanical glands in accordance with an
approved International Standard.

The gland shall be of a type to provide adequate mechanical support by locking on

the armour, with outer seal, shroud and earthtag.

18/24.5 PVC INSULATED CABLES

Single-core PVC insulated cables shall comply with an approved International

Standard and shall be 450V/750V grade.

Multi-core PVC insulated cables shall comply with an approved International

Standard and shall be 600V/1000V grade.

The cable used shall not be less than 1.5mm2 cross-sectional area.

18/24.6 PVC INSULATED MICC CABLES

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PVC MICC insulated cables shall comply with an approved International Standard
and shall be 600V/1000V grade.

The cable used shall not be less than 1.5mm2 cross-sectional area. For fire alarms
and associated uses they shall be coloured orange

18/25 CABLING METHODS

18/25.1 GENERAL

All cables shall be either clipped to walls or ceilings of structures or run in ducts and
trenches.

All cable hangers, cleats, saddles, brackets and similar supporting devices shall be
of an approved type and of adequate strength for the cable they are supporting.
They shall be non-ferrous and so treated as to withstand site conditions without
corroding.

Every cable whether in or out of sight shall be neatly run vertically horizontally or
parallel to adjacent walls, beams or other structural members. Bending of cables
shall be in accordance with the criteria shown in Table 18-2

Table 18- 2: Bending of cables critera

Minimum
Insulation Finish Overall diameter internal radius
of bend (times
overall
diameter* of
cable)

Rubber or Not exceeding 10 3(2)+

PVC(Circular or Unarmoured mm
circular stranded Exceeding 10
copper or aluminium mm, but not
conductors) 4(3)+
exceeding 25 mm
Exceeding 25
mm
6
Armoured Any 6
PVC or XLPE (SAC Armoured or 8
or shaped copper Unarmoured Any
conductors)
Mineral Copper 6
sheath with or Any
without PVC
covering
* For flat cables, the factor is to be applied to the major axis.
+ The figures in parentheses relate to single core circular conductors of stranded
construction installed in conduit or trunking.

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Spacing of clips, saddles and cleats shall be such to prevent sagging of the cables
at all times during their installed life.

Cables run in indoor trenches shall be segregated and run on trays or brackets
secured to the trench wall. No cables shall be run on the bottom of these trenches.

Where a number of cables are terminated to any particular item of equipment then
special care shall be taken to ensure that the cables finally approach the equipment
from a common direction and are individually terminated in an orderly and
symmetrical fashion.

The Contractor shall prepare drawings showing his precise requirements for cable
trenchwork detailing the width and depth of trenches and indicating the road
crossing cable ducts required. These drawings shall be prepared in consultation
with the Engineer and be approved before issue.

The sanding and laying of cables shall satisfy the following requirements:-

(a) Cables shall be laid at a depth of 750mm for LV and 1000mm for H.V cables.
The depth shall be assessed from finished ground level unless otherwise
directed by the Engineer.

Generally LV and H.V cables should not be run in the same trench but should
be laid staggered. However where necessary to pass through ducts it may be
necessary to lay one above another and H.V cables should be laid first and
sanded before laying the LV cables.

(b) Before laying cables the Contractor should inspect the trenchwork to ensure
that the bottom of each trench is firm and of smooth contour and free from
broken stones or rock.

(c) 75mm of riddled sand shall be placed in the trench to form a bedding for the
cables.

(d) Cables up to and including 50 mm cross-sectional area may be hand-drawn.

Heavier cables shall be treated as follow :-

(1) They shall be laid using rollers not more than 3 m apart and where drawn
round corners skid plates and additional rollers shall be used.

(2) The cable shall be pulled by means of a suitable winch with a pulling eye and
cable-sock or equal approved device to ensure even load distribution on the
cable.Cables shall be laid with adequate separation and shall be gently
"snaked" to avoid tension during backfilling and subsequent settlement.

(e) Before sanding and backfilling all laid cables shall be inspected by the
Engineer.

(f) After cables have been laid they shall be covered with a further 75mm of
riddled sand which shall be well tamped around the cables. Mechanical
punners shall not be used for this work.

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(g) The Contractor shall supply cable cover tiles. These shall be of the precast
concrete type complying with an approved International Standard and engraved
"Electricity".

(h) After sanding cable covers shall be placed in position to overlap the cables by a
minimum of 50mm either side of the cables.

(j) A second inspection following sanding and tiling shall be made by the Engineer
before backfilling.

(k) The Contractor shall carry out backfilling and be responsible for ensuring that
tiles are not disturbed and that no large rocks or stones are dropped on tiles or
included in the backfill material.

(l) After backfilling the Contractor shall reinstate to finished ground level.

(m) The Contractor shall supply and lay in position the necessary cable route
marker posts at a maximum of 10 metres apart and at any change in direction
of cable route.

Where cables enter or leave buildings the ducts shall be sealed at the points of
entry into the building. The Contractor shall include for caulking with an
approved compound, followed by not less than 40mm of bitumen compound or
a weak sand/cement mixture as directed by the Engineer. Care must be taken
to ensure that the PVC sheathing of cables is not damaged during caulking due
to excessive temperature if heated bituminous compound is employed.

Wherever it is necessary to remove the PVC sheath of cable (e.g. at a joint) the
minimum length necessary shall be removed and the exposed copper sheath or
armouring shall be adequately covered by a PVC tape or sleeve or other suitable
means.

All cable shall be delivered on robust cable drums with cable ends treated to form
an effective seal. When a cable is cut from a drum the cable end left on the drum
shall be immediately sealed in an approved manner to prevent the ingress of
moisture.

Each and every cable shall be permanently identified at each end by its cable
number. Cable markers shall comprise oval markers with semi-rigid black PVC
carrier strip and shall be fixed axially by means of two PVC covered aluminium
strips with buckles. Cable markers shall also be installed at entry and exist points of
buried ducts, exits from buildings and in such other positions as are necessary to
identify and trace the route of any cable.

All power shall be connected to main switchboards and other items of plant so that
the correct phase sequence colour coding are preserved throughout the system. All
such cables shall be identified with phase colours for 3 and 4 wire systems and blue
and brown for single phase. On rotating plant, where to achieve the required
direction of rotation it is necessary to connect the phase cores to the appropriately
identified terminals, special core ferrules shall be fitted to identify each core with the
terminal to which it is finally connected.

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In addition control cables shall have individual cores identified by means of suitable
permanent ferrules bearing the same numbers at both ends. Core identification
shall occur at every point of termination using an approved system of ferrule
markers. Numbering shall read from the terminal outwards on all cores. At those
points of interconnection between wiring where a change of number cannot be
avoided double ferrules shall be provided on each wire. The change of numbering
shall be shown on the wiring diagrams of the equipment at which the change is
made.

Where the termination of control cable cores or the supervision of termination of

cores is specified as being the responsibility of another party (e.g. the termination of
certain control and instrumentation cables) any necessary temporary means of core
identification shall be agreed with that party. Should the Contractor propose to use
junction boxes in auxiliary control cable circuits for the purpose of marshaling a
number of cables feeding to a common item of equipment full details shall be given
to the Engineer and the Contractor shall only proceed after receipt of the Engineer's
written approval. Any such junction box shall be of the wall mounting pattern with
double terminals, with cores ferruled and identified in accordance with the system
schematic and cable diagrams.

18/25.2 CONDUIT SYSTEM AND ASSOCIATED CABLES

All conduit systems and their component materials shall comply with an approved
International Standard.

Conduit shall be neatly run on the surface or buried. Ways shall be provided for
additional conduits at all distribution boards. The size of conduit shall be as detailed
for a particular position or as determined by the number of cables to be drawn in. In
no case shall conduit less than 20mm diameter be used. Sunken and concealed
conduit systems shall support fittings independently of any false ceiling.

All conduits shall be installed in an approved manner and arranged with adequate
ventilation and drainage where necessary. All bends or sets shall be formed in the
conduit itself. The Contractor shall ensure that conduit draw-in boxes and junction
boxes are of sufficient capacity to allow all cables to be installed.

The whole of the conduit system shall be completely swabbed through to remove
any loose matter or dirt before cables are drawn in. Where conduits connect to
switch boxes, draw-in boxes and the like, the conduits shall have a machined faced
socket screwed on to the end which when tightened is flush with the outside of the
box. The conduit is then to be secured to the apparatus by means of a hexagon
smooth bore brass bush screwed from the inside of the apparatus into the conduit
socket in order to make a sound and tight mechanical joint.

All horizontal runs shall be supported at no more than 900mm. Vertical runs shall be
supported at no more 1200mm. Where directional changes occur support shall be
provided at no more than 150mm either side of the bend.

Bending of conduit shall be carried out as follows:-

a. PVC - a bending spring of the correct size shall be used in all cases. The heat
source shall be provided by a hot air torch. When the conduit is in a pliable

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state it shall be bent around a suitable former and held in position until the
conduit has set. No other method will be approved.

b. Steel - Purpose manufactured bending machine complete with formers.

Bending blocks may be used at the discretion of the Engineer for special
applications.

Only couplers, bends and spouted fittings supplied by the manufacturer shall be
used. Expansion couplers shall be used in surface installations where straight runs
exceed 8 metres and at all expansion joints in the structure.

Standard junction or adaptable boxes shall be provided at all junctions and at sharp
changes of direction in addition to any special positions where they are called for by
the Engineer. Inspection couplers may be used in long runs to facilitate drawing in
cables. All junction boxes must be accessible in the completed works.

Particular care must be taken to ensure that no water is allowed to enter the conduit
at any time and all conduits shall be arranged with adequate ventilation and
drainage where necessary or as directed by the Engineer.

For buried conduit continuous lengths shall be installed between boxes. Positioning
of joint boxes within floor screeds is not permitted.

The ends of conduits laid or set in formwork prior to concreting shall be temporarily
sealed off with a coupler and a plug.

Fixing to surfaces of walls shall be by spacer bar saddles securely fixed by screws.
Where conduits are concealed or laid in structural floors they shall be held in
position with substantial fixings of make and pattern to be approved by the
Engineer.

Weather-proof boxes and accessories shall be used outdoors where agreed on Site
by the Engineer or where indicated in this Specification or on the Drawings.

Conduit shall be installed such as to permit complete rewiring without the need to
carry out builders work.

No single conduit serving phase socket outlets lighting points and switches shall
contain more than one phase.

Wiring shall be carried out on the looping-in system and no joints other than at
looping-in points will be allowed.

18/25.3 FLEXIBLE CONDUIT

Where the conduit system terminates at any equipment requiring a non-rigid

connection a flexible conduit shall be installed of the PVC sheathed metallic type
fully watertight with factory made connection adapters.

Each flexible connection shall include not less than 400 mm length of flexible
conduit and a separate earth conductor shall be run within the conduit connected to
the earth terminals in the equipment and the fixed conduit run. The flexible conduit
shall not be used as an earth continuity conductor.

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18/25.4 CABLE TRUNKING AND ASSOCIATED CABLES

The trunking shall be manufactured, as specified, from either heavy gauge

continuous hot dipped galvanised steel, stainless steel or heavy duty rigid
unplasticised PVC ( self extinguishing, and unaffected by sunlight and/or water; the
material shall be suitable for continuous ambient temperatures of 65oC). Each
length shall be supplied with the necessary connection sleeves and shall have
joggled sides to allow flush fitting.

Each length of trunking shall be fitted with easily removable covers attached to the
trunking by an efficient fixing.

The trunking system shall be complete with purpose made angle and set
accessories designed to afford easy installation of and to avoid tight right angle
bends in the circuit cables installed in the trunking. All trunking accessories shall be
complete with removable covers. No site made mitred joints will be allowed.

Where cable trunking is installed in vertical runs efficient circuit cable clamps are to
be installed at not greater than 500mm intervals.

The Contractor shall ensure that the size of the trunking is adequate for the number
of cables passing through it but as a minimum the size should be 50mm x 50mm.
All bends tees and intersections shall be of the gusset type and manufactured by
the maker of the trunking and to similar standard.

18/25.5 CABLE TRAY

Cable tray shall be manufactured as specified from heavy duty perforated

galvanised or stainless steel or rigid unplasticised PVC with deep flanges (PVC
shall be self extinguishing and non-inflammable and shall be unaffected by sunlight
or water; It shall be suitable for continuous ambient temperatures of 65oC).

The cable tray shall be complete with approved type fixings while cleats shall be of
the aluminium or nylon pattern. Cables which shall be attached to cable tray or
structure by saddles or cleats respectively shall be spaced to ensure compliance
with an approved International Standard. The spacing of supports shall be 1200mm
in all cases where cables are supported by cable tray and 750mm where supported
from tray or by cleats. All cables shall be saddled or cleated in position as they are
installed along the route. All cable tray changes in direction or level shall be made
via sets and adequately sized angles to provide a support to the cables. The cable
runs on trays shall be fixed to the tray by purpose made approved fixing clamps.
Cable trap brackets shall be of galvanised steel. Site manufactured bends and
junctions will not be permitted.

18/26 EARTHING

The earthing system shall comply with the requirements of an approved

International Standard and the Dubai Electricity and Water Authority regulations.

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OF MECHANICAL AND ELECTRICAL ITEMS

Earth tapes on 11 kV 6.6 kV and 3.3 kV plant shall comprise a minimum of 50mm x
6mm copper tape and on 380V equipment, a minimum of 38mm x 4mm copper
tape.

The metalwork of ALL items of electrical equipment provided under the Contract
shall be securely bonded to earth. Earthing shall be effected by means of the metal
sheath of cables which shall be securely bonded to the metalwork of the apparatus
concerned at each end or a separate earth conductor. A separate conductor shall
be provided for all items of plant rated 20 kW or greater.

Armour wires on main cables shall be solidly bonded as additional earth paths but
cables from standby generators shall be insulated or bonded to the main earth
system depending on instructions received from the Engineer. Particular care shall
be taken on cable termination boxes to ensure that the cable sheath and armour is
adequately bonded to the associated item of plant. If continuity is inadequate
copper connections shall be made between the apparatus frame and the cable
sheath.

Where the cable sheath and armour is used as the earth path return then it shall be
established that the impedance is sufficiently low to carry the fault current and
disconnect the equipment. If not a separate copper earth conductor shall be
installed.

Particular care shall be taken to ensure earth continuity across items of equipment
situated within a cable run, should the design of such equipment not give adequate
and lasting continuity through its structural body then additional earthing clips and
conductors shall be provided to independently bond the cable sheaths together.
Similarly additional earthing clips shall be provided to bond the cable sheaths to any
piece of apparatus fitted with a special earth terminal should the earth connection of
the terminating gland prove inadequate. Any additional clips shall be contained
within the apparatus wherever possible.

The earth tapes shall be protected against corrosion and be complete with test
links. Earth tapes shall be held in position by saddles screw fixed to the substrate.

Connections shall be sweated and riveted and shall be electrically and mechanically
continuous. Joints between the main conductor and the earth electrodes shall be
readily accessible for periodic inspection and shall be protected against damage
and corrosion.

Where rigid or flexible conduit and/or trunking is incorporated into the Works a
separate internal earth conductor shall be run which shall be securely bonded to the
terminating apparatus by means of a special earth terminal.

When instructed by the Engineer an earth electrode system shall be installed. This
will comprise a system of vertically mounted rods. Leads from each electrode shall
be brought to concrete disconnection chambers to enable each electrode to be
disconnected for testing purposes. Each electrode shall be capable of providing an
effective earth within the limits specified. The earth pit containing the earth rods
shall be of the preformed type with concrete inspection covers.

When standby generators are specified it may be necessary to install two earth
electrode systems, depending upon local conditions.

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OF MECHANICAL AND ELECTRICAL ITEMS

Earth rods shall be copper or steel cored with a metallic bonded copper outer
surface.

Rods shall be internally connected via threaded connections forming part of the
earth rod and provided with special hardened tips and caps to avoid distortion when
driven into the ground. Approved non-ferrous clamps for connecting the rod to the
copper strip shall be provided.

All excavation trenches and disconnecting chambers will be the responsibility of the
Contractor including the supervision of the backfilling of trenches setting and
alignment of disconnection and inspection chambers.

On completion of the earth installation the Contractor shall demonstrate to the

Engineer that the resistance of the electrodes and the earth network is within the
specified limits. Test equipment shall be supplied by the Contractor.

18/27 ELECTRIC ACTUATORS

Where required valves and penstocks shall be operated by means of electrically

driven actuators with integral reversing starters.

Actuators shall be suitable for use with a nominal 380 volt 3 phase 50 Hz power
supply and shall incorporate a motor, integral reversing contactor starter, local
control facilities and terminals for remote control and indication connections.

The actuator shall be capable of opening or closing the valve or penstock against
an unbalanced head equal to the maximum working pressure.

The safety margin of motor power available for sealing and unsealing the valve or
penstock shall be sufficient to ensure torque switch trip at maximum valve torque
with the supply voltage 10% below nominal. The operating speed shall give valve
opening and closing at approximately 300mm per minute.

The actuator shall be capable of functioning at ambient temperature ranging from

0o to 55oC for twice the valve stroking time at an average load of at least 33% of
maximum valve torque. Where actuators are required for modulating purposes
continuously rated motors shall be provided.

Overload protection shall be provided by a direct sensing thermostat embedded in

the motor windings.

The gearbox shall be of the total enclosed oil bath lubricated or grease filled type
suitable for operation at any angle and provided with appropriate filling and drain
plugs. The drive shall incorporate a lost motion hammer blow feature. The output
shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the
ball or roller type. The design shall permit the gear case to be opened for
inspection or disassembled without releasing the stem thrust or taking the valve out
of service.

All operating spindles, gears and headstocks shall be provided with adequate points
for lubrication.

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OF MECHANICAL AND ELECTRICAL ITEMS

A handwheel shall be provided for manual operation engaged when the motor is
declutched by a lever which shall be padlockable in either position. The drive shall
be restored to power automatically by starting the motor. The handwheel drive
must be mechanically independent of the motor drive, and any gearing should be
such as to permit emergency manual operation in a reasonable time. Clockwise
operation of the handwheel shall give closing movement of the valve or penstock.
The effort required for manual operation shall not exceed 250N.

Handwheels shall be clearly marked with the words "OPEN" and "CLOSE" and
arrows in the appropriate directions. The rims of handwheels shall have a smooth
finish.

The actuator shall be fitted with a drive bushing which is easily detachable for
machining to suit the valve stem or gearbox input shaft. Bushings shall be fitted in
the base of the actuator to enable standard length valve stems to be used.

Transparent PVC covers shall be fitted to protect the threads of rising spindles.

Actuators shall be provided with open and close torque and/or position limit
switches as required by the type of valve or penstock plus two additional limit
switches at each end of travel for remote indication and interlocking. A mechanical
latch shall be provided to prevent the open torque switch tripping while the initial
unsealing hammer blow is applied. Two additional sets of limit switches consisting
of 3 switches per set shall be provided. Each set shall be independently adjustable
to any valve or penstock position. Switch contact ratings on inductive circuits shall
be 5 amp. AC up to 440V, 50 watts DC up to 250V.

An illuminated mechanical dial indicator shall be provided to show continuous

movement valve position, and the actuator shall incorporate a sealed potentiometer
of at least 3 watts rating for continuous remote position transmission.

The reversing contactor starter and local controls shall be integral with the valve
actuator and housed to prevent breathing and condensation build-up. The starter
shall be suitable for 60 starts per hour and shall comprise mechanically and
electrically interlocked reversing contactors of approximate rating to the motor size
with coils fed from a 120V control transformer of 40VA minimum rating.

The common connection of the contactor coils at the transformer shall be grounded
so that the contactors drop out on the event of leakage to earth. The primary
winding shall be separated from the secondary by a grounded screen and shall be
protected by two easily replaceable cartridge fuses. Secondary windings shall also
be protected by cartridge fuses.

Local controls shall comprise push-button switch for Open, Close and Stop, and a
Local/Off/Remote selector switch padlockable in any one of three positions:-

(a) Local control only.

(b) Off/On electrical operation.

(c) Remote Control with local stop.

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OF MECHANICAL AND ELECTRICAL ITEMS

It shall be impossible to operate both open and close pushbuttons simultaneously.

Stop pushbuttons shall be mushroom headed "Stay-put" type.

Each actuator shall incorporate the following:-

(a) Easily replaceable phase discriminator to prevent starting with an incorrect

phase rotation or dead phase.

(b) Plug-in interposing relays with dust covers for Open/Close/Stop control from
a specified remote DC supply.

(c) Plug-in instantaneous reversal monitor relay with normally open contacts and
having its coil energised from the control transformer only when the
Local/Off/Remote switch is in the remote position to show that the actuator is
electrically operable by remote control.

Internal wiring shall be of a tropical grade PVC insulated stranded cable of 5 amp.
minimum rating for control circuits and appropriate size for the motor 3 phase
power. Each wire shall be clearly number identified at each end. The terminal
compartment shall include a moulded "transfer back" terminal block of the stud type
the 3 phase power terminals being segregated by a separate insulating cover. The
terminal compartment shall include a double O-ring seal to provide a watertight
barrier to the electrical enclosure so that electrical components are protected from
moisture ingress while the terminal cover is removed.

The actuator enclosure shall be watertight and where specified shall be explosion-
proof to an approved International standard.

The actuator starters shall be integrally housed with the actuator in robustly
constructed totally enclosed weatherproof housings. The motor starters shall be
capable of starting the motors under the most severe conditions.

The starter housing shall be fitted with internal heaters so as to provide protection
against damage due to condensation. Heaters shall be suitable for single phase
operation. The heaters shall be switched "on" when the actuator is stopped and
shall be switched "off" when the actuator is running.

18/28 PLC’s and Microprocessor Equipment

i) Microprocessors and PLC Equipment

All telemetry, micro-processor and PLC equipment shall comply with this
Clause, and the relevant clauses in Section 17 to 20.

For telemetry, computers, micro-processors and similar solid state

equipment, status inputs and outputs shall be isolated by opto-isolators or an
approved alternative and analogue inputs shall be as differential circuits.
Individual noise filtering shall be provided as necessary for each application.
Series mode rejection and over-ranging protection shall be fully adequate.

Where applicable components shall be mounted on high grade flame

retardant printed circuit boards which shall comply with the relevant part(s) of

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OF MECHANICAL AND ELECTRICAL ITEMS

BS 4584, have gold plated edge connections, be equipped with test points to
facilitate checking of major functions and have mechanical keying to prevent
accidental insertion of an incorrect card.

The equipment shall accept status inputs from site and panel mounted volt
free contacts and 4-20 mA analogue signals from site and panel mounted
transmitters. Analogue inputs shall be scanned into a 10 bit binary analogue
to digital converter with buffered inputs.

Status outputs shall be suitably rated for switching filament indicator lamps,
connecting into alarm systems, operating hardwire control circuits or other
switching functions in accordance with the requirements of the application
Clauses.

Analogue outputs shall be 4-20mA suitable for driving control circuits,

indicating meters, recorders and integrators. The overall accuracy of
transmitted analogue signals shall be within ±0.5% of FSD over the operating
temperature range of 0oC to 50oC.

The power supply unit shall be suitable for operation on a supply having a
voltage variation ±6% and a frequency variation of ±2%. The power unit shall
have an isolated output and incorporate protection against voltage spikes on
the mains supply, over-voltage and short circuit.

The equipment shall maintained in operation during a period of mains failure,

either drawing power from the main instrumentation and control
battery/charger system or from a separate UPS system, as appropriate.

Each system unit shall include spare installed capacity of not less than 15%
of each type of input and out put module, together with a minimum of 20%
spare system logic capacity.

All systems and equipment shall include diagnostic and automatic self test
routines with volt-free contacts to initiate an alarm in the event of malfunction.

As far as possible all computers, micro-processors, plc’s and similar system

elements provided throughout the whole system shall operate with similar
protocol/language so as to provide a compatible system with all peripherals,
programs, program development units, file management routines, data
storage facilities and similar facilities being common to all elements.

All equipment shall be fully programmed in accordance with the requirements

of the application Clauses. All programs, in the form of flow diagrams or logic
circuits shall be submitted to the Engineer for approval not less than 6 weeks
before the equipment is to be inspected.

In all cases the facility shall be provided for modifying the program, altering
set points and adjusting time settings while the equipment is "on line". There
shall be a permanently connected means of accessing set points and timer
settings.

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OF MECHANICAL AND ELECTRICAL ITEMS

All equipment associated with an operator interface shall utilise a high level,
engineer orientated language to permit programming, editing and similar
functions by engineers and operators.

ii) PLC’s

All PLC's shall be provided with the following facilities/accessories unless

specified elsewhere

Program to be stored on an EPROM

EPROM eraser
3 No. Spare EPROM's
Serial Computer Interface
Hand held programmer for local programming
Computer Software for programming
Computer interface and EPROM programmer to enable programs prepared
on the computer program to be transferred and stored on the EPROM.
Local battery backup for RAM.

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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TABLE OF CONTENTS

19/1 FINISH ....................................................................................................................... 2

19/2 MATERIALS ............................................................................................................... 2
19/3 VALVES ..................................................................................................................... 2
19/4 PUMPS ...................................................................................................................... 6
19/5 PRESSURE AND COMPOUND GAUGE FOR SEWAGE AND SLUDGE .................. 9
19/6 CENTRIFUGAL FANS (AIR BLOWERS) ................................................................... 9
19/7 SUPPORTS AND FIXINGS ...................................................................................... 10
19/8 SETTING OF MACHINERY ..................................................................................... 11
19/9 SUPPORT OF PIPE WORK AND VALVES.............................................................. 11
19/10 PENSTOCKS........................................................................................................ 11
19/11 LIFTING EQUIPMENT .......................................................................................... 14

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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19/1 FINISH

All covers flanges and joints shall be properly faced, bored, fitted, fixed, hollowed
moulded or chamfered as the case may be according to the best approved practice.
All working parts of the plant and other apparatus shall in like manner be well and
accurately fitted, finished, fixed and adjusted.

19/2 MATERIALS

All materials incorporated in the Works shall be the most suitable for the duty
concerned and shall be new and of first class commercial quality, free from
imperfection and selected for long life and minimum maintenance.

19/3 VALVES

19/3.1 GENERAL

Valves and penstocks shall be capable of withstanding corrosion in the ambient

conditions.

Nylon or other thermoplastic materials liable to attack shall not be used where
hydrogen sulphide is likely to be present.

All valve waterways shall be coated internally with a solvent free epoxy or polyester
lining of 100% solid content to be applied at the place of manufacture. The lining
shall be of 250 micron nominal thickness and holiday free.

All valves and penstocks will normally be witness tested at works.

Unless otherwise specified all valves and penstocks shall be anti-clockwise opening
and the maximum effort required, applied at the circumference of the hand wheel to
operate the valves against the maximum unbalanced head shall not exceed 55kg.

All hand wheels shall have the words "to open" and "to close" in Arabic and English
with arrows indicating the direction of rotation cast on and shall be coated in plastic,
nylon or other approved materials in order to withstand the ambient conditions.

Unless otherwise specified or agreed spindles and extension spindles shall be of

stainless steel Grade 316 S16.

Extension spindles, where required, shall be connected by suitable muff type

couplings manufactured from stainless steel grade 315S16. The muff couplings
shall be supplied drilled with nuts and bolts for connection to the spindles.

A clear polycarbonate tube shall be securely fitted to protect the thread of rising
spindles.

The nuts shall be of gunmetal or synthetic material and mating surfaces of gates
and bodies shall be of gunmetal, copper alloy or synthetic material.

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.

Where "Operation by Tee Key" is specified the valve or penstock shall be supplied
with a suitable yoke with a squared cap of standard size to receive the tee key.

The key shall be supplied at the rate of one key per two valves or two penstocks
unless the valve or penstock is to be installed in an isolated location in which case
one key shall be supplied for each fitting location.

Before delivery to site all working surfaces shall be thoroughly cleaned, and, if
metal, protected by grease.

Packing must be sufficient to ensure complete protection of the fitting during transit
and storage.

Valves under 300 mm diameter together with all hand wheels and other easily
detachable items on both valves and penstocks are to be packed in timber packing
cases and properly bound with steel packing bands.

All valves of 300 mm and over are to be protected with wood or plywood discs or
flanges together with straw rope and hessian wrapping.

19/3.2 NON-RETURN VALVES

Unless higher pressure ratings are required for the pipelines non-return valves shall
have a pressure designation of 10 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanged valves shall have
their flanges to a pressure of 10 bar and be drilled accordingly. The face to face
lengths of the valves shall be either 2 x ND + 100 mm or to an approved
international standard, the longer length to be allowed for in all cases using make
up pieces where necessary to achieve the required lengths.

Non-return valves shall be manufactured to conform to the requirements of an

approved international standard. Valves shall be of the single door swing check
type and shall have bodies of cast iron with copper alloy seatings and resilient faced
disks. Valve spindles and all construction bolts shall be stainless steel grade 316
S16. Door to spindle connections shall incorporate a keyway.

All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly
purposes shall be removed.

Valves shall, unless impracticable through size or otherwise specified shall be

capable of passing 90 mm dia solids.

Valves shall be provided with a removable cover on top of the body casting, to
enable the hinge and door to be inspected or removed.
0
The door opening shall be restricted to a maximum angle of 70 at the hinge,
measured from a plane passing through the hinge at right angles to the axis of flow.
Valves shall be provided with extended door spindles fitted with lever arms suitable
for balance weights.

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There shall be enough space between reflux valve and the wall of the valve
chamber so that the valve spindle could be withdrawn to the sides for
repair/maintenance of swing door without removing valves.

When specified limit switches, operated by external cams rigidly attached to the
door spindles shall be provided. The limit switch shall operate when the valve door
has moved through an angle of approximately 100. The switch shall provide
normally open and normally closed electrically separated contacts of the make
before break type.

19/3.3 GATE VALVES FOR SEWAGE AND RELATED FLUIDS

Unless higher pressure ratings are required for the pipeline, gate valves shall have
a nominal pressure designation of 10 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipe work, flanges shall have a
nominal pressure designation of 10 bar and shall be drilled accordingly. The face to
face lengths of the valves shall be in accordance with an approved international
standard.

Gate valves shall be manufactured to conform to the requirements of an approved

international standard and shall normally be metal seated with valve bodies of cast
iron and the seatings copper alloy faced. The gates shall be of wedge pattern,
copper alloy faced with inside screw non-rising stems of forged bronze or stainless
steel grade 316 S16. They shall have a packed gland stuffing box seal.

Where resilient seated gate valves are detailed the valve bodies shall be cast iron.
The gates shall be of cast iron and wedge pattern with nitrile rubber covering and
with inside screw non-rising stems of stainless steel or forged bronze. They shall
have a seal of nitrile rubber ‘O’ rings to an approved international standard.

Actuator operated valves larger than 300 mm dia. shall have copper alloy faced
guides and slippers. 300 mm dia. and smaller actuator operated valves installed
other than in a vertical position shall have machined guides and gates.

Valves shall normally be provided with drain plugs.

All cast iron shall be to an approved international standard.

19/3.4 AIR VALVES

Unless higher pressure ratings are required for the pipeline, or otherwise indicated
in the Contract Documentation air valves shall have a nominal pressure rating of 10
bar which shall be marked on the valve body and shall be designed for a liquid
temperature of 500C and air temperature of 700C. Air valves for pumped pressure
pipelines shall be the special high pressure ‘Dual’ large orifice type. The following
shall be used as a guide for the general sizing of large orifice air valves (Table 19-1)

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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Table 19 - 1 Size of large orifice air valves

Pipeline (mm) 200 300 350 450 60 900 1000*
Bore 0

Air Valve (mm) 20 25 50 80 100 150 200

size
Ball size (mm) 100 100 100/12 100/12 125 125/20 150/20
5 5 0 0

* For larger mains air valves may be fitted in clusters of two or more as required.

For other duties, such as distribution mains single, small orifice type standard air
valves having a nominal 25mm male thread inlet and with a ball size of 100 mm
shall be used. The test pressure for different components of the air valves shall be
as follows (Table 19-2):-

Table 19 - 2 Air valve details

Body Seat Ball/Float
20 bar 10 bar 10 bar
The materials of construction for air valves
Body, Cover & Duct Cast Iron to an approved international standard
Cover
Ball/Guide Polypropylene
Seat Nitrile Rubber
Air Release Moulded Rubber
Nipple
All Bolts Stainless Steel, Grade 316 S16

All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. All internal components shall be strong in
design and of stainless steel grade 316 S16.

The access cover for air valves shall be in such a position that the valves could be
easily removed for repair/maintenance.

The sitting of the air valves shall be at locations shown on the drawings, as
recommended by the pipeline surge analysis or as decided by the Engineer on site.

19/3.5 FLUSH VALVES

An automatic flush valve shall be attached to the pump volute to provide a flushing
stream from the pump’s discharge to flush the station sump and to keep it free from
sludge build up. The valve shall close after a predetermined period of time or when
the pump stops whichever occurs first and shall be totally leak proof in the closed
position. The valve shall open automatically in readiness for the next pumping
cycle.

The valve shall be suitable for operation based on the ejector principle utilising a
ball as the closing device or shall be suitable for operation on AC supply.

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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The material of construction for the flush valve shall be of cast iron to an approved
international standard.

19/3.6 FLAP VALVES

Metal Flap Valves

Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 500C.

Flaps and frames shall be of cast iron to an approved international standard with
end flange faced and drilled to an approved international standard. Mating surfaces
of flaps and frames shall be of an approved non-ferrous metal machined to ensure
a watertight fit in the closed position.

Hinge pins shall be of phosphor bronze to an approved international standard all

flaps shall be double hung and seated off the vertical.

Springs shall be of stainless steel, grade 316 S16.

All cast iron surfaces shall be cleaned by grit or shot blasting to be free from
grease, then coated as specified for the environment. Hinge pins and mating
surfaces shall be smeared with grease.

Plastic Faced Flap Valves

Flap valves shall be faced in an approved synthetic material so as to be corrosion-

free in the ambient conditions. The flap shall be weighted to assist closing and shall
be suitably braced and reinforced.

Hinge pins shall be of stainless steel and all flaps shall be double hung and seated
off the vertical.

Mating surfaces shall be accurately moulded or machined to ensure a watertight fit

in the closed position.

19/4 PUMPS

19/4.1 GENERAL REQUIREMENTS

Rotary Pumps are required to pump storm/groundwater or raw sewage containing

rags, fibrous material and general waste matter including grit and other abrasives,
partially treated sewage, sewage sludge and/or grit laden sewage.

Pumps shall be designed to pump satisfactorily solids of 90 mm diameter unless

otherwise specified. Freedom from choking is essential and is more important than
high pumping efficiency.

Pumps unless otherwise specified shall be designed to have stable head/quantity

characteristics, so as to avoid large changes of quantity with small changes of

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 SECTION 19 MISCELLANEOUS METALS AND PLASTICS
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head. The pumps shall be capable of operating with the sump surcharged to its
maximum level and the Pump motors shall be rated accordingly.

The fluid velocity at entrance to pump impellers shall not exceed 3.6 m/s for pumps
with suction pipe work larger than 200 mm dia. nor 5.5 m/s for smaller pipe work.
The fluid discharge velocity shall not exceed 3.6 m/s for all pumps.

Pump bodies, covers, brackets, bearing housings, wearing plates, eye rings,
support brackets, etc., shall be manufactured from close-grained cast iron or nickel
iron.

Pump castings shall be of substantial construction to give long life under abrasive
conditions and to enable them to withstand shock loads caused by solids in
suspension.

Impellers shall be of best quality close-grained cast iron or nickel iron for sewage
pumps and stainless steel grade 316 S16 or equal for storm/groundwater pumps.

Impellers shall be keyed onto shafts.

Shafting shall be of stainless grade 316 S16 or equal of adequate size to avoid the
possibility of fatigue failure. The duty speed range shall be well below the first
critical speed. At any change in diameter of the shaft the shoulder shall be
generously radiused to reduce stress concentration.

The rotating elements shall be dynamically balanced before final assembly.

Pump casings shall be hydraulically tested before assembly to a pressure of 1.5

times the closed valve head of the pump plus the maximum suction pressure.

Cathodic corrosion protection shall be provided for the storm/ground water pumps.

Pumps shall be performance witness tested at the manufacturer’s works by the

Engineer in accordance with the appropriate standard using clean cold water.
Unless otherwise specified pumps shall be tested with the motor which will drive
them after installation.
Mass produced pumps shall be tested to prove the duty/guarantee point.

Special pumps (ie. those for which the impeller is specially trimmed or otherwise
designed) shall be tested to prove the duty/guarantee point and to develop
Quantity/Head, Quantity/Power, Quantity/Efficiency curves for the pump at
operating speed, or if the pump is multi or variable speed, at maximum and
minimum speeds.

19/4.2 SUBMERSIBLE PUMPS

Submersible pumps shall comply with the General Requirements for Pumps.

They shall be close coupled units comprising a single, stainless shaft, a squirrel
cage electric motor and a single entry, end suction pump.

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Stainless steel lifting frames or eye bolts shall be fitted to casings for connection of
lifting chains.

Motors shall have IP68 protection and be continuously rated for use both when
submerged in sewage or storm/ground water at ambient temperature and when in
air. Motor windings shall be fitted with normally closed thermistors complying with
relevant specifications and providing protection when the pump is running.

Motors above 30 kW rating shall also be fitted with a lower bearing temperature
monitor and stator housing liquid level monitor. The monitoring equipment shall be
designed and installed so that automatic re-starting of the motor is not possible in
the event of a fault. The monitoring units shall be manufactured by the pump
supplier and supplied as free issue to the control panel manufacturer to form part of
the control panel.

Two mechanical seals shall be fitted on the shaft between the electric motor and the
pump impeller. The space between these two seals shall be oil filled.

Motor feed cables shall be ethylene propylene rubber insulated flexible cable, with
each power core of tinned copper wire nylon earth screened and polychloroprene
sheathed overall. Suspension of motor cables shall be via stainless steel cable
socks from suspension brackets.

Discharge bends shall be of close grained cast iron or stainless steel and shall
provide both pump support and lower guide rail/rope location. The pump discharge
connection system shall be designed so that the weight of the pump provides a
clamping force. Sealing between the pump and bend shall be achieved by the
weight of the pump and there shall be no leakage at the joint between the faces.

Mounting brackets for the pump shall be of Grade 316 S16 Stainless Steel.

Guide rails and holders shall be manufactured from stainless steel grade 316 S16
rigidly supported at both ends. Alternatively stainless steel guide wire arrangement
with stainless upper guide holder may be used.

Lifting chains shall be of stainless steel and shall include shackles for connection to
pump lifting points. They shall be at least 1.50 m longer than the guide rails.

The lifting chain shall be fitted with a stainless steel tag detailing the safe working
load, the test load, the date of testing and the name of the testing authority. Pump
materials shall be according to Table 19-3

Table 19 - 3 Schedule of pump materials

Cast parts Cast iron
Studs, nuts, screws and washers Stainless steel
Lifting handle Stainless steel
O-rings Nitrile rubber (700 IRH)
Stationary wear ring Nitrile rubber-clad steel
Rotating wear ring Stainless steel
Upper Mechanical shaft seals Tungsten carbide/Tungsten carbide
Lower mechanical shaft seals Tungsten carbide/Tungsten carbide

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Impeller for Storm/Ground water Stainless steel

Impeller for Sewage Cast Iron
Shaft Stainless steel

19/5 PRESSURE AND COMPOUND GAUGE FOR SEWAGE AND SLUDGE

Pressure gauges for use with sewage and sludge shall be Bourdon gauges. The
pressure transmission system shall be of the air-filled or oil-filled sealed type
incorporating reinforced plastic or stainless steel capillary tubing and diaphragm
transmitter.

For the air-filled system, the diaphragm shall be mounted in a clean-out housing.
The transmitter housing shall be mounted directly onto a 25 mm or greater bore
straight through isolating cock. The cock shall be mounted directly onto the
pressure tapping.

Where the gauge is mounted directly on the pressure tapping a Schaffer diaphragm
gauge may be used. Schaffer diaphragm gauges shall be fitted with 20 mm or
greater bore straight through isolating cocks.

Gauges shall be graduated in metres of water and bars gauge, together with
vacuum where appropriate. The accuracy of the system shall be  1.50% of range
or  2.50m bar.

Gauges shall have 150 mm diameter circular faces. Gauge graduations shall be
such that the gauge is never used continuously beyond 60% of the maximum
graduation.

The gauges shall not be connected to air release pipes or auxiliary suction pipes.

The gauges shall be fitted with a pressure snubber to dampen pressure pulsation.

The face shall have a warning label marked in red “IMPORTANT - TURN OFF
WHEN NOT IN USE” both in English and Arabic.

Before delivery, each gauge shall be tested in accordance with an approved

international standard and the test certificate sent the Engineer.

19/6 CENTRIFUGAL FANS (AIR BLOWERS)

Centrifugal Fans to be used as air blowers shall be of heavy duty, single inlet direct
drive type. They shall be suitable for handling temperature up to 800C, dust free air,
and aggressive gases and moisture normal to the sewage environment. The fan
shall be low-noise, explosion proof and corrosion resistant.

The blower shall be designed to handle, as a minimum, the rated air volume against
the stated head, as indicated in the Contract Documentation.

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General Construction

Mating flanges and/or flexible connection, as appropriate, shall be provided for the
inlet and outlet.

The fan shall be mounted together with motor support pedestal on a common base
frame. Fan blades, casing and other parts normally in contact with gases shall be
of stainless steel or plastic construction.

The fan shall have a backward curved centrifugal impeller which shall be overhung
on the motor shaft.

Driving motors shall be of well known manufacture with protection and insulation
appropriate to their location.

Blower Enclosure

Enclosure panels shall be of GRP modular construction materials consisting of

chopped strand mats, roving and unsaturated polyester resin to approved
international standards.

The GRP material shall be composed of :- 0.5 mm minimum thickness gel-coat to

provide chemical resistance, layers of chopped strand mat reinforcing in resin
content 60-70% by weight. Woven roving glass fabric layers to provide strength
and rigidity with resin content 45-55%, surface layers shall consist of “C” glass
surface mat (45-50 gm per square metre) with resin content of 90% by weight.

All cut edges shall be made smooth using a resin top coat and are to be gel coat
sealed. Rigidity of the enclosure can be increased by adding sufficient stiffeners.

The enclosure shall be U.V. resistant, have high impact resistance, high abrasion
resistance, low sound absorption dB 10-15 in the 100 - 500 Hz range, low thermal
2 0
conductivity of 1.4 W/m C and be non combustible.

19/7 SUPPORTS AND FIXINGS

Unless otherwise specified all supports, fixing bolts, screws, etc., and other fixings
shall be provided, shall be of minimum Grade 316 S16 stainless steel and shall be
as follows;

i) Threaded and fitted with 3mm thick washers beneath bolt and nut. The
length shall be such that when tightened down with a nut & bolt the threaded
portion will not protrude more than half a diameter of the bolt.

ii) When fastening galvanised components or aluminium alloy components.

PTFE washers shall be fitted beneath the stainless steel washers for both
bolthead and nut.

iii) Stainless steel grade 316S31 shall be used for construction of pumps,
fastening galvanised or aluminium alloy components, holding down and
anchor bolts.

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Not withstanding the above, the Contractor shall consider galvanic corrosion
between various metals when selecting materials for proposal.

19/8 SETTING OF MACHINERY

The machinery shall be mounted on flat steel packing of thickness selected to take
up variations in level of the concrete foundations.

The packing shall be bedded by chipping or grinding of the concrete surface.

Packing shims of the appropriate thickness shall be located adjacent to each

holding down bolt. The number of shims shall not exceed three at each location.

The machinery shall be aligned, leveled and pulled down by the nuts of the holding
down bolts with a spanner of normal length. No grout shall be applied until the
machinery has been run and checked by the Engineer for stability and vibration.

Where specified an approved high performance non shrink grout shall be poured to
bed the equipment.

19/9 SUPPORT OF PIPE WORK AND VALVES

All necessary supports, saddles slings, fixing bolts and foundation bolts shall be
supplied to support the pipe work and its associated equipment in an approved
manner. Valves, meters, strainers, and other devices mounted in the pipe work
shall be supported independently of the pipes to which they connect.

All brackets or other forms of support, which can conveniently be so designed, shall
be rigidly built up of sections.

No point of passage of pipes through floor or walls shall be used as a point of

support, except with the approval of the Engineer.

19/10 PENSTOCKS

19/10.1 GENERAL

Fixings shall be of the drilled anchor type and made of stainless steel.

All penstocks shall be suitable for an on/off seating head of 10m minimum but in no
instances shall be less than 1.5 the maximum working head.

Penstocks shall conform to the following specifications:

(i) Austenitic Ni Resist Cast iron

(ii) Stainless Steel

(iii) Plastic

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The size of penstock to be used in any particular location shall be as described in

the Contract Documentation and approved by the Engineer.

The frame, doors, sealing faces and spindles of each type of penstock shall be as
specified in the appropriate clauses herein.

Unless otherwise described in the Contract Documentation all penstocks shall be

provided with hand wheels of adequate diameter with suitable gearing where
necessary to ensure that the required operating force applied by hand does not
exceed 55 kg.

Hand wheels shall have the works “To open” and To close” in Arabic and English
with arrows indicating the direction of rotation cast on them. The direction of closing
shall be clockwise and a vandal/weatherproof, clear polycarbonate tube cover shall
be securely fitted to protect the thread of rising spindles. The tube shall be clearly
and permanently engraved to indicate the position of the penstock.

Spindles shall have machine cut robust trapezoidal or square form threads as
necessary. They shall be of stainless steel. Extension spindle coupling shall be of
the muff type and they shall be drilled and provided with a stainless steel nut and
bolt for securing the spindle to the penstock spindle head which likewise be drilled
to take the bolt.

All penstocks shall be of the rising type unless otherwise stated. Headstocks shall
be provided except in cases where the hand wheels can be mounted on the
penstock frames. Unless otherwise stated for penstocks of 300mm (square or
circular) or more thrust tubes shall be provided. For all motorised/actuator operated
penstocks thrust tubes shall be provided between the penstock frame and
headstock in order to absorb the thrust in both directions of operation. Thrust tubes
shall incorporate all necessary fixing brackets and spindle guide plates.

Permissible rates of leakage under the specified working head shall be as follows;

On seating installation : - 5 litres per meter of slide perimeter per hour.

Off seating installation: - 30 litres per meter of slide perimeter per hour.

The slide perimeter shall be measured as the total length of contact faces between
the gate and frame in the closed position.

All materials used in the manufacture of penstocks shall conform to approved

international standards.

19/10.2 AUSTENITIC NI RESIST IRON PENSTOCKS

The frames, doors and stems guides for iron penstocks shall be made from
austenitic Ni resist iron. The penstocks shall be designed so as to ensure tight
closure while maintaining freedom of door movement during operation and
minimising sliding wear of the sealing faces. They shall incorporate adjustable
wedges manufactured from a material that shall not be susceptible to corrosion.

Non-ferrous metal sealing faces shall comprise accurately machined phosphor

strips bedded and fixed to the frame and door. The strips shall be secured by

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countersunk screws that shall not be susceptible to corrosion. The faces of the
strips shall then be brought together in the operating position and hand scraped to a
water-tight finish.

Non-ferrous metal strips shall be fitted to the frame guides and gate.

Penstocks shall be prepared and painted in accordance with painting specification.

19/10.3 STAINLESS STEEL PENSTOCKS

The frames and doors of stainless steel penstocks shall be of Grade 316 S31. The
design of the doors shall be such that the required working pressures can be
withstood without deflection or distortion that would affect the operation of the
penstocks. Any strengthening of doors by the provision of ribs and gussets shall be
carried out by welding and not by bolting.

The side sealing faces may consist of simple metal to metal contact between the
door and frames or by synthetic rubber seals and plastic guides as necessary to
withstand the required working pressure without leakages.

Spindles shall be manufactured in stainless steel grade 316 S31.

19/10.4 PLASTIC PENSTOCKS

The frames of plastic penstocks shall be made from continuously welded stainless
steel. Frames shall be reinforced and gusseted to ensure rigidity without
dependence upon the bridge which shall be bolted for ease of removal.

The doors of plastic penstocks shall be made from sheets of approved rigid cellular
polymer sandwiched between sheets of approved rigid compressed composite
plastics. The linear coefficient of thermal expansion of the material shall not be
greater than 1.6 x 10 per oC. No PVC or GRP materials shall be used. The doors
thus formed shall have sufficient strength to withstand the required working
pressures without deflection, distortion or that would affect the water-tightness of
the penstocks. Totally enclosed steel matrices shall be incorporated in the door
construction to ensure adequate rigidity.

The sealing faces and side guides shall be to the approval of the engineer and shall
consist of plastic strips having a high resistance to sliding wear and a coefficient of
friction of less than 0.10. The sealing strips shall be securely fixed to the inner
faces of the frames and shall incorporate removable stainless steel adjusting
devices.

Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra

high molecular weight polyethylene material. The operating nuts for the spindle
retaining blocks shall be fixed in a visible position inside a separate gate lifting
bracket bolted on to the top of the door with stainless steel fasteners. The
operating nut or spindle retaining block shall not be contained within the door.

All plastic materials shall be non toxic ultraviolet stabilised and shall have fire
resistance in accordance with an agreed internationally approved standard.

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19/10.5 ACTUATORS

Where electric actuators are required for valves or penstocks they shall comply with
the requirements of Section 18 the Electrical Specification.

19/11 LIFTING EQUIPMENT

19/11.1 ELECTRICALLY OPERATED TRAVERSING CRANES

Cranes shall be electrically operated traversing type and be complete with gantry
rails and all accessories including a set of slings.

The gantry joists and rails shall be provided with provision for jointing and fix to the
structure. The lifting capacity of the apparatus shall be sufficient for the heaviest
load which will be obtained when erecting or dismantling the plant or other parts of
the installation. The capacity of the cranes proposed shall be stated in the
equipment supply schedule.

The crane shall be tested at the makers works at 25% above the rated load, and
test certificates shall be provided.

The crane shall be of the double girder traveling type. The traveler carriage shall
run on bridge rails which shall be securely fixed to the gantry.

The crane shall be provided with a maintenance platform over the full span. The
maintenance platform shall be provided with double handrails throughout and a
fixed ladder access.

Longitudinal and traverse motions shall be provided for the crane and shall be such
that operation is speedy without impairing safety in working. The hook and load
chains shall be such that the hook will reach to the maximum depth.

Ball or roller bearings shall be employed on all motions and the load hook shall
revolve on a ball swivel. All gears shall be machine cut and all runway wheels
machined.

A reliable braking and locking arrangement shall be provided.

The crane structure shall be designed in accordance with the requirements of an

approved international standard.

Two hoist speeds shall be provided, not exceeding 3 m/min across the working
range of the crane. Cross travel speeds shall be approximately 15 m/min. All
motions shall be electrically driven. The speeds of all motions shall confirmed in
the appropriate schedule the speeds on all motions.

The load shall be carried on a flexible steel wire rope coiled onto a cast iron barrel
having right and left hand machine cut spiral grooves to ensure a true vertical lift.
The load rope shall be of sufficient length to reach the maximum depth. The load
hook shall comply with an approved international standard and shall revolve on a
ball swivel. A safety catch shall be fitted to the hook.

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The crane shall be remote controlled on all motions from a non-metallic pendant
push button station. Buttons shall be of the hold-to-operate type. The pendant
enclosure shall give protection to IP54 requirements. Operation of the crane shall
be possible from any position across the full span. The pendant legends shall be
inscribed in English and Arabic.

The power supply to the hoist shall be of festooned cable type running on a rigid
support system. An earth conductor shall also be provided.

The electrical equipment shall be controlled at 110 volts. The transformer shall be
protected by HRC fuses on both primary and secondary circuits.

A main supply isolator shall be provided and mounted at operating height from
ground level. Three sets of red "conductor alive" warning lamps shall be provided.

All motors and electrical equipment shall be rated in accordance with the climatic
and other Specification requirements.

The integrity of the hermetic seal to the box girders is to be maintained. All cables
shall be enclosed in a steel conduit which is to fastened to the exterior of the girder.

19/11.2 MANUALLY OPERATED LIFTING EQUIPMENT

A close lift, hand operated gear driven lifting block, on a single runway beam, shall
be provided when specified in the Contract Documentation. The Safe Working Load
of block and beam shall be at least 25% above the weight of the heaviest item
which will require lifting for maintenance purposes. Equipment shall have the
following minimum ratings: 500 kg for the hoist and 1000 kg for the beam.

The whole assembly including beam, gear driven traveling trolley, pulley block and
chains shall be subject to a capacity test carried out on site by an approved
independent body. The proof load applied for certification shall be 50% in excess of
the Safe Working Load (SWL) shall be clearly marked on the lifting block and on
the runway beam. The test date is to be displayed on the runway beam.

The bottom block shall be of the steel fully swiveling type with a safety catch fitted
to the hook.

A secondary load chain/cable and hook shall be supplied, suspended from the
trolley. The chain/cable shall be fixed length so that the hook is suspended
approximately 1000 mm below the bottom flange of the beam. The hook, and
chain/cable shall be tested to the same safe working load as the main hoist. The
secondary load chain/cable shall be used to support a lift at intermediate levels
whilst the main load chain is re-slung.

19/11.3 LIFTING FRAMES

Lifting Frames shall comprise an "A" frame or portal supporting a composite beam
over the lift centre lines which will carry a hoist block with traverse. The composite
parts of the device shall comply with the relevant specification clauses.

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19/11.4 LIFTING DAVITS

Lifting davits shall comprise of a simple single mounting; capable of traversing the
uispan of the area of lift and be fitted with a chain block as Clause 19/11.2 above. A
socket shall be provided which is to be cast into the reinforced concrete of the
associated structure.

APPROVED INTERNATIONAL STANDARDS

ASTM C418
BS 466
BS 476
BS 970
BS 1452
BS 1780
BS 2061
BS 2374
BS 2494
BS 2573
BS 2853
BS 2903
BS 3243
BS 3468
BS 3499
BS 3532
BS 3643
BS 3691
BS 4504
BS 5153
BS 5163
DIN 1690
DIN 1691
ISO 5752
ISO 5996

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TABLE OF CONTENTS

20/1 METAL AND PLASTIC MATERIALS ......................................................................... 2

20/2 METAL AND PLASTIC PREFABRICATED ITEMS .................................................... 7
20/3 ODOUR CONTROL EQUIPMENT ............................................................................ 8
20/4 VENTILATION ......................................................................................................... 11
20/5 AIR CONDITIONING ............................................................................................... 14
20/6 STANDBY DIESEL GENERATING PLANT ............................................................. 16
20/7 FIRE ALARM AND EXTINGUISHING SYSTEMS .................................................... 26
20/8 ACCESSORIES ...................................................................................................... 29
20/9 GAS DETECTORS .................................................................................................. 30
20/10 SURGE ................................................................................................................... 32

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20/1 METAL AND PLASTIC MATERIALS

20/1.1 ALUMINUM ALLOY

Aluminum alloys shall be selected as having properties appropriate to the duty of

the unit, the method of fabrication and the environmental conditions.

The materials shall be manufactured in accordance with an approved International

Standard and shall be anodized when specified.

Alternative alloys may be proposed by the Contractor if the manufacturer

considers its properties more appropriate to the application, the environmental or
the physical conditions prevailing.

20/1.2 STEEL

Steelwork shall be manufactured/fabricated in accordance with an approved

international standard. Where specified or detailed steel work shall be hot dipped
galvanized in accordance with an approved International Standard at the place of
manufacture / fabrication.

20/1.3 STAINLESS STEEL

Stainless steel shall have the following composition with mechanical properties to
the appropriate approved standard (Table 20-1).

Table 20- 1 Required properties for stainless steel

Percentage Chemical Composition

Element Welded Fabrication Cold Fabrication

% % maximum % % maximum
minimum minimum
Carbon - 0.03 - 0.07
Silicon 0.20 1.00 0.20 1.00
Manganese 0.50 2.00 0.50 2.00
Nickel 11.00 14.00 10.00 13.00
Chromium 16.50 18.50 16.50 18.50
Molybdenum 2.25 3.00 2.25 3.00
Sulphur - 0.03 - 0.03
Phosphorous - 0.045 - 0.045

Alternative, higher grade, stainless steel may be proposed by the Contractor if the
manufacturer considers its properties more appropriate to the environmental or
physical conditions.

20/1.4 REINFORCED THERMOSETTING PLASTICS

Reinforced plastic shall be as follows unless otherwise agreed in writing by the

Engineer.

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(1) Manufacturing Standards

The specification for design, materials, construction, inspection, and testing of

plant manufactured from reinforced plastics shall conform to the appropriate
sections of the approved standard.

(2) Resins

(a) Isophthalic, Terephthalic, Bisphenol and Vinyl Ester resins may be

specified and they shall comply with the approved standard. The
resins used shall have a minimum strain to failure of cured cast resin
of 2%.

(b) Pigments or fire retardant resins (or fillers) shall only be used when
specified or ordered in writing.

(c) Additives shall not be included in the resins unless they are required
for viscosity control.

(d) Due attention must be paid to preclude the possibility of air inhibition
occurring on the laminate surfaces. The inclusion of paraffin wax,
etc., must be in accordance with resin suppliers recommendations.

(e) Where protection against Ultra Violet light degradation is required, a

translucent UV inhibitor should be included in the outer layers of the
laminate.

(3) Curing

Curing systems shall be in accordance with the Resin Manufacturer's

recommendations. The manufacturer of the laminate shall demonstrate that
the laminate has been adequately cured prior to its acceptance at the
laminator's works.

(4) Reinforcement

(a) 'E' type glass chopped strand mat reinforcement shall be to the
approved standard and shall be to a maximum unit weight of 600
2
gm/m .

(b) 'E' type glass woven roving fabrics shall be to the approved standard
2
and shall be to a maximum unit weight of 800 gm/m .

(c) 'C' type glass veil (or synthetic fabric veil, where use is agreed by the
Engineer), shall be used to reinforce all surface sealing resin layers
on laminates.

(d) Use of 'ECR' Corrosion Resistant glass will be permitted.

(5) Structural Design

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(a) The laminate shall be designed to withstand all the loadings normally
carried by the laminates.

(b) Under the worst combination of loading conditions, a maximum strain

of 0.2% shall be permitted in the laminate.

(c) A minimum laminate thickness of 6 mm shall be maintained for all

GRP laminates including the facings over or under stiffener sections.

(d) Stiffener sections may be used to increase the rigidity of a structure.

The minimum glass reinforcement content shall be 1.2 kg/m 2 in these
areas. Stiffener sections may be manufactured from the following
materials.

(1) Polyurethane Foam

(2) Marine Plywood
(3) Other material agreed in writing

Stiffener sections shall not be made from steel or metal sections

unless written consent has been previously obtained. Where
stiffening sections are employed they shall not be construed as
adding to the strength of the section to which they are added.

(6) Moulds

Moulds shall be of adequate rigidity to retain dimensional stability and permit

a high level of laminate consolidation., The mould surfaces shall be of a
quality which will ensure the surface finish of the product.

(7) Fabrication Methods

Manufacture shall be by approved mechanical methods wherever possible.

Items produced by hand lay-up processes will only be permitted if a suitable
mechanically manufactured product is not available. If deposition of resin by
gun is used, this must be carried out by airless spray technique.

(a) Unreinforced gel coats shall have a maximum thickness of 0.5 mm.
Unreinforced flow (top) coats shall be fully brushed out to remove
resin rich areas. The flow coat shall not exceed 0.3 mm in thickness.

(b) Surface veil or synthetic fabric reinforced layers shall consist of

approximately 90% resin by weight. The thickness of this reinforced
layer shall not exceed 0.5 mm.

(c) Chopped strand mat layers shall have a resin content of between 65%
and 75% by weight.

(d) Woven roving glass fabric layers shall have a resin content of
between 40% and 60% by weight.

(e) Where edges of laminates are cut or exposed these shall be sealed
with a continuous layer of fully cured resin.

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(f) Bisphenol or vinyl ester protective layers to isophthalic/terephthalic

laminates, shall be applied with a 'C' type glass veil (or synthetic fabric
veil) reinforcement after hardening of the substrata. When this has
sufficiently cured to prevent movement, a continuous flow (top) coat of
bisphenol or vinyl ester resin shall be applied and fully cured. In such
cases it is anticipated that an appropriate paraffin wax additive will be
required to prevent air inhibition of the surface.

(8) Samples

(a) A sample measuring 1 metre square and typical of each different

laminate proposed shall be submitted for approval together with a
detailed descriptive specification at least 4 weeks prior to the
commencement of manufacture.

(b) Production samples measuring 300 mm square and typical of each

different section of laminate shall be submitted to the Engineer's duly
authorised Inspecting Engineer throughout the period of manufacture
for the purpose of testing.

(c) Samples of liquid and cast resin together with reinforcements and
surfacing veils (or fabrics) required to manufacture the samples
indicated in (b) above shall also be made available to the Engineer.

Failure to provide any of the samples designated in (a), (b) and (c)
above shall be construed as representing a delay in completion of the
Contract under the terms and conditions contained therein.

(9) Tolerances for Moulded GRP (Table 20-2)

Table 20- 2 Thickness tolerances for moulded GRP

Nominal Molding from Molding from Matched
thickness Open mould. closed mould metal
(mm) (mm) (mm) moldings
(mm)
Up to but not p 0.50  0.20  0.18
including 1.5
1.5 to but not  0.75  0.30  0.20
including 3.0
3.0 to but not  1.10  0.50  0.30
including 6.0
6.0 to but not  1.50  0.75  0.40
including
12.0
12.0 to but  2.00  1.40  0.50
not including
25.0
25.0 and  3.00  1.90  0.65
over

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(10) Quality Control and Testing

(a) The following tests for inspection and quality control shall be carried
out:-

(1) The laminate shall be fully cured and shall show full resistance
to a commercial acetone sensitivity test.

(2) The laminate shall give Barcol Hardness of at least 90% of the
resin manufacturer's recommendations. The measurement of
hardness by means of a Barcol Impresser shall be carried out in
accordance with the approved standard.

(b) Resin burn off tests shall be performed on cut-outs, where no such
cut-outs exists the Engineer reserves the right to have 50 mm
diameter cut-outs for checks to be made on local glass reinforcement
content. The tests shall be conducted in accordance with the
approved standard and the result shall define glass content.

(c) The following strengths of the laminate shall be determined in

accordance with the approved standard.

(1) Ultimate tensile unit strength

(2) Flexural strength

(3) Lap shear strength

(4) Shear and Peel strength of bond between thermoplastic linings

and laminate shall be at least 95% of the minimum value
specified by the laminate manufacturer.

(d) Where a laminate has been designed to take bolts in the make up of
the structure tests for bolt bearing strength shall be performed. Bolt
bearing strength tests shall be performed in accordance with the
approved standard.

(e) Where a laminate is to be used in conjunction with electrical control

equipment all or part of the following additional tests may be called up
which shall be carried out in accordance with the approved standard.

(1) Electrical strength of sheet parallel to the plane of the sheet.

(2) Electrical strength of sheet normal to the plane of the sheet.

(3) Electrical strength of casting laminating resin system.

(4) Insulation resistance of laminated sheet using IEC taper pins.

(f) Additional tests may be called up at the discretion of the Engineer.

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(g) (1) Test Certificate shall be obtained from the resin supplier for
the heat distortion temperature of resin and the unreinforced
resin extension to failure.

(2) Test Certificates shall be obtained from the glass

reinforcement manufacturer for each grade and type of glass
employed in the fabrication of the laminate.

(h) All the tests referenced in (a) to (f) above shall be witnessed by the
Engineer or his Representative unless waived in writing by the
Engineer.

(11) Trial Election

A sufficient proportion of the fabricated sections of the structure must be trial

assembled to demonstrate the correctness of fit of the various sections.

20/2 METAL AND PLASTIC PREFABRICATED ITEMS

20/2.1 LADDERS AND SAFETY HOOPS

Ladders and safety hoops shall be manufactured from either stainless steel or
glass reinforced plastic, as specified in the contract documentation.

The materials and manufacture of ladders and safety hoops shall be in

accordance with an approved international standard.

For all stainless steel ladders the stringers shall be 65 mm by 12 mm and spaced
375 mm apart. The rungs shall be 25 mm dia. reduced to 20 mm dia. at the ends
and rivetted over. They shall be spaced at 225 mm centres. The ladders shall be
provided with fixing brackets or the ends of the stringers shall be turned over to
form fixings. The fixings shall be drilled for 16 mm diameter bolts.

Stainless steel safety hoops shall be of circular pattern fabricated from 50 mm by

10 mm flats. Fixing shall be by 12 mm dia. countersunk screws with washers and
nuts, the screws being inserted from the inside of the ladder stringers.

Glass reinforced plastic ladders shall be dimensionally similar to stainless steel

ladders for rung widths and spacings. The treads of rungs shall be roughened.

All fixing brackets, screws, bolts and nuts, etc. shall be SS grade 316 S16.

20/2.2 UNDERGROUND HYDRANTS AND COVERS

Underground Hydrants shall be of the screw-down pattern manufactured in

accordance with the approved International Standard.

20/2.3 OPEN MESH AND CHEQUER PLATE FLOORING

Open mesh and chequer plate flooring shall be of mild steel, aluminium or
reinforced plastic as specified in the Contract Documentation.

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Unless higher loadings are called for floorings shall be designed to take
pedestrian loading based on a central point load of 100 kg under which the
deflection shall not exceed span/200 for metal flooring and span/100 for
reinforced plastic flooring. Reinforced plastic flooring shall have a non slip tread
surface.

Unless a higher grade of protection is detailed all mild steel flooring shall be hot-
dipped galvanised after fabrication.

20/2.4 GALVANISED STEEL GUARD RAILS

Tubular handrails and standards shall be of 10 gauge thickness 32 mm nominal

internal diameter steel tube. Solid handrails shall be 25 mm diameter and solid
standards 32 mm diameter. The balls on the standards shall be of adequate size
to accommodate the rails which shall be fixed by grub screws for tubular rails and
by welding for solid rails or by similar approved fixings.

Heights of rails, overall dimensions and details of the bases for the standards,
fixing bolts and any other special requirements relating to the guard rails are
shown on the drawings.
All components shall be galvanised after fabrication.

20/2.5 ALUMINUM GUARD RAILS

Unless otherwise specified or ordered, aluminum guard railing shall be

constructed with tubular rails fixed to double ball pattern solid forged standards.
Both rails and standards shall have a minimum outside diameter of 38 mm.

The rails and standards shall be of aluminum alloy anodized after fabrication.
The standards shall be fitted with base plates approximately 150 mm x 65 mm x
16 mm thick.

Heights of rails, overall dimensions and details of the bases for the standards,
fixing bolts and any other special requirements relating to the guard railing are
shown on the drawings.

20/3 ODOUR CONTROL EQUIPMENT

20/3.1 DESIGN PARAMETERS

The Tenderer shall submit detailed proposals for the effective control of odours
emitted from wet wells.

Concentrations of H2S are likely to be as high as 250 ppm under natural

ventilation conditions with an average concentration of 50 ppm.

The odour control system shall be based on the use of bulk activated carbon of
the regenerative type. The system shall be designed for regeneration of the
carbon without the removal of any part of the plant from site.

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Performance guarantees to reduce the H2S levels at 1.5 m above ground level to
0.1 ppm and in the Wet Well to 3 ppm shall be included in the proposals and shall
be binding on the successful Tenderer.

The Deodoriser shall be designed during normal operation to give a minimum of

16 air changes per hour.

A warning light of the flashing beacon type shall be placed at the entrance to the
wet well which shall operate if the system fails. It shall operate on the fail safe
basis and additional signage is to be provided warning operators not to enter if the
flashing/warning light is illuminated. Safe working practices shall be followed
before any entry. A notice shall be placed underneath the warning light and shall
read as follows:-

DANGER
VENTILATION FAILURE
DO NOT ENTER WHEN THE RED LIGHT IS FLASHING

20/3.2 DESCRIPTION AND ARRANGEMENT OF PLANT

20/3.2.1 General

The odour control plant shall comprise a rechargeable activated carbon bulk plant
with pre-filter as follows:-

A. Filter media housing

B. Sufficient Activated Carbon to give continuous operation for five years
(inclusive of regeneration)
C. Pre-filter inclusive of housing, washable nylon filter etc.
D. Extract fan (s)
E. H2S monitor
F. Differential pressure gauge
G. Interconnecting pipework and valves
H. Ductwork between sump, fan(s), carbon filter and pre-filter

20/3.2.2 Filter Media Housing

The filter media housing shall be manufactured in uPVC and wrapped externally
with glass reinforced white pigmented polyester resin (GRP) in accordance with
the general specifications. Conductive resin strips behind weld lines shall be
included to alleviate static build up and be bonded to earth.

It shall consist of a vertical cylindrical sections with flat base as follows:

A. Flanged access covers

B. Discharge stack
C. Connections for earth bonding, pre-filter inlet, differential pressure detector,
H2S monitor etc.

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All materials shall be resistant to corrosion from chemicals encountered in the

process.

Design calculations shall be submitted in respect of the stack height required to

prevent down-draft occurring due to the possible effect of adjacent structures.

20/3.2.3 Filter Media

The filter media shall be activated carbon and must be effective in dealing with
odours arising from concentrations of Hydrogen Sulphide gas.

A full specification of the type and grade of activated carbon proposed is to be

included with the Tender.

The Contractor shall state the expected life of the activated carbon and guarantee
sufficient supplies for five years of operation.

The activated carbon shall be suitable for insitu regeneration by water wash. For
which all necessary equipment shall be provided.

20/3.2.4 Extract Fans

Extract fans shall be provided as necessary in the system prior to the main filter to
transfer foul air as described previously.

Each fan shall be of the multi-vane centrifugal type and fabricated from stainless
steel Gr. 316S31

A direct coupled drive is preferred but alternatives will be considered providing it

can be shown that belts and pulleys are fully protected.

Motors shall be in accordance with the electrical section of the specification. They
shall be suitable for continued operation within the hazardous location.

20/3.2.5 Differential Pressure Switch

An air pressure switch for detection of the efficiency of filters shall be provided. It
shall be of the differential pressure type and be protected for the environment.
The switch shall be intrinsically safe and shall be arranged to initiate an alarm one
week before filters require cleaning.

20/3.2.6 H2S Monitor

H2S Monitor for deodorising plants shall be of the "sensitised pad" type enclosed
in a factory manufactured clear UV protected housing mounted in a clearly visible
location on the filter media housing. The sampling point shall be in the air stream
just above the carbon bed level such that it detects the level of H2S that is emitted
from the filter.

The sensitised pad shall change colour relative to its exposure to H2S. A colour
chart with H2S (ppb) graduated against time (min) shall be supplied for
comparison.

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20/3.2.7 Ductwork

Ductwork, casings, sun covers, louvers etc. shall be constructed of chemically

reinstated glass reinforced plastic or Upvc, or stainless steel as specified and
comply with the following:-

Comply with HVAC and SMACNA or similar approved publications

Obtrusions to air flow with the exception to dampers, vanes, splitters will not be
accepted.

All joints, fittings, support etc. shall have all sharp edges removed.
Where ductwork passes through ceilings, roofs, walls etc.; purpose made vermin
proof fittings are to be used.

Connection of individual components between an assembly and ductwork shall be

carried using angled flange joints.

Ducts in close proximity to walls and ceilings shall be mounted in such a way as to
exclude vermin runs.

Flexible joints are to be provided at all fan inlets and outlets

Where uPVC is exposed to direct sunlight it shall be enclosed in GRP for

protection.

The external noise levels due to the operation of the ventilation equipment shall
be unobtrusive at all times.

20/3.2.8 Filters

The filter designed should be as follows:-

Filters shall be installed at all points of entry to ventilation and air conditioning
systems. To reduce the ingress of dust around the frame to a minimum and so
constructed to facilitate maintenance.

Manufactured from approved corrosion resistant material.

Have a Minimum efficiency of 95%.
Have a maximum air velocity of 2.5 m/sec.
Provided with drainage points as necessary
Pressure of clean air > 90 Pa for 95% efficiency & > 125 Pa for 98% efficiency.

20/3.2.9 Flexible Joints

Flexible joints shall have the effective cross sectional area as adjoining ductwork
or fan housing and shall be manufactured from material with a 15 minute fire
penetration time.

20/4 VENTILATION

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20/4.1 GENERAL

Ventilation equipment shall be supplied and installed for the areas specified.

The noise level due to ventilation equipment shall be no greater than sound power
level 65 dB(A) re 10-12 watts.

The Contractor shall include for sound absorbers and anti-vibration mountings as
necessary.

All inlets and outlets through the roof shall be fitted with approved GRP or
Aluminium cowls and bird screens. All inlets and outlets through walls shall be fitted
with sand trapped de-mountable aluminium louvers. All materials used for external
fittings shall be highly resistant to ultra-violet light degradation.

All louvers shall be of the sand trap type and shall be fitted with internal sand filters
and mosquito screens.

20/4.2 EXTRACT FANS

Extract fans shall be roof, wall or duct mounted electric motor driven axial flow type.
They shall be complete with weather protecting cowls of GRP or aluminium if
mounted externally, and any necessary ductwork.

Extract fans shall be sized to provide the minimum number of air changes per hour
for the area specified:-

Toilets 12

Stores 6

Workshops 15

Garages/Car park areas 8

Messes (two speed) 6-20

Motor Room 10 - 20

Dry Well 20/

20/4.3 WET WELL VENTILATION

Refer to odour control equipment

20/4.4 DRY WELL VENTILATION

Ventilation equipment shall provide 20 air changes per hour to the dry well area.

The system shall operate on the principle of forced draught outlet/ natural ventilation
inlet via the stairways and other apertures.

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20/4.5 MOTOR ROOM VENTILATION

Ventilation equipment shall be two speed to provide 10 or 20 air changes per hour
to the Motor Room area.

The system shall operate on the principle of forced draught outlet/ natural ventilation
inlet via inlet louvers. All inlet louvers shall be fitted with 50mm thick metallic
washable filters. Access shall be provided for cleaning/changing filters.

20/4.6 FANS

Fans shall be of the axial flow or centrifugal types suitable for handling air of high
humidity and having concentrations of hydrogen sulphide.

They shall be of non-ferrous construction or be protected with suitable epoxy resin

coatings.

Wet well fans shall be constructed entirely from stainless steel to an approved
International Standard.

All bearings shall be of the roller or ball race type and shall be sealed for life.

20/4.7 FAN MOTORS

Fan motors shall be suitable for continuous operation in hot, humid atmospheres at
an ambient temperature of up to 55oC at 100% humidity.

The degree of protection provided shall be appropriate to the installed location and
approved by the Engineer.

All motors shall comply with the requirements of the electrical section of the
Specification in so far as it applies.

20/4.8 DUCTING

Ventilation ducting shall be of GRP, Reinforced uPVC or Stainless Steel. Material

thickness, stiffening and joint arrangements shall be in accordance with an
approved International Standard.

Ducting shall be complete with all necessary supports. Stainless steel nuts and
bolts shall be used for all ducting joints and all Supports and brackets shall be
galvanised except where otherwise specified. All supports, brackets and fixings in
wet wells shall be stainless steel.

Ducting shall be sized so that the air velocity within the ducts shall not exceed 5.5
m/s.

Flexible connections and anti-vibration mountings shall be provided as necessary

between the ductwork and fans and provision shall be made for thermal expansion.

Where ducts pass through walls roof or floor slab the gap shall be sealed with a non
degradable approved material.

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20/5 AIR CONDITIONING

20/5.1 WALL MOUNTED AIR CONDITIONING UNITS

Air cooled 'window-type' air conditioning units, as supplied by an approved and

accepted manufacturer, shall be installed in positions approved by the Engineer.
They shall be provided complete with slide out chassis and frame, suitable for clear
openings set not higher than 1.5m above floor level. They shall be suitable for
continuous efficient operation in the climatic conditions prevailing and the materials
of construction (particularly concerning the fins or extended surfaces of the
refrigerant to air heat exchangers) shall be subject to the Engineer's approval.

Both fresh air and re-circulated air shall be filtered and the filter shall be arranged for
ease of removal from the main unit for cleaning and replacement.

Depending on the size of the room space and the heat load therein, the air
conditioning units shall be of 1 ton, 1.5 tons or 2 tons refrigeration capacity
(equivalent to an air cooling capacity of 13,250; 19,880 or 26,500 B.T.U.’s per hour)
or multiples thereof.

Each unit shall be provided with a manually adjustable thermostatic air temperature
control and such other controls necessary to allow the following modes of
operation:-

1. Off.

2. Fan only with two speeds.

3. Cooling at two possible fan speeds.

4. Re-circulation of air from room, through unit and back to room.

5. Part re-circulation of air with some exhaust air flow.

6. Part re-circulation of air with some fresh air inlet flow.

Each unit shall also be fitted with an automatic delay timer in the compressor control
circuitry to prevent the compressor having to start against gas pressure in the event
of an interruption in the power supply or the cooling mode being switched off and on
rapidly.

20/5.2 CENTRALISED AIR CONDITIONING SYSTEMS

Centralised air conditioning systems shall comply with the requirements of the
Particular Specification.

The system shall be complete with all necessary ductwork, diffusers, air grilles etc.
Two single package units shall be provided and installed. Each unit shall be
capable of providing 60% of the total cooling load.

Machinery shall be from an approved manufacturer, of types readily available in

Dubai and suitable for installation in direct sunlight. Filters, re-heaters and/or

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humidifiers shall be provided as necessary to maintain the condition of the

equipment.

Supply and return air ducting shall be run in the void above the suspended ceiling
where applicable. Air vents to conditioned areas shall be via slot diffusers integral
with the suspended ceiling. The whole system shall be designed to give an even
temperature distribution throughout the air-conditioned areas.

Single package units shall be of the type with two compressors and split coils
arranged so that the failure of a compressor shall not lead to total failure of the air
conditioning to any area. The two units shall be identical to limit the quantity of
spares.

Work on installation of air conditioning systems is only to be undertaken by an

approved local air conditioning contractor or by an international air conditioning
contractor who is associated with an approved local air conditioning contractor.

It is recommended that the Contractor engages the services of an air conditioning

specialist who is familiar with local requirements and conditions to design and
specify the system and liaize with Dubai Electricity and Water Authority, regarding
approvals and inspections.

Copies of the design calculations, unit specifications and system descriptions and
drawings are to be submitted to the Engineer for approval by the Dubai Municipality
who will finally be responsible for the air conditioning system. The Dubai
Municipality will require two additional copies of the operating manuals for the air
conditioning system. Representatives of the Dubai Municipality will require to be in
attendance during commissioning.

A five year guarantee shall be provided against all malfunctions of the compressor
by the Dubai Electricity and Water Authority approved local air conditioning
contractor appointed.

20/5.3 SPLIT UNIT AIR CONDITIONERS

All materials used in the manufacture of the units shall be produced to approved
International Standards. The cooling tubes shall be manufactured from solid drawn
copper and shall be tested to 20 bars. Fins shall be of Aluminum and shall be
permanently bonded to the tube. Cabinets shall be manufactured from
pre-galvanised sheet steel and the outer panels electro-statically powder coated
with epoxy and stoved. Panels shall be removable for access.

Condensate trays shall be fitted and the outlets piped to a suitable drain point.

Fans shall have corrosion resistant steel impellers. Motors shall comply with the
relevant parts of the Specification. Anti-vibration mountings shall be provided.

Air filters shall be fitted having 90% efficiency. If they are of the throw-away type a
five year supply of spare elements shall be provided.

The condenser unit shall be suitable for outdoor installation.

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The coils shall be pressure tested to 20 bars and fins shall be permanently bonded
to them.

Motors shall be weatherproof and shall comply with the relevant parts of the
Specification.

Compressors shall be hermetically sealed. Crank-case heaters and anti-vibration

mountings shall be provided.

High and low pressure switches and overload protection shall be provided and also
an anti-recycling timer.
o
The units shall be sized to maintain a dry bulb temperature of 26 C and a relative
humidity of between 40% and 60% when the external shade temperature is 52oC
and the external relative humidity is 50%.

20/6 STANDBY DIESEL GENERATING PLANT

20/6.1 APPLICATION

The diesel generating plant is required to provide a standby source of power and
shall be suitable to start and take-up continuous full load after lengthy periods of
standing un-operated. It is the supplier's responsibility to ensure that the plant is
fully suitable for this class of duty and suitable for the electrical loads to be applied
o
to the plant. The equipment shall be suitable for operation at a temperature of 50 C
and should be derated accordingly.

20/6.2 GENERAL DESCRIPTION OF THE PLANT

The engine and alternator shall be mounted upon a purpose built one piece robust
rolled steel fabricated base frame which shall be provided with lifting lugs complying
with an approved international standard. Steel support channels shall be cast into
the concrete base slab to which the base frame shall be bolted. Jacking points and
dragging points shall also be provided.

Anti-vibration mountings (oil resistant) may be included below the base frame if the
Tenderer considers these desirable but the inherent vibration level of the complete
unit from zero to 10% above working speed should not necessitate anti-vibration
mounting. Oil drip trays, with drainage facility, shall be provided below the engine to
prevent floor contamination.

The Contractor shall supply the first fill of lubricating and fuel oil as well as any
necessary consumables for testing.

20/6.3 ENGINE - GENERAL

The engine shall be as follows:-

Rated for kW loading of the applied load with consideration given to sizing in such a
way that it is not subject to running for long periods of time under light loading.

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Of four stroke, compression ignition, self- lubricating, water cooled type complying
with approved international standard, as is applicable, running at a nominal speed
not exceeding 1500 rpm and shall be suitable for operating on automotive diesel
fuel. The rating shall suit the load requirements in the ambient conditions stated.

The following shall be incorporated in the design:-

Replaceable plated cylinder liners

Replaceable valve seats
Replaceable valve guides.
Replaceable silicon bronze small ends
Valve gear shall be of the enclosed pattern
Cam shaft and crankshaft to be supported by lined steel shells
Crankcase pressure relief breather to be of the closed circuit type.
Air filter of the extra heavy duty “Desert” centrifugal type

The engine shall directly drive the generator with the coupling arrangement being
flexible. A flywheel shall be fitted to ensure stable operation. Means shall be
provided for manual barring of the engine for maintenance purposes.

All exposed rotating or moving parts shall be protected by suitable guards with
brackets and securing arrangements of substantial construction and shall comply
with an approved international standard. Special attention shall be given to
guarding the flywheel-coupling and the radiator fan drive.

The guards shall be readily removable for plant maintenance purposes as

necessary.

Lifting eyes or lugs shall be provided on the cylinder head blocks if necessary. The
Tenderer shall include with the offer a drawing showing all necessary lifting
requirements with unit weights both for installation and maintenance.

Remote alarm contacts, where referred to, shall be voltage free SPDT suitable for 1
amp at 24 V DC/220 V A.C.

20/6.4 ENGINE - LUBRICATION

The lubricating system shall be of the closed circuit type suitable for fast automatic
start of the unit. The oil shall be pumped round the oil circuit by an engine
mechanically driven pump having a suction strainer and the oil system shall not
require priming prior to starting the engine.

The oil pump shall have associated with it a pressure regulating valve and a
separate over pressure relief valve. Large capacity dual filters with auto bypass
shall be fitted immediately after the oil pump. The filters shall be of the replaceable
type. Each filter shall be fitted with a pressure gauge and drain cock. The oil cooler
shall use the coolant of the engine cooling system.

The lubrication system shall be designed to allow at least 400 hours of continuous
running between oil and filter changes and shall be provided with a filler cap,
dipstick and plugged oil drainage valve.

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Dial type gauges showing the oil pressure and temperature after the filters shall be
provided.

20/6.5 ENGINE - FUEL SYSTEM

This shall include a fuel tank with the necessary mounting brackets, and pipework
(including a flexible connecting pipe if the tank is not engine mounted). The tank
shall be of sufficient capacity for 8 hours continuous operation or as specified at full
load and shall be complete with a fuel shut off valve, a dial type level indicator,
minimum and maximum level switches having SPDT contacts suitable for 24 V
DC/220 V A.C. at 1 amp (for filling control and alarm), a protected vent, an overflow
connection and a plugged drain valve.

A fuel feed pump driven from the engine shaft shall be provided, together with a
hand priming pump, also dual filters and a drip tray to collect any fuel spill or
leakage. The drip tray to have a drainage cock and flexible draw-off pipe.

A dial type gauge showing the pressure after the filters shall be provided.

20/6.6 ENGINE - COOLING

The coolant shall be a proprietary anti-corrosive type in a closed circuit system with a
radiator mounted on the engine bedplate and having an engine driven cooling fan
arranged to discharge the cooling air to the outside of the enclosing structure.

A mixture of coolants, rust inhibitor recommended by the generator manufacturer for

the climatic conditions prevailing in Dubai shall be used. Quantities and mixture
ratios shall be clearly identified in the Operational Manuals provided for the project.

A flexible connection shall be provided between the radiator and the surround
opening to prevent hot discharge air escaping backwards. The opening shall be large
enough to allow installation and removal of the generator plant and shall have an
external rain protecting removable grille.

The radiator shall be sized to allow for the ambient conditions and the plant layout at
110% of the engine full load rating.

The coolant shall be circulated by an engine driven pump having a pressure gauge
on the outlet pipework. The cooling system shall incorporate a thermostatic valve to
bypass the radiator to provide rapid warm up and automatic temperature control. A
dial type indicator showing the coolant temperature at the hottest point of the cooling
system shall be provided.

The coolant system shall include at the highest level in the system a volume
capacity either in the upper part of the radiator or by a separate header tank to allow
for coolant expansion and make-up. A coolant level indicator shall be fitted.

The cooling system shall be provided with plugged valves as necessary to enable all
parts of the system to be drained.

20/6.7 ENGINE - EXHAUST SYSTEM

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Each plant set shall be complete with all exhaust pipework including stainless steel
flexible exhaust piping or stainless steel bellows pieces from the engine and suitable
silencers either mounted above the engine or complete with the necessary brackets
and hangers for supporting from the enclosing structure.

The exhaust system shall be complete with all pipework, fittings and mountings to
carry the exhaust gases away from the enclosing structure. All pipework within the
enclosing structure shall be provided with efficient lagging.

The engine exhaust system shall be fitted with temperature indicators at the outlet
of each cylinder block manifold arranged so that the indicators may be satisfactorily
observed from floor level.

20/6.8 ENGINE - SPEED CONTROL

An electronic governor system shall be fitted to maintain engine speed and recovery
time within the limits of an approved international standard. The system shall be
arranged such that an adequate range of speed together with fine speed adjustment
is obtained.

Means shall be provided for electrical remote control of the speed over a range of
+5% of the normal speed.

An entirely independent overspeed trip shall be fitted to shut down the engine if the
speed exceeds 10% above the normal speed. This device shall not operate if full
load is suddenly thrown off the engine. Provision shall be included to provide a
remote electrical alarm. This overspeed safety trip shall be hand reset at the
engine.

20/6.9 ENGINE - STARTING

The engine may be started either electrically or by means of compressed air.

The starting system capacity shall be adequate to allow 6 consecutive start attempts
each of 15 seconds with 1minute intervals.

After receipt of the starting signal, the starting system shall carry out all sequential
operations necessary to drive the unit up to normal voltage and frequency. In the
event of failure to start on the first starting control signal, the system
shall automatically initiate the starting sequence two further consecutive times with
the appropriate time spacing. Should no result be obtained the system shall prevent
further starting attempts and actuate a circuit to provide a 'Failure to Start' alarm.

It shall be possible by means of a selector to alter the starting sequence to provide a

single start attempt of up to 1 minute before lockout and alarm.

An engine shut down solenoid shall be fitted, this shall be of the "energised to run
type" for operation from the engine control system battery. An emergency stop
push button shall be provided.

Stopping shall be attained by interrupting the shut down solenoid circuit and this
shall also cancel any outstanding repeat start attempts.

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If compressed air starting is provided, an electrically driven air compressor shall be

provided capable of recharging the air bottles automatically within 15 minutes. A
hand start diesel or petrol engined standby re-charging compressor shall also be
provided. The air system shall be complete with all valves, gauges and stainless
steel or copper pipework. The air supply vessel shall be located off the engine bed
and shall comply with an approved international standard. Means shall be provided
whereby any condensed water is automatically drained from the system. A
pressure switch shall be incorporated to provide a low air pressure alarm.

With air starting, an Alkaline type battery unit shall be provided suitable to energise
the diesel plant control system continuously for a minimum of 24 hours. This battery
unit shall be fitted with a voltmeter and means to provide remote alarm in the event
of low battery volts. Mains operated automatic high-low rate charging shall be
included having a charging ammeter to show high rate with an adjacent push switch
which when held depressed changes to low rate scale. A "No Charge" remote
alarm circuit shall be incorporated to operate after 15 minutes delay.

If electric starting is used an Alkaline type battery shall be provided together with
rapid recharge by means of an engine driven charging generator with automatic
charging control and cut-out and including a generator charging ammeter (which
may be on the 'Engine Panel', referred to elsewhere). An automatic mains operated
constant potential type battery charger shall also be provided incorporating self-
protecting current limiting arrangements and shall also be suitable to remain
connected to the battery when charging is proceeding by the engine generator.

The battery unit shall be fitted with a voltmeter also a mains charging ammeter to
show high rate with an adjacent push switch which when held depressed changes to
low scale. Means to provide remote alarm of low battery volts and "No Charge"
shall be incorporated to operate after 15 minutes delay excepting that the "No
Charge" alarm shall not be given when generator charging is proceeding.

The interconnecting cables between the starting battery and the engine starter shall
be provided.

The battery used for electric starting may also be used to energise the diesel plant
control system but shall have enough capacity remaining after three engine start
attempts to energise the control system continuously for 24 hours.

The control system shall be suitable to continue operating correctly during the
voltage dips occurring on the battery during the engine starts.

20/6.10 ENGINE PANEL

A panel shall be provided on the engine unit, supported on anti- vibration mountings
at a convenient height and position for observation and operation and shall have on
the panel face:-

1. Lubricating oil pressure gauge

2. Lubricating oil temperature indicator
3. Fuel line pressure gauge
4. Coolant system temperature indicator
5. Engine stop push button
6. Charging Ammeter (Engine Generator)

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7. Engine Speed Indicator with non-re-setable hours counter (Mechanical

Tachometer).

20/6.11 ENGINE - SAFETY DEVICES

The following safety devices shall be fitted and arranged to stop the engine:-

1. Oil pressure low

2. Oil temperature high
3. Coolant temperature high
4. Overspeed
5. Fuel low.

20/6.12 ENGINE WIRING

All wiring associated with the engine shall be insulated with heat resistant type
insulation to an approved international standard for use at temperatures of up to
o
85 C 600/1000 volt grade. Conductor section shall be stranded and to suit the
currents involved at the ambient temperatures arising but not less than 1.5 mm2
excepting special types such as compensated or screened cables.

All wiring on the engine (excluding starting cables) shall be brought out to a
common shielded terminal board mounted on the engine. Starting cables may be
connected directly to the items concerned on the engine.

20/6.13 ALTERNATOR OUTPUT

The output shall be suitable for the load after the alternator has provided for its own
auxiliaries, and shall have an overload capacity of 10% for one hour at the ambient
conditions.

20/6.14 ALTERNATOR CONSTRUCTION

The alternator shall comply with an approved international standard and be of the
brushless self excited type fitted with heavy duty lubricant packed ball or roller
bearings to give at least 4000 hours running without attention. The machine shall
be screen protected and drip-proof to an approved international standard. The
cooling air inlets shall be screen protected at the end remote from the engine and
shall be designed to deflect and remove dust from the incoming air stream so that,
as far as possible, it shall be prevented from entering and accumulating within the
ventilation spaces or elsewhere where a build up of dust may be deleterious to the
performance or reliability of the machine. When specified outlet ducting shall be
provided to duct the alternator cooling air out of the building.

The frame of the alternator shall be fitted with lifting lugs or eye bolts to an approved
international standard.

20/6.15 ALTERNATOR - TERMINALS

Main terminal boxes shall be mounted on the alternator and shall contain both
phase and neutral terminals. The neutral end of each phase shall be brought to a
separate neutral terminal to facilitate testing of the windings and a neutral link bar

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provided. The terminal box shall meet the requirements of an approved

international standard.

The alternator frame shall be provided with a bolted earthing lug.

20/6.16 ALTERNATOR - INSULATION

The alternator windings insulation and temperature rise shall be in accordance with
an approved international standard and de-rated to allow for the ambient conditions.

20/6.17 ALTERNATOR - HEATERS

The alternator shall be fitted with 110V anti-condensation heaters. The connections
to these heaters shall be brought to a separate terminal box (or a separately
enclosed section in the main terminals box) and conspicuously marked to indicate
the danger that the terminals are likely to be alive from a separate supply.

20/6.18 ALTERNATOR - WAVEFORM, REGULATION AND RADIO FREQUENCY

INTERFERENCE

The alternator waveform shall meet the requirements of an approved international

standard. Voltage regulation shall be controlled by an electronic type automatic
voltage regulator, the regulation shall be in accordance with an approved
international standard.

Provision shall be included to ensure adequate excitation of the alternator under

electrical fault conditions such that the output current would be not less than 250%
of full load current to ensure the tripping of protective devices.

Provision shall also be made for manual adjustment of the regulated output voltage
over the range of 10% above and 10% below the normal specified voltage.

Radio frequency interference suppression equipment shall be included as

necessary for electrical parts of the generator to ensure that interference levels
conform to an approved international standard.

20/6.19 CONTROL PANEL CONSTRUCTION

The panel shall be constructed generally as described for FBA’s and shall be
suitable for indoor installation in the ambient conditions separately specified, its
construction shall be such as to allow full accessibility from the front and to be
suitable for mounting against a vertical wall with no rear access. Floor fixing bolts
shall be provided.

The panel shall be sealed so as to be substantially dust and vermin proof to the
requirements of an approved international standard. Cables will enter and leave
from the bottom. The panel shall be provided with a removable rustproof plated
gland plate. The Contractor shall provide and fit all necessary cable glands. The
control panel shall comply with the specification for FBA's as and where applicable.

20/6.20 CONTROL PANEL - FRONT PANEL

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The following shall be mounted on the front face of the panel at suitable viewing and
operating heights:-

1. Voltmeter and selector switch

2. Ammeter and selector switch (Suitable current transformers are to be provided

by the Contractor and located to suit the general layout, typically in the
alternator cable box).

3. Frequency meter (47 - 53 Hz)

4. Voltmeter for battery voltage

Ammeter for Battery Charge
Push switch for range change (If not fitted on a separate charging unit)

5. Selector switch, key operated, having positions:-

'Local' - 'Locked Out' - 'Remote' (Key to be removable in the 'locked out'

position only)

6. 'Raise/Lower' Alternator Voltage adjuster

7. Push buttons:-

'Increase Speed' (White)

'Decrease Speed' (White)
'Start' (Green)
'Stop' (Red)
'Sequence Reset' (White)
'Lockout Reset' (White)
'Check Alarm' (Orange)
'Lamp Test' (White)

The 'start' push button to be functional only when the control selector switch is
at the 'Local' position.

8. Lamp Indications:-

'Alarm Checked' (Orange)

'Incomplete Starting Sequence (White)
'Overspeed' (White)
'Fuel Low Level' (White)
'Coolant High Temperature' (White)
'Lubricant High Temperature' (White)
'Lubricant Low Pressure' (White)
'Charging Fail' (If not on a separate charging unit) (White)

Push buttons and lamp indicators may be combined together where

appropriate (i.e. 'Check Alarm'/'Alarm Checked').

20/6.21 CONTROL PANEL - ALARM ANNUNCIATOR

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All alarms shall be displayed on an alarm annunciator which shall be mounted at the
front upper part of the panel. The alarm system shall be of the "first up" type and
each alarm shall be provided with a volt free SPDT contact for remote repeat alarm.

The annunciator shall be generally as described elsewhere.

20/6.22 CONTROL PANELS - GENERAL

Important Instruction

Generators shall not be provided with the manufacturers standard control panel.
Printed circuit boards and electronic components shall be kept to a minimum. All
control functions shall be effected by eight or eleven pin plug in relays and all push
buttons, lamps and fuses shall be as described else where. All control components
such as Automatic Voltage Regulator, Speed Controller, Frequency Controller,
Over/Under Voltage Controller, Pressure and Temperature Controllers, Level
Controllers, Timers, Counters etc. shall be separate, independent items fixed to the
back plate and prominently labelled. Each unit shall be individually removable and
100% spare units shall be provided. Under no circumstances will a PCB or control
unit which controls more than one function or variable be acceptable.

The panel shall be designed and constructed such that a general electrician with no
electronics experience or knowledge and with the use of standard multimeter type
instrumentation only can carry out fault finding, maintenance and repair work with
the guidance of the Operation and Maintenance Manual.

The control panel shall contain the following items:-

1. Automatic voltage regulator (unless mounted on the generator unit) to be self

protected against under and over voltage and frequency.

2. Battery charger (unless a separate unit).

3. Contactor for alternator anti-condensation heaters.

4. Emergency engine shutdown from alarms as listed elsewhere. Engine to be

'locked out' until the 'Lockout Reset' push button is operated. Lockout, to
provide contacts for the tripping of the generator (remote) circuit breaker.

5. Monitoring and control relays as necessary.

6. MCB cut-outs, fuses etc. as necessary.

7. Terminals as necessary, including for remote stop/start operation and indication,

remote speed control and voltage adjust and remote circuit breaker trip, also
terminals for anti-condensation heater and local supply (separately enclosed
and with warning label). All terminals to be coded in accordance with an
approved international standard.

8. Wiring, as necessary, PVC insulated of not less than 1.5 mm2. copper cross
section, to an approved international standard, with each conductor reference

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coded at both ends for identification Green colour to be used for earth circuits
only.

20/6.23 BULK FUEL TANKS

Bulk fuel tanks shall be as follows:-

i. Sufficient quantity to provide approximately seven days operation

ii. Manufactured in accordance with an approved international standard and be

fabricated from good commercial quality mild steel plate of minimum 5 mm
thickness, ends dished and flanged, electrically welded throughout and spatter
removed.

iii. Provided with a 480 mm diameter raised manhole with joint and 8 mm thick
bolted on cover.

iv. Provided with galvanised access ladder and platform to manhole

v. BSTP connections shall be provided for fill, vent, outlet and drain.

vi. Receive approved corrosion protection appropriate to its location.

20/6.24 FUEL TRANSFER PUMPS

Electric fuel transfer pumps, if necessary shall be of the progressive cavity type, self
priming and capable of achieving a suction lift of at least 7 metres. They shall be
capable of pumping approximately 400 litres of diesel fuel per hour from the bulk
fuel tank to the day tank. Two number shall be provided for each installation
located immediately below the day tank. They shall operate in an automatic
duty/standby mode with automatic interchange of duty to equalise wear.

Manual fuel transfer pumps shall be of the self priming diaphragm type with
detachable handle arranged to pump diesel fuel from the bulk fuel tank to the day
tank.

Provision shall also be made to pump fuel from the day tank to the bulk fuel tank to
empty the day tank for maintenance purposes.

20/6.25 FUEL SYSTEM

The fuel system shall comprise the following:-

Fuel transfer pumps controlled by a float type level switch in the day tank.

Overflow back to the bulk fuel tank to be provided to guard against float switch
failure.

Mesh type filters not coarser than 120 mesh to be provided on the draw-off line.

Free-fall fire shut-off valves to be fitted operated from the local fire alarm system
(where applicable) or a wire rope and heat sensitive fusible link.

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Daily service tank to accommodate fuel for 8 hours running at full load.

Fuel supply piping system to be in suitably sized copper tubing.

20/6.26 ENCLOSURE

Where specified the diesel generator shall be housed in a purpose built GRP
enclosure as follows:-

GRP fabrication as described elsewhere.

Protection against the ingress of dust and moisture to an approved international

standard.

Provide ample access for maintenance by way of hinged and removable covers

Controls, indication etc. to be enclosed in an integral panel with a polycarbonate

hinged clear cover.

Small power & lighting system as per GRP enclosures described for submersible
pumping stations.

In all cases the maximum sound level shall not exceed 85dbA at 1m radius from
the generator and/or enclosure.

20/7 FIRE ALARM AND EXTINGUISHING SYSTEMS

20/7.1 GENERAL

The Contractor shall arrange for an approved Sub-Contractor who shall be on the
list of Approved Contractors, to supply, install, wire and commission the complete
manual/automatic fire alarm system comprising manual fire alarm call points,
alarm bells and sounders, smoke and heat detectors and control panels as
indicated on the drawings. The fire alarm system equipment shall be selected
from equipment approved by the Fire Department. The system shall be installed
and maintained in accordance with the recommendations of an approved
international standard. The wiring shall be 1.5 mm2 MICC/PVC for bell and
battery circuits.

20/7.2 MANUAL FIRE ALARM CALL POINT

Manual fire alarm call points shall consist of a die cast plastic cover locked in
position with screws. The enclosure shall house a micro switch. The micro switch
plunger shall bear onto an inset break glass panel fixed into the cover. The call
point shall be arranged for surface mounting. The cover and the enclosure shall
be self coloured red. The words “BREAK GLASS FOR ALARM” shall be printed
on the frangible glass. A testing facility using a special key shall be provided to
enable the call point to be tested without breaking the glass and the frangible

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glass shall be covered with plastic film to prevent injury when the glass is broken.
The mounting height shall be 1500 mm above finished floor level.

The switching unit contacts shall be gold or silver plated or an alloyed metal which
will not corrode when left unattended in a highly polluted environment. Contact
blades and other metal parts of the switching unit shall also be constructed from
plated or alloyed metal which will not corrode when left unattended. Contacts shall
be normally open or normally closed to suit the alarm monitoring system. The
voltage and current rating of the contacts shall be marked within the enclosure.

The call point shall comply with an approved international standard Specification
for manual call points”.

The call point shall be resistant to the ingress of dust and water, and shall be
suitable for operation in the environmental conditions at the site of installation.

20/7.3 OPTICAL SMOKE DETECTOR

Optical smoke detectors shall comply with an approved international standard.

20/7.4 DETECTOR BASE

An operation indicator lamp of the light emitting diode type and a time delay unit to
override spurious alarms shall be fitted to the base.

20/7.5 FIRE ALARM PANEL

The fire alarm panel shall be wall mounted adjacent to the motor control centre.
The fire alarm system shall protect risk areas within the premises by giving
warning of a fire condition relayed by an automatic detector or by the operation of
a break glass callpoint. Operation of an individual detector is to be displayed by an
indicator fitted into the base of the detector. This indicator will illuminate when its
detector goes into alarm. Fixed temperature heat detectors will not have this local
indication facility. Upon receipt of an alarm, the control units shall perform the
following actions:

a) Illuminate fire zone detector

b) Activate alarm warning devices within the building

c) Operate internal fire sounder

d) Operate ancillary devices as appropriate

Alarm warning devices shall be de-activated by operation of the “Silence Alarms”

switch. The internal sounder will continue to operate and the fire indicators remain
lit until the key switch controlled push switch is operated. This should only be
achieved if the alarm initiating device is no longer in alarm.

Reset of the controller, after the fire incident has been investigated, will be
achieved by operation of the “Reset” switch.

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The enclosures of the panels shall be fabricated from sheet steel, minimum
thickness 1.5 mm and shall be provided with a hinged lockable door. Protection to
an approved international standard shall be provided.

The control unit should be designed to comply with the compulsory requirements
of an approved international standard, relating to “Automatic fire alarm systems in
buildings, control and indicating equipment”.

Alarm panels shall as a minimum requirement be equipped with the following:

a) Mains supply on indicator

b) DC supply on indicator

c) DC supply faulty indicator

d) Alarm indicator for each zone

e) Alarm accept push-button to acknowledge fire alarm signals, silence external

audible alarms and energise as internal bleeper unit.

f) Reset push-button to restore monitoring systems to the quiescent condition

g) Integral sealed battery and trickle battery charger where appropriate

h) Alarm transmission facilities via the telephone alarm system

i) Terminations for incoming and outgoing wiring systems

j) Voltage free normally closed circuits which shall open in the event of an
alarm to shutdown ventilation and air conditioning equipment in the
immediate vicinity.

k) Suitable fault indication both visual and audible.

Alarm indicators shall be of the light emitting diode type. Indicators shall be
provided in pairs for each function.

Alarm panels shall continuously monitor all alarm circuits, including wiring and
control devices. When a fault monitoring circuit has been energised it shall not
reset until the fault condition is cleared.

Batteries shall be of the sealed lead acid type and shall have a capacity capable
of maintaining the system in normal working condition for at least 24 hours without
recharging and subsequently to operate in the alarm condition for at least one
hour.

Battery charging to be of sufficient capacity to power the system whilst recharging

a fully discharged battery. The battery shall be fully charged within 8 hours.

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Monitoring circuits shall utilise solid state components. Output relay contacts shall
be gold or silver plated and shall be rated for the circuit conditions into which they
operate.

Alarm bells shall be of the gong type with a minimum diameter of 200 mm. They
shall be continuously rated and be mounted 2200 mm above finished floor level.

Bells shall be marked with the words “FIRE ALARM”.

20/7.6 FIRE EXTINGUISHING EQUIPMENT

The Contractor shall supply and install in the respective positions:

2.5 kg hand held CO2 operated for extinguishers and 4.5 kg hand held dry
powder type fire extinguisher, suitable for Class A, B and C fire risks, flammable
liquid, and fires from electrical sources. The extinguisher shall comprise a light
alloy or steel cylinder finished in blue epoxy resin fitted with a controllable brass
valve with pressure gauge or aluminum head cap for CO2 operated cylinders.
Valves to be fitted with safety pin lever.

All equipment supplied shall be suitable for the high temperatures, humidities, and
dusty atmospheres experienced in Dubai, with a minimum jet range of 5-7m
discharging in approximately 15 seconds.

All equipment supplied under this section shall be obtained from a company
regularly engaged in the manufacture and supply of fire protection equipment. It
shall essentially be a duplicate of equipment that has been in satisfactory use for
not less than five years prior to the bid date and be supported by an approved
service organisation capable of carrying out regular inspection and maintenance
of fire protection systems.

All portable fire extinguishers shall be manufactured in accordance with an

approved international standard and are to be wall mounted on secure brackets
with the base approximately 760 mm above floor level.

Fire extinguishing devices shall be clearly and indelibly labelled with clear
instructions for their use in English, Arabic and pictorial form.

20/8 ACCESSORIES

The Contractor shall supply and install where specified the items listed below:

a. FIRST AID BOX - wall mounted first aid box marked with a red crescent
and containing:

40 nr individually wrapped adhesive dressings

2 nr sterile eye pads and bandages
2 nr sterile triangular bandages
6 nr safety pins
6 nr sterile unmedicated dressings No. 8

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6 nr sterile unmedicated dressings No. 9

2 nr sterile unmedicated dressings extra large
1 nr roll elastic bandage 2 inch
1 nr pair scissors
1 nr eyebath
1 nr bottle eye wash solution
25 g cotton wool
1 nr bottle antiseptic
1 nr card or booklet giving simple instructions

b. ELECTRIC SHOCK FIRST AID INSTRUCTION - Instructions in both English

and Arabic for the treatment of persons suffering from electric shock. The
instructions shall be printed on a substantial wall mounted plate with a wipe
clean surface.

c. DANGER NOTICE - Danger notices inscribed “DANGER DO NOT

OPERATE - MAN WORKING ON EQUIPMENT” in both English and Arabic.
The plates shall be of laminated plastic with white letters on a red background
and arranged to hang on isolator handles.

d. RUBBER GLOVES - One pair of heavy duty insulating rubber gloves. The
gloves are to be stamped with their date of manufacture and shelf life.

20/9 GAS DETECTORS

20/9.1 PORTABLE GAS DETECTORS: GENERAL

The detector shall be housed in a robust case sealed to comply with an approved
international standard. The case shall be provided with harness-type straps to
allow the equipment to be worn. Alternatively, a purpose-made carrying case, also
with harness straps, shall be supplied. In use, such a carrying-case shall allow the
display to be clearly visible.

The detector shall be explosion proof with an internationally recognised

certification as “intrinsically safe” allowing use in hazardous areas. The detector
shall be suitable for gas groups commonly found at sewage treatment works.

The detector shall be powered by a rechargeable nickel cadmium battery pack

which shall be replaceable. A fully charged battery pack shall operate the detector
continuously for a minimum of 10 hours. In use, low battery power shall initiate an
audible alarm.

The detector shall incorporate sensors to detect gas concentrations and initiate
alarms as follows (Table 20-3):

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Table 20- 3 Gas detectors

Mode Display range Alarm initiate

combustible gas or 0 - 100% by volume of air, > 20%

vapour calibrated for methane

hydrogen sulphide 0 - 25 ppm >10 ppm

oxygen 0 - 25% by volume of air >24%

<19%

The display may be switchable between the three modes. However, should any
one of the three gas hazards occur, a warning lamp shall light and an audible
alarm shall sound, irrespective of the position of the switch.

Due to the limited life of gas sensor cells, the cells in the detector or any spare
cells provided shall be less than 3 months old at the time of handover to the
employer. Each cell shall have its date of manufacture indicated on its cover.

The detector shall be provided with an extension tube 2 m long and manual pump
for sampling inaccessible places.

Only equipment which is supported by a service workshop in Dubai authorised by

the manufacturer shall be provided.

20/9.2 PORTABLE GAS DETECTOR

One complete set of portable gas detection equipment shall comprise:

1 nr Portable gas detector complete with sensors for combustible gas,

hydrogen sulphide and oxygen, and including rechargeable battery pack,
harness/carrying case and extension tube.

1 nr Single way charger to suit above battery pack

1 nr Stainless steel probe for extension tube

Test gases in 20 litre canisters:

1 nr 2.5% methane in air

1 nr 25 ppm hydrogen sulphide in air

1 nr 17% oxygen in nitrogen

1 No. box to house above equipment, suitable for wall mounting and labelled
“Portable Gas Detector”.

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20/10 SURGE

The Contactor shall be responsible for supplying suitable pumping plant and
surge suppression equipment (if any) to ensure that transient pressure surges do
not exceed the following limits:

a) less than – 5m head at any point along the pumping main

b) greater than 50% of the pressure rating of pipes and fittings installed on the
pumping main.

These limits shall not be exceeded under any condition of normal working or
power failure.

The Contractor shall include for all necessary surge suppression equipment.
The equipment (if any) should be compatible with the characteristics of the
pumping plant proposed. It is therefore recommended that the Contractor
should perform his own assessment of the pressure transients.

To confirm the results of his initial assessment, the Contractor shall instruct
the pump manufacturer to carry out a comprehensive pressure surge
analysis on the complete hydraulic pumping system under all operating
conditions, and submit three copies of a report and calculations on the surge
in the system within 3 months of contract commencement to enable surge
suppression equipment to be manufactured in time for delivery and
installation if found necessary.

APPROVED INTERNATIONAL STANDARDS

BS 649
BS 800
BS 2594
BS 2869
BS 3116
BS 4278
BS 4999
BS 5000
BS 5169
BS 5266
BS 5304
BS 5345
BS 5420
BS 5423
BS 5445
BS 5472
BS 5501
BS 5514
BS 5559
BS 5839
BS 6746
BS 6899

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 1 SECTION 21 AUTOMATIC IRRIGATION

TABLE OF CONTENTS

21/0 IRRIGATION SYSTEM, GENERAL ............................................................................ 2

21/1 SUBMITTALS ............................................................................................................. 3
21/3 IRRIGATION SYSTEM, EXECUTION ...................................................................... 31
21/4 AUTOMATIC IRRIGATION SYSTEM, COMMISSIONING ........................................ 37
21/5 IRRIGATION SYSTEM, CIVIL WORKS .................................................................... 39
21/6 SWEET SOIL FILLING, CONTOURING AND PLANTATION ................................... 46
21/7 ANCILLARY WORKS (Not applicable) ..................................................................... 47

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21/0 IRRIGATION SYSTEM, GENERAL

Scope

The contract shall include for the complete installation, testing and commissioning
and one year maintenance of the automatic irrigation system summarized below
and as per this specification and contract drawings.

1. Constructing two irrigation filtration chambers with connections to the existing

adjacent 500 m dia AC main network.

The Contractor shall propose and construct Filtration Chamber(s) per drawings
and make connections to DM Effluent line, which is available along the side of
the road. Location of Filtration Chamber(s) should be approved by the
Engineer and RTA Roads and Planning Departments.

The size, placement and orientation of filtration chamber(s), valve chambers,

etc. has to be in such a way that sufficient room for laying other services are
maintained. Connection of permanent power supply for filtration chambers from
the nearest DEWA sub-station is part of the contract. Approval of DEWA for
using the substation should be arranged by the Contractor.

The Contractor shall be responsible for providing telephone line(s) for the
Cluster Control Units CU(s) from Etisalat.

2. Laying the Main, Sub main and lateral lines for Automatic Irrigation scheme;

3. Providing isolation valve chambers & air valve chamber.

4. Laying of Ducts for Mains, Sub mains, Laterals and Control cables under
footpaths and roads.

5. Laying bubbler, drip, pop-up sprayer (sprayer) and rotor pop-up sprinkler
(sprinkler) systems as shown on the contract drawings;

6. Providing Automatic control system for irrigation network through Satellite

Controllers, Communication & Power supply cables, electric remote control
valves, etc.;

7. Excavation to foundation level for sweet soil filling including excavation of plant
pits.

8. Providing sweet soil in planted areas and maintaining the existing sweet soil in
good condition. The levelling & contouring shall be done as per the landscape
drawings. (Note: Soft landscaping works / planting will be carried out by DM
Horticulture Department)

9. Reinstatement of the affected areas as and when required during the progress
of the project;

10. Testing & commissioning of the system and demonstration of automatic

operation.

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 3 SECTION 21 AUTOMATIC IRRIGATION

11. Operation and maintenance of complete irrigation system for a period of one
year after commissioning of the system including trained operator and labours.
12. Provision of concrete block edges & gravel mulch areas.

The Contractor shall include for all materials, labour, plant and tools.

All crossings across major roads/dual carriageways and U-turns shall be either
through ducts or no dig method.
Back filling and road base to be tested by an approved independent laboratory at
least one test per 100 m interval or as requested by RTA Roads Dept. and by the
Engineer at specific locations.

Sweet soil filling, levelling and contouring for landscape areas shall be as per the
landscape drawings and also providing the tree pits is part of the contract. The
sweet soil shall be taken from Khawaneej borrow pits. The landscape patterns
should be marked with lime powder, stakes and nylon ropes. Shapes and
dimensions of these patterns are shown in detail in the landscape drawings.

The Contractor to modify the existing manhole chambers; if required in order to

match top levels with the proposed landscaping levels.

The Contractor shall reinstate all roads and footpath where affected by the
installation of irrigation system to the approval of the engineer and RTA Roads
Department.

Refer to the attached “Particular specification and relevant application of

Administrative order No. 16 and 22 for Drainage, Sewerage and Irrigation
Projects.” (Annex I).

The Contractor shall be responsible for maintaining the main irrigation system in
the contract area and for existing plantations.

21/1 SUBMITTALS

The Contractor shall submit to the Engineer the following documentation for review
and approval, before commencing work:

21/1.1 MATERIALS AND EQUIPMENT SCHEDULE

All catalogue cuts, diagrams, samples, drawings and such other data as may be
required to demonstrate compliance with the specification.

21/1.2 NO OBJECTION CERTIFICATES

Prior to start of any work at site the contractor has to approach all Service
Authorities in Dubai to get their no objection for the work included in this contract
and record drawings for their existing services. Copy of these drawings and no
objection certificate should be submitted to the Engineer before starting the actual
work at site.

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 4 SECTION 21 AUTOMATIC IRRIGATION

Trial Trenches: Contractor to make detailed survey of project area, note existing
levels in the project area and take trial trenches for all the locations where
plantation and irrigation system has been proposed.

All these details to be submitted to the Engineer along with digital format.

Based on the information of existing levels and trial trenches made Contractor to
propose final location of tree plantation and irrigation services and submit shop
drawings.

21/1.3 SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS

The successful Contractor shall submit shop drawings, for approval by the
Engineer, for the following:

a) In case of any conflict between contract drawings and any existing or future
services which may necessitate re-routing proposed irrigation Main or laterals,
the contractor has to prepare the shop drawings accordingly and submit it to the
Engineer for approval. This should be considered as integral part of the
contract.

b) The Pump/Filtration Chambers mechanical, electrical and civil works shop

drawings. Necessary modifications to the existing feeding chambers (civil and
mechanical). Valve chambers including valves, pipe works and civil works.
Electrical control equipment with circuit diagrams.

c) Details of mainline, lateral pipes and other typical connections.

d) Wiring diagrams including conduits, pull boxes, sizing and calculations to verify
that cable sizing is in accordance with DEWA regulations and equipment
manufacturers recommendations.

e) Electrical power and control wiring diagrams for irrigation controllers, field wiring
and grounding and CCU system including all decoders and interfaces.

f) Sketch plans for drip line layout and bubbler layout.

g) Sketch plans for Sprayer and Sprinkler layouts.

h) Detail of valve chambers and any modification to the existing feeding

chambers.

The approval shall not relieve the Contractor of any of his responsibility under the
contract for successful completion of the work.

21/1.4 MANUFACTURERS CERTIFICATIONS

a) uPVC Pipe and fittings

Certification by a recognized certification mark scheme such as "The Kitemark"
or by an independent third party testing organization approved by the Engineer,

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 5 SECTION 21 AUTOMATIC IRRIGATION

that production has been carried out under a system for supervision, control
and testing, applied during manufacture, in accordance with BS 5750 or an
approved equal procedure.

b) Valve, and Special Steel Fitting

Manufacturer's certificate for pressure testing, and coating, including holiday
and DFT test reports for each valve, fitting, spool if applicable.

c) Emitters
Certification of coefficient of manufacturer's variation.

21/1.5 RECOMMENDATION OF THE MANUFACTURERS

The Contractor shall submit manufacturers' recommendations for installation and

commissioning of each material or piece of equipment for approval prior to
commencing work. Recommendations shall include testing methods, storage
requirements, (if applicable) maintenance and operational data. The contractor
shall have a copy of the manufacturers' instructions available on site at all times
while work is in progress and shall follow these instructions unless otherwise
authorized to deviate by the Engineer.

21/1.6 SPARE PARTS

The Contractor shall submit manufacturer's list of spare parts for approval prior to
commissioning any piece of equipment. Recommendations shall include stocking
recommendations, exploded assembly diagrams illustrating location and spare
parts to be utilized and all relevant operational data.

21/1.7 INSTALLATIONS AND TESTING

The Contractor shall submit his proposed work method statement for approval prior
to commencing work. The statement shall detail proposed sequence of work, hold
points, testing frequency and document control.

21/1.8 PROGRAM/PROGRESS REPORTS

The Contractor shall submit a program of works as per the Clause 14 of the
condition of the contract for approval.

The Contractor also shall submit monthly progress report at the end of each month
including all the works constructed during the month with photographs, numbers of
staff and labourers, cash flow, test reports, overall progress and general details as
per engineer approval.

21/1.9 MANUFACTURER'S LITERATURE

At such time as the list of materials has been approved by the Engineer, the
Contractor shall provide four (4) sets of manufacturer's technical and maintenance

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 6 SECTION 21 AUTOMATIC IRRIGATION

literature to the Engineer. Data sheets shall provide sufficient technical information
to identify each product and shall include the name and the address of the nearest
supply firm, which should have a local representative in the Emirates of Dubai.

21/1.10 CIRCUIT DIAGRAM

CONTRACTOR MUST SUBMIT ALL CIRCUIT DIAGRAMS OF ELECTRICAL

INSTALLATION ALONG WITH SAMPLES AND SPECIFICATIONS OF
MATERIALS PROPOSED IN ORDER TO OBTAIN APPROVAL PRIOR TO
FABRICATION OR INSTALLATION.

21/1.11 AS-BUILT DRAWINGS AND OPERATION & MAINTENANCE MANUAL

A) As-Built Drawings

The Contractor shall maintain one set of contract drawings for the sole purpose of
recording accurate changes made as the work progresses ("As-Built" conditions) of
the irrigation system. All changes previously approved and all completed work shall
be recorded on these drawings.

The Contractor shall prepare as-built drawings clearly showing all location, depths,
slopes, heights, shapes and dimensions of all works as executed. All valve
locations and piping shall be dimensioned and recorded (except that wire locations,
common to pipe ditches, need not to be dimensioned). The Contractor must submit
as-built drawings for all electrical installations. Sizes of all the as-built drawings
should be the same as that of DM Drainage & Irrigation Department Standard
(approx. 120cm x 60cm) size.

All as-built drawings should be prepared using Micro-station program (latest

version for windows). Mainline layouts to be on DM Survey sheets (scale 1:1000)
as per Dubai Municipality Drainage & Irrigation Department requirements and
approval. As-built drawings of mainline layouts of Automatic Irrigation system and
Main Irrigation Network should be on separate drawings for each.

The contractor should prepare and submit as-built drawings for the mainline
pipeline profiles that are 150mm and greater. Pipeline profile drawings should be in
Horizontal scale of 1:1000 and Vertical scale of 1:100. Pipeline profiles to be
submitted on separate drawings with clear references to mainline layout drawings
marked on the same.

The Contractor to follow the Standards (regarding Legend, line styles, colours,
levels, size of drawings etc.) of DM Drainage and Irrigation Department while
preparing As-Built Drawings.

Chambers Schedule is to be prepared indicating all relevant construction items and

giving co-ordinates for each manhole in compliance with DM grid System.

The Contractor must submit as-built drawings for all the electro-mechanical
installations. All the details of the installed equipments regarding Manufacturer
and Model Number, Type, size etc. shall be provided in the legend of the drawings.

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Pipeline profile drawings should be in Horizontal scale of 1:1000 and Vertical scale
of 1:100.

Lateral line layouts for sprinklers/sprayers drip and bubblers shall be to a scale that
provides clarity and all layouts shall incorporate background as-built details of
planting for clarity.

The Contractor should follow the Standards (regarding legend, line styles, colours,
levels, size of drains, title block etc.) of DM Drainage and Irrigation Department
while preparing As-Built Drawings.

After final approval to the As-Built Drawings, Contractor to submit the following
before the final taking over of the project:

1) Three complete sets of “As-Built Drawings” folded properly and provided in

plastic folders as a part of Operation and Maintenance Manual;
2) A set of Mother Prints (on Heavy grade Polyester) and;
3) A copy of computer discs, CDs (with proper titles and plastic enclosure box)
please note that zip files will not be accepted.

Provisional acceptance will not be considered unless Contractor submits all the
above said As-Built Drawings.

Notes:

1) Contractor to check all existing irrigation system within the contract area (along
with existing filtration chambers) and shall record those details in the as-built
drawings of the project.
2) Contractor to prepare and submit the detailed results of trial pits and trenches.
Record of all trial holes executed under this contract shall be made available in
the form of drawings (Scale 1:1000 for Plans & 1:100 for sections) to be the
part of as-built set of drawings. These drawings shall be made available to
Utilities Department and Roads Department, Roads and Transport Authority. All
such information shall be submitted to RTA in digital format and hard copies.

B) Operation And Maintenance Manuals

01 Assemble three (3) copies of manuals containing Operating & Maintenance

instructions for each piece of equipment and systems requiring service and
Prints of As-Built drawings as described above. O & M Manuals shall be bound
in a hard cover 3-ring binder of suitable size and properly indexed. Cover and
Manual shall be as per DM standards and to be approved by RTA or DM DCL.
Contractor should also submit digital copy of Maintenance Manual on CD.

02 O & M Manuals shall include the following information:-

a. Description of equipment
b. Operation of equipment
c. Maintenance of equipment and lubrication Schedule
d. Servicing of equipment
e. Control Diagrams

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 8 SECTION 21 AUTOMATIC IRRIGATION

f. Irrigation Valve Operation Schedule c/w Controller Station No., Valve No.,
valve size, flows, operating time, etc.
g. Diagrams of the system
h. Logic of operation of the systems
i. Valve charts
j. Performance characteristics: Curves and charts for equipment (Data shall
refer to, and identify specific modeling service and shall not be general
advertising data).
k. Spare parts list
l. Names, contact numbers and addresses of spare part suppliers.
m. Test reports
n. Certificates
o. Bill of Quantities of Material used in the Contract
p. Letter of Satisfaction
q. Guarantees.

03 Submit one copy of the manual to the Engineer for review and three final copies
to the Client after the final approval of the Engineer. Provisional acceptance
will not be considered unless Contractor submits completed O & M manuals
and as-built drawings.

21/1.13 SILENCE OF SPECIFICATION

The apparent silence of the specification, drawings or other contract documents as

to any detail or the apparent omission from them of a detailed description
concerning any point shall be regarded as meaning that only the best general
practice is to be used. All interpretations of the specifications will be made by the
Engineer on this basis.

21/1.14 SYSTEM EXPLANATIONS

During site visits by the Engineer, the operation of the system will be delineated to
all authorized persons requesting such information.

Three copies detailed system operation and maintenance brochure will be provided
to the Client at the completion of the project by the Contractor.

21/1.15 LAYOUT OF WORK

The Contractor shall stake out the irrigation system in accordance with the scaled
plans. Staking shall be erected in such a manner as to insure permanency of the
staked locations until such time as the irrigation system is installed. Stakes shall
be placed to show location of valves, pipelines and control head. Stakes shall be
flagged with bright flagging for ease of location. All staking by the Contractor shall
be subject to approval of the Engineer.

The Contractor shall stake the landscape patterns as shown on the landscape
drawings. These patterns shall be marked with lime powder and nylon ropes for
future use by DM Horticulture section during plantation phase.

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21/1.16 CLEAN-UP

During the course of construction, the Contractor shall remove waste material from
the site continually as is necessary to keep the site in an orderly manner. Waste
material shall be removed from the work site and not to be used as back-fill
material. Upon completion of the contract, the Contractor shall remove all waste
equipment and parts and leave the site in a neat and orderly condition.

21/1.17 WARRANTY

All work included under this Contract shall be warranted by the Contractor against
all defects and malfunction of materials and workmanship for a period of one year
from the date of completion of works. Should problems arise with the system during
the warranty period, all necessary repairs and/or replacements shall be made by
the Contractor in an expedient manner at no additional cost to the Client.

The Contractor shall be responsible for operation and maintenance of the system
for a period of one year from the completion date.

21/1.18 PRODUCT STORAGE AND HANDLING

All products shall be delivered in the manufacturers' original protective packaging

and shall be inspected at time of delivery. Any product, which are damaged and
not in accordance with specifications, or date stamp expired, shall be immediately
removed from the site and replaced.

Evidence must be submitted to verify materials, such as uPVC pipes, solvent

cement, rubber gaskets etc., have been properly protected during transport and
storage prior to delivery to the site.

All products shall be handled and stored in accordance with printed

recommendations of the manufacturer.

All site storage areas shall be shaded at all time. Pipe stacks shall be designed to
ensure that pipes and especially pipe sockets are not deformed during storage
and/or effected by sunlight.

Precautions shall also be taken to protect items sensitive to sunlight or heat prior to
backfilling operation. uPVC pipes shall on no account be exposed to sunlight for
more than two days in summer, or one week in winter.

Any pipe, whether installed or not, which is observed to be sunburn, or oval, shall
immediately be removed from the site and replaced.

21/2 IRRIGATION SYSTEM, MATERIALS

Scope

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 10 SECTION 21 AUTOMATIC IRRIGATION

The scope of this section includes a description of materials and methods for the
hydraulic element of the system.

All materials covered by this specification shall be from an approved local

representative in the Emirate of Dubai qualified to provide the appropriate level of
technical support.

All equipment, fittings and accessories shall be suitably rated to comply with the
system design and operating parameters.

Note: Following are general specifications of D.M. for the Irrigation materials, the
items which are not required in this project shall not be considered in the scope of
the works.

21/2.1 PIPES AND FITTINGS

21/2.1.1 UPVC Pipe and Fittings

uPVC piping shall be fabricated from unplasticized polyvinyl chloride according to

BS 3505:1968 and BS 3506:1969. Rating and size shall be as shown on the
drawings but not less than class D. Pipe shall be supplied in lengths no smaller
than six (6) meters. Each length of pipe shall bear markings of identify type and
grade. All piping shall show no evidence of blisters, grooves or other extrusion
marks.

The Contractor shall provide three (3) samples of each size, one meter in length for
approval prior to supply and installation. All pipes 75mm and above to be with Lock
Ring Socket. The socket to be integral part of the pipe and in accordance to BS
4346 Part 2: 1970 and it should incorporate a triple compression rubber seal
complying with BS 2494: Part 2 and when jointed offers three-fold hydraulic
security under both positive and negative pressure heads. The socket should have
the same wall thickness as the pipe with an extra sleeve to maintain the correct
pressure rating at the joint.

All joints in pipe shall be made by solvent welding using adhesive solvent and
primer as recommended, in writing, by the manufacturer and approved by the
Engineer. All cans of solvent and primer shall have labels intact and shall be
stamped with date of manufacture. No cans dated over two years old will be
permitted. No thinning of solvent or primer will be permitted. Lubricant and solvent
cement used to make joints shall be approved in writing by the pipes manufacturer
or his designated representative and the Engineer.

Only male joints may be used up to 50mm. Joints larger than 50mm shall not be
threaded. All threaded joints shall be made up using PTFE tape or an approved
equal thread sealant.

Pipes sized 30mm and larger shall be of class D (12 bars working pressure) and
smaller pipes shall be class E (15 bars working pressure). Fittings shall be
fabricated from UPVC according to BS 4346.

All uPVC pipes and fittings should be covered by licensed Kite mark.

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 11 SECTION 21 AUTOMATIC IRRIGATION

On no account shall saddle and cross type connections be made to uPVC pipe. All
pipes passing through ducts shall be solvent weld joints.

Flange couplers shall be PN 16 and in accordance with BS 4504. Bolts and nuts
(whether part of the coupler or for fixing) shall be A4 – 70 stainless steel.

Threaded riser pipe used to support valves and sprinklers and fittings may be
galvanized steel, or brass. All galvanizing shall be carried out after threading.

All valve chambers 200mm and above shall have GRP fittings.

21/2.1.2 Polyethylene Pipe and Fittings

Polyethylene pipes for drip lines shall be manufactured from linear low-density
polyethylene incorporating a minimum of 2.8% carbon black and shall have a
working pressure of 4 kg/cm2.

Random samples of drip pipes shall be subjected to the Teepol crack resistance
test. The samples shall be immersed in a bath containing a solution of 10% Teepol
and 90% water maintained at 50 degrees C. The pipe should resist the solution
without showing any fatigue or crack for a period of 150 hours.

The test should be carried out in an independent laboratory within U.A.E.

accredited by RTA or Dubai Central Laboratory.

All fittings for drip line shall be compression type. Insert barbed type fittings
secured by plastic ratchet clips shall not be used.

Trees planted in planters within the tiled areas shall not share a common drip line.
A separate drip line riser from PVC lateral line shall be provided for each planter.

The pipes for bubbler and drip line risers connections shall be as per BS. 1972-67
class “C”. The fittings for the above pipes should be of compression quick joint type
with minimum 12 bar nominal pressure.

21/2.1.3 Steel Pipe and Fittings

Steel pipe shall conform to API standard schedule 80 or other equal and
approved. Welded fittings shall be schedule 80 and weldneck. Flanges shall be in
accordance with BS4504 PN16. All bolts, nuts and washers used for flange
assembly or integral with bolted couplers shall be stainless steel (A4 - 70).

All Pipes and fittings to be coated inside and outside by electrostatic fusion
bonded epoxy to average DFT 150 microns, or by fusion bonded plastic
powder coating to average DFT 500 microns.

21/2.1.4 Threaded Steel Pipes & Fittings (For 75mm and Below)

Threaded steel pipes and fittings used for risers shall be hot dip galvanized mild
steel class (C) in accordance with BS 1387.

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All G.I. & Steel Pipes and fittings to be coated, inside and outside with
electrostatic fusion bonded epoxy to average DFT 150 microns or by fusion
bonded plastic powder coating to average DFT 500 microns.

Any galvanized pipe installed in contact with the soil shall be wrapped with at least
two layers of an approved petrolatum impregnated tape of min. thickness of
1.15mm and applied with 50% over lap. The wrapping tape shall extend a
minimum of 100 mm above the soil. Steel piping and fittings shall only be installed
above ground or otherwise specified.

Joints shall be threaded and sealed with PTFE tape or some other approved
method. Connections to the flanged equipment shall be via threaded flanged
adopters. All bolts, nuts and washers used for flange assembly or integral with
bolted couplers shall be stainless steel A4-70.

21/2.1.5 Ductile Iron Pipe and Fittings

Ductile iron pipe and fittings shall be in accordance with BS 4772 or ISO 2531.
They shall be supplied by an internationally known and approved manufacturer.
Ductile iron pipes and fittings shall be supplied, stored, laid, back-filled and tested
in accordance with CP 2010. The pipes shall not exceed 5.5 meters in length and
push-in or flexible mechanical joints shall be used unless otherwise stated.

Where flanged joints are used, the flanges shall be faced and drilled to PN16 as
defined in BS 4504, unless directed otherwise. Flanged joints shall be made with
inside bolt circle gaskets as described in BS 4865 part 1, and gaskets from plain
rubber to BS 1737. Bolts shall be stainless steel Grade A4-70, complete with nuts
and washers.

The threaded portion of bolts shall be of such length that at least two threads shall
protrude beyond the nut when tightened.

Pipe barrels shall be class K9, tapers, bend and pipes with cast on flanges shall be
class K12, and tees shall be class K14.

The internal and external surfaces of all-ductile iron pipes and fittings shall be
coated according to one of the following methods:

i) Fusion Bonded Plastic Powder Coating (average 500 microns)

ii) Fusion Bonded Epoxy Coating (minimum 300 microns)

21/2.1.7 GRP Pipes and Fittings

All pipes and fittings shall have a resin rich inner layer, having a minimum thickness
of 1.0 mm and a resin rich outer layer having a minimum thickness of 0.25mm
incorporating one layer of "C" glass. The remainder of the liner shall consist of at
least one layer of 450 g/m powder bound acid resistant chipped glass strand mat
having a glass content between 25 and 30 % by weight.

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 13 SECTION 21 AUTOMATIC IRRIGATION

All glass reinforcement shall be of the "ECR" type. All pipes and fittings shall have
an stiffness of not less than 10,000 N/M and satisfy the requirement of ASTM D
3262-87. Pipes shall withstand longitudinal tensile force of 100 N/mm of
circumference. All the flanges shall be PN16.

21/2.1.8 Staple Stake

All drip tubes shall be held on the soil by Staple stake. The stake should be
polypropylene, minimum 220mm long, durable and heat resistant. Tails of the
stakes shall be provided with integral barb type flaps to increase retention in soil.
The drip line shall be hold on the soil by the same length staple stake at 10 m
interval. The stake shall be featured separated surface to grip the drip line.

21/2.2 VALVES

21/2.2.1 Solenoid Valves

Automatic remote control valves shall be of the sizes prescribed on the plan. The
valves shall be normally closed diaphragm type with slow opening and closing
action for protection against surge pressure. Actuation shall be by encapsulated
type solenoids and rated 24 volts, 50 cycle unless otherwise specified.

The valve shall able to operate under very low flow and pressure conditions.

Construction shall provide for convenient access to functional parts without removal
of valve from system plumbing. A manual flow control adjustment, with shut-off
capability, shall be furnished on all valves. Valve pressure rating shall not be less
than 200 PSI.

The diaphragm shall be of nylon reinforced BUNA-N rubber, and provide for a
positive seal between bonnet and body. The solenoid functional parts shall be of
stainless steel, brass or bronze for corrosion resistance. Diameter shall be as
shown on plan. A mechanism shall be provided for bleeding of the diaphragm
chamber for manual operation. Valves shall be fabricated from heavy cast brass or
bronze. The valve shall be capable of working under dirty (Treated sewage) water
conditions. Inlet and outlet shall be threaded B.S.P.

All valves shall be provided with a pressure regulator capable of regulating

downstream pressure between 15 to 100 PSI (within an accuracy of +or- 5PSI)
regardless of upstream pressure. It shall provide full and accurate pressure
regulating capabilities irrespective of whether it is operated electrically or manually.
The pressure measurement should be possible via schrader valve or integral
pressure gauge.

21/2.2.2 Check Valve

Check valves 75mm and above shall be double flanged single door swing type
having ductile iron body and gunmetal seat to BS1400. Pressure Rating to be PN
16 or more. All valves shall be coated with epoxy internally and externally to
average DFT 300 microns for protection against corrosion of body components. All
nut bolts to be of stainless steel grade 316/ A4-70.

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 14 SECTION 21 AUTOMATIC IRRIGATION

Check valves of 50mm and smaller shall be spring type manufactured from Brass
or Bronze. Inlet and outlet to be BSP female threaded. The spring to be of
stainless steel. Pressure rating to be PN16 or more.

21/2.2.3 Gate Valve

Gate valves 75mm and larger shall be double flange, ductile iron waterworks
valves, with wedge type gate and non-rising stem. Valves shall be manufactured in
accordance with DIN3352. All valves shall be coated with epoxy internally and
externally to average DFT 300 microns for protection against corrosion of body
components. Valves installed below ground shall be provided with stem cap for key
operation.

Valves to have non-rising stem of stainless steel, stem nut brass or cast aluminium
bronze with gun metal. Body components shall be of ductile cast iron SG GGG-50.
Stem sealing by elastomer/ NBR rubber ‘O’ rings.

Up to size DN 400 resilient seated Gate valves are preferred with ductile iron
wedge fully covered with special grade elastomer EPDM rubber. Heavy duty steel
keys with head configuration to fit operating nut and handle length as required for
proper above ground operation shall be provided in numbers specified by the
Engineer.

Valves above ground shall be provided with hand wheel. Nominal pressure for the
valves shall be 16 bar or more. All bolts and nuts to be stainless steel grade A4-70.

Gate valves 50mm in diameter and smaller shall have non-rising stem and be
manufactured from brass or bronze according to BS 5154. Inlet and outlet to be
screwed BSP. Rating to be PN16 or above.

21/2.2.4 Air Valve

Provide automatic double orifice air vents at all high points on the pressure mains.
Air valves and other similar items shall confirm to BS 2591. Automatic air valves
shall have non-corrosive floats in chambers with clear space ensuring blockage
free operation. All components for the air valve actuating mechanism including
lever shall be stainless steel.

The body and cover of the valve should be of bronze or ductile iron with phenolic
primer coating. Nozzles with seals and actuating mechanism to be located in the
removable upper plate connected to the valve body using stainless steel (grade
316/A4) bolts. Valves shall be coated with epoxy internally and externally to
average DFT 300 microns for protection against corrosion of body components. All
nut bolts to be of stainless steel grade 316/ A4-70.

Pressure rating of the valve shall be 16 bar. The internal components shall be
stainless steel. The valve size and installation shall be as per site conditions and
engineer instruction.

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21/2.2.5 Electrically Actuated Butterfly Valve

Electrically actuated Butterfly valves shall comply in all respects with DIN 3354 -
PN16 Body of Ductile cast iron SG GGG-50 Valve disc shall be of Stainless steel
316.

All valves shall be coated with epoxy internally and externally to average DFT 300
microns for protection against corrosion of body components.

Valves shall be flanged type or mounted between flanges to DIN 250, part 1 for PN
16, face to face dimensions to DIN 3202-K1 corresponds to ISO 5752, concentric
type, streamlined design.

With replaceable seat ring, fusion bonded on backing ring, leak tight closure on
both directions. For operation at differential pressure at maximum 16 bars with
operating gears with electric part turn actuator.

Variant DN-40-300, K1, Seat ring NBR (BUTA N), Shaft S.S. 1.4005, Maximum
working temperature +80 degree Celsius with maximum working pressure 16 bars.

All nut bolts to be of stainless steel grade 316/ A4-70.

Electric actuators shall have to open and close of at least 60 seconds and shall be
provided with an auxiliary operating wheel. The motor control should allow for
stepped closing of valve pausing at ½ closed and ¼ closed.

Motor and electrical protection shall be in strict accordance with the electrical
specifications and DEWA regulations; motors shall be rated to operate at an
ambient temperature of 50 degrees centigrade, and a relative humidity of 100 %.

Electrical components shall be protected from condensation.

21/2.2.6 Pressure Reducing, Pressure Sustaining & Check Valve

These valves shall be installed as indicated on drawings to maintain a constant

downstream pressure regardless of demand fluctuations. The valve shall be
automatic, fluid actuated, with a flexible non-wicking, FDA approved, nylon fabric
reinforced elastomer diaphragm. The pilot shall be brass and tubing of
copper/brass. The valve shall be flanged and of ductile iron body. All internal and
external exposed surfaces shall be FDA approved epoxy coated to minimum DFT
300 microns. Valve sizes 100mm and above shall be standard with an externally
mounted Y stainer for protection of control circuit and ball valves to isolate the pilot
system from Main valve. All nut bolts to be of stainless steel grade 316/ A4-70.

The valve shall open and close in modulating action. On pressure reversal, valve
shall close tightly. Adjustable pressure range shall be from 1.0 kg/cm2 to 8.5
Kglcm2

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 16 SECTION 21 AUTOMATIC IRRIGATION

21/2.2.7 Pressure Relief Valve

These valve shall be installed in the pump room as shown on drawings to release
excess pressure away from the system.

The valve shall be flanged, diaphragm type, hydraulically operated, pilot controlled,
and modulating type. The pilot shall be brass and tubing of copper/brass. The valve
shall be fast opening and slow closing. The valve shall be flanged and of ductile
iron body. All internal and external exposed surfaces shall be FDA approved epoxy
coated to minimum DFT 300 microns. All nut bolts to be of stainless steel grade
316/ A4-70.

21/2.3 VALVE BOXES

Air valves (25mm or smaller), quick coupling valves, solenoid valves and wires pull
boxes to be installed in an access box of sufficient size to permit ready removal of
the valve inner assemblies without removing the box from the ground. Valve names
and numbers must be clearly marked inside and outside of the box with permanent
plastic tags. Valve boxes shall be fabricated from reinforced plastic and minimum
recommended size shall be as follows:

Item COVER DEPTH

Q.C.V. 250mm (dia) 230mm
Pull box, Air valve 25mm & Flush 430 x 300mm
valve 295mm
Solenoid valves up to 50mm 590 x 380mm
349mm
Solenoid valves above 50mm and
Isolation valves up to 75mm 825 x 450mm
495mm

Measurement is taken from the top of boxes. Covers shall be secured by stainless
steel (A4-70) bolts.

For hard paved and Sikka areas, valve boxes and pull boxes shall not be used.
Valve assemblies shall be installed in concrete valve chambers with heavy duty
manhole covers.

21/2.4 BASKET STRAINER

Ductile iron basket strainer with bolted cover, inlet and outlet to be flanged and
drilled to PN 16. The strainer should be stainless steel with 1/8 inch perforations.
Working pressure is 150 psi. All bolts and nuts to be stainless steel grade 316/A4-
70. The basket strainer shall be coated internally and externally with coal tar epoxy
300 DFT micron.

21.2.5 PRESSURE COMPENSATING DRIP LINE:

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 17 SECTION 21 AUTOMATIC IRRIGATION

Irrigation equipment- Drip line shall consists of linear low density Polyethylene
tubing with pressure compensating, self flushing type integral drip emitters. The
tubing shall have an minimum outside diameter (O.D.) 16mm and thickness of 1.1
mm + 0.05mm. Pipes for drip lines shall be manufactured from low density
polyethylene incorporating a minimum of 2.8% carbon black, antioxidants in an
amount not exceeding 0.5% and shall have a nominal pressure PN 6.

Random samples of drip pipes shall be subjected to the Teepol crack resistance
test. The samples shall be immersed in a bath containing a solution of 10% Teepol
and 90% water maintained at 50 degrees C. The pipe should resist the solution
without showing any fatigue or crack for a period of 150 hours.

The test should be carried out in an independent laboratory within U.A.E.

All fittings for drip line shall be compression type.

The emitters must be pressure compensating according to ISO 9260 and emission
rate of the emitter shall remain constant at varying water pressure from 1bar to 4.5
bar. The flow path in emitter must ensure turbulent flow and emitter must confirm to
excellent pressure compensation and self-cleaning/Flushing mechanism.

The emitter must be clogging resisting and the filtration requirement not more than
150 mesh. Coefficient of variation shall be less than 5%. the flow of emitter must
remain same/constant at temperatures varying from 0 to 60 deg. Celsius.

The product must have warranty against cracking and performance for 7
Years.

Drip stakes shall be provided at each point of change in direction of drip line and
spacing between drip stakes shall not be more than 10.0 meters.

The capacity and spacing of the inbuilt emitters in the drip line shall be as follows:

For ground covers: Emitter discharge rate shall be 0.9 GPH and spacing between
emitters shall be 50 cm in drip line and 50cm between drip lines.

For seasonal flowers: Emitter discharge rate shall be 0.6 GPH and spacing
between emitters shall be 30cm in drip line and 50cm between drip lines

For hedge: Emitter discharge rate shall be 0.6 GPH and spacing between emitters
In drip line shall be 50 Cm.

For trees: A loop of drip line (around tree) with 0.9 GPH in line emitter at every 30
cm length of drip line in a loop shall not be less than 3.2 metre.

For shrubs: Two in line PC emitters per plant (each emitter 3.4 l/h [0.9 GPH]) shall
be used for shrubs if spacing between shrubs is less than or equal to 1m. For shrub
spacing that is 1 m or greater, use a loop of drip line with three (3) inline PC
emitters per plant (each emitter 3.4 l/h [0.9 GPH]).

21.2.6 PRESSURE COMPENSATING BUBBLERS

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 18 SECTION 21 AUTOMATIC IRRIGATION

Bubblers shall be constructed from UL stabilized engineering grade plastic and

rubber, delivery shall be pressure compensating in the range of 2.00 to 5.00 bar,
delivery shall be umbrella pattern, flow shall be 1 gpm. Inlet shall be ½ inch female
threaded.

Stakes for bubblers shall be constructed from strong temperature resistant

polypropylene plastic construction with protective stop collar, length shall be 12
inches each side of inlet with barbed side inlet suitable for class “C” polyethylene
pipes, outlet shall be ½ inch external male thread.

Each palm tree shall have two (2) bubblers (0.06 l/s per bubbler) per tree.

21/2.7 POP-UP SPRAYERS

The sprayers shall have a high level impact strength corrosion resistant body, stem
and nozzle. Pop - up height should be 100mm. The sprayer shall have a heavy-
duty stainless steel retraction spring and piston with slip clutch to facilitate nozzle
positioning.

The sprayer shall incorporate a wiper seal to protect the internal mechanism
against ingress of foreign material and prevent pressure blowout and shall have an
easily accessible under nozzle screen. The wiper seal should be co-moulded type
that ensures flow-by of less than 0.10 US.gpm at low pressure and complete
sealing at pressure greater than 10 psi. The sprayer shall have 12mm threaded
inlet.

ALL SPRAYERS SHOULD BE PROVIDED WITH BUILT-IN SEAL-A-MATIC

CHECK VALVE AND IN STEM PRESSURE REGULATOR TO MAINTAIN
CONSTANT OUTLET PRESSURE OF 30 PSI.

The sprayer shall have the following performance specification at 2 Bar operating
pressure:

The nozzles shall have precipitation rates matched across sets and across
patterns. The standard nozzle shall be capable of covering 4,5 metre radius at 2.0
bar pressure.

Spacing for the sprayers with standard nozzle shall be 4 meters. For small areas
sprayers with low flow nozzles shall be used as shown on drawings.

Standard Sprayers shall have the following performance at 30 PSI and 30
trajectory (Table 21-1):

Table 21- 1: Standard Sprayers performance criteria at 30 PSI and 30 trajectory
Type Radius (M) Flow GPM

Full Circle 4.5 3.70

Three Quarter 4.5 2.78

Half Circle 4.5 1.85

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 19 SECTION 21 AUTOMATIC IRRIGATION

Quarter Circle 4.5 0.92

Low angle/low volume sprayers shall have the following performance at 30 PSI and
15 trajectory (Table 21-2):

Table 21- 2: Low angle/low volume Sprayers performance criteria at 30 PSI and 30 trajectory
Type Radius (M) Flow GPM

Full circle 3.1 1.58

Half 3.1 0.79

Quarter 3.1 0.39

All nozzles for standard and low angle shall be MPR. Sprayers / sprinklers should
be installed in such a way that water will not hit the stem of the palm trees.

Sprayers and sprinklers shall be installed 30cm away from heel kerb / edge of
footpath.

21/2.8 ROTOR POP UP SPRINKLERS

Turbine or gear drive rotor pop up sprinklers, full and part circle operation with
Memory-Arc to automatically return nozzle stream to set arc. Part circle adjustment
shall be from minimum 40 deg. to 350 degrees. All adjustments of the sprinklers
shall be from the top.

The internal mechanism is water lubricated. Heavy duty plastic case with multi-
function wiper seal and heavy duty retraction stainless spring shall be used. All
sprinklers should be provided with seal-A-mastic check valve. Bottom inlet to be
19mm BSP female threaded. Pop up height to be not less than 90mm. The nozzles
of all the sprinklers shall be low pressure models for proper performance even at
low pressures.

The sprinkler shall approx. match the following performance specification at 2.0 bar
operating pressure:

A) Standard (25 deg Trajectory)

Type Radius (metre) Flow (I/2)

Full Circle 11.0 0.35

Three Quarter Circle 11.0 0.26
Half Circle 10.6 0.19
Quarter circle 8.9 0.11

Spacing for these sprinklers shall be not be more than 10.0 meters.

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 20 SECTION 21 AUTOMATIC IRRIGATION

B) Low angle (7 deg Trajectory)

Type Radius (meter) Flow(GPM)

Full Circle 6.2 0.22

Three Quarter Circle 6.5 0.15
Half Circle 6.5 0.12
Quarter circle 6.5 0.06

Spacing for these low angle sprinklers shall be not be more than 6.5 meters.

Sprinklers in tree areas should be with low trajectory angle.

21/2.9 PUMPS

21/2.9.1 Main Pumps (Not Applicable)

Centrifugal pumps shall be in-line vertical, multistage, having cast iron body and
base. The pump section (shaft, impellers, guide vanes and chambers) shall be
of stainless steel. The mechanical shaft seal shall have diamond polished
Tungsten Carbide or Silicon Carbide seal faces and heat resistant O-ring. Thrust
bearing shall have ample capacity to carry the weight of all rotating parts plus the
hydraulic thrust of the impellers. Motors shall be closed coupled type.

Pumps shall be suitable for Treated Sewage/brackish water

The inlet and the outlet shall be flanged PN 16. Duty of each main pump shall be
____ at total head greater than or equal to ___. Jockey pump shall deliver _ lit/sec
at _ bar.

___ main pumps (__ duty and __ stand-by) and One jockey pump should be
installed,

Motors shall nominally 2900 rpm, TEFC Class F, manufactured generally in

accordance with DEWA regulations and electrical specifications. The power rating
for the electric motor should be 30% above the rated power shown in the
manufacturer catalogue.

21/2.9.2 Sump Pump

Sump pump is required for the Pump Chamber, location and arrangement should
be as per details drawings.

The pump shall be of robust construction and suitable for pumping corrosive,
treated effluent with high sand content. It should operate at minimum 100mm depth
of water. Pump body, impeller as well as vital pump components to be of Stainless
steel

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 21 SECTION 21 AUTOMATIC IRRIGATION

Capacity of these pumps should be 20 m3/hr at 8 metre head. Delivery line of

these pumps to be connected to the drainage pump chamber located at the corner
of the football pitch.

Float switch to be provided to operate these pumps automatically if the level of

water inside the filtration chambers comes up.

All switches and control devices related to these pumps to be fixed in the electric
control panel.

Drain line to be connected from fertilizer room to sump pump pit in Filtration
Chambers.

21/2.10 GRP STORAGE TANKS

___ Nos. of under ground GRP Water storage tanks shall be installed for the
project. Capacity of tank shall be _____ Gallons each and to be connected to the
pump room as shown on drawings. A ___ water supply line complete with inlet
chamber as shown of drawings shall be provided.

The tank shall be manufactured by a machine filament winding process and shall
include a chemical resistant liner, a structural wall and an exterior surface as
follows:

The liner shall be approximately 0.5 mm thick. The liner surface shall be reinforced
with “C“ glass mat or veil backed by chopped ‘ ERC ‘ type glass, all impregnated
with high Vinyl ester resin. The structural wall shall consist of ‘ERC‘ type glass
reinforcement, quartz sand, all impregnated with high grade Isophthalic Polyester
resin. The shell shall have a minimum thickness of 14.0mm.

The tank construction shall include minimum stiffener ribs as follows:

Rib width at bottom 180 mm

Rib height 40 mm
Rib spacing, centre to centre 750 mm
Rib reinforcement thickness 5 mm

The tank manufacturer shall be certified to meet the requirement of BS6920. The
tank shall be supplied complete with a fibreglass manway and cover and Filament
wound GRP flanges.

Tanks shall be undergo a negative pressure test of 2.5 psi for 3 minutes and air
test at 5 psi for 3 minutes prior delivery to the site in presence of the engineer.
Installation of tanks shall done on proper R.C.C foundation and shall strictly as per
manufacturer’s recommendations.

The vent pipe shall be of GRP. The size of the vent shall be larger than size of
outlet pipe.

All nuts and bolts shall of stainless steel grade 316 or A4-70.

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 22 SECTION 21 AUTOMATIC IRRIGATION

The installation of tanks shall strictly as per manufacturer’s recommendations c/w

concrete foundation, anchoring etc. The contractor shall fix the tank as per contract
drawings with all necessary level sensors, valve chambers including electrically
actuated butterfly valve, gate valves, flexible joints, float valves, pressure reducing
valve, etc. Size of float valves shall be same as that of size of incoming water
supply line.

GRP STORAGE TANK (PANEL TYPE) (Not applicable)

___ Nos. of GRP panel type Water storage tanks shall be installed for the project.
Capacity of tank shall be _____ Cubic metre each and to be connected to the
pump room as shown on drawings. A ____mm water supply line complete with inlet
chamber and tie-in connection to TSE network main shall be provided.

The tank shall be of sectional GRP panel type. The panels are to be made of Hot
Pressed GRP and shall be highly durable. Tanks shall be manufactured well within
the requirements of JIS A4110. The allowable light transmittance through water
tank should not exceed 0.005% in order to prevent algae growth within the tank.

The tank shall be strong, uniform and stable construction. Stainless steel tie rods
shall be provided to give sufficient strength and stability to the tank. All nuts and
bolts shall be of stainless steel grade 316 or A4. Internal bolts shall be synthetic
rubber capped. Corner angles and internal ladder shall be of GRP. All standard
accessories like external ladder, air vent, drain valve, overflow, manholes, float
valves etc. shall be provided to the Engineer’s approval.

The tank shall be installed on strong concrete foundation and steel footing as per
manufacturer’s recommendation. The tank shall be guaranteed against failure for a
minimum period of ten years.

21/2.11 FILTERS

Automatic self-cleaning filters specifically designed for use with organic

contaminants. Cleaning shall be effected by a hydraulically powered suction
scanner, automatically activated when the differential pressure across the filter
reaches an adjustable level, nominally 5 psi.

The screen shall be stainless steel grade 316 with 200 micron mesh size. Flushing
line to be connected to the soak pits or nearest storm water drainage manhole.

The control system shall feature a fail safe timer to prevent continuous flushing due
to malfunction.

Automatic flushing shall occur only during irrigation system operating hours.

Two filters to be installed in each Filtration chamber, one duty and one standby.
The capacity of each filter should be minimum 350 gpm & at 2.5 psi maximum
pressure loss. The screen area shall not be less than 450sq. inch.

All the filters shall have isolation valves in the suction as well as delivery side for
easy maintenance. The controller for the filters shall be equipped with timer and
pressure differential control unit. Controller will be fixed in the Electric control panel.

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 23 SECTION 21 AUTOMATIC IRRIGATION

The filter body and internal parts including flanged connection shall be stainless
steel. Pressure gauges to be connected to suction and delivery side of each filter,
pressure gauges to be mounted in the Electric control panel in isolated
compartment.

21/2.12 PRESSURE GAUGES

Pressure gauges for filtration chambers shall be stainless steel, direct reading,
Glycerin filled capable of 0-10 kg/cm2 register with 0.25 graduation. Gauge shall
be of glass or Plexiglas faced, drip-proof and minimum dia. of 50mm. Gauge cock
shall be of same size as pressure gauge and be fabricated from stainless steel.

21/2.13 UNDERGROUND WARNING TAPE

Warning tape shall be laid above main pipes. Tapes shall be durable and
detectable by Electro-Magnetic means using low output generator equipment.
They shall remain legible and color fast in all soil conditions at PH values of 2.5 to
11.0 inclusive.

The tapes shall be flexible and subject to the Engineer's approval. Width of the tape
should be at least 150 mm.

Tape shall be Orange colour with Black text in Arabic and English as "CAUTION:
IRRIGATION PRESSURE MAIN BELOW". The text on the tape shall be
permanent ink bonded to resist prolonged chemical attack by corrosive acids and
alkaline with message repeated at a maximum interval of two meters. The tapes
shall be laid 300 mm above the pipeline.

The tape shall be continuous over pipelines and at joints there should be a
minimum of one meter over lapping.

21/2.14 ELECTRICAL EQUIPMENT

All electrical equipments shall be in accordance with DEWA regulations and

electrical specification. Enclosures shall be protected in accordance with IP55
for equipment installed above grade and IP58 for equipment installed below grade.

Wiring to and from control panels shall be routed in pvc conduit below the ground.
Above grade conduit to be liquid tight flex, or galvanized steel, provision to be
made for inspection tee's and ells to facilitate removal in the future.

Name of approved manufacturers for electric components are as follow:

1. SIEMENS
2. TELEMECANIQUE
3. ABB.
4. RAIN BIRD INTERNATIONAL FOR IRRIGATION CONTROL SYSTEM

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21/2.14.1 Electrical Wire For Solenoid Valves And Satellites

All electrical wire for underground use shall be single core solid "Underground
Feeder" type insulated with a flame-retardant thermoplastic compound, rated for
600 volts and direct burial. The Contractor shall prepare a wire-sizing chart with
effective lengths of each station and common wires, which shall be submitted, for
approval prior to commencement of work. Cable markers shall be used for
indicating valve number each cables at both ends as well as at splices. Cables
shall be laid in PVC conduits.

Power cables and signal cables for satellites should be laid in separate conduits.
Separate wire to be laid for each solenoid valve, and valve combination to be
arranged at the respective field satellite.

Signal wire between the C.C.U. unit and the satellite controllers should be double
jacketed, two conductor cable intended for control of the RAIN BIRD MAXI COM
Computerized system.

The cable manufacturer should certify that the insulated conductors have been
tested for and meet the requirements of U.L.

The two conductors shall be color coded with one conductor BLACK and the other
RED. The conductors shall be tin coated, soft drawn, annealed solid copper
conforming to the requirements of ASTM -33.

The cable shall be suitable for direct burial in the earth, whenever and wherever it
is required to be installed in ducts or conduits.

Pull boxes shall be provided at every place of change in direction of conduit piping,
near to solenoid valves. In any case spacing between adjacent pull boxes in a line
shall not exceed 50 meters.

Size of the cable depends on the distance between the CCU unit and the field
satellites and according to RAIN BIRD recommendation.

Sizes of the conduits should be as follows.

25mm up to 4 wires
37mm up to 8 wires
50mm up to 15 wires
75mm up to 30 wires
100mm more than 30 wires

Provide minimum one spare cable for every five cables. A Separate common wire
shall be provided for Sprinkler and Sprayer valves in order to control their operation
through wind controller.

Irrigation control cables shall be color coded as follows

1. Common wire for drip………………… ………….. Green
2. Common wire for Sprayers/ Sprinklers ………….. Black
3. Drip valve wire ………..…………………………… Blue
4. Bubbler valve wire ………………………………… Red
5. Spray valve wire … ……………………………. …Yellow
6. Sprinkler valve wire … …………………………… Orange

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 25 SECTION 21 AUTOMATIC IRRIGATION

7. Spare wire……………… …………………….…… White

SEPARATE PULL BOXES SHOULD BE USED FOR POWER CABLES AND

MAXI COM SIGNAL CABLES.

21/2.14.2 Wire Connectors

All wire connections at electric remote control valves and all splices of wire in the
field shall be made using wire connectors. The wire connectors shall be
specifically designed to ensure waterproof underground wire connections. The
connectors shall be under-writers laboratories listed water-resistant wire
connectors, rated 600 volts for PVC insulated copper wire with insulation
temperature rating of 105 degree C.

The connector shall be insulated with color coded, pliable, vinyl skirt. They shall
feature alive spring which assures a tight grip even on small wire combinations.

All wire connections to be arranged in plastic pull boxes at fixed interval distances
of max. 100 meters and/or at any change of direction.

All valve combinations shall be arranged at the controller.

21/2.14.3 Electric Pressure Switches

Pressure switches shall be fabricated from die cast aluminium per ASTM B-85 and
designed to meet IP65 specifications. Transducers shall be fabricated from brass
and buna N.

The pressure switches shall incorporate an alternating fulcrum balance plate

allowing independent adjustment of both set and reset point over the full range.

Both set and reset points shall be adjustable 1.40 to 14 bar, having a minimum
dead band range less than or equal to 1.40 bar. Repeatability shall be +/-0.5% to
2% of full scale. Switches shall be vibration resistant and shall have front access to
electrical connections and adjustment nuts.

21/2.14.4 Flow Sensing And Control System

Flow sensing and control system to sense the flow data and display that data as
both flow rate and volume on digital indicator.

Sensor to be adjustable insertion paddle wheel type corrosion resistance. Flow

pulse controller should provide automatic interface with RAIN BIRD MAXI COM
SYSTEM.

Digital Indicator displays for both flow rate and total volume to be provided and to
be mounted inside the panel. The digital indicator unit should be powered with
external 220 volts AC power supply and rechargeable Lithium battery. The unit can
run of internal or external power and should have automatic changeover switch
which is activated during a power failure. The battery will be automatically
recharged during normal mains operation.

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 26 SECTION 21 AUTOMATIC IRRIGATION

Flow sensing and control system should sense high flow rate (above the max. flow
rate for any combination of valves) and close the butterfly valve in filtration
chamber.

21/2.15 SYSTEM CONTROLLING EQUIPMENT

21/2.15.1 Electrical Control Panel

ALL CONTROL PANELS SHOULD BE ASSEMBLED BY ONE OF THE

FOLLOWING APPROVED COMPANIES:
1 - BLACKBURN STERLING.
2 - SCIENTECHNIC.
3 - BIN GHALIB.
4 - ABB.
5 - DANWAY

A - MAIN CONTROL PANELS

Electrical control panels for this project shall be constructed of mild steel sheet
enclosures with stainless steel 316 lock and hinges front opening door having a
protection range not lower than IP 65 according to IEC and to be class 3. The panel
shall have provision for connecting to generator.

The Control Panel shall be Class3 (Form 4) and to be fixed in GRP kiosk on
concrete base (300 mm above ground level)

The panels to be fixed above the filtration chamber/pump room as per the
Engineer’s approval and shall include the followings:

1- C.C.U. UNIT.
2- IRRIGATION PUMP CONTROL SYSTEM
3- FLOW METER DISPLAYS.
4- SUMP PUMP CONTROL SYSTEM.
5- EXHAUST FAN CONTROL.
6- WIND-SENSING CONTROL SYSTEM.
7- BUTTERFLY VALVES CONTROL GEAR.
8- LIGHTING SYSTEM
9- PROVISIONS FOR FUTURE IRRIGATION CONTROL SYSTEM AND
PROTECTION

Panel shall have main circuit breaker for the power main and earth leakage
protection. Each power circuit should have circuit breaker, earth leakage protection
and power indication lamp. Each switch and light on the exterior of the panel shall
be marked with an engraved plastic name identifying each item.

Truncking shall be used when wiring the panel.

The panels shall have serially numbered terminals for terminating all incoming and
outgoing cables. Anti-condensation heaters should provided inside the panel. The
panel shall be installed above Pump or filtration chamber.

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 27 SECTION 21 AUTOMATIC IRRIGATION

Pump or filtration system Control panels shall strictly be as per DEWA and /or RTA
standard Specifications in all aspects and subject to the Engineer’s approval.

B - CONTROL PANEL FOR FERTILIZER INJECTION UNIT

Same as above to accommodate the control system and injection pump switch
gear.

21/2.15.2 Satellite Controllers

The satellite controllers shall be solid state type RAIN BIRD ESP -SAT Series and
shall have 220 Volts power input and 26.5 Volts, 50 cycles.

If the input Voltage to the controller is other than 220 Volts AC, the Contractor must
ensure continuous regular Voltage to controllers equivalent to the input Voltage
marked out on the controllers. If Voltage fluctuations are noted, controllers must be
equipped with automatic voltage regulations.

The controllers shall have 24 stations as mentioned on drawings. The controller

should be weather- proof lockable cabinet with minimum one meter high stainless
steel pedestal. The pedestal to fixed on proper concrete base, 300 mm above
ground level. Satellite Controller(s) along with wind controller(s) shall be
installed in GRP Kiosk enclosure.

It shall be controlled by the central computer and a switch shifting should allow the
satellite to be operated independent of the cluster control unit.

It shall give random access of all stations by central computer. The signal cables
from the controllers shall be laid up to the Cluster control unit inside the electric
control panel. The power supply for all satellites on a pumping station / filtration
chamber should be taken from single source.

The Contractor has to check the number of electric valves connected to each
station, if number exceeds the manufacturer recommendation a multi-station relay
has to be included with the corresponding controller. Lightening protection shall be
provided for all controllers.

Satellite controllers to be connected to existing CCU by two wire signal

cable. As shown on contract drawings.

21.2.15.3 Cluster Control Unit (Ccu)

The satellites shall be operated by the Cluster Control Unit (CCU).The unit must be
fully compatible with RAIN BIRD MAXI COM. SYSTEM, and have the following
features:

- A CCU modem contains a modem, IBM computer interface, site control

functions and encoder module.

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 28 SECTION 21 AUTOMATIC IRRIGATION

- The CCU will be capable of being directly linked with the central computer by
standard telephone line.

- The unit will have 28 channels each, with a visual indicator light showing
operational status.

- The unit will be capable of operating field satellites, switching, sensor and pulse
decoders.

- Communication from the CCU satellite and decoders will be via 2-wire path
cable configuration.

- The CCU encoder will be capable of transmitting two way information between
the field satellites and the central computer.

- The unit will have a heavy duty baked coated epoxy coated enamel enclosure
and be suitable for 240 Volt/50 HZ operation.

- The unit will be mounted inside the electric control panel, Lightning protection
shall be provided for the CCU unit.

TELEPHONE LINE SHOULD BE ARRANGED FOR TRANSMITTING

INFORMATION AND INSTRUCTIONS BETWEEN THE CCU AND THE
CENTRAL COMPUTER.

Cost of the telephone connection shall be borne by the contractor

21/2.15.4 Filter Controller

Allow cascade flushing of filters if differential pressure exceeds 0.30 bar, or on

command from central controller. Flush time to be adjustable. Control panel to be
provided with a flush counter (resetable) and a selector switch to allow manual
flushing, and/or cancelling each automatic function.

Controller to be provided with circuits to flow switch mounted in the flush lines to
detect any flow of water after the flushing cycle has ceased, and linked to the alarm
circuit, time delay 2.00 minutes. The controller will be mounted inside the electric
control panel.

21/2.16 EXHAUST FAN

Extra heavy duty industrial type Aluminium body exhaust fan size 450mm to be
fixed in the Pump/filtration chambers, minimum two nos. of 150mm dia GRP vent
pipes to be fixed in each Pump/filtration chamber for circulation of the air in the
chambers.

21/2.17 VALVE CHAMBER COVERS

The isolation valves shall be in R.C.C. chambers as shown in the detail drawings.

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 29 SECTION 21 AUTOMATIC IRRIGATION

The Contractor has to propose a design for chambers to suit the site conditions.
The covers shall be double triangular heavy-duty ductile iron cover with clear
opening 600x900 mm, bitumen epoxy coated. The cover should be loosely coupled
by stainless steel bolts and nuts. Covers to be painted green and should as per DM
standard. The word of "IRRIGATION" in English and Arabic should be casted on
the covers.

Valve chambers with depth more than 1.5 meters shall be provided with a
heavy duty Aluminium ladder.

21/2.18 FILTRATION CHAMBER

Two chambers are required for filters arrangement, flow sensors and
Fertilizer injection System.

The filtration chambers shall be in reinforced cement concrete (with Proper

finishing including painting and lights) as per detailed drawings and shall be as per
RTA general specifications.

The access cover for filtration chamber shall be minimum 1200x1400mm overall in
two pieces of Heavy duty aluminium checkered plate with stiffeners and lifting
handles. The cover should be lockable and easy to open and should be tight to
prevent dirt or soil into the chamber. The contractor has to propose a design for the
chamber to suit the site condition.

The filtration chambers shall be provided with two spare electrical sockets
(Capacity 15 KW each) for future use.

There should be two covers for each chamber as shown on drawings.

Separate sump pump discharge line and flushing pipe line from filtration chambers
to be ended ten meters away of the chamber in 2m x 2m x 3m soak pit filled with
gravel or to be connected to the nearest storm water system as per Engineer’s
approval

Soak away shall have heavy duty ductile iron cover 600x900mm.

Monitoring facility should be provided to warn against continuous flushing.

THE CONTRACTOR MUST PROVIDE THE ENGINEER WITH STRUCTURAL,

MECHANICAL AND ELECTRICAL SHOP DRAWINGS FOR APPROVAL. THESE
DRAWINGS MUST BE PRESENTED FOR APPROVAL UPON AWARD OF
CONTRACT.

All the chambers shall be in reinforced concrete to the approval of Engineer.

21/2.19 CHAMBER IDENTIFICATION PLATE

Chamber Identification plate is to be made to sizes shown on drawing and shall be

of "Admiralty Brass" BS Code No.CZ III BS 2871. The plate to be 5 mm thick with
two lags 150 mm long 20 mm wide by 5 mm thick welded at the back. The plate is

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 30 SECTION 21 AUTOMATIC IRRIGATION

to have engraving 2 mm deep as shown on the drawings for each relevant

chamber.

21/2.20 ELECTRICAL CONTROL PANEL

The electrical control panel shall be constructed of mild steel sheet enclosures with
stainless steel hinges and lock front opening door having a protection range not
lower than IP 55 according to IEC and to be class 3. The panel shall have provision
for connecting to generator.

21/2.21 FILTRATION CHAMBER LIGHTING

The Contractor should provide single phase and three phase waterproof power
sockets (one each), and three fluorescent light for filtration chamber.

21/2.22 FERTILIZER INJECTION UNIT

The fertilizer/chemical injection unit shall comprise of 300 liter rigid polypropylene
make tank with reinforced ribs mounted on a pedestal and dosing pump with a
range of 2 to 20 l/h, calibrated in 2 l/h or less increments, complete with valves and
fittings, filters and connecting pipes.

The elevated make up tank shall have level marks molded into the side of the tank.
A second outlet complete with stop-cock shall be provided in bottom of tank for
draining and washing out. An agitator shall be provided to ensure that there is no
separation of liquids. The agitator unit shall be removable to allow access for
cleaning the tank.

The dosing pump shall be constructed of corrosion resistant material, close

coupled to a suitable splash proof electric motor. The unit shall have an operating
head of 70m over the full flow range. The injection rate shall be set manually to
required flow.

21/2.23 DUCTING

uPVC ducts shall be class B to BS3506. Asbestos cement ducts shall be class
12, to ISO-R-160 made with sulfate resistant cement bitumen coated from outside
and shall be pressure tested.

Duct markers shall be used and should be aluminium and shall clearly indicated the
name in Arabic and English: IRR ".

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 31 SECTION 21 AUTOMATIC IRRIGATION

21/3 IRRIGATION SYSTEM, EXECUTION

21/3.1 EXCAVATION AND BACK-FILLING

Prior to trenching all services crossing or running close to the line of the trench
shall be identified and exposed. In addition the line of the trench shall be swept
using an approved detection device, capable of detecting both live and 'dead'
cables.

Trenches shall be made as narrow as practicable, but not less than the pipe
diameter plus 300mm, and shall provide sufficient room for laying jointing and
testing. The width of the trench at the crown of the pipe shall not exceed the pipe
diameter plus 600mm. Sheeting, bracing and shoring shall be used to provide for
the safety of all personnel for all trenches.

The trench bottom shall be composed of stable uniform sand with no

protuberances that might cause point loading of the pipe. The trench formation
shall be trimmed to an even finish which will provide continuous support for the
pipe. Additional excavation shall be carried out at the position of the pipe socket to
ensure proper joint assembly and pipe support.

If the existing formation is unsuitable for direct laying, the pipes shall be laid on a
bed of imported sand 100 mm thick (minimum). This sand may be sourced from
sieved excavated material, but should not contain any particles larger than 5 mm,
and should have good self compacting properties.

De-watering shall be provided to remove any surface or ground water entering the
excavations. Ground water level shall be maintained at least 100 mm below the
bottom of each excavation.

The trench should not be excavated more than 3 days production rate in front of
pipe laying.

Pipes shall be centre loaded leaving joints exposed within three days of laying.
Initial back-fill shall be by hand in 300 mm lifts, and carried out in such a manner as
to ensure adequate support under the pipe and distributed evenly to ensure there
are no voids under or to the side of the pipe.

Back-fill material shall be sand and shall be compacted by water tamping once the
level of back-fill reaches the crown of the pipe.

For pipe sizes 100mm (dia.) and above, back-fill material shall be deposited in 300
mm lifts in general areas and compacted to 90% (by water tamping or by any other
approved method). In paved areas lifts shall be 150 mm and back-fill shall be
compacted layer by layer to RTA roads department approval. Mechanical
compactors shall not be used until there is a minimum of 300 mm above the crown
of the pipe.

Back-fill material shall be sand and shall not contain any particles larger than 25
mm for the first 100 mm above the pipe; thereafter back-fill material shall contain
no particles larger than 50 mm.

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 32 SECTION 21 AUTOMATIC IRRIGATION

Whenever ambient temperatures exceed 35 degrees centigrade, center loading for

PVC pipes greater than 75mm shall only be carried out in the early morning, or
shall alternatively be preceded by cooling of the pipe string by application of water.

For pipe sizes of 75mm and below compaction as mentioned is not required.

21/3.2 PVC PIPE INSTALLATIONS

PVC pipes shall be stored on site in a covered pipe store. Pipe stacks shall not be
greater than seven layers or two meters high. Pipes shall be shielded from the sun
at all times and shall be placed on a sand bed, or on supports at least 75 mm wide
and placed not greater than 1.50 m apart; side supports shall be similarly
constructed and placed not greater than 3.00 m apart. The pipe store shall allow for
circulation of air. Rubber sealing rings shall be stored inside closed boxes in a
shaded place, and shall on no account be exposed to sunlight for more than a few
hours.

Pipes shall be transported on the site on a flatbed trailer, and should never be
dropped or dragged along the ground.

Spigot ends of all pipe shall be chamfered to a depth of half the wall thickness at an
angle of 15 degree. Pipes cut on site should be cut square to the pipe axis with a
fine toothed saw. All swarf and burrs should be removed from the pipe prior to
assembly of joints. Pipe cutters may be used for 25mm pipe. Spigot insertion
depth shall be measured and marked on all pipe larger than 75mm using indelible
ink to allow checking at a later date.

Ring joints shall be made using an approved non ionic lubricant compatible with the
sealing ring. Pipes sized up to 200mm may be jointed using a crowbar and a
timber protection piece, joints larger than 200mm shall be assembled using a
clamped lever device. Before back-filling joints shall be checked to ensure that the
spigot is inserted to at least 90% of the socket depth in all circumstance.

Solvent welding shall be carried out by experienced fitters who fully understand the
technique, and have successfully made a solvent weld joint in the presence of, and
to the approval of the Engineer. Helpers brought up on site may only be allowed to
make solvent joints after inspection of their technique by the Engineer.

Solvent welded joints made on pipe 75mm and above shall be preceded by lightly
sanding both surfaces to be jointed using a medium glass paper or clean emery
cloth. Solvent "cleaner" shall be applied to all mating surfaces using a dauber or
brush (application using rags will not be allowed). After ensuring that mating
surfaces are clean and dry solvent cement shall be applied in sufficient quantities
to ensure bonding, but not in excessive quantities that will leave appreciable
residues inside the pipe.

Brush size shall be 7mm round for 25mm pipe, 25mm flat for 37mm pipe and
50mm flat for larger pipes. Solvent cement should be applied by two people
simultaneously for pipe 75mm and above. Immediately after application of solvent
cement pipes shall be pushed together in a smooth continue motion, that ensures
that the spigot is at least 90% inserted into the socket, the joint shall be held for a

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 33 SECTION 21 AUTOMATIC IRRIGATION

minimum of 20 seconds after insertion, and then surplus cement shall be cleaned
from the outside of the pipe using a rag or paper.

Solvent cement and cleaner shall be provided in tins with brush or dauber fixed to
the lid of the tin.

The lids shall be firmly closed at all times except when the joint is being made. Any
tins of solvent cement that become viscous or hardens shall be disregarded.

Brushes on which solvent cement has hardened shall not be used for making
joints. All fitters involved in solvent cement jointing shall be provided with safety
gloves that prevent solvent touching the skin, gloves shall be kept in good condition
and shall be replaced periodically.

Jointing shall not be carried out in windy conditions (wind speeds greater than 18
km/hour). All lines shall be capped at the end of the days work.

21.3.3 DRIP LINE PIPE

Drip line pipe shall be installed above ground as shown on the drawings and shall
be anchored to the ground with staple stake at every 10m interval.

21/3.4 VALVES

Butterfly valves, Gate valves, air valves and solenoid valves shall be installed as
shown on the drawings. Installation shall be neat tidy. Valve boxes shall be
installed level and aligned with the pavement.

Cover of the valve chambers and valve boxes shall be level and aligned with
pavement as instructed by the Engineer.

21/3.5 IRRIGATION EQUIPMENT

Equipment shall generally be installed to achieve optimal irrigation efficiency and to

accommodate the requirements of the landscaping. All irrigation equipment such
as spray heads and emitters shall be installed only after all the laterals and risers
are flushed thoroughly. The half circle spray heads should be installed at least
50 cm away from kerb stone.

21/3.6 IRRIGATION CONTROL EQUIPMENT

The Contractor has to follow strictly the instruction of the suppliers and provide the
Engineer with all technical information related to this equipment.

21/3.7 TESTING

21/3.7.1 Pipeline Pressure Test

The length of test section shall be maximum 500 m or as directed by the Irrigation
Engineer. The pipe length to be tested may be blanked off using a blank iron or
steel flange previously drilled and tapped for test equipment connection and

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 34 SECTION 21 AUTOMATIC IRRIGATION

strutted as necessary against end thrust. The blank flange may be attached to the
pipeline by a V.J. flange adopter or similar fitting.

Testing should not be carried out against closed valves. All charging and testing
should preferably be carried out from lowest point of the under test section and all
testing equipment should be located at this point.

The pressure gauge also should be located at the lowest point or adjustment must
be made for the level of the pressure gauge relative to the pipes location.

Prior to testing, care should be taken to ensure that all anchor blocks have attained
adequate maturity and that any solvent welded joints included in the pipe system
have developed full strength. Correct support and anchorage of any above ground
sections of the pipeline is also necessary. Underground pipelines should be back-
filled, taking particular care to consolidate around lengths which may have been
deflected to negotiate curves.

All joints should be left exposed until testing is completed.

The main pipe should be charged slowly, preferably from the lowest point with any
air cock in the open position. They should be closed in sequence from the lowest
point only when water visibly free from aeration is being discharged through them.

Satisfactorily charged, the main should be allowed to stand overnight to allow any
residual air to settle-out. Reventing is then necessary and any water deficiency
should be made-up.

Pressure testing can then begin by pumping slowly until it reaches to 9 bar. This
pressure shall be kept for 24 hours.

A permissible water loss of 3 liters per 1000m length per 25 mm nominal bore per
24 hours shall be considered reasonable for PVC pipe.

For AC pipes the pressure test should be according the manufacturer's

recommendation.

21/3.7.2 Painting

Dry film thickness (DFT) of all painted valves and spool pieces shall be measured
on delivery to site. DFT shall be the average of no less than three measurements,
with no one measurement less than 75% of nominal average DFT. Holiday tests
shall be carried out on internal and external surfaces on delivery, and also on
external surfaces prior to back filling.

21/3.8 ROAD CROSSINGS

All crossings across major roads/dual carriageways and U-turns shall be

either through ducts or no dig method.

Where it is necessary to cross roads in order to complete the work, the Contractor
should first obtain N.O.C. from service companies and submit where appropriate

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 35 SECTION 21 AUTOMATIC IRRIGATION

for road cutting to RTA's road Department. The Contractor should follow strictly
RTA's regulations. Ducts to laid at least 100 cm below tarmac surface.

Road cutting will only be permitted if it can be shown that the horizontal drilling is
not possible because of existing services.

Properly marked drums (Red and White) and required diversion sign etc. shall be
provided during the execution of the work. If the trench is left open overnight,
proper lights and caution signs shall be provided.

Trenches to be backfilled with fine gravel around ducts to minimum depth of 50 cm.
Remaining depth to be backfilled with 50cm thick layers of Subkha properly
compacted by Rammer.

Tarmac re-instatement shall be as specified by the Municipality Roads Department.

Sketches on traffic diversion shall be provided including road signs to be used and
distances between such signs.

Only a Municipality approved sub-Contractor shall be allowed to carry out the thrust
boring or cutting and reinstatement.

All ducts should be at least 50 mm larger than pipe size.

Road crossings for the main and lateral pipes or cables should be carried out
preferably by horizontal drilling. Wherever it becomes impossible to drill because of
existing services or any other reasons acceptable by Irrigation Engineer, the road
cutting shall be done as specified above.

Any tiled area damaged during construction, drilling or road cutting should be
reinstated.

Separate ducts shall be used for irrigation pipes, electrical cables, control wires and
maxi-com signal wire.

21/3.9 THRUST BLOCKS

At each bend, diversion or at the end of pipeline, a thrust block shall be provided.
Heavy duty polyethylene sheet shall be used to wrap the pipe at the point of
contact between pipeline fittings and the thrust block. Design of the thrust blocks
shall be done by the Contractor and to be approved by the Engineer.

21/3.10 ELECTRICAL CODES

All the electrical installations shall operate at a system voltage of 380 volts AC
three phase four wire 50 cycles.

The entire works shall be carried out in strict accordance with this specification and
instruction as issued by the Dubai Electricity and Water Authority.

21/3.11 ELECTRICAL TESTS

Each electrical equipment, cable and complete system shall be thoroughly

inspected and tested before finally placing in service under the full responsibility of

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 36 SECTION 21 AUTOMATIC IRRIGATION

the Contractor. All tests shall be made in compliance with respective regulations,
recommendations and standards. Any modifications or repairs deemed necessary
upon completion of the tests shall be executed at the Contractor's expenses.
Further tests shall be carried out on any modified or repaired equipment until it is
certified trouble free and acceptable for its intended service. All testing shall be
demonstrated to the Engineer in a manner to be agreed later.

21/3.12 ELECTRICAL INSTALLATIONS

All electrical equipment under these contract documents shall have passed
adequate routine factory tests. Field tests shall be made by qualified personnel,
approved by the Engineer. The Contractor shall furnish all apparatus, material,
labour and facilities for performing the required tests. Unless otherwise specified
the individual electrical equipment shall undergo the following tests in accordance
with the IEC recommendations or other approved standards.

In Workshop:
- High voltage test
- Check on mechanical function
- Pre-test of functional sequences
At Site:
- Visual inspection
- Insulation test (megger test)
- Check of functional sequences

The Contractor shall submit to the Engineer acceptance test certificates of all tests
carried out in his workshop including all measuring data and subsequent
evaluation.

The following tests are to be carried out for all cables as a minimum:
- Resistance measurements
- Insulation test with specified AC power frequency test voltage
- Insulation resistance measurement of every individual cable length at site
- Electrical continuity test for all controls.

The following test shall be carried out upon completion of the earthing system:

- Measurement of the conductance of the earthing wires

- Measurement of the intermediate resistance of the earthing electrodes

The Contractor shall provide at his expense the necessary qualified personnel and
measuring instruments of the above measurements.

21/3.13 CONTROL PANEL INSTALLATIONS

Panels shall be installed onto concrete bases (300mm above ground level). Control
wire shall be color coded, and provided with tags. Control cable shall be bundles
and tied with a plastic cable tie at least every 5 meters, installation of cable bundles
in conduit shall be carried out in such a way as to preclude the possibility of
stretching the cable, or damaging the insulation. All cable splices shall be

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 37 SECTION 21 AUTOMATIC IRRIGATION

waterproof, and made inside valve or conduit boxes, leaving at least one meter of
spare cable neatly coiled at each joint, and bend.

Panels shall be individually earthed by an approved copper clad grounding rod

minimum length 15 mm x 3 meter rod driven down into the water table and
connected to the controller by a brass clamp and a 4 mm2 grounding wire as per
DEWA and engineer approval.

All stages of the control system installation shall be supervised by a factory-trained

engineer, recommended by the manufacturer who has previously been in charge of
all aspects of installation of a similar control system and approved by the engineer.

21/3.14 SATELLITE CONTROLLER INSTALLATIONS

The field satellite controllers shall be installed near the Pump/Filtration Chamber.
Controller shall be installed on the concrete bases (300mm above ground level)
and shall be in pedestal enclosure as specified, control wire shall be color coded,
and provided with tags.

Control cable shall be bundles and tied with a plastic cable tie at least every 5
meters, installation of cable bundles in conduit shall be carried out in such a way as
to preclude the possibility of stretching the cable, or damaging the insulation.

All cable splices shall be waterproof, and made inside valve or conduit boxes,
leaving at least one meter of spare cable neatly coiled at each joint, and bend.

Controllers shall be individually earth grounded by an approved copper clad

grounding rod minimum length 15 mm x 3 m rod driven down into the water table
and connected to the controller by a brass clamp and a 4 mm grounding wire as
per DEWA and Engineer approval. Decoders, encoders, and terminators shall be
installed in plastic valve boxes, and their function and reference number shall be
clearly indicated in indelible ink.

All stages of the control system installation shall be supervised by RAIN

BIRD REPRESENTATIVE IN DUBAI AND THE LOCAL DISTRIBUTOR.

21/4 AUTOMATIC IRRIGATION SYSTEM, COMMISSIONING

21/4.1 FLUSHING

See section 8/3.

21/4.2 FIELDWORK

Commissioning of fieldwork and equipment shall include all works required to bring
the system into service, and to make sure that it is operating efficiently, and shall
include but not be limited by the following:-

1. Adjust valve outlet pressure +/- 10% of nominal.

2. Measure head loss from first to last sprayer in up to 50 different cases.

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 38 SECTION 21 AUTOMATIC IRRIGATION

3. Adjust sprayer to ensure spray onto pavement and paths is minimized.

Replacing any spray nozzles that have uPVC burrs, or sand lodged inside.
Adjust spray patterns to ensure optimal coverage.

4. Ensure that all sprayers and valve boxes are flush with the finish grade.

5. Replacing any clogged or partially clogged emitters(delivering less than 50% of

nominal flow) or any emitter overflowing by more than 50% (squirting).
Carrying out emission uniformity test involving at least 40 emitters on up to 10
valves, as directed by the Engineer.

6. Controllers shall be adjusted to give an optimal flow regime, generally in

accordance with the drawings and as instructed by the Engineer. Valves
sequence may be modified to ensure that valves operate in a logical sequence
to facilitate maintenance operations.

7. Irrigation cycles for sprinklers and sprayers should be programmed during night
time and early morning (from 12 mid night up to 5 am).

A full cycle shall be run four times, and total system flow rates shall be recorded,
and stations shall be adjusted in accordance with the instructions of the Engineer,
base on the results of these trials.

Trials shall only be carried out after all valve's pressure have been adjusted. During
these trials main line head losses shall be verified by installing pressure recorder at
the start and the end of the main line.

21/4.3 IRRIGATION CONTROL SYSTEM

Three standard irrigation schedules shall be developed in accordance with the

requirements of the Engineer, and tested per controller schedule as above. Each
particular function of the system shall be demonstrated in accordance with an
approved commissioning procedure developed by the Contractor.

21/4.4 OPERATION AND MAINTENANCE MANUAL

Operational and maintenance manuals shall be prepared and submitted for

approval in draft form prior to commencement of commissioning. Manuals shall
contain comprehensive operational schedules, recommended spare parts list,
manufacturers' operating data, Catalogues and exploded parts diagrams where
applicable for the entire irrigation scheme. The materials used for the system shall
be listed in the manual.

Manuals shall be revised in accordance with Engineers instructions, and reflect,

and record the results of the commissioning procedures described above. Three
bound copies of the manual shall be delivered to the Engineer prior to the
date of substantial completion certificate issuing.

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21/4.5 AS-BUILT DRAWINGS

The Contractor must submit As-Built drawings for all works included in this
contract. Completion certificate will not be issued unless the contractor submits the
As-Built drawings.

Three complete set of "As Built" drawings along with a negative and all diskettes
should be submitted before handing over of the project.
All As-Built drawings to be of DM Drainage and Irrigation Department
Standard size and prepared using MICROSTATION FOR WINDOWS VERSION
5.5 OR LATEST). As built of Mainline Layouts to be prepared on DM Survey
sheets (scale 1:1000) as per the requirements of DM Drainage & Irrigation
Department.

Note : Contractor to check and include all existing irrigation system (along
with existing filtration chambers) in the as-built drawings

21/5 IRRIGATION SYSTEM, CIVIL WORKS

The civil works of the project shall be carried out by Main contractor or an
approved sub-contractor as per general specifications of Dubai Municipality
and subject to approval of the Engineer.

21/5.1 EARTHWORK AND EXCAVATION

21/5.1.1 Pre-Excavation

a) Excavation site shall be surrounded by new painted fence of corrugated

galvanized or plywood sheets. Fence sides shall be properly supported, such
supports shall not project outside the site.

b) Contractor shall check with all the concerned Service Authorities for any existing
buried plants inside the excavation site. Contractor shall be responsible for any
damages of service plants caused by excavation.

c) Ground levels shall be agreed at suitable intervals with the Engineer.

d) Top soil and other surfacing materials shall be stopped and stored separately
from the subsoil. Subsequent spreading of top soil shall be as directed on site.

21/5.1.2 All excavated material shall be deposited so that it will cause as little damage and
inconvenience as possible. Different classes of material shall be handled and
deposited separately.

21/5.1.3 Excavated material for use as back-fill shall be as approved, and shall be kept in a
suitable safe place and surrounded by a suitable fence as directed by the Engineer.

21/5.1.4 Where ordered if necessary for reasons of limited access or any other reason,
excavation shall be carried by hand.

21/5.1.5 All excavation shall be kept free of water. In addition, precautions shall be taken to
prevent floatation of partly built structures, completed structures to be filled on

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 40 SECTION 21 AUTOMATIC IRRIGATION

commissioning of the works and unback-filled pipelines. All necessary precautions

shall be taken to prevent any adjacent ground from being adversely affected by
loss of fines through any dewatering process.

21/5.1.6 The sides and or the bottom of excavation shall be adequately supported.
21/5.1.7 Back-filling shall be carried using selected excavated materials and in layers not
greater than 150 mm thick (compacted thickness) and compacted such that
throughout each layer placed the dry density is not less than 95% of the site dry
density of the soil prior to excavation. If directed by the Engineer, Back-filling shall
be tested to ensure the specified compaction.

21/5.1.8 All surplus material shall be either spread on site or shall be removed and disposed
off the approved Municipality tips, immediately after excavation as directed by the
Engineer.

21/5.1.9 In case of extra excavation deeper than the level required by the Engineer,
Contractor shall fill the same with selected well-compacted material or plain
concrete as directed by the Engineer.

21/5.1.10 Excavation to the required level shall be carried out by the contractor as part of the
contract regardless of the kind of soil strata or rock to be excavated.

21/5.1.11 Contractor shall bear the responsibilities and consequences of any damage
caused by the excavation to the adjacent structures, roads or plants.

21/5.1.12 Contractor shall take all the necessary precautions at the excavated sites to
protect his own staff, Engineer's representative, site visitors, pedestrians, traffic
movement by supporting excavation sides, providing proper guard rails fences,
cones, warning tapes and traffic signs, and by keeping 24 hrs. guard attendance to
all excavated locations.

Contractor shall bear all the legal responsibilities in case of accidents caused by
lack of safety precautions.

21/5.2 CONCRETE

21/5.2.1 General

a) All materials forming the concrete mix shall be approved by the Engineer.

b) Complete detailed design of all the reinforced concrete structures shown on

drawings shall be carried out by the Contractor following the relevant British
Standard. Drawings and calculation shall be submitted to the Engineer and
subject to his approval. However, it shall be understood that the Engineer's
approval of the design and calculation does not release the Contractor from his
responsibility in case of any structural failure due to design faults.

c) The Contractor may use premixed concrete from an approved source.

d) Concrete used shall conform to the following (Table 21-3):

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 41 SECTION 21 AUTOMATIC IRRIGATION

Table 21- 3 Properties of concrete

PROPERTY GRADE
A B
Nominal max aggregate size 20 20
Cement content kg/m3 (min) 370 300
Cement content kg/m3 (max) 400 400
Water Cement ration (max) 0.45 0.45
Min mean cube strength N/mm2 35 25
Fine aggregate/coarse aggregate 35 35

e) Immediately following the land excavation to formation level for floor where
shown on the drawing or as ordered by the Engineer, a sealing coat of 75 mm
minimum thickness of concrete grade "c" shall be placed on polyethylene sheet
(1000 gauges) placed on the surface of the formation a carefully spade finished
to an even surface floors shall be laid on the sealing coat as soon as may be
practicable and if required by the Engineer, the sealing coat shall be kept
thoroughly damp by watering.

f) Unless tolerances for particular surfaces are specifically shown on drawings,

they shall be as follows:
1) FLOORS: The level of the surface at any point shall be plus or minus 5 mm of
the level desired from drawings.
2) WALLS: The position of the face at any point shall be within 10 mm of its
position desired from the drawings. There shall be no irregularity exceeding 3
mm in 3 meter template.
3) CURVED SURFACES: Shall be within plus or minus 2 mm of the level desired
from the drawings.
g) Concrete shall not be placed when the sheds temperature exceeds 40 degrees
C.

The temperature of batched concrete at time of placing shall not exceed 30

degrees C.

21/5.2.2 Materials

a) AGGREGATES:

Coarse aggregate shall consist of crushed stones free from salt and clay or any
other materials harmful to the concrete such as organic, coal, mica, gypsum and
fines. In any case the percentage of fines shall not exceed 1% of the dry weight.

Fine aggregate shall consist of Natural Sand with hard grains of any other similar
inert material. Sand shall be free from organic, salts, clay, mica and fossils. It shall
also be sieved and washed. Percentage of Sulphate and Chloride in aggregates
shall not exceed the figures listed in Table 21- 4 below:

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Table 21- 4 Chloride & Sulphate content in concrete

Type of Specification
Cement Used Standard
Test Concrete Fine Coarse
Reinforced SRC 0.03% max 0.01%
concrete BS 812: max
OPC & SRPC P 117: 0.03% max 0.02%
1988 max
Mass Concrete SRC 0.03% max 0.02%
Acid sol.
max
Chloride
OPC & SRPC 0.03% max 0.04%
max
Pre-stressed
& Steam cured 0.03% max 0.01%
concrete max
Acid sol. BS EN
Sulphat Any Any 1744,Par 0.3% max
e t1:1998

Aggregates shall be protected from contamination to the Engineer's approval.

b) CEMENT:

Cement shall be supplied from approved factories in closed bags. In case of bulk
cement supply, it shall be delivered using special containers for the same purpose.
Cement shall always be accompanied with its origin certificate showing its test
results and date of manufacture.

When stored on site, cement shall be kept in a dry place raised above the floor and
not touching the walls of the store. It shall not be allowed to use the cement which
is more than 4 months old, nor that which has hardened in the form of grains
regardless of its age.

Ordinary Portland Cement shall be used for all concrete works unless it is
otherwise specified in any of the contract documents.

c) WATER:

Water used for the concrete mix and aggregate washing and cleaning of formwork
and curing of cast concrete shall be potable water. In any case it shall comply with
the following conditions:

1) Should be clean and free from oil, organic, metals, acids and bases.

2) Should not contain more than 600 mg/l of Chlorides or 500 mg/l of Sodium
Sulphate.

3) PH should be between (7-9).

4) Should not contain more than 0.25% by weight of suspended solids.

5) Chemical limitations for mixing water should be as follows:

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 43 SECTION 21 AUTOMATIC IRRIGATION

Table 21- 5 Chemical requirements for mixing water

SL. No Max. Concentration Limit, ppm Test Method

1) Chloride as Cl 250 ASTM D512

2) Sulphates as SO4 350 ASTM D516

3) Alkali carbonates and 500 ASTM D513

bicarbonates
4) Total dissolved solids, 2000 BS1377: Part 3:Test
including 1, 2 & 3 above 8

5) PH min.7/max. ASTM D1293

9

In general, mixing water shall not contain any harmful materials which are sufficient
to change the concrete setting time by more than 25% or to decrease the concrete
compressive strength by more than 20% of that which is made of distilled water.

d) ADMIXTURES:

Concrete admixture shall be used in case it is specified in any of the contract

documents. In case the Contractor requires to use any of them (such as plasticizer
and retarders), it shall be subject to the Engineer's approval who might require a
modified concrete mix design to suite the used admixture.

e) REINFORCING STEEL:

Reinforcement shall be epoxy coated and free from rust or other extraneous
matters. They shall be cut and placed as detailed in the drawings and as approved
by the Engineer.

21/5.3 CONCRETE MIXING

Concrete shall be mechanically mixed until getting a homogeneous viscosity and

colour mix. Mixing time shall not be less than two minutes or twenty revolutions of
the mixing machine or which ever is greater. Mixing time is considered to start
when all the contents of the concrete mix including the mixing water are loaded
inside the mixer. Concrete mix unloading shall be carried out in such a way that
will not cause separation of the mix contents.

21/5.4 CONCRETE TESTING

Contractor shall make the standard concrete cubed and test them as directed by
the engineer for all the structural concrete elements.

Number of cubes and method of their making and testing shall comply with the
relevant British Standard.

21/5.5 TRANSPORTATION

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 44 SECTION 21 AUTOMATIC IRRIGATION

In case of pre-mixed concrete, the concrete shall only be transported to the casting
site, using special containers equipped for the same purpose to prevent the
separation of the materials forming the concrete mix.

21/5.6 CASTING OF THE CONCRETE

Concrete casting shall always be subject to the written approval of the Engineer on
the reinforcing steel and suitability of the concrete mold and formwork and
supports. Reinforcement and mold shall be sprayed with water prior to casting. It
shall not be allowed to cast the concrete which was mixed before more than 30
minutes unless plasticizing agents are used, in such cases the time allowance shall
be decided by the Engineer.

21/5.7 CONCRETE COMPACTION

All concrete works shall be compacted during casting using mechanical vibrator.
Care shall be taken so that the vibrator's rod does not touch the reinforcements or
the mold. In any case, the cast concrete which has started setting should not be
distributed as a result of casting or working nearby.

21/5.8 CURING OF THE CONCRETE

Exposed concrete surfaces shall be completely covered with polyethylene sheeting

immediately after placing and within two or three hours this shall be quickly
replaced by wet hessian covered with polyethylene. The hessian shall be wet
damp continuously using water for a period of at least 7 days or such period as the
Engineer may direct. Approved curing compounds may be applied earlier to
supplement use of wet hessian and polyethylene.

21/5.9 MOVEMENT AND CONSTRUCTION JOINTS

21/5.9.1 Movement joints or construction joints in concrete shall be provided as directed by

the Engineer.

21/5.9.2 Water Bars shall be manufactured of extruded PVC or of nitrile rubber. They shall
be of the types and general shape indicated on the drawings and shall have the
minimum characteristics:

DENSITY: 1300 Kg/m3

TENSILE STRENGTH (25 degree C): 13.7 N/mm2

ELONGATION AT BREAK (25 degree C): 285%

WEB THICKNESS: 10 mm

DIMENSION OF CENTRAL BULB: 18 mm

Water bars shall not be displaced during the placing of concrete which shall be fully
compacted around them. Jointing of water bars shall normally be carried out by
clamping and welding or adhesion and shall be in accordance with the
recommendations of the manufacturer. Water bars shall be arranged so that there
is a minimum distance of 25 mm from the water bars to the reinforcement.

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21/5.9.3 Joint fillers shall be utilized as directed by the Engineer.

21/5.10 DEFECTIVE CONCRETE WORKS

21/5.10.1 Unless tolerances for particular surfaces are specifically shown on drawings, they
shall be as follows:

FLOORS: The level of the surface at any point shall be plus or minus 5 mm of
the level desired from drawings.

WALLS: The position of the face at any point shall be within 10 mm of its position
desired from the drawings. There shall be no irregularity exceed 3 mm in to 3 m
template.

CURVED SURFACES: Shall be within plus or minus 2 mm of the level desired

from the drawings.

21/5.10.2 As directed by the Engineer, contractor shall repair or demolish and re-build the
concrete works which had any concrete quality or dimension or reinforcement or
segregation defects, or any other defects that the Engineer might decide they
cause the concrete to be unsatisfactory to its required purpose. In case of repair, its
method and results shall be subject to the Engineer's approval.

21/5.10.3 Where required by the Engineer, the Contractor shall fill cracks which have
developed in concrete structures using an approved resin based sealing
compound. Method of injection may include pressurized injection techniques.

21/5.11 FORM WORK AND SUPPORTS

21/5.11.1 Formwork shall be designed and constructed so that the concrete can be placed
and compacted without disturbing or displacing the reinforcement. It shall be firmly
supported, braced, guyed or tied back so that it is stable against vertical and
horizontal formwork. Internal spacers and ties shall be of approved types that do
not produce holes completely through the concrete. Joints in the formwork should
be close fitting to prevent leakage.

The arrangement shall allow for removal of formwork from the sides and members
without disturbing soffit formwork. Rough faced formwork may be used for surfaces
which are normally never exposed to view.

Formwork shall be designed so that splays, fillets, chamfers and projection are cast
as the work proceeds. Unless specifically deleted all external angles on exposed
concrete shall have a 25mm x 25mm chamfer.

Before placing concrete all extraneous material shall be removed from the interior
of the formwork and the faces in contact with the concrete shall be wetted or
treated with a non-staining composition to prevent adhesion.

Concrete shall be placed in the formwork only after examination and approval of
the formwork by the Engineer.

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 45

 46 SECTION 21 AUTOMATIC IRRIGATION

21/5.11.2 Formwork shall not be struck until the structure has attained sufficient strength and
in no case less than the period given below:

BEAM SIDES, WALL, COLUMNS: 2 days

SOFFITS TO SLABS OR BEAMS (props left under): 5 days
PROPS TO SLABS OR BEAMS: 10-14 days

21/5.11.3 CONCRETE SPACERS AND COVERING BLOCKS The minimum possible

number of concrete spacers and covering blocks which provides the concrete
covers for the reinforcing steel, shall be made of concrete which has same
compressive strength of that to be cast.

21/6 SWEET SOIL FILLING, CONTOURING AND PLANTATION

21/6.1 SWEET SOIL FILLING.

The Contractor has to refer to the landscaping drawings and levels shown on
landscape drawings. Sweet soil finished level shall be generally 100mm below top
of kerb. The minimum acceptable depth of sweet soil filling is 500mm.

Contractor to make tree pits and fill them with fresh sweet soil. The size of tree pits
to be as follows:

Pits for Date Palms: 2m X 2m X 2m

Pits for Ornamental trees: 1.5m X 1.5m X1.5m
Pits for shrubs: 1m X 1m X 1m

THE EXISTING SWEET SOIL SHOULD NOT BE USED FOR FILLING THE TOP
500mm LAYER AND TREE PITS.

Sweet soil shall be collected from DM’s pit in Khawaneej or any approved source.

The Contractor shall modify the existing manhole chamber levels (if required) in
order to match the proposed landscape levels.

21/6.2 CONTOURING

The Contractor has to level the landscaped areas and bring it to the contours as
shown in the landscaping drawings. The contractor shall make arrangements to
prevent the loss/ drifting of soil due to wind. The contractor will be responsible for
maintaining the levels and contours of the sweet soil through project completion

21/6.3 GRAVEL

The Contractor has to use cream white crushed gravel size 20mm to fill the areas
as shown on landscape drawings. Depth of filling with gravel shall be at least 10 cm
.
21.6.4 POLYETHYLENE EDGER (N/A)

The edger shall be manufactured with polyethylene having a 3.5% - 4% carbon

black concentrate added for UV stabilization and medium density with a melt factor
under 2. Minimum average wall thickness shall be 95/1000 to 105/1000 of an inch.

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 46

 47 SECTION 21 AUTOMATIC IRRIGATION

Overall height shall be 5 inches minimum. Edger shall have horizontal grooves and
steel anchoring stakes.

21/7 ANCILLARY WORKS (Not applicable)

21/7.1 PAVING DESCRIPTION

This works shall consists of covering certain areas (Top of filtration chamber and
1.0 meter around and 0.6 metre wide strip by the side of road kerbs all around
landscape areas) with paving blocks and heel kerbs in accordance with
specifications, the drawings and Engineer’s instructions.

21/7.2 PAVING BLOCKS

Paving blocks and heel kerbs shall be as per D.M. Roads Department standard
Specification.

Paving blocks shall be concrete blocks, coloured where specified, laid on sand
laying course. Their thickness shall be 6 cm on side walks unless otherwise shown
on the drawings or instructed by the Engineer.

21/7.3 OVERALL REQUIREMENTS FOR PAVINGS BLOCKS

The materials, dimensions and tolerances, test for comprehensive strength, test for
water absorption and certificate of compliance for the paving blocks shall conform
to the requirements of Local Order of 44/90. Water absorption and abrasion
resistance shall be carried out in accordance with the requirements of particular
specifications.

21/7.4 BLOCK LAYING REQUIREMENTS

21/7.4.1 Laying Course

The laying course shall consists of sharp black sand containing not more than 3%
silt and clay by weight and not more than 10 % retained on 4mm sieve. The sand
shall be obtained from single source, allowed to drain before use and shall be
covered with suitable sheetings to minimize moisture changes. Permissible
sulphate (as SO3) and chloride (as Cl) shall not exceed 0.3% and 0.5%
respectively (expressed as a percentage by weight.).

The profile of laying course before compaction shall be similar to that of finished
surface. During laying, the sand shall be in uniform moisture content and screened
carefully., screened to form smooth compacted surface to receive the paving
blocks. The maximum deviation from design shall be 5 mm.

The edge restrained to the paved areas shall be laid in advance of the laying
course and all permanent obstacles within the area, such as manhole covers shall
be adjusted to the correct finished levels.

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 47

 48 SECTION 21 AUTOMATIC IRRIGATION

21/7.4.2 Surface Course

The paving blocks shall be laid on sand laying course in such a manner as not to
disturb the blocks already laid. Each block shall be placed firmly against its
neighbour so that they fit closely together. The joints between the blocks shall not
exceed 3 mm. Laying of paving blocks shall commence at right angles to the main
pavement axis starting at one end of the area.

The paving blocks shall be laid in a herringbone pattern unless otherwise shown
on the drawings or instructed by the Engineer at 45 degrees to main pavement
axis.

Where blocks do not fit the edge restraints or other obstructions such as manholes
or upstands the gaps shall be filled using cut blocks.

Blocks shall be cut only by using a mechanical block splitter.

Dimensional accuracy, uniformity of joint gaps alignment and squareness shall be

checked after laying the first three layers of the blocks and thereafter at regular
intervals. If joints begin to open, the blocks shall be knocked together using a hide
mallet.

After every 20 sq. m or such areas that has been agreed with the Engineer, has
been laid the blocks shall be compacted to the required levels using plate vibrator.

The plate vibrator shall have a plate area of .2 to 0.35 sq. m. and have compaction
force of 12-24 KN and a frequency of approx. 75 to 100 hz.

A minimum of two passes of plate vibrator shall be made in each direction i. e. at

90 deg to each other. Vibration shall continue until no further compaction of sand
layer is apparent. The laying course shall have compacted thickness of 50 mm.
Fine dry sand with particle size of 0.3 mm shall be then brushed over paving. And
further passes of plate vibrator shall be made in each direction, until sand is no
longer absorbed in the joints.

The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.

No paving shall be left uncompacted overnight except for the 1m strip at the
temporarily unrestrained edge.

On compaction the finished surface level shall be within 5 mm of the design level
and maximum deviation within the compacted surface, measured by 3 m straight
edge shall not exceed 3mm. The level of any two adjacent blocks shall not differ
more than 3 mm. Any areas of paving which do not comply with these tolerances
shall be removed. The sand laying course adjusted and paving blocks re-laid to
the correct levels.

21/7.4.3 Kerbs Description

This work shall consist of the construction of kerbs in accordance with

specifications and in conformity with the lines grades and typical sections shown

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 48

 49 SECTION 21 AUTOMATIC IRRIGATION

on the drawings or established by the Engineer. These specifications refer to the

following types of precast kerbs to be constructed: Non mountable Kerbs,
Dropped kerbs, Heel kerbs, Quadrants and Flush kerbs. All kerbs and edgings
shall be hydraulically pressed and shall comply with the requirements of BS7263
Part 1. They shall be uniform in colour, free from cracks, flaws or other defects
and they shall have well defined arises.

21/7.4.4 Materials and Manufacture of Kerbs

Materials shall confirm to the requirements specified in part 4 “concrete” of the

specifications and as specified here in.

As per RTA Roads Department standard specification, the Kerbs shall be

prepared with a concrete mixture containing not less than 400 kg/m3 of sulphate
resisting Portland cement. The aggregate shall meet the requirements of the
General Specifications and confirm to the required gradation.

Volume 2, Part 2, General Specifications-Services Works March 2017 Page 49

 ANNEXURE A – RTA ROADS SPECIFICATIONS

APPENDICES

February 2022 Page 1/1

 VOLUME 2, PART 1 - GENERAL SPECIFICATIONS

Appendix A
Laboratory Testing

March 2019 Page 1/1

 ANNEXURE A, PART 1 – RTA ROADS SPECIFICATIONS

APPENDIX “A”

LABORATORY TESTING

Testing of all materials and completed work shall be carried out in accordance with DM
Administrative Decision No. 160/2000:

1. Dubai Municipality — Dubai Central Laboratory (D.C.L) in accordance with

Appendix “Al”.

2. Independent Laboratory in accordance with Appendix “A2”.

March 2023 Page A/1

 ANNEXURE A, PART 1 – RTA ROADS SPECIFICATIONS

APPENDIX “Al”
(1) TESTING AT DUBAI MUNICIPALITY -Dubai Central Laboratory Department
(DCLD)

1.1 All transportation of personnel and materials on site and to/from the DCL shall be
borne by the contractor. Suitable approved transport with driver shall be
maintained for this specific use by the Contractor.

1.2 The contractor shall pay for all the tests carried out by the DCL.

1.3 Any testing which is required under the contract which cannot be carried out by
the DCL shall be carried out at Contractor’s expense at an Independent
Laboratory in accordance with Appendix “A2”. Copy of such sampling and testing
reports shall be forwarded to the DCL and to the DM Department concerned for
information not later than a week from the date of the issuance of the reports.

1.4 The testing of the works by the DCL shall in no way absolve the contractor from
his responsibilities to carry out his own job control testing of the quality of his
work and the materials used.

1.5 Representatives of the Consultant and the Contractor shall be permitted to witness
the testing carried out by DCL.

1.6 DCL will not be held liable for interpreting test data, since this will be the
responsibility of the Consultant.

March 2023 Page A/2

 ANNEXURE A, PART 1 – RTA ROADS SPECIFICATIONS

CONTINUATION OF APPENDIX “Al”

1.7 All sampling for such tests shall be earned out by the Consultant’s Representative
and labeled as per relevant standard sampling requirements and submitted by the
Consultant to DCL along with the sampling reports.

1.8 The Contractor shall submit to DCL Monthly Laboratory Testing Program. The
program shall detail the specific test requirements for the coming month which
includes the type, number and approximate date that testing will be required.

1.9 Minimum twenty-four (24) hours notice shall be given to DCL before any tests are
scheduled to be carried out.

1.10 The Consultant shall inform DCL and RTA/DM Department concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.

March 2023 Page A/3

 ANNEXURE A, PART 1 – RTA ROADS SPECIFICATIONS

APPENDIX “A2”
(2) TESTING AT AN INDEPENDENT LABORATORY.

2.1 Any testing which is required under the contract and as detailed in DM
Administrative Decision No. (160) for year 2000 may be carried out at the
Contractor’s expense at an approved Independent Laboratory, provided this
laboratory meets the following requirements.

2.1.1 Independent laboratories that operate in Dubai Emirate shall meet all the
requirements of DM rules and regulations including DCL accreditation
requirements.

2.12 Independent laboratories that operate outside Dubai Emirate shall be accredited to
one of the National Accreditation Systems for laboratories such as UKAS, NATA,
etc. The Contractor shall forward a copy of the accreditation certificate to DCL for
approval prior to approaching such laboratories for testing services.

2.2 All sampling for such tests shall be carried out by the Consultant’s Representative
and labeled as per relevant standard sampling requirements and submitted by the
Consultant to the independent laboratory along with sampling reports.

2.3 Representatives of the Consultant and the Contractor shall be permitted to witness
the testing carried out by the independent laboratory.

2.4 The testing of the works by the independent laboratory shall in no way absolve the
Contractor from his responsibilities to carry out his own job control testing of the
quality of his work and the materials used according to the contract specifications.

March 2023 Page A/4

 ANNEXURE A, PART 1 – RTA ROADS SPECIFICATIONS

CONTINUATION OF APPENDIX “A2”

2.5 The Consultant shall inform D.C.L and RTA/DM Department concerned of all
failed test results along with his course of action in addition to submission of
compliance materials testing reports.

2.6 The independent laboratory shall give original copies of the sampling and testing
reports to the Consultant and copies to:

2.6.1 RTA / DM Department concerned

2.6.2 DCL

2.6.3 Contractor

2.7 The independent laboratory shall divide non - destructive samples into four
representative sub-samples:

Part “A” : to be tested by the independent laboratory;

Part “B” : for RTA / DM Department concerned/Consultant Recheck;

Part “C” : for independent laboratory internal quality control;

Part “D” : for DCL Cross-check.

2.8 Contractor shall enter into an agreement with an independent laboratory. This
agreement shall include all conditions as detailed in appendix “A2”

2.9 Any material requiring certification as per DM regulation shall not be used unless
certified by DCL.

March 2023 Page A/5

 VOLUME 2, PART 1 - GENERAL SPECIFICATIONS

Appendix B
Schedule of Engineer’s
Office and Equipment

March 2023 Page 1/1

 Appendix B, PART I – RTA Roads Specifications

Appendix B -Schedule of Engineer’s Offices and Equipment.

C.1 GENERAL

The Contractor shall supply, erect and maintain in good repair (inclusive of daily cleaning)
site offices to the satisfaction of the Engineer and his staff. The office, access roads and
hard-standing together with equipment, furnishing, fittings and supplies as indicated in the
appropriate appendix hereto shall be ready for occupation not later than one week before
any temporary or permanent works commence, and will be required during the currency of
the works and for up to 1 month after completion of the works. On completion of the
Contract it shall revert to the ownership and responsibility of the Contractor.

The Contractor shall bear all expenses incurred, no matter of what nature, by the Engineer
due to the failure of the Contractor to complete and hand over to the Engineer the office or
any of their fittings, furniture and equipment within the stipulated period.

The Employer will provide free of charge area of land shown on the drawings for the
location of the Engineer’s office and compound. The Contractor’s own offices may also be
located on the land provided but no workshops, stores, fabrication or manufacturing
facilities will be permitted therein.

All utilities necessary for operating the engineer’s office shall be supplied by the Contractor
including provision of power, hot and cold water supply, sanitary fittings and drainage
connections.

The Contractor shall ensure an uninterrupted supply of water and power to the office and
the electrical installation shall provide for simultaneous use of all electrical appliances. The
drinking water supply shall be to the satisfaction of the appropriate Health Authority and the
Engineer.

The Contractor shall take measures for the disposal and treatment of sewage from the
office and by means of enclosed underground tanks sufficient in number and size and shall
further take care of the regular disposal of the contents of the tanks and domestic water
from the office.

The Contractor shall bear all installation, rental, recurring and removal charges and
expenses related thereto including payment for electricity, fuel and water used.

The Contractor shall provide supplies of consumable materials such as general office
equipment, stationery, and refreshments, pegs, paint, brushes and other similar items as
directed by the Engineer.

The Contractor shall provide within the office a dry process photocopying machine capable
of producing A3/A4 sizes together with all spares and maintenance etc. for the exclusive
use of the Engineer.

The Contractor will provide 3 no. 7 seats, brand new 4 x 4 vehicles to full Gulf Specification,
full maintenance, insurance, registration, salik and fuel for the duration as stated above. On
handover of the project the vehicle will revert to the ownership of the Contractor. (To be a
Toyota Land Cruiser or similar to the approval of Engineer.)

The Contractor shall install in the Engineer’s office a telephone/intercom system with 3
external lines together with G3 compatible telefax machine on an additional line. The
Contractor shall make due allowance within the appropriate item in the Bill of Quantities for
the cost of telephone calls within the U.A.E.

The Client shall be the owner of the software and all licenses should be registered in the
name of Client. The Contractor is responsible for providing all software updates during the
contract period at no expense to the Client.

Page B| 1
September 2022
 Appendix B, PART I – RTA Roads Specifications

The Contractor shall provide network switches 100 base cache certified structural cabling
system for the workstations and servers and peripheral devices, 100 mbs 24 port giga
switches. Contract shall also include 5 no port switches for peripheral devices including
configuration, set and maintenance of a secure internet / intranet security system.

All software shall be legal as per local and international copyright regulations. Contractor
shall provide original license / registration details of all software and allow for a fire proof
cabinet at site to safely store all the information technology details, media and other
information. Software for the server have to be as per the specs.

The Engineers office shall have a floor area and the number of working rooms and utility
rooms as indicated in Appendix C hereto. Shaded parking areas for 12 No vehicles shall
be provided adjacent to the office for the Engineer. The Contractor shall include for
cleaning the Engineer’s offices and washing of vehicles.

The Contractor shall provide for the whole duration of the Contract, 1 nos. four wheel drive
double cabin vehicle with qualified driver including all running and maintenance costs, for
the sole use of the Engineer’s site staff to assist with performing all material testing and site
inspections. The condition of the vehicle shall be excellent and not more than 2 years old.

The Contractor shall be responsible for the security of and the insurance of the office and
contents and for all plans, documents, paper, and other articles contained therein.

The area of the office shall be properly fenced off with gates to the satisfaction of the
Engineer.

Upon completion of the whole of the works, the Engineer’s office complete with all fittings
and facilities thereto including sewage and waste water disposal facilities, shall become the
property of the Client and be removed and the site made good.

C.2 CONSTRUCTION OF OFFICES

All materials for the office shall be new and shall have the approval of the Engineer. They
shall comprise prefabricated proprietary units supported on steel skids mounted on
concrete plinth foundations. The external walls shall be weather and dust proof and shall
be baked enameled sheet metal galvanized internally with polyurethane foam insulation
and with an internal face of decorative plywood.

Roofing shall be insulated with a minimum of 50 mm rigid polyurethane and shall be fully
weatherproofed.

Flooring should be of 18 mm ply covered with vinyl sheet and to be insulated by 30 mm

polyurethane with 6 mm ply backing.

Windows shall be pre-glazed with 6 mm glass with frames of anodized alloy with blinds or
shading to those windows affected by sun. All windows shall be fitted with fly-screens.

All units shall be prewired for lighting, power outlets and air conditioning and pre-plumbed
where necessary.

This office shall be equipped with air conditioners capable of maintaining a temperature
differential of 250 C against ambient air temperature. Canopies at least one metre wide
shall extend round the full perimeter of the building.

The Contractor shall provide the office with equipment listed in Appendix C. The
equipment shall remain the property of the Contractor.

Alternative materials and construction for Engineer’s office from those specified may be
permitted provided they are adequate for their intended purpose and of an equivalent
standard to those specified.

Page B| 2
March 2023
 Appendix B, PART I – RTA Roads Specifications

SCHEDULE OF PERMANENT OFFICES FOR THE ENGINEER

The space requirements for the Engineer’s office are as follows: -

Room Description Size Requirements

No.

1. Client Representative 6m x 4m Yes (plus

Toilet)
2 Resident Engineer / Construction Manager 6m x 4m Yes (plus toilet
with shower)
3. Conference Room 8m x 4m Yes
4. Assistant Resident Engineer 4m x 4m Yes
5. Mechanical / Electrical Engineer 4m x 4m Yes
6. Safety Engineer 4m x 4m Yes
7. Civil Engineer / Planner 4m x 4 m Yes
8. Materials Engineer 4m x 4 m Yes
9. Quantity Surveyor 4m x 4m Yes
10. Land Surveyors / Site Inspectors 8m x 4m Yes
11. Material Inspectors 4m x 4m Yes
12. Document Controller 6m x 4m Yes
13. Toilet (European type) 4m x 2m Yes x 3
14. Shower 2m x 2m Yes
15. Kitchen with attached store room 4m x 4m Yes
16. Filing room (shelving as required) 4m x 4m Yes
17. Prayer Room 4m x 4m Yes

Page B| 3
March 2023
 Appendix B, PART I – RTA Roads Specifications

FURNISHINGS FOR THE ENGINEERS OFFICE

Main items of equipment to be provided by the Contractor to the approval of the Engineer. The list
is not limiting and the Contractor shall provide such further items of equipment as the Engineer may
require for the proper functioning of the offices:

Quantity Required

Description Room Nos.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
a. Executive desk with
1 1 - - - - - - - - - - -
four locking drawers
and swivel chair &
conference table
with 4 chair
b. Not used - - - - - - - - - - - - -

c. Conference table - - 1 - - - - - - - - - -

d. Desk with two

- - - 1 2 1 2 1 1 6 3 2 -
locking drawers plus
side table and
revolving chair
e. Chair cushioned -
2 2 12 2 4 2 4 2 2 6 3 2
with steel frame
f. Typist desk and - - - - - - - - - - - -
chair
g. A0 size drawing
- 1 - - - - - 1 - - - - -
board with parallel
motion, stand and
stool
h. Inclined plan table or
- 1 - - - -
large laying out table
for drawings
j. Six drawer plan
1 1 - 1 - 1 2 1 1 - - - -
chest or drawing
hanger (A1 size)
k. Samples cupboard - - - 1 - 1 - 1 - - 1 - -

l Four drawer
1 1 1 1 2 1 2 1 1 6 2 4 -
lockable steel filing
cabinets

m. Shelving pin boards

AS REQUIRED ON SITE
and book cases
n. In/Out tray 1 1 - 1 2 1 2 1 1 6 3 2 -

o. Four tier filing tray 1 1 - 1 1 1 2 1 1 6 3 2 -

p. Waste paper basket 1 1 1 1 2 1 2 1 1 6 3 2 -

q. Telephone handset 1 1 1 1 2 1 1 1 1 2 1 2 -
3 lines (1 line
exclusively for RE) –
including all charges
within U.A.E.

Page B| 4
March 2023
 Appendix B, PART I – RTA Roads Specifications

Quantity Required
Description Room Nos.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
a. Portable dry powder fire
extinguisher 1 1 - 1 - 1 1 1 1 1 - -
No.
b. Maximum-minimum thermometer
- 1 - 1 - - - - - - - - -
c. Water Heater 1 3 1
d. European WC Suit - - - - - - - - - - - 3
e. Wash hand basins, shelf, mirror,
towel rail and coat hooks - 1 - - - - - - - - 3
f. Extractor Fan - 1 - - - - - - - - 3
g. Ring gas burner - - - - - - - - - - - - 1
h. Refrigerator 6 cubic feet - - - - - - - - - - - - 1
i. Water filter - - - - - - - - - - - - 1
j. Sink Unit - - - - - - - - - - - - 1
k. Electric kettle - - - - - - - - - - - - 1
l. Plan paper colour photo copier
(A3/A4 Format reduction/
enlargement facility, cassette
feeds and sorting, scanning &
printing facility connected to the - - - - - - - - - - - 1 -
network
m. Intel Core i7
8GB DDR3 RAM (1333 MHz)
(Minimum)
N vidia Ge Force GTx670M
Intel Series (HDD 1TB) 1 1 - 1 2 - - 1 1 3 1 2 -
Dell Ultra sharp 2005 FPW wide
Aspect Flat Panel – 20-1 inch
LCD Monitor – T6130
Sound Max HD Audio
Intel 82566 DM-2 Gigabit
Network Connection
Min 2 Front side 2 rear side USB
port
Optical Mouse
US/UK Multimedia keyboard
Multimedia kit including speakers
and microphone
Approved Makes DELL, HP

n. 1)Microstation (network ver) - - - - - - 1 2 - - -

2)AutoCAD (network ver.), - 1 2
3)AutoCAD (Standalone), - 1 2
4)AutoCAD (Civil 3D) -
4)Primavera. 1
o. Color Printer A4/A3 (Max. Value
Dhs. 3,500) - 1 - - - - 1 - 1 -
p. Digital Still Camera, 24 Mega
Pixel, with Zoom lens, built in
automatic - - - - - - - - - - 2 -
flash and date imprint facility
q. High Definition LED Projector - - 1 - - - - - - - - - -
r. Fax machine - - - - - - - - - - 1 -
s. Mobile phone with sim card - 1 - - - - - - - - -
t. Internet Connection 1 1 - 1 2 - - 1 1 3 1 2 -
u. Refreshments and other AS REQUIRED ON SITE
consumables

Page B| 5
March 2023
 Appendix B, PART I – RTA Roads Specifications

EQUIPMENT FOR THE ENGINEER’S OFFICE

The Contractor shall provide and maintain for the Engineer’s exclusive use surveying equipment
and consumables which shall include the following:

SL. No. DESCRIPTION QUANTITY REQUIRED

1. Wild TC-1610 VIP total station with module reader
REC build with 3 prisms and accessories or similar 1 No
2. Tribar with tripods and target complete in all 2 Nos.
respects
3. Reflectors (Prism) for above distance measuring
device with 2 No. x three prism holder and 2 No. x 6 Nos.
single prism holder
4. Battery and charger for total station equipment 2 Nos.
5. External Car battery cable 1 No.
6. Automatic level – Wild NAK 2 or similar complete 1 No.
with tripod7
7. 4 metre Sectional staff 2 Nos.
8. Parallel plate micrometer for above NAK 2 2 Nos.
9. Plumbing pole 2 Nos.
10. Tribrach with optical plumnet and tripod 5 Nos.
11. Target (with carrier) 4 Nos.
12. Double prism optical square 1 No.
13. Prismatic Compass 1 No.
14. Ranging road (2.5 m long) with stands 6 Nos.
15. Sheradised plastic coated graduated steel 1 No
measuring band 100 m long
16. 50 mm long steel measuring band similar to above 1 No.
17. 30 m long fibreglass measuring tape 1 No.
18. 5 m long measuring tape 1 No.
19. 3 m long measuring tapes - As required
20. Tape repair kit 1 No.
21. 1 mtr long precise spirit level 1 No
22. 1 Kg Plumb bob 1 No.
23. Survey umbrella 1 No.
24. 3 Kg. Hammers 1 No.
25. Chaining arrows 5 Nos.
26. Level plate 2 Nos.
27. Not Used
28. Red and White Survey Flags 5 Nos.
29. Casela wet and dry thermometer 1 No.
30. Manhole lifting keys for:
Heavy duty covers 1 No.
Medium duty covers 1 No
Light duty covers 1 No.
31. Weatherproof rubber coated torches 1 No.
32. Safety Equipment : Helmets, Harnesses etc. - as required
33. Consumables: Wooden survey pegs, Steel survey pins, nails various sizes,
marking chalk, paint and paint brushes, surveyors field
books, other stationery items such as pens, pencils, writing
pads, books etc.

Page B| 6
March 2023
 Appendix B, PART I – RTA Roads Specifications

MISCELLANEOUS TESTING EQUIPMENT TO BE PROVIDED FOR THE USE OF THE

ENGINEER

In addition to the furnishings and equipment scheduled before the following equipment for recording
and testing materials shall also be provided: -

Sl.No. Test Equipment Required to

Test in Accordance With:
1. Determination of Surface 3 m straight edge with calibrated wedge
2. Cover to Reinforcement Concrete Cover Meter
3. Record of Temperature Maximum – Minimum Thermometer
Asphalt Thermometer (2 No.)
Concrete Thermometer (4 Nos.)
4. Picks, Shovels, Spades, Trowels, Chisels, 1 Kg.
Hammers (2 each)
5. Screwdriver, Pillars, adjustable spanner (2 each)
6. Sieve Brush, Wire brush, Soft brustle brush (2
No. each)
7. Preparation and curing of 150 mm Cube moulds to Part 108 and curing Tanks to
concrete test cubes Part 111 of BS 1881. Sufficient capacity shall be
provided to hold the cubes from 1 months
concrete production at peak production rates.
(The curing tanks shall be maintained in a
secure location under the sole control of the
Engineer or shall have lockable covers).
8. Concrete Slump Test 3 sets of equipment to BS 1881 Part 102.
9. Determination of surface regularity UK Transport and Road Research Laboratory
of road pavement (TRRL) Rolling Straight Edge. (Not required for
Arterial Roads, Expressways and Freeways).

Page B| 7
September 2022
 Appendix B, PART I – RTA Roads Specifications

Engineer’s Staff Requirements.

The Contractor shall provide the following vehicles with full maintenance, insurance, registration,
Salik and fuel for the exclusive use of the Engineer’s team for the duration of the Contract. On
handover of the project the vehicle will revert to the ownership of the Contractor:
• 1 No. Type1 SUV Vehicles (with driver)
• 2 No. Type 2 SUV Vehicles (with driver)

Vehicles Specification/Models:

Type Vehicle Model Engine (CC) Transmission No. of Condition

No. Type Seats

Type 1 SUV (4X4) Toyota Prado 4000 Automatic 7 Brand New

Toyota Fortuner
2700 7
Automatic Brand New
or
Type 2 SUV (4X4)
Mitsubishi Pajero Automatic Brand New
3000 7
(LWB)

Automatic or
Type 3 Pickup Hilux or equivalent 2700 5 Brand New
Manual

Note: All vehicles must have a petrol card and Salik.

Page B| 8
September 2022
 VOLUME 2, PART 1 - GENERAL SPECIFICATIONS

APPENDIX C

Schedule of Surveying Equipment to be Supplied

by the Contractor for the Use of the Engineer

The Contractor shall supply and maintain in full working order during the progress of the
Works, Surveying Equipment and other items, and the supply of expendable surveying
material as required from time to time in connection with the Works. All equipment
specified shall be new, approved by the Engineer, and for the exclusive use of the
Engineer, but shall remain the property of the Contractor.

ITEM DESCRIPTION NO.

a. LEIRA TC1202 or 1205 Total Station and Tripod. 1

b. TRIMBLE Model SPS985, TDL450H, TSC3 GPS 1
c. Wild NAK Universal Automatic Level with tripod 3
(or approved equal).
d. Sectional leveling staves with leveling bubble, 5m long. 2
e. Ranging rods, painted, 2.5m long. 4
f. 30m steel measuring tape graduated in meters and mm, 2
Rabon Permaline or approval equal.
g. 30m long non-metallic measuring tape graduated in meters 2
and mm, Rabon Permaline or approved similar.
h. 5m steel pocket tape graduated in mm Stanley or approved 4
equal.
i. Universal straight edge 3m with edge gauge. 2
j. Aluminum spirit level 1m long with four plumb and two level 2
tubes.
k. Safety helmets, reflective jackets and other safety As required*
equipments as required.
l. Rolling Straight Edge when required. As required*
m. One copy of all standards referred to in the Specifications. As required*
n. Target reflection with 3km range. 3
o. Plumbing pole to target and reflector. 1
p. Tripod and Tribarch. 3
q. Weather proof rubber-cased torches. 2
r. Surveying umbrellas, level books etc. As required*
s. Digital thermometer for asphalt and concrete 2
t. Manhole lifting keys for
i) heavy duty covers 1
ii) medium duty covers 1
iii) light duty covers 1

March 2023 Page C/1

 VOLUME 2, PART 1 - GENERAL SPECIFICATIONS

ITEM DESCRIPTION NO.

u. GPS receivers and ancillaries As required*

v. Other miscellaneous equipment and tools necessary for the As required*
carrying out of the Engineer's duties.
w. Laser road surface testing machine for testing rideability. As required*
x. Travelling beam for testing surface evenness/levels As required*

* As required by the Engineer

March 2023 Page C/2

 MBRAMC District One West - Enabling
Works Project number: 60684494

aecom.com

Prepared for: Meydan A

 ROADS & TRANSPORT
AUTHORITY

‫ ﺗطوﯾر وﺻﻠﺔ اﻷﺻﺎﯾل‬- ‫ ﺗﺣﺳﯾﻧﺎت ﻣﺣور اﻟﺷﯾﺦ راﺷد‬- 1060/2‫ط‬

PROJECT: R1060/2
– IMPROVEMENT OF SHEIKH RASHED
DEVELOPMENT OF AL ASAYEL LINK

TENDER DOCUMENT

VOLUME 2 – PART II – BOOK 1

DUBAI MUNICIPALITY SPECIFICATIONS, PART 1

EMPLOYER: CONSULTANT:

Roads & Transport Authority AECOM Middle East Ltd.

Roads Department P.O. Box 51028
P.O. Box 118899 Dubai – U.A.E.
Dubai – U.A.E.

RTA MAY 2024

 R1060/2 - Improvement of Sheikh Rashed – Development of Al Asayel link
Tenderer & Contract Conditions

PROJECT R1060/2:
IMPROVEMENT OF SHEIKH RASHED –
DEVELOPMENT OF AL ASAYEL LINK

GENERAL INDEX

VOLUME 1 - TENDERER & CONTRACT CONDITIONS

VOLUME 2 - SPECIFICATIONS

 PART I - RTA SPECIFICATIONS

o BOOK 1 – ROAD WORKS

o BOOK 2 – SERVICE WORKS & APPENDICES

 PART II - DM SPECIFICATIONS

o BOOK 1 - DM GENERAL SPECIFICATIONS, PART-1

o BOOK 2 - DM GENERAL SPECIFICATIONS, PART-2

& APPENDICES

Volume 3 - BILL OF QUANTITIES

Volume 4 - DRAWINGS

Volume 5 - GEOTECHNICAL INVESTIGATION REPORT

May 2024 Tender Document 1

 General Specifications
Dubai Municipality
Drainage and Irrigation Department

DUBAI MUNCIPALITY

DRAINAGE AND IRRIGATION DEPARTMENT

General Specifications
PART 1

Table of Contents
Section 1 General

Section 2 Site Clearance and Earthworks

Section 3 Concrete

Section 4 Pipe, Pipework, Manholes and Chambers

Section 5 Brickwork and Blockwork

Section 6 Inspection and Testing of Pipelines and Structures

Section 7 Corrosion protection and Surface Coatings

Section 8 Buildings Specifications

Section 9 Metals and Plastic Materials

Section 10 Safety Procedures

Section 11 Pipeline Renovation , Replacement and Abandonment

Section 12 Manhole Renovation and Abandonment and Pumping

Station and Rising Main Abandonment

Section 13 Piles and Piling

Section 14 Microtunnelling and Pipejacking

Section 15 Geotechnical Instrumentation and Monitoring

Section 16 Protection of Existing Structures and Services

 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 1

GENERAL

DM/DNID Section 1 General Rev 00 June

2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 1 General Rev 00 June Page i of iii

2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 1
GENERAL

CONTENTS
1 GENERAL........................................................................................................................... 1
1.1 GENERAL INFORMATION ................................................................................................ 1

1.1.1 Preamble .............................................................................................................. 1

1.1.2 Abbreviations and Standards ................................................................................ 1
1.1.3 Datum ................................................................................................................... 7
1.1.4 Right of Way ......................................................................................................... 8
1.1.5 Borehole Data ....................................................................................................... 8
1.1.6 Interpretation of Drawings ..................................................................................... 8
1.1.7 Responsibility of Contractor .................................................................................. 8
1.1.8 Governing Standards ............................................................................................ 8
1.1.9 Groundwater Levels in Dubai ............................................................................... 9
1.1.10 Pollution of Khor Dubai and the Arabian Gulf ..................................................... 10

1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE ................................................... 10

1.2.1 General ............................................................................................................... 10

1.2.2 Specific Requirements ........................................................................................ 17
1.2.3 Location of Contract Offices and Other Contract Facilities ................................. 17
1.2.4 Service Authorities .............................................................................................. 18

1.3 GENERAL REQUIREMENTS .......................................................................................... 18

1.3.1 Materials and Manufactured Items ..................................................................... 18

1.3.2 Submittals ........................................................................................................... 24
1.3.3 Setting Out the Work .......................................................................................... 38
1.3.4 Notice of Operations ........................................................................................... 39
1.3.5 Traffic Safety and Control ................................................................................... 39
1.3.6 Access to Private Land ....................................................................................... 40
1.3.7 Roads and Site to be Kept Clean ....................................................................... 40
1.3.8 Compensation for Damage to Property .............................................................. 41
1.3.9 Existing Services ................................................................................................ 41
1.3.10 Continuous Working ........................................................................................... 42
1.3.11 Temporary Staging for Structures ....................................................................... 42
1.3.12 Water Supply ...................................................................................................... 43
1.3.13 Filling in Holes and Trenches ............................................................................. 43
1.3.14 Protection of Works from Weather ...................................................................... 43
1.3.15 Keeping the Works Free from Water .................................................................. 43

DM/DNID Section 1 General Rev 00 June Page ii of iii

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

1.3.16 Sign Boards ........................................................................................................ 43

1.3.17 Templates ........................................................................................................... 44
1.3.18 Assistance to the Engineer ................................................................................. 44
1.3.19 Surveying Equipment .......................................................................................... 46
1.3.20 Laboratory ........................................................................................................... 49
1.3.21 Minimum Test Requirements .............................................................................. 50
1.3.22 Sources of Materials ........................................................................................... 56
1.3.23 Programming the Progress of the Works ............................................................ 56
1.3.24 Progress Reports ................................................................................................ 57
1.3.25 Progress Photographs ........................................................................................ 58
1.3.26 Suppression of Noise .......................................................................................... 58
1.3.27 Closing of Roads ................................................................................................ 58
1.3.28 NOC from Relevant Authorities .......................................................................... 59

1.4 TOPOGRAPHICAL SURVEY........................................................................................... 59

1.4.1 GENERAL REQUIREMENTS ............................................................................. 59

1.4.2 SURVEY CONTROL POINTS ............................................................................ 59
1.4.3 SURVEY WORK ................................................................................................. 60
1.4.4 NON COMPLIANCE ........................................................................................... 61

1.5 SPECIFIC OBLIGATIONS ............................................................................................... 61

1.5.1 Sequence of Construction .................................................................................. 61

1.5.2 Safety Requirements .......................................................................................... 62
1.5.3 Setting Out .......................................................................................................... 63
1.5.4 Progress Reports, Photographs and Site Records ............................................. 63
1.5.5 As-built Records ................................................................................................. 65
1.5.6 Contract Correspondence ................................................................................... 65
1.5.7 Corrosion Control ................................................................................................ 65
1.5.8 Provision and Final Removal of Temporary Site Roads ..................................... 66
1.5.9 Use of Highway ................................................................................................... 66
1.5.10 Access to Private Land ....................................................................................... 67
1.5.11 Return of Materials to Store ................................................................................ 67
1.5.12 Flows in Pipelines and at Pumping Stations ....................................................... 68
1.5.13 Issue of Taking - Over Certificate ....................................................................... 68

1.6 VENDOR LIST FOR CIVIL ITEMS.................................................................................... 69

DM/DNID Section 1 General Rev 00 June Page iii of iii

2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

1 GENERAL
1.1 GENERAL INFORMATION

1.1.1 Preamble

These Specifications shall be read in conjunction with the other documents of the
Tender and Contract Documents and Drawings. The Contractor shall comply with all
the provisions contained within these Documents. The Contractor shall take note of
the Appendices contained in these Specifications. Where items of the Specifications
are also covered in the Appendices the requirements of the Appendices shall take
precedence.

The provisions contained in the specification shall prevail over the provisions
contained in the referenced standards in each section of the specification.

Any clause in these Specifications which relates to work or materials not required by
the Contract shall be deemed not to apply.

In order to avoid needless repetition of such phrases as "to the Engineer" and "by the
Engineer" or "the Engineer's Representative" throughout these Specifications it shall
be understood that when an order, instruction, decision, exercise of judgment or other
similar act is indicated, such order, instruction, decision, exercise of judgment or other
similar action will be issued, given, made or referred to the Engineer or the Engineer's
Representative.

1.1.2 Abbreviations and Standards

The following abbreviations are used in the Specifications:

cm Centimetre
d Day
dia Diameter
ha Hectare
h Hour
kg Kilogram
kN Kilo Newton
kW Kilowatt
l Litre
MDD Maximum Dry Density

DM/DNID Section 1 General Rev 00 June Page 1 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

m Metre
m², sq m Square Metre
m³, cu m Cubic Metre
mg Milligram
mm Millimetre
months Months
MPa Mega Pascal
Nr, No Number
Pa Pascal
Sec Second
Set Set
T Tonne
Reference to a technical society, institution, association or governmental authority is
made in the Specifications in accordance with the following abbreviations as well as
these indicated on the Drawings.

AA Aluminium Association

AABC Associated Air Balance Council

AAN American Association of Nurserymen

AAMA Architectural Aluminium Manufacturers Association

AASHTO American Association of State Highway and Transportation Officials

ACI American Concrete Institute

ADC Air Diffuser Council

AFI Air Filter Institute

AGCA Association General Contractors of America

AIA American Institute of Architects

AIMA Acoustical & Insulating Materials Association

DM/DNID Section 1 General Rev 00 June Page 2 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

AIEE American Institute of Electrical Engineering

AISC American Institute of Steel Construction

AISI American Iron & Steel Institute

AITC American Institute of Timber Construction

ALS American Lumber Standards

AMCA Air Moving & Conditioning Association

ANSI American National Standards Institute

AOAC Association of Official Agricultural Chemists

APA American Plywood Association

ASA American Standard Association

ARI Air Conditioning & Refrigeration Institute

ASAHC American Society of Architectural Hardware Engineers

ASHRAE American Society of Heating, Refrigerating and Air conditioning

Engineers

ASSE American Society of Sanitary Engineers

ASTM American Society for Testing and Materials

AWI Architectural Woodwork Institute

AWPA American Wood Preservers Association

AWPI American Wood Preservers Institute

AWS American Welding Society

AWWA American Water Works Association

BHMA Builders Hardware Manufacturers Association

BIA Brick Institute of America

DM/DNID Section 1 General Rev 00 June Page 3 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

BRI Building Research Institute

BS British Standard

BSCP British Standard Code of Practice

BS EN European Standards

BSI British Standards Institution

CDA Copper Development Association

CEE International Commission on Rules for Approval of Electrical

Equipment (Europe)

CIRIA Construction Industry Research and Information Association

CRSI Concrete Reinforcing Steel Institute

CS Commercial Standard, US Department of Commerce

CSI Construction Specifications Institute

CTI Cooling Tower Institute

DEWA Dubai Electricity and Water Authority

DM Dubai Municipality

DIN Deutsche Institute for Norming, Germany

ETISALAT Emirates Telecommunications Corporation

FGMA Flat Glass Marketing Association

FPL Forest Products Laboratory

FS Federal Specification

FSIWA Federation of Sewage and Industrial Waste Association

FTI Facing Tile Institute

GA Gypsum Association

DM/DNID Section 1 General Rev 00 June Page 4 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

GTA Glass Tempering Association

HPMA Hardwood Plywood Manufacturers Association

IEC International Electro-technical Commission

IEE Institute of Electrical Engineers of London

IEEE Institute of Electrical & Electronics Engineers

IES Illuminating Engineering Society

ISA Instrument Society of America

ISO International Organisation for Standardisation, Switzerland

MIA Marble Institute of America

MLMA Metal Lath Manufacturers Association

MSSVFI Manufacturers Standardization Society of the Valves and Fittings

Industries

NAAMM National Association of Architectural Metal Manufacturers

NAFM National Association of Fan Manufacturers

NAPF National Association of Plastic Manufacturers

NBGQA National Building Granite Quarries Association

NBHA National Builders Hardware Association

NBS National Bureau of Standards

NCMA National Concrete Masonry Association

NEC National Electrical Code (NFPA No.70)

NEMA National Electrical Manufacturers Association

NEMI National Elevator Manufacturing Industry Inc.

NFC National Fire Code

DM/DNID Section 1 General Rev 00 June Page 5 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

NFPA National Fire Protection Association

NFPA National Forest Products Association

NHLA National Hardwood Lumber Association

NHPMA National Hardwood & Pine Manufacturers Association

NPA National Particleboard Association

NRMCA National Ready Mixed Concrete Association

NSC National Safety Council

NSF National Sanitation Foundation

NTMA National Terrazzo & Mosaic Association

NWC National Water Council, UK

NWMA National Woodwork Manufacturers Association

OSHA Occupational Safety & Health Administration

PCA Portland Cement Association

PCI Prestressed Concrete Institute

PDI Plumbing & Drainage Institute, USA

PEI Porcelain Enamel Institute

PS Product Standard, US Dept of Commerce

ROS Redwood Inspection Service

RTI Resilient Tile Institute

SCMA Southern Cypress Manufacturers Association

SDI Steel Door Institute

SIGMA Sealed Insulating Glass Manufacturers Association

DM/DNID Section 1 General Rev 00 June Page 6 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SJI Steel Joint Institute

SMACNA Sheet Metal & Air Conditioning Contractors National Association

SMFMA Sprayed Mineral Fibre Manufacturers Association Inc

SPIB Southern Pine Inspection Bureau

SPR Simplified Practice Recommendation, US Dept of Commerce

SSPC Steel Structure Paining Council

SWFPA Structural Wood Fibre Products Association

TCA Tile Council of America

TEMA Tubular Exchange Manufacturing Association

TIMA Thermal Insulation Manufacturing Association

TPI Truss Plate Institute

UL Underwriters Laboratories Inc

UPC Uniform Plumbing Code

USCGS US Coast & Geodetic Survey

WCLB West Coast Lumber Inspection Bureau

WRI Wire Reinforcement Institute

WPA Western Wood Products Association

1.1.3 Datum

The levels shown on the Drawings are referred to Dubai Municipality datum. The
location and details of benchmarks to be established by the contractor shall be
obtained / transferred by him from Dubai Municipality datum Level / Survey
Department. The Contractor shall make his own arrangements to ensure that the
Works are constructed to the levels shown on the Drawings or as amended by the
Engineer, and if it is found necessary to cover or destroy any of such bench-marks
the Contractor shall transfer the level of such bench-marks to other approved fixed
points, which shall then be surveyed and marked on the Drawings. The survey station

DM/DNID Section 1 General Rev 00 June Page 7 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

details obtained by the Contractor from the Dubai Municipality Survey Section shall
be at Contractor’s cost.

1.1.4 Right of Way

The Contractor shall make all the necessary arrangements for any land required for
working areas outside the right of way, including payment when necessary, and the
Employer does not accept any liability in connection with such land. This includes
land for compounds, temporary working shafts and roads, detours, diversions and
stock piling materials.

1.1.5 Borehole Data

Any soils and materials test results and information provided for the Contractor with
the Contract Documents at Tender stage is for his information only. The Contractor
shall be deemed to have studied this information during the preparation of his Tender
and to have carried out any further tests as he may consider necessary. No claims for
additional payment will be considered from the Contractor on the grounds that the
information is insufficient, incorrect, or misleading. The Contractor shall submit copies
of all geotechnical tests performed for review by DM/Dubai Central Laboratory.

1.1.6 Interpretation of Drawings

The Employer and the Engineer accept no responsibility for any omissions from or for
correctness of the representation of existing features on the Drawings.

1.1.7 Responsibility of Contractor

Where the approval of the Engineer is required under these Specifications such
approval shall not relieve the Contractor of his duties, responsibilities or liabilities
under the Contract.

1.1.8 Governing Standards

Wherever in the Specifications tests on materials, tests on completed work and

construction control tests are called for or implied, they shall be carried out
accordingly to, and the materials shall comply with, the requirements of the
Specifications (latest edition) with the priority of latest edition of standard shall be as
follows:

(a) National standards such as UAE & DM Standards

(b) International standard such as ISO
(c) Secondary international standard such as BSI & DIN
(d) Others as stated in this Specification such as ASTM, etc.

DM/DNID Section 1 General Rev 00 June Page 8 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

The Contractor shall provide for the exclusive use of the Engineer copies of each and
any codes of practice, international standard, test methods, etc. relevant to the works,
properly indexed and maintained in good order and readily available to the Engineer
at all times. Upon completion of the works the said codes, standards, etc., shall be
handed over to the Engineer.

In addition the Contractor shall retain on site for the use of the Engineer all
manufacturers’ literature relating to all the products to be used in the works, current
BSI Handbook No. 3 and the manufacturers’ installations instructions for all relevant
products, materials components and installations.

The Contractor shall comply with all codes, regulations and standards referred to
throughout the specification.

All references to codes, regulations and standards referred to in the specification

shall, unless otherwise stated, mean the latest edition, amendment or revision of such
reference in effect as of the date of the specification.

For all materials where no governing standard is quoted in the Specification then a
suitable national / International standard approved by the Engineer (BS, BS EN,
AASHTO, DIN or ANSI/ASTM) shall be used.

Present an affidavit from the manufacturer certifying that the product complies with
the applicable section of the specification. Where requested or specified, submit
supporting test data to substantiate compliance with the applicable section of the
specification.

Where a standard referred to in the specification is in the form of a recommendation

or suggestion, such recommendation or suggestion shall be deemed to be mandatory
unless conflicting with any particular specification.

Neither the contractual relationship duties nor responsibilities of the parties in contract
nor those of the Engineer shall be altered by mention or inference otherwise in the
Specification

1.1.9 Groundwater Levels in Dubai

The Contractor will be deemed to have carried out his own investigations at the time
of Tender to ascertain for himself the nature of the soil conditions and in particular the
groundwater levels that will be encountered.

Method statements for dealing with groundwater shall be submitted within three
weeks of the signing of the Contract.

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

1.1.10 Pollution of Khor Dubai and the Arabian Gulf

The Contractor shall ensure that no extraneous matter, rubbish or polluting liquid is
deposited or discharged to the Khor Dubai (Creek) or to the foreshore or sea of the
Arabian Gulf.

1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE

1.2.1 General

a) The Contractor shall provide, maintain and keep clean temporary site offices with
all associated equipment and services for the exclusive use of the Engineer's
Representative and his staff, from commencement until completion of the whole
of the Works.

b) The temporary site offices shall be as-new prefabricated portable unit/s or

alternatively of some other form of weatherproof design and construction to the
approval of the Engineer. The building shall be erected on suitable solid
foundation.

c) The offices shall have full partitions and room sizes shall be as shown in the
Schedule of Offices. All rooms shall have individual entrance doors.

d) Corridor and entrance areas shall be additional to the office sizes.

e) The offices shall be air-conditioned with the exception of the Toilet, Shower and
Kitchen areas.

f) All rooms shall have glazed windows complete with fly screens and Venetian sun
blinds.

g) Adequate fitted hardware, electrical switches, sockets, lighting, plumbing fittings,

sanitary ware and fittings and fixtures, etc., shall be provided as necessary for the
different areas.

h) The electrical installation shall provide for simultaneous use of all electrical
appliances.

i) The electrical supply shall be 220-250 volts, 50 Hz. The Contractor may either
arrange for a temporary power supply to the offices or alternatively provide and
maintain adequate diesel generator sets. All electricity bills throughout the
contract period until completion of construction and defects liability period shall be
paid by the Contractor.

j) The Contractor may either arrange for a temporary mains water supply or
alternatively provide tankered water supply. All water bills shall be paid by the

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Contractor throughout the contract period until completion of construction and

defects liability period.

k) A minimum of two telephone lines with extensions shall be provided for the offices
along with a third line for an independent telefax facility and a fourth ISDN line as
shown in the Schedule of Fittings and the Contractor shall pay all installation and
rental charges, and call charges, if any, for UAE calls only, throughout the
contract period until completion of construction and defects liability period.

l) Covered car parking areas of approved construction for ten (10) cars shall be
provided adjacent to the offices. The final requirements shall be based on
Engineer’s approval.

m) The Contractor shall submit any necessary drawings and calculations for the
construction of the offices for the Engineer's approval before commencing
construction and shall be responsible for ensuring that the offices are structurally
sound. The Engineer may request alterations at this stage. The drawings shall be
approved in writing by the Engineer before installation/construction shall
commence.

n) The offices shall be completed and all the equipment provided by the end of the
Mobilisation Period.

o) Throughout the duration of the Contract (including defects liability period), the
Contractor shall ensure an uninterrupted supply of gas, water and electricity to the
offices.

p) The Contractor shall provide all items listed in the following Schedule of Offices
and Schedule of Fittings. The Contractor shall obtain the Engineer’s approval for
all furniture and equipment proposed.

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Table1.1 SCHEDULE OF OFFICES

Room No of Room
Description Number Remarks
No. Staff Size

1 Resident Engineer 1 (6 x 4) m 1 Toilet

attached

2 Conference Room - (10 x 4) m 1 - do -

3 Asst. Resident Engineer 1 (4 x 4) m 1

(Civil)

4 Mechanical / Electrical 2 (8 x 4) m 1
Engineer

5 Quantity Surveyor 1 (4x 4) m 1

6 Material Engineer 1 (4 x 4) m 1

7 Inspectors 2 (8 x 4) m 1

8 Surveyor & Draughtsman 2 (8 x 4) m 1

9 Typist/ Clerk 1 (4 x 4) m 1

10 Record Room (8 x 4) m 1

11 Toilet with Ablution facility (2 x 2) m 2

12 Shower room (4 x 3) m 1

13 Kitchen (4 x 4) m 1

14 Dubai Muncipality Liaison (4 x 4) m 1 Toilet

Officer attached

15 Ladies Toilet (4 x 2) m 1

16 Sample and Material (3 x 3) m 1

Storage

17 Covered Parking Area 10

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Table 1.2 SCHEDULES OF FURNISHINGS & FITTINGS

The fittings required under this contract for the rooms within the Engineer’s site
offices indicated in the schedule of offices, shall be as per the Engineer’s approval
and are as follows:

Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 Executive desk with nr 1 - 1 - - - - - - - - - - 1 - - -

two locking drawers
and swivel chair

2 Conference table for nr - 1 - - - - - - - - - - - - - - -

14 person meeting

3 Desk with two locking nr - - - 2 1 1 - - - - - - - - - - -

drawers and swivel
chair

4 Desk with two nr. nr - - - - - - 2 2 - - - - - - - - -

locking drawers and
chair

5 Chair, cloth fabric nr 3 14 2 4 2 2 2 2 2 - - - - 2 - - -

covered, padded steel
frame

6 Typist Desk and chair nr - - - - - - - - 1 - - - - - - - -

8 Inclined plan table for nr 1 - 1 1 1 1 1 1 - - - - - 1 - - -

drawings

9 Six drawer plan chest nr 1 - 1 1 - - - 1 - - - - - - - - -

10 Samples cupboard nr 1 - 1 1 1 1 1 - - - - - - - - - -

11 Four drawers steel nr 1 - 1 1 1 1 - - 1 - - - - 1 - - -

filing cabinet

12 Shelving & pin boards nr As required on Site

13 In / out tray nr 1 - 1 2 1 1 2 2 1 - - - - - - - -

14 Lockable Filing cabinet nr 1 - 1 1 1 1 - - 1 - - - - - - - -

15 Waste paper basket nr 1 2 1 2 1 1 2 2 1 1 - - - 1 - - -

16 Telephone handset nr 1 1 1 2 1 1 2 2 1 - - - - 1 - - -

17 Mobile Phones nr 1 - - - - - - - - - - - - - - - -

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Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

18 Misc desk equipment, nr 1 - 1 2 1 1 2 2 1 - - - - 1 - - -

punch, stapler, pencil
sharpener, etc.

19 Portable dry powder nr - 1 - - - - - - - 1 - - 1 - - - 1

fire extinguisher (as per
EHS requirement)

20 Fire Blanket nr - - - - - - - - - - - - 1 - - - -

21 First Aid Kit (as per nr - - 1 1 - - - - 1 - - - - - - - -

EHS requirement)

22 Maximum – minimum nr - - - - - - - - - - - - 1 - - - 1
thermometer

23 Refrigerator 0.28 m³ nr 1 - - - - - - - - - - - 1 - - - -

24 Water filter nr - - - - - - - - - - - - 1 - - - -

25 Microwave nr - - - - - - - - - - - - 1 - - - -

26 Plastic 5 litre insulated nr - - - - - - - - - - - - 1 - - - -

cold water container

27 Oil Filled Room nr 1 2 1 1 1 1 1 1 1 - - - - 1 - - -

Heaters

28 Sink unit nr - - - - - - - - - - - - 1 - - - -

29 Electric kettle nr - - - - - - - - - - - - 1 - - - -

30 Plain paper heavy duty nr - - - - - - - - 1 - - - - - - - -

photocopier (A3/A4
format reduction/
enlargement facility,
cassette feeds, sorting
facility (LATEST
MODEL)

31 Desktop computer for nr - - - - - - - 2 - - - - - - - - -

Draughtsman as
specified (2) below

32 Desktop computer for nr - - - - - - - - 1 1 - - - - - - -

secretary as specified
(3) below

33 Desktop computer for nr 1 - 1 2 1 1 - - - - - - - 1 - - -

engineer as specified

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Item Description Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

(4) below

34 Heavy duty colour nr - - - - - - - - 1 - - - - - - - -

A4/A3 Laser Printer as
specified (5) below

35 Light duty A4 Laser nr 1 - 1 - 1 - - - - - - - - - - - -

Colour Printer as
specified (6) below

36 A3/A4 Scanner: nr - - - - - - - 1 1 - - - - - - - -
Flatbed Scanner as
specified (7) below

37 A0 Inkjet Plotter as nr - - - - - - - 1 - - - - - - - - -
below

38 Electronic calculators nr 1 - 1 2 1 1 2 2 1 - - - - - - - -

39 Digital Still Camera nr 1 - - - - - - - - - - - - - - - -

5MEGA Pixels or
Higher Resolution

12 x Optical zoom 2.5"

LCD Screen 32MB or
Higher Memory Card

40 Punch large nr - - - - - - - - 1 - - - - - - - -

41 Binding machine nr - - - - - - - - 1 - - - - - - - -
(adjustable for A4 size
to full scap size)

42 Stapler large nr - - - - - - - - 2 - - - - - - -

43 Filing racks nr As required on Site

44 Personnel Protection nr As required on Site

Equipment

45 Refreshments nr As required on Site

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NOTES:

1. All consumables including Ink Cartridges, Photocopy papers, Plastic Binding Rings, films and developing etc. to
be at the Contractor’s cost.

2. Desktop Computer (Draughtsman)

Quad Core Xeon E3-1245 (3.30 GHz, 8M L3, 2GT, Turbo) .
Operating System: Genuine Windows® 7 Professional, Media, 64-bit
Memory: 8GB, 1333MHz, DDR3 SDRAM, ECC (2 DIMMS)
Graphics: 1.0GB NVIDIA® Quadro® 600, Dual MON, 1 DP & 1 DVI NVS600 1 [320-1896] 6
Boot Hard Drive: 500GB 7200rpm 3.5 Inch SATA Hard Drive with NCQ and 16MB Cache
DVD and Read-Write Devices: 16X DVD+/-RW SATA

3. Desktop Computer (Secretary)

Intel® Core™ i5 2400 Processor (3.1GHz, 6M)
Operating System(s): Genuine Windows® 7 Professional, 64-bit
Memory: 4GB DDR3,Non-ECC,1333MHz Dual Channel SDRAM,2x2GB
Boot Hard Drives: 250GB 3.5 6.0Gb/s SATA with 8MB DataBurst Cache
Removable Media Storage Device: 8X Slimline DVD+/-RW, Roxio Creator™ CyberlinkPowerDVD™ No
Video Cards: Integrated Video, Intel® HD Graphics 2000 (1DP & 1 VGA)

4. Desktop Computer for Engineers

Intel® Core™ i5 2400 Processor (3.1GHz, 6M)
Operating System(s): Genuine Windows® 7 Professional, 64-bit
Memory:4GB DDR3,Non-ECC,1333MHz Dual Channel SDRAM,2x2GB
Boot Hard Drives:250GB 3.5 6.0Gb/s SATA with 8MB DataBurst Cache
Removable Media Storage Device: 8X Slimline DVD+/-RW, Roxio Creator™ CyberlinkPowerDVD™ No
Video Cards:Integrated Video, Intel® HD Graphics 2000 (1DP & 1 VGA)

5. Heavy duty colour A4/A3 Laser Printer

25 to 30 PPM with Duplex facility, 1200x1200 dpi print quality, A3 and A4 separate trays, 1 GB Memory, maximum: 1 GB,
Hard disk: Standard 8 GB Built in Memory, Connectivity, standard: 1 Hi-Speed USB 2.0 ,1 Gigabit Ethernet 10/100/1000,
IPv6, BiDi.

6. Light duty A4 Laser Colour Printer

20 to 30 PPM with Duplex facility, 600x600 dpi print quality, A4 separate, 1 GB Memory or 512MB, Connectivity,
standard: 1 Hi-Speed USB 2.0 ,1 Gigabit Ethernet 10/100/1000, IPv6, BiDi.

7. Light duty A4 Laser Colour Printer

Flatbed Scanner, 4800x9600 dpi Resolution, Auto Document feeder, USB compatible.

8. Server with back up facility

Dell Power Edge T420 Server with internal tap drive.

9. Microsoft office latest version 2013 and Acrobat standard for all computers
10. Primavera –P6 one license ( for RE or QS)

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1.2.2 Specific Requirements

a) The Contractor shall be responsible for making all arrangements and payments in
respects of any land required for the site of the building.

b) The Contractor shall be responsible for the security of the building and its
contents at all times and shall employ watchmen for this purpose.

c) The Contractor shall supply the Consultant's staff with all safety clothing and
equipment that shall be necessary for site working such as safety helmets,
reflective waistcoats, etc.

d) The building shall be well constructed, burglar proof, mosquito proof and weather
proof and shall have sufficient doors and glass covered windows for proper light
and ventilation. Floors shall be covered with suitable, approved flooring.

e) The Contractor shall retain on site for the exclusive use of the Engineer all codes
and standards referred to in the Specification.

f) The building and services shall be available, fully maintained, until 1 month after
the issue of the Taking Over Certificate for the whole of the Works.

g) Following the completion of the whole of the Works and the Defects Liability
period respectively, the Contractor shall remove the offices from the Site and
reinstate the area to natural condition or as directed by the Engineer.

h) The building and all equipment, materials, fittings, etc., supplied for the office,
shall become the property of the Contractor after the completion of the Works.

1.2.3 Location of Contract Offices and Other Contract Facilities

Within 14 days of the date of the Letter of Acceptance issued by the Employer the
Contractor shall submit a plan or plans showing his proposed locations for and details
of:

a) Offices for the Engineer and Engineer's Representatives.

b) The Contractor's Site Offices.

c) The Contractor's Stores, Plant and Maintenance Yard, Concrete Batching and
Materials Stockpiling Facilities.

d) Principal routes for heavy plant and lorries.

e) Areas for the temporary storage and permanent dumping of excavated material.

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The Offices of the Contractor's Project Manager will normally be adjacent to or

close to those of the Engineer for ease of communication.

The plan(s) shall be submitted to the Engineer in six (6) copies for approval. Any
reasonable changes or modifications suggested by the Engineer shall be
incorporated. All locations shall be subject to the approval of the Employer.

Departures from the approved details shall not be permitted unless written
consent is obtained from the Engineer.

1.2.4 Service Authorities

Arrangements for mains water supply, mains electricity supply and telephone
connections shall be made through:

a) Dubai Electricity and Water Authority -Water Division

b) Dubai Electricity and Water Authority -Electricity Division

c) Etisalat Emirates Telecommunications Corporation (Dubai)

The Service Authorities shall be deemed to also include Departments and/or Sections
of Dubai Municipality and any other public or private authority responsible for
services.

1.3 GENERAL REQUIREMENTS

1.3.1 Materials and Manufactured Items

a) Materials and manufactured items shall be suitable for the climate and
environmental conditions described in this specification.

b) The environmental conditions may be different in different parts of the Works and
materials shall be selected and manufactured items designed accordingly to
withstand the relevant corrosive elements. In particular all products or materials in
contact with sea water, sewage or a saline/ sewage environment shall be non-
biodegradable.

c) All local customs, laws and regulations laid down by the Employer or other
governing body relating to the supply or source of materials shall be complied
with.

d) All materials and equipment specified in the Contract Documents which are to be
incorporated in the Works must be obtained from or through a Dubai Emirate
supplier and /or manufacturer. The supplier or manufacturer must be registered
with Dubai Municipality. If such specified materials or equipment are not available
from the Dubai Emirate market, any other source would be acceptable.
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e) The contractor shall be responsible for liaising with the suppliers; obtaining,
checking for accuracy and issuing all drawings and other documents and for co-
ordination of supply and installation.

f) Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a "Certificate of Guarantee" signed by the authorised
representative of the manufacturer, which will legally bind the manufacturer to the
product delivered.

g) Such Certification shall state that the materials specifications and test results are
in compliance with the specified requirement of the pertinent designations of the
most recent edition of ASTM, BS or any other approved equivalent National
Standard unless otherwise directed.

h) Falsification of such Certificates, Materials, Specifications or Test Results shall be

just cause for the rejection of the materials.

1.3.1.1 Quality of Materials, Manufacture and Standards

a) All materials and manufactured items supplied for incorporation into the
permanent works shall be new, of high quality and of sound workmanship. They
shall be purchased only from approved suppliers who shall be capable of
demonstrating the suitability of their products by reference to similar works and
certified test results, and be suitable for the purpose for which they are intended
as stated in the Specification.

b) Materials and manufactured items shall normally be certified as complying with

relevant specifications of a recognised national or international standards (ISO)
organisation which shall be subject to the approval of the Engineer but in
dimensional respects they shall be compatible with ISO standards. Where pipes
and access covers are produced to British Standard (BS) they shall be kitemark-
certified or similarly approved.

c) All materials and manufactured items shall also have an approved national
certificate of conformance similar to BSI quality kite mark or national agreement
certificate such as BBA for non – standard products and systems which shall be
subject to approval by the Engineer and verification by Dubai Municipality – Dubai
Central Laboratory.

d) Materials not covered by a third party product certification scheme shall be

assessed by acceptable tests on each batch. Sampling and testing shall be
carried out by an organisation independent of the producer at the producer’s
works or in the stockholder’s yard.

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e) The Contractor shall provide, for the sole use of the Engineer, original copies of
the latest editions of any national or international standards, in English, which
may be called for as being required in the execution of the Contract. These may
include alternative standards to those to which the materials are manufactured for
use as a comparative quality guide. The standards will become the property of the
Engineer and will not be returned to the Contractor at the end of the Contract. The
rates inserted in Volume 3 shall be deemed to cover provision of any standards
so provided.

1.3.1.2 Approval of Materials and Manufactured Items

The Contractor shall submit to the Engineer full information as detailed below, for all
proposed materials and manufactured items.

a) Prior to the placing of any order for materials or manufactured items, the
Contractor shall submit, in triplicate, a Request for Approval. The information shall
be clearly and neatly presented in a standard format to be agreed with the
Engineer. No orders shall be placed until one copy of the Request for Approval
has been returned duly signed and dated. The information required is as follows:-

(i) Name and address of proposed supplier or manufacturer.

(ii) Reference numbers and titles of relevant specifications of a recognised

national or international standards organisation with which the materials or
manufactured items will comply together with relevant copies of the
specifications in English as indicated in Clause 1.3.1.1 above.
(iii) Samples of materials representing the quality of the bulk of such materials
the Contractor proposes to use.
(iv) Manufacturer’s literature and data sheets for articles and fabricated items.
(v) Sufficient information to demonstrate that the materials or manufactured
items are suitable and comply with Specification.

b) Following approval of an order for manufactured items designed for incorporation

in the Works the Contractor shall submit detailed drawings and installation
drawings for approval. Following approval three copies of such drawings shall be
submitted.

c) Prior to despatch to site or to a designated place of storage the Contractor shall

provide the following:-

(i) Facilities for inspection and testing at suppliers’ pits or quarries,

manufacturer’s works or approved independent testing centres as
appropriate. Inspection and or witness testing may be carried out by the
Engineer or other appointed Inspector.

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(ii) Details of the supplier’s or the manufacturer’s quality control test procedures
and copies of test certificates.

(iii) Shipping and consignment identification details.

1.3.1.3 Approval of Construction and Testing Methods

For all elements of the Works the Contractor shall submit to the Engineer in duplicate,
fully detailed method statements describing his proposed construction and testing
techniques and programme for execution. These shall be supported, where
applicable, by calculations for temporary works for supporting excavated faces and
shuttering of concrete.

Written approval shall be obtained before any work is commenced.

1.3.1.4 Contractor’s Staff

The final requirements for the contractor’s staff shall be based on the project requirement
and subjected to Engineers approval .

a) Project Manager

A qualified and experienced Project Manager who holds a bachelor’s degree in

engineering from a recognised university with minimum 20 years of experience
out of which a minimum 7 years of experience in similar role of
handling/managing the projects involving civil, mechanical, electrical &
instrumentation control works.

b) Construction Manager

A qualified and experienced Construction Manager who holds a bachelor’s

degree in engineering from a recognised university with minimum 15 years of
experience out of which a minimum 7 years of experience in similar role of
handling/managing the projects involving civil, mechanical, electrical &
instrumentation control works.

c) Senior Site Engineer

A qualified and experienced Senior Site Engineer who holds a bachelor’s degree
in civil engineering from a recognised university with minimum 10 years of
experience out of which a minimum 5 years of experience of site works in similar
role.

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d) Mechanical Engineer

A qualified and experienced Mechanical Engineer who holds a bachelor’s degree

in mechanical engineering from a recognised university with minimum 10 years of
experience out of which a minimum 5 years of experience of site works in similar
role of handling the mechanical works of the project.

e) Electrical Engineer

A qualified and experienced Electrical Engineer who holds a bachelor’s degree in

electrical engineering from a recognised university with minimum 10 years of
experience out of which a minimum 5 years of experience of site works in similar
role of handling the Electrical, Instrumentation and control works of the project.

f) Tunnel/ Microtunnelling/ Pipe jacking Engineer

The Contractor shall appoint a fully qualified and experienced Pipe jacking
Engineer having Engineering Degree in appropriate discipline, At least 10 years’
experience out of which not less than 5 years should be related experience,
Possess direct experience of design and laying of pipes by pipe jacking and
microtunneling methods, Good knowledge of pipe design for NDM works . He will
be responsible for microtunneling / pipe jacking design and execution activities.
Details for the qualifications and experience of the proposed Pipe jacking
Engineer shall be given in the appropriate schedule of the Schedule of
Particulars.

g) Materials Engineer

The Contractor shall appoint a fully qualified and experienced Materials Engineer
to be in charge and responsible for the testing, investigation and quality control of
soils, aggregates, cement, concrete, building materials generally, and to be
responsible for the operation of the Contractor’s Materials laboratory. Details of
the qualifications and experience of the proposed Materials Engineer shall be
given in the appropriate schedule of the schedules of particulars.

h) Engineering Geologist

The Contractor shall appoint a fully qualified and experienced Engineering

Geologist to prepare the report on aggregate sources for concrete as required by
Specification. The Geologist shall be appointed at least for the period up to the
approval by the Engineer of the proposed aggregate sources, and shall be
available for short periods thereafter for consultancy purposes. Details for the
qualifications and experience of the proposed Engineering Geologist shall be
given in the appropriate schedule of the Schedule of Particulars.

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i) Planning Engineer

A qualified and experienced Planning Engineer who holds a bachelor’s degree in

engineering from a recognised university with minimum 10 years of experience
out of which a minimum 5 years of experience in similar role. He should have
hands on experience in planning and monitoring of the project. Advanced
software skills are a must including MS project and Primavera.

j) Technical Office Engineer

A qualified and experienced Technical Office Engineer who holds a bachelor’s

degree in mechanical or in civil engineering from a recognised university with
minimum 10 years of experience and with minimum 3 years of experience in
similar role of handling the material data sheets submission and approvals.

k) Site Engineer

A qualified and experienced Site Engineer who holds a bachelor’s degree or

diploma in civil engineering from a recognised university/ institution with minimum
5 years of experience and with minimum 2 years of experience of site works.

l) Quantity Surveyor

A qualified and experienced Quantity Surveyor who holds a bachelor’s degree in

engineering or relevant Quantity Surveying degree from a recognised
university/institution with minimum 7 years of experience or diploma in
engineering with 10 years of experience and with minimum 5 years of experience
in similar role.

m) Safety Officer

The Contractor shall appoint an experienced Safety Officer, who shall be

responsible for the implementation of safe working practices throughout the
Contract.

The Safety Officer shall when required, deal directly with the Engineer’s
Representative on matters of safety, and shall submit Accident Reports as
required in the Conditions of Contract in a form to be agreed.

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1.3.2 Submittals

1.3.2.1 Contents

This Section includes:

1. Submittal Procedures

2. Product Data

3. Shop Drawings

4. Samples

5. Initial List of Spares

6. Operation and Maintenance Manuals

7. Certificates and Affidavits

8. Project Documentary

9. Miscellaneous Submission

1.3.2.2 Definitions

a) Product Data and Shop Drawings

(i) Includes drawings, diagrams, illustrations, brochures, schedules, bill of

materials, and other data prepared specifically for the Work.

(ii) Information may be prepared by Contractor, his subcontractors, suppliers or

distributors, equipment manufacturer, or fabricators.

(iii) Information must illustrate or describe manufacture, fabrication,

construction, and installation of the Work or a portion thereof.

b) Manufacturer’s Representative

(i) Person actively working at manufacturer’s factory with minimum 5 years

experience

(ii) Familiar with actual problems of manufacturing, installing, and operating the
product.

(iii) Sales representative or agents are not acceptable.

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c) Working Drawings

(i) Contractor prepared plans for temporary structures and facilities.

(ii) Elements of work which may affect the safety of persons or property shall
be certified by a qualified engineer.

(iii) Calculations demonstrating adequacy of Contractor’s design shall be

submitted with the working drawings.

(iv) Follow submittal requirements for shop drawings.

d) Samples

(i) Physical examples illustrating materials, plant/equipment, or workmanship

for permanent Works.

(ii) Establish standards by which the Work will be judged.

e) Manuals

(i) Manufacturer’s written installation, start-up, operating, maintenance and

repair instructions.

(ii) Include parts lists, pictures, sketches and diagrams specific to the
equipment supplied to document the manufacturer’s requirements.

1.3.2.3 Submittal Procedures

a) Contractor shall make submissions only to the Engineer. All submittals, requests
for action, notifications, etc. shall be through the Engineer.

b) All data and correspondence prepared by subcontractors and suppliers shall be

submitted through the Contractor as follows:

(i) All submittals shall be in English.

(ii) Make all corrections and changes to submittals as required by the Engineer
and resubmit until approved.

(iii) Review submittals returned by the Engineer.

c) The Contractor shall ensure the following:

(i) Determine if changes requested by the Engineer result in extra cost.

(ii) Notify Engineer in writing within 5 days of receiving submittal if contractor

believes extra costs are incurred.

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(iii) Failure of the contractor to notify the Engineer of the extra costs or
Contractor’s proceeding with the work waives Contractor’s claim for
compensation.

d) The Contractor shall review and approve all shop drawings, product data,
samples and manuals required by the contract documents prior to submitting
them to the Engineer. Review and approval shall be for compliance with the
contract requirements and shall have the following significance:

(i) Approval indicates Contractor has verified all materials, field measurement,
field construction criteria and similar items.

(ii) Approval also indicates Contractor has co-ordinated information contained

in submittal with Work requirements of other trades and with the Contract
Documents.

e) The Contractor’s reviews and submissions to the Engineer shall be such as to not
delay the work. The Contractor shall prepare submittals in such a manner that no
more than one re-submittal is necessary to obtain the Engineer’s approval.

f) Submissions of manufacturer’s data, including data specified as “for information

only” shall be made prior to beginning any portion of the work using materials
contained in the submittals.

g) Contractor shall submit shop drawings and product data in accordance with
approved submittal schedule and allow adequate time for the Engineer’s view,
approval and transmittal back to the Contractor.

h) Contractor shall detail items not completely described on the Contract Drawings
in accordance with standard engineering practice.

(i) Adjust dimensions shown on the Contract Drawings to reflect dimensions of

equipment provided.

(ii) Co-ordinate dimensions shown on the Contract Drawings as well as actual

equipment dimensions with measurements of existing, adjacent,
incorporated, and completed work to ensure all components fit into the
space available.

(iii) Verify all dimensions before beginning any work depending on such data.

i) The Contractor shall identify each and every deviation from the Contract
Documents to the Engineer either on the shop drawing or in the letter of
transmittal and:

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(i) Explain reason for deviation.

(ii) Compare requested deviation with contract requirement.

(iii) Explain why deviation is equal to or better than contract requirement.

(iv) Contractor shall not be relieved of responsibility for executing work in

complete conformance with Contract Documents for submittals not
identifying deviations, even when such submittals may have been approved.

j) Contractor shall submit shop drawings and product data for related equipment
items and integrated system components at the same time.

k) Partial submissions may be returned to the Contractor without review.

l) Contractor shall co-ordinate shop drawings and products:

(i) Co-ordination shall include:

 Drawings and data previously submitted.

 Drawings and data being prepared.

 Drawings and data previously approved.

(ii) Contractor’s approval and submission of shop drawings and data to the
Engineer indicates that such co-ordination has been performed and
completed.

m) Contractor shall direct Engineer’s attention either in writing or on the re-submitted

documents to each and every revision including those requested by the Engineer
on previous submittals and explain, in writing, the reasons for the revision. The
Contractor shall not deliver materials or equipment either to storage or at the
project site and not incorporate into the works until such items have been
approved or authorised in writing by the Engineer.

n) The Contractor shall not perform any work until shop drawings have been
submitted to and approved by the Engineer.

o) All submittals from the Contractor shall include a label or stamp which indicates
that the submittal has been reviewed and approved by the Contractor for
conformance to the contract requirements.

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(i) The labels or stamp shall generally conform to the following:

SUBMITTAL NO. ________________

FOR CONTRACT NO. ________________

PROJECT NO. ___________________

CONTRACTOR: ___________________________

REVIEWED AND APPROVED for Conformance with the Contract

Documents

By: ______________________ DATE:_________________

___________________________

(Signature)

REFERENCE:

DRAWINGS NOS. _______________________

SPECIFICATION NOS. _______________________

BoQ ITEM NOS. _______________________

(ii) A ten-character submittal identification and numbering system shall be

used. Submittals for Civil, Mechanical and Electrical items shall be
submitted separately.

i. The first character shall be either “D”, “S”, or “M”

representing shop or working drawing (D,) sample (S), and
operation/ maintenance manual (M).

ii. The next five digits shall be the applicable specification

Section number.

iii. The next three digits shall be the numbers 001 through
999 sequentially number each separate package
submitted under each specific Section number.

iv. The last character shall be the letter “A” through “Z”
indicating whether the submittal is the first submission (A)

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or a re-submission (B through Z). The letter “B” indicates

the second submission (first re-submittal), “C” the third
submission (second re-submittal), etc.

v. An example of a submittal number is D-03300 – 008 – B

which indicates:

D - Shop Drawing

03300 - Specification for Concrete

008 - The eighth separate submittal under this

Section

B - The second submission (first re-submittal)

of that particular information.

p) Engineer’s Review

(i) Revised submittals will be returned to the Contractor with the Engineer’s
comments, if any.

(ii) Engineer’s review is for general conformance with the contract requirements
only.

1. All works are still subject to the detailed requirements of the

Contract Documents.

2. Engineer’s review is to help the Contractor by discovering errors

and omissions.

(iii) The Engineer’s review does not relieve the Contractor of the obligation and
responsibility to co-ordinate and plan the details of the Work and fulfil the
intent and purpose of the Contract.

(iv) The Engineer’s review shall not relieve the Contractor of the responsibility
for accuracy, proper fit, or proper functioning and performance of the work.

(v) The Engineer reserves the right to require written confirmation from the
Contractor that the comments placed on submittals stamped “Approved as
Noted” will actually be implemented.

(vi) The Engineer will make every reasonable effort to process and return each
submittal within 30 calendar days after its receipt in the Engineer’s office.

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i. Large or multiple submittals may require up to 45 calendar

days.

ii. Contractor may prioritize submittals and Engineer will review

and return them in the order of the highest priority.

iii. Individual drawings from large submittals with numerous

drawings may be returned as they are reviewed rather than
waiting for the entire review to be completed.

iv. The need for re-submissions or delays in obtaining the

Engineer’s review or approval shall not entitle the Contractor
to a time extension for contract completion.

(vii) Categories used by the Engineer to evaluate submittals are defined below:

i. Approved

No discrepancies have been identified.

ii. Approved As Noted

The submittal is acceptable subject to incorporation of the

comments listed.

iii. Disapproved

The submittal is unacceptable for the reasons cited.

iv. Incomplete

. The submittal is being returned without review.

2. Insufficient information has been provided or the
submittal does not comply with the contract
requirements.
v. Noted

1. The submittal is not required by the contract

documents.
2. The Engineer will include it in the project files for
information only.
(viii) Incomplete submittals including those not correctly transmitted, incorrectly
titled and identified, or not bearing the Contractor's review and approval

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stamp may be returned to the contractor without review. This may not be
used by the Contractor as a cause for delay.

(ix) Minimum Copies for Engineer's Review

i. Two (2) reproducible copies plus two photocopies or blue line

prints for each shop drawing.
ii. Four (4) copies of all product data and manuals.
iii. The Engineer will return one (1) reproducible and one copy or
print of each shop drawing and two (2) copies of product data or
manuals to the Contractor.
iv. The Engineer may require additional copies of all submittals (in
either electronic or hard copy format) by notifying the Contractor
in writing and such additional copies will be at no extra cost.
1.3.2.4 Product Data

a) Shall be explicit with regard to details of the actual products being furnished, and
shall provide sufficient information to the Engineer to determine that the products
submitted conform to the specification requirements.

b) The country of origin for all equipment and material to be used on project.

c) Affidavit from manufacturer of each equipment item that it has been installed and
is successfully operating in at least five facilities of a similar size and type as
specified.

d) Submittals with more than one style, size, capacity, etc. of a product on a page
shall clearly indicate which product type is being submitted for approval. Failure to
do this shall be cause for disapproval.

e) Present information on pages not larger than size A4.

f) Include the name of the product manufacturer on all catalogue data.

1.3.2.5 Shop Drawings

a) Provide detailed drawings and written descriptions of both the assembly and all
components.

b) Drawings shall indicate proposed installation of Work as well as materials and

equipment being furnished.

c) Identify proposed deviations from the details or component arrangement as

specified or shown on the Drawings.

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(i) Present reasons for the proposed deviations.

Explain why proposed deviation is "equal to" that specified.

d) Information shown on shop drawings shall be complete and sufficient for Engineer
to review for compliance with contract requirements, and shall include but not
necessarily be limited to the following:

(i) Layout dimensions and component sizes including bases, foundations,

anchors, and similar items.

(ii) Design criteria.

(iii) Materials of construction.

(iv) Component and assembly weights.

(v) Utility requirements (power, water, etc.).

(vi) Manufacturer's rating or performance curves.

(vii) Wiring diagrams and control schematics.

(viii) Recommended spare parts.

(ix) Special tools.

(x) Deviations from contract requirements.

(xi) Additional requirements contained in individual specification sections.

e) Copies of the Contract Drawings are not acceptable for submission as component
arrangement (layout) drawings.

f) Manufacturer's model numbers or catalogue numbers alone shall not be

acceptable for describing equipment or components.
1.3.2.6 Samples

a) Furnish samples as required by the individual specification section.

b) Unless otherwise specified, samples shall be submitted as follows:

(i) Submitted to Engineer as specified.

Labelled and properly identified as follows:

i. Date.
ii. Project / Work Area for which offered.

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iii. Specification section and applicable paragraph numbers.

iv. Contractor.
v. Supplier / Manufacturer.
vi. Product Identification (Trade Name).
c) Samples shall be accompanied by an approved transmittal form, specifications
and other pertinent data required for Engineer to determine that the material
conforms to the specification.

d) Three sets of samples shall be submitted unless otherwise specified.

(i) One set of approved samples and all disapproved samples will be returned
to the Contractor.

(ii) If requested in writing by the Contractor, samples of value will be returned to

the Contractor after completion of the Work.

(iii) Approved samples returned to the Contractor may be incorporated into the
work upon written approval of the Engineer.

1.3.2.7 Initial Spare List

a) Initial list of spares as recommended by the respective manufacturers shall be

submitted along with the material submittals.

1.3.2.8 Operation and Maintenance Manuals

The Contractor shall:

b) Submit manuals for all equipment and components specified.

c) Manuals shall be as specified.

d) Submit two copies for review.

(i) The Engineer will return one copy of the reviewed manual to the contractor
for correction.

The Engineer will retain one copy for project files.

e) Submit six copies of approved manuals incorporating all of Engineer's comments

and corrections prior to beginning training.

1.3.2.9 Certificates and Affidavits

a) The Contractor shall provide the original and three copies of manufacturer's
certificates in accordance with the requirements specified in the Specification.

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b) Definitions

(i) Certificate indicates test results, component manufacture, or installation

complies with specified standards.

(ii) Affidavit is a sworn statement by an officer of the company manufacturing

the product indicating that the information on the certificate is true and
accurate.

c) An affidavit shall accompany all certificates.

d) A statement from the contractor, sub-contractor, equipment supplier, or agent

indicating the product meets the requirements of the Contract Documents shall
not be considered as a certificate.

(i) Such submittals shall not be approved.

Corresponding equipment, products, or components shall not be accepted.

1.3.2.10 Project Documentary

The Contractor will be required to develop a professional documentary movie on the

project scheme covering each aspect of the project including startup, construction and
commissioning phases, The documentary movie should be oh high quality and the
content and duration of movie should be agreed with the Engineer at the start of the
project.

1.3.2.11 Construction Environmental Management Plan

The Contractor shall prepare and submit a construction environmental management

plan for the project as per Dubai Municipality guidelines given in the appendix.
1.3.2.12 Miscellaneous Submissions

a) Manufacturer's guarantees and warranties

(i) Submit 3 copies unless otherwise specified.

(ii) Submit prior to final acceptance.

b) Work plans

(i) Submit 3 copies, unless otherwise specified, at least 30 days prior to

beginning work.

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c) Submittal Schedule

(ii) Show the proposed date the contractor will deliver each required submittal
to the Engineer for review.

(iii) Submit within 10 calendar days of receiving notice to Commence.

d) Health, Safety and Fire Protection Plan

(i) Submit 3 copies unless otherwise specified.

(ii) Refer to relevant Section for specific requirements.

e) Accident Reports

(i) Submit 3 copies unless otherwise specified.

(ii) Refer to relevant Section for specific requirements.

f) Progress Reports

(i) Prepare and submit the Progress Reports described hereinafter in a form
provided by the Engineer.

(ii) Work activities and procurement reports should be referenced where

relevant to the approved Contractor's Construction Schedule.

(iii) Submit 3 copies unless otherwise specified.

(iv) Daily Construction Reports.

 Submit on a daily basis.

 Describe labour force and its allocation.

 Describe material and equipment utilised.

 Describe work progress during the day.

 Describe temperature and weather conditions.

 Describe any occurrence which may affect the progress of the Works.

(v) Procurement Status Reports

 Submit on a weekly basis.

 Include a list of materials and items procured.

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 Include list of items delivered to the site.

 Provide references to all correspondence and transmittals between the

Contractor and the Engineer regarding approval of such materials and
items.

(vi) Monthly Report

 Reflect monthly progress and status of the Work.

 Describe problem areas.

 Describe current or anticipated causes of delay along with their

estimated impact on progress and the corrective measures taken or
proposed.

 Include construction photographs.1

g) Inspection and Test Reports

(i) Submit 3 copies unless otherwise specified.

h) Survey Data

(i) Submit 3 copies unless otherwise specified.

(ii) Survey data is required to develop quantitative record of actual work

constructed, as part of damage and settlement surveys, surveys of adjacent
construction and similar efforts.

i) Close-out Submittals

(i) Refer to Section or specific requirements.

j) Record (As Built) Drawings

k) Schedule of Values

(i) Submit 3 copies unless otherwise specified.

l) Letter of Authority

(i) Submit within 10 days after receipt of the Letter of Acceptance.

(ii) Identify the Project Manager and detail the extent of his authority and
responsibility.

 All work to be under direct supervision of Contractor's on-site

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representative who shall be the Project Manager.

 Project Manager shall be present at the job site whenever Work is

underway.

 Project Manager shall have full authority to represent the Contractor.

 Communication given to or received from the Project Manager shall be

as binding as that given to or received from the Contractor.

m) Organisation Chart

(i) Submit for Engineer's approval not later than 14 days after receipt of the
Letter of Acceptance.

(ii) Show the executive, administrative, and construction supervision

organisation.

 Include all personnel from Project Manager through foreman level.

 Describe personnel duties.

 Amplify details provided after submission of Tender.

 Provide qualifications and experience of all personnel shown on the

Organisation Chart.

(iii) Update the Organisation Chart whenever key personnel are reassigned.

(iv) The Engineer may interview any of the Contractor's proposed staff prior to
approval.

(v) The Engineer may direct the Contractor to remove personnel from the site
who, in the Engineer's sole opinion,

 Exhibit inappropriate conduct.

 Who are incompetent or negligent in the performance of their duties.

 Who are otherwise considered undesirable.

n) Site Layout for Contractor’s Facilities

(i) Submit within 14 days after receipt of the Letter of Acceptance.

(ii) Site plan should include but not necessarily be limited to the following:

 Temporary facilities including accommodation.

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 Storage areas including permanent dumping of excavated material and

all debris

 Crane positioning.

 Fences, gates and security lighting.

 Access for other Contractors, vendors, plant staff, visitors, etc.

o) Evidence of Insurance as required in Conditions of Contract.

p) Correspondence

(i) Provide one original and three photocopies of transmittals and letters
including attachments and enclosures.

(ii) Submit on A4 size whenever possible.

(iii) Clearly indicate the following on each document.

 Contract Number.

 Title of Project.

 Contractor's Name.

 Date.

 Correspondence Reference Number.

1.3.2.13 Spare Parts Recommended by the Manufacturer

The Contractor shall submit with the Operation and Maintenance Manuals a list of
spares as recommended by the respective manufacturers which would be required for
operating the equipment for a period of two (2) years on completion of the Defects
Liability Period.

Each item in the list shall be priced and the employer retains the option of purchasing a
part or all of the spares thus recommended by the Contractor.

1.3.3 Setting Out the Work

a) The Contractor shall set out the work as to lines and grade in accordance with the
Drawings and secure the approval of the Engineer's Representative before
constructing the work. The Engineer's Representative will, if he deems it necessary
revise the lines or grades and will require the Contractor to adjust and to stake-out
accordingly. The Contractor shall give the Engineer's Representative not less than 24
hours’ notice of his intention to set out or give levels for any parts of the Works, in
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order that arrangements may be made for checking. The Contractor shall be
responsible for obtaining any setting-out data he may require from Dubai Municipality
Survey Section. The Contractor shall also be responsible for obtaining Dubai
Municipality Survey Section’s approval on right-of-way. Any costs incurred in this
shall be borne by the Contractor.

b) The Contractor shall, as a requirement of the Contract and without extra charge,
provide all necessary instruments, appliances, surveyor personnel and labour, and
any other material or staging, which the Engineer's Representative may require for
checking the setting out or for any relevant work to be done. Any marks made by the
Engineer's Representative or Contractor shall be carefully preserved and, if
destroyed, shall be replaced by the Contractor at his own expense and to the
approval of the Engineer. Work shall be suspended for the time necessary for
checking the lines and levels on any part of the work, and shall proceed only after
approval of measurements.

c) In the case of any variation from the approved works, the Contractor shall give the
Engineer three copies of cross-sections and profiles of the graphical record or notes
and computations of his stake-out as required by the Engineer. At his option he may
submit cross mark on one copy with his approval of the proposed lines of the work or
his revisions thereof and return it to the Contractor. The Contractor shall resubmit for
approval any cross-sections the Engineer may amend.

1.3.4 Notice of Operations

a) The Contractor shall, when required, supply in writing full information regarding
the localities in which the materials are being obtained and in which the work is
being prepared.

b) No permanent work shall be carried out without the consent in writing of the
Engineer's Representative. Full and complete notice, in writing, shall be given 24
hours in advance of the time of the operation in order to make such arrangements
as deemed necessary for inspection.

1.3.5 Traffic Safety and Control

a) The Contractor shall provide, erect and maintain such traffic signs, lamps barriers
and traffic control signals as may be necessitated by the construction of the
Works in accordance with Road and Transport Authority and Dubai Traffic Police
requirements. The Contractor shall submit proposals for dealing with such
situations to the Engineer, RTA and Dubai Traffic Police for consent. Compliance
with this Clause shall not relieve the Contractor of any of his other obligations and
liabilities under the Contract.

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b) The Contractor shall, after consultation with any statutory or other authority
concerned, submit to the Engineer for his approval a programme based on such
consultation showing the scheme of traffic management he proposes for carrying
out the Works before commencing any work which affects the use of the public
highway rights of way or parking areas and thereafter furnish such further details
and information as necessitated by the Works or as the Engineer may require.

c) The Contractor shall not commence any work which affects the public highway
until all traffic safety measures necessitated by the work are fully operational.

d) The traffic diversion and signs, lamps, barriers and traffic control signals shall be
in accordance with the requirements of regulatory authorities.

e) Traffic signs shall comply with the requirements of RTA. The flashing rate for
flashing lamps shall be within the range 120-150 flashes per minute. The
minimum luminous intensity of the lamps shall be 0.5 candelas for steady lamps,
1.0 candela for ripple lamps at their peak, and 1.5 candelas for flashing lamps at
their peak.

f) The Contractor shall keep clean and legible at all times all traffic signs, lamps,
barriers and traffic control signals and he shall position, reposition, cover or
remove them as necessitated by the progress of the Works.

g) Where road diversions roads are approved these must be maintained at

frequencies to suit the traffic volume using them. A good running surface must be
maintained and must at all times be free from ruts and potholes.

1.3.6 Access to Private Land

The Contractor shall give three weeks’ notice to the owner/occupier before entering
private lands and the Contractor shall not enter on to those lands until given
permission by the Engineer.

1.3.7 Roads and Site to be Kept Clean

a) The Contractor shall take great care and all reasonable precautions to ensure that
roads and thoroughfares used by him either for the construction of the Works or
for the transport of plant, labour and materials are kept clean during such
construction or transport and in the event of their requiring cleaning in the opinion
of the Engineer the Contractor shall take all necessary and immediate steps to
clean them.

b) On completion of dewatering the Contractor shall immediately dismantle and

remove from the Site disused discharge pipes and dewatering points.

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c) Each individual site of work must be clean during the work and must be
thoroughly cleaned up on completion.

1.3.8 Compensation for Damage to Property

a) The Contractor shall reinstate all properties whether public or private affected by
the Works, Temporary Works, constructional plant, labour materials or transport
to a condition at least equal to that existing before his first entry on to them.

b) If in the opinion of the Engineer the Contractor shall have failed to take
reasonable and prompt action to discharge his obligations in the matter of site
clearance or reinstatements the Engineer will inform the Contractor in writing of
his opinion in which circumstances the Employer reserves the right to carry out
the reinstatement himself or to arrange for it to be carried out by others or to
make payments to the owners and occupiers in respect of such matters for which
the Contractor is responsible. All such costs incurred and payments made will be
deducted from any monies due or which shall become due from the Employer to
the Contractor.

1.3.9 Existing Services

Drains, pipes, cables and similar existing services encountered in the course of the
Works shall be protected from injury or damage by the Contractor at his own cost so
that they may continue to function uninterruptedly to the satisfaction of the owners
thereof and the Contractor shall not store materials or otherwise occupy any part of
the site in any manner likely to hinder the operations of such owners.

a) The Contractor shall protect and support, during the progress of the Works, all
pipe mains, cable wires and other apparatus which might be endangered by his
operations. The approximate positions and alignments of known services are
indicated on the Drawings, but no guarantee of exact location can be given, and
the Contractor must communicate with the authorities and/or proprietors
concerned to locate them exactly, and he shall then prepare shop drawings 1/500
scale for each Utility as directed by the Engineer. When approaching each
indicated position, the Contractor shall search, by safe methods which will not
endanger the service, to determine its precise position.

b) The Contractor shall make his own arrangement with the owners of the services
and with other persons interested, for any diversions, temporary stoppages and
reinstatements, and he shall allow in his programme for all such arrangements.

c) If any underground service is encountered unexpectedly, excavation shall cease,

and the Engineer's Representative shall be notified immediately. Emergency

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work, as necessary, should be put in hand without delay and without prejudice to
the indemnity of the Employer.

d) The Contractor shall give notice, in writing, to the Engineer and to the appropriate
service company of all damages to existing services caused by him or by any
Subcontractor in the course of the Works. He shall be held responsible for any
such damage and shall immediately have such damage made good at his own
expense and shall relieve the Employer of all claims in respect of any loss or
interruption involved.

e) If in the opinion of the Engineer, it is necessary or expedient that any pipe, drain,
ditch, cable or overhead wire (including supports) should be broken out, stopped
up, diverted, taken down, or altered, the cost of doing so shall be the
responsibility of the Contractor. Such work shall be executed only on the written
instruction of the Engineer.

f) All existing sewers, culverts, water courses and drains of every kind and condition
that have been altered, extended or otherwise interfered with either directly or
indirectly by the work, or that may by leakage, silting, stopping of free flow or
otherwise interfere with or delay the execution of the work, shall be made good,
cleaned, placed in working order, supported, maintained, and protected and the
Contractor shall provide everything necessary for efficiently dealing with,
protecting, pumping or removing, as the case may be, all water, sewage, or spoil
there from.

1.3.10 Continuous Working

If in the opinion of the Engineer it is necessary for the safety of the Works or for any
other reason, the Contractor shall, when so ordered, carry out the Works, or any
portion thereof continuously by day and night. The Contractor will be reimbursed the
agreed extra costs, provided the necessity for the order is not a result of the
Contractor's negligence.

1.3.11 Temporary Staging for Structures

Temporary staging shall be provided by the Contractor to enable the construction

operations to be performed in the required sequence. The staging shall be properly
designed and constructed for the loads which it will be required to support, and
complete details of the arrangements proposed shall be submitted to the Engineer for
approval.

Such approval, however, will not relieve the Contractor of his responsibility for the
adequacy of the staging. The cost of such staging is to be included in the tendered
rates and prices entered in the Bills of Quantities.

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1.3.12 Water Supply

The Contractor shall carry out an investigation prior to submitting his Tender as to the
availability of water for the purpose of the Works and shall consult and arrange with
the appropriate authorities and consider all legal aspects. The Contractor shall be
entirely responsible for the supply of sufficient water of the specified quality at all
times throughout the Contract, and the costs shall be deemed to be covered in the
Contract rates and prices.

1.3.13 Filling in Holes and Trenches

The Contractor, immediately on completion of any part of the work, shall, at his own
expense, fill up all holes and trenches which have been made or dug by him and are
not part of the Works. Holes, cavities, trenches or depressions shall be backfilled with
suitable materials and compacted to the grade required or as directed by the
Engineer. The Contractor shall clear away all rubbish and materials that is no longer
required for the execution of the work, whether his own or any other party to the
satisfaction of the Engineer.

1.3.14 Protection of Works from Weather

The Contractor, at his own expense, shall protect all works and materials from
damage by weather. All damage caused by adverse weather conditions, whether by
flooding or intense heat or any other weather conditions shall be rectified by the
Contractor at his own expense. Abnormal weather conditions shall not be considered
any reason for a claim by the Contractor for compensation for damage.

1.3.15 Keeping the Works Free from Water

The Contractor shall at his own expense keep the works at all times well drained and
excavations whether above or below the normal water level of the water table free
from storm or percolating water which may accumulate on the Site and which may
interfere with progress of construction or has or is likely to have deleterious effect on
the work in progress or the use thereof, by provision of temporary open drains and
sub-soil drains, diversion of ditches and other surface water channel or by pumping or
other means as required.

1.3.16 Sign Boards

a) The Contractor shall provide and erect signboards as detailed in the BoQ, at the
Site and at the Offices of the Engineer and the Contractor. Normally signboards
will be required on all major road approaches to the Site.

b) The layout and lettering size and location of all signboards and their siting shall be
subject to the approval of Dubai Municipality.

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c) The signboards shall give, in English and Arabic, the name of the Project and the
names, Post Office Box numbers and contact telephone numbers of the
Employer, the Engineer and the Contractor. The boards shall be of dimensions
as shown on the drawings and shall be of durable construction capable of
withstanding the effects of the climate for at least the period of the construction
and the Defects Liability Period. The boards shall be mounted on substantial
frames.

d) The signboards shall be periodically cleaned, remain legible and be maintained in

a structurally safe condition throughout the period of construction and Defects
Liability Period. Upon issue of the Defects Liability Certificate they shall be
removed from the Site within two weeks.

1.3.17 Templates

a) When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of certain
work. The templates will be in accordance with the Specifications and Drawings
where such are provided.

b) All templates must be approved and shall be maintained in good order to provide
the section required for the entire works. Templates may be checked from time to
time and any deficiencies noted shall be rectified immediately.

c) The Contractor shall also supply straight edges and lines when required to control
the work.

1.3.18 Assistance to the Engineer

a) The Contractor shall provide and maintain for the use of the Engineer such
surveying and engineering instruments as the Engineer may require for his duties
as detailed in (Clause 1.3.19). The Contractor shall provide the Engineer with all
necessary assistance in checking the setting out of the Works and interpreting
any information used by the Contractor for this purpose including the sole use of a
minimum of three (3) chainmen.

b) The Contractor shall provide the Engineer with all assistance, equipment and
material required to document and record progress of the Works.

c) The Contractor shall provide all assistance, equipment and material required by
the Engineer for all the measurement of the Works for monthly valuation and for
the final certificate payment.

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d) The Contractor shall be responsible for all follow up and co-ordination with all the
service departments. (Electricity, Water, Drainage, Street Lighting, Telephone,
Horticultural, etc.).

e) The Contractor shall provide all unskilled labour and necessary tools as directed
by the Engineer.

f) If at any time before the commencement or during the progress of the work it
appears to the Contractor that for the proper execution of a specified part of the
Works, shop drawings are necessary, these drawings shall be established by the
Contractor and submitted to the Engineers' Representative for approval. The
Engineer's Representative shall have authority to order at any time and the
Contractor shall agree to provide any number of shop drawings which, in the
opinion of the Engineer's Representative are necessary for the proper execution
of a specified work. The Contractor shall not proceed with the above mentioned
work until these shop drawings are approved by the Engineer's Representative.
The Contractor shall not be entitled to any extra compensation or extension of
time for the preparation of the above mentioned drawings.

(i) These details shall be dimensioned in the metric system and shall describe
accurately the method of fabrication, applied finish and sizes of all members
and fixings and shall indicate methods of marking of components for site
erection.

(ii) The Engineer shall furnish the Contractor with paper print and digital
contract drawings, to be updated as the Works proceed. The Contractor
shall provide full details of revisions to these drawings, both digitally and
hard copies, in accordance with Dubai Municipality Drainage and Irrigation
Department requirements. Required information shall include the following:

Main Drawings:

 1 set of paper prints on hangers.

 1 set of paper prints bound.

 1 set of digital drawings on CD.

The information should be sufficiently detailed to include, but not be limited

to the following:

 Offsets from permanent references such as road edge, road centerline,

kerb line, building line, etc., at suitable intervals as directed by the
Engineer, for all services encountered during the Works and during trial
trenches including description of offsets.
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 Level profiles for all sewerage, drainage, rising mains.

 House connection layout and details to be completed as separate

drawings and included on main sewer layout drawings.

 Modifications to any standard details for specific constructions.

 Service Details determined from trial excavations and at crossing points.

 Mechanical and Electrical details

The Contractor shall at the commencement of works, provide the Engineer's

Representative for his full and exclusive use sufficient number of water, soil, concrete,
asphalt, and room thermometers as required by the Engineer.

1.3.19 Surveying Equipment

1.3.19.1 General

The contractor shall provide and maintain in good condition at all times, the following
new survey equipment and materials during the continuance of the Contract for the
exclusive use of the Engineer and his staff:

Table 1.3 Schedule of Equipment

Item Description No. Required

1. Rolling Straight Edge As required

2. Electronic total station (TC 1800 or equivalent) with data 1

recording and transfer facilities to computer including
data logger etc.

3. Target reflectors with 2 km range 2

4. Tripod for reflector 2

5. Automatic level, tripod and staff (NAK 2 or equivalent) 3

6. Staff Levelling Plate 3

7. 3 metre ranging poles (folding or detachable type) 10

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Item Description No. Required

8. 50 metre steel tape ( Non-corrosive) 8

9. 30 metre steel tape ( Non-corrosive) 8

10. Fibre tape, 30 m length with case 3

11. 5 metre steel tape ( Non-corrosive) 4

12. 3 metre steel pocket tape graduated in mm 2

13. Conical Plummet 2

14. Steel straight edge , 1 m length 1

15. Spirit Level , 1 m Length Aluminium spirit level 1 metre 1

long with four plumbs and two level tubes

16. Spirit Level , 4 m Length 1

17. Mason string line , 100 m length 6

18. Portable concrete thermometer, ELE Model EL 34 – 112 6

or approved equal

19. Shovel 3

20. Flask, with thermal insulation, 1 litre capacity 3

21. Water containers, 5 litre capacity 3

22. Thermometers, wet and dry bulbs, graduated in degrees 3

C and F

23. Crack detection pocket microscope, latest model or 1

approved equal

24. Pocket penetrometer ELE latest model or approved 3

equal

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Item Description No. Required

25. Optical Square 1

26. Manhole lifting keys for : heavy duty covers 6

medium duty covers 6
light duty covers 6

27. Weatherproof, rubber-cased torches 6

28. Survey arrows, wooden pegs, hilti nails etc As required

29. Safety helmets As required

30. Marking chalk, paint As required

31. Copy of all standards referred to in the Specification 1

32. Digital camera 6 mega pixel or better 1

33. Hammer 1 kg 2

34. Hammer 3 kg 2

35. Level books, field books, surveying umbrellas As required

36. Silica gel bags As required

37. Universal straight edge 3 metre with edge gauge 1

1.3.19.2 Expendable Materials

The Contractor shall provide adequate supplies of expendable materials such as

stationary, pencils, inks, drawing paper, pens, pegs, brushes, paint and other similar
items required for the satisfactory completion of survey and as required by the
Engineer's Representative.

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1.3.20 Laboratory

See Appendix for Laboratory Testing.

1.3.20.1 General

Testing of all materials and completed work shall be carried out in accordance with
DM Administrative Decision No. 160 for 2000.

a) For testing of materials, etc., the Contractor shall use either:

(i) the services of an accredited independent laboratory.

(ii) The services of Dubai Municipality Dubai Central Laboratory (DM-DCL)

b) All transportation of personnel and materials together with the provision of all
assistance to laboratory testing shall be borne by the Contractor. For this purpose
one (1) approved long wheel base 4WD vehicle shall be maintained for this
specific use by the Contractor to be at the sole and full time disposal of the
Engineer. The role of this vehicle will include the delivery and uplifting of all
material for the laboratory including test results. Contractor's technician shall not
participate in the testing. Notice of tests shall be given to the Dubai Municipality at
least one day prior to the proposed testing.

c) Dubai Municipality shall charge the Contractor for all testing and re-testing. Also
Dubai Municipality shall, at the discretion of the Engineer, have the right to charge
for additional material testing where this additional testing is, in the view of the
Engineer, caused by negligence or insufficient testing prior to submission of
materials on the part of the Contractor. All charges for testing and/or re-testing will
be at Dubai Municipality standard rates current at the time of testing/re-testing.

d) The testing of the Works by the Dubai Municipality does not absolve the
Contractor of his responsibility for the quality control of workmanship and
materials.

e) The Engineer and the Contractor's authorised representative shall be permitted to

witness any testing carried out by the Dubai Municipality Dubai Central
Laboratory (DM-DCL)

f) Dubai Municipality Dubai Central Laboratory (DM-DCL) will not be held liable for
the interpretation and correctness of test data. This will also be the responsibility
of the Engineer and the Contractor, respectively.

g) All sampling for such tests shall be carried out by the Consultant's Inspectors and
labelled as per the relevant standard sampling requirements (as listed in Clause
1.3.21).
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h) Copies of the tests carried out by independent laboratories shall be forwarded to

the Dubai Municipality Dubai Central Laboratory (DM-DCL) for information if they
so require.

i) Wherever there is a reference to Dubai Municipality Construction Quality Control

and Research Section (DM CQC & RS) it shall be read as Dubai Municipality
Dubai Central Laboratory (DM-DCL).

1.3.21 Minimum Test Requirements

The following is the schedule of minimum requirements governing tests of materials

which shall be carried out during the execution of the Works. Should the Engineer's
Representative deem it necessary to increase or reduce the number of the following
mentioned tests, he shall issue his written instructions to the Contractor as and when
required, following due consultation with the Employer.

Table 1.4. Minimum Test Requirements of Materials

Materials Frequency Relevant Standard and test methods

Water for concrete One test for each source and as BS 3148 or BS EN 1008
directed by the Engineer
thereafter the minimum ASTM D512, ASTM D513, ASTM
frequency test as specified in Cl. D516, ASTM D1293 BS 1377
3.2.2.2. Part 3

Portland Cement One bag of cement for Quality BS 12 (BS EN 197) – O.P.C.&
testing shall be taken from each MSRPC/ASTM C150 Type II
200 tonnes or fraction thereof
for each source or BS 4027 – SRPC or ASTM C150
manufacturer. Frequency test as Type 5
specified in Clause 3.2.2.2. Test Method : BS EN 196 & BS
4550 :P3 Section 3.8:1978

Coarse Aggregate One sample for quality testing BS EN 12620 :2002 – Latest Edition.
for Concrete shall be taken from each
designated source. After BS 812 – Parts 103, 105, 111, 112, ,
approval frequency test shall be BS EN 933.1:2012, BS EN 933-
carried out as specified in Table 7:1998, BS EN 1744-1:2009 , BS EN
3.4. 1367-4:2008, BSEN 932 & 1097,

ASTM-C88, C131/C535

C123, C142, C117, C127/C128,

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Materials Frequency Relevant Standard and test methods

C289, C295, C586, C227 and P214

Fine Aggregate for As for Coarse Aggregate above. BS EN 12620:2002+A1:2008

Concrete
As for Coarse Aggregate above.

ASTM C40, C128

Bitumen Binder for As specified in Clause 3/47.1, As specified in Clause 3/26.3 of

Bituminous mixers Section 3 of Roads Specification Section 3 of Roads Specification
(Refer Appendix). (Refer Appendix).

Coarse Aggregates As specified in Clause 3/47.2, As specified in Clause 3/22.4, Section

for Bituminous Section 3 of Roads Specification 3 of Roads Specification (Refer
Mixtures (Refer Appendix). Appendix).

Fine Aggregate for As for Coarse Aggregate above. As specified in Clause 3/23.4, Section
Bituminous mixtures To be followed as specified in 3 of Roads Specification (Refer
Clause 3/47.2 of Section 3 of Appendix).
Roads Specification (Refer
Appendix).

Bituminous Mixtures As specified in Clause 3/47.3, To be followed as specified in Clause

3/47.4 and 3/47.5 of Section 3 of 3/47.3, 47.4 & 47.5 Section 3 of
Roads Specification (Refer Roads Specification (Refer Appendix).
Appendix).

Suitable fill materials As specified in Clause 2.18. To be followed as specified in Clause

for Earthworks & 2/12.
Embankment

Materials for As specified in Clause 2.22.7. To be followed as specified in Clause

Structural Fill 2/12 & 3/8 of Section 3 Pavement
Construction (Refer Appendix).

Natural rounded One sample at the start of the Grading : BS EN 933.1:2012

coarse aggregate for project. After approval, samples
pipe bedding and of each nominal sizes of Compaction fraction : BSEN 752
specified aggregate for every
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Materials Frequency Relevant Standard and test methods

surround 1000 m3. Sulphate Content as SO3 : BS EN
1744-1:2009

Improved Subgrade As specified in Clause 2/18. To be followed as specified in Clause

Material 2/12.

Soil classification, soil chemical

tests and soil strength tests.

Soil compaction tests:

i. MDD/OMC test as specified. To be followed as specified in Clause

2/17

As specified in Clause 2/18.

Insitu density test.

If directed by the Engineer the

following tests may also be
carried out on the material as
laid on site.

iii. Field C.B.R. with a speedy BS 1377: Part 9: Test 4.3

estimate for moisture content
and dry unit weight.

Sub-bases, i. As specified in Section 3 of To be followed as specified in Section

Aggregate Road Road Specification Clauses 3 of Road Specification Clauses 3/6.2,
base and Wet mix 3/6.5, 3/13.1, 3/20.1 and 3.20.2 3/6.3, 3/6.4, 3/6.5, 3/8.2, 3/8.3, 3/10,
( Refer Appendix). 3/15.1, 3/15.3 and 3/18.1 ( Refer

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Materials Frequency Relevant Standard and test methods

Appendix) .

After laying and compaction the

following testing procedure shall
be followed as specified in
Clause 3/6.5, 3/13, 3/20 of
Section 3 - Pavement
Construction ( Refer
Appendix)..

BS 1377: Part 9: Test 2.2

Field density (3 no.)

Reinforcing Steel Reinforcement steel shall be BS 4449 of Latest Edition

supplied to site with
(uncoated) manufacturer’s mill certificate
and third party compliance
certificate for each load for all
diameters. When directed by the
Engineer:

a) at the start of the project all

specified test on reinforcement
shall be performed for the
following types:

i. Steel fabric reinforcement.

ii. Mild steel and high yield

(hot rolled) bars.

iii. Cold worked steel bars.

) Frequency test for the

reinforcement not covered by
third party certification scheme
shall be tested for every 100
tons as directed by the

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Materials Frequency Relevant Standard and test methods

Engineer.

Fusion bonded Epoxy coated reinforcement ASTM A775 / A775 M

epoxy coating on shall be supplied on site with
steel reinforcement coating applicators compliance
for concrete certificate for each load. When
directed by the Engineer all
specified tests shall be
performed:

at the start of the project on

each diameter of reinforcement

frequency tests on every 100

tons of reinforcement

Concrete Shall be obtained from each BS 8500 – 1&2 : 2006

mixer for each individual pour.
AMD: BS EN 206-1: 2002

a) Slump tests and compaction ) Sampling of fresh concrete

factor tests shall be carried-out
at the site of the actual placing BS EN: 12350-1: 2009
of concrete as directed by the ) Method & determination of slump BS
Engineer. EN 12350-2:2009

) Method of determination of
compacting factor BSEN 12350-3:
2009.

)
Preparation of concrete
specimens & curing of ) Sampling of fresh concrete
specimens. BS EN: 12350: 2009 Part 1

) Method of making concrete cubes

from fresh concrete BS EN 12390-2

) Method of curing test cubes BS EN

12390-2

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Materials Frequency Relevant Standard and test methods

) Method of making test cylinders
ASTM C496:1996.

b) Frequency test as specified in ) Sampling of fresh concrete

Table 3.18.
BS EN: 12350:2009 Part 1

Precast Concrete a) Flexural / transverse strength BS 7263-1:2001 , BS 7263-3:2001

and water absorption for each
supplier of precast kerbs and
slabs (3 no. samples).
Subsequently, on approval of a
source or supplier, 3 samples Sampling in accordance with BS 7263
will be tested every 1000 unit for P1: 2001
kerbs and 1000 units for slab
tiles.

b) At the start of the project, BS 5911-P3:2010

crushing strength of concrete
encased GRP microtunnelling
pipe on 1% of total length.

Concrete mix design One trial mix for each class of

concrete shall be verified by
DCL prior to approval by the
Engineer. For every mix design
the following test shall be
included

Fresh Concrete One test for each class of RCC

concrete
ASTM C232:1999
i. Bleeding test

ii. Air content in air-entrained

concrete BS EN 12350 P7:2009/ASTM C173

iii. Free water cement ratio BS 1881

iv. Workability BS EN 1250-2:2000

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Materials Frequency Relevant Standard and test methods

v. Wet Density BS EN 12350-6

vi. Drying shrinkage BS EN 12390-7-2000/ BS EN 772-

2:1998 , BS EN 771-3:2003
vii. Total sulphate and chloride
content in the mix As specified in Table 3.10

viii. Durability test as specified in Table 3.13

Hardened Concrete i. Density and compressive BS EN 12390-7, BS EN 12390-3

strength of concrete

ii. Depth of water penetration

BS EN 12390 P8:2009
iii. Initial surface absorption
ISAT-BS 1881:P208:1996
iv. Flexural Strength of
Concrete Prism BS EN 12390-5

v. Tensile Strength of Con.

Cylinder ASTM C496 or BSEN 12390-2
vi. Chloride permeability

vii. Water absorption ASTM C 1202: 1999

viii. Durability test As specified in BS1881: P122

As specified in Table 3.13

1.3.22 Sources of Materials

The Contractor shall be responsible for obtaining the Approval of the local Authorities
for the sources of materials and he shall have no right to claim for any compensation
if he is to pay for the material at its source.

1.3.23 Programming the Progress of the Works

a) A detailed computer-based programme using critical path methods shall be

produced by the Contractor as set out in the Conditions of Contract. This shall
include full details of resources and rates of progress. The Engineer may require

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the Contractor to modify the programme on occasions during the course of the
Contract. The Contractor shall work to the latest approved programme at all
times.

b) In planning his programme the Contractor shall allow reasonable time for the
Engineer to confirm setting out details as the Works proceed in accordance with
the programme.

c) The Contractor shall indicate on his programme whether the work is to be carried
out during normal site hours or whether overtime or a shift system is necessary to
execute the Works.

d) The Contractor shall present a weekly summary to the Engineer detailing

personnel, plant materials and equipment orders and shipping movements of
same.

e) Before the close of Site on each working day the Contractor shall submit a brief
programme for the following working day stating in which area of the site work will
be carried out and the location of plant and labour. The format of the programme
shall be agreed with the Engineer. The Contractor shall also submit for the
Engineer’s approval a daily record of manpower and plant resources.

1.3.24 Progress Reports

The Contractor shall be required to submit to the Engineer weekly and monthly
progress reports on the first day of the week following and the first day of the month
following respectively.

a) Weekly Report

The report shall include: the meteorological data; Contractor's plant and labour
returns; a brief summary of work completed.

b) Monthly Report

The report shall include: a description of the month's work; details of any
problems relating to the Works; quantities; records of test results; charts
illustrating progress in terms of work done against programmed work and the
financial status of the Contract including value of works completed, certified and
monies received; progress photographs.

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1.3.25 Progress Photographs

a) The Contractor shall arrange to take monthly record photographs of the Works in
progress. These photographs shall cover such extent of the Works as the
Engineer shall direct. The days upon which the photographs are to be taken shall
be decided by the Engineer.

b) The Contractor shall provide the Engineer on the last day of each month one set
of progress photographs, with dates imprinted on it, which shall comprise the
following:

(i) One colour negative of each photograph for an anticipated maximum of fifty
exposures per month.

Ten colour prints (294 x 210 mm) of each of a maximum of twenty of the
negatives as selected by the Engineer.

Soft copy of Photograph on a memory card

c) The prints are to be processed by an approved professional and shall be in colour

on heavy weight paper with matt finish. The photographs shall have computer
produced descriptions incorporated thereon. Each photograph shall be provided
with an approved clear plastic cover for binding.

d) The copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of exposure.

1.3.26 Suppression of Noise

The Contractor shall make every reasonable endeavour both by means of temporary
works and by the use of appropriate plant or silencing devices to ensure that the level
of noise resulting from the execution of the Works does not constitute a nuisance.

1.3.27 Closing of Roads

a) The Contractor shall give four weeks’ notice in writing to the Engineer of his
intention to commence work on any public road (which shall include un-made
rights-of-way).

b) The closure of public roads will not be permitted without the written permission of
the Roads & Transport Authority, the Dubai Traffic Police and the Engineer. The
Contractor shall submit five (5) copies of his proposals for diverting traffic
indicating positions of all signs, cones, lights and anything else which may be
necessary. The Contractor shall comply with any Specification for traffic
diversion, including surfacing requirements, safety and control laid down by the
Authorities in Dubai and shall be responsible for continuous maintenance.
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c) A period of up to 30 days may be required by the authorities to process permits

authorising the cutting of existing carriageways.

d) In the event of such permission being refused the Contractor shall have no claim
for any additional payment.

e) No work will be permitted on a public road verge, central reservation or garden

without the SIGNED approval of the respective Authorities copies of which must
be submitted to the Engineer before work commences.

f) The Contractor’s work shall be so arranged that use of the roads affected by the
work shall be restored to the public with the minimum of delay. 24 hour
construction work, subject to fulfilling the regulatory requirements, is expected in
ROW area to restore the road at the earliest. Laying of the pipelines, backfilling,
testing of the pipeline, temporary reinstatement and clearance of the Site shall
follow closely behind excavation and the Engineer may limit the length of
excavation when necessary.

1.3.28 NOC from Relevant Authorities

Notwithstanding the requirements of clause 48 of "Conditions of Contract for Works of

Civil Engineering Construction, (Part 1 - General Conditions)" it shall be the
Contractor's responsibility to obtain all required No Objection Certificates (NOC) from
the relevant Authorities and submit them to the Engineer prior to the Engineer issuing
a Taking Over Certificate.

1.4 TOPOGRAPHICAL SURVEY

1.4.1 GENERAL REQUIREMENTS

a) The Contractor shall maintain in good working order at all times the instruments
provided by him for the setting out of the works, and shall make such instruments
available to the Engineer as required for checking out or taking measurements.
All equipment must be calibrated by an independent agency.

b) The Contractor shall employ a surveyor acceptable to the Engineer to perform

survey work.

1.4.2 SURVEY CONTROL POINTS

a) Site bench marks shall be accurately and safely established, maintained and
cleared away upon completion of the works all to the satisfaction of the Engineer.
Such bench marks shall be related to the nearest permanent Municipality bench

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mark. Record locations, with horizontal and vertical data, on project record
documents.

b) Prepare a plan detailing the location of the bench marks and keep up to date
throughout the period of the contract. Reproducible copies of the plan so
prepared shall be supplied to the Engineer as and when he may require.

c) Protect survey control points prior to starting site work and preserve during
construction.

d) Promptly report to Engineer the loss or destruction of any control point or

relocation required because of changes in grades or other reasons.

e) Replace dislocated survey control points based on original survey control. Make
no changes without prior written notice to Engineer.

1.4.3 SURVEY WORK

a) Verify locations of survey control points prior to starting work and check
periodically and whenever required.

b) Before the works or any part thereof are commenced, the Contractor and the
Engineer shall together make a complete survey and take levels of the site and
agree all particulars upon which setting out of the works shall be based, including
existing plant, buildings and services.

c) Such levels shall be related to the temporary bench marks and plotted by the
Contractor and after agreement of the drawings, shall be signed by the Engineer
and the Contractor and shall form the basis of setting out of the works. Three
copies of the drawings shall be submitted to the Engineer.

d) Failing such surveys and agreements being prepared and/or signed by the
Contractor, the surveys of the Engineer shall be final and binding upon both
parties.

e) Confirm elevations and locations of the work are in conformance with the
drawings.

f) Promptly notify Engineer of any discrepancies discovered in control points,

elevations and locations of the work.

g) Accurately set out the positions, levels and dimensions of all parts of the works in
relation to reference data given on the drawings. Any delay or loss resulting from
errors in the setting out of the works shall not be accepted.

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h) Provide all assistance which the Engineer may require for checking setting out
and for taking measurements of the works, including labour, equipment and
transportation.

i) Setting out shall be approved by the Engineer before commencing the works, but
such approval shall in no way relieve the Contractor of his responsibility for the
correct execution of the work.

j) The Engineer reserves the right to order levels to be taken at any time considered
necessary for the full and proper supervision and measurement of the works.

k) On request the Contractor shall submit documentation verifying accuracy of

survey work.

1.4.4 NON COMPLIANCE

a) Work which fails to meet the specified levels of accuracy must not be rectified
without approval.

b) Propose rectification measures for parts of the works which do not meet the
specified levels of accuracy to the Engineer for approval. Rectification measures
necessitating removal and replacement of sub- standard work may not be
approved. Pay all costs and losses associated with rectification of sub-standard
work.

1.5 SPECIFIC OBLIGATIONS

1.5.1 Sequence of Construction

a) The Contract Programme to be submitted in accordance with Clause 14 of the

Conditions of Contract shall propose in comprehensive detail a sequence of
construction. The programme shall be accompanied by histograms showing the
Contractors expected regular interim work valuations and the proposed variation
in manpower necessary throughout the Contract Period to meet the Contract
Programme.

b) The Contract Programme shall take account of all safety requirements and liaise
with other Contractors working within or next to the area in order to minimise
interference with the other Contracts and to keep disruption of public access
within the area to a minimum.

c) The works are to be left in a safe and tidy condition to the complete satisfaction of
the Engineer. Any road closures or traffic diversions must be arranged between
the Contractor and the Roads Department and all costs involving any road
closures or traffic diversions are deemed to be included in the Contractors rates.

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d) The programme shall also make due allowance for the maintenance of access to
all residential and commercial properties and for a sequence of work satisfactory
to the Emergency Service Authorities in maintaining facilities for their operations
should the need arise, and for the general safety of the public.

e) Particular attention is drawn to the problems, which may arise with the disposal of
flows from dewatering operations. Careful consideration must be given to the
minimisation of surface disruption and obstruction and to the likelihood that
permission for dewatering or other stabilisation operations from or through the
surface of paved areas is unlikely to be granted.

f) Disruption of the existing service networks in the area must be avoided,

particularly to the existing water, sewerage, drainage and irrigation systems, and
overhead/ underground electricity cables. Due consideration for maintaining the
existing systems shall be allowed for when preparing the Contract Programme.

g) The Contractor shall take all necessary precautions and responsibility while
crossing or carrying out works close to the vicinity of high voltage transmission
towers and overhead transmission lines. No claim for damages or additional work
arising from such damages will be considered by the Employer.

h) The Contractor shall pay particular attention to the problems of vehicular access
in the areas of work. Vehicular access shall be maintained along roads affected
by the works so far as possible. Should it become necessary to close a road then
the Contractor shall obtain the necessary permits and arrange an alternative
detour for the duration of the road closure. The details of road closures for traffic
diversion should be submitted to the authorities for approval at least 14 days in
advance of commencement of the works.

i) The Contractor shall restrict his hours of work to daylight hours only unless
specific approval has been obtained from the authorities to carry out work during
night time hours.

1.5.2 Safety Requirements

a) The Contractor's attention is directed to the requirements of Section 10 of this

Specification and to improve safety during the execution of the Contract the
following information is specifically required to be submitted as part of the
Contract Programme. No approval to the programme will be given until the
Engineer is satisfied that adequate safety procedures exist.

(i) Entry procedures and instructions to staff working in confined spaces.

It should be noted that there is NO confined space which may be considered

safe and EVERY entry or re-entry into chambers, drains etc. should be treated
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with as much respect as entry into an obviously dangerous atmosphere such

as a live sewer. There is ALWAYS the risk of accidental spillages/discharges
upstream, which may cause contamination of an otherwise safe environment.
These can occur at any time and without notice.

(ii) Details of training provided to staff together with dates of original training
and dates of subsequent refresher courses.

(iii) Procedures to be followed in case of an incident, accident or emergency

including liaison with the Emergency Service Authorities.

(iv) Details of special safety equipment held and names of personnel certified
for its use.

(v) Chart detailing both the Company and the contract management chains of
command together with clearly defined areas of responsibility.

(vi) All procedures must be in writing with clearly defined areas of responsibility.
Where appropriate they should conform to accepted practices and
procedures.

b) Copies of certain relevant publications are held by the Resident Engineer, in a

bound volume entitled, ‘Entry into confined spaces: Hazards and Precautions’, to
which reference may be made.

c) Particular problems of health and safety may arise with respect to non-disruptive
methods of trenchless construction employed for new pipeline construction or for
pipeline replacement or manhole renovation and the Contractor must ensure that
adequate precautions and satisfactory working practices are adopted in the
execution of such works to protect the health and safety of all personnel engaged
in executing the works and in their supervision.

1.5.3 Setting Out

The Contractor shall note that the alignment of pipelines and the location of chambers
and other structures as indicated on the drawings are for guidance only. The specific
setting out details, alignment and location, will be confirmed on site following the
review of actual site conditions, trial trenches and existing and proposed services.

1.5.4 Progress Reports, Photographs and Site Records

1.5.4.1 General

The Contractor will be required to submit to the Engineer, in an A4 format unless

otherwise indicated, weekly and monthly progress reports as detailed below. Reports
shall be neatly presented and shall be submitted in triplicate
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1.5.4.2 Weekly Reports

Weekly Reports shall be submitted on the first working day of the following week, and
shall include but not be limited to the following:

a) Average, maximum and minimum daily ambient temperatures and humidity; all
readings to be taken at one time.

b) Rainfall data, if appropriate, and general weather report.

c) Contractors labour and plant returns in an A4 format to be agreed with the

Engineer.

d) Brief summary of work completed.

1.5.4.3 Monthly Reports

Monthly Reports, including mounted selected photographs shall be submitted by the

twenty-eighth day of the month concerned, and shall include but not be limited to the
following:

a) Description of the extent and nature of the month’s work.

b) Details of any problems relating to the Works with substantiating documentation if

relevant.

c) Cumulative summaries of excavation and concrete quantities and lengths of

pipeline laid and tested.

d) Records of materials, equipment and plant tested with copies of test results where
relevant.

e) Charts illustrating progress achieved compared to the Contract Programme in an

A4 or A3 format to be agreed with the Engineer.

f) Charts illustrating the financial status of the Contract including value of works
completed, certified and monies received in an A4 or A3 format to be agreed with
the Engineer.

g) Copies of site instructions and variations issued by the Engineer.

h) Progress Photographs as detailed below.

i) A detailed programme of work to be carried out in the following month in chart

form to an A3 or A4 format to be agreed with the Engineer and a general
summary of work for the coming three months.

j) Copies of the agreed weekly labour and plant returns.

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k) Coloured progress photographs to be taken, illustrating progress and work

completed on each section of the Works. Photographs shall be taken under the
direction of the Engineer by a professional or other approved photographer and
shall be automatically stamped with the date on which the photographs are taken.
Seven prints of each photograph, at least 150 mm by 100 mm, shall be submitted.
Six prints of each photograph shall be separately mounted, with typewritten titles, on
headed sheets in an A4 format to be agreed with the Engineer.

1.5.4.4 Monthly Reports

The Contractor will supply three sets of finalised and approved record drawings to the
Engineer upon completion of the works in the latest Microsoft format on CD. The
record drawings will use the DLTM coordinate system unless otherwise specified by
the Engineer.

1.5.5 As-built Records

a) Complete and As-Built Record Drawings will be prepared by the Engineer for
submission to the Employer.

b) The Contractor shall assist the Engineer to ensure that information regarding as-
built structures, pipelines and the final materials testing report in accordance with
Dubai Municipality Central Laboratory requirements is presented in a concise and
clear manner. For this purpose, the Contractor shall supply marked up dye-line
prints of the Contract drawings.

c) The Contractor will supply three sets of finalised and approved record upon
completion of the works in the latest Micro station format on CD. The record
drawings will use the DLTM coordinate system unless otherwise specified by the
Engineer.

1.5.6 Contract Correspondence

Unless the Contractor wishes to correspond directly with the Engineer on specific
subjects all correspondence will be addressed to the Engineer's Representative and
be submitted in duplicate.

1.5.7 Corrosion Control

a) The Contractor shall be deemed to have apprised himself of the particular

problems of corrosion of materials in Dubai by study of this Specification and
visiting the site. The sea water contains high amount of salinity and chlorides.

b) Attention is drawn to the corrosive nature of hydrogen sulphide gas in the

presence of moisture on Cementitious and some metallic materials.

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Drainage and Irrigation Department

c) In addition windblown chlorides are present in the atmosphere and the

groundwater contains sulphates and chlorides.

d) All materials must be appropriate to withstand the corrosive effects of their

environments.

1.5.8 Provision and Final Removal of Temporary Site Roads

Suitable subkha roads will be provided by the Contractor to allow access to all
sections of the works at all times. Suitable precautions will be taken to prevent
misuse of site roads by the general public. The Contractor shall be responsible for
reinstating these areas to their original condition after completion of the work.

1.5.9 Use of Highway

a) The Contractor shall give 4 weeks’ notice in writing to the Engineer of his intention
to commence work on a public highway.

b) The closure of public highways will not be permitted without the written
permission of the Dubai Municipality, Road Transport Authority, the Dubai Traffic
Police and the Engineer. The Contractor shall submit 5 no. copies of his
proposals for diverting traffic, indicating positions of all signs, cones, lights and
anything else which may be necessary. The Contractor shall comply with any
specifications for traffic diversion, including surfacing requirements, safety and
control laid down by the Authorities in Dubai and shall be responsible for
continuous maintenance.

c) Where a temporary diversion of the public highway is approved which will be

utilised by public traffic then the route shall have an asphalt surface. A subkha
only track will not be acceptable.

d) No work will be permitted on a public highway verge, central reservation or

garden without the SIGNED approval of the respective Authorities copies of which
must be handed to the Engineer before work commences.

e) The Contractor's work shall be so arranged that use of the highways affected by
the Works shall be restored to the public with the minimum of delay. Laying of the
pipelines, backfilling, testing of the pipelines, temporary reinstatement and
clearance of the Site shall follow closely behind excavation and, unless written
permission is obtained, the Contractor shall not occupy more than a 100 meters
length of highway at any one location at any time.

f) The work shall be carried out in such a manner as to cause minimum interference
with the public use of highways, footpaths and other thoroughfares, and only such
plant, materials, tools, etc., as shall from time to time be required for immediate

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use shall be deposited thereon. Storage depots, offices, etc., shall be sited
elsewhere.

g) The Contractor shall comply in all respects with current Local Orders issued by
regulatory authorities with respect to excavation and reinstatement in public roads
corridors.

h) The Contractor shall maintain a clean, safe and adequate passageway for
pedestrians along highways and to each adjoining property. Unless he shall
obtain the written consent of the Statutory Authority to close the road, he shall
also maintain a satisfactory passageway for vehicular traffic.

i) The Contractor shall maintain those parts of the highway, etc., not temporarily
occupied by the Works in a clean, passable and safe state.

1.5.10 Access to Private Land

The Contractor shall give 3 weeks’ notice to the owner / occupier before entering
private land.

1.5.11 Return of Materials to Store

If acceptable to Dubai Municipality and with their prior approval, any materials ordered
and intended for incorporation in the permanent works such as pipes and fittings, DI
covers etc., which are certified by the Engineer to be in excess of requirements at the
end of the contract, due to design changes or the cancellation of works subsequent to
the placing of the order, payment for materials returned to the Dubai Municipality
Stores will be made at the values shown on manufacturers’ quotations current at the
time of Tender as obtained by the Contractor at the time of Tender plus an
appropriate percentage addition and no additional payment will be made for the cost
fluctuations.

The Contractor is responsible for transporting and stacking these materials to the
Storekeeper's satisfaction. The associated transportation and stacking charges will be
paid for at the rates determined under the Contract.

The inventory of returned surplus materials shall clearly indicate the source from
which the Contractor originally purchased / collected the materials together with the
purchase price.

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Drainage and Irrigation Department

1.5.12 Flows in Pipelines and at Pumping Stations

The Contractor must also maintain normal flow conditions in any other existing
irrigation pipelines affected by the construction of the pipe line. Any diversion works,
under-pressure tapping, over pumping or temporary pipelines required to comply with
this requirement are deemed to be included in the Contractor’s rates for the
completion of the connection of the works.

No claim for delay, damage or additional work arising from this requirement will be
considered by the Employer.

During the execution of the Works the Contractor shall maintain flows in pipelines and
at pumping stations or alternatively provide adequate means of diverting the flows or
over pumping of the flows to the satisfaction of the Engineer.

The Contractor should note that the Employer may decide to carry out over pumping
utilising his own plant and resources and the Contractor shall make due allowance for
the necessary coordination with the Employer with respect to the Contract
programme. Such arrangements will not relieve the Contractor of his obligations for
the maintenance of flows and the safety of the Works, personnel and the general
public.

No claim for delay or additional work arising from this requirement will be considered
by the Employer.

1.5.13 Issue of Taking - Over Certificate

Notwithstanding the requirements of Clause 48 of "Conditions of Contract for of Civil

Engineering Construction, (Part 1 - General Conditions)" it shall be the responsibility
to obtain all required "No Objection Certificates (NOC) from the relevant Authorities
and submit them to the Engineer prior to the Engineering issuing a Taking Over
Certificate.

The Contractor shall note that it is a Dubai Municipality requirement that No Objection
Certificates must be obtained from all Service Authorities in compliance with Dubai
Municipality Administrative Order No. 123/98 regarding satisfactory completion of the
Works. Dubai Municipality will not approve the issue of the Taking Over Certificates
by the Engineer until all such certificates have been obtained.

In connection with the obtaining of final No Objection Certificates, the current

Standard Procedure for obtaining Dubai Municipality No Objection Certificate for
project completion (Taking-Over) is applicable. The Contractor must ensure that the
DM/DNID Section 1 General Rev 00 June Page 68 of 76
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Drainage and Irrigation Department

latest requirements of Dubai Municipality are compiled with prior to making the
application for final.

No Objection Certificate to Roads Department ( RTA). The Contractor's attention is

drawn for Technical circular 28/94 for Final Material Test Report and Technical
Circular No. 5/2001 for NOC from General Maintenance Department. The Contractor
is obliged to comply with various local orders, circulars, letters issued from time to
time for the purpose of Taking Over Certificate.

The Contractor's attention is also directed regarding the provision of Approved

Operation and Maintenance Instruction Books prior to issue of the Taking Over
Certificate.

1.6 VENDOR LIST FOR CIVIL ITEMS

Tenderer to select the civil items from the list of recommended vendor list given in
Table 1 below and they shall select only one manufacturer or supplier from the list
below and mention in the tender proposal.

It is Tenderer’s responsibility to ensure that the offered make / supplier fully comply
with the tender specifications & functional aspects, delivery, construction requirement
as required by specifications, drawings.

Tenderer may propose for any civil item(s) where vendor name are not specified or
not included in the recommended vendor list in the table below. Such proposal will
be subject to Engineer clarifications during tender clarifications and tender evaluation.
All the necessary information required by Engineer will be requested and it shall be
submitted by Tenderer immediately to the Engineer for tender assessment.

Table 1 Vendor List

Sr. Item Manufacturer Supplier

1 Readymix Concrete M/s. Conmix Ltd.Sharjah - M/s. Conmix Ltd.Sharjah

U.A.E / M/s. Emirates - U.A.E / M/s. Emirates
Beton Readymix L.L.C.Dubai Beton Readymix
- U.A.E / M/s. Technical L.L.C.Dubai - U.A.E /
Readymix Concrete Co. M/s. Technical Readymix
L.L.C.,Dubai - U.A.E / Concrete Co.
Austrian Arabian Ready Mix L.L.C.,Dubai - U.A.E /
Concrete LLC, Dubai-UAE / Austrian Arabian Ready

DM/DNID Section 1 General Rev 00 June Page 69 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

Unibeton Ready Mix LLC Mix Concrete LLC,

,Dubai- UAE Dubai-UAE / Unibeton
Ready Mix LLC ,Dubai-
UAE

2 Manholes Cover M/s. Veralco, Cyprus / M/s. M/s. Mac Al Gurg,Dubai,

and Frames Ducast Factroy L.L.C,Dubai - U.A.E / M/s. Ducast
U.A.E / M/s. Carnation Factroy L.L.C,Dubai -
Industries Ltd.,West Bangal U.A.E / M/s. Dutco
– India / M/s. Plasma Alloys Tennant LLC, Dubai -
Pvt. Ltd, Gujarat – India / U.A.E / Ducast Factory,
M/s. Majid Bukatara Building Dubai- UAE
Materials Trading LLC,
Dubai - U.A.E / Elkington
Gatic-UK / Ducast Factory,
Dubai- UAE

3 Double Triangular Ducast Factory, Dubai- UAE Ducast Factory, Dubai-

DI cover & frame UAE

4 GRP Sealing Plate M/s. Mechanical Engineering M/s. Mac Al Gurg,Dubai,

Services Est.,Dubai - U.A.E / U.A.E / Mechanical
Scott Bader, Dubai-UAE Engineering Services
Est.,Dubai - U.A.E

5 GRP Manhole Liner Gulf Eternit Ind Co. Ltd, Gulf Eternit Ind Co. Ltd,
Dubai-UAE / Dubai Pipes Dubai-UAE / Dubai Pipes
Factory, Dubai-UAE Factory, Dubai-UAE

6 GRP In-situ Al Nahar Fibre Glass Al Nahar Fibre Glass

lamination, GRP- Products LLC, Dubai-UAE / Products LLC, Dubai-
Performed M/s. Dubai Pipes Factory UAE / M/s. Dubai Pipes
Benching, GRP-Flat Co. L.L.C, Dubai - U.A.E / Factory Co. L.L.C,Dubai
Sheet, GRP M/s.Extraco Sharjah, U.A.E / - U.A.E / M/s.Extraco
Circular sheet Notredame Fibre Glass & Sharjah, U.A.E /
Ind. Marble Est., Sharjah – Notredame Fibre Glass &
UAE / Arabtec Engg. Ind. Marble Est., Sharjah
Services (GRP section) LLC, – UAE / Arabtec Engg.
Dubai-UAE / Union Fibre Services (GRP section)
Glass Factory LLC, Dubai- LLC, Dubai-UAE / Union
DM/DNID Section 1 General Rev 00 June Page 70 of 76
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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

UAE Fibre Glass Factory LLC,

Dubai- UAE

7 Epoxy coating for M/s. Hempel Paints M/s. Mechanical

Manhole Cover & (Emirates) , Sharjah-UAE Engineering Services
frame Est.,Dubai - U.A.E

8 Detectable Warning M/s. Kangaroo Plastics M/s. Dutco Tennant LLC,

Tapes Middle East LLC, Dubai - Dubai - U.A.E / M/s. Al
U.A.E / M/s. Al Samir Plastic Samir Plastic Factory
Factory (L.L.C),Sharjah - (L.L.C),Sharjah - U.A.E
U.A.E

9 Reinforcement M/s. Emirates Steel, Abu M/s. Ghantoot Building

Steel (Epoxy Dhabi - U.A.E / Cicon Epoxy Materials Trading L.L.C,
Coated) & steel cutting Plant LLC, Dubai - U.A.E /Cicon
Abu Dhabi- UAE / Habas Epoxy & steel cutting
Fuatpsa Sokak No. 26 Plant LLC, Abu Dhabi-
34880 Soganlik / Istanbul- UAE / RAK Middle East
Turkey Traders LLC, RAK-UAE /
Al Jaber Protective
Coating LLC, Abu Dhabi-
UAE

10 Polyethylene sheets M/s Dubai Plastic Factory M/s Dubai Plastic

LLC, Ajman- UAE Factory LLC, Ajman-
UAE

11 Geotextile Filter M/s. Terram Limited, U.K. / M/s. Geco Chemical Co.
Membrane M/s. Dupont, Luxembourg / Ltd., Sharjah - U.A.E /
Dupon DE Nemours M/s.Chabros nternational
International Luxembourg Group FZCO, Dubai -
U.A.E / Cloisall Co LLC
Dubai-UAE

12 Independent M/s. Geoscience Testing

Testing Laboratory , Laboratory,Dubai - U.A.E
Geotechnical / M/s. Material Lab,
Investigation Dubai - U.A.E / M/s Arab
Centre for Engineering

DM/DNID Section 1 General Rev 00 June Page 71 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

Studies, Dubai-UAE

13 Concrete Repair M/s. Corrotech Construction M/s. Corrotech

Mortar Chemicals,Dubai - U.A.E Construction Chemicals,
Dubai - U.A.E

14 Pipe Bedding and M/s. Al Amara Crushers, M/s. Flagstone

Surround Hattah, Dubai / M/s. Emaar L.L.C,Dubai - U.A.E /
Mahdha Company M/s. Alma Mechanical
Crusher,Oman / Wadi Al Cont., Sharjah - U.A.E /
Rawda / Emmar Mahdha Co. Dubai Al Ahlia Transport
Crusher-Oman Est., Dubai-UAE / Al
Akhilaa General Trading
LLC, Dubai - UAE

15 Annulus Grout M/s. Emirates Beton M/s. Emirates Beton

Readymix L.L.C, Dubai - Readymix L.L.C, Dubai -
U.A.E / Austrian Arabian U.A.E / Austrian Arabian
Ready Mix Concrete LLC, Ready Mix Concrete
Dubai-UAE LLC, Dubai-UAE

16 Aggregate Road M/s. Al Amara Crushers, M/s. Flagstone L.L.C,

Base Hattah, Dubai / M/s. Ajman Dubai - U.A.E / M/s.
Land Crusher,Ajman - U.A.E Flagstone L.L.C, Dubai -
/ Golden Swan Crusher & U.A.E / Dubai Al Ahlia
Transport LLC, Dubai- UAE Quick Transport LLC,
Dubai-UAE

17 Water Proofing M/s. Henkel Polybit M/s. Henkel Polybit

Membrane Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E / Duproof Trading (L.L.C), Dubai -
LLC, Dubai-UAE / Alyaf U.A.E / SAG Roofing,
Industrial co. Ltd., KSA Dubai- UAE

18 Controlled M/s Fibretex A/S, Specilised Industries

Permeability Svendborgvej 2, Box 8029, LLC, Dubai- UAE
Formwork (CPF) DK-9220 Aalborg, Denmark
Liner

DM/DNID Section 1 General Rev 00 June Page 72 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

19 PVC Water Stop M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E / M/s. Trading (L.L.C), Dubai -
Corrotech Construction U.A.E / M/s. Corrotech
Chemicals, Dubai - U.A.E / Construction
Greenstreak, 3400 Tree Chemicals,Dubai - U.A.E
Court Industrial Boulevard / Peninsula Int’l General
St. Louse, Missouri Trading LLC, Dubai-
UAE

20 Hydrophilic Polymer M/s. Henkel Polybit M/s. Henkel Polybit

Based Water Stop Industries Ltd., Umm Al Industries Ltd., Umm Al
Quwain - U.A.E / M/s. Quwain - U.A.E / M/s.
Corrotech Construction Corrotech Construction
Chemicals,Dubai - U.A.E Chemicals,Dubai - U.A.E

21 Epoxy Coating M/s. Corrotech Construction M/s.Corrotech

Chemicals,Dubai - U.A.E / Construction
M/s. Henkel Polybit Chemicals,Dubai - U.A.E
Industries Ltd., Umm Al / M/s. Henkel Polybit
Quwain - U.A.E Industries Ltd., Umm Al
Quwain - U.A.E

22 Ductile Iron M/s. ACO, Australia M/s. Al Mostaqbal

Concrete Infill Type Building Materials
Covers & Frames Trading L.L.C,Dubai -
U.A.E

23 Joint Sealant M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Building Materials
Quwain - U.A.E Trading (L.L.C), Dubai -
U.A.E

24 Concrete Curing M/s. Henkel Polybit M/s. Henkel Polybit

Compound Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Quwain - U.A.E Quwain - U.A.E

25 Interlocking Tiles, M/s. Phoenix Concrete Block M/s. Phoenix Concrete

Kerbs & Concrete Factory L.L.C,Dubai - U.A.E Block Factory L.L.C,
/ National Tiles & Block Co. Dubai - U.A.E / National

DM/DNID Section 1 General Rev 00 June Page 73 of 76

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

Blocks Ltd , RAK Tiles & Block Co. Ltd ,

RAK

26 Safety Chain, M/s. Dutco Tennant LLC, M/s. Dutco Tennant LLC,
Eyebolt and D- Dubai - U.A.E Dubai - U.A.E
Shackle

27 SS Grab Bar ( Hand M/s. Dutco Tennant LLC, M/s. Dutco Tennant LLC,
Hold) Dubai - U.A.E Dubai - U.A.E

28 SS Material Standard Fabrication & Engg Standard Fabrication &

(Platform, ladder, Works, Dubai-UAE Engg Works, Dubai-UAE
safety cage,
handrail, spindle,
support bracket
etc.)

29 Neoprene Rubber International Rubber Corrotech Construction

Sheet Company, Dubai UAE Chemicals, Dubai-UAE

30 Polycrete M/s. Henkel Polybit M/s. Henkel Polybit

(Cementitious Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Repair mortar Quwain - U.A.E Quwain - U.A.E
/Cementitious
fairing coat)

31 Hydroseal P M/s. Henkel Polybit M/s. Henkel Polybit

Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Quwain - U.A.E Quwain - U.A.E

32 Polycoat M/s. Henkel Polybit M/s. Henkel Polybit

Rubberized Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Bitumen Emulsion Quwain - U.A.E Quwain - U.A.E

33 Polygrout Non M/s. Henkel Polybit M/s. Henkel Polybit

Shrink Free Flow Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Cementitious Grout Quwain - U.A.E Quwain - U.A.E

34 Polyprime solvent M/s. Henkel Polybit M/s. Henkel Polybit

based bitumen Industries Ltd.,Umm Al Industries Ltd.,Umm Al

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

Primer Quwain - U.A.E Quwain - U.A.E

35 Polyquick ( Quick M/s. Henkel Polybit M/s. Henkel Polybit

Setting Repair Industries Ltd.,Umm Al Industries Ltd.,Umm Al
Mortar) Quwain - U.A.E Quwain - U.A.E

36 Renderoc for Al Gurg Fosroc LLC, Dubai- Al Gurg Fosroc LLC,

concrete repairing UAE Dubai-UAE

37 Damp Proof Course Ruberoid Building Emirates Specialities Co.

Products,UK LLC, Dubai- UAE

38 Epoxy resin patch Al Gurg Fosroc LLC, Dubai- Al Gurg Fosroc LLC,
mortar for use in UAE Dubai-UAE
damaged concrete
joint edges

39 Mortar for sealing BASF Construction chemical BASF Construction

crack LLC, Dubai-UAE chemical LLC, Dubai-
UAE

40 GRP Vent Cowl Gulf Pipe Industries LLC, Gulf Pipe Industries LLC,
Dubai-UAE Dubai-UAE

41 GRP Grated Covers Union Fibre Glass Factory Union Fibre Glass
with Chequered LLC, Dubai- UAE Factory LLC, Dubai- UAE
Finish

42 Hollow Blocks Phoenix Concrete Products, Phoenix Concrete

Dubai-UAE Products, Dubai-UAE

43 Concrete Tiles for Terrazzo Dubai Co. LLC, Terrazzo Dubai Co. LLC,
roofing Dubai- UAE Dubai- UAE

44 Block work and Ancon Wall Ties, UK / Emirates Specialities Co.

Plaster Accessories Expamet, UK / Xpa wall LLC, Dubai-UAE
Ties, UAE

45 Premixed Mortars SODAMCO Holding Tyar SODAMCO Holding Tyar

and Plasters ( Center, Abu Dhabi-UAE Center, Abu Dhabi-UAE
Premix SRC-2,
DM/DNID Section 1 General Rev 00 June Page 75 of 76
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Dubai Municipality
Drainage and Irrigation Department

Sr. Item Manufacturer Supplier

SRC-S & SP-1)

46 Aluminium Windows M/s Al Ghurair / Gulf Blossom Aluminium &

Extrosions Co. / GGI (UAE) Glass Ind. LLC, Ajman-
/Domus Greece, Ajman-UAE UAE

47 Fire Rated Roller Duodex Engg & trading Bin Dasmal Doors Est.,
Shutter SDN.BHD, Malaysia Dubai-UAE

48 External paint Caparol Farben Lacke Caparol LLC, Dubai-

Bautenschutz GmbH, UAE.
Germany

49 Steel Doors ( Fire Qatar Metal Const. Ind. LLC, Qatar Metal Const. Ind.
rated) Sharjah-UAE LLC, Sharjah-UAE

50 Aluminium Gates Link Middle East Ltd., Dubai- Link Middle East Ltd.,
UAE Dubai- UAE

51 Chain Link fence Link Middle East Ltd., Dubai- Link Middle East Ltd.,
UAE Dubai- UAE

52 Asphaltic Concrete Al Futtaim Tarmac Nablus Road Contracting

Wearing Course LLC, Dubai-UAE

DM/DNID Section 1 General Rev 00 June Page 76 of 76

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 2

SITE CLEARANCE AND EARTHWORKS

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 2 Site Clearance and Earthworks Rev 00 June Page i of iv

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 2
SITE CLEARANCE AND EARTHWORKS
CONTENTS
2 SITE CLEARANCE AND EARTHWORKS ........................................................................ 1

2.1 SITE CLEARANCE – DESCRIPTION ................................................................................ 1

2.2 SURVEY BEFORE COMMENCEMENT ............................................................................ 1
2.3 DEMOLITION REQUIREMENTS ....................................................................................... 1
2.4 GENERAL SITE CLEARANCE.......................................................................................... 2
2.5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS ............... 2
2.6 ROAD SIGNS ..................................................................................................................... 2
2.7 DISPOSAL OF MATERIAL ................................................................................................ 3

2.7.1 Disposal of Surplus Material ................................................................................. 3

2.7.2 Disposal of Historical Artifacts .............................................................................. 3

2.8 EARTHWORKS AND SITE PREPARATION ..................................................................... 3

2.8.1 General ................................................................................................................. 3

2.8.2 Earthwork .............................................................................................................. 4
2.8.3 Site Earthwork ...................................................................................................... 4
2.8.4 Levels to be recorded ........................................................................................... 6
2.8.5 Bracing and Shoring ............................................................................................. 6
2.8.6 Inspection by Engineer ......................................................................................... 7
2.8.7 Existing Services .................................................................................................. 7
2.8.8 Control of Water .................................................................................................... 7
2.8.9 Excess Excavation to be Made Good ................................................................. 11
2.8.10 Foundation Preparation ...................................................................................... 11

2.9 CLASSIFICATION OF EXCAVATION AND BACKFILL ................................................. 11

2.9.1 General Classification ......................................................................................... 11

2.9.2 Excavation Materials ........................................................................................... 12
2.9.3 Identification of Common and Rock Excavation ................................................. 12

2.10 EXCAVATION REQUIREMENTS .................................................................................... 13

2.11 BORROW PIT SITE WITHIN PROJECT WORK AREA .................................................. 15
2.12 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS
MATERIALS .............................................................................................................................. 15

2.12.1 Top Soil ............................................................................................................... 15

2.12.2 Suitable Material ................................................................................................. 15
2.12.3 Unsuitable Material ............................................................................................. 16
2.12.4 Material for Improved Subgrade Layer ............................................................... 16

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Drainage and Irrigation Department

2.13 MAIN PLANT AND EQUIPMENT FOR EARTHWORKS CONSTRUCTION ................... 17

2.13.1 General ............................................................................................................... 17

2.13.2 Compacting Equipment ...................................................................................... 18
2.13.3 Hauling and Weighing Equipment ...................................................................... 20

2.14 EMBANKMENT CONSTRUCTION .................................................................................. 21

2.14.1 General ............................................................................................................... 21

2.14.2 Embankment Foundation and the Designated Filling Area ................................ 23
2.14.3 Suitability Testing on Materials ........................................................................... 25

2.15 PLACING AND COMPACTION REQUIREMENTS ......................................................... 25

2.16 MOISTURE CONTROL REQUIREMENTS ...................................................................... 26
2.17 STANDARD EARTH WORKS COMPACTION PROCEDURE ........................................ 26

2.17.1 General ............................................................................................................... 26

2.17.2 Compaction Tests ............................................................................................... 27
2.17.3 Testing ................................................................................................................ 27

2.18 MINIMUM TEST REQUIREMENTS ................................................................................. 27

2.18.1 Embankment and Filling Works .......................................................................... 27

2.18.2 Improved Subgrade ............................................................................................ 28
2.18.3 Rock Fill and Rock Soil Mixtures ........................................................................ 28

2.19 STABILISING CRUSHED MATERIAL............................................................................. 29

2.20 EXCAVATING AND FILLING FOR STRUCTURES ........................................................ 31
2.21 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS ......................................... 35

2.21.1 Activities prior to excavation starting .................................................................. 35

2.21.2 Setting out ........................................................................................................... 36
2.21.3 Topsoil and Surfacing Materials ......................................................................... 36
2.21.4 Land Drains ........................................................................................................ 36
2.21.5 Hand Excavation ................................................................................................. 36
2.21.6 Support to Excavations ....................................................................................... 36
2.21.7 Dewatering .......................................................................................................... 37
2.21.8 Formation ............................................................................................................ 41
2.21.9 Excavation at or near roads ................................................................................ 41
2.21.10 Surface condition of excavated area .................................................................. 43

2.22 PIPELINE TRENCH AND THE RELATED STRUCTURES EXCAVATION .................... 43

2.22.1 Excavation for Pipelines ..................................................................................... 43

2.22.2 Excavation for Cables/Ducts ............................................................................... 43
2.22.3 Excavated Material for Pipe Trench .................................................................... 44
2.22.4 Replacement of Unsuitable Material ................................................................... 44
2.22.5 Disposal of Material ............................................................................................ 45
2.22.6 Cofferdams ......................................................................................................... 45
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2.22.7 Backfilling Pipe Trench Excavations and the Related Structures ....................... 46
2.22.8 Filter Material ...................................................................................................... 49
2.22.9 Backfilling of Trenches for Cables/Ducts ............................................................ 49
2.22.10 Reference Standards .......................................................................................... 50

2.23 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT ............................... 50

2.23.1 General ............................................................................................................... 50

2.23.2 Reinstatement of Unpaved Land ........................................................................ 51
2.23.3 Reinstatement within Road Corridors ................................................................. 52
2.23.4 Reinstatement of Other Surfaced Areas ............................................................. 52
2.23.5 Excavation and Reinstatement in Developed Reservations ............................... 52

2.24 PROTECTION TO EMBANKMENT SLOPE .................................................................... 52

2.25 CEMENT-STABILISED AGGREGATE CAPPING LAYER ............................................. 53
2.26 BACKFILLING AROUND STRUCTURES ....................................................................... 53

2.26.1 Definition ............................................................................................................. 53

2.26.2 Backfill ................................................................................................................ 53
2.26.3 Backfill Materials ................................................................................................. 53
2.26.4 Control of Water .................................................................................................. 54
2.26.5 Inspection by Engineer ....................................................................................... 54
2.26.6 Backfilling - Placement ....................................................................................... 54
2.26.7 Backfilling - Compaction ..................................................................................... 54

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2 SITE CLEARANCE AND EARTHWORKS

2.1 SITE CLEARANCE – DESCRIPTION

This work shall consist of the removal, wholly or in part, and satisfactory disposal of
all fences, structures, abandoned pipelines, contaminated soil, logs, hedges, shrubs,
brush, grass, weeds, other vegetation, stumps of diameter less than 150 mm
including wet or dried sludge, concrete slabs and any other obstruction which are not
designated or permitted to remain. It shall also include the salvaging of designated
materials and backfilling the resulting trenches, holes and pits.

Clearing shall be performed wherever necessary in preparation of the performance of

works such as excavation, fill or embankment or any other construction where shown
on the plans as specified or directed by the Engineer.

Grubbing shall follow the operation of clearing where ordered by the Engineer or as
shown on the plans and shall consist of removing all stumps, roots and objects of
similar nature. Grubbing shall be carried out in such a manner that roots and stumps
will not grow again or otherwise cause any damage.

2.2 SURVEY BEFORE COMMENCEMENT

Prior to starting the site clearance, the Contractor shall carry out a thorough survey of
structures, fences, trees, etc. that are to be removed. The Engineer shall be fully
informed of the results of this survey and the amount and extent of the demolition and
site clearance shall then be agreed with the Engineer.

2.3 DEMOLITION REQUIREMENTS

a) The Contractor shall in a careful manner, raze, remove and dispose of all
foundation structures, fences and other obstructions or any portions of which are
within the right-of-way, except utilities and those for which other provisions have
been made for removal. All designated salvageable material shall be removed,
without unnecessary damage, in sections or pieces which may be readily
transported, and shall be stored by the Contractor at specified places within the
project limits or at designated storage areas as directed by the Engineer. All such
salvageable material shall be deemed the property of the Employer.

b) Where directed by the Engineer, the Contractor shall excavate in trench and
break out redundant pipe ducts and surrounds. Where pipes are to be removed
and either salvaged or re-laid they shall be carefully removed and every
precaution taken to avoid breaking or damaging the pipe. The pipes shall be
stored when necessary so that there will be no loss or damage before relaying.
The Contractor will be required to replace sections lost from storage or damage
by negligence or by the use of improper methods in their removal.

c) Trenches and pits resulting from demolition and site clearance below ground level
shall be properly cleaned out (including pumping) and filled with suitable material
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and compacted in accordance with the relevant Specifications up to sub-grade

level or as otherwise directed by the Engineer.

d) Where required, the Contractor shall be responsible, prior to demolition, for the
disconnection of all services and clearance from the Dubai Municipality and all
other Service Authorities.

2.4 GENERAL SITE CLEARANCE

a) Before commencing any excavation or fill, the area shall be cleared of all trees,
stumps, roots, bushes, vegetation, debris, materials or other obstructions.

b) Before removal of any trees or shrubs the Contractor shall obtain written consent
from Dubai Municipality Horticultural Section at least two weeks in advance of the
planned removal.

c) The Engineer's approval of any removal of trees and undergrowth must be

obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of in tips
off site (Sub section 2/7). Holes left by stumps or roots shall, within one week, be
filled with suitable material, and compacted to the Engineer's satisfaction in
accordance with Specification Clause 2/17.

2.5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS

a) Attention is directed to the Contractor's obligations under law and under this
Contract with regard to damage, particularly with regard to protection of property,
plants and landscape and to responsibility for damage claims.

b) Existing highways, improvements, facilities, adjacent property, services, and trees

and plants designated for preservation shall be protected from injury or damage
which could result from the Contractor's operations.

c) The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.

2.6 ROAD SIGNS

a) All existing road signs, street name plates and the like affected by the works are
to be carefully taken down and stored.

b) Signs to be re-erected shall be cleaned, provided with new fixings where

necessary and the posts re painted in accordance with the Specifications.

c) Redundant signs shall be transported to the stores or depots of relevant

Authorities.

d) Any sign, street name plate or the like damaged by the Contractor during his
operation shall be repaired or replaced at the Contractor's cost.

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2.7 DISPOSAL OF MATERIAL

2.7.1 Disposal of Surplus Material

All materials arising from site clearance which are surplus to or unsuitable (as defined
in Section 2/12) for use in the Works shall become the property of the Contractor and
shall be disposed of by him either off the Site to an approved tip (Al Warqaa, Al
Bayadia / Al Lussaily on Al Ain road etc.) or if directed or otherwise agreed by the
Engineer on the Site in an approved manner.

2.7.2 Disposal of Historical Artifacts

a) Where specified, certain materials arising from the site clearance and excavation
shall remain the property of the Employer.

b) All fossils, antiquities and other objects of interest or value which may be found or
uncovered on the site shall remain or become the property of the Employer and
upon discovery of such an object the Contractor shall forthwith:

c) Use his best endeavours not to disturb or damage the object;

d) Cease work which would endanger the object or prevent or impede its removal;

e) Inform the Engineer of the discovery and precise location of the object;

f) The Engineer will issue instructions on the procedure to be adopted which may
include conditions to permit the examination, excavation or removal of the object
by a third party.

2.8 EARTHWORKS AND SITE PREPARATION

2.8.1 General

a) Principal work in this Section includes general requirements for earth including
site preparation.

b) The entire area within the limits of earthwork as indicated shall be constructed to
the lines, grades, elevations, slopes, and cross sections indicated on the
Drawings with added allowance for the thickness of any pavement, blinding
concrete, lining and riprap if required.

c) Slopes shall present a neat uniform appearance upon completion of the work and
shall be approved by the Engineer.

d) Excavated materials meeting the requirement of fill materials shall be conserved

for subsequent use or placed as earth fill immediately after excavation upon
approval of the Engineer. If not immediately re-used, excavated materials shall
be stockpiled within or adjacent to the project work area approved by the
Engineer.

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e) Suitability of all excavation materials for specific purposes shall be determined by

the Engineer.

f) Contractor shall not waste or otherwise dispose of suitable excavated materials.

All excavation shall be performed under the limitations and requirements set out
in the sections of this specification pertaining to control of water.

2.8.2 Earthwork

a) Earthwork shall include all site preparation to the lines and grades indicated on
the drawings including, but not limited to the following:

(i) Excavation of all materials of whatever nature encountered

(ii) Handling, hauling and compaction of required fill materials

(iii) Disposal of all excess excavated material

(iv) Shoring and protection work

(v) Preparation of subgrade

(vi) Dewatering as necessary

(vii) Protection of adjacent property

(viii) Backfill

(ix) Surface reinstatement

(x) Forming embankment

(xi) Construction temporary cofferdam / bund for construction works.

2.8.3 Site Earthwork

2.8.3.1 Borehole Data

Borehole data is provided in the Volume-5 of tender document.

a) This data is for information only and without any warranty as to the correctness of
the information contained therein.

b) Availability of this data to the Contractor does not relieve him of his:

(i) Obligation to thoroughly investigate for himself the nature of the site and the
sub-soil conditions therein;

(ii) Obligations and responsibilities under the terms and conditions of the
Contract.

2.8.3.2 Contractor’s Responsibilities

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a) The Contractor shall be deemed to have visited the site prior to submitting his
tender and made all necessary inspections and investigations and allowed for the
following in his tender:

(i) Means of access and working space

(ii) Nature of the ground and sub-soils

(iii) Presence of existing foundations or other hidden obstructions

(iv) Level of the water table

(v) Extent of rock

(vi) Support to neighbouring properties and structures

(vii) All factors affecting the work

b) Any information made available to the Contractor, either in these documents or by

any other source, will not relieve the Contractor of his responsibility to decide for
himself the nature and extent of the work nor will it guarantee that similar
conditions will apply on other parts of the site.

c) The Contractor shall be deemed to have contacted the relevant statutory bodies
to establish the existence of any existing, live or redundant services adjacent to or
passing through the works and shall be deemed to have allowed in his tender for
their location, diversion, demolition or removal.

d) Boring logs and related information depict subsurface conditions only at the
specific locations and at the particular time designated on the logs.

(i) Soil conditions at other locations may differ from conditions occurring at the
boring locations.

(ii) Passage of time may result in a change of the sub-surface conditions or

water levels at the boring locations.

(iii) Employer does not guarantee any statements, opinions, or conclusions

contained in the report.

(iv) Contractor shall assume all responsibility for:

 Deductions and conclusions made by him regarding the nature of the

materials to be excavated.

 Difficulties involved

 Dewatering

 Maintaining the required excavations

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 Carrying out the work affected by the subsurface conditions at the site of
the works.

 Carrying out his own investigation to satisfy himself the validity of the
above data.

e) Neither the Employer not the Engineer shall be liable for any loss sustained,
indicated by or deducted from said borings, samples, tests, and / or reports, and
the actual conditions encountered during progress of the work.

2.8.4 Levels to be recorded

a) Bench marks and setting out baselines are to be agreed with Engineer.

b) Before the surface of any part of the site is disturbed or the works thereon are
begun, the Contractor shall take and record levels on 10m grids of such part, in
the manner specified or as agreed with the Engineer.

c) Two (2) working days’ notice is to be given to the Engineer so that the recording
of levels can be performed in the presence of the Engineer.

2.8.5 Bracing and Shoring

a) Excavated surfaces shall be supported as necessary to safeguard:

(i) Work and workmen

(ii) To prevent sliding or settling of the adjacent ground

(iii) To avoid interruptions in existing services

(iv) Damage to existing improvements and utilities infrastructure

b) Width of the excavation shall be increased if necessary to provide for sheeting,

bracing, shoring, and other supporting installations.

c) Contractor shall also obtain the permission of the relevant authorities for the
surface width of the excavation required.

d) Contractor shall furnish, place and subsequently remove such supporting

installations unless ordered otherwise by the Engineer.

e) Contractor shall furnish before commencement of excavation for any structure,

three copies of drawings showing details of the bracing he proposes to use,
together with all relevant calculations, demonstrating the sufficiency of the
proposals.

f) No excavation work shall commence until the Engineer’s consent has been
obtained. Such consent shall in no way relieve the Contractor from any of his
contractual obligations and responsibilities.

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2.8.6 Inspection by Engineer

a) When the specified levels of trench or structure excavation are reached, the
Engineer shall inspect the ground exposed.

b) If he considers that any part of the ground is by its nature unsuitable, he may
direct the Contractor to excavate further and to refill the further excavation with
such materials as he may direct.

c) If the bottom of any trench or structure excavation, while acceptable to the

Engineer at the time of his inspection, may subsequently become unacceptable
due to exposure to weather conditions, equipment traffic, due to flooding or
become puddled, soft or loose during the progress of the works, the Contractor
shall remove such damaged, softened or loosened material and excavated further
by hand.

d) In this case the cost of the extra excavation and of the additional foundation
materials required will be the Contractor’s responsibility if necessitated by his
negligence.

2.8.7 Existing Services

a) The Contractor shall check with the relevant authorities to determine what existing
underground services are present in the site area and locate and effectively seal
off drain ends.

b) When necessary, the Contractor shall divert services still in use and provide all
temporary works necessary to maintain such services in full functional order. He
shall also reinstate such services to the approval of the relevant authorities at the
earliest opportunity in compliance to the regulations and obtain necessary permits
and NOCs.

c) Bench marks and other permanent structures in the site area are protected from
damage or displacement.

2.8.8 Control of Water

2.8.8.1 General

a) The Contractor shall furnish, install and operate all necessary machinery,
appliances, and equipment to keep excavations free from water during
construction and shall remove all water so as not to cause damage to private
property, or to cause a nuisance or menace to the public all as specified herein.

b) Berms shall be provided to prevent surface water from draining into structural
excavations. Earth banks shall be suitably protected from damage by erosion
during construction. The Contractor shall ensure that at all times during
construction:

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(i) No groundwater shall come into contact with any concrete surface or
reinforcement

(ii) Any structure shall be capable of withstanding any hydrostatic pressure to

which it may be subjected during construction and until completed.

2.8.8.2 Drainage Provisions

a) Drainage ditches, diversions, and temporary pipes shall be constructed as

required to maintain drainage of the work areas.

b) Shall be constructed with cross-sectional area and gradient at least equal to that
of the intercepted watercourses, as approved by the Engineer.

2.8.8.3 Dewatering

a) Contractor shall perform dewatering as required so that all work under the
Contract is installed on dry areas and excavations, including without limitation the
construction of all structures and underground piping.

b) Contractor shall ensure that dewatering is carried out only to a depth sufficient for
the required excavation.

2.8.8.4 Qualified Personnel

Contractor shall, where extensive dewatering is required:

a) Be fully qualified to perform the dewatering operations or

b) Shall furnish the services of an experienced, qualified and equipped dewatering

subcontractor to design and operate the dewatering and groundwater recharging
systems required for the work, all subject to the Engineer's approval.

2.8.8.5 Monitoring

a) Where required to do so by the Engineer, the Contractor shall establish a

specified number of groundwater level monitoring stations at each site which will
be observed during the work. These shall be located as directed by the Engineer
and consist of acceptable open tube piezometers.

b) Settlement gages shall be provided to the approval of and as designated by the

Engineer at each site, times and locations to monitor settlement of new and
existing facilities as directed.

2.8.8.6 Submittal

a) Where deemed necessary by the Engineer, shop drawings and data shall be
submitted for record purposes only, but not for review or approval showing the
intended plan for dewatering and recharging operations.
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b) Details of locations and capacities of dewatering wells, well points, pumps,

sumps, collection and discharge lines, standby units, water recharge system,
water disposal methods, monitoring and settlement measuring equipment, data
collection and dissemination shall be included. These shall be submitted not less
than 30 days before start of dewatering operations.

2.8.8.7 Operation

a) Contractor shall furnish, install and operate all necessary pumping, well-point
dewatering appliances and equipment to keep excavations free from water during
construction.

b) The Contractor shall dewater and dispose of water so as not to cause injury to the
public or private property or to cause a nuisance or a menace to the public.

c) Contractor shall at all times have on hand sufficient pumping equipment and
machinery in good working condition for all ordinary emergencies including power
outage.

d) Contractor shall have available at all times competent workmen for the operation
of the pumping equipment.

e) Excavations shall be kept free of water during:

(i) Excavation, construction of chambers, etc.

(ii) Installation of pipelines.

(iii) Placing of structural and trench backfill.

(iv) Placing and setting of concrete.

f) Contractor shall control surface runoff so as to prevent entry or collection of water

in excavations.

g) Static water level shall be drawn down a minimum of 300 mm below the bottom of
the excavation to:

(i) Maintain the undisturbed state of the foundation soils.

(ii) Allow the placement of any fill or backfill to the required density.

h) Dewatering system shall be installed and operated so that the groundwater level
outside the excavation is not reduced to the extent that would damage or
endanger adjacent structures or property.

2.8.8.8 Maintenance of Existing Water Table Level

a) All required operations shall continuously maintain the level of the water table
outside the dewatered areas to prevent damage to structure, pipelines, etc.,
adjacent to the excavations.
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b) A water injection recharging system shall be maintained to replenish the

groundwater supply as required to maintain the water table including pumps,
piping, well points, standby units, other required equipment and a source of water
sufficient to meet the recharge requirements should supply of water from
dewatering operations be interrupted or become inadequate.

2.8.8.9 Protection of Existing Facilities

a) Where any sloped excavation infringes on, or potentially endangers any existing
facilities or structures.

(i) Shoring, sheeting, and bracing shall be provided according to plans and
calculations made by a qualified Engineer.

(ii) A copy of such plans and calculations shall be given to the Engineer for
record purposes.

b) At his expense, the Contractor shall repair and make good:

(i) all damage or resettlement to foundations or other portion of any existing

facilities or structures

(ii) damage to existing works caused by permanent or temporary failure of

excavation protection, operation of the dewatering or recharging systems or
failure to maintain the existing groundwater level outside the dewatered
areas.

2.8.8.10 Disposal of Water

Water not injected back into the ground shall be disposed of lawfully without damage
to new and existing facilities or adjoining properties.

2.8.8.11 Removal

a) Release of groundwater to its static level shall be performed to:

(i) Maintain the undisturbed state of the natural foundation soils.

(ii) Prevent disturbance of compacted fill or backfill.

(iii) Prevent flotation or movement of structures, pipelines and sewers.

b) Equipment shall be removed when no longer required, but monitoring and

settlement measurement systems shall be maintained in operation until removal
is approved by the Engineer.

c) To the extent approved by the Engineer, well points and such items may be
abandoned in place.

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2.8.9 Excess Excavation to be Made Good

The Contractor at his own expense shall remove from the site all materials resulting
from excess excavations below that required for the foundation, lining or bedding and
shall make good the same with Grade 25 concrete or suitable fill materials as
instructed by the Engineer.

2.8.10 Foundation Preparation

2.8.10.1 General

a) Foundations for earth fill shall be stripped to remove all obstructions, vegetation,
debris, or other unsuitable materials.

b) Except as otherwise specified:

(i) Foundation surfaces shall be graded to remove surface irregularities

(ii) Shall be scarified and loosened to a minimum depth of 100 mm.

c) Moisture content shall be controlled as specified for engineered fill. Surface

materials of the foundation shall be compacted and bonded with the first layer of
earth fill as specified for subsequent layers of earth fill.

2.8.10.2 Rock Foundations

a) All rock foundation and abutment surfaces shall be cleared of all loose materials
by hand or other effective means and shall be free of standing water when fill is
placed.

b) Previous rock foundations shall be excavated to 150 mm below finished grade

shown on the drawings and a lining shall be placed as specified herein.

c) Fill placed immediately adjacent to such rock foundations or where not accessible
with large compaction equipment shall be compacted to the specified density by
means of hand tamping or manually directed power tampers or plate vibrators.

2.8.10.3 Benching

a) Where slope of existing soils to receive fill exceeds 1:4 horizontal benches shall
be cut to key the new fill material to the existing soils.

b) At least 600 mm of existing soil normal to the original slope shall be removed and
recompacted as the new fill is brought up in layers.

2.9 CLASSIFICATION OF EXCAVATION AND BACKFILL

2.9.1 General Classification

Excavated material shall be classified as:

a) Road Excavation
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b) Borrow excavation

c) Structural excavation

d) Trench excavation

2.9.2 Excavation Materials

a) Excavations include all materials of whatsoever nature, suitable or unsuitable,

excavated to the required profile within the project work site and excavated within
the limits of the Right of Way for the preparation up to the formation levels of each
structure.

b) All such materials after deduction for material declared unsuitable by the Engineer
shall be considered to be available for use at locations requiring fill.

c) All excavations shall be sub-classified as Common Excavation and Rock

Excavation.

2.9.3 Identification of Common and Rock Excavation

Authority to identify and define the physical characteristics which determine the
classification as "Common Excavation" and "Rock Excavation" in accordance with the
intent of the following provisions shall be vested by the Engineer.

2.9.3.1 Common Excavation

a) Shall consist of the excavation and satisfactory disposal of all soils, rock soil
mixtures of sand stone features and silty sand, certain strata and rock boulders
less than one (1) cubic metre in volume.

b) Strata which are altered and weathered and are in place, but which are not firm
enough, or in the opinion of the Engineer are not rigid enough to have all the
characteristics of rock excavation shall be classified as common excavation.

2.9.3.2 Rock Excavation

a) Shall consist of the excavation and satisfactory disposal of all unaltered and un-
weathered firm and rigid igneous, metamorphic and sedimentary solid rock that in
the opinion of the Engineer is impracticable to remove by heavy mechanical
excavating equipment (e.g. Cat.D8) or by heavy duty hydraulic ripper, or by
approved pneumatic tools.

b) These types of rocks would normally be removed by blasting with explosives, or

by heavy duty hydraulic breakers or by drilling and broaching with wedges and
sledge hammers if removed by hand.

c) Also individual boulders or detached pieces of rock exceeding one cubic meter in
size in trenches or excavations necessitating blasting or breaking as above are
considered as rock.

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d) Cemented granular materials requiring the use of pneumatic tools or rippers will
not be defined as rock.

2.9.3.3 Borrow Excavation

a) If the demand for fill material exceeds the quantity of suitable material obtained
from the project work structures, trench excavations and the roadway excavation
then suitable material shall be imported to the worksite from the approved borrow
pit within project work area.

b) The excavation, haulage and discharge of material in its final place from a borrow
pit shall be classified as Borrow Excavation.

2.10 EXCAVATION REQUIREMENTS

a) All materials removed from the area of structural excavation and borrow pit shall
be reused in the designated backfill area around the structures, trench backfill
and in the formation of the embankment, shoulders and at such other places as
directed, unless it is declared unsuitable and ordered to be sent to tip by the
Engineer. No excavated material shall be wasted without written permission from
the Engineer, and when such material is to be wasted, it shall be hauled to the
approved tip or as otherwise directed by the Engineer.

b) Material suitable for top soil, base material, mineral aggregate or other specified
purpose, encountered in excavation, shall be reserved, if so directed, until it can
be placed in its proper position in the roadway. When specified or designated,
top soil shall be used as cover on embankment slopes to aid the regrowth of
vegetation or other purposes.

c) Excavated materials wasted by the Contractor without written permission of the

Engineer shall be replaced by the Contractor at his own expense.

d) During the construction of the roadway, the prepared formation shall be

maintained in such condition that it will be well drained at all times.

e) Rock, shale and other unsuitable material encountered in cuts shall be excavated
to the lateral limits and depth indicated on the plans or as otherwise directed. Any
over breakage below the depth shown on the plans or as otherwise directed will
not be paid for. Backfill of the over breakage shall be approved suitable material
and shall have the same density requirements as specified by the Contract and
shall be at the expense of the Contractor. If the backfill of the over breakage area
designated by the Engineer is to be a crushed aggregate concrete or other
special aggregate the entire cost of the backfill of the over breakage shall be at
the expense of the Contractor. Un-drained pockets shall not be left in the surface
of the rock, but they shall be treated as directed by the Engineer.

f) All slopes, except in solid rock or other material which, in the judgement of the
Engineer, require a modified slope, shall be trimmed accurately to the slopes

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shown on the cross-section drawings, and care must be exercised that no

material shall be loosened beyond the required slopes. Side ditches if required
shall be excavated in conformity to line, grade, and cross-section as shown on the
Drawings or as directed by the Engineer.

g) In cut areas, excavation shall be for the full construction width down to
'earthworks formation level' as shown in the approved drawing. For a further
depth of 15 cm the existing material shall be scarified, watered as necessary,
mixed and compacted to not less than 95% of maximum dry density as
determined by BS 1377 Part 4 : 1990 (Method 3.5 or 3.6). Field density shall be
determined by BS 1377 Part 9: 1990 (Method 2.1 or 2.2).

h) The 'improved subgrade layer', using specified imported material, shall then be
placed and compacted to not less than 95% maximum dry density as determined
by BS 1377 Part 4: 1990 (Method 3.5 or 3.6) to bring the embankment level up to
'top of improved subgrade level'. Field density shall be determined by BS 1377
Part 9 : 990 : (Method 2.1 or 2.2).

i) For cuttings 1.5 metres or more in depth the technical requirements, of the
Specification for "Excavation for Structures" (Sub-Section 2/20) shall be complied
with.

j) Where excavation to the finished graded section, that is 'earthworks formation

level', results in a formation or slopes of unsuitable soil, the Engineer may require
the Contractor to remove the unsuitable material to a depth directed and backfill
to the finished graded section with approved material compacted in accordance
with specified requirements for embankment construction. The Contractor shall
conduct his operations in such a way that the necessary cross-sectional
measurements can be taken and agreed with the Engineer before the backfill is
placed.

k) When the Contractor is required or directed to excavate unsuitable material in fill

areas, following general clearance of the area (see Specification Sub-Section
2/14.1 "Embankment Foundation"), the depth to which these unsuitable materials
are to be removed will be determined by the Engineer. The Contractor shall so
schedule the work so that authorised cross-sections can be taken before and
after the material has been removed.

l) All slopes, lines and grades shall be true, correct, and accurate and according to
those on the drawings or otherwise directed and approved by the Engineer. The
'earthworks formation level' in cuts shall be accurate to the authorised profile
grade to plus or minus two (2) centimetres and, for 'top of improved subgrade'
level, plus or minus one (1) centimetre. Where discrepancies are found in the
Work the Contractor shall make necessary corrections.

m) The Engineer will check all or any part of the Work, as he deems necessary, to
determine conformance to the lines, grades, elevations and cross-sections.

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2.11 BORROW PIT SITE WITHIN PROJECT WORK AREA

a) The Contractor shall obtain approval from the Employer for the location of the
borrow pit site. The Contractor shall be responsible to determine the quantities
and quality of the available material in the approved borrow site to meet the
requirements of the Contract. When required the borrow area shall be cleared
and grubbed in accordance with the requirements of Section 2/1.

b) The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such notice
from the Employer, the Contractor shall immediately cease removing material
from said borrow site. In the event the Employer revokes approval of the borrow
site, the Contractor shall locate a new borrow pit site as specified above.

c) The Contractor shall not claim any additional payment for any costs by reason of
the necessity of changing borrow site locations due either to the shortage of the
supply of borrow material available from the borrow pit site approved by the
Employer, or due to the Employer's decision to revoke approval of the borrow site
where the Contractor is obtaining borrow material for the Works.

d) The Contractor shall leave borrow pits in a condition acceptable to the Employer
and to the Engineer.

e) The Contractor will be solely responsible for ascertaining the location of such
approved borrow areas during the tender preparation stage. Locations, distances
to the work site and haulage from such approved borrow areas shall be taken into
consideration when preparing the unit tender price for Borrow Excavation.

2.12 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS

MATERIALS

2.12.1 Top Soil

a) Top soil shall be fertile, friable soil obtained from well drained arable land and
shall be free draining, non-toxic and capable of sustaining healthy plant growth.

b) The organic matter content of the topsoil material shall be 2% max.(BS 1377: Part
3: 1990: Method 3) with the minimum out of tolerances of individual tests by +
0.5% and have pH value between 7.0 and 9.0 (BS 1377: Part 3: 1990: Method 9).

2.12.2 Suitable Material

a) Suitable material shall comprise all well graded sandy soil from coarse to fine
material that is acceptable in accordance with the Contract for use in the Works.

b) Suitable material for earthworks shall be approved soil with a plasticity index not
exceeding 6 when tested according to BS 1377 Part 2 1990 Clause 5.4 (liquid
limit shall not exceed 40% when tested according to BS 1377: Part 2: 1990:

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Clause 4.5) obtained from excavations within the works or from borrow pits
approved by the Engineer.

c) Suitable material It shall not contain excess of 425 micron passing material 50%
when tested in accordance BS1377:P2: 1990 Cl.9.2 and of fines (not more than
20% passing Sieve Size 0.075mm determined by BS 1377: Part 2: 1990 Clause
9.2 "Determination of particle size distribution by wet sieving") and in excess of
2% organic matter content (BS 1377 Part 3:1990).

d) Suitable material for earthworks shall have a soaked CBR value at 95% of
maximum dry density not less than 10% when tested according to BS 1377 Part
4: 1990 (Method 7). The maximum particle size shall not exceed 63 mm.

e) Soluble salt content must be less than 5% by weight of dry soil tested to BS 1377
Part 3: 1990 (Method 7 & 5 for water soluble Chloride & Sulphate respectively).

f) The material shall possess satisfactory binding characteristic to enable it to be

compacted to give a well-knit surface as judged by the Engineer. The maximum
dry density of the soil shall not be lower than 1.75gm/cu.cm.

2.12.3 Unsuitable Material

Unsuitable material shall comprise of:

a) Rock particles exceeding 63 mm in size.

b) Organic matter (BS1377 Part 3 : 1990 method 3) containing greater than 2%

(stumps and other perishable material).

c) Material susceptible to spontaneous combustion.

d) Alluvial clay and silts, gypsum which contain high concentration of water soluble
sulphate greater than 5% and pyritic shale.

e) Soils of liquid limit exceeding 40% (BS 1377 Part 2 1990 Clause 4.5) and or
plasticity index exceeding 6 (BS 1377 Part 2 1990 Clause 5.4).

f) Material containing more than 5% of water soluble salts by weight of dry soil. BS
1377 Part 3: 1990 (Method 7.2 and 5.5 AMD 9028-1996) for water soluble
chloride and sulphate respectively.

g) Materials having CBR value less than 10%.

h) Any other material which the Engineer may deem to be unsuitable for earthworks.

i) Soil groups A-6, A-7 (silt-clay materials more than 35% passing 75 micron sieve)
as specified in ASTMD 3282.

2.12.4 Material for Improved Subgrade Layer

Material for Improved Subgrade Layer shall meet the following requirements:
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a) Not more than 20% by weight passing Sieve Size 0.075mm determined by BS
1377: Part 2: 1990 Clause 9.2 "Determination of particle size distribution by wet
sieving".

b) Soaked CBR value at 95% maximum dry density (soaked) BS 1377 Part 4 : 1990
(Method 3.5 or 3.6) not less than 30% when tested according to BS 1377 Part 4 :
1990 (method 7).

c) A chemical analysis of the proposed material shall be carried out to satisfy the
following requirements:

(i) The material shall be shown to have an acid soluble sulphate content of 2%
or less and a chloride content in the form of acid soluble chloride of 2% or
less by dry weight. The applicable

(ii) Test methods should be in accordance with BS1377 Part 3: 1990 (Method
5) and BS 1377 Part 3 : 1990 (Method 7) respectively.

d) When approved by the Engineer a sulphate content greater than that specified
may be acceptable when the carbonate content is in the region of 30 40% (BS
1377 Part 3: 1990 Method 6.3 AMD 9028-1996).

e) Higher chloride contents may be tolerated provided that the ratio of (carbonate +
sulphate) to chloride contents is maintained at approximately 15:1.

f) The moisture content of the material before compaction shall not vary by more
than +/- 3% of the optimum moisture content when tested in accordance with BS
1377: Part 2 : 1990 Test 3.2.

g) The material for improved subgrade shall be approved soil with a plasticity index
not exceedingly 6 (BS 1377 Part 2 1990 Clause 5.4) and liquid limit shall not
exceed 40% when tested according to (BS 1377: Part 2: 1990 Clause 4.5).

h) The material shall possess satisfactory binding characteristics to enable it to be

compacted to give a smooth well-knit surface as judged by the Engineer.

i) No excavated suitable material shall be removed from the Site without the
Engineer's written permission. Should the Contractor be permitted to remove
suitable material from the site to suit his operational requirements, then he shall
make good any consequent deficit or filling arising there from at his own expense.

2.13 MAIN PLANT AND EQUIPMENT FOR EARTHWORKS CONSTRUCTION

2.13.1 General

a) The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in situ state or during handling and placing
or in its final compacted state. Unsuitable or faulty plant shall be removed from
the work site and borrow pits at the order of the Engineer.
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b) The plant and equipment used for earthworks construction shall be maintained in
good working condition for the duration of the works. The Contractor shall apply
adequate quantities of plant and equipment necessary for the proper execution of
the works in an expeditious manner.

c) Main plant and equipment shall meet the requirements specified below:

(i) Equipment shall mean, where mentioned in these Specifications, all

machines, tools, equipment and all necessary parts for its operation and
maintenance. Also, the laboratory tools and instruments and/or equipment
necessary for the proper construction of the road and the proper completion
of all the works.

(ii) The Contractor shall submit, as stipulated in the "Instructions to Tenderer" a

detailed list of plant equipment which he shall undertake to bring to the site
to carry out the work. The list shall include for each piece of equipment, the
type, size, quantity, manufacturer, model, identification number and year of
manufacture.

(iii) The Contractor shall supply all plant and equipment necessary for the
construction of each phase of the work and it must be on the site, inspected
and approved by the Engineer prior to the commencement of the particular
phase of work. Any plant or equipment of portion thereof, which becomes
worn or defective shall be immediately repaired or replaced to the
satisfaction of the Engineer.

2.13.2 Compacting Equipment

The compaction equipment for earthwork may be towed or self-propelled and shall
include a suitable combination of tamping rollers, grid rollers, segmented pad rollers,
vibrating rollers, pneumatic rollers and other compaction equipment that can
satisfactorily and uniformly obtain the required compaction.

2.13.2.1 Tamping or Sheep foot Rollers

a) Tamping or sheep foot rollers shall consist of metal rollers, drums, or shells
surmounted by metal studs with tamping feet projecting not less than sixteen and
one-half (16.5) centimetres from the surface of the roller, drum or shell.

b) Tamping feet shall be spaced not less than fifteen (15) centimetres or more than
thirty (30) centimetres measured diagonally centre to centre and the cross section
area of each tamper foot, measured perpendicularly to the axis of the stud, shall
be not less than twenty-five and eight-tenths (25.8) square centimetres.

c) The weight of tamping rollers shall be such that when fully loaded, the load on
each tamper foot will be determined by dividing the total weight of the roller
(loaded) by the number of tamper feet in one (1) row parallel to the axis of the
roller.

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2.13.2.2 Pull-type Steel Rollers

Pull-type steel rollers shall have not less than one and two-tenths (1.2) metre
effective width of roller and shall be designed and constructed so that the weight per
linear centimetre of roller can be varied from thirty five and seven-tenths (35.7)
kilograms to at least fifty-three and six-tenths (53.6) kilograms.

2.13.2.3 Self-Propelled Steel Rollers

a) The power mechanism shall be capable of propelling the roller smoothly and
without jerking when starting, stopping, or reversing directions free from backlash,
loose link motion, faulty steering mechanism and worn king bolts.

b) The steering mechanism shall have no lost motion, shall operate readily and
permit the roller to be directed on the alignment desired. The faces of all rollers
shall be smooth and free from defects which mark the finished road surface.
Rollers shall be equipped with water tanks and sprinkling devices which shall be
used for wetting the roller to prevent adherence of the placed material.

c) Two-axle tandem steel rollers shall weigh not less than eight (8) tonnes or more
than twelve (12) tonnes and shall have a weight per centimetre width of roll
between 35kg and 70kg.

d) Three axle tandem steel rollers shall weigh not less than eleven (11) tons. Three
axle tandem roller shall be so constructed that the roller, when locked in position
for all treads to be in one plane, are held with a rigidity which will satisfy the
following test under full load: with the weight of the roller supported on the central
roller, the tread of the central roller shall not be more than three (3) millimetres
above the plane tangent to the tread of the end roller. With the weight of the roller
supported on the end rollers, the tread of the central roller shall not be more than
six (6) millimetres below the plane tangent to the treads of the end roller.

2.13.2.4 Trench Rollers

The trench roller shall be of an approved type and shall weigh not less than fifty-three
and six tenths (53.6) kilograms per centimetre of width and shall be equipped with
water and sprinkling device that shall be used for wetting the roller to prevent
adherence of the placed material.

2.13.2.5 Pneumatic Tic-Tyre Rollers

a) The tyres on the front and rear axles shall have wide smooth treads and shall be
staggered to provide complete coverage of the entire area which the roller travels.
The tyres shall be inflated to a pressure that has been approved by the Engineer
and the pressure shall be reasonably uniform in all tyres. The Contractor shall
provide a suitable gauge for determining air pressure in each tyre.

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b) Light self-propelled pneumatic-tyre rollers shall be so constructed so that they

may be loaded to provide a gross weight of at least forty (40) kilograms per
centimetre of width of tyre tread.

c) Heavy self-propelled pneumatic-tyre rollers shall be constructed so that they can

be loaded to provide a gross weight of not less than twenty five (25) tonnes and
they shall have tyre pressures of 6-6.3 kg/cm2.

2.13.2.6 Vibration Compactors

a) Equipment using principle of vibration as a tamping force shall be in good

mechanical condition and shall be capable of transmitting forceful vibrations or
impacts to the various materials placed in construction.

b) The equipment may be the roller or pad type or a combination of roller and pad
type. Vibrating compactors shall be of the type and force approved by the
Engineer.

2.13.3 Hauling and Weighing Equipment

2.13.3.1 Hauling Equipment

a) Hauling equipment for aggregate shall consist of vehicles having dump bodies
suitable for dumping materials in a windrow or in spreader boxes. The bodies
shall be so constructed that their volume measurement can be accurately
determined. They shall be so constructed and maintained to prevent loss of
materials during hauling operations.

b) The equipment shall be provided with dump controls that can be operated from
the driver's seat. The bodies of hauling equipment using public roads shall be
fitted with tarpaulins to prevent the nuisance of spillage.

2.13.3.2 Weighing Equipment

a) Weighing equipment for truck -hauled material shall consist of accurate and
reliable platform scales and they shall be accurate to one per cent throughout the
range of use.

b) The scale shall have a platform of adequate length to weigh the longest truck or
truck-trailer combination which is in use on the Project, in one operation.

c) Scales shall be inspected and sealed or certified by an approved scale company,

as often as the Engineer deems necessary to ensure their accuracy.

d) The seal or certification shall show the date of the inspection. Where no approved
scale company exists or at the option of the Engineer, the Contractor shall check
and adjust the scale in the presence of the Engineer in the method recommended
by the manufacturer and/or approved by the Engineer.

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e) It is the Contractor's responsibility to have sufficient standard test weights for

each scale on the Site.

f) The Engineer, as often as he deems it necessary, shall direct the Contractor to

check and adjust any scale on site to ensure its accuracy.

g) The Contractor, shall when directed by the Engineer, make weight comparisons
with other permanently located scales that meet with the approval of the
Engineer. These weight comparisons shall be for the purpose of providing
information on the performance of the Contractor's scale and will not be used as a
basis for adjusting the scale.

h) The approaches to the scale platform shall be maintained by the Contractor to the
satisfaction of the Engineer.

i) The Contractor shall furnish a suitable weather tight building to enclose the
indicating mechanism and shall have adequate lighting for the scale operator's
use.

j) The Contractor shall have on hand not less than ten (10) twenty-five (25) kilogram
weights for testing the scale.

2.13.3.3 Controlled Water Distribution Equipment

a) Equipment for distribution of water shall consist of distributors or tanks equipped

with spray bars, and when required, pumps to operate under pressure.

b) The pumps shall be of sufficient capacity to provide uniform and adequate

distribution. They shall be mounted on pneumatic-tyre trailers pulled by
pneumatic-tyre equipment.

c) The minimum capacity of any tank shall be four (4) cubic metres (m³) where
applicable.

d) The distributor equipment shall be constructed to permit accurate and uniform

distribution of the desired quantities of water per unit of surface area.

e) The control valves shall be constructed to permit full closing and to prevent
leakage.

f) The water control valves shall be constructed to operate from the driver's seat or
provisions made for an additional operator to operate the control valves while the
equipment is travelling at the proper speed for distribution.

2.14 EMBANKMENT CONSTRUCTION

2.14.1 General

a) The work of embankment construction shall consist of cutting and filling the
designated fill areas as shown in the drawing and constructing roadway

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embankment with suitable material, including the preparation of the areas upon
which they are to be placed and the placing and compacting of approved material
within roadway areas where unsuitable material has been removed.

b) All operations for embankment construction shall be performed in accordance

with the Specifications and in conformity with the lines, grades, and thickness and
typical cross-sections shown on the drawings or as estimated by the Engineer.

c) Compaction equipment shall conform to the number and type outlined in the
Contractor's detailed programme of work as approved by the Engineer and
satisfactory performance shall be the basis for such approval.

d) All materials derived from excavation shall be used in the general filling including
trench backfill, backfill around structures for embankment unless otherwise
declared unsuitable by the Engineer. When suitable materials of widely divergent
characteristics are drawn from different sources such materials may, if approved,
shall be mixed to meet filling requirements.

e) Prior to the commencement of embankment the Contractor shall construct trial

compaction lengths as directed by the Engineer. The soils used in the trials shall
be those encountered along the line of the road and project work area as
approved by the Engineer and/or those originating item the approved borrow pit.
The object of the trials is to determine the field compatibility of the material with
the plant and compaction equipment available with the Contractor. The Engineer
may order additional compaction trials when he deems them necessary.

f) During the construction of road /embankments the Contractor shall control and
direct construction traffic uniformly over the full width of the embankment?
Damage to compacted layers by construction traffic shall be made good by the
Contractor at his own expense.

g) The Contractor shall be responsible for the stability of all embankments and shall
replace all sections which, in the opinion of the Engineer, have been damaged or
displaced due to carelessness or neglect on the part of the Contractor, or due to
natural causes, such as storms, and not attributable to the unavoidable
movement of the natural ground upon which the embankment is made.

h) During construction, the roadway shall be kept shaped and drained at all times.
When unsuitable material has been placed in the embankment, its removal shall
be at the expense of the Contractor.

i) Throughout the duration of the Contract all damage to completed earthworks

attributable to rain and rainfall run-off or to any other cause shall be made good
by the Contractor without delay and whenever possible within 24 hours of such
damage occurring.

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2.14.2 Embankment Foundation and the Designated Filling Area

a) All debris, unsuitable material and vegetable matter shall be removed from the
surface upon which the embankment and the filling area is to be placed and the
cleared surface shall be completely broken up by ploughing, scarifying or
stripping to a minimum depth of twenty centimetres (20 cm).

b) The foundation material shall be adjusted to a moisture content within the

moisture range of ±3% of the optimum moisture content and compacted to not
less than ninety five per cent (95%) of the Maximum Dry Density as determined
by BS 1377 Part 4: 1990 (method 3.5 or 3.6).

c) Rock-soil mixtures of sandstone fractures and silty sand deposits obtained from
the excavation shall also be used at the lower part for the construction of the
embankment provided such materials fully comply with the following properties.

Table 2.14-1: Rock soil mixture suitable for embankments

Sr. Properties Standard Specs

1. Size 25% larger than 30 cm –

2. Size 50% larger than 7.5 cm –

3. Bulk Specific Gravity not less than 2.25 –

4. Water Absorption not more than 6% –

5. Testing by plate bearing test –

6. Filling material shall not be A-6, A-7 Type soil AASHTO M-145

d) If the original surface upon which the embankment is to be placed is an old

roadbed, the surface shall be ploughed scarified or broken up, regardless of the
height of the embankment to be placed and compacted to a density as
determined by the Engineer.

e) Where the embankment and the filling is to be placed on appreciably sloping

ground, this surface shall be benched in steps or trenched to key-in the new
construction in accordance with the Engineer's instructions, including if necessary
any under-draining of the affected part of the site.

f) In circumstances where backfill has to be deposited below standing water, the

Contractor shall use only an approved granular material of maximum size not
greater than 37.5 mm and which on analysis by sieving (BS 812: Part 103:
Section 103.1:85 c1.7.2 or 7.3, or BS 1377: Part 2: 1990: 9.2 or 9.3 latest edition)
complies with the requirements of Table below. Such material shall have a "ten
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percent fines" value of not less than 5 tonnes when tested in accordance with
B.S. 812 : 1990 : P111 and may be deposited below water without the associated
use of compaction plant.

Table 2.14-2: Free draining material

BS Sieve Size % by Weight Passing

10 mm Up to 100

5 mm Not more than 85

0.600 mm Not more than 45

0.075 mm Not more than 5

g) In circumstances where filling has to be deposited in a soft area, methods of soft

area treatment which may be directed by the Engineer shall be:

(i) Non-friable boulders of sizes between 150-300 mm shall be end dumped

over the soft area and rolled until the area is stabilised to the satisfaction of
the Engineer. Further stones of 10-70 mm size shall be rolled into the area
until all the areas are levelled and well blinded.

(ii) Crushed rock material shall be free from dirt, organic matter, shale and any
other deleterious material. The acceptance criteria shall be as follows:

Table 2.14-3: Crushed rock material acceptance criteria

Parameter Limit value

1. Grading (BS EN 933-1:2012 and BS 1377

Part 2 method 9.2 or 9.3: 1990)
Sieve (mm) Passing (%)

150 100

200 80-100

37.5 -

25 20-50

19 -

9.5 0-15

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Parameter Limit value

2. Bulk specific gravity (ASTM C127 & C128) Not less than 2.65

3. Absorption (ASTM C127 & C128) Not more than 2%

4. Loss of Abrasion (ASTM C131 or C535) Not less than 30%

5. Loss of magnesium sulphate soundness 10% maximum

(ASTM C88 5 cycles)

h) The following field tests are to be carried out to confirm the load bearing nature of
the soft area prior to start stabilizing work:

(i) Field density test in accordance with BS 1377: P9:C2:1990

(ii) Plate bearing tests shall be carried out in accordance with ASTM
D1194/D1196. Frequency and unit shall be as directed by the Engineer.

(iii) CPT test in accordance with BS 5930: 1999.

2.14.3 Suitability Testing on Materials

a) During excavation, care should be taken to avoid indiscriminate mixing of soils of

widely differing classification and characteristics.

b) Excavated materials obtained from the cutting and borrow pit shall be stockpiled
within the respective areas and shall be used (after suitability test) for filling and
embankment construction.

c) Alternatively sufficient numbers of trial pit excavation from various locations and
depths shall be carried out to test the material to confirm its suitability
requirements specified in Clause 2/12.

d) All such trial excavations or stockpiling shall be carried out without extra charges.

2.15 PLACING AND COMPACTION REQUIREMENTS

a) Only approved materials shall be used in the construction of road embankments.

b) In the formation of the embankment it is strictly forbidden to push the excavated

materials from the side of the road to the embankment by means of bull dozers.

c) The fill material shall be delivered and spread in layers not exceeding 25 cm
compacted thickness. The layers of fill shall be graded, levelled, pulverised and
mixed, with water added as necessary, to ensure homogeneous conditions
through the full depth of the un-compacted layer. For field density testing refer to
specification sub-section 2/18.

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d) The compacted density of the fill shall be equal to or greater than as required
under Clause 2/18 as determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6).

e) The material to be imported for the "improved sub-grade layer" to be constructed

above "earthworks formation level" up to "top of improved sub-grade" level as
shown on the drawings shall conform to the Specification Sub-Section 2/12.

2.16 MOISTURE CONTROL REQUIREMENTS

a) When the moisture content of the embankment soil does not fall within 3% of the
optimum moisture content, water shall be added and thoroughly mixed into the
soil, by approved methods or the material shall be aerated, whichever is needed
to adjust the soil to the proper moisture content.

b) The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide moisture content in the soil
within the required range plus a reasonable amount to compensate for
evaporation and other unavoidable losses.

c) Water added in excess of this amount shall be considered as excess water and
must be removed by aeration or other suitable means as directed by the
Engineer.

d) Satisfactory methods and sufficient equipment shall be used for furnishing and
handling of the water so that there will be no undue loss due to evaporation or
waste. If water is added to cut areas or borrow pits, the surface of the areas or
pits shall be maintained in such a manner that will prevent undue loss of moisture
and segregation.

e) Use of saline water for earthworks will only be permitted if the percentage of
water soluble salts in the compacted fill does not exceed 3% by weight of dry soil
when tested in accordance with BS 1377 Part 3 : 1990 tests 5 & 7.

f) For subgrade material moisture range refers to sub-clause 2/12.

2.17 STANDARD EARTH WORKS COMPACTION PROCEDURE

2.17.1 General

a) A dry density moisture content relationship test in accordance with BS 1377 Part
4: 1990 (method 3.5 or 3.6) will be made for each type of soil to be used in the
construction of the work to determine the Maximum Dry Density, the Optimum
Moisture Content and the Moisture Range required of the soil for satisfactory
compaction.

b) This method will be used to determine the maximum dry density of each type of
soil used in compacted fills, backfills, embankments and to measure the relative
compaction at optimum moisture content of compacted fills, backfills,
embankments and subgrades.

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2.17.2 Compaction Tests

During the course of the work, tests shall be carried out under supervision of the
Engineer to:

a) Identify materials

b) Determine compaction characteristics

c) Determine moisture content

d) Determine density of fill in place

2.17.3 Testing

a) Regular testing shall be performed as detailed in 2/18 of the Specification.

b) Contractor shall adjust his operations so as to permit time to make tests and shall
excavate and fill such holes as may be required for sampling and testing.

c) Compaction tests shall be made prior to removal of dewatering systems.

d) A subsequent layer cannot be placed until the compaction density of the

proceeding layer has been approved by the Engineer.

2.18 MINIMUM TEST REQUIREMENTS

For the Contractor’s general guidance, the following tests will be required prior to use,
and during the construction of filling area, the embankment and of the sub-grade.

2.18.1 Embankment and Filling Works

a) Soil samples for Soil classification according to BS 1377: Part 1 and Part 2: 1990
latest edition, laboratory moisture/density relationship tests and California Bearing
Ratio shall be taken prior to use, from any proposed source of material.

b) Each sample shall represent not more than 5,000 m³ or part of as directed by the
Engineer. Sampling shall be in accordance with ASTM D75: 2003, BS 1377 Part
1: 1990 and BS 5930:1999.

c) For every completed layer of fill at least:

(i) Three field density tests shall be performed for every unit of carriageway.
(One unit being 2250 sq.m) or as directed by the Engineer in accordance
with BS 1337 :P9 : 1990

(ii) Every compacted layer shall not be less than 95% of MDD. One test per
backfill layer for each structure or one test per 500 m2.

d) The Contractor shall carry out any additional compaction tests as ordered by the
Engineer at no additional cost.

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2.18.2 Improved Subgrade

a) Samples for soil classification, laboratory moisture density relationship tests and
CBR tests shall be taken prior to use, from any proposed source of material. Each
sample shall represent not more than 3,000 m³ or as part of as directed by the
Engineer.

b) For every completed layer of subgrade, three field density tests shall be
performed on each unit of carriageway (one unit being 1500 m²) or as directed by
the Engineer.

c) The frequency of field compaction tests on the shoulders shall be three every unit
constructed or as directed by the Engineer (one unit being 1500 m²).

2.18.3 Rock Fill and Rock Soil Mixtures

a) Where embankments to be compacted are formed of material consisting

predominantly of sand stone or rock fragments of such size that the material
cannot be placed in layers of the thickness prescribed without crushing,
pulverising or further breaking down the pieces resulting from normal excavation
methods, the material may be placed in the embankment in layers not exceeding
a thickness twice the average size of the larger rocks, except that no layer shall
exceed 600 mm of loose measurement.

b) Materials shall be carefully placed so that all large stones will be well distributed
and the voids completely filled with smaller earth, sand or gravel to form a solid
embankment.

c) Each layer shall be bladed or levelled with motor grader, bull dozer or similar
equipment capable of shifting and forming the layer into a neat and orderly
condition.

d) No rocks larger than eighty (80) mm in any dimension shall be placed in the top
one hundred and fifty (150) mm of the embankment unless otherwise noted on
the drawings.

e) Conformance to these provisions and compaction in a manner and to a point of

consolidation approved by the Engineer will be considered as fulfilment of the
requirements for the type of compaction shown on the drawings.

f) Normally, compaction tests will not be performed in these areas but the Engineer
reserves the right to test compaction in some other manner if he deems a test
necessary to ensure consolidation. Each layer must be approved by the Engineer
before the next layer is placed.

g) Embankments, which are formed of materials that contain rock but also sufficient
compatible material other than rock or other hard material to make rolling feasible,
shall be placed and compacted in the manner and to the point of consolidation
approved by the Engineer.
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h) Moisture shall be added as directed by the Engineer. Compaction tests will be

made wherever the Engineer determines they are feasible and necessary. Each
layer must be approved by the Engineer before the next layer is placed.

Table 2.18-4: Rock fill material characteristics

Parameter Limit value

Bulk specific gravity (ASTM C127 & C128) Not less than 2.65

Absorption (ASTM C127 & C128) Not more than 2%

Los Angeles Abrasion (ASTM C131 or C535) 30% maximum

Loss of magnesium sulphate soundness 10% maximum

(ASTM C88 5 cycles)

2.19 STABILISING CRUSHED MATERIAL

a) In the event the foundation on which the embankment or the subgrade materials
will be laid is saturated by water and unstable, the Engineer may decide to lay
crushed granular material to stabilise the foundation. Stabilising crushed material
shall not be laid directly on ground soil but it shall always be laid on geotexti1e
fabric covering the area to be stabilised as shown on the drawings or directed by
the Engineer.

b) Such stabilising crushed material when tested in accordance with BS 812:Part

103: Section 103.1: 1985 (Clause 7.2 or 7.3) or BS 1377 Part 2: 1990 method 9.2
or 9.3 latest edition shall have the following grading:

Table 2.19-5: Stabilising crushed material grading

Sieves (mm) % Passing

50 100

25 80-100

12.5 60-85

5 40-70

2 20-50

0.85 5-25

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Sieves (mm) % Passing

0.425 0-10

0.180 0-2

c) The stabilising crushed material shall have the following characteristics:

Table 2.19-6: Stabilising crushed material characteristics

Parameter Limit value

Bulk specific gravity (ASTM C127 & C128) Not less than 2.65

Absorption (ASTM C127 & C128) Not more than 2%

Los Angeles Abrasion (ASTM C131 or C535) 30% maximum

d) The stabilising crushed material will be laid in layers of 15 cm and compacted

until the foundation is fully stabilised such that the total thickness of the stabilising
layer shall not be less than 30 cm. Only after inspection and approval by the
Engineer the Contractor may be allowed to continue the construction of the
embankment with other layers of embankment material and/or subgrade material.
The Engineer may decide, after having taken the levels of the existing water table
in the area, and keeping in consideration the finished road levels, to excavate
portions of the foundation saturated by water, disposing of the excavated
material, and replacing it with stabilising crushed material.

e) Before starting any stabilising of the foundation the Engineer will instruct the
Contractor specifying the areas to be stabilised and the final levels to be reached
with the stabilising crushed material.

f) The surface to receive the geotextile fabric shall be prepared to a relatively

smooth condition free of obtrusions, depressions, and debris. The geotextile
fabric shall not be laid in a stretched condition, but shall be laid loosely with the
long dimension parallel to the centreline of the roadway. In the event that the
width of the proposed area for fabric requires more than one panel width of fabric,
the panels shall be overlapped a minimum 15 per cent of the panel width.
Longitudinal joints in the fabric shall have an overlap of 50 cm. To prevent
slippage of the overlapping fabric, the areas of overlap shall be stabilised as
approved by the Engineer with pins, anchor blocks, or aggregate piles. In the
event construction machinery is used to place the fabric, the working platform for
the machinery shall be the soil and not the previously laid fabric.

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g) Prior to placement of the granular material (stabilising crushed material) the

Contractor shall spread a layer of sand over the geotextile fabric as directed by
the Engineer. The aggregate material shall not be dumped directly on the fabric,
nor shall haul trucks be run on the fabric. The aggregate shall be spread by a
wheeled front-end loader.

h) The blade or bucket shall be kept sufficiently high so that the aggregate is not
being pulled over the fabric, but being dropped at a minimum height to the
satisfaction of the Engineer.

i) Fabric damaged or displaced before or during installation or during placement of

overlaying aggregate material shall be replaced or repaired to the satisfaction of
the Engineer at the Contractor's expense.

2.20 EXCAVATING AND FILLING FOR STRUCTURES

a) This work shall consist of all excavation for the construction of buildings, tanks,
structures, minor structures, culverts, headwalls, catch basins, manholes, inlets
and retaining walls and shall include all necessary clearing and grubbing, all
necessary bailing, drainage, pumping, sheeting, strutting and the construction of
coffer dams or cribs, if found necessary, and their subsequent removal; also the
disposal of all material obtained from such excavation and backfilling to the level
of the original ground; it shall include the removal of that portion of existing
structures below the ground which is necessitated by the construction of the new
structure. The line and level of the structural excavation shall be as shown on the
drawings or as may be directed by the Engineer.

b) Prior to commencing any structural excavation work 1.5 metres or more in depth,
the Contractor shall design and submit to the Engineer for review and approval,
within a minimum period of 1 week before the intended commencement date,
detailed working drawings of the structural excavation support member materials,
sizes, spacing and engineering calculations to validate their design, including the
maximum theoretical deflections of the support members. The system shall be
designed in such a manner that no raked struts or any other support members
extend through surfaces exposed in the finished construction, and no shoring or
bracing is placed under permanent structures. Before commencing the
excavation:

(i) The structure shall be pegged out correctly

(ii) Natural ground levels shall be agreed with Engineer.

c) The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation and
removal and concrete placement, the anticipated equipment loads, surcharge
loads of any description, the maximum design loads to be carried by various
members of the support system and strut preload forces.

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d) If the structure support system proposed includes tieback anchors, the

Contractor's submittal drawings shall show the profile of the soil in which each
anchor is to be installed, the design load for the full depth of the excavation, the
maximum design and proof loads, surcharge loads of any description; equipment
loads, forces at various stages, support during installation and removal, and the
criteria proposed for deformations under proof loads. Where a proposed system
of tie back anchors projects beyond the vertical projection of the Contract limit
lines shown on the Drawings on to the adjoining property, the permission of the
owner shall be obtained in writing and such permission submitted to the Engineer
at the time the shop drawings of the support systems are submitted.

e) At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the hydrostatic
pressure and lower the ground water levels below excavation levels, as required
for the safe and proper execution of the work and which will result in obtaining a
stable, dry subgrade for the execution of subsequent operations. The Contractor
shall design dewatering methods and settling basins so that no critical amounts of
soil, sand or silt are removed during either the initial operations or the
construction operations. Complete working drawings showing the type of
dewatering and ground water control system proposed shall be submitted to the
Engineer for his review.

f) The Contractor's submittal drawings shall show the arrangement, location and
depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedures to be followed shall
be shown, together with the standby equipment, standby power supply and the
proposed location or locations of points of discharge of water. Any required
dewatering system design shall also include the measures taken to prevent
damage due to settlement of pavement, utilities, sewers, buildings and other
structures outside the excavation but within the area affected by the procedures.

g) The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Structural
Engineer approved by the Engineer specialising in this type of design work.
Approval of the designs and shop drawings shall not relieve the Contractor of the
adequacy and performance of these temporary works.

h) Pre-Construction Inspection-prior to the beginning of construction, the Contractor

and the Engineer shall make a detailed inspection of all adjacent buildings,
pavements, wells and other structures in order to determine its pre-construction
condition and the Contractor shall prepare, for the Engineer's approval, a typed
Inspection Report of the findings.

i) The Report shall include photographs, drawings and sketches with levels and
dimensions illustrating the structures condition, noting in particular any existing
damage or structural inadequacy. Deficiencies and damage shall be suitably
marked on the structure such that it is not permanently defaced.
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j) Three copies of the Report shall be submitted for the approval of the Engineer.
Once approved, five additional copies shall be supplied to the Engineer.

k) The Contractor shall notify the Engineer sufficiently in advance of the beginning of
any excavation so that cross-sectional elevations and measurements may be
taken of the undisturbed ground. The natural ground adjacent to the structure
shall not be disturbed without the permission of the Engineer.

l) Trenches or foundation pits for structures or structure footings shall be excavated

to the lines and grades or elevations shown on the drawings, or as ordered by the
Engineer. They shall be of sufficient size to permit the placing of structures or
structure footings of the full width and length shown. The elevations of the
bottoms of footings, as shown on the Drawing shall be considered as approximate
only and the Engineer may order, in writing, such changes in dimensions of
elevations of footings as may be deemed necessary, to ensure a satisfactory
foundation.

m) Unless otherwise provided for in the Drawings or Contract Documents or directed

by the Engineer structural excavation shall be carried out for a width of at least
500mm beyond the horizontal outside limits of the foundation, footing, box culvert
or structural member to which the excavation relates. Concrete blinding or sub-
foundations are not to be considered as structure for the purpose of defining such
excavation.

n) If during the progress of the work, loose or improperly compacted soil is

encountered below the structural foundation levels, or adjacent thereto, which is
the result of prior removal of utilities or structures, such material shall be
completely removed within the limits as directed by the Engineer, backfilled with
suitable material and it should be not less than 95% of the maximum dry density
as determined by BS 1377 Part 4:1990 (method 3.5 or 3.6). Any previous
excavations encountered which would in the opinion of the Engineer be
detrimental to load distribution of new foundations to the under laying soil, shall
be excavated and backfilled with Class C 25/20 concrete.

o) After each excavation is completed, the Contractor shall notify the Engineer, for
approval of the depth of excavation and the character of the material, prior to
further structural works. Any over excavation shall be backfilled with Class C
25/20 concrete at the Contractors expense.

p) In-situ plate bearing test shall be carried out in all formation level of each major
RCC structure is accordance with BS 5930 : CL 31 or ASTM D1194/D1196 test
methods and should satisfy that the safe bearing capability of the foundation soil.

q) All rock or other hard foundation material shall be cleaned of all loose material
and cut to a firm surface, either level, stepped, or serrated as directed by the
Engineer. All seams or crevices shall be cleaned and grouted. All loose and
disintegrated rock and thin strata shall be removed.

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r) When the footing is to rest on material other than rock, excavation to final grade
shall not be made until just before the footing is to be placed and special care
shall be taken not to disturb the excavation. When the foundation material is soft
or otherwise unsuitable as determined by the Engineer, the Contractor shall
remove the unsuitable material and backfill with approved granular material. This
foundation fill shall be placed and compacted in 150mm layers up to the
foundation elevation and compacted to not less than 95% of the maximum dry
density as determined by BS 1377 Part 4 : 1990 (method 3.5 or 3.6).

s) The placing of concrete shall follow as closely as practicable the structural

excavation.

t) Control of Ground Water- Prior to the commencement of construction at any

particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area which in
the opinion of the Engineer is likely to be affected by the dewatering. The number,
location and depth of all standpipes shall be to the satisfaction of the Engineer.

(i) The Contractor shall check ground water levels at weekly or where
instructed by the Engineer, more frequent intervals and submit within 24
hours written reports to the Engineer in a form to be agreed.

(ii) In the case of uncontrolled flow of water into any excavation, the Engineer
reserves the right to order an immediate cessation of work and to order the
Contractor to take immediate action to control the inflow of water. Such
actions and remedial works shall be to the Engineer's approval.

u) Notification of Damage - The Contractor shall notify the Engineer immediately of

any movement or any damage not noted in the pre-construction report, to any
structure. The Contractor shall immediately cease his construction operations in
the vicinity and shall take immediate action to prevent further movement or
damage. The Contractor shall keep the Engineer fully informed of all such action.

v) Remedial and Preventive Works - Should remedial works be necessary due to

damage caused to the structure or should the Engineer direct the contractor to
carry out any works necessary to prevent damage to the structure due to the
Contractor's construction works, the Contractor will present, without delay,
detailed drawings and specifications, as necessary, showing his proposed
remedial or preventive works for the Engineer's approval.

In either case the Contractor will suspend all construction activities in the vicinity
of the structure until such time as the remedial or preventive works are carried out
to the Engineer's satisfaction at the Contractor's expense.

w) Post Construction Inspection - On completion of, but prior to final acceptance of

the works, the Contractor and the Engineer shall re-examine the structure to
determine any change from the original conditions. The Contractor shall supply to
the Engineer for approval five copies of a report describing measures he
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proposes to take to correct any damage which resulted from the construction of
the works. The approved corrective measures shall be carried out by the
Contractor at his expense, to the Engineer's satisfaction before final acceptance
of the works.

x) Utilisation of Excavated Materials - All excavated material determined as suitable

by the Engineer, shall be utilised as backfill or roadway fill. The surplus material,
shall be disposed of as specified in sub-section 2/7 para 2. Excavated material
shall not be deposited, at any time, so as to endanger the partly finished structure
or cause an obstruction of any kind. All unsuitable material shall be disposed of to
approved tips.

y) Backfill - Excavated areas around structures shall be backfilled with excavated

materials or imported granular material approved by the Engineer. Backfill
materials shall be placed in horizontal layers not exceeding 150mm in depth after
compaction to not less than 95% of the maximum dry density as determined by
BS 1377 Part 4: 1990 (Method 3.5 or 3.6). The field density shall be determined
by BS 1377 1990 Part 9: 1990: 1990 (Method 2.1 or 2.2). Each layer of material
shall be moistened or dried as required to enable thorough compaction as
specified. Backfill shall be placed to the original ground level or as indicated on
the drawings.

z) Backfill or embankment shall not be placed behind the walls of concrete

structures or rigid frame structures until the top slab is placed and cured. Backfill
and embankment behind abutments when held at the top of the superstructure
shall be carried up simultaneously behind opposite abutments. Backfill shall be
carried up equally on either side of box culverts.

For frequency of testing of backfill material refer to sub-section 2/18.

2.21 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS

2.21.1 Activities prior to excavation starting

a) Before an excavation is started:

(i) Ground levels shall be agreed at suitable intervals with the Engineer's
Representative.

(ii) Surface materials and conditions will be recorded in collaboration with the
Engineer's Representative and where appropriate the owners or occupiers
of the land.

(iii) The Contractor shall take photographs to illustrate existing damage or

conditions which may prove contentious at the time of reinstatement.

b) This information shall be neatly presented in bound volumes and submitted to the
Engineer. To this shall be added details of any existing natural or piped subsoil
drainage or other underground features as work proceeds.
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c) Trial excavations may be ordered by hand or other methods to reveal sub surface
conditions of any kind. The Contractor shall submit a written report or sketch
drawings of data so obtained and the excavations shall not be backfilled without
approval.

2.21.2 Setting out

a) Before any structural excavation is commenced the Contractor shall define the
centre line or other agreed reference line of the Works and erect the necessary
profiles throughout their full length if so required by the Engineer.

b) The Contractor shall be responsible for obtaining all verifications from the Dubai
Municipality Survey Section and the Contractor shall bear all associated costs.

2.21.3 Topsoil and Surfacing Materials

Before commencing excavations or filling to an area, topsoil and other surfacing

materials shall be stripped and stored separately from the subsoil.Subsequent
spreading of topsoil shall be as directed on site.

2.21.4 Land Drains

Where pipelines are to be laid in agricultural land the surface and subsoil drainage
shall be maintained whether natural or artificial. Before commencing work the
Contractor shall ascertain from the owner or occupier of the land the location of any
existing land drains or mole drains.

2.21.5 Hand Excavation

Where instructed or necessary for reasons of limited access or any other reason,
excavation shall be carried out by hand at no additional cost.

2.21.6 Support to Excavations

a) The sides and/or the bottom of excavations in excess of 1.2 metres shall be
adequately supported.

b) The Contractor shall provide the necessary support for excavations and shall
submit to the Engineer his proposals for the supporting of excavations by trench
sheeting or other approved means at least seven days prior to the
commencement of any excavation works. His proposals shall take into account
the nature of the ground to be excavated, the level of the water table at the site
and the proximity of buildings and roads.

c) If in the opinion of the Engineer the support proposed for the excavations by the
Contractor is insufficient then the Engineer will order the provision of stronger
support than that provided by the Contractor and in this event the Contractor shall
adopt the methods so ordered by the Engineer and shall have no claim against
the Employer for any costs incurred in adopting the additional measures.

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d) Trench supports shall be so arranged to permit withdrawal during the placing of

the pipe bedding and backfilling so as to prevent voids.

e) The Contractor shall not remove temporary works supporting the excavations until
in the opinion of the Engineer the permanent work is sufficiently advanced to
permit such removal which shall be executed under the personal supervision of a
competent foreman.

f) All temporary works supporting the excavation shall be removed during backfilling
unless previous approval has been obtained from the Engineer. Where
temporary supports have been used in the excavation any such supports left in
because it is impracticable to remove them shall be left in at the expense of the
Contractor.

g) Should temporary supports need to be left in any excavation carried out in open
cut owing to the Engineer deciding that their permanent installation is necessary
for the stability of an adjacent structure or service the Contractor shall be
reimbursed in accordance with the provisions of the Contract.

h) Any advice, permission, approval or instruction given by the Engineer relative to

such support or the removal thereof shall not relieve the Contractor from his
responsibilities or liabilities under the Contract.

i) Timbering steel sheeting strutting and sheet piling for the support of excavations
where provided shall be fixed in accordance with BS 6031.

j) Battered sides to trenches or other excavations will only be permitted if they can
be constructed within the limits of the site, without damage or interference to
existing services, properties or structures, without undue interference with
pedestrians and traffic and to slopes which are sufficiently flat to ensure stability
of the ground.

2.21.7 Dewatering

2.21.7.1 General

a) A high water table is expected on this site and the Contractor must take all
necessary measures to ensure proper dry conditions are maintained at all times
during construction.

b) The Contractor shall provide and maintain ample means and devices (including
spare units kept ready for immediate use in case of breakdowns) with which to
intercept and/or remove promptly and dispose properly of all water entering
trenches and other excavations. Such excavations shall be kept dry until the
structures, pipes, and appurtenances to be built therein have been completed. In
addition precautions shall be taken to prevent floatation of partially built
structures, completed structures to be filled on commissioning of the Works and
pipelines awaiting backfilling.

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c) Dewatering methods proposed in the Contractor’s method statements may

include temporary drains, intercepting ditches, cut-off drains, sub drains, sumps,
wells, pumps, well points or other dewatering equipment and shall include all
other things necessary to keep water out of the excavations or to lower
groundwater around structures liable to floatation.

d) All necessary precautions shall be taken to prevent any adjacent ground from
being adversely affected by loss of fines through any dewatering process.

e) Method statements shall include proposals for disposal of the water arising from
dewatering systems.

f) All water pumped or drained from the work shall be disposed of in a suitable
manner without undue interference with other work, damage to pavements, other
surfaces, or property. Suitable temporary pipes, flumes, or channels shall be
provided for water that may flow along or across the site of the work. No such
water is to be disposed of into the existing sewer systems of the town or
otherwise without prior written approval of the Dubai Municipality Drainage and
Irrigation Department.

g) If permission is given to use new or existing pipes or culverts which are not part of
the live sewerage system, they shall be thoroughly cleaned of all silt and any
resulting damage made good after use.

h) When the Contractor proposes to make use of existing dewatering pipelines,

ducts, etc., he shall satisfy himself as to their condition prior to his use of them. If
any of these items is found to be in an unsatisfactory condition then, before use,
the Contractor shall notify the Engineer who may give instructions for the item to
be replaced or repaired. Time taken to carry out such work will not be considered
as delay to the Contractor's operations.

i) During use the Contractor shall be responsible for the condition of the pipeline,
duct, etc., and any defect or failure shall be made good at the Contractor's
expense. Any delay to the Contractor's works caused by such defect or failure
shall be deemed as the Contractor's responsibility.

j) After use by the Contractor such pipeline, duct, etc., shall be handed back to the
Municipality in a condition not less than that at the commencement of use. Any
repairs or replacement required shall be at the Contractor's expense.

k) It cannot be guaranteed that permission will be given to use existing ducts and
pipelines.

l) All temporary works for control of water shall be sited clear of the Works, except
where temporary sub drains under the Works are approved in which case the
pipes shall be laid with a 75 mm surround of gravel, and the top surface of the
surround shall be covered with tarred felt cloth or other approved material.

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m) Unless otherwise directed all temporary drains and sub drains shall be finally
sealed with concrete at approved intervals and all temporary ditches, sumps,
wells, etc., shall be refilled and reinstated as specified elsewhere.

n) In the exceptional event that lagoons for the storage of groundwater are
permitted, they must be suitably protected with fencing and attended by day and
night to prevent access by the general public and will not be sited adjacent to
buildings. Approved means of preventing the formation of mosquito larvae on the
surface of the lagoons will be employed.

o) All necessary precautions shall be taken to prevent any groundwater from

entering mains to be used for the conveyance of potable water.

2.21.7.2 Temporary Under drains

a) Temporary under drains, if used, shall be laid in trenches, beneath the grade of
the structure. Trenches shall be of suitable dimensions to provide room for the
chosen size of under drain and its surrounding gravel.

b) Under drains, if used, shall be laid at an approved distance below the bottom of
the normal excavation and with open joints wrapped in geotextile, and entirely
surrounded by graded gravel, or crushed stone to prevent the admission of sand
or other soil into the under drains.

c) The distance between the bottom of the pipe or structure and the top of the bell of
the under drain pipe shall be at least 8 cm. unless otherwise permitted. T

d) he space between the under drain and the pipe or structure shall be filled with
screened gravel or crushed stone which shall be rammed if necessary and left
with a surface suitable for laying the pipe or building the structure.

2.21.7.3 Well Point Drainage System

a) Where the nature of the Works necessitates, the Contractor shall dewater the
excavations by means of an efficient well point drainage system which will drain
the soil and prevent saturated soil from flowing into the excavation.

b) The well points shall be designed especially for this type of service. The pumping
unit shall be designed for use with the well points, and shall be capable of
maintaining a high vacuum and of handling large volumes of air and water at the
same time.

c) If required by the nature of the Works, the installation of the well points, pumps,
surge tanks, settlement tanks, geotextile and other such requirements shall be
done under the supervision of the competent representative of the manufacturer.

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d) The Contractor shall do all special work such as surrounding the well points with
sand or gravel or other work which is necessary for the well point system to
operate for the successful dewatering of the excavations.

e) Material to be used in the well point system is to be corrosion resistant where

possible.

2.21.7.4 Submittal and approval of dewatering activities

a) Submit working drawings and data for review and acceptance showing the
intended plan for dewatering operations, where deemed necessary by the
Engineer.

b) Include details of locations and capacities of dewatering wells, well points, pumps,
sumps, collection and discharge lines, standby units, water disposal methods,
monitoring and settlement.

c) Submit these entire not more than 30 days prior to start of dewatering operations.

d) Draw the static water level down to a minimum of 300mm below the bottom of the
excavation so as to maintain the undisturbed state of the foundation soils and to
allow for the placement of any fill or backfill to the required density.

e) Install and operate the dewatering system so that the groundwater level outside
the excavation is not reduced to the extent that would damage or endanger
adjacent roads, structures or property.

f) Establish at several site locations, approved by the Engineer, groundwater level

monitoring stations, e.g. open tube piezometers which can be observed during
the work. Also, provide settlement gauges as directed, accepted and designated
by the Engineer at several locations to monitor the settlement of new and existing
facilities.

g) Perform dewatering so that no flow of water occurs along the pipe zone material.
Use where applicable cut-off walls or other agreed methods to reduce the
potential groundwater flow along pipe trenches. Submit to the Engineer for his
approval details of the proposed method of working and temporary works
installations to achieve this

h) Perform the restoration of groundwater to its original static level so as to maintain

the undisturbed state of the natural foundation soils, prevent disturbance of
compacted fill or backfill and prevent flotation or movement of structures,
pipelines and sewers.

i) Do not remove any dewatering systems without the Engineer’s acceptance.

Maintain monitoring and settlement measurement systems in operation until
removal is accepted by the Engineer. Where necessary, maintain these until final
compaction is completed. Well points and like items may be abandoned to the
extent accepted by the Engineer.
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2.21.8 Formation

a) Damage to the formation shall be prevented by bottoming up with hand

excavation immediately before placing concrete or pipe laying. Any damaged
formation shall be excavated and refilled with concrete or selected material as
instructed.

b) The formation of excavations for pipelines shall be dry, even and free of stones
and other protrusions.

c) No permanent works of any kind shall be constructed on an excavated surface

until the formation has been approved by the Engineer’s Representative.

2.21.9 Excavation at or near roads

2.21.9.1 Safety

a) When excavating at or near roads, to protect persons from injury and to avoid
interference with traffic, adequate barricades, construction signs, torches, guards,
flashing lights, etc., as required by the Engineer shall be provided and maintained
during the progress of the construction work (in accordance with the requirements
of the Roads & Transport Authority and Dubai Traffic Police).

b) All materials, stockpiles and equipment shall be placed in such a way that no
obstruction or interference to traffic is made and that these are enclosed by
fences or barricades and protected by lights.

c) All excavations shall be protected on all sides by an approved temporary yellow

plastic safety fencing, barricades and lights. The yellow plastic safety fencing
shall be manufactured of durable HDP polymer with Ultra Violet stabilizers. The
safety fencing shall be a minimum of 1.0 metre high.

2.21.9.2 Description

a) The Contractor shall make excavations in such a manner and to such minimum
widths as will give adequate room for building the structures or laying and jointing
the piping; shall furnish and place all sheeting, bracing, and supports; shall carry
out all coffer damming, pumping, and draining, and shall render the bottom of the
excavations firm and dry and acceptable in all respects.

b) In no case, except with the approval of the Engineer, shall the earth be ploughed,
scraped, or dug by machinery so near to the finished subgrade as to result in the
disturbance of material below said subgrade, the last of the material to be
excavated shall be removed by hand immediately before the placing of the pipe,
masonry, or other structure.

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2.21.9.3 Extent of Open Excavation

The extent of open excavation at any one time will be controlled by the conditions, but
shall always be confined to the limits prescribed by the Engineer.

2.21.9.4 Separation of Surface Materials

a) The Contractor shall remove only as much of any existing pavement as is

necessary for the work. The Engineer may require that the pavement be cut with
pneumatic tools, cold planer, milling machine or the like without extra
compensation to the Contractor, when in the opinion of the Engineer it is
necessary to prevent damage to the remaining road surface. Where pavement is
removed in large pieces, it shall be disposed of before proceeding with the
excavation.

b) From areas within which excavations are to be made, loam and topsoil shall be
carefully removed and separately stored to be used again as directed, or if the
Contractor prefers not to separate surface materials, he shall furnish, as directed,
loam and topsoil at least equal in quantity and quality to that excavated at no cost
to the Works.

2.21.9.5 Sheeting and Bracing

a) In addition to the general requirements of Clause 2.21.6 the Contractor shall

furnish, put in place, and maintain such sheeting, bracing, etc., as may be
necessary to support the sides of the excavation and to prevent any movement of
earth from beneath the adjacent road surface which could in any way diminish the
width of the excavation to less than that necessary for proper construction, or
could otherwise injure or delay the work, or endanger adjacent road and
structures. If the Engineer is of the opinion that at any point sufficient proper
supports have not been provided, he may order additional supports placed at the
Contractor's expense.

b) For any excavations in or adjacent to roads all trenches must be supported by an

approved method to ensure no settlement of roads either during construction,
when withdrawing supports or thereafter.

2.21.9.6 Bridging Trenches

The Contractor shall, at his own expense, provide suitable and safe bridges and other
crossings where required for the accommodation of travel, and to provide access to
private property during construction, and shall remove said structures thereafter.

2.21.9.7 Road Signs

a) All existing road signs, street name plates and the like affected by the Works are
to be carefully taken down and stored.

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b) Signs to be re-erected shall be cleaned, provided with new fixings where

necessary and the posts repainted as required.

c) Redundant signs shall be transported to the stores or depots of relevant

Authorities.

d) Any sign, street name plate or the like damaged by the Contractor during his
operation shall be repaired or replaced at the Contractor's cost.

2.21.10 Surface condition of excavated area

a) Where concrete is to be placed on an excavated surface other than rock, special

care shall be taken not to disturb the bottom of the excavation. When the nature
or condition of the bearing material upon which concrete is to be placed is
determined to be such that the use of heavy excavating equipment will reduce the
stability of the soil, the final half meter of excavation to grade shall be performed
either by means of light equipment or by hand labour methods.

b) Where rock, in either ledge or boulder formation or other unyielding material, is

encountered in one portion of structural excavation for a box culvert and yielding
material (with bearing capacity less than 1000 kN/m2 - determined by appropriate
tests) is encountered in an adjacent area of the structural excavation for the same
box culvert, such unyielding material shall be removed for a minimum depth of
half meter below grade and replaced with special backfill.

c) Where such unyielding material is encountered in excavation other than for box
culverts or where an entire excavation for a box culvert bears on such materials,
the rock or other unyielding material shall be cleared of all loose fragments and
cut to a firm surface as directed.

d) The placing of concrete shall follow as closely as practicable the structural

excavation.

2.22 PIPELINE TRENCH AND THE RELATED STRUCTURES EXCAVATION

2.22.1 Excavation for Pipelines

a) Trenches for pipes shall be excavated to a sufficient depth and width to enable
the pipe and any specified or agreed joint, bedding, haunching and surrounding to
be accommodated. Trenches shall be of width as specified and as shown on the
drawing.

b) Where rock, in either ledge or boulder formation or other unyielding material is

encountered, such unyielding material shall be removed for a minimum depth of
half metre below grade and replaced with special backfill.

2.22.2 Excavation for Cables/Ducts

a) The Contractor in carrying out excavation for cables/ducts shall, where required,
erect and maintain an approved type of temporary yellow plastic safety fencing
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around any work and shall provide fenced access ways across the trenches, for
public access to DM Health & Safety requirements.

b) The bottom of the trench shall be accurately graded. Care shall be taken not to
excavate below the depths indicated. Where rock is encountered, the rock shall
be excavated to the required depth. Uneven surfaces of the bottom of trench shall
be excavated 150 mm deeper. Such depth in rock shall be backfilled with
approved fill material and compacted as specified and/or as directed by the
Engineer.

c) Whenever unsuitable soil is encountered, which in the opinion of the Engineer is

to be removed, it shall be removed to the depth required and the trench backfilled
to the proper grade with approved fill material and compacted.

d) The width and depth of the trenches for electrical and telephone cables/ducts
shall be as specified in the relative drawings or as ordered by the Engineer.
Banks may be sloped or widened to facilitate placement of cables, but not the
extent that will cause interference with other utilities and structures. No battering
of trenches shall be allowed under existing carriageways, unless otherwise
agreed by the Engineer.

2.22.3 Excavated Material for Pipe Trench

a) All excavated material will remain the property of the Employer unless designated
as surplus to the Contract requirements in which case it will be removed from site
immediately.

b) All excavated material from the pipe trench shall be deposited so that it will cause
as little damage and inconvenience as possible.

c) Excavated material for use as backfill in trenches shall be as approved. Different

classes of material shall be handled and deposited separately.

d) The excavated material, if found unsuitable as trench backfill, shall be removed

from site and shall be replaced with suitable imported backfill to the approval of
the Engineer.

2.22.4 Replacement of Unsuitable Material

Where exceptionally poor ground conditions and unsuitable materials are

encountered at the limits (formation level) shown for structural excavation, the
Contractor shall, at the direction of the Engineer, excavate down to firm ground or
300 mm below formation, whichever is less. The extra excavation shall be backfilled
with either Class C 25/20 concrete or special backfill in accordance with clause 3/8
Section of pavement construction under road specifications( refer Appendix).

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2.22.5 Disposal of Material

a) The Contractor shall seek approval for all the proposed disposal sites from the
Dubai Municipality before work commences and disposal at such sites shall be at
no extra cost to the Employer.

b) No excavated material shall be wasted without written permission from the

Engineer, and when such material is to be wasted, it shall be hauled to the
approved tip or as otherwise directed by the Engineer. Excavated materials
wasted by the Contractor without written permission of the Engineer shall be
replaced by the Contractor at his own expense.

c) The Contractor shall adhere rigidly to the requirements of Dubai Municipality

Circulars on the temporary storage and disposal of excavation material. These
include but are not limited to:

(i) All material shall be stockpiled at an approved location and surrounded with
approved barricades. The Contractor shall also display his name and
contact telephone number.

(ii) Certain separate areas will be designated for the disposal of hard debris
such as building rubble, broken concrete, kerbing, road pavement and the
like. The Contractor shall use only these designated areas and shall keep
these disposal areas neat and tidy at all times.

2.22.6 Cofferdams

a) Suitable and practically watertight cofferdams shall be used wherever water

bearing strata are encountered above the elevation of the bottom of the
excavation.

b) The Contractor shall, on request, submit detailed drawings for approval showing
his proposed method of cofferdam construction and other pertinent features not
shown in detail on the Drawings. No construction shall be started until such
Drawings are approved, however, such approval shall not relieve the Contractor
of any responsibility for the successful completion of the construction.

c) No timber or bracing which will extend into the concrete shall be left in cofferdams
or cribs.

d) Any pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of any portion of the concrete material being
carried away. No pumping will be permitted during the placing of concrete or for a
period of at least 12 hours thereafter, unless it is done from a suitable sump
separated from the concrete work by a watertight wall. Pumping to remove water
from a sealed cofferdam shall not begin until the seal has set sufficiently to
withstand the hydrostatic pressure.

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e) Cofferdams or cribs, including all sheeting and bracing, shall be removed by the
Contractor after the completion of the substructure. This removal work shall be
carried out in such a manner as not to disturb or mar the concrete.

2.22.7 Backfilling Pipe Trench Excavations and the Related Structures

2.22.7.1 General

a) Backfilling around structures and in pipe trenches shall be carried out as detailed
below except where otherwise designated/directed.

b) The Contractor shall backfill all excavations in an expeditious manner to minimize

disruption to the general public.

c) Backfilling of trenches other than in roads and paved/tiled areas shall normally be
carried out using selected excavated materials similar to the in-situ materials in
which the trench or structure is being constructed.

d) Special backfill shall be used where designated or directed.

e) Where the excavation is near an existing structure liable to subsidence, where

part of the Works may later be constructed over or near it or in emergencies the
Contractor may be instructed to backfill with concrete.

f) The following test shall be carried out :

Table 2.22-7: Backfill tests

Parameter Standard Limit value

Acid soluble chloride BS 1377: P3 1990 M7.3 2% max

Acid soluble sulphate BS 1377: P3 1990 M5.5 2% max

Organic matter contents BS 1377: P3 1990 M3 2%max

Carbonate contents BS 1377: P3 1990 M6.3 30 to 40%

AMD 9028:1996

2.22.7.2 Selected Backfill for back filling trench excavation and the related structures

a) Material for backfilling may be selected from any part of the site and methods of
selection may include sieving to remove large particles or methods of hand or
machine sorting together with soil classification and soil property testing.

b) Backfilling with selected material shall be carried out as defined below.

(i) Degree of Compaction Requirements:

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In-situ density shall not be less than 95% of the maximum dry density for
depths less than 1.5 m from original ground level or finished formation level.

In-situ density shall not be less than 90% of the maximum dry density for
depths greater than 1.5 m from original ground level or finished formation
level.

(ii) Cohesive Soils

Cohesive soils shall be placed in layers not greater than 150 mm thick
(compacted thickness) and compacted such that throughout each layer
placed the Insitu dry density is not less than 90% or 95% of the maximum
dry density of the soil as determined by BS 1377:Part 4:Test 3.5, as
required.

If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill
in layers of greater thickness, but not exceeding 250 mm, provided the plant
utilised is that used for the trials.

The placement moisture of the soil shall be within the range 2% above to
2% below OMC of the soil.

(iii) Determination of moisture content of Soil – Calcium Carbide (Speedy)

Method:

The moisture content of soil may be determined in the field by the calcium
carbide gas pressure test method (Speedy) in accordance with ASTM
D4944. All calibration and testing shall be carried out by DM-DCL or a
suitably accredited laboratory in accordance with DM Administrative
Decision No. 160 for 2000.

(iv) Granular Soils

Granular soils shall be placed in layers not greater than 150 mm thick
(compacted thickness) and compacted such that throughout each layer
placed the in situ dry density is not less than 90% or 95% of the maximum
dry density as determined by BS 1377:Part 4:Test 3.5 or 3.6 on the same
soil, as required.

If site trials show that the specified compaction can be achieved with layers
greater than 150 mm compacted thickness approval may be given to backfill
in layers of greater thickness, but not exceeding 250 mm, providing the
plant utilised is that used for the trials.

Unless otherwise directed the moisture content shall be maintained and if

necessary adjusted by approved means to fall within ±1.5% of the optimum
moisture content.

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(v) Testing of Pipe Trench Backfill and the related structures (MH’s , IC’s ,
PSTs etc..)

Tests to determine the optimum dry density of the backfill material shall be
carried out as directed, the frequency depending on consistency of material
and test results. Unless directed otherwise on site testing for density and
moisture content of in situ soils shall be at the minimum rate of :

(1) One test per backfill layer for each structure.

(2) One test per backfill layer for every 30 linear metres of pipeline trench
backfill laid in one operation.

or

(3) Three field density tests for each 900 m² or less.

(vi) Backfill for a Replacement Land Drain

Where a land drain passes through an excavation the backfill shall first be
taken up to form a bed for replacement pipes. The severed drains shall then
be exposed at each side of the trench to allow for connection and laying of a
new drain across the excavation. This new drain shall be of similar pipes of
the same diameter as those in the existing drain. Before any further
backfilling is done the Contractor shall notify the owner or occupier to
enable him to inspect the reinstated land drain. The replacement drain shall
be surrounded with pipe bedding to a minimum thickness 150 mm before
further backfilling.

Immediately after completion of in-situ-density tests, summary sheets, in an

approved format, are to be updated and original test results submitted.

2.22.7.3 Special Backfill

a) The material used for special backfill shall be obtained from designated and
approved sources.

b) Special backfill complying with the properties of Aggregate Road base Material
specified in Clause 3/8 of Section 3 pavement construction of the
Specifications(refer appendix) shall be placed as fill or backfill in the areas
required and in reasonably close conformity to the lines, grades and dimensions
shown on the Drawings. Special care shall be taken to keep rocks away from
structures.

c) The materials shall be placed in layers of not more than 20 centimetres in depth
before compaction, and each layer shall be compacted by means of mechanical
or pneumatic tamping devices or other suitable equipment to density of at least 95
per cent of the maximum dry density as determined by BS 1377:Part 4:Test 3.6.

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The field density test shall be carried out in accordance with BS 1377:Part 9:Test
2.2, as required.

d) Water shall be added to the material, by pre-wetting or by applying uniformly to

each layer, when required for compaction, but only of sufficient quantity to ensure
proper compaction.

e) The layers of material placed around structures shall be placed on opposite sides
to approximately the same elevation at the same time.

f) Special care shall be taken in placing and compacting material under haunches of
all pipe to prevent moving or raising the pipe from its bedding.

g) Material shall not be placed against any concrete abutment, wing wall, retaining
wall, box culvert or similar structure until the concrete has been in place at least
14 days, unless otherwise authorised.

2.22.8 Filter Material

When required, filter material shall be placed in backfilling structures in accordance

with the details shown on the Drawings. Filter material shall conform to the specified
requirements for Fine Aggregate.

2.22.9 Backfilling of Trenches for Cables/Ducts

a) After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer being
well compacted by hand with iron rammers weighing not less than 5 kg, until the
trench has been filled to a height of 300 mm above the top of the cable/duct.

b) The remainder of the trench shall then be refilled in compacted layers not
exceeding 200 mm in thickness, each layer being well compacted with power
rammers, vibrating plate compactors or other mechanical means of a type to be
approved until the ground is thoroughly consolidated up to the required level for
surface reinstatement. Each layer shall be compacted to 95% of its maximum dry
density. Should the quantity of the excavated materials be not sufficient, due to
unsuitability or otherwise, for the process of backfill and fill, the Contractor shall
obtain the quantity required of such backfill and fill from approved borrow pits and
transport same to the site of work at his own expense.

c) Trenches shall not be backfilled until all required tests are performed and until the
Engineer has verified that the cables, etc., have been installed in accordance with
the Specifications and Drawings.

d) Lumps and clods shall be broken up before use. Materials shall not be dropped
from a height and where directed water shall be added to assist in adequate
consolidation.

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e) Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided according
to an approved drawing or as ordered by the Engineer.

2.22.10 Reference Standards

a) Modified AASHTO T180 - Moisture Density Relations of Soils Using a 4.54 kg

Rammer and a 457 mm Drop.

b) ASTM D698 Test Methods for Moisture Density Relations of Soils and Soil
Aggregate Mixtures, Using 2.49 Kg Rammer and 304.8 mm Drop.

c) ASTM D1556 Test Method for Density of Soil in Place by the Sand Cone
Method.

d) ASTM D1557 Test Methods for Moisture Density Relations of Soils and Soil
Aggregate Mixtures Using 4.54 Kg Rammer and 457 mm Drop.

e) ASTM D2167 - Test Method for Density and Unit Weight of Soil in Place by the
Rubber Balloon Method.

f) ASTM D2487 - Classification of Soils for Engineering Purposes.

g) ASTM D2922 - Test Methods for Density of Soil and Soil-Aggregate in Place by
Nuclear Methods (Shallow Depth).

h) ASTM D3017 - Test Method for Moisture Content of Soil and Soil-Aggregate in
Place by Nuclear Methods (Shallow Depth).

i) ASTM D4944

j) BS1377 – Part 1 to Part 9 Methods of Test for Soils for Civil Engineering
Purposes.

k) Dubai Municipality Specification for Backfilling of Trenches and Excavations in

Asphaltic Roads, Tiled/Paved Parking and Roads.

l) BS 6031:1981 - Code of Practice for Earthworks.

2.23 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT

2.23.1 General

a) Where new pipes, mains, cables/ducts, etc., are to be laid alongside, over or
under the existing, the Contractor shall take care to interfere as little as possible
with the existing services and connections thereto and any damage shall be
repaired by the Contractor to the approval of the appropriate Authority or by
appropriate Authority at the cost of the Contractor.

b) The Contractor shall make all arrangements for protecting existing services and
for temporarily diverting them to maintain the services without interruption.
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c) Existing services, pipes, mains, ducts, etc., exposed in trenches for new work
shall be protected in accordance with the requirements of the relevant Authority
before trenches are refilled.

d) The Contractor shall lay cables, fittings, specials, etc., under hedges, fences,
walls, etc., as necessary.

e) Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in an
approved manner and fenced on each side with post and rail stock proof fences
finished on top with one strand of galvanised barbed wire, or otherwise protected
as required by the owners or occupiers and the Engineer.

f) Where fences or walls are damaged or destroyed the whole shall be restored and
reinstated with like materials to the satisfaction of the owners or occupiers and the
Engineer.

g) The Contractor shall ensure that no trees are damaged or permanently removed
in carrying out the Contract except where directed due to the presence of
permanent works.

2.23.2 Reinstatement of Unpaved Land

a) In general the reinstatement of stripped areas of unpaved land shall restore the
ground to a condition not inferior to that which existed before the site was
occupied.

b) The compacted backfill shall be taken up to a level which allows for settlement. In
arable, grassed and similar areas the surface to be top soiled shall then be
loosened to a depth of 200 mm and topsoil replaced on it to the specified depth
without compaction using approved topsoil of comparable quality to make up any
deficiency.

c) Areas where grass is to be sown shall be worked to a fine tilth, levelled, graded
and rolled with a light roller. The seed shall be sown evenly at the specified rate
of application in the proper season and in suitable weather conditions, and the
areas again rolled. Restoration and re seeding of any areas where the new grass
is inadequate shall be carried out as instructed.

d) As an alternative to seeding the 'dibbing in' at 200 mm centres of 'Bugunda' or

similar tropical grass tufts may be required.

e) The grass shall be well watered four times a day and the Contractor will be
required to keep the grass cut short until the Defects Liability Certificate has been
issued.

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2.23.3 Reinstatement within Road Corridors

Trenches and other excavations within road corridors may be opened in four types of
ground:

(1) in paved carriageways

(2) in footpaths and other paved areas (other than carriageways)

(3) in grassed verges and planted areas

(4) in unmade ground which does not fall into any of the above three categories.

In addition there are four classes of carriageway construction as follow:

(5) Estate roads: single carriageway

(6) Main access: single/dual carriageway

(7) Primary distributors

(8) Main arterials/highways, etc.

All reinstatement works falling into the above categories/classes shall be carried out
either in compliance with the current Local Order and any subsequent revision thereof
issued by Dubai Municipality or in compliance with the details shown on the Contract
Drawings, whichever is the greater in either construction depth or asphalt thickness.

2.23.4 Reinstatement of Other Surfaced Areas

Surfaced areas not in road corridors shall be reinstated using materials similar to and
not inferior to those existing prior to commencement of the Works.

2.23.5 Excavation and Reinstatement in Developed Reservations

The Dubai Municipality Horticulture Section will remove any trees, bushes and plants
from developed reservations that they wish to preserve prior to the commencement of
work by the Contractor. The Contractor must allow in his rates for the removal and
disposal of any remaining trees, bushes and plants necessary for the execution of the
Works and to keep sweet soil separate in accordance with the current Local Order.

The reinstatement of the developed reservation shall be in accordance with Dubai

Municipality’s requirements.

2.24 PROTECTION TO EMBANKMENT SLOPE

This work shall be carried out as specified in CL 5/27, Section of ancillary works
under road specifications ( refer Appendix).

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2.25 CEMENT-STABILISED AGGREGATE CAPPING LAYER

This work shall be carried out as specified in CL 5/44, Section of ancillary works
under road specifications ( Refer Appendix).

2.26 BACKFILLING AROUND STRUCTURES

2.26.1 Definition

Principal work in this sub-section includes backfilling around tanks, building

structures, footings or other minor structures.

2.26.2 Backfill

a) All structural backfills shall have uniform moisture content within the range of ±2%
of optimum moisture content (OMC) recorded in the compaction test.

b) Equipment for placing of backfill shall produce the specified compaction, type and
capacities as required and approved by the Engineer.

c) All working areas shall be protected from damage by water.

d) Site drainage shall be maintained at all times

e) Heavy equipment shall not be operated within 1m of any structure

f) Vibration rollers shall not be used within 1.5 m of any structure

g) Vibration rollers weighing in excess of 4 tonnes (gross) shall not be used within
the project work premises.

2.26.3 Backfill Materials

2.26.3.1 Structural Backfill

a) Selected from locally excavated material or imported borrow material shall

conform to the requirements specified.

b) Shall consist of uniform readily compactible material

c) Free from vegetable matter, building rubbish and frozen material, or materials
susceptible to spontaneous combustion.

d) To be free from plastic fines and weakly cemented lumps of sand.

2.26.3.2 Water

Water used for compacting fill or for washing crushed stone shall be clean and free
from oil, grease, organic matter, suspended fine sediment and other deleterious
substances.

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2.26.4 Control of Water

All excavation and construction of structures and backfill shall be carried out in the
dry as described in Section “Earth-works and Site Preparation”.

2.26.5 Inspection by Engineer

As specified in Clause 2/8.6

2.26.6 Backfilling - Placement

a) Earth backfill shall not be placed until the required excavation and foundation
preparation have been completed and the foundation and / or structure to be
backfilled has been inspected and approved by the Engineer.

b) Backfill shall be placed in approximately horizontal layers of thickness that can be

uniformly compacted by the equipment used but of maximum 200 mm loose
thickness.

c) Hand compacted backfill, including backfill compacted by manually directed

power tampers, shall be of maximum 100 mm loose thickness.

d) Backfill adjacent to structures shall be placed in a manner which will prevent

damage to the structures and will allow structures to assume the loads from the
backfill gradually and uniformly.

e) Height of the backfill adjacent to a structure shall be increased at approximately

the same rate on all sides of the structure.

2.26.7 Backfilling - Compaction

Unless otherwise shown on the drawings, backfill shall be compacted using the
minimum 8 passes with a roller to not less than 95% of MDD.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 3

CONCRETE WORKS

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 3
CONCRETE WORKS
CONTENTS
3 CONCRETE WORKS ......................................................................................................... 1
3.1 GENERAL...................................................................................................................... 1
3.2 MATERIALS .................................................................................................................. 1
3.2.1 Cement, Cementitious Materials and Aggregates ................................................ 1
3.2.2 Water and Admixtures ........................................................................................ 18
3.2.3 Polypropylene Fibre Mesh Micro-Reinforcement ................................................ 23
3.2.4 Concrete Mixes and Specification ...................................................................... 24

3.3 CONCRETE MIX DESIGN ........................................................................................... 37

3.3.1 General – Samples of Aggregate ....................................................................... 37
3.3.2 Concrete Mix Design Submittal and Method Statement ..................................... 37
3.3.3 Design Mixes for New Batching Installations ...................................................... 41
3.3.4 Trial Mixes for Concrete ...................................................................................... 42
3.3.5 Design Mixes from a Continuing Source ............................................................ 45
3.3.6 Slump, Flow, Temperature and Air Content Testing of Fresh Concrete at Site .. 45
3.3.7 Consistency Testing (Slump & Flow) .................................................................. 48
3.3.8 Durability Tests ................................................................................................... 48
3.3.9 Other Tests ......................................................................................................... 48
3.3.10 Method Statements ............................................................................................. 49
3.3.11 Prescribed Mixes for Minor Works ...................................................................... 49

3.4 PLANT TRIALS WITH APPROVED CONCRETE MIX DESIGN ................................ 50

3.4.1 Quality Control .................................................................................................... 53
3.4.2 Minimum Routine Concrete Testing ................................................................... 58
3.4.3 Routine concrete coring and testing ................................................................... 60
3.4.4 Test on Hardened Concrete ............................................................................... 61
3.4.5 Non – Compliant Concrete ................................................................................. 61

3.5 CONCRETE DESIGN LIMITS ..................................................................................... 62

3.5.1 Limits of Specifications ....................................................................................... 62
3.5.2 Measurement of Ingredients ............................................................................... 63
3.5.3 Making Concrete ................................................................................................. 63
3.5.4 Mixing Concrete at Batching Plant and the Procedure to deliver the Concrete to
Site 64
3.5.5 Waterproof Concrete .......................................................................................... 68
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3.5.6 Self-Compacting Concrete .................................................................................. 70

3.5.7 Precast Concrete ................................................................................................ 73
3.5.8 Under Water Concrete ........................................................................................ 89
3.5.9 Concreting Deep lifts and large Volume Pours ................................................... 93
3.5.10 Cementitious Mortar, Grout & Anchoring System ............................................. 103

3.6 FORMWORK AND CONCRETE PRACTICE ............................................................ 106

3.6.1 Shop Drawing ................................................................................................... 106
3.6.2 Blinding Concrete (Sealing Coats) .................................................................... 107
3.6.3 Design and Construction of Formwork ............................................................. 107
3.6.4 Type of Formwork ............................................................................................. 109
3.6.5 Tolerances and Finishes of Concrete Surfaces ................................................ 110
3.6.6 Tolerances for Unexposed Surfaces ................................................................ 111
3.6.7 Preparation of Formwork for Concreting ........................................................... 111
3.6.8 Approval of Formwork before Concreting ......................................................... 112
3.6.9 Removal of Formwork ....................................................................................... 112
3.6.10 Formation of Holes for Fixing ............................................................................ 112

3.7 BATCHING, TRANSPORTING, PLACING & COMPACTION OF

CONCRETE ............................................................................................................... 112
3.7.1 General ............................................................................................................. 112
3.7.2 Ready Mixed Concrete ..................................................................................... 113
3.7.3 Time of Transport ............................................................................................. 113
3.7.4 Concrete Placement ......................................................................................... 114
3.7.5 Compaction of Concrete ................................................................................... 115
3.7.6 For underwater Concrete .................................................................................. 116
3.7.7 Placing of Concrete in Water (Tremie Concrete) .............................................. 116
3.7.8 Concreting in High Temperatures ..................................................................... 116
3.7.9 Concrete Curing and Protection ....................................................................... 118
3.7.10 Concrete in Adverse Weather ........................................................................... 120
3.7.11 Batching of admixtures ..................................................................................... 120
3.7.12 Concreting at Night ........................................................................................... 120
3.7.13 Striking Formwork ............................................................................................. 120
3.7.14 Re-use of Formwork ......................................................................................... 122

3.8 GRANOLITHIC CONCRETE SCREEDS TO FLOORS, SURFACINGS,

BENCHINGS AND CHANNELS ................................................................................ 122
3.8.2 Inspection of Concrete ...................................................................................... 122
3.8.3 Repairs to Concrete .......................................................................................... 123
3.8.4 Supervision of Concrete Work .......................................................................... 123
3.8.5 Cracks in Concrete Structures .......................................................................... 123
3.8.6 Quality of Finish ................................................................................................ 123
3.8.7 Classes of Finish Formed Surfaces .................................................................. 124
3.8.8 Classes of Finish Unformed Surfaces .............................................................. 124
3.8.9 Defective Concrete ........................................................................................... 125
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3.8.10 Concrete Surface Repairs ................................................................................ 126

3.9 JOINTS IN CONCRETE STRUCTURES ................................................................... 128

3.9.1 Construction Joints ........................................................................................... 128
3.9.2 Movement Joints ............................................................................................... 130
3.9.3 Expansion Joints ............................................................................................... 131
3.9.4 Water Bars ........................................................................................................ 131
3.9.5 Bond Breakers .................................................................................................. 135
3.9.6 Joint Fillers for Expansion Joints of Water Retaining Structures ...................... 135
3.9.7 Expansion Joint Filler for Precast Units ............................................................ 136
3.9.8 Submittals for Sealants ..................................................................................... 136
3.9.9 Environmental Conditions ................................................................................. 137
3.9.10 Pre-Installation Meeting .................................................................................... 137
3.9.11 Sample Application ........................................................................................... 137
3.9.12 Delivery, Storage and Handling ........................................................................ 138
3.9.13 Materials - General ........................................................................................... 138
3.9.14 Types of Area and application other than Water Retaining Structures ............. 140
3.9.15 Joint Sealing in water retaining Structures ....................................................... 144
3.9.16 BOND BREAKING COMPOUND FOR DOWEL BARS .................................... 145
3.9.17 Expansion Joint Sealing Compound ................................................................. 145
3.9.18 Properties of Sealant to fix GRP MH Liners...................................................... 147
3.9.19 Dowel Bars ....................................................................................................... 147
3.9.20 Bond Breaker Tape ........................................................................................... 148
3.9.21 Sealing Strip Membrane Based On Hypalon-Elastomer ................................... 148
3.9.22 Slip Membrane and Installation ........................................................................ 149

3.10 REINFORCEMENT STEEL ....................................................................................... 149

3.10.1 General ............................................................................................................. 149
3.10.2 Material Specifications ...................................................................................... 149
3.10.3 Testing of Reinforced Steel .............................................................................. 153
3.10.4 Construction of Reinforcement ......................................................................... 154
3.10.5 Placing Reinforcement ...................................................................................... 155

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3 CONCRETE WORKS

3.1 GENERAL

The applicable standards for all concrete work shall be BS EN 1992-1-1:2004, BS

8500 – 1 & 2: 2006 with amendment No. BSEN 206 –1, BRE Special Digest No.1:
2003 and CIRIA guide to Concrete Construction in the Gulf Region. Concrete for
water retaining structures shall be as per BS EN 1992-3:2006.

Concrete work shall consist of furnishing all materials and constructing structures of
the forms, shapes and dimensions shown on the Drawings or as directed, using
Portland Cement concrete, in accordance with the details shown on the Drawings
and these Specifications.

Portland cement concrete shall consist of a mixture of Portland Cement, fine

aggregate, coarse aggregate, water and additives when required. The mixture shall
be proportioned, mixed, placed and cured in accordance with the requirements of BS
EN 1992-1-1:2004. Where an additional clause conflicts or is inconsistent with the
requirements of BS EN 1992-1-1:2004, the additional clause shall always prevail. The
concrete mixes shall be designed mixes for special or ordinary concrete as defined in
the above standards, the design requirements of which are laid down in this
Specification.

3.2 MATERIALS

3.2.1 Cement, Cementitious Materials and Aggregates

3.2.1.1 Portland Cement

Suitable type of cement shall be used in conformity with the above relevant
applicable standards, and DM administrative note no: 01/1990.

The choice of cement type to be used for underground structures shall depend on the
classifications of soils for chemicals aggressive to concrete. The tenderer shall verify
the characteristics of different types of Portland cement and blended cements and
consider in his offer the usage of OPC/SRPC/MSRPC/Blended cement with mineral
additions may be required for underground /above ground structures. For above
ground structures normal OPC made to BS 12 shall be used.

3.2.1.2 Ordinary Portland Cement

Ordinary Portland Cement (OPC) shall comply with BS EN 197-1:2000 (Strength

Class 42.5N or ASTM C150 Type 1). The tri-calcium aluminate content shall lie within
the range of 4% to 13% when tested as per BS EN 196:2 (2005).

3.2.1.3 Sulphate Resisting Cement

Sulphate Resisting Cement (SRPC) shall comply with BS 4027: 1996 or ASTM C150
Type V (Strength Class 42.5N). The limit for tri-calcium aluminate content is 3.5%
max. when tested according to the test method BS EN 196: Part 2 (2005).
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3.2.1.4 Moderate Sulphate Resisting Cement

Moderate sulphate resisting cement (MSRPC) shall comply with ASTM C-150 type 2
1990 Strength class 42.5 N. The tri-calcium aluminate content shall be within the
range 4% - 8% when tested according to the test method BS EN 196: Part 2: 2005.

3.2.1.5 Cementitious Materials

Cement plus ‘GGBS’ or cement plus ‘GGBS’ plus microsilica fume or cement with
water proof powder plus admixture.

Combinations manufactured in the concrete mixer from Portland cement to BS EN

197-1:2000 and ground granulated blast furnace slag (GGBS).

a) The ‘GGBS’ shall comply with BS EN 15167 part1 & 2 : 2006 , in addition to the
following requirements, unless otherwise approved by the Engineer.

(i) Raw material (slag) is limited to one source. Slag supplied or blended from
several different plants or steel mills will not be accepted unless approved
by the engineer.

(ii) ‘GGBS’ shall be supplied to the concrete batching plant in bulk powder
form.

(iii) Inter-ground slag cements shall not be used.

(iv) Pre-blended slag cements shall not be used.

b) The combination proportion shall not exceed 50% slag by mass of nucleus. Slag
with Al2O3 content over 14% shall be used only with Portland cement having C3A
content less than 10% i.e. SRPC or MSRPC.

[OR]

c) Combinations manufactured in the concrete mixer from Portland cement made to

BS EN 197-1:2000 or BS 4027 and the concentrated water proofing (CWP)
powder approved by BSI or equivalent.

d) C.W.P Powder shall be a multi-component waterproofing, plasticising,

permeability reducing, corrosion inhibiting hydrophobic admixture approved by
BSI or equivalent. The system produces concrete with enhanced durability and
improved protection against reinforcement by minimising the water/cement ratio
of the concrete mix resulting in the reduction of the capillary network of the cured
concrete and providing hydrophobic action that protects resulting concrete against
water ingress in absorption or hydrostatic pressure. CWP powder shall be
compatible with all types of cement for making water proof concrete.

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[OR]

a) Combinations manufactured in the concrete mixer from Portland cement made to

BS EN 197-1:2000 / BS 4027 and microsilica (MS) conforming to ASTM C1240.

b) Microsilica shall comply with an internationally recognised standard, in addition to

the following requirements, unless otherwise approved by the Engineer.

(i) Raw material (Microsilica) is limited to one source. Microsilica supplied by

more than one vendor will not be accepted, unless approved by the
Engineer.

(ii) Microsilica shall be supplied to the concrete bacthing plant in bulk powder
form.

c) The percentage addition of microsilica shall not exceed 10% by weight of the
Cementitious materials.

NOTE: The performance of the above blended cements has not yet been
evaluated in the environment of the Gulf region. Therefore the usage of blended
cement with mineral additions will require written approval of the Engineer who must
be satisfied that proposed blended cements are suitable for the intended use and the
concrete production plant technical supervision at site, testing and quality control
facilities to be of an exceptionally high standard.

3.2.1.6 Conformity procedure for Combination of Cementitious Materials

a) Suitability of specific source of addition and limits on the proportions of additions

to be used in combination with specific source of Portland cement shall be
established so as to ensure the conformity criteria for strength classes are met.

b) The Contractor shall undertake the procedures set out in Annex A of BS 8500 – 2:
2006 and declare the conformity of combination to count fully towards the cement
content and strength class 42.5 N. A third party certification with test data for the
proportions selected in the mix is required to justify the strength class of blended
cement.

c) Cement shall be certified by the manufacturer as complying with the requirements

of the relevant BS or appropriate standards. Before ordering cement, the
contractor shall submit details of proposed supplier and information on the
proposed methods of transport, storage and certification for approval and show
that the quantity and quality required can be attained and maintained through the
construction period.

d) Representative samples of the proposed cement to be taken and forwarded to an

independent laboratory approved by the Engineer for analysis before the source
is approved.

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e) Locally produced ‘GGBS’ and ‘microsilica’ produced as a separate material stored

in silos and handled in a similar manner to cement only will be permitted.

f) Having obtained approval, the Contractor shall not change the agreed
arrangements without permission.

g) Each consignment of cement shall be accompanied by a certificate showing the

place of manufacture and the results of standard tests carried out on each day’s
bulk production and also at monthly intervals during storage.

Table 3.1: Characteristics of different types of Portland and blended cement

Type of Cement Relevant Resistance to Chemical Protection of Rate of gain of
Specification Sulphate attack reinforcement strength and rate of
against chloride – heat evolution
induced corrosion

Portland cement BS 12 Not resistant: aggregates The protection given Taken as ‘normal’ for
or ASTM Type 1 should be virtually free by this cement is comparative purposes
ASTM C 150 from sulphates and taken as ‘normal’ for
concrete should be comparative
isolated from purposes.
groundwater.

ASTM Type II ASTM C150 Partially resistant If this cement Lower than Portland
contains 5% or more cement
(no BS equivalent) of C3A it may give
near normal
protection

Rapid- hardening BS 12 ASTM Same as Portland Same as Portland Hydration usually too
Portland cement C150 cement cement rapid for use in hot
or ASTM climates

Low-heat Portland BS 1370 May be more resistant Less than normal if Lower rate of heat
cement or ASTM ASTM C 150 than Portland cement if C3A content is lower evolution, strength gain
Type IV C3A content is lower, but than that of Portland and lower final strength
the specification does not cement than Portland cement
guarantee this.

Sulphate- resisting BS 4027 Moderately resistant This cement contains Lower rate of heat
Portland cement ASTM C150 little or no C3A and evolution and strength
or ASTM Type V gives significantly gain than Portland
less protection cement or Type I, but
against chloride – usually not as low as
induced corrosion low-heat Portland
than Portland cement cement or ASTM Type
or ASTM Types I or II IV

High slag blast BS EN 197- Properties vary but Low permeability to Gains strength slower
furnace cement 4:2011 sulphate resistance will chloride and high but continues to gain
be equivalent to Type V binding capacity strength at later ages.
or SRPC if 70% or more Low heat evolution
equivalent or lower than
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Type of Cement Relevant Resistance to Chemical Protection of Rate of gain of

Specification Sulphate attack reinforcement strength and rate of
against chloride – heat evolution
induced corrosion

GGBS is used low-heat Portland

cement Type IV
depending on GGBS
content.

Portland blast BS EN 197- Properties vary, but Good Impermeability Gains strength and
furnace cement 4:2011 sulphate resistance could to chloride evolves heat more
and low-heat be equal to or better than penetration and slowly than Portland
Portland blast ASTM Type II binding capacity cement but not as
furnace cement depending on GGBS slowly as low-heat
content Portland cement or
ASTM Type IV, unless
made to a low-heat
specification

Other cements The properties of these cements depend on the materials they are made from and on the
containing GGBS proportions of GGBS or Pozzolana incorporated in them.
or Pozzolana
incorporated in the
cement during
manufacture.

Unless otherwise approved by the Engineer all cements shall comply with the
following requirements:

h) The strength class of cement or blended cement shall not be lower than 42.5 N
(L.A)

i) The chloride content of cement shall not exceed 0.10% by weight when tested in
accordance with BS EN 196: Part 2 (2005)

j) The heat of hydration at 7 days shall not exceed 290KJ/kg when tested in
accordance with BS 4550: Part 3, Section 3.8.

k) The cement shall be low alkali type having a total acid soluble alkali level
measured as Na2O + 0.658 K2O shall not exceed 0.6% by weight determined by
the test method described in BS EN 196: Part 2: 2005.

l) The specific surface (fineness) shall not be greater than 375 m²/kg and not less
than 280 m²/kg when tested in accordance with BS EN 196-6: 2010.

m) The temperature of cement at the time it is added into the Concrete shall not
exceed 75C.

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n) The contractor shall complete a Technical Schedule for each proposed source
and type of cement. The information in this schedule shall be provided for every
proposed manufacturer’s works likely to supply cement. Preliminary and
secondary sources of the required cements shall be proposed and only an
approved source shall be brought onto the site.

o) The cement shall be of approved manufacture and shall be delivered in bags with
seals unbroken, or delivered in bulk in approved containers which shall bear the
manufacture’s name, cement type and the date of manufacture. Test certificates
from the manufacturer or supplier shall be submitted for each consignment and
shall indicate the result of the tests for compressive strength, setting time,
soundness and fineness etc. carried out in accordance with the requirements of
the relevant BS or ASTM standards. Further tests may be required by the
Engineer after the cement is delivered and stored on the site. The failure of any
sample to satisfy the BS or ASTM requirements shall entitle the Engineer to reject
the entire consignment from which it was taken.

p) Cement shall be stored immediately upon receipt at site in such a way to keep it
away from water and moisture at all times. The Contractor shall provide a method
statement for the storage of cement which shall be approved and implemented
before any cement is delivered to site.

q) Cement consignments shall be used in the order in which they were delivered.
Any consignment not used within 2 months from the date of manufacture will not
be allowed to be used in the Works.

r) No cement from any consignment shall be used in permanent works without the
approval of the Engineer. Cement which the Engineer considers to have
deteriorated in any way shall not be used and shall be removed from site without
delay.

s) One brand of cement as approved by the Engineer shall be used throughout the
Works unless otherwise authorised by the Engineer in writing. Differing types of
brands shall not be mixed together for use in the Works.

t) The type of cement required for each structure will normally be stipulated
elsewhere in the Contract Documents. Where no such stipulation exists, and
unless otherwise directed by the Engineer, cement shall be used as follows:

(i) Ordinary Portland cement for reinforced concrete above ground level.

(ii) Sulphate resisting Portland cement for reinforced concrete below ground
level and for unreinforced concrete.

(iii) Moderately sulphate resisting Portland cement, where there is considered

by the Engineer to be a risk of both chloride and sulphate attack.

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u) Samples of cement shall be taken in the presence of the Engineer on request, for
testing in an approved independent laboratory and the Engineer shall have
access to cement store at all reasonable hours.

3.2.1.7 Testing Cement

The contractor shall store the cement so that separate consignments can be identified
until the results of the testing are available. Tests should be carried out for the
properties listed in the following table with test methods and limits to BS or ASTM as
appropriate:

Table 3.2: Properties of Cement

Property Test method Permissible Limits

Sampling BS EN 196-1 :
2005

Type of Cement BS 1881 : P 124 SRC MSRPC OPC

Strength @ 28 BSEN 196 : Part > 42.5N >42.5N 42.5N

days 1:2005

Fineness BSEN 196 : Part 280-375 280-375 280-375

6:2010 m²/kg m²/kg m²/kg

Heat of Hydration BS 4550: P3 : 290 KJ/kg as 290 KJ/kg as 290 KJ/kg as

Section 3-8:1978 per Spec: per Spec per per Spec
requirement requirement requirement

Setting Time BSEN 196 : Part As per As per As per

3:2005 +A1:2008 standard standard standard
requirement requirement requirement

Soundness Ditto Ditto Ditto Ditto

Reactive Alkali BSEN 196: Part  0.60%  0.6%  0.6%

Level as Na2O 2: 2005
Equivalent

Chloride Content BSEN 196: Part  0.10%  0.10%  0.1%

2: 2005 CL: 14

Loss on Ignition BSEN 196 : Part As per As per As per

2 : 2005 Standard Standard Standard
Requirement Requirement Requirement

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Property Test method Permissible Limits

Insoluble Residue BSEN 196 : Part As per As per As per

2 : 2005 Standard Standard Standard
Requirement Requirement Requirement

Tri-calcium BSEN 196 : Part 3.5% Maxi: 4 – 8% 4-13%

Aluminate 2 :2005
Content

SiO2, MgO, BSEN 196 : Part As per As per As per

A12O3, Fe2O3, 2: 2005 Standard Standard Standard
contents Requirement Requirement Requirement

SO3 BSEN 196 : Part <2.5 <3 <3.5

2 :2005

3.2.1.8 Aggregates for Concrete

(1)Aggregate Sources

Primary and secondary sources of both coarse and fine aggregate shall be proposed.

In assessing the Contractor’s request for approval to a proposed source of aggregate

the Engineer will normally require to:

a) Accompany the Contractor to the source for examination of the types of deposit
and the methods of extraction, stockpiling, loading and quality control.

b) Supervise the sampling of aggregates both at the point of production and at the
stockpiles.

c) Inspect test report of physical, chemical, aggregate carbonate range and

petrological analyses of the samples carried out by an approved independent
laboratory.

d) In order to reduce the ‘THAUMASITE form of Sulphate Attack’ (TSA) on below

ground concrete, the coarse and fine aggregate containing certain Dolomitic
(Calcium Carbonate) or Dolomite (Magnesium Carbonate) type of limestone
aggregates shall not be incorporated in the proposed concrete mix design.

e) Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall also not to be
used.

The concrete producer shall assess the carbonate range of the proposed aggregate
combination by test as specified in BRE Special Digest No. 1: 2003, Part 2: Cl 2.2
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and App.3 Cl. A-3.1 and confirm that the source and type of aggregate are well within
the restricted ‘ACR’ (Aggregate Carbonate Range) levels specified in Table 4 of BRE
Digest No.1, Part 3.

(2)Aggregates – General Requirements

a) Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS EN 12620:2002 + A1 :2008
and BSEN 13055-1 “Concrete aggregates from natural sources” and the fine
aggregate shall also comply with Dubai Municipality Administrative Order No.
143/91.

b) The aggregates used in the permanent works shall be naturally occurring or

crushed materials obtained only from approved sources.

c) Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the
necessary tests and analysis to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.

d) The results of these tests etc shall be submitted to the Engineer and his approval
shall be obtained before any of the material is used in the works. Part of each
sample will be required for concrete trial mixes and part shall be retained for
comparison with subsequent deliveries.

e) Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS EN 932-1:1997.

f) The maximum size of the aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the member for which the concrete is to be used and
not larger than 3/4 of the maximum clear distance between reinforcing bars.

g) Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.

h) Coarse aggregate shall be crushed aggregate obtained from a quarry approved

by the Engineer.

i) Unless otherwise authorised by the Engineer coarse aggregate shall be delivered

to site in separate sizes according to the maximum specified aggregate size for
each grade of concrete.

j) Aggregates shall meet the requirements of Table 3.3

k) The frequency of testing of aggregates shall be in accordance with Table 3.4 or

as directed by the Engineer.

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(3)Aggregates – Sampling and Testing

a) When an aggregate source has been approved, representative samples shall be

taken of each aggregate type and retained on site for reference purposes by both
the Engineer and the Contractor.

b) Fresh samples shall be taken and be analysed regularly throughout the Contract
Period to demonstrate consistency of quality and of gradings. The frequency of
such sampling will be dependent on the continued adequacy of the samples as
demonstrated by the results of the analysis, but shall be not less than the
frequency test period specified.

c) Aggregates shall be hard, strong and durable and shall contain no harmful
material that will adversely affect the strength and durability of the concrete or
attack steel reinforcement.

d) Aggregates shall not be composed of or contain any inclusions of materials likely

to cause staining or otherwise to disfigure finished concrete surfaces.

e) The properties of the aggregates shall be such that the drying shrinkage when
prepared and tested in an approved laboratory shall not exceed 0.045% and the
limit specified in clause 5.7.2 of BS EN 12620 unless the Engineer relaxes this
requirement to suit local supply constraints. It should be noted that this test
involves a testing period of about eight weeks.

f) Aggregates for use in concrete or mortar that will be subject to wetting, extended
exposure to humid atmosphere, or contact with moist ground shall be examined
for constituents which may be potentially reactive with alkalis. If accelerated tests
indicate that reactivity is likely then testing shall be extended to the Mortar Bar
Test (which can take in excess of six months to complete) unless the Contractor
proposes an alternative source of aggregate.

g) If such constituents are present in a proposed aggregate the Contractor shall

arrange for the necessary testing to assess total acid ,soluble alkali contents from
all sources. These shall include: the cement; the mixing water; water which will be
in contact with the concrete or mortar; and those additionally present in the
aggregates.

h) The Engineer will then assess the risks of localised or general, long term
expansion of the concrete and will give a ruling as to whether the aggregate
source should be rejected or whether the aggregate may be used with low alkali
cement.

(The Tenderer should note that past tests on aggregate from the Siji area have not
complied with the shrinkage limit of 0.045% stated above).

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(4) Fine Aggregates

a) Except where otherwise approved on the basis of evidence of acceptable

performance in concrete the grading of a fine aggregate, or of a combined fine
aggregate, shall comply with the limits in the approved standard.

b) Fine aggregates shall be natural sand, manufactured crushed rock sand, or a

combination of both. The Contractor shall note that the term 'manufactured
crushed rock sand' does not include crushed rock fines which are by-products of
coarse aggregate production. A combination of natural sand and manufactured
crushed rock sand will only be permitted where the two materials are separately
batched and where each material separately complies with the requirements of
this Specification. In addition the evidence of full scale comparative site trials shall
clearly demonstrate that a combined fine aggregate provides improved concretes
in relation to the use of either material as a sole fine aggregate.

c) The organic content of fine aggregate shall be determined in accordance with an

approved standard test procedure. The Engineer will decide on the basis of trial
mixes whether failures to meet the limits of the approved standard are sufficient
grounds to reject the sample.

(5)Aggregates used for Granolithic Concrete

Aggregates for granolithic concrete shall be selected for hardness, surface texture
and particle shape as being suitable for use as a wearing finish and shall consist of
crushed rock which exhibits a 10% fines value of not less than 250 kN. They shall not
contain deleterious substances such as clay, flaky, elongated or laminated particles,
coal or other inorganic impurities, iron pyrites or soluble salts.

(6)Aggregate Grading

i. Fine Aggregates for Concrete

Fine aggregate shall be clean sharp natural and / or crushed sand and shall be within
BS EN 12620:2002+A1:2008 zones ‘C’ and ‘M’ only.

The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified. Each batch of aggregate
delivered to site shall be kept separate from previous batches and shall be stored for
at least 3 (three) working days before use to allow inspection and tests to be carried
out.

ii. Coarse Aggregates for Concrete

Coarse Aggregate shall be crushed rock prepared as single sized aggregate and
blended to produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS EN 12620:2002+A1:2008.

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iii. All-in Aggregates for Concrete

a) Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions as specified in BS EN 12620:2002+A1:2008 .

b) The combined aggregate gradation used in the work shall be as specified, except
when otherwise approved or directed by the Engineer. Changes from gradation to
another shall not be made during progress of the work unless approved by the
Engineer.

c) All aggregates shall be produced to the grading limits in the approved standard.

d) Grading shall be consistent for all deliveries and the proportion of coarse and fine
aggregate shall be selected to comply with the requirements of Clause 3.2.1.8
(Aggregate for Concrete).

e) The coarse aggregate shall be graded to the larger aggregate from 20 mm to 4

mm.

f) For blinding grade and mass concrete the coarse aggregate may be either an all-
in grading or a combination of single size grading.

g) For granolithic concrete the aggregate shall be produced by combining coarse

and fine grading for use for floors but all-in aggregate may be permitted for
benching.

Table 3.3: Limits for Physical, Chemical and Mechanical Properties of

Aggregates for Concrete
Sr. Requirement Test Methods Permissible Limits

BS / ASTM Fines Coarse

1. Moisture content in BS 812: Part 109 Standard Standard

coarse and fine aggregate

2. Grading BS EN 933-1 :2012 Standard Standard

(dry)

3. Loose bulk density & BSEN 1097-3 Standard Standard

voids

4. Material finer than 0.063 BS EN 933-1 :2012 Max. 3% Max. 1%

mm - natural, uncrushed. (wet) (Natural)

Crushed rock ,, Max 7% Max 1%

5. Clay lumps and friable ASTM C142:1997 Max 1% Max 1%

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Sr. Requirement Test Methods Permissible Limits

BS / ASTM Fines Coarse

particles

6. Light weight pieces ASTM C123 Max 0.5% Max 0.5%

7. Organic impurities for fine ASTM C40: 1999 The colour of the N/A
aggregate supernatant
liquid is lighter
than standard
colour solution.

8. Water absorption ASTM C128: 2001 Max 2.3% Max 2%

ASTM C127: 2001

9. Specific gravity ASTM C128:2001 Min 2.6 Min 2.6

ASTM C127: 2001

10. Shell content in BS EN 933-7:1988 Note 1

aggregates:

Coarser than 10 mm
Max 5%

11. Particle shape:

Flakiness index BS812: Part 105.1 N/A Max 25

or BSEN 933-
3:2012
Elongation index
BS812: Part 105.2
Max 25

The index shall be max.

25 for combined
aggregates but should not
exceed more than 30 for
individual sizes.

Partially crushed faces of DMS 8: 2001 N/A 100%

coarse aggregate shall be
100% with at least one
crushed face.

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Sr. Requirement Test Methods Permissible Limits

BS / ASTM Fines Coarse

12. Acid Soluble Chlorides, Cl

For reinforced concrete BSEN 1744-1: 2009

made with

SRPC cements Max: 0.03% Max

0.01%

OPC & MSRPC cements Max: 0.03% Max

0.02%

For mass concrete made

with SRPC cements Max: 0.03% Max

0.02%

OPC & MSRPC cements Max: 0.03% Max

0.04%

For pre-stressed concrete Max: 0.03% Max

and steam cured 0.01%
structural concrete

13. Acid Soluble Sulphates, BSEN 1744-1: 2009 Max: 0.3% Max
SO3 0.30%

14. Acid soluble material in BS812: Part 119 N/A

fine aggregate

15. Soundness, MgSO4 (5 ASTM C88:1999 or Max 12% Max 12%

cycles) BSEN1367-2

16. Mechanical Strength

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Sr. Requirement Test Methods Permissible Limits

BS / ASTM Fines Coarse

10% fines value or BS812 Part 111 N/A Min 150

KN
Impact value BS812 Part 112 N/A
Max 30%

Los Angeles Abrasion ASTM C131:2001 N/A

Max 30%
ASTM

C535: 2001

17. Drying Shrinkage BS812 or N/A Max

0.045%
BSEN 1367-4

18. Potential reactivity

Note 2

Of Aggregates, chemical ASTM C289 Innocuous Innocuous

method of cement
aggregate combination
ASTM C227 6 month
expansion 0.10%
max

19. Alkali content of BSEN 1744 1:2009

aggregates Na2O Eq.

20. Aggregate Carbonate BRE Special Min : 0 Min : 0

range CaCO3 equivalent Digest No.1 & 2,
Max: 2 Max :12
2.2 and App:3 Cl
A-3.1
BS812: P102 Cl 5 Both
coarse and
BS812: P104:1994 fine
BSEN196-2:2005 & fraction
BSEN 932-1 combined

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Sr. Requirement Test Methods Permissible Limits

BS / ASTM Fines Coarse

Min: 0

Max 2-
12%

Or Carbonate content by BS EN 12620:2002

petrographic procedures + A1 :2008
as optional
BS812 P104:1994

Notes:

1. There is no requirement of shell content in sands passing 5 mm sieve size.

2. Aggregates may initially be assessed for its reactivity in accordance with ASTM C289 and if potential
reactivity is indicated, then mortar bar tests in accordance with ASTM C227 shall be carried out.

Table 3.4: Frequency of Routine Tests on Aggregates

Sr. Kind of Requirement / Test Method Test Frequency Rate

1. Grading – BS 812: 1990 P103 / BS EN 12620 Per 1000m³

2. Moisture content in coarse and fine aggregate (by Daily – for fine aggregate
micro-oven dry method) or speedy moisture test Daily - if coarse aggregates
method are wet.

3. Material finer than 0.063 mm – BS 812: 1989 1000 m³

P103.1 / BS EN 12620

4. Clay lumps and Friable particles – ASTM C142 Per 4000 m³

5. Organic impurities ASTM C 40:1999 Per 2000 m³

6. Water absorption ASTM C128: 2001/C127:2001 Ditto

7. Specific Gravity – ASTM C128: 2001/C127: 2001 Ditto

8. Shell content – BS EN 933-7:1988 / BS EN 12620 Ditto

9. Particle shape BS 812: 1990 P 105.1 Ditto

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Sr. Kind of Requirement / Test Method Test Frequency Rate

10. Acid soluble Chlorides, Cl

Qualitative – BS EN 1744-1:2009 / BS EN 12620 Per 1000 m³

Quantitative – BS EN 1744-1:2009 / BS EN 12620 Each 12 concrete days if

result is more than 75% of
the limit and each month if
result is less than 75% of the
limit.

11. Acid soluble sulphates Per 1000 m³ or each 24

concrete days if result is
S03 – – BS EN 1744-1:2009/ BS EN 12620 more than 75% of the limit
and each 2 months if result
is less than 75% of the limit
whichever is less.

12. Soundness, Mg S04 (5 cycles) ASTM C88: 1999 Each 48 concrete days or
4000m³

13. Mechanical Strength

10% fines or impact value BS 812 Parts 111, 112 Each 72 concrete days or
6000m³

Ditto
Los Angeles Abrasion – ASTM C131/C535

14. Moisture variation in sand by moisture meters Twice daily

15. Drying shrinkage BS EN 1367-4:2008 At the start of the project and

whenever there is a change
in the source of supply.

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Sr. Kind of Requirement / Test Method Test Frequency Rate

16. Potential Reactivity of aggregates (ASTM C295, At the start of the project and
C298) whenever there is a change
in the source of supply.

Of Carbonate (ASTM C586)

Of Cement aggregate combination (ASTM P214

and C227)

17. Aggregate carbonate range CaCO3 equivalent Ditto

Note: Drying shrinkage, potential reactivity of aggregates and the carbonate range shall be determined
initially at the start of the project or whenever there is a change in the source of supply.

3.2.1.9 Grading of Aggregates

Fine / coarse aggregate for concrete shall conform to the gradings as per BS EN
12620:2002+A1:2008 & tested as per BS EN 933-1:2012.

3.2.2 Water and Admixtures

3.2.2.1 Water - General

a) Water for washing aggregate and for mixing or curing of concrete shall be fresh,
clean and substantially free from oil, acids, alkali, sewage, deleterious mineral or
organic matter. Water shall comply in all respects with BS 3148 or BSEN 1008. It
shall not contain impurities in sufficient amounts to cause discoloration of the
concrete.

b) Water used for concrete mixes, washing aggregates and washing of equivalent
shall be potable water and shall comply with the requirements specified unless
otherwise stated herein or in Table 3.5. The pH of water used in concrete work
shall be in the range of 7 – 9. Ice if used, shall be flake ice and shall be the
product of frozen water which complies with the acceptance criteria of Table 3.5
unless otherwise accepted by the Engineer. Every effort should be made to
protect water pipes and tanks from the sun, by burying, sharing, insulation and /
or painting white. The Contractor shall make his own arrangements and obtain
approval for the supply of water. Whenever required to do so by the Engineer, the
Contractor shall take samples of the water being used for mixing concrete and
test them for quality as directed by the Engineer. No source of water shall be
used unless approved by the Engineer.

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Table 3.5: Chemical Limitations for Mixing Water

Sr. Maximum Concentration Test Method Limit (mg/l)

1 Chloride (as Cl) ASTM D512:1989 or BSEN 196- 250

2 : 2005

2 Sulphates as SO4 ASTM D516:2002 350

3 Alkali carbonates and ASTM 513 or BS 1377: P3:1990 500

bicarbonates

4 Total Dissolved ions, ASTM D1888 or BS 1377: 2000

including 1, 2 & 3 above P3:1990

5 pH ASTM D1293:1999 Min 7/max 9

3.2.2.2 Minimum Test Requirements for Cement & Water for Concrete

a) Portland Cement: One 2 kg sample for quality test shall be taken from each 1700
bags or equivalent weight in accordance with BSEN 196-7.

b) Water: One 1-gallon sample shall be obtained prior to use from each source and
at least once every week for quality testing.

c) Monthly strength test on blended cement with cementitious material in

accordance with BS EN 196-1 and establish the strength criteria achieved
throughout the contract period.

3.2.2.3 Admixtures

Admixtures shall comply with one of the following standards, unless otherwise
approved by the Engineer.

a) ASTM C494, ASTM C260, ASTM C1017: as applicable

The Contractor shall provide at least the following technical data for each type of
admixture.

(i) Solid content

(ii) Specific gravity

(iii) The typical dosage and the effects of under dosage and over dosage.

(iv) The generic type(s) of the main active constituent(s) in the admixture

(v) Whether or not the admixture contains chloride

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(vi) Whether or not the admixture leads to the entrainment of air when used at
the proposed dosage.

(vii) Where more than one admixture is used simultaneously in the same
concrete, details shall be provided on their interaction and compatibility.

When admixtures are used in the Works very strict control is to be maintained to
ensure that the correct quantity of admixture is used at all times. The equipment
to be used for dispensing and the method of incorporating the admixture in the
concrete shall be to the approval of the Engineer. The dispensing unit shall be
translucent such that the operator can see the discharge of the admixture.

Where approved or specified air entrainment agents, admixtures, waterproof

powder or microsilica shall be used as a means of:

 Increased workability of the concrete without increasing water/cement

contents

 Controlled and limited retardation of setting

 Increasing concrete durability

 Reducing bleeding and associated settlement and cracking

 Increasing water proof properties

 Reducing heat of hydration

 Reducing water permeability

b) Hydrophobic Pore Blocking Admixture

Where directed by the Engineer a hydrophobic pore blocking admixture based on

Ammonium Stearates and Hydrocarbon Resin shall be used at no additional cost
to the Employer.

(i) Admixture is to be added at a rate recommended by the manufacturer at the

time of mixing.

(ii) Manufacturer’s representative is to be present for all additions of the

hydrophobic pore blocking compound to ensure correct dosage rates are
used.

c) For self-compacting concrete, hyper plasticisers and viscosity enhancing agents

shall be used to provide necessary workability.

d) Viscosity Enhancing Admixture

The viscosity enhancing admixture having high workability and viscosity shall be
used for making self-compacting concrete that can become compact without

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vibration even with strongly reinforced structures. It shall be chloride free and
compatible with all type of cement.

e) Corrosion Inhibiting Admixture

(i) The corrosion-inhibiting admixture shall be added in an aqueous solution

form at batching plant and shall be specially formulated for Gulf area of hot
weather. The manufacturers of this product shall be ISO 9001 and ISO
14001 certified. With the above certificates the manufacturer/supplier shall
submit documented case histories.

(ii) The corrosion inhibiting admixture product, when used in accordance with
the manufacturer’s recommendations, shall impart changes to three
important properties of concrete compared to similar concrete without the
product. The changes are increased corrosion resistance (durability); no
adverse effects on physical properties of concrete and effective even where
corrosion is active.

(iii) Corrosion inhibitor when used in accordance with the manufacturer’s

recommendation shall form a suitable alternative for compliance with design
to the relevant sections of BS 1881, ASTM C1202-91, and ASTM G109.
The corrosion inhibitor shall comply with international standards such as
ANSI / NSF standard 61 certification confirming the products compatibility
with potable water.

(iv) The corrosion inhibitor shall be incorporated into the mixing water for the
purpose of determining the water cement ratio of the concrete. The
corrosion inhibitor shall be added to all reinforced concrete works (piles,
substructures & superstructures)

In order not to affect the W/C ratio, the corrosion inhibitor dosage shall not
exceed 1.0 lit/m³. The addition shall be made at the concrete plant.

f) High Performance Concrete Super plasticiser based on modified Polycarboxylic

Ether

A high performance super plasticiser based on sulphonated melamine and

naphthalene formaldehyde condensates at the time of mixing shall be used for
ready mixed concrete for ‘precast units’. Normal dosage shall be as
recommended by the product manufacturer.

g) Anti-Washout Admixture

(i) Anti-washout liquid admixture specially developed for concrete placed under
water shall be used for all ‘underwater concrete’. It shall have superior
resistance to washout of cement and fines. The minimum dosage use shall
be as recommended by the product manufacturer.

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(ii) Samples of proposed admixtures shall, if required, be submitted to an

approved testing authority by the Contractor in order to ascertain its
suitability for use in the Works. The test shall be carried out for the
properties specified in Table 3-10.

(iii) The cost of such admixtures or water proof powder or microsilica and
polypropylene fibres shall be included in the cost of concrete and no extra
payment shall be made if they are used. The proportions of cement, fine
aggregate and water shall be determined by the Contractor before
concreting commences and submitted together with mix design test results
that are required by the Engineer based on the verification by DCL, for
approval and the Contractor shall not commence concreting before such
approval is given nor shall he alter or vary in any way the proportion of mix
unless he submits fresh test results and mix proportions to the Engineer for
approval.

(iv) Mix design of all classes of concrete shall be verified by DCL prior to
approval by the Engineer. The approval by the Engineer of such mix
designs does not in any way absolve the Contractor of any of the
requirements of the Specifications.

(v) If two or more admixtures are to be used simultaneously in the same mix,
they shall not be pre-blended before use and the required data shall be
provided to assess their interaction to ensure compatibility.

Table 3.6 – Testing Admixtures

Sr. Uniformity Test Test Method & Test method &

Requirements Requirements as per
as per ASTM BSEN 934
C494

1. Colour – Similar to manufacturer’s

description

2. Settlement – Not to exceed

manufacturer’s limit

3. Specific gravity Manufacturer’s Manufacturer’s stated

stated value value ±0.03
±10%

4. Solid content Ditto ±5% Ditto ±5%

5. pH – Ditto ±1

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Sr. Uniformity Test Test Method & Test method &

Requirements Requirements as per
as per ASTM BSEN 934
C494

6. Ash content – –

7. Chloride content – BSEN 480 – Part10

<0.1% or less than

manufacturer’s stated
value

8. Chlorine content – <0.1% or Ditto

9. Alkali content – BSEN 480-12

Manufacturer’s stated
value

10. Infra-red Spectrum Essentially similar Essentially similar to

to manufacturer’s manufacturer’s reference
reference

11. Air void BSEN 480-11 as BSEN 480-11 as

characteristics described in the described in the standard
standard

3.2.3 Polypropylene Fibre Mesh Micro-Reinforcement

a) Fibrous concrete reinforcement shall be 100% virgin polypropylene micro fibres

specifically manufactured and developed as crack controlling additives and so
certified by the manufacturer.

b) It is available in two grades designated by its fibre length, 10 mm and 50mm for
concrete and 6 mm for mortar. 10 – 50 mm fibre is designed for cementitious mix
wherein the maximum aggregate size shall be greater than 5mm and 6mm fibre
length for cementitious mortar mix wherein the aggregate size shall be less than
5mm. It shall be compatible with all types of cement and admixtures. It improves
the concrete finishing characteristics, plastic shrinkage cracks, durability, alkali
attack, increases impact, abrasion resistance and reduced risk of subsequent
damage. Over dosage of fibre will generally produce a reduction in workability
and an increase in the cohesiveness of the mix. The performance of fibrous
concrete is to be assessed after conducting preliminary lab trial or plant trial using
the actual mix constituents under consideration to determine the effect of

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concrete properties. Fibres may be monofilament or fibrillated. The minimum

dosage shall be 0.60 to 0.9 kg/m³ depending on fibre diameter or as
recommended by the product manufacturer.

Table 3.7 – Physical Properties of Polypropylene Fibre

Constituents Polypropylene (C3 H6)

Young’s modulus 3.5 KN/m m²

Alkali content Nil

Absorption Nil

Specific surface area 225 m²/kg

Specific gravity 0.90 gm/cm³

Fibre length 10-50mm

Melting point 160-170oC

Ignition point 590oC

Acid and salt resistance High

Chloride & sulphate content Nil

Fibre thickness 18 micron

3.2.4 Concrete Mixes and Specification

3.2.4.1 Definitions, Glossary and General Requirements

The following definitions are used in this Specification:-

Design Mix: a mix in which the Engineer specifies the strength required to ensure
durability and sets the limits for aggregate size, cement content and water cement
ratio. The Contractor or ready-mix manufacturer is responsible for the selection of the
mix proportions.

Prescribed Mix: a mix, for which the Engineer specifies the proportions by weight
and accepts the resultant strengths, provided the Contractor has produced a properly
mixed concrete containing the constituents in the specified proportions.

Minimum Cement Content: the lowest permitted mean mass of cement present in
one cubic metre of fully compacted concrete.
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Free Water / Cement Ratio: the ratio by mass of free water to cement where free
water is the water in the concrete mix in excess of that absorbed by the aggregates
which is available for the hydration of the cement and for workability of the fresh
concrete.

Moisture Content of the Aggregate: this is the mass of free water in the aggregate
expressed as a percentage of the mass of saturated surface dry aggregate and does
not include any absorbed moisture.

Density of Fresh Concrete: mass of a quantity of compacted fresh concrete divided

by its volume expressed in kg/m³.

Characteristic Strength: the value of compressive cubes strength below which 5%

of all possible strength measurements of the specified concrete are expected to fall.

Governing Strength: the value of average 28 days’ concrete cube compressive

strength obtained from the approved trial mix

Mean Strength: the mean strength of all the cubes tested.

Working Margin: the difference between the characteristic strength and the mean
strength.

Certified Average Alkali Content: the average of 25 consecutive determination of

equivalent alkali content carried out on samples each of which is representative of a
days production.

Declared mean alkali content: the alkali content expressed as the sodium oxide
(Na2O) equivalent, which is not exceeded without prior notice from the cement or
additive manufacturer.

Guaranteed alkali content: the alkali limit expressed as the sodium oxide (Na2O)
equivalent which the constituent material supplier guarantees will not be exceeded by
any test result on any spot sample.

Cementitious Materials: cement, cement plus GGBS, or cement plus GGBS plus
Microsilica or cement plus water proof powder.

Admixtures: a material other than water, aggregate, cementitious materials or fibre

reinforcement, used as an ingredient of concrete or mortar.

Hot weather: when the shade temperature is above 40°C on a rising thermometer or
43°C on a falling thermometer.

Coarse Aggregate: considered as that size predominately passing a 28mm sieve

and predominately retained on a 5mm sieve.

Fine Aggregate: considered as that size predominately passing a 5mm sieve and
predominately retained on a 0.075mm size.

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OPC: ordinary Portland cement.

SRPC: sulphate-resisting Portland Cement

MSRPC: moderate sulphate-resisting Portland cement.

GGBS: ground granulated blast furnace slag.

MS: Microsilica.

Gap-graded aggregate: graded aggregates without one or more of the intermediate

sizes.

Single-sized Aggregates: aggregates containing a major proportion of particles of

one size.

Target Mean Strength: the specified strength plus the margin.

Acceptable or Accepted: acceptable or accepted by the Engineer.

Approval or approved: approval from the Engineer or approved by the Engineer.

All-in aggregate: the materials composed of a mixture of coarse aggregate and fine
aggregate.

Glossary

Air entrainment : The intentional incorporation into a concrete mix by means of an

admixture, of minute discrete bubbles of air typically less than
0.3mm (300 microns).

Autogeneous : The natural sealing of a crack in concrete by siltation together

healing with further hydration of cement or by the deposition of calcium
hydroxide with consequent conversion to calcium carbonate.

Bleeding : The phenomenon of water migrating to the surface of fresh

concrete due to settlement of particulate materials.

Blended cement : See Composite cement.

Cohesiveness : The degree to which fresh concrete resists segregation.

Cold joint Plane of weakness caused by interruptions to placing which

results from new concrete being cast against unprepared stiffened
concrete.

Cold weather : Cold weather placing and finishing concrete when air
concreting temperatures are below 5°C or when freezing is likely to occur
soon after concreting

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Compressive : Classification comprising the type of concrete, the minimum

Strength Class characteristic 150mm cube strength and the 150mm dia x 300
mm cylinder strength.

Comp actability : The ease with which the entrapped air in concrete can be
expelled.

Cement content : Mass of cement contained in a cubic metre of fresh, fully

compacted concrete expressed in kg/m³.

Composite : A cement or combination containing two or more main

cement constituents, one of which is Portland cement, mixed at a cement
works or at a ready-mix plant or on site.

Combination : Restricted range of Portland cement and additions which having

been combined in the concrete mix.

Consistence The resistance to flow of fresh concrete

Core : The innermost part of a (thick) concrete section which is generally

unaffected by external ambient temperatures.

Creep : The continuing deformation of concrete under sustained stress.

Curing : The action of preventing or minimizing the loss of moisture from

fresh concrete and maintaining a satisfactory temperature so that
desired properties may develop.

Curing Initial : Deliberate action taken between placement and final finishing of
concrete to reduce the loss of moisture from the surface of the
concrete.

Curing final : Deliberate action taken between the final finishing and termination
of curing.

Evaporation : A material that generates a continuous thin film when spread over
Reducer water on the surface of fresh concrete and thus retards the
evaporation of bleed water.

Design Chemical : Designations used to describe a concrete quality capable of

Class (D,C Class) resisting the selected aggressive chemical environment for the
concrete

Drying shrinkage : The long-term reduction in size of a concrete element caused by

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the loss of water upon drying.

Early age thermal : The reduction in length of a concrete element caused by its
contraction cooling from the elevated temperatures developed during
hydration of the cement.

Finishing : Mechanical operations carried out on the surface of placed

concrete to achieve the required texture, appearance and
serviceability.

Fresh concrete : Concrete which has insufficient reaction between the cement and
water to exhibit significant mechanical properties.

Hardened : Concrete which exhibits mechanical properties as a result of the

concrete reaction of cement and water

Heat of hydration Heat generated by the chemical reaction of cement and water.

Hot weather : Placing and finishing concrete when air temperatures are above
concreting 25°C and the combination of temperature and humidity is such
that the quality of fresh or hardened concrete may be impaired
unless preventive measures are taken.

Joint construction : A monolithic joint with no provision for movement.

Joint movement : A joint formed or induced to allow movement to occur with one or
more degrees of freedom

Laitance : A layer of cement and fine sand with excess water content on top
of concrete

Matrix : The part of concrete which is composed of cement paste and

sand.

Minimum cover : Cover to reinforcement assumed for the purpose of durability

Mobility : The ease with which fresh concrete can be made to flow.

Nominal cover : Cover to reinforcement shown on the drawings comprising the

minimum cover plus a tolerance c to accommodate fixing
precision.

Placing : All operations necessary for introducing the fresh concrete into
form work or other enclosures.

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Plastic concrete : See fresh concrete

Plastic settlement : Cracks which form due to differential settlement of concrete while
cracks still in a fresh (plastic) state.

Plastic shrinkage : Cracks which form because of excessive loss of moisture from
cracks concrete while still in a fresh (plastic) state

Restraint : Anything (internal or external) which prevents the free movement

of concrete

Re-tempering : Addition of water and remixing of concrete to increase its

workability

Rheological : Pertaining to the flow of concrete

Segregation : Loss of uniformity of fresh concrete mix due to separation of one

or more of the constituents of the mix.

Settlement : Sedimentation or the act of the heavy solid particles settling in

fresh concrete.

Stability : See Cohesiveness.

Stiffening time : Time beyond which reworking of concrete would be detrimental.

Tensile strain : The tensile strain at which a concrete will crack.

capacity

Transporting : The conveying of fresh concrete from the point of discharge from
the mixer to the point of discharge into the form work or other
enclosure

Warping : The distortion of a slab caused by temperature or moisture

gradients across the depth of section.

Consistency : The rheological properties of fresh concrete influencing the ease

with which it can be placed, compacted and finished

3.2.4.2 Concrete with Special Requirements

Except where otherwise required by another approved standard specified herein,

concrete shall comply with the recommendations contained in the approved standard
or such modifications as may be agreed with the Engineer.
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All below ground concrete structures are to be tanked as a protection from the
aggressive groundwater both below the ground water table and in the capillary zone
above.

a) The concrete mix for water retaining structures shall be designed to achieve the
structural performance level to “HIGH” as given in the table ‘5’ of BRE Special
Digest No.1 part 3: 2003 and as per BS8500-1:2006.It shall also be watertight as
described in BS EN 1992-3:2006. Concrete to be used in aggressive ground shall
be designed as recommended in Part 2 of BRE Digest No.1Part 2 and 3 and for
precast products it shall be as specified in Part 4 of BRE Digest No.1.

b) The choice of cement to be used for underground structures shall depend on the
sulphate and chloride concentrations in ground water and the soil. The tenderer
shall consider in his offer the sampling and testing of soil and ground water in
accordance with BS 5930 :1990+A2:2010. The concrete mix is to be designed
after assessing the classification of aggressive ground conditions at site. (Refer
BRE special DigestNo.1and CIRIA guide recommendation). The chemical
classification of the site is to be decided after considering step No.1 to 5 specified
in BRE Digest No.1:2003 Part I cl:6.

c) The choice of constituent materials of concrete and its limitations given in BS EN

1992-3:2006 , BRE Digest No.1 and BS 8500:2002 are to be taken into
consideration to satisfy the structural performance level of buried concrete (Ref.
Section ‘3’ of BS EN 1992-3:2006 and BRE Digest No.1:2003 part 1-4).

d) The qualities of concrete that are required to resist chemical attack shall be as
recommended in CL 4 to 6 of BRE Digest No.1:2003 Part 2.

e) Usage of fibrillated polypropylene fibres in concrete may reduce the rate and
amount of bleeding as well as the effect of plastic settlement cracks in concrete.
Therefore where approved/ or use by the Engineer fibrous concrete shall be
designed as stated in the mix design specification.

f) Controlled Permeability formwork(CPF) on structural concrete shall be used

(i) To prevent loss of fines from concrete during Vibration.

(ii) To evacuate the excessive air from concrete, avoid air voids on concrete
surface and improve the surface quality (Ref. CIRIA guide CL 15.5.4 and
17.6.3)

(iii) To substitute an insulation layer on external concrete surface to control the

in situ concrete temperature gradient and concrete surface temperature.

(iv) To increase the concrete surface and wear resistance.

(v) To decrease the ratio of chloride penetration, water penetration and

carbonation effect.

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(vi) For textured surface finish to avoid sand blasting before painting and to
acquire an ideal substrate base.

(vii) To reduce bacterial and algae growth due to dense surface without cracks
and blow holes.

3.2.4.3 Ready Mixed Concrete

The contractor may use ready –mixed concrete from an approved source with the
written authorization of the Engineer. Ready-mixed concrete and all constituent
materials shall conform to this specification.

3.2.4.4 Mix Design Constraints

All design mixes shall comply with the following constraints:

a) The structural design of the concrete elements shall be in accordance with BS EN

1992-1-1:2004.

b) Concrete for water retaining structures and below ground structures in this
Contract shall be water tight and shall comply with the requirements and
recommendations of BS EN 1992-3:2006 : and BRE Digest No.1: 2003 and CIRIA
Guide Publications. Classification of sites, choice of cement and aggregates,
concrete in aggressive grounds and the additional protective measures as
recommended in BRE Digest No.1 also to be taken into consideration.

c) Characteristic strength are basic mix strengths and do not allow for any reduction
in strength due to the use of air entrainment agents. Air entrainment agents will
be used only where specified.

d) Only air entrainment agents based on vinsol resins will be approved. Where air
entrainment is specified, the average air content by volume of fresh concrete
(measured in accordance with the approved standard BS12350 P7:2009) shall be
5% for 20 mm nominal maximum aggregate size. This will produce concrete
having strength approximately 70% that of non-air entrained concrete.

e) If bleeding occurs in any trial mix it shall be assessed in accordance with the
approved standard ASTM C230:1999 (non-vibrating) and where necessary the
mix design or sand grading shall be adjusted to prevent recurrence.

f) The mix proportions shall be adjusted to achieve the maximum density from the
available materials. Unless otherwise agreed by the Engineer, the saturated
surface dry density of fully compacted cubes shall be not less than 2500 kg/m³ for
those concretes for which air entrainment has not been specified. As a guide the
Contractor should note that for non-air entrained concrete, United Arab Emirates
aggregates dredged sand normally achieve densities greater than 2450 kg/m³.

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g) In general the actual cement content will need to be higher than the minimum
value specified to ensure adequate workability and compliance with the maximum
water/cement ratio. Approved plasticiser may be used to maintain workability.

h) Mean strengths may exceed those required to achieve the characteristic strength
in order to comply with the maximum water/cement ratio.

i) The initial drying shrinkage of all the proposed concrete mixes, prepared and
tested in an approved laboratory shall not exceed 0.05%. It should be noted that
the above involves a testing period of about eight weeks.

j) The basic requirements as specified in BS 8500 – 1:2006 Cl. 4.3.2 and the
additional requirements where required as specified in Cl. 4.3.3 shall strictly be
followed for designed concrete and a compliance statement is to be provided to
the Engineer by the concrete mix designer.

3.2.4.5 Concrete Mix Specification

Concrete mix shall be as shown in Table 3.8. The number of mixes may require to be
increased. The criteria given in the Table are designed to produce concrete of the
required strength durability and the area of use. If the maximum aggregate size is
10mm then the cement content stipulated for the class of concrete given in Table 3.8
shall be increased by 40kg per m³. All structural concrete mixes shall be verified by
Dubai Central Laboratory.

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Table 3.8 - Concrete Classification, Mixes and Area of Use

Sr. Classification Concret Type of Strength Min Free Max size Characteristi Governing Other Area of use
e Grade Cement as per Class of Cement WCR of c strength mean Cube Compliance
ASTM/BS Cement Content (Max) Aggregate @28 days Strength @28 requirements
Standards N/m m² (kg/m³) (mm) days
1. PC – BL ** C25 SRC to BS 42.5 340 0.50 20 As As derived Basic Plain concrete
4027 or calculated from the requirement blinding under
ASTM from the concrete trial s as per Cl structural concrete
concrete batch 4.3.2 of
Type V production BS8500:P1
& as per BS
EN 1992-
3:2006

2. PC – UR** C30 Ditto ,, 380 0.45 20 Ditto Ditto Ditto Plain unreinforced
mass fill concrete
and reinforced
concrete for minor
structures similar
to Manholes,
chambers, pipe
surround,
protection slab,
anchor blocks etc.

3. PC-GR** C35 Ditto ,, 400 0.42 10 Ditto Ditto Ditto Benching grano
concrete

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Sr. Classification Concret Type of Strength Min Free Max size Characteristi Governing Other Area of use
e Grade Cement as per Class of Cement WCR of c strength mean Cube Compliance
ASTM/BS Cement Content (Max) Aggregate @28 days Strength @28 requirements
Standards N/m m² (kg/m³) (mm) days
4. RCC/WS/ C40 Ditto ,, 400 0.35 20 Ditto Ditto Ditto RCC for water
F** retaining
structures and the
related adjoining
chambers similar
to Air valve
washout chambers
, Access Shafts
etc.

5. RCC/PU/F C50 Ditto ,, 400 0.35 20 Ditto Ditto Ditto RCC Precast units
**

6. SCC ** C60 OPC/SRC ,, 400 0.35 20 Ditto Ditto Ditto In situ piling works

7. UWC** C40 OPC/SRC ,, 400 0.40 20 Ditto Ditto Ditto Under water
concrete

8. Pc – BR ** C40 OPC ,, 400 0.40 10 Ditto Ditto Ditto Precast Bricks

9. RCC/AG/F C40 OPC /SRC ,, 400 0.38 20 Ditto Ditto Ditto RCC for Building
** structures above
BSEN 197- ground with OPC
1:2000 and below ground
foundation with

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Sr. Classification Concret Type of Strength Min Free Max size Characteristi Governing Other Area of use
e Grade Cement as per Class of Cement WCR of c strength mean Cube Compliance
ASTM/BS Cement Content (Max) Aggregate @28 days Strength @28 requirements
Standards N/m m² (kg/m³) (mm) days
/Type 1. SRC

BS4027

Type V

NOTES:
1. PC-BL plain reinforced concrete with protective measures as specified for blinding
2. PC-UR - plain unreinforced mass fill concrete and reinforced concrete for minor structures with protective measures as specified
3. PC-GR - Granolithic concrete for benching / haunching works with protective measures as specified.
4. RCC/WS/F - structural reinforced water proof concrete contains polypropylene fibres with protective measures as specified for water retaining structures.
5. RCC-PU/F RCC - Precast units including surround concrete for Micro tunnelling pipes.
6. SCC - self compacting concrete for insitu piling works and concrete having congested reinforcement
7. UWC - underwater concrete
8. PCBR - concrete for precast corbel bricks/blocks/surround to gully pot etc.
9. RCC/AG/F RCC - structural concrete for the above ground structures with polypropylene fibres for building and similar other above ground structures and its foundation below
ground.
** Double starred concrete requires to have aggregate carbonate range ‘C’ (lowest carbonate content).

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3.2.4.6 Chloride and Sulphate Levels in Concrete

The chloride and sulphate levels in the concrete mix shall comply with the
requirements of Table 3.9.

Maximum limits of chloride and sulphate content as a percentage by weight of

cement in the mix.

Table 3.9 – Maximum Limits of Chloride and Sulphate Content in Concrete Mix

Type of Concrete Chloride as Cl% Sulphates as SO3 %

according to BS 1881:
BS 1881:1988
Part 124 Addendum
01:1988 Addendum 06:2002

For reinforced
concrete

if made with
0.30 3.70
OPC/MSRPC
0.06 3.70
if made with SRPC

For mass concrete

if made with

OPC/MSRPC 0.60 3.70

if made with SRPC 0.12 3.70

For Pre-stressed
concrete and heat-
cured reinforced
concrete 0.10 3.70

Note: The OPC and MSRPC cements can also contain chlorides, the relevant standard BS EN 197-
1:2000 latest edition allows up to 0.1% Cl. Therefore any chloride content present in the cement
as determined by BS EN 196 Part 2:2005 has to be taken into account while computing total CI in
the mix. In case the cement contains the maximum limit of 0.1% Cl, then the aggregates, water
and admixtures used for pre-stressed concrete or heat-cured reinforced concrete should be
absolutely free of chlorides

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3.3 CONCRETE MIX DESIGN

3.3.1 General – Samples of Aggregate

Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the necessary
tests and analysis to show that the samples comply with the Specification. During the
progress of the Works, the grading and chemical characteristics may be checked at
frequent intervals. Sampling of aggregates shall be carried out in accordance with BS
812: Part 101 and Part 102.

The results of these tests shall be submitted to the Engineer and his approval shall
be obtained before any of the material is used in the Works. Part of each sample will
be required for concrete trial mixes and part shall be retained for comparison with
subsequent deliveries.

No deliveries in bulk are to be commenced until such samples are approved by the
Engineer as complying with this Specification.

3.3.2 Concrete Mix Design Submittal and Method Statement

The concrete mix design submittals shall have:-

a) Manufacturer’s Data: Submit manufacturer’s product data, specifications with

application and installation instructions for proprietary materials and items,
including admixtures, polypropylene fibre, waterproofing powder etc.

b) Product Data, test results and other information as required to prove compliance
with the specification shall be submitted for approval according to Section on at
least the following products.

(i) Cement

1. Recent independent tests results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards.

2. Manufacturer’s certificates shall also be supplied with each consignment

of cement certifying compliance with the relevant standard for each type
of cement.

(ii) GGBS

1. Recent independent test results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards

2. Manufacturer’s certificates with all information necessary to verify

compliance with BS 6699 shall also be supplied with each consignment
of GGBS.

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(iii) Microsilica & Water Proof Powder

1. Recent independent tests results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards

2. Manufacturer’s certificates with all information necessary to verify

compliance to an internationally recognized standard shall also be
supplied with each consignment with microsilica and water proof
powder.

(iv) Aggregates

1. Recent independent tests results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards

2. Full details of the proposed sources of aggregates.

(v) Water

Recent independent test results acceptable to the Engineer confirming

compliance with the specified requirements and referenced standards

(vi) Admixtures

1. Manufacturer’s technical specifications and recommendations.

2. Recent trial results acceptable to the Engineer illustrating the efficiency

of the product for its particular application

(vii) Polypropylene fibre:

Manufacturer’s technical specifications and recommendations.

c) Concrete Mix design for each class of mix with at least the following information:

(i) Type of cement

(ii) Cement content

(iii) GGBS content

(iv) Microsilica content

(v) Water proofing powder content

(vi) Polypropylene fibre content, the source and properties

(vii) Max. aggregate size, type and source

(viii) Combined grading curve

(ix) Quantities of all individual materials

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(x) Name of admixture, type and source

(xi) Target slump (at discharge)

(xii) Details to calculate W/C ratio

(xiii) Compressive strength

(xiv) Hardened density

(xv) Water permeability & water absorption

(xvi) RCP

(xvii) Bleeding

(xviii) SO3 and Cl contents in the mix

(xix) Slump profile

(xx) Target unit weight

(xxi) Target temperature

(xxii) Structural performance level of the designed mix

(xxiii) Aggregate carbonate range limit in the aggregate mass

(xxiv) Temperature gradient anticipated in the concrete

(xxv) Compliance statement in accordance with BS8500-1: 2006 Cl. 4.3.2 &
4.3.6.

d) Method statements

The Contractor shall submit a method statement for concrete batching and
delivery which shall include at least the following details:

(i) Type of plant proposed

(ii) Layout of concrete production facility

(iii) Proposed method of organization of the concrete production facility.

(iv) Quality control procedures for concrete and concrete materials

(v) Batching and transport of concrete.

e) Purchase orders: Copies of all purchase orders shall be certified by the

Engineer’s Representative before being issued for procurement.

f) Delivery Tickets: With each load of concrete delivered to the job, duplicate tickets
shall be furnished by the ready-mix concrete producer. Furnish one (1) to the
Engineer’s Representative.
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g) Samples

(i) Provide samples of all materials and concrete accessories of every type
proposed for use including component parts of prefabricated formwork
systems and manufacturer's technical literature relating thereto. Prepare
mock-ups and carry out such tests on the proposed prefabricated formwork
systems as may be required by the Engineer in order that he may be
satisfied as to the system's suitability.

(ii) Furnish reinforcement and accessories for sample panels and mocked-up
portions of the structure as required using all materials and techniques as
they will be used in actual construction.

h) Samples of the following concrete mix material shall be submitted.

(i) Cement

1. Provide cement samples from each consignment delivered to the site as

required by the Engineer for testing.

2. Samples shall be taken in the presence of the Engineer’s

Representative

(ii) GGBS

1. As requested by the Engineer for independent testing.

2. Samples shall be taken in the presence of the Engineer’s

Representative

(iii) Microsilica & Water Proof Powder

1. As requested by the Engineer for independent testing.

2. Samples shall be taken in the presence of the Engineer’s

Representative

(iv) Aggregates

1. Provide samples of both fine and coarse aggregates for testing at least
three weeks prior to beginning deliveries to the site and at regular
intervals as required by the Engineer.

2. Samples shall be taken in the presence of the Engineer’s

Representative

(v) Polypropylene Fibre

1. Provide samples with test report.

2. Samples shall be taken in the presence of the Engineer’s

Representative
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(vi) Water

1. Provide samples of water proposed for concreting works.

2. Samples shall be taken in the presence of the Engineer’s

Representative

(vii) Admixture: as requested by the Engineer.

i) Mill Tests:

Furnish the Engineer with certified mill test reports for cement.

j) Test Reports:

Submit preliminary test results for the Engineer’s approval at least three weeks
prior to the beginning of the work. In addition to the test reports specified under
“Quality Control”, submit the following directed to the Engineer:

(i) Preliminary Design Mix Reports

(ii) All related test reports to Aggregate and Cement outlined here in this
Section.

3.3.3 Design Mixes for New Batching Installations

3.3.3.1 General Requirements

a) Concrete shall be batched only with approved materials, approved mix designs,
and at approved facilities.

b) The Contractor shall define the method of design of the mix, by reference to a
recognised published design method. The design method shall be approved by
the Engineer.

c) Plant trials shall be carried out for each grade and type of concrete in the
contract, unless approved otherwise by the Engineer.

d) Aggregate proportions shall be based on measured and not assumed relative

densities.

e) If requested by the Engineer, concrete mix designs which include an admixture

shall be prepared and tested both with and without the admixture to give a clear
indication of its effects on the physical characteristics of the mix.

f) Results of the trial mixes must demonstrate that the proposed mix complies with
the strength, workability and durability requirements of this specification.

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3.3.4 Trial Mixes for Concrete

a) Following the Engineer’s approval of the materials for each class of concrete, the
Contractor shall prepare laboratory trial mix on one batch for each grade of
concrete in the presence of the Engineer’s Representative. Each trial mix shall
comprise not less than 1/3 of a cubic metre of concrete and shall be mixed in an
approved type of concrete mixer similar to that which the Contractor propose to
employ on the Works. The quantities of all ingredients of trial mix including water
shall be carefully determined by weight according to the approved mix design.
Each trial mix shall show no tendency to segregate when handled and compacted
by the methods by which the Contractor proposes to handle and compact the
grade of concrete in the Works and it shall be capable of adequate compaction by
such methods.

b) Preliminary laboratory tests on lab trial mixes shall be carried out to determine the
mixes to satisfy the specification with the approved materials. Approval of the
laboratory mix proportions shall in no way relieve the Contractor of his
responsibility to produce concrete which meets the requirements of these
Specifications. All costs connected with the laboratory trials and the design of the
proposed mixes shall be borne by the Contractor. Whenever a change of brand or
source for any of the concrete ingredients occurs, additional laboratory mixes may
be required and the cost of these trials shall also be borne by the Contractor. The
suitable and economical mix designs selected from the lab trials shall be
subjected to plant trial.

c) The mean strength of concrete at 28 days from each batch shall exceed the
characteristic cube strength (CCS) by a margin of 1.64 times the standard
deviation expected from the concreting plant, except that no standard deviation
less than 3.5 N/m m² shall be used as a basis for designing a mix. Unless
otherwise approved a standard deviation of 7 N/m m² and the working margin of
minimum 11.5 N/m m² shall be used to work out the target mean strength for
design mixes for new batching installations.

d) All the trial mixes for each class of concrete shall be tested to determine the
following properties of mixes proposed for initial field tests:

Table 3.10 Lab Trial Testing of Concrete

Properties Test Method Specification Limit

Fresh and hardened BSEN 12350:P6 & BSEN 12390:  2500 kg/m³
densities of Concrete P7 or BS EN 12350-6:2000

Bleeding of wet fresh ASTM C232 Non vibrating  0.50%

concrete method and vibrating method

Air content in concrete if BS12350: P7:2009 / ASTM C173  2%

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Properties Test Method Specification Limit

applicable for air entrained

concrete

 5%

Fresh and fully compacted ASTM C 138: 1992 N/A

wet concrete yield

Cement content and free BS 1881  Mix design

water cement ratio of requirement
concrete

Concrete temperature, flow BSEN 12350 Part 1, 2 & 5  Specification

and consistency of concrete requirement
(slump)

Initial, 30 min, 60 min and

90 min

Total chloride & sulphate BS 1881: P124 or BSEN 196-2  0.3% by weight of
content in the concrete mix :2005, cement

BSEN 1744-1 & BSEN 480-10  3.7% by weight of

cement

Total alkali content in the BSEN 196-1 and BS 8500:1 & 2  3.5 kg /m³ concrete
mix Na2O Eq:

Permeable pores in ASTM C642 or BSEN 480-11  7% at 7days

concrete

Mortar fraction of concrete By calculation 55-67%

Overall grading of BS EN 12620 : 2002+A1:2008 As per clause 3.2.1.8

aggregate (Wet analysis of
concrete)

Initial setting time of ASTM C403, C494 As per standard

concrete

Compressive strength of BS EN 12390-1:2000 & BS1881: Spec requirement

hardened concrete P116

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Properties Test Method Specification Limit

Flexural strength of BSEN 12390: P5 Concrete grade upto

concrete prism C40 3.5 N/m m²

For C40-C50 grade

concrete 4N/m m²

For concrete C50 and

above 5N/m m²

Tensile splitting strength of ASTM C 496: 1996 or BSEN  4N / m m²

concrete cylinder 12390-2

Surface tensile strength of BS 1881: P207: 1992  3 Mpa

concrete

Initial surface absorption of BS 1881: Part 122 or  0.03ml/ m²/sec

concrete @7days
BS 1881: P208: 1996
 0.02 ml/ m²/sec@28
days

Capillary absorption of BSEN 480-5 7 days cure @7 days

concrete absorption 0.6% (90
days cure) @ 28 days
absorption 2.5%

Water absorption of BS 1881: P122:2011 As specified in Table

concrete 3.13

Chloride permeability (RCP) ASTM C 1202: 1999 As specified in Table

3.13

Depth of water permeability BSEN 12390: P8:2009 -ditto-

(RCP)

Drying shrinkage of BS EN 12390-7:2000 , BS 1881- Drying shrinkage

concrete 121:1983, BS 1881-122:2011, BS 0.05%
1881-209:1990 , BS 1881-
208:1996 or BS EN 772-2:1998 ,
BS EN 771-3:2003

Wetting expansion of -Ditto- Max. 0.03%

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Properties Test Method Specification Limit

concrete

Temperature gradient of the Mock up sample  15oC.

concrete

Note:
1. Durability test is required only for RCC structural concrete.
2. The most suitable mix shall be selected after the full properties are verified and shall be subjected to
plant trial as specified.

3.3.5 Design Mixes from a Continuing Source

For mixes proposed from a continuing source for which the necessary test results of
concrete materials and concrete are available and for a batching installation which
has been operated for a sufficient period to produce the required cube results the
following procedure shall be adopted.

The mean 28 days compressive strength calculated from 'n' cube results, from
separate batches of concrete shall exceed the specified characteristic strength by a
margin equal to:

1.64 × SD {(0.86 + ( 2 / n) }

where:

'SD' is the standard deviation from 'n' results but not less than 3 N/sq.mm.

'n' is the number of results not less than 10 and not greater than 100

When 'n' exceeds 100, the margin shall be calculated as:

1.64 × SD

where 'SD' is as defined above.

Previous production data for use in the above criteria shall be 28 day cube test
results from separate batches of concrete sampled at random over an immediately
prior period exceeding one month and not exceeding one year using materials and
plant which are proposed for the Works.

3.3.6 Slump, Flow, Temperature and Air Content Testing of Fresh Concrete at Site

3.3.6.1 Sampling

The sampling shall utilise a spot sample obtained from the initial discharge, if
concrete is delivered in a truck mixer or agitating equipment. The spot sample shall
be taken after a discharge of approximately 0.3 m³ by taking six increments from the

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moving stream of the concrete in accordance with BS EN 12350-1. The sample shall
be remixed on a non-absorbent surface and tested for slump or flow.

Table 3.11 Identity Criteria and General Guidance for Slump & Flow of In-situ
Concrete at Site

Use of concrete Form of (Dimensions in mm)

compaction
Spot sample taken from initial discharge

Slump Not less Not greater Flow Flow

Class than than Class Range

Kerb bedding and Tamping S1 25 70 N/A

backing

Floors and hand placed Poker or S2 30 120 N/A

pavements beam
vibration

Strip footings Poker or S3 80 120 N/A

beam
vibration

Mass concrete And/or S3 80 120 N/A

foundations tamping

Blinding S3 80 120 N/A

Normal reinforced S3 80 120 N/A

concrete in slabs,
beams, walls and
columns

Sliding formwork S2 30 120 N/A

construction

Pumped concrete S4 100 150

Vacuum processed S4 100 150

concrete

Trench fill Self-weight S5 140 240 F1 53070

compaction mm

In-situ piling -ditto- S5 140 240 F1 53070

mm

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Use of concrete Form of (Dimensions in mm)

compaction
Spot sample taken from initial discharge

Slump Not less Not greater Flow Flow

Class than than Class Range

Underwater Concrete S5 140 240 F1 53070

mm

Under no circumstances shall a slump and flow test be used as a means of

monitoring water content and it shall be noted that for any concrete mix the slump will
reduce with increasing temperature.

Concrete mixes shall be designed such that the minimum consistence at the time of
placing is adequate to allow the concrete to be placed and compacted as specified.

3.3.6.2 Temperature Records

a) The Contractor shall supply suitable maximum / minimum thermometers and

record the shade and sun temperatures adjacent to all parts of the works concrete
is being placed.

b) Procedure to measure the temperature of fresh concrete at site:

(i) Sampling shall be as given in Cl. 3.3.6.1

(ii) Within 2 minutes of taking sample at delivery, insert a type A100 mm

immersion thermometer (having a range of –5oC + 110oC, graduated in
intervals of 1oC (calibrated and conforming to BS 1704) in the concrete
sample to a depth not less than 100 mm.

(iii) When steady condition have been maintained for 1 minute record the
temperature to the nearest 1oC.

Use an alternative form of temperature measurement device with a precision at

least that of a thermometer conforming to BS 1704, to record the steady-state
temperature to the nearest 1oC.

c) Method of Taking Air Content in Fresh Concrete

(i) Sample shall be a composite sample taken in accordance with BSEN

12350-1.

(ii) Air content shall be a measured in accordance with BS EN 12350-7

(iii) The identity criteria for air content shall be as specified.

d) Method of Making Test Cubes from fresh concrete shall be as follows:

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(i) Fresh concrete sample shall be emptied into a metal tray 1.2m x 1.2m x 50
mm deep and thoroughly mix by square mouthed shovel to turn the
concrete from outside toward the centre.

(ii) Place the cube mould on a rigid horizontal surface or vibrating table. By
means of 100 mm wide scoop place the concrete in the cube mould in
layers approximately 50mm and compact each layer by using either the
steel compacting bar having 25mm square ramming face, 300 mm long and
1.8 kg weight or the vibrator. The number of strokes per layer required to
produce full compaction will depend on the workability of the concrete but in
no case shall the concrete to be subjected to less than 35 strokes per layer
for 150 mm cubes or 25 strokes per layer for 100 mm cubes, except in case
of high workability concrete. The concreted mould shall be covered with
plastic sheets and keep under the shade and be protected from harmful
effects of sunshine, drying winds, rain or running water. The concrete cube
specimen shall be removed from the mould after 24 hours, transported
carefully without damage and is to be immersed in water in a curing tank of
specified temperature.

3.3.7 Consistency Testing (Slump & Flow)

The Contractor shall carry out slump test in accordance with BSEN 12350-2, Vebe
time shall be performed in accordance with BSEN 12350-3 and flow test shall be
performed in accordance with BSEN 12350-5 and degree of compactibility shall be in
accordance with BSEN 12350-4 at such frequency as the Engineer’s Representative
considers necessary to ensure that the workability and consistency of the concrete is
maintained in accordance with the specified mix or accepted mix design and the trial
mix.

3.3.8 Durability Tests

Concrete shall be tested for durability properties by undertaking all the tests where
appropriate, or directed by the Engineer, as given in Table 3.13.

Water absorption tests shall be carried out in the laboratory on 75 mm diameter cores
cut at an age of 24 to 28 days to enable the tests to be carried out between 28 and
32 days in accordance with BS 1881 Part 122.

Depth of water penetration test as described in (BS EN 12390: Part 8) shall be

carried out.

Durability tests for concrete are applicable on reinforced concrete.

3.3.9 Other Tests

a) Concrete shall be tested for Tensile Strength as per ASTM C496 and BSEN
12350-5: 2009 for flexure strength. When instructed by the Engineer, concrete
shall be tested for drying shrinkage and wetting expansion, for which 75 x 75 mm
prisms shall be prepared and tested in accordance with BS EN 12390-7-2000 ,
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BS 1881-121 :1983 , BS 1881-122 : 1983, BS 1881-209 : 1990 , BS 1881-2008 or

BS EN 772-2: 1998, BS EN 771-3:2003 . The maximum acceptable limits shall
be: as given in table 3.10

b) Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.

c) The air content of the concrete shall be determined (BS EN 12350-7:2000) for
each batch produced until consistency has been achieved, when batches may be
tested. The maximum value shall not exceed 2%.

d) Compaction factor, slump, Vebe or other workability tests shall be carried out as
required during concreting or permanent works to control workability at the
batching plant and at the site of the pour. The degree of workability shall be as for
trial mixes; permitted tolerances shall be in accordance with BS 8500 – 1 & 2.

e) For new proposals to use a continuing source, such as a ready mix concrete
supplier, the suitability of the proposed mix shall be tested by preparing 2
separate batches on each of two days from the Plant with cement and aggregates
known from past records of the suppliers of the materials to be typical of those
specified and tested to demonstrate compliance with the strength, durability and
workability requirements of this Specification. The specified water cement ratio of
the both trial batches shall not exceed when their workability is the same as that
which is proposed to be used in the work.

3.3.10 Method Statements

Method statements shall be prepared for each grade and type of concrete in the
contract and shall include: -

a) Definition of the method of design of the mix, by reference to a recognized

documented design method. Designed aggregate proportions shall be based on
measured and not assumed relative densities.

b) Proposed mix proportions including any proposed admixtures and, for new
batching installations, results of preliminary batch testing.

c) Results of testing of trial mixes to demonstrate that the proposed mix complies
with the strength and workability requirements of this Specification.

Method statements shall be approved before any concrete is placed and any
alteration in the source or quality or proportioning of any of the materials in the mix
will necessitate a new method statement.

3.3.11 Prescribed Mixes for Minor Works

Prescribed mixes shall only be used with the Engineer’s agreement and where
isolated quantities of less than one cubic metre are required. They shall comply with
Table 3.12 and be either site batched or supplied dry in bags ready for mixing with a
set volume of water. Concrete shall not be hand mixed.
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Table 3.12 Prescribed Concrete Mixes

Grade Nominal Fine Coarse Cement

Maximum Aggregate Aggregate Content
Aggregate Size Content Content
kg/m³
mm kg/m³ kg/m³

C30/20 20 650 1150 450

P

Weight requirements given are per cubic metre of compacted concrete. Aggregate
grading shall comply with clause 3.2.1.8 .

3.4 PLANT TRIALS WITH APPROVED CONCRETE MIX DESIGN

General

At least 35 days before commencement of concreting trial mixes shall be prepared

under full-scale site conditions or in batching plant and tested in accordance with BS
1881: 1983.

a) Samples of concrete incorporating the reinforcing details and formwork similar to

be used at site shall be cast and examine the peak temperature and the
temperature gradient during hardening, and after hardening by coring to assess
the quality of the mixes. Cores shall be taken in accordance with BS EN 12504-
1:2000.

b) The Plant trials must prove compliance of all criteria set forth, unless otherwise
accepted by the Engineer.

c) Plant Trials shall be mixed for the same time, by the same means and with the
same equipment which the Contractor proposes to use in the Works.

d) The proportions of cement, GGBS, Microsilica, aggregate, admixtures, P.P. fibre

and water shall be carefully determined by weight to correspond with the
Contractor’s approved mix proportions.

e) Contractor shall make three separate batches in three different days for each
class of concrete mix, unless otherwise approved by the Engineer.

(i) Each batch on each day shall be not less than 3.0m³ of concrete, unless
otherwise accepted by the Engineer.

(ii) Required no. of test cubes shall be made from each batch for conducting
the relevant strength and durability tests.

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(iii) Methods of making and curing cubes shall be in accordance with BS EN

12390-1 & 2 :2000 respectively and as follows:

 Cubes shall be stored in insulated boxes with identification marks until

removed from the moulds.

f) The slump and temperature of each batch during each plant trial shall be
measured and recorded, by the method described in relevant BS standards.

g) Further trial mixes shall be made if the range (the maximum minus the minimum
of the three cube strength results in any batch) exceeds 15% of the average of
that batch, or if the range of the three batch averages exceeds 20% of the overall
average of the batches.

h) The mixes of each batch shall be tested to determine the following properties:

(i) Bleeding in accordance with ASTM C232 : 1999

(ii) Air content if applicable BS 12350 : P7 : 2000

(iii) Free water/cement ratio BS 1881

(iv) Compressive strength of concrete: BS EN 12390-3:2002

(v) Tensile strength in accordance with BS EN 12390-6:2006 and BS EN

12390-5 :2000. Splitting tensile strength of concrete cylinder shall be in
accordance with ASTM C 496: 1996. Flexural strength of concrete prism in
accordance with BS EN 12390 : P5

(vi) Total sulphate & Chloride content in the mix as specified in Table 3.3 &
Table 3-9

(vii) Water absorption of concrete: BS 1881: P122.

(viii) Durability tests as specified.

(ix) Initial setting time of concrete.

The average 28-days Governing Compressive Strength of Concrete Cubes

of the three trial mixes shall not be less than the target designed mean
strength, and the results of the above tests shall be acceptable before the
mix is approved. Otherwise the mix shall be re-designed.

i) The engineer will review the Contractor’s trial-mixes, verify the test cubes strength
results at seven (7) and twenty-eight (28) days and the durability test results. The
Engineer will then determine which of the most suitable trial mixes shall be used
for the work. If none of the trial mixes for a class of concrete meets the
Specification, the Engineer will direct the Contractor to prepare additional trial-
mixes. No class of concrete shall be prepared or placed until its job-mix
proportions have been approved by the Engineer.

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j) The approval of the job-mix proportions by the Engineer of his assistance to the
Contractor in establishing those proportion, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements of these
Specifications.

k) The Engineer may also require practical tests to be made on the Site by filling trial
moulds to confirm the suitability of the mix for the works, the type of plant used for
mixing, the method of compaction used, and the formwork face intended for use
in the works and the temperature gradient of the mix.

l) All costs connected with the preparations of trial-mixes tests and the design of the
job-mixes shall be borne by the Contractor.

Trial Slabs

m) For grades C40, C50 and C60 at least one reinforced horizontal slab measuring
1.0m x 1.0m x 0.2m and one reinforced wall section measuring 1.0m x 1.0m x
0.2m shall be cast utilizing the same placement and curing methods as proposed
for the works.

n) Each slab shall be sampled and tested for RCP values.

o) Each sampling shall consist of three 100mm dia. Cores of suitable length for RCP
testing.

(i) A cover meter shall be utilised to locate the rebars to avoid rebar in the
core.

(ii) The cores will be given to the Engineer for delivery to an independent
laboratory of the Engineer’s choice.

p) The cores shall be promptly tested for RCP values and the results promptly given
to the Engineer.

q) The average RCP value from the cores taken from trial slabs shall not exceed the
specified value given in Table 3.13.

r) All associated costs for coring and testing shall also be borne by the Contractor.

s) Contractor shall only use the approved mix of each grade of concrete in the
Works.

t) If at any time during the construction of the Works, the source of cement, GGBS,
Microsilica, aggregate, admixture or mix proportions are changed, the concrete
shall be rejected /or new trial mixes shall be made, tested and approved for use.

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3.4.1 Quality Control

3.4.1.1 General

a) The Contractor is to employ a laboratory technician at batching plant and at site

and install on site a testing laboratory approved by the Engineer to perform the
workability tests, making concrete cubes and cylinders for the testing described in
this specification.

b) Sampling and testing for quality control of the placement of concrete shall include
the following as directed by the Engineer.

3.4.1.2 Test Cubes

Cubes shall be manufactured in an on-site laboratory, specially equipped for the

purpose, in controlled conditions. They shall be made, cures, stored, transported and
tested to BS EN 12390-1, 2 & 3: 2000, BSEN 12390-7. The method of compacting
cubes shall be an approved method of hand compaction or either using a vibrating
table in the laboratory or 25 mm vibrating poker on site.

3.4.1.3 Sampling Cubes

a) A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each day.
The standard deviation shall be calculated from at least 40 individual cube results
each representing separate batches of similar concrete produced by the same
plant under the same supervision. The current margin for the plant shall be thus
established as 1.64 times the standard deviation.

b) Thereafter one sample shall be taken at random for each class of concrete in
accordance with Table 3.15 of the Specification. A quality analysis of concrete
cubes of minimum 100 batch results shall be used in assessing whether the
moving strength of concrete is being maintained at a sufficient level to comply
with specification requirements.

c) It is then possible to form an estimate of the future distribution of results. Should

these show greater variability as time goes on, due to various factors then the
increased variability shall be investigated.

d) In addition to the above requirement, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of a
single pour.

e) From each sample three cubes shall be made for testing at 28 days and three for
testing at 7 days for control purposes.

f) Six cylinder samples shall also be taken to determine the spilt tensile strength of
the concrete 3 at 7 days and 3 at 28 days, as specified in ASTM C496: 1996.
These samples shall be taken from every 100 batches, but at least once a week

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during concreting operations, and shall coincide with samples taken for test
cubes.

g) The frequency of sampling may require to be varied as directed by the Engineer.

h) The procedures shall be repeated when materials or design mixes are changed.

3.4.1.4 Cube Strength Results

a) Concrete production results will be acceptable if:

(i) The average strength determined at the age of 28 days from a sample of
three or more cube test results exceed the specified CCS by 0.5 times the
current margin,

(ii) No individual result of the sample is less than that specified CCS minus 4
N/m m²),

(iii) Number of individual results in the sample below the specified CCS is not
more than one.

b) If the above criteria are not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate:

(i) Cutting and testing cores from placed concrete.

(ii) Non-destructive testing of placed concrete

(iii) Load-testing relevant structural units.

(iv) Cutting out and replacing defective concrete.

c) If the range of individual cube strengths made from the same sample exceeds
15% of the mean, then the method of making, curing and testing cubes shall be
checked. In the event of a sample having a range exceeding 20%, then the result
shall be unacceptable and the Engineer may order any of the following actions:

(i) Changing the mix.

(ii) Improving quality control

(iii) Cutting and testing cores from placed concrete.

(iv) Non-destructive testing of placed concrete.

d) In the event of cutting and testing of cores are required, the Contractor shall cut
cores from approved locations and test them to BS 1881 or by BS 6089. The
acceptance criteria shall be as specified in BS 6089.

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3.4.1.5 Durability Tests

a) Concrete shall be tested for durability properties by undertaking absorption and

permeability tests where appropriate, or directed by the Engineer, as directed
below:

b) Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out between
28 and 32 days in accordance with BS 1881 Part 122: 2011.

c) Effective permeability tests in accordance with the method described in BS EN

12390 Part 8: 2009 shall be carried out. The maximum acceptable penetration at
seven days and the maximum acceptable penetration at 28 days shall be as
given in Table 3-13.

d) Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried out.

3.4.1.6 Other Tests

a) When instructed by the Engineer concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and tested
in accordance with BS EN 12390-7-2000 , BS 1881-121 :1983 , BS 1881-122 :
1983, BS 1881-209 : 1990 , BS 1881-2008 or BS EN 772-2: 1998, BS EN 771-
3:2003. The maximum acceptable limits shall be as given in Table 3-13.

b) Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to curing and to check testing and sampling
errors.

c) The air content of air-entrained concrete shall be determined (ASTM C231) for
each batch produced until consistency has been achieved, when batches may be
tested. The maximum value shall not exceed 2%.

d) Compaction factor, slump, vebe or other workability tests shall be carried out as
required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree for workability shall be as for the
trial mixes; or as given in Table 3.12.

3.4.1.7 Documentation

a) A summary of all concrete cube results at 7 days and 28 days, histogram and
quality analysis chart showing the moving average, mean strength distribution
and the standard deviation of concrete strength shall be submitted on a monthly
basis.

b) The temperature differential chart of each concrete pour.

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Table 3.13 Concrete - Durability and other Performance Requirements

Sr. Specified Concrete Area of Use Exposure Method CCS at Chloride Water Initial surface 30 min Max Max Surface
Concrete Grade Classes of 28 days permeabili permeability absorption to water drying wetting Tensile
Class to BS placing (Mpa) ty to ASTM to BSEN BS1881 absorpti shrinkag Expansion Strengt
8500-1 12390:P8:200 (Part5) / Part on to BS e to BS to BS h
2002 & C-1202 9 208 (m1/ 1882 1881 : 1881: BS1881
Table A-1 (Coulombs m²/Sec@30 Part 122 P5 1970 1970: P5 : Part
to A-5 of ) min. (%) Test (5) Test: (5) or 207:
BSEN or BS BS 6073
206-1 6073: P1 Part 1 1992
App: D App: D

1. PC-BL C25/20 Blinding Crane N/A N/A N/A N/A N/A N/A N/A
SRC or Pump

2. PC-UR C30/20 Mass Crane N/A N/A N/A N/A N/A N/A N/A
SRC Concrete or Pump
including
minor RCC
structures

3. PC-GR C35/10 Granolithic Crane N/A N/A N/A N/A N/A N/A N/A
SRC concrete or Pump

4. * RC-S/F C40/20 Water Crane 1000 12mm; 8mm @7days=0.03 1% 0.05 0.03 3.0 MPa
SRC retaining or Pump
RCC/WS/F structures @7days @28
@28days days=0.02

5. * RCC/PU/F C50/20 Pre-cast units Crane 1200 15mm; @7days=0.03 1.5% 0.05 0.03 3.0 Mpa

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Sr. Specified Concrete Area of Use Exposure Method CCS at Chloride Water Initial surface 30 min Max Max Surface
Concrete Grade Classes of 28 days permeabili permeability absorption to water drying wetting Tensile
Class to BS placing (Mpa) ty to ASTM to BSEN BS1881 absorpti shrinkag Expansion Strengt
8500-1 12390:P8:200 (Part5) / Part on to BS e to BS to BS h
2002 & C-1202 9 208 (m1/ 1882 1881 : 1881: BS1881
Table A-1 (Coulombs m²/Sec@30 Part 122 P5 1970 1970: P5 : Part
to A-5 of ) min. (%) Test (5) Test: (5) or 207:
BSEN or BS BS 6073
206-1 6073: P1 Part 1 1992
App: D App: D

SRC , or Pump 10mm @28

days=0.02
@7days
@28days

6. * S.C.C C60/20 In-situ piling Crane 1500 15mm; @7days=0.03 1.5% N/A N/A N/A
OPC / SRC works or Pump 10mm
@28
@7days days=0.02
@28days

7. U.W.C C40/20 Under-water Crane N/A N/A N/A 1.5% N/A N/A N/A
OPC/ SRC concrete or Pump

8. PC - BR C40/10 Precast bricks Crane N/A N/A N/A 2.0% N/A N/A N/A
OPC or Pump

9. * RCC/AG/F C40/20 Building Crane 1200 15mm; @7days=0.03 1.5% 0.05 0.03 3.0 MPa
OPC structures or Pump 10mm
@28
days=0.02

* Note: Durability tests for concrete are applicable only to reinforced concrete.
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3.4.2 Minimum Routine Concrete Testing

3.4.2.1 General

Under the supervision and direction of the Engineer, the Contractor shall perform all
tests as shown in Table 3.14 unless otherwise instructed by the Engineer.

Table 3.14 - Frequency of Testing for Fresh and Hardened Concrete Sampled
from Site

Minimum Frequency
Test
C25 C 40 and Above

Temperature As directed by the Each load

Engineer

Concrete Slump and Every 25m³ Each load (flow test applicable
flow only for self compacting
concrete)

Visual Examination of As directed by the Each load

Aggregates (after Engineer
washing)

Concrete density & 6 cubes, minimum once As given in Table 3.15

Compressive Strength per day

Concrete unit weight – Every 100m³

(wet) & WCR

Split tensile strength – From every 100 batches

Flexural Strength – From every 100 batches

Concrete bleeding – From every 100 batches

Water permeability – Every 500m³/ As directed by the

Engineer

ISAT – Every 300m³ or as directed by

the Engineer

Rapid chloride – Every 250m³ or as directed by

penetration (RCP) the Engineer

SO3 and Cl contents – Every 250m³ or as directed by

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Minimum Frequency
Test
C25 C 40 and Above

the Engineer

Concrete temperature – For each concrete pour of all

difference between water retaining structures
core & the surface

3.4.2.2 Minimum Test Requirements for Concrete

One set of 6 cubes for each class of concrete and for each particular application
represent a maximum quantity of concrete as shown in Table 3-15. The point of
sampling of fresh concrete shall be at delivery into the construction unless otherwise
directed by the Engineer. Each set of cubes shall be made from a separate batch.

Table 3.15 Sampling Rates for making Cubes

Sr. Type of Structure Sampling to Represent a

Volume of m³ up to

1 Critical structures e.g. masts, cantilevers, 10

columns

2 Intermediate structures e.g. beams, slabs & 20

walls

3 Heavy concrete construction e.g. solid rafts 50 or as agreed on site

& mass fill concrete

3.4.2.3 Routine Test Cubes & Cylinders

a) Test cubes shall be randomly taken from the concrete which is being used in the
work and prepared in accordance to the relevant standard and the following
provisions, unless otherwise approved by the Engineer.

(i) All cubes shall be made at the point of delivery and all cubes for each set
must be from the same load (transit mixer truck)

(ii) Use approved cube moulds of the same type and manufacture for making
all test specimens.

(iii) All cubes shall be kept in closed insulated boxes for initial curing until
removed from the mould and placed directly in a suitable curing tank.
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(iv) Six cubes (150 mm) shall be made for density and compressive strength
testing.

(v) Six cubes (150mm) shall be made for water permeability testing.

(vi) Six cubes (150mm) shall be made for RCP testing.

(vii) Each grade of cubes shall be numbered consecutively throughout the work
and marked with the date.

(viii) Six cylinders 150mm dia & 300 mm long shall be made for tensile splitting
strength.

b) For compressive strength and density, test 3 cubes at 7 days and 3 at 28 days.

c) The Mean of 3 cube strength results shall be taken as the test result.

d) For Water Permeability, test 3 cubes at 7 days and 3 cubes at 28 days.

e) For Rapid Chloride Penetration, test 3 cubes at 7 days and 3 cubes at 28 days.

f) For Tensile Splitting strength, 3 cylinders at 7 days & 3 cylinders at 28 days.

g) If the test cubes fail to meet the requirements of Spec Cl. 3.4.1.4 & Table 3.13
then the following action shall be taken by the Contractor.

(i) Suspend concreting operation and do not proceed further without

Engineer’s approval.

(ii) Take test cores in accordance with BS EN 12504-1:2000, from the suspect
concrete and test as directed by the Engineer. Cylindrical core specimens of
150 mm nominal diameter shall be cut perpendicular to the face of the
hardened concrete in the Works for the purpose of examination and testing.

(iii) Prior to preparation for testing, specimen shall be made available for
examination by the Engineer

(iv) If the crushing strength of the specimen tested in accordance with BS EN

12504-1:2000 is less than the minimum crushing strength specified or if , in
the opinion of the Engineer, the concrete fails to meet the specified
requirements in other respects, the concrete in that part of the Work will be
considered not to comply with the specified requirements.

3.4.3 Routine concrete coring and testing

a) From every 500 cubic meters of concrete cast in water retaining structures the
Engineer shall designate a structure (or portions of a structure) to be core
sampled and tested for RCP values.

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b) Each sampling shall consist of three 100mm dia. Cores of suitable length for RCP
testing. Extreme care shall be taken while coring and be taken without cutting the
reinforcement.

(i) The Contractor shall provide a cover meter to locate the rebars.

(ii) Core locations shall be marked by the Engineer.

(iii) The cores will be given to the Engineer for delivery to an independent
laboratory of the Engineer’s choice.

c) The cores shall be promptly tested for RCP values and the results promptly given
to the Engineer.

d) The average value shall not be more than that given in Table 3.13

e) All associated costs for coring and testing, refilling core holes shall be borne by
the Contractor.

3.4.4 Test on Hardened Concrete

The following tests are to be conducted on hardened concrete as directed by the

Engineer.

a) Analysis of hardened concrete in accordance with BS 1881: P 124 to determine

the cement content, aggregate grading, aggregate content, water content, water
cement ratio, type of cement, sulphate and chloride content and alkali content in
the concrete.

b) Non- destructive tests as referred in BS 1881: Part 201.

c) Core test in accordance with BS 6089.

3.4.5 Non – Compliant Concrete

a) Concrete shall be considered to be non-complaint if any of the following

conditions are found to exist.

(i) Compressive strength results less than those specified value.

(ii) Unapproved mix is utilised.

(iii) Approved mix proportions or materials have been changed.

(iv) Sulphate and chloride content in excess of those specified values.

(v) Water/cement ratio in excess of those specified.

(vi) Cementitious material contents and the proportion less than those specified.

(vii) GGBS content in excess those specified.

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(viii) Microsilica content in excess those specified.

(ix) Cube results for, water permeability or RCP in excess of those specified.

(x) Mean core results for RCP values taken from water retaining & other
structures in excess of that specified in Table 3.13.

(xi) Concrete that fails to meet one or more requirements of the specification.

b) Any part of structures containing non-complaint concrete shall be completely

broken out and removed, unless otherwise accepted by the Engineer.

c) The Engineer’s decision shall be final in all aspects related to non-complaint

concrete.

d) Any additional costs associated with non-complaint concrete shall be at

Contractor’s expense.

3.5 CONCRETE DESIGN LIMITS

3.5.1 Limits of Specifications

The following will be designated by the Engineer within the limits of the
Specifications:

a) Limiting composition and properties of concrete as specified in Table A11 to A20

of BS 8500-1:2006.

b) The minimum cement content in kg per cubic metre of concrete

c) The alkali content in the concrete mix

d) The fineness of cement in m²/kg

e) The maximum allowable water/cement ratio including surface moisture, but

excluding water absorbed by the aggregates.

f) Type of aggregate and cement

g) Slump or slumps and the concrete temperature designated at the point of delivery

h) The peak temperature of concrete within the pour

i) Changes requested by the Contractor in mix proportioning previously approved

shall be made only with the agreement of the Engineer.

j) The maximum temperature differential within a single concrete pour

k) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as directed by
the Engineer. No additional payment shall be made for the added cement.

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l) Initial surface absorption of concrete

m) Failure of the mixed concrete to meet specifications as determined by the

Engineer will be grounds for the Engineer to reject the concrete.

n) Surface hardness and tensile strength of hardened concrete.

o) Bleeding limitations when tested in accordance with ASTM C 232.

3.5.2 Measurement of Ingredients

a) The aggregates for the concrete shall be measured by weight but measurement
by volume may be allowed in special circumstances with the approval of the
Engineer.

b) When the aggregates are to be measured by volume, the proportions of fine and
coarse aggregates shall be measured in well-constructed gauge boxes of
dimensions approved by the Engineer’s Representative to guarantee that whole
multiples of such gauge boxes will ensure the use of one more whole bags or
containers of cement and the capacity of the concrete mixer shall be such as to
ensure that no splitting of cement bags or containers is required. Gauge boxes
shall be properly filled and struck off level, addition of fine aggregates to allow for
bulking due to moisture content being made as required.

c) An efficient water measuring device shall be fitted to each concrete mixer

d) Any cement container shall be such as to contain an accurately weighed amount

of cement.

3.5.3 Making Concrete

3.5.3.1 General

a) The weighting and water dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in BS
1305 and checked against accurate weights when required by the Engineer.

b) The mass of the fine and coarse aggregates shall be adjusted to allow for the free
water contained in them. The water to be added to the mix shall be reduced by
the quantity of free water contained in the fine and coarse aggregates.

Table 3.16 - Batching Accuracy

Material Accuracy

Cement

a. Above 30% scale capacity 1%

b. Below 30% scale capacity -0- +4%

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Material Accuracy

Aggregates

a. Individual batches 2%

b. Cumulative weight, % of the required cumulative 1%

weight
3%
1. Above 30% capacity

2. Below 30% scale capacity

Water

a. Added by weight or volume 1%

b. Total water (including any wash water) 3%

Admixtures

a. By weight or volume 3%

c) Any admixture which may be used shall be measured separately in calibrated and
transparent dispensers which are easily visible to the operator, unless otherwise
approved by the Engineer.

d) Admixture shall be added to the mixture with the water preferably in a single shot.

e) Dispenser shall be capable of dispensing the agent in quantities varying by not

more than 3% from the quantities required and in such manner to ensure
uniform distribution of the agent throughout the batch during the time of mixing.

(i) Capability of the dispenser to achieve the required dosing and delivery
requirements shall be demonstrated to the Engineer.

(ii) Shall be checked each day before concrete mixing commences.

f) Contractor shall provide weights, containers and equipment necessary for testing
the accuracy of the weighing system, water-measuring system and admixture
dispenser.

3.5.4 Mixing Concrete at Batching Plant and the Procedure to deliver the Concrete to
Site

a) All concrete batching shall comply with the following requirements, unless
otherwise approved by the Engineer.

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b) All concrete shall be manufactured in a fully automated, computer controlled

batching plant.

c) The plant shall be equipped with a suitable water chiller along with sufficient
insulated storage and flake ice making facility with automatic feed to ensure
concrete temperatures are maintained within specified limits.

d) Dry mixing or mixing in the truck drum is not allowed.

e) Automatic moisture control probes set in the hoppers shall be used to

continuously determine the moisture content of any washed or sprinkled
aggregates.

f) Mixing and transporting of concrete shall be in accordance with the requirements

for ready mixed concrete specified in BS 8500 or ASTM C94 except as modified
hereunder or as directed by the Engineer.

g) Concrete shall be transported from the mixer to the point of placing as rapidly as
practicable in approved agitators.

h) Concrete shall be mixed in batches with suitable equipment capable of combining

the aggregates, cement, GGBS, Microsilica, water proof powder and water
(including admixtures, if any) into a mixture of uniform colour and consistency and
of discharging the mixture without segregation.

i) Amount of concrete mixed in anyone batch shall not exceed the rated capacity of
the mixer.

j) Manufacturer's rated capacity shall be displayed on the mixer in terms of the

volume of mixed concrete.

k) The mixing time shall not be less than that used by the mixer manufacturer in
assessing its performance or as determined by trials carried out in the presence
of Engineer.

l) All materials from the previous batch shall be removed before materials for a
fresh batch enter the drum.

m) If work is suspended, including any periods exceeding twenty minutes, the mixers
and all handling plant shall be washed with clean water.

n) All mixing and batching equipment shall be maintained free of set concrete or
cement and shall be clean before commencing mixing.

o) The natural moisture contents of the aggregates shall be determined before the
commencement of each day's concreting and at such intervals during each day
as may be necessary.

p) The amount of water added to each mix shall be adjusted to maintain the
approved free water/cementitious ratio of the mixed concrete.
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q) Limitation of water/cementitious ratio - No concrete shall exceed the

water/cementitious ratios as given in the approved mix design.

r) Whenever required by the Engineer free water/cement ratio shall be determined

in an approved independent laboratory on concrete samples cored from locations
selected by Engineer. The Contractor shall bear all the costs.

s) In no circumstances shall the consistency of the concrete be such as to permit a

separation of the aggregate from the mortar during handling.

t) Excess water shall not be permitted and any batch containing such excess will be
rejected.

u) Manufacturing and delivery resources of the proposed supplier shall be adequate

to ensure proper and timely placement and shall be subject to the approval of the
Engineer.

v) Each load shall be accompanied by a batch ticket containing at least the following
information:

(i) Name of Ready Mix Co.

(ii) Batch Ticket No. and serial No. of computer printout.

(iii) Location of Plant

(iv) Name of Customer

(v) Date

(vi) Concrete Grade

(vii) Type and Manufacturer of Cement, GGBS and Microsilica

(viii) Quantity of Concrete in the Transit Mixer (m³)

(ix) Total Quantity Ordered (m³)

(x) Truck Identification Number

(xi) Signature of Ready Mix Representative

(xii) Tel. No. of Technical Manager

(xiii) Type and Brand of each Admixture per batch (litres)

(xiv) Type of all Aggregates

(xv) Enough space to write comments by the Site Staff

w) Each load shall be accompanied by a computer controlled non-simulated printout

listing at least the following:

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(i) Name of Ready Mix Co.

(ii) Serial No. of computer printout.

(iii) Concrete Grade

(iv) Mix Identification Name or Number

(v) Confirmation of non-simulated print out

(vi) Time (hr: min.) when water is first added to the mix

(vii) Mixing Time (sec.)

(viii) Target Quantities

(ix) Individual Weight of Aggregates (per batch) in kg.

(x) Cumulative quantity of each ingredient per truck (or load)

(xi) Weight of Cement per Batch (kg)

(xii) Weight of GGBS per Batch (kg)

(xiii) Weight of Microsilica per Batch (kg)

(xiv) Weight of Pozzolanic Materials per Batch (kg)

(xv) Quantity of each admixtures (per batch) in litres

(xvi) Quantity of Flake Ice per Batch (kg)

(xvii) Moisture content of each Aggregate (%)

(xviii) Water Absorption of each Aggregate (%)

(xix) Total Quantity of Water, added per Batch (kg)

(xx) Total Quantity of Moisture in each Batch

(xxi) Variation of individual Batch Quantities, of all Materials per Batch (% errors)

(xxii) Total Quantity of Water absorbed by each aggregate in a Batch

(xxiii) Actual free Water / Cementitious ratio total variation of

(xxiv) accumulated individual Ingredients per Batch (% error)

(xxv) Concrete slump at plant

(xxvi) Concrete temperature at plant

x) A copy of the batch ticket and computer printout shall be given to the Engineer's
site representative upon delivery for each and every truck.

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y) The print out and batch ticket may be combined provided the minimum
information is included. Loads may be rejected for insufficient information at the
Engineer's discretion.

z) Unless approved otherwise in advance of batching, all concrete of a particular mix

for any one day's pour, or for each structure shall be from the same batching plant
with the same type of materials.

aa) Concrete mixes containing aggregate and cement from different sources shall not
be permitted in a single structure, unless otherwise approved by the Engineer.

bb) No water shall be added into the transit mixer during transport of concrete to the
site or at the site.

cc) Each mixer truck shall arrive at the job site with its water container full.

dd) In the event that water container is not full or field test results are outside the
acceptable limit, the load shall be rejected.

ee) Except for grade C25 concrete temperature in each load shall be recorded at the
point of discharge.

ff) Perform slump tests in accordance with BS 1881 at plant and at site for each load
delivered to site, except of grade C25 which shall be at the Engineer's decision.

gg) Concrete placement shall proceed only following satisfactory verification of slump
and concrete temperature or other specified field test results.

hh) The Contractor shall provide at no extra cost, all facilities and services of
technician, including suitable transport, acceptable to the Engineer, for the sole
use of Engineers staff or persons authorised by him to monitor the concrete
batching, mixing, sampling and testing.

3.5.5 Waterproof Concrete

Concrete for all water retaining structures shall be of water proof concrete as
described below.

a) Waterproof concrete shall consist of structural concrete as specified herein and

with the addition of an approved waterproofing additive. This shall be mixed in
accordance with the manufacturer’s instructions. Supervision from manufacturer’s
technical representative or approved applicator shall also be provided.

b) Contractor’s attention is drawn to the special care required for casting water
retaining structures. These are all designed to BS EN 1992-3:2006 and the
contractor’s attention is to ensure that the workmanship and curing are as per BS
EN 1992-3:2006.

c) All water retaining concrete structures will be water tested in accordance with BS
EN 1992-3:2006 and should comply the requirements specified therein.
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d) The contractor shall take full responsibility for ensuring that the resulting
construction is completely watertight and free from penetration of moisture without
the application of membrane. Should there be any leakage or damp patches in
the finished work after water test, the affected works shall be rectified to the
Engineer’s approval at the Contractor’s cost.

e) Water bars shall be provided in all construction joints and the type of water bar
will be as specified or to the approval of the Engineer. All water bars will be joined
by welding strictly in accordance with the manufacturer’s recommendations and
all multiple joints and special intersections shall be manufactured by the supplier.

f) All services holes cast in shall incorporate sleeves with puddle flanges, and
temporary openings for services should incorporate water bars.

g) The maximum allowable drying shrinkage of aggregate shall be 0.045%

h) Care shall be taken at all times to ensure that water bars are not perforated or
damaged in any way and the concrete shall be carefully placed and compacted
around the water bars to ensure void free impervious concrete.

i) All kickers or starter plinths to walls (if used) on the periphery of the water tight
construction shall be cast monolithically with the base and shall be minimum
height as shown in the approved drawing.

j) The formwork shall comply with this Specification and in addition any bolt or
fastening embedded in or passing through the concrete shall be to the water
tightness of the structure. Ties passing through liquid retaining structure shall be
approved by the Engineer and shall be of a type that will not form a potential
drainage path through the concrete and will permit their removal or partial
removal without damage to the concrete. All ties shall incorporate an anti-torsion
bar or other device to ensure that they do not twist on striking. They shall be
degreased before being placed in position and the use of grease on the outside of
any end-former, later removed from the concrete, will not be allowed. The ties
shall not foul or touch the reinforcement. The use of through bolts will not be
permitted. The surface of the concrete in all tie bolts holes shall be roughened by
mechanical wire brushing or similar means after which the hole shall be sealed in
an agreed manner with an approved patent expanding mortar or filling compound.

k) Special attention shall be given to the elimination of shrinkage or thermal

cracking. The size of any bay or slab or wall and sequence of pouring shall be
such as to minimise cracking. Where box-outs are permitted to take the passage
of pipes or ducts through concrete structures, the opening so formed shall be
grouted up using the same concrete mix as in the main structure after fixing of the
pipework. Where directed by the Engineer the sides of the opening formed shall
be scabbled prior to fixing of the equipment. Shuttering shall be provided as
required.

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l) Slotted inserts or sockets cast into the structural concrete shall be provided for all
fixing including services. The cutting of holes in watertight concrete is strictly
prohibited. Where box-outs are permitted below water level, the shuttering shall
be provided with joggle joints and the sides of the opening formed shall be
scabbled prior to fixing of the equipment. Where ordered by the Engineer, the
box-out shuttering shall include a water bar and the concrete joint at the water
face shall be provided with an approved sealer in a pre-formed sealing chase.

m) For structural design purposes the horizontal reinforcement should be completely

continuous at vertical joints.

n) A central water stop shall be used together with sealing compounds on both faces
and a sealing strip as specified in Clause 3.13.

o) Where roofs and walls are monolithic, movement joints in roofs shall correspond
with those in walls are to be provided to avoid possibility of cracking.

3.5.6 Self-Compacting Concrete

3.5.6.1 General

The concrete used for piling works or having congested reinforcement shall generally
be with self-compacting concrete which is able to flow under its own weight, even in
the presence of dense reinforcement, without the need for any vibration, while
maintaining homogeneity and avoiding segregation.

3.5.6.2 Concrete Mixes

a) Normal Designed Mix for Piling works

(i) To the relevant clauses of BS 5328-2, BS 8500 and BS EN 206-1:2000.

(ii) Grade: C60 Self Compacting concrete

(iii) Nominal maximum size of aggregate : 20mm

(iv) Aggregates(s):

1. Coarse: Coarse aggregate content shall be between 28 to 35% of the

mix volume to BS EN 12620:2002 + A1:2008 .

2. Sand: The sand content shall be minimum 38% of the mix, to BS EN

12620:2002 + A1:2008.

3. Special requirements: maximum dry shrinkage when tested to BS EN

1367-4:1998 0.05%

(v) Cement: (OPC)

(vi) Minimum cement content : 400kg/m³

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(vii) Maximum free water cement ratio: 0.35

(viii) Maximum cement content: 450 kg/m³

(ix) Admixtures: Refers to clause 3.2.2.3 (c&g)

(x) Cement replacement: condensed silica fume conforming to ASTM C 1240,

maximum weight 7% of the total cementitious materials.

(xi) For concrete containing Portland cement the maximum total percentage of
chloride ion by mass of cement: 0.2%

(xii) The total content of acid soluble sulphate shall not exceed 3% by weight of
cement

(xiii) Rate of sampling for compressive strength testing: one sample per 10 m³ or
10 batches whichever represents the lesser volume, but not less than one
for each day of use.

(xiv) The alkali content (Na2O and K2O) of the concrete shall not exceed 3 kg/m³

(xv) Information to be provided by the producer: As BS 8500-1/2, BS EN 206-

1:2000 Clause 6.

3.5.6.3 Trial mixes:

a) The Contractor’s mix proposals for each mix require the Engineer’s approval.
Existing data provided as evidence of satisfactory previous performance shall
include the workability and water/cement ratio.

b) During production the Contractor shall inform the Engineer of all changes in
sources of materials or cement content.

c) Trial mixes shall be made initially as well as before any substantial change is
made. No changes shall be made without the Engineer’s approval.

3.5.6.4 Performance Testing of Trial Mixes:

The following testing shall be carried out at the trial mix design stage and periodically
during production to verify the mix design.

a) Consistency and segregation of self-compacting concrete

(i) The consistency shall be verified by slump flow using Abrams cone. The
acceptable range for this test is between 530 mm – 600 mm.

(ii) The proportions of the ingredients of the concrete, including the water, shall
be so chosen that the concrete will be workable enough to be fully
compacted and not be prone to segregation or bleeding.

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(iii) Segregation of aggregates in self-compacting concrete shall be verified

using the V-funnel test. The acceptable range for results is 6 to 10 seconds.

b) Bleeding

The bleeding test for self compacting concrete shall be performed in accordance
with ASTM C232-90 and shall indicate no bleeding of the concrete. Testing shall
be carried out on all trial mixes and on every 500m³ of concrete produced.

c) Durability Tests

The following tests shall be carried out on all trial mixes:

(i) Chloride permeability to ASTM C 1202 Maximum Charge Pass (Coulombs)

age 28 days

Self-compacting concrete 1,500

(ii) Water permeability to BSEN 12390: P8: 2009 Maximum Penetration (mm)
Age 28 days

Self-compacting concrete: 10 mm

(iii) Initial surface absorption to BS 1881 Part 208 Maximum ISAT at 28 days:
30 minute test

Self-compacting concrete: 0.02ml/ m²/sec

(iv) 30-minute absorption to BS 1881 Part 122: Maximum Penetration (mm) Age
28 days

Self-compacting concrete: 2%

d) Strength Tests

(i) For each mix of concrete the Contractor shall prepare three separate
batches of concrete using the materials which, have been approved and the
mixing plant which he proposes to use for the Permanent Works.

(ii) Six test cubes shall be cast from each batch.

(iii) The making, curing and testing of all test cubes shall comply with the
requirements of BS 1881. The consistency test of the concrete carried out in
accordance with BS 1881 shall be recorded for a range of mixing
temperatures and at various times after mixing. The mixing temperature
shall be temperature after the water has been added. Slump control graphs
shall be prepared for use on site.

(iv) Two cubes from each batch shall be tested for compressive strength at 7
days, three at 28 days and one cube shall be kept as spare.

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(v) The density of all cubes shall be determined before the cubes are crushed.

(vi) The strength of the mix shall be approved if the mean strength at 28days of
the set of none cubes from the mix (three cubes from each of the three
separate batches) exceeds the Characteristic Strength plus 11.5 N/m m².

3.5.7 Precast Concrete

3.5.7.1 General

The work included in this Section comprises furnishing all labour, equipment,
appliances and materials and performing all operations in connection with structural
precast concrete Work.

3.5.7.2 Quality Assurance

a) This Specification Section shall govern all structural precast concrete work for the
project except where more stringent or specialised requirements are indicated.

b) Precast concrete pipes are generally made with concrete surrounded GRP pipes
for micro-tunnelling. Pipe line systems shall be as conforming to design chemical
class DC-4 specified in CL 3.2 & Table ‘4a’ of BRE Digest No.01 Part 4: 2003.
Design guides shall be as specified in CL 3 of BRE Digest No.1, Part 4: 2003.

c) All work shall be performed to secure for the project homogeneous concrete
having the required strength, surface finish, materials, durability, and weathering
resistance, without planes of weakness or other structural defects, and free of
honeycombs, air pockets, voids, projections, offset of plane and other
defacements of concrete.

d) Be fully responsible for any defects or damage in the structure or building arising
from faulty materials or workmanship and the costs of remedial measures in order
to ensure that the completed work complies with the Contract Documents.

e) Base construction methodology on the construction indicated in the Contract

Documents.

f) No alternations or substitutions of the structural systems shown on the Drawings

are permitted unless otherwise specified.

g) Supervise and co-ordinate all phases of the structural precast concrete

construction process and be responsible for the complete manufacturing process.

(i) 1. All methods of manufacture and practices of handling raw materials and
manufactured concrete shall be reviewed by the Engineer prior to execution
of the structural precast concrete work.

h) Only materials of known quality shall be incorporated in the work.

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(i) 1. All materials shall be properly selected, reviewed and approved by the
Engineer before use and maintained during shipment, storage and use.

(ii) Construction systems and techniques shall be properly selected, reviewed

and approved by the Engineer before use and maintained throughout the
complete structural precast concrete construction phase.

(iii) Adequate spare equipment, parts, additional components and repair

facilities shall be available for all tools and equipment.

i) Regardless of approvals by the Engineer, the Contractor shall be responsible for

all materials and methods of structural precast concrete work.

If any work does not satisfy the Contract Documents the Contractor shall at no
additional cost to the Employer:

(i) implement removal, replacement or remedial work.

(ii) revise procedures or materials to prevent recurrence of unacceptable work.

3.5.7.3 Qualifications

a) Structural precast work shall be executed by an approved specialist Sub-

Contractor.

b) Contractor may execute this work himself if he can satisfy the Engineer that he
has sufficient experience and expertise in this field.

(i) Provide satisfactory evidence that his tradesmen and their supervisory
personnel engaged in such work have successful experience with work
comparable to that shown and specified.

(ii) Provide details of organised quality control and testing procedures.

3.5.7.4 Testing

a) Concrete shall be tested as specified in relevant sections.

b) Conduct load tests in accordance with BS EN 1992-1-1:2004 or as specified

separately before erection and also after erection.

(i) Casting of topping slab to substantiate the performance characteristics of

structural precast element so designated by the Engineer.

(ii) Review itinerary with the Engineer prior to testing.

(iii) Provide calibrated instrumentation for measuring and recording load,

deflection, stresses and strains.

c) The Engineer will evaluate the adequacy of the Contractor’s quality control.

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In addition to the requirements hereinafter specified under Paragraph “MIX

DESIGN”, the Contractor shall:

(i) Furnish labour required to facilitate testing.

(ii) Inform the Engineer with at least one day’s advance notice when concrete is
to be placed.

(iii) Provide storage facilities for concrete test cubes

(iv) Provide materials samples and access to materials as required for testing.

d) Be responsible for the expenses of testing or inspection resulting as a

consequence to the following:

(i) Work not evidencing compliance with this Specification.

(ii) Additional testing such as additional cubes for early breaks etc., for
construction purposes.

(iii) Testing to verify the adequacy of work done without prior notice, without
proper supervision, or contrary to standard construction practice.

(iv) Providing additional tests as requested by the Engineer.

e) Contractor shall station a qualified technician at the batching plant during the
entire time of batching and shall continuously test, inspect and report on the
following:

(i) The batching equipment and procedures.

(ii) The conformance of the materials (cement, aggregates, water and

admixtures) to the approved materials.

(iii) Correct dosage of admixtures as prescribed by the manufacturer are used.

(iv) The proportioning of the concrete.

(v) Mix transport equipment.

f) Should the batching plant be located more than 500 meters away from the site
offices, the Contractor shall provide suitable transport acceptable to the Engineer,
for the sole use of the Engineer’s staff.

g) Contractor shall station a qualified technician at the casting site to continuously

witness the test, inspect and report on the following:

(i) For each forty cubic meters of each different concrete type or portion
thereof cast per day, the following tests will be performed in accordance
with the applicable standards.

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1. Six strength tests using 150 x 150 x 150 mm cubes per BS 1881, made
from a mix selected at random.

a. Break three cubes at age 7 days and three cubes at age 28 days.

b. Additional test specimens may be cast for construction progress

control purposes.

2. Slump Tests :One per each batch of concrete as per BSEN 12350 –2.

3. Temperature Tests: Use thermometer calibrated to +/- 0.5% accuracy.

a. Immerse the thermometer probe into each concrete batch at the

time of placement.

b. Stabilized temperature of concrete shall be less than the specified

30C.

(ii) Check and verify conformance with Contract Documents and approved
shop drawings the following:

1. Reinforcing bars

2. Embedded items

3. Formwork

(iii) Check all openings and provisions for full co-ordination with all trades in the
Contracts as shown on approved shop drawings.

h) Contractor shall provide facilities and equipment for conducting of all tests
specified herein except for the strength test which should be carried out by an
approved independent testing agency.

i) Test specimens may be cured by immersion.

j) All welding of steel supports, anchorages, connections and attachment will be

visually inspected by the Engineer.

3.5.7.5 Quality Control

a) Contractor shall prepare and provide his quality control programme for structural
precast concrete work with particular attention to details, pre-checking processes,
procedures and close supervision.

(i) In order to assure that proper work is performed to prevent later corrective
actions, the Contractor shall provide at least one experienced supervisor full
time to provide quality control for structural precast concrete work.

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(ii) The assignment will not relieve the Contractor’s other quality control
personnel of their duties relative to the quality control of the structural
requirements and surface finish of the structural precast concrete work.

b) Contractor shall arrange for the training of his quality control personnel who will
perform quality control of structural precast concrete work. Training shall include
but is not limited to:

(i) Materials evaluation

(ii) Special mix design techniques.

(iii) Mix placement

(iv) Vibrator selection and use.

(v) Formwork details formwork protection.

(vi) Release agent use.

(vii) Reinforcing steel

(viii) Detailing and installation

(ix) Finishing equipment and techniques.

(x) Corrective procedures and protection of completed work

c) Contractor’s quality control personnel shall be responsible for verifying all details
necessary to produce the final structural design objectives.

d) Contractor’s quality control personnel shall also verify the quality of the structural
precast concrete work and guide the production of results which will be within
acceptable physical tolerances.

3.5.7.6 Pre-construction Meeting

a) Within a reasonable time prior to commencement of structural precast concrete

work, the Contractor shall schedule a pre-construction meeting at a mutually
agreeable time with the Engineer and his designated Representative. The
purpose of the meeting is to discuss design, materials, methods of work and
forming systems for structural precast concrete work.

b) Prior to this meeting, the Contractor shall submit to the Engineer the following all
pertinent information.

(i) Written procedural outlines.

(ii) Description of forming systems.

(iii) Brochures of proposed equipment.

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(iv) Sources of all materials.

(v) Characteristics of all materials.

(vi) The above information shall be received by the Engineer at least 30 days
prior to the pre-construction meeting.

c) During the pre-construction meeting the Contractor shall present an outline plan
for all concrete work to be accomplished and indicating special procedures
relative to the structural precast concrete work. The outline shall include:

(i) Reviews of sources of materials with a commentary on source.

(ii) Source variations during the course of the work.

(iii) Storage and use of materials.

(iv) Description of all equipment necessary for batching, mixing, conveying,

placing, forming, reinforcing, and compacting.

(v) Finishing of structural precast concrete.

3.5.7.7 Submittals

a) Manufacture’s Literature

Copies of manufacturer’s specification and installation instructions for each item

of proprietary material used, showing compliance with these Specifications.

b) Mill Certificates

Copies of manufacturer’s certificates of mill tests of all cement and reinforcing

steel.

c) Design Mixes

Copies of mix designs with support materials, as requires by Contract

Documents.

d) Product Design Criteria

Loadings for design:

(i) Initial handling and erection stresses.

(ii) All dead and live loads as specified on the Contract Drawings or as
required.

(iii) All other loads specified for member where they are applicable.

e) Product Design Calculations

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(i) The Design calculation shall be performed by a qualified Structural Engineer

experienced in precast concrete design.

(ii) Calculations for the design of any precast member shall be supported by a
statement explaining the principle of design and type of analysis adopted.

(iii) The influence of any member in achieving the overall stability of the
structure should be considered.

(iv) Any computer programmes used in the designs shall be fully described and
details of input and print out shall be presented in a manner which can be
readily understood.

1. Programme manuals and any instruction to programme users shall be

made available to the Engineer upon request.

2. Where any such programme cannot be demonstrated by the Contractor

to have been fully checked or where the Engineer considers it
necessary, the Contractor shall run such test examples as the Engineer
may choose, in order to verify the completeness and accuracy of the
programme.

(v) Design members exposed to the weather to provide for movement of

components without damage, failure of joint seals, undue stress on
fasteners or other detrimental effects, when subject to seasonal or cyclic
day/night temperature ranges.

(vi) Design system to accommodate construction tolerances, deflection of other

building structural members and clearance of intended openings.

(vii) Calculate structural properties of framing members in accordance with BS

8500 , BS EN 206-1:2000 and BS EN 1992-1-1:2004.

f) Shop Drawings

(i) Layout plans and detailed fabrication and placement drawings for each
structural precast element.

(ii) Shop drawings are to include the following information.

(iii) Size, grade, profile and dimensions of all materials used.

(iv) Connection and anchorage details.

(v) Lifting devices, locations and handling limitations.

(vi) Steel reinforcement details.

(vii) All openings, sleeves, inserts and other provisions in full co-ordination with
all trades in the Contract.

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(viii) Identification marks.

g) Erection Procedures

Detailed outline of sequence and methods of erection.

h) Fabrication Records

A record shall be kept for every piece of precast element produced showing the
following:

(i) Type and Number

(ii) Date of pour

(iii) Concrete test results

(iv) Ref. Shop drawing number

(v) Type and duration of curing

(vi) Date of delivery to site

(vii) Date of fixing in position

i) Test Reports

Copies of all testing and Inspection Reports.

3.5.7.8 Delivery, storage and Handling

a) Remove the structural precast elements from the form without damaging or over
stressing and store or place for transportation on a stable bed that will not allow
further distortion of the member.

b) Separate stacked members with suitable battens and bracing.

c) Mark each member with an identifying reference or piece mark and the date of
casting.

d) Transport the structural precast element with sufficient battens, bracing, and
supports so as not to over-stress by vibration or impact loadings.

e) Transport, store and handle structural precast units in a manner to avoid undue
strains, hair cracks, staining, or other damage.

f) Deliver units from casting site to project site in accordance with schedule and
proper setting sequence.

g) Store structural precast units free of the ground and protected from wind or rain
splashes.

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h) Cover units, secure covers firmly, and protected the units from dust, dirt or other
staining materials.

i) During fabrication, construction and after erection, protect castings to avoid

possibility of any damage.

3.5.7.9 Design Loadings, Actions & Structural Members Selection

Precast elements shall be designed to withstand all loading conditions against which
strength and serviceability must be measured.

a) Vertical loads shall include own weight of precast elements, floor covering and
live loads indicated on the contract drawings.

b) Wind pressure shall be calculated in accordance with the provisions of BS CP3

chapter V Part 2: 1972 “Basic data for the design of buildings – Wind Loads”
using basic wind speed of not less than 160 km/hr.

c) Account must be taken of the loads and deformation caused by temperature and
time dependent deformations. For such purpose 55C temperature variation and
90% relative humidity should be considered for all members, except exterior
elements and façade elements shall consider 85C.

d) Floor systems are assumed to function as rigid diaphragm with respect to in plane
forces. Forces due to lateral loads should be considered to achieve this assumed
condition when designing peripheral beams and continuity ties etc.

e) Precast elements shall be designed in accordance with BS EN 1992-1-1:2004.

Design tensile stresses should not exceed the design flexure tensile stress of
concrete.

f) Nominal cover to steel including links must meet the durability requirement of
severe condition of exposure and to meet requirements for 2 hour period of fire
resistance.

g) Total deflection of any precast element should be limited to 1/350 of the span of
this element.

h) Plan & Design for opening for building services, where required or necessary.

3.5.7.10 Coordination

a) The Work of this Section shall be completely co-ordinated with the work of other
sections.

b) Verify dimensions and Work of other trades which adjoin or pass through
materials of this Section before the installation of items herein.

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3.5.7.11 Precast Concrete Products - Materials

a) General

(i) Obtain cement, aggregates and water from single source, sufficient to
complete the entire structural precast concrete work to assure regularity of
appearance and uniformity of colour.

(ii) Provide all materials in accordance with and meet all applicable
requirements of Section Precast Concrete Production and microtunnelling
pipe system.

b) Manufacturers

(i) The products and manufacturers specified hereinafter are specified for the
purpose of establishing minimum quality.

(ii) Products equivalent to or better than those specified will be considered

acceptable.

(iii) The decision of acceptability will rest with the Engineer.

c) Reinforcing Bars: as specified in Section – “Construction of Reinforcement”.

3.5.7.12 Mix Design

Precast concrete units, unless otherwise specified or ordered shall be constructed

from Grade 50/10 concrete but the coarse aggregate shall be 10 mm to 5 mm.

Precast units shall be either:

a) Cast in vibrated moulds.

b) Formed in hydraulically compressed moulds.

c) Cast in a spun process

d) Cast in open moulds with approved compaction techniques.

In every process, the CPF formwork shall be of adequate quality to produce a

completely smooth finish.

3.5.7.13 Strength Requirements:

Structural Precast Concrete shall be as follows unless otherwise stated:

a) Characteristic cube strength 50 N/m m² at 28 days and 40 N/m m² at the time of

transfer.

b) The Characteristic flexural strength shall be

(i) For Concrete grade up to C40 shall be 3.5N/mm²

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(ii) For Concrete grade C 40 – C 50 shall be 4N/m m²

(iii) For Concrete grade greater than C 50 shall 5N/m m²

(iv) For Precast Paving slabs - 3 N/ m² when tested to BS 12390:P5:2009

(v) The crushing strength of Precast kerb shall be as specified in BS 7263.

3.5.7.14 Formwork

a) As required to constantly maintain dimensional and surface finish controls

specified in BS 5975.

b) Formed surfaces of the structural precast elements are to be at least as smooth,

flat and joint free.

c) Construct forms of non-staining metal, fibre glass reinforced polyester, or other

approved material with ‘CPF’ liner at exposed faces.

(i) Fabricate and reinforce for close control of dimensions, shapes, profiles,
curvatures, smooth and perfect edge and corner finishes and details.

(ii) Make forms sufficiently rigid so that precast units will meet the casting
tolerances.

(iii) Construct forms tightly to prevent leakage of water or mortar.

(iv) Form joints will not be permitted on faces exposed to view in the finished
work.

3.5.7.15 Bearing Pads

a) Elastomeric neoprene pads.

b) Conforming to Standard Specifications for Highway Bridges (Section 25) adopted

by AASHTO.

c) Use un-factored loads for design.

d) Properties

(i) Hardness (Shore A Durometer): 50  5

(ii) Tensile Strength: min. 15.5 N/m m²

(iii) Ultimate Elongation: min. 400%

(iv) Compression set at 100C, 22hrs: 35%

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3.5.7.16 Grout

As specified in Section – “Grout”.

3.5.7.17 Execution – Forming

a) General

(i) Forms and casting beds are to be firmly seated so as not to deflect or be
displaced under concreting or tensioning loads.

(ii) Correct for thermally induced strains or forces.

1. For member penetrations larger than 150 mm, coring or field cutting is
not permitted unless prearranged with the approval of the Engineer.

2. Clean and coat forms with release agent prior to installation or

reinforcing or embedment’s.

b) Refer to Section – “Form Work” for other requirements of formwork.

c) Tolerances: permissible deviations of formed surfaces are not to exceed

tolerance outlined in PCI Manual 116, summarized and / or modified as follows:

(i) Length: +/- 5 mm.

(ii) Width: +/- 3 mm

(iii) Thickness: Stem +/- 3 mm, Flange +/- 2.0 mm

(iv) Embedment or Penetration Location: +/ - 0.2 %

(v) Straightness: +/-3 mm for 3 m

(vi) End Squareness: +/- 3 mm

3.5.7.18 Reinforcing Steel Placement

a) Place reinforcing steel in accordance with properly executed shop drawings.

b) Embedment, inserts and lifting devices are to be firmly anchored to resist

misplacement during concreting.

c) Tolerance: maximum permissible deviation from detailed placement.

(i) In Plane: ±1/200.

(ii) In Position: ±6 mm

3.5.7.19 Concrete Placement and Finishing

a) Batch, transport, deposit, consolidate and strike off the concrete to produce dense
homogeneous concrete elements.
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b) Surface Finishes

Tee Beams

(i) To Receive Bonded Topping: Broomed perpendicular to axis with brush just
sufficient to remove the outer mortar skin and expose the larger aggregate
without disturbing the aggregate.

(ii) Exposed: Hand trowelled

(iii) Concealed: Floated

3.5.7.20 Curing

a) Retain moisture to ensure complete hydration of the cement.

b) Membrane forming curing compounds shall not be used in surfaces to which

topping is eventually to be bonded.

c) Steam curing

(i) Do not apply steam until concrete undergoes initial set (2 to 4 Hours).

(ii) Heat Gain in Enclosure: maximum 4C per hour

(iii) Maximum Heat in Enclosure: 65 C.

3.5.7.21 Surface treatment and Repair

a) Minor cracks and spalls not affecting the structural integrity of the element can be
patched with epoxy type bonding agents and patching compounds.

b) Cracks and honeycombs in anchorages, bearings or otherwise critical zones will

be unacceptable unless repair can be affected and substantiating testing
performed.

c) Do not attempt structural repair without the Engineer’s knowledge and approval.

3.5.7.22 Installation

a) General

Erection responsibilities include the safe and proper placing, aligning and levelling
of the structural precast elements on the accepted bearing surfaces and affecting
their proper securement.

b) Survey

(i) Before placement of structural precast elements, survey and maintain all
temporary supports shown or required to control alignment, deflection.

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(ii) Retain temporary supports until framing elements braced thereby have
attained integral stability in accordance with the design.

c) Guying, Bracing and Shoring

(i) Install in proper sequence and maintain all temporary supports shown or
required to control alignment, deflection and stress levels.

(ii) Retain temporary supports until framing elements braced thereby have
attained integral stability in accordance with the design.

d) Adjustment and Correction

Compensate and correct for misaligning effect of temperature, draw from welding,
bolting or erection sequence or grouting.

e) Erection Tolerance

Comply with the following erection tolerances:

(i) Variations from Plumb: 6 mm in any 6m run; 12 mm total in any

12m or longer run.

(ii) Variation from Level or Elevation: 6 mm in any run; 12 mm in any 12m

run; total 12 mm at any location.

(iii) Variation from Position in Plan: +/-12 mm maximum at any location

(iv) Offsets in Alignment of: 1.5 mm in any 3m run; 6 mm

(v) Adjacent members at Any Joint: maximum

f) Welding

In accordance with AWS recommendations:

(i) Do not weld until all adjacent elements to be connected have been aligned,
firmly seated and braced.

(ii) Control heat build-up by limiting voltage, electrode size and rate.

(iii) Spalled or heat damaged concrete around weldments is not acceptable.

g) Grouting

Complete joints, gaps and connections by filling with grout as shown on the
Drawings and as approved by the Engineer.

3.5.7.23 Field Cutting

Field cutting of holes may be done only with the Engineer’s concurrence and only
with power saws or core drills.

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a) Maximum hole size is 150mm diameter or as limited by member size or strand

location.

b) Cracks, spalls and sharp corners created by field cutting are to be ground, eased
and patched with epoxy type bonding and patching compounds.

3.5.7.24 Precast Concrete Production

a) Precast concrete gullies shall comply with the relevant requirements of the
approved standard.

b) Curing methods shall be as specified. Precast concrete bricks, tiles and similar
small units shall be immersed in water curing tanks.

c) Units shall not be transported until they have matured under suitable conditions
for a period of not less than 14 days.

d) The units shall be so handled, stacked, stored and transported that they are not
subjected to undue stress or damaged in any way and large units shall have
suitable lifting holes or hooks incorporated into their design. No unit shall be built
into the work until it has matured for 28 days.

e) Units may be rejected if they have any of the following defects:

(i) Broken edges.

(ii) Cracks (other than hair cracks)

(iii) Repairs

(iv) Misplaced reinforcement

(v) Honeycombing or air holes

(vi) Finished dimensions different from those specified or shown on the

Drawings.

f) The Engineer may order extra precast units to be manufactured for testing to
destruction. These units will be paid for if the tests show that they comply with the
Specification.

3.5.7.25 Bedding Precast Concrete Units

a) Precast concrete units, except where otherwise specified shall be bedded and
jointed in 1:3 cement/sand mortar true to line and level as shown on the
Drawings, each unit being firmly pressed into position and the joints flush pointed
as the work proceeds.

b) Where units are to be subjected to internal or external water pressure, mortar

joints shall be completely watertight.

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3.5.7.26 Post-Tensioned Wall Panels, Jointing and Post-Tensioning

a) Post-tensioned wall panels for circular tanks shall be reinforced with fabric
reinforcement. The reinforcement shall be cut from flat sheets and not from rolls.
A lifting hole shall be provided in each panel.

b) Joints between precast concrete panels shall be packed with a stiff 1:3
cement/sand mortar. On no account shall liquid grout be used for this purpose.

c) High tensile steel strand shall be cut to length with a high speed disc or other
cutter. Burning is prohibited.

d) For the purpose of attaching the tensioning jacks the length of each cable shall be
1.50 meters longer than the net anchorage length.

e) The top cable shall be tensioned first followed by the third cable from the top, both
sets of anchorages being in the same anchor blocks. The tensioning of the
second and fourth cables shall next be carried out in that sequence, the
anchorages being in the alternative blocks.

f) The Contractor shall secure and maintain the circularity and level of the wall
panels before and during stressing and shall obtain the Engineer’s prior approval
of the methods he proposes to use.

3.5.7.27 Chamber Rings and Cover Slabs

a) Precast concrete chamber and shaft sections and chamber and shaft cover slabs
shall all be to the approved standard and be constructed to the dimensions shown
on the Drawings.

b) Details of the design of all chamber cover slabs shall be submitted to the
Engineer for his approval before manufacture.

c) They shall be suitably protected internally and externally in accordance with this
Specification.

d) Cover slabs shall be arranged so that they are supported on the surround
concrete and not on the chamber or shaft sections.

e) The slabs shall be designed to support their own weight, imposed dead loads
from any shafts, backfill and access covers and live loads based on individual
wheel loads of 112kN.

f) A representative slab of each size shall be tested at the place of manufacture and
test certificates submitted to the Engineer before delivery and/or acceptance.

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3.5.7.28 Precast Concrete Paving Slabs

a) Precast concrete paving slabs shall be to the approved standard and shall be laid
on 1:3 cement mortar. They shall be laid at a level not exceeding 4 mm above the
top of the kerb or concrete edging.

b) The joints shall be thoroughly cleaned out and grouted with cement mortar well
brushed in and flushed off. No cracked or broken slabs shall be used.

3.5.8 Under Water Concrete

3.5.8.1 General

a) Where concrete is to be placed under water the Contractor shall submit his
detailed proposals for the method of working, equipment and personnel for the
approval of the Engineer. No such work shall be undertaken until this approval
has been given.

b) Concrete which is to be placed under water using the Tremie method shall have
the following characteristics: -

(i) The minimum cement content of the concrete shall be 400kg/m³. The
cement shall be ordinary Portland cement or rapid hardening Portland
Cement. Cement containing cement replacement material may be used
subject to the approval of the Engineer.

(ii) The consistency of the concrete shall be increased so that the slump is 185
mm or the flow 530 – 600 mm.

(iii) Maximum aggregate size shall be 20mm and fine aggregate proportions
shall be between 45% and 55% of the total aggregate content.

(iv) An anti-washout liquid admixture specially developed for concrete placed

under water shall be included in the mix at the rate of 0.8 – 1.6 lit/100kg
cementitious material in accordance with the manufacturer’s
recommendations.

c) Concrete to be placed under water shall be placed continuously and sufficient

supplied of aggregates, cement and water shall be available at the mixing plant
prior to the commencement of the tremie concreting. No concrete shall be placed
until the Engineer has approved all preparations for the work.

3.5.8.2 Trial Pours

On- shore trials shall be carried out to ensure a proper understanding of the method
of working followed, if considered necessary by the Engineer, by underwater trials
which shall be carried out in such a way that the resultant work can be retrieved and
examined.

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3.5.8.3 Tremie Pipes

a) The maximum distance between tremie pipes shall be 4 to 5 meters and pipes
shall be located in such a way that concrete does not flow horizontally more than
3.0 meters from a pipe position.

b) When two or more pipes are used in the same pour simultaneously, care shall be
taken to ensure that the concrete level at each pipe position is maintained equal.
The pipes shall be suspended from staging mounted so that the pipe can be
moved vertically. The pipes will be fed through a hopper. Each pipe shall
comprise removable sections to allow the pipe to be shortened as concreting
proceeds.

c) All removable items and loose constructions shall have chain connections to
prevent loss.

3.5.8.4 Tremie Pipes

a) Tremie pipes shall be clean, watertight and of adequate diameter to allow the free
flow of concrete not less than 200 mm diameter nor greater than 300mm.

b) The method of plugging tremie pipes shall be approved by the Engineer.

c) The tremie pipe shall extend to the formation level prior to the commencement of
concrete pouring and care shall be taken to ensure that all water is expelled from
the pipe during the initial charging process.

d) A minimum embedment of 0.5m of the tremie pipe in concrete shall be maintained

throughout concrete pouring to prevent re-entry of water into the pipe.

e) Horizontal movement of the tremie pipe will not be permitted after

commencement of the pour.

3.5.8.5 Formation Preparation

a) The formation of each pour shall be kept clean, free of silt and other harmful
material.

b) If necessary the direction of the pour shall be ordered by the Engineer, to enable
harmful material to be displaced by the fresh concrete.

c) All gaps and lifting holes exceeding 10 mm minimum dimension in and between
formwork shall be sealed prior to pouring tremie concrete.

d) All surface laitance and poor quality concrete from previous pours shall be
removed prior to placing new concrete.

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3.5.8.6 Tremie Pours

a) The concrete pour shall be completed in such a manner and within such time that
the concrete above the foot of the tremie remains workable until the pour is
complete.

b) The method of placing shall be such as to prevent any concrete from dropping
through the water into the construction area, and to ensure that the maximum
density of the concrete is achieved in its final position. Divers shall be employed
as necessary to ensure that even placing of the concrete, which shall be placed
as far as possible in horizontal and not with steep unsupported faces.

c) The rate of placing concrete shall be such that the pressure on the formwork shall
not endanger its stability.

3.5.8.7 Minimum Cover to Reinforcement in Concrete

Table 3.17 Limiting values for composition and properties of concrete exposed to risk
of corrosion of reinforcement induced by chlorides. Maximum size of aggregate is 20
mm, cement and combination types based on BS 8500.

Table 3.17

Exposure Nominal Exposure Applicable Tolerance

class Cover* to Conditions Examples
reinforceme C
Table A. 1 of nt (mm)
BS 8500 – 1

XD2 40 +  c Wet & Reinforced 15 mm internal

Concrete
10 mm external
rarely dry Elements one
surface immersed
in water and
external surface
exposed to air at
dry surface

XD3 50 +  c Cyclic

Wet & dry R.C.C buried 10 mm internal

structures
10 mm external

XC2 45 +  c Moderate R.C.C buried 10 mm internal

structures
15 mm external

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Exposure Nominal Exposure Applicable Tolerance

class Cover* to Conditions Examples
reinforceme C
Table A. 1 of nt (mm)
BS 8500 – 1

humidity & Foundation

cyclic wet &

dry

XC3 40 +  c Cyclic wet & Buildings 5 mm internal &

dry external

Columns, beams
and parapets

XO 40 mm No Risk of -Ditto- –
Corrosion

*Expressed as the minimum cover to reinforcement plus a tolerance,  c, to accommodate fixing

precision. This tolerance is typically in the range 5 mm – 15 mm.

 XD means corrosion induced by chloride other than from seawater.

 XC means corrosion induced by carbonation.
 XO means no risk of corrosion.
 Cover to reinforcement refers to the minimum distance from the surface of the concrete to any
steel reinforcement links.
 The ends of binding wire should be turned away from the cover zone and into the body of the
concrete.
 The cement or combination content of concrete shall not exceed 450 kg/m³.

 Water – cement ratio limits are the ruling parameters over minimum strength class or minimum
cement content.

3.5.8.8 Spacing Blocks and Temporary Construction Ties

a) Internal spacing blocks and construction ties shall be avoided as far as, in the
Engineer's Representative opinion, possible and practicable.

b) Where it is intended that the spacing blocks or construction ties shall be removed
whether before or after the concrete has set, the making good of the concrete
shall be subject to the Engineer's Representative's approval.

c) The removal of the blocks or ties must not jeopardise the stability of the
construction.

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d) If, with the approval of the Engineer's Representative, the spacing blocks and
construction ties are allowed to remain in the concrete then they shall be of such
material and of such quality that they do not prejudice the strength of the work.

e) Concrete spacing blocks shall be made of concrete at least equal in quality to the
main concrete. Metal ties shall be positioned such that they do not come into
contact with any of the reinforcement or fittings and no part of the tie shall be
permanently embedded in the concrete nearer than 5 cm to the exterior surface of
the concrete.

3.5.9 Concreting Deep lifts and large Volume Pours

3.5.9.1 Deep Lift Construction – General

The main advantage of construction in deep lifts is the reduction in the number of
horizontal joints. This results in both an improvement in surface appearance and a
reduced number of potential zones of weakness (or leakage in the case of liquid
retaining structures).

3.5.9.2 Achieving successful deep lift construction

For successful deep lift construction the contractor shall have the following planning:

a) Techniques for placing and compacting concrete at the base of deep lifts must be
decided in advance of construction and proper consideration given to access and
construction sequence.

b) Formwork shall be designed to resist high hydrostatic pressures and particular

attention shall be paid to sealing joints in the formwork.

c) Formwork shall remain in place long enough to prevent excessive deflection

leading to misalignment of panels.

d) Concrete pour lift height at a stretch is to be minimised to a maximum of 3m and

the concrete dropping height to be restricted to 1.0m.

e) A full-scale mock-up of any particularly difficult section shall be constructed and

filled with concrete in order to identify and prevent any potential problems during
construction.

f) The contractor shall provide his method statement of work and can demonstrate
his capability by providing a work procedure, defining management, method,
programme and inspection and testing regime, which takes account of the unique
features of the pour to be cast.

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3.5.9.3 Plant

a) For deep lifts, the contractor shall give following considerations with regard to
plant:

(i) The limited space on the working platform at the top of the lift

(ii) The limited access for concrete distribution and compaction and possible
poor visibility within the pour.

(iii) The high pressure on the formwork, and the need to prevent leakage.

b) The delivery of concrete to the pour may be by any of the conventional methods,
e.g. crane and skip, pumped. However, boom pumps have an advantage in that
the line takes up space and required less handling.

c) To distribute concrete to the bottom of the form without segregation, tremie pipes,
drop chutes or flexible hosing shall be used. In the latter case, this may fixed to
the end of the pump boom.

d) As it is difficult to control the location of a poker at the bottom of a deep lift, it may
be appropriate to consider jigs with fixed vibrators which are raised as the lift
progresses. Because of the difficulty of raising pokers from the base of a deep lift
before inserting them in a new position, a greater numbers of pokers than normal
may be required.

e) External vibrators shall also be used to overcome access problems. These may
either be attached to the form work in fixed positions, or demountable fixings
which would allow a smaller number of vibrators to be moved up the formwork as
the height of the concrete rises. It shall be noted, however, that formwork shall be
specifically designed with external vibration in mind and shall be both rigid
enough to with stand the effects of the vibration and capable of transmitting this
vibration to the concrete.

f) Formwork design is also important with regard to stability, stiffness and the
avoidance of grout leakage at joints.

g) Lighting may also be required in very deep lifts where visibility is poor and for
concreting at night.

3.5.9.4 Contractor’s Check List

In the planning stage, the contractor shall pay particular attention to the following and
the methods of works are to be provided for Engineer’s approval.

a) Advanced warning to all parties involved, and in particular, the material supplier.

b) Concrete production – if ready mixed concrete is to be used the contractor must

check:

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(i) Location of the plant in relation to transit time and risk of delays (e.g. in rush
hours)

(ii) Throughput as determined by storage capacity, mixing rate, number of

delivery trucks.

(iii) Quality control in relation to risk of rejecting non-compliant mixes

(iv) Back-up plants, or use of several plants.

c) Access to the site – separating incoming and outgoing mixer trucks, provision on
site space for queuing and washdown.

d) Concrete distribution – appropriate selection of plant to achieve the required

placing rate. Pumps are most commonly used for very large volume placement
but skips, chutes and conveyors are also used. Arrangement of back-up plant in
case of breakdown. Lighting may be needed for deep lifts and is essential for time
concreting.

e) Concrete placing sequence – planning of sequence of placing from one or more

points, and thickness of layers.

f) Placing and compaction – ensure sufficient labour and plant for through
compaction.

g) Finishing – this may be delayed if the mix has a slow set.

h) Condition for non-standard working hours-check local by-laws for night and
weekend working. Agree conditions with labour force, e.g. shift working, and
cover during breaks.

i) Quality control – rate of sampling of concrete; storage of test specimens; action

the event of non-conformance. In the case of contract concrete subject to third
party certification, the quality assurance scheme of the concrete producer must
be examined and approved by both contractor and designer.

j) Temperature monitoring – location of measuring points; method recording

temperature; agreed action limits; actions in the event of non-conformance.

k) Achievement of specified temperature limits – mix selection, trials to measure

temperature rise or heat of hydration, cooling of the fresh concrete, in-situ cooling
with embedded pipes, thermal curing.

l) Contingency plans for:

(i) Delays or failure of concrete delivery

(ii) Breakdown of plant for concrete distribution and compaction

(iii) Extension beyond anticipated pour time (particularly if running beyond

normal working hours)
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(iv) Severe weather, especially heavy rain.

3.5.9.5 Effect of formwork on surface finish

a) The formwork panels must be flat and flush with each other with no steps or gaps.
Welding steel panels may introduce distortions that will be apparent when the
formwork is removed.

b) The formwork material and its interaction with the CPF liner must minimise
blowholes. Although blowholes are usually concentrated at the top of the lift, they
can occur throughout the height of the pour if the formwork materials are
unsuitable or poorly covered in release agent. This is particularly noticeable with
low workability or ‘sticky’ concrete mixes.

c) Impermeable materials such as steel, plastics or resin-coated plywood are

particularly prone to excessive blowholes as water and air moving away from
internal vibration becomes trapped at the concrete-formwork interface. In contrast
more permeable materials absorb some of this water and reduce blowholes.

d) Controlled Permeability Formwork (CPF) is an effective means of eliminating

blowholes in vertically formed surfaces. Although the surface is darkened as a
result of a low water/cement ratio, the darkening is uniform due to the controlled
permeability of surface. This technique has to be applied to deep lift construction.

3.5.9.6 Insulation

a) Insulation shall be used to minimise temperature differentials by enabling the

surface temperature to increase. However, when appropriate, insulation can be
achieved by various methods, including:

(i) maintaining the formwork in place if it has insulating properties e.g. plywood
or steel backed with expanded polystyrene or CPF liner.

(ii) foam mats, blankets and quilts

(iii) soft board

(iv) sand on polythene

(v) tenting

(vi) ponding

b) Applicable method shall be adopted depend on whether the surface is vertical or

horizontal, the period for which the insulation must maintained, and the access
required to the surface.

c) Guidance on the minimum period for insulation in relation to the minimum pour
dimension is given in Reference and is reproduced in Table 3.18 below. For very
thick elements, the insulation may need to remain in place for up to three weeks.

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Table 3.18 - Minimum periods of insulation to avoid excessive temperature

differentials

Minimum pour dimension Minimum period of insulation

(m) (Days)

0.5 3

1.0 5

1.5 7

2.0 9

2.5 11

4.5 21

d) When using insulation care must be taken to avoid its early age removal, as this
can generate thermal differentials which are much worse than might have
occurred if no insulation had been used.

e) Once the commitment to insulate has been made it must be maintained until the
temperature within the pour has cooled to a level which can accommodate the
change which will occur when the insulation is removed.

3.5.9.7 Monitoring of concrete temperatures

a) In large volume pours, the avoidance of excessive temperature rises and

differentials is essential to minimise problems of thermal cracking.

b) The temperature limits is important in this respect, the following shall be

considered:

(i) Maximum placing temperatures

(ii) Maximum temperature achieved within the section

(iii) Maximum temperature differential between the centre and surface of the
section

(iv) Maximum temperature difference between the centre of the pour and
ambient temperature

(v) Maximum temperature differential between successive pours of lifts.

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c) The quantitative limits placed on these parameters should reflect the

consequences of any cracking and the properties of the concrete actually used
during construction. The type of aggregate used in the concrete has a significant
effect on the temperature differential that can be sustained without cracking and
the effects of peak temperatures on in-situ concrete properties are much less
deleterious when composite cements are used.

d) Embedded thermocouples are an appropriate technique and may usefully be

combined with embedded strain gauges (e.g. vibrating wire gauges). The
minimum number of thermocouples together with additional thermocouples
together with appropriate location consists of a thermocouple at the centre of the
pour with additional couples close to the top, bottom and side surfaces of the
section. In view of the application, the thermocouples need only be accurate to
the order of  1C and reference calibration is not necessary. It is useful to have a
detailed monitoring of the first few pours, relaxing the requirements once a pattern
of behaviour has been established (perhaps just monitoring a smaller number of
selected locations).

3.5.9.8 Placing Methods

a) The four principal methods of concrete delivery into large volume pours are:

(i) Skip

(ii) Pump

(iii) Chute

(iv) Conveyor

b) The method selected shall depend on the required rate of placing, the ease of
access and the plan area of the pour.

c) However for large area, large volume pours, mobile boom pumps provide the
greatest degree of flexibility combined with very high placing rates, typically of the
order if 40-50 m³/hr, but with reported throughputs approaching 100 m³/hr for
individual pumps. This compares with typical rates of 8-12 m³/hr achieved using
crane and skip.

3.5.9.9 Compaction

a) For large volume pours, the only practical means of compaction is by the use of
immersion (poker) vibrators. Recognised good practice involves placing the poker
vertically into the concrete and at about 0.6m centres. At each location, the time
required to ensure expulsion of air will depend on the workability of the concrete.

b) The use of internal (poker) vibrators with long airlines shall be proposed for
compacting concrete in deep lifts. However, if the vibrator is controlled from the
top of the form and just dropped into the concrete at the base of the form, it is

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difficult to control its position and areas of poor compaction may result. More than
one poker may often be required in order to produce efficient compaction.
Increased numbers of vibrators are essential if the design of the reinforcement
does not permit the poker to be raised easily and repositioned. The workability
and consistence of the concrete will also influence the number and spacing of the
vibrators. The maximum diameter of the poker will, of course, be controlled by the
section dimensions and reinforcement spacing, and pokers of different diameters
may be needed for different sections of the lift. In some circumstances, it may be
possible to prefabricate a jig for holding the pokers in such a way as to allow more
accurate positioning and controlled upward movement. Vibrators should be
inserted vertically and allowed to sink under self-weight. The radius of action (or
area of influence) of the vibrator should preferably be larger than the wall
thickness in narrow sections as shown in table below.

Table 3.19 Typical radius of action of poker vibrators

Vibrator dia Radius of action

(mm) (mm)

20-40 80-150

30-60 130-250

50-90 180-360

80-150 300-510

130-180 400-610

c) Vibrators should be inserted at spacing generally around 1.5 times the radius of
action so that the areas affected by vibrators overlap. Vibrators should always be
withdrawn slowly from the concrete.

d) If possible contact between the vibrator and the formwork of reinforcement should
be avoided.

e) Proper access for poker operations must be provided, as this is much more
difficult operation in deep lift construction than in other forms of construction.
Concrete pumps and articulated placing booms can be used as a means of
reducing the number of placing personnel required on the access platforms, thus
allowing the poker operators adequate room for manoeuvre.

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3.5.9.10 Finishing

Large volume pours will generally be either trowelled or floated. Normal practice shall
apply, but it must be recognized that the concrete mix may have been designed to
have an extended stiffening time to avoid cold joints. For this reason, there may be a
longer than usual delay before initial stiffening has taken place and the moisture film
has disappeared from the surface.

3.5.9.11 Thermal Control

The control of temperature rise and temperature gradients is often a key feature of
large volume concreting and various precautionary measures shall be taken to
minimize the risk of early age thermal cracking, or to limit its extent as follows:

a) Select a low heat generating mix by minimising the cement content, within the
constraints of the specification and requirements of the fresh concrete.

b) Use composite cements (i.e. blends of PC with ggbs) to reduce the rate of the
evolution and the peak temperature rise.

c) Select aggregates with a low coefficient of thermal expansion

d) Select aggregates which result in concrete with a high strain capacity

e) Reduce the concrete mix temperature by cooling of the component materials or

the use of ice with the mix water.

f) Use liquid nitrogen to cool the fresh concrete

g) Cool the concrete in-situ by the use of embedded cooling pipes.

h) Use insulation to increase surface temperatures and to minimize thermal

gradients.

3.5.9.12 Reducing the mix temperature

a) Reducing the mix temperature has a number of benefits:

(i) It reduces the rate of workability loss

(ii) It delays the stiffening time

(iii) It slows down the rate of heat generation

(iv) It reduces the peak temperature and thus the temperature drop from peak
to ambient.

b) As aggregates comprise the largest single component, cooling them will have the
greatest effect on the concrete mix (except where ice is used). This can be
achieved practically by:

(i) Shading aggregate stockpiles, to prevent solar gain

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(ii) Sprinkling the stockpiles with water (preferably chilled).

c) Other more extreme measures include immersion in tanks of chilled water,

spraying chilled water on aggregate on a slow moving belt, or blowing chilled air
through the stockpiles. When the aggregates are cooled with water, this water
must be taken into account during batching, by adjustment to the added mix
water.

d) An alternative method is to cool the aggregate using liquid nitrogen (LN2).

e) While the aggregate constitutes the greatest mass in the mix, the water has the
greatest heat capacity, and hence cooling efficiency. The specific heat of water is
about five times that of the aggregate and cement (4.18 kJ/kgK compared with
0.75 kJ/kgK respectively). In addition, water is much easier to cool and the
temperature can be controlled more accurately. As it is practical to cool water to
about 2C this is a very effective method of cooling the mix.

f) For very effective cooling, ice can be used. The latent heat of ice is 334kJ/kg, and
the heat absorbed by 1 kg of melting ice is equivalent to cooling 1 kg of water
through about 80C or 1 kg of aggregate through 445C. Hence, a relatively small
volume of ice can have a significant cooling effect. Ice is usually added to the mix
in crushed or shaved form as it is important to avoid incorporating larger fragment
that melt slowly leading to the formation of voids in the hardened concrete. To
obtain an indication of the requirements for cooling the individual mix constituents,
the following general rules shall be applied. To cool the concrete by 1 requires
that:

(i) The aggregate is cooled by 3C

(ii) The mixing water is cooled by 7C.

(iii) 7 kg of mixing water is replaced by ice.

3.5.9.13 Monitoring and actions in the event of non-compliance

a) Temperature monitoring is required in order to demonstrate compliance with

specified temperature limits. The simplest and most cost-effective method,
particularly in very deep or thick pours greater than 500 mm is to use embedded
thermocouples. These are simple to install and to monitor. The output can be
monitored with simple manual devices. On large projects, automatic logging
systems can be set up.

b) In its simplest form, the monitoring will involve thermocouples at the centre of a
section and close to the surface (about 10 mm). The maximum value at the centre
and the difference between the centre and the surface will then be assessed
against specified limits.

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c) The contractor shall obtain specific details from the designer on how compliance
is to be demonstrated in relation to the location and number of monitoring points
and the interpretation of the results obtained.

3.5.9.14 Full Scale Mock-up

a) Full-scale mock-ups are to be conducted for providing data on temperature

profiles and hence for identifying the precautions needed in terms of insulation,
and increasing use is being made of computer models.

b) If the pour is a one-off, or if it is the first of many, pairs of thermocouples should

be installed at critical locations to provide back-up in the event of a failure. The
mix selection and adopted site procedures should be such that the temperature
limits will be met. However, contingency plans should be defined which can be
implemented when the results exceed ‘action levels’. If the allowable temperature
differential is being approached, and is likely to be exceeded, additional insulation
may be applied.

c) If the maximum allowable temperature is approaching its limit, no actions can be

taken in thick sections unless embedded cooling pipes are being used. However,
this value is much easier to predict based either on the mix constituents and the
mix temperature or, if available, on laboratory test results for adiabatic
temperature rise.

d) If allowable limits on temperature differential are exceeded the following action

shall be taken:

(i) inspect the surface for cracks after the pour has cooled back to ambient

(ii) if the cracks are excessive, initiate remedial measures

(iii) Consider the consequences of internal cracking- it is possible that this may
occur even if there is no evidence of surface cracking. In this case, it is
difficult to establish the extent of cracking without extensive coring and even
this is unlikely to indicate crack widths. The value of carrying out a detailed
investigation to find cracks which do not propagate to the surface is,
therefore, still doubtful, except in circumstances where such cracks are
clearly detrimental to the performance and safety of the structure.

3.5.9.15 Formwork Striking and Curing

a) There are a number of potential problems when formwork is removed from deep
concrete lifts, the most serious being collapse of the structure of excessive
deflection. Factors to be considered are:

(i) collapse

(ii) excessive deflection

(iii) mechanical damage

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(iv) freeze/thaw attack

(v) thermal cracking

b) The minimum striking time is usually based on an assessment of the in-situ

strength and the temperature gradient of the concrete.

c) Minimum 30N/m m² in-situ strength and the temperature differential of 20C are
recommended for deep lift construction. This is primarily to ensure that the lift is
able to withstand wind loads without causing deflections that will produce
misalignment with adjacent panels.

d) In massive deep lift construction, striking times may be controlled more by

thermal requirements than concrete strength.

e) Following the removal of the formwork, it is important that the concrete surface is
protected from moisture loss (particularly in thin sections) in order to promote
continued cement hydration leading to strong durable concrete.

f) This may be achieved in a number of ways, including:

(i) covering the surfaces with wet hessian and then with polythene

(ii) application of an efficient membrane forming curing compound

g) Recommended minimum curing periods are given in BS EN 1992-1-1:2004. The

choice of curing method will be influenced by practical considerations and any
subsequent treatment to be applied to concrete.

3.5.10 Cementitious Mortar, Grout & Anchoring System

3.5.10.1 Cement mortar

a) Normal cement mortar shall be composed of ordinary Portland Cement and sand
in the following proportions :

Grade OPC Sand

G1 1 1

G2 1 2

G3 1 3

b) The amount of water added shall just be sufficient to make the mortar workable
consistent with its purpose.

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c) The sand used in mortar must be dry when proportioning. Allowance for bulking
shall be made when gauging by volume. The mean compressive strength at 28
days for each mortar shall conform to BS EN 1052-1:1999.

d) Sand shall be natural sand or crushed natural stone or a combination of both as

specified in BS 1200.

e) Mortar shall be mixed by approval mechanical mixers. No handmixing will be

permitted and instead small drum type mixer shall be used. Mortars containing
plasticisers shall not be overmixed. Mixers shall be kept clean at all times.

f) Mortar shall be used within thirty minutes after mixing. Hardened mortar shall not
be used in the work and shall be removed immediately from the site. Mortar shall
be prepared in the proportions shown with the addition of a minimum quantity of
water for workability.

3.5.10.2 Cementitious Mortar, Grout and Anchoring System

Only non-shrink, corrosion resistant grouts and anchoring which shall be either
cementitious, Epoxy and Polyester resin based to be used for various
applications to suit the locations as instructed and approved by the Engineer.

Table 3.20: Properties of Cementitious Mortar, Grout and Resin Anchoring

Systems

Location to use Type of Consistency Compressive Flexural Strength Bond

Grout Strength in N/m In N/m m² Strength
m² (Pull off)

7 days 28 days 7 days 28 days

A Heavy duty Epoxy Free Flow 100 - 26 - -

support beneath Resin minimum minimum
machine plate & Based
similar structural
elements

B Filling voids up to Cementiti Free Flow 55 64 9 11 -

section thickness ous minimum minimum minimum minimum
100mm between shrinkage Or
base plate & compensa
Pumped
substructure, ted
concrete anchors,
machine
foundation

C Filling annulus Cementiti Free Flow Or - 5 - - -

gap of abandoned ous minimum
pipe lines Pumped

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Location to use Type of Consistency Compressive Flexural Strength Bond

Grout Strength in N/m In N/m m² Strength
m² (Pull off)

7 days 28 days 7 days 28 days

D Bolt Anchoring Polyester Poured 115 - 30 - 70 kN

Dowels, Resin minimum minimum minimum
Foundation Bolts Based Or
& Similar
Pumped

E For concrete Fibre Trowel or wet - 50 9 - 2.5N.m m²

Repairs reinforced spray
Polymer application
modified
repair
mortar

F Structural repairs Free Free flow 65 80 7 10 3N/m m²

of deteriorated flowing
Concrete micro
concrete
for
Grouting
repair

G Water Proof Cementiti Trowel 60 80 8 10 3N/m m²

Concrete ous silica application
fume
modified
rigid
sealing
mortar

H Damaged Epoxy Trowel - 75 25 35 10N/m m²

Concrete joints resin
edges, vertical patch
and overhead mortar
filling of cavities

I On top of Grano Epoxy Roller & by 65 80 - - Concrete

Concrete resin hand Failure
flooring
with
enhanced
slip
resistance

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Location to use Type of Consistency Compressive Flexural Strength Bond

Grout Strength in N/m In N/m m² Strength
m² (Pull off)

7 days 28 days 7 days 28 days

J Resin anchor Capsule Mixed in bolt 115 - 30 - 70KN

system to fix bolts contains holes with
in concrete resin drilling
quartz machine
granules
and phial
of
hardener

K Sealing cracks on High Mixed with - - - - >3N/m m²

concrete, joints performan low speed drill Elongation
between rigid & ce epoxy >400%
flexible surfaces resin
and joints with based
extreme adhesive
movement

3.6 FORMWORK AND CONCRETE PRACTICE

3.6.1 Shop Drawing

Contractor shall submit details of fabrication and placement drawings for all formwork
and reinforcement steel which are correlated with forming and concrete placement
techniques and requirements.

a) Reinforcing shall be detailed based on construction joint locations which shall

have been shown on shop drawings reviewed and approved by the Engineer.

b) The drawings shall be in such detail as to assure that difficulties in execution of

the work in the field are minimized.

c) The drawings shall consist of sections, plans and details clearly showing
locations, sizes and spacing of all reinforcing steel, supporting bars and
accessories including bends, sizes and lengths of all reinforcing steel beams.

d) A separate set of shop drawings, which shows the construction joint locations,
shall show all floor openings, wall openings and edges of concrete. Floor wall
openings and sleeves for all mechanical, plumbing and electrical work shall be
coordinated with the respective trades and shown on these shop drawings in
accordance with the criteria indicated on the contract drawings and contained in
the various applicable Sections of the Specification.

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e) No work shall be fabricated until all shop drawings have been reviewed and
approved by the Engineer (with corrections and resubmittals as required by the
Contract Documents). After review and approval by the Engineer, furnish all
copies needed for use of other trades.

f) Be fully responsible for furnishing and installing all materials called for or required
by the Contract Documents even through these materials may have been omitted
from the reviewed shop drawings.

g) Submit shop drawings for all formwork showing locations of joints, tie bolts,
cones, dummy cones, openings, chambers, inserts, fittings and accessories for
the approval of the Engineer before fabrication of formwork.

h) Submit design calculations in accordance with BS 5975 – falsework wherever

required for the supporting system of the formwork along with the shop drawings
for the supporting system, for approval of the Engineer.

3.6.2 Blinding Concrete (Sealing Coats)

a) Where aggressive soil or aggressive ground water is expected the concrete

should not be weaker than Grade C25 and if necessary SRC or other special
cement may be used for blinding layer concrete.

b) Immediately following the hand excavation to formation level for floors or

foundations where shown on the Drawings or as ordered by the Engineer, one
layer of 1000 gm/ m² gauge, 250 micron thick polyethylene sheet shall be spread
over the formation and a sealing coat of blinding concrete of minimum specified
thickness shall be placed on the surface of Polyethylene at the formation and
carefully spade finished to an even surface. The utmost care shall be taken to
preserve the natural water content of the ground below formation level as far as
possible. Should the ground be exposed to the weather by delay on the part of
the Contractor in placing the blinding concrete and become wetter or drier than its
natural state the Contractor shall excavate such ground as may be affected and
replace it with concrete of the same grade as the blinding.

c) Floors or foundations shall be laid on the blinding as soon as may be practicable,

this being especially important during hot weather. If required by the Engineer the
blinding shall be kept thoroughly damp by watering.

3.6.3 Design and Construction of Formwork

a) Contractor shall be responsible for the design of the formwork and shall submit

b) to the Engineer for approval.

c) Formwork shall in every respect be adapted to the structure and the required
surface finish of the concrete. It shall include all special moulds with insulation for
forming the concrete to the required shape, temperature condition and finish and
for the support of such moulds. It shall be fixed in perfect alignment and securely
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ledged and braced so as to be able to withstand, without displacement deflection

or movement of any kind, the weight of the construction and working platform for
the movement of persons, materials and plant. Joints shall be close enough to
prevent the leakage of liquid and fine materials from the concrete

d) The Engineer's Representative may at any time require the prior submission for
approval of the Contractor's proposals for design and construction of formwork
including supports and insulation details. The formwork shall be constructed so as
to permit its removal without damage to the concrete.

e) It shall be designed and constructed so that the concrete can be efficiently placed
and compacted without displacing or deforming the reinforcement. It shall be
firmly supported, braced, guyed or tied back so that it is stable against vertical
and horizontal forces. It shall be capable of adjustment and sufficiently strong not
to distort significantly by the pressure of the concrete or by other loads and
influences.

f) Internal spacers and ties shall be of types that do not produce holes completely
through the concrete and any permanently embedded parts shall not be nearer
the finished surface than the cover to the reinforcement. All permanently
embedded parts shall be of materials compatible with the coating of fusion
bonded epoxy coated reinforcement and all permanently embedded metallic parts
shall be treated with patching material obtained from the reinforcement coating
factory applied in accordance with their recommendations.

g) Joints in the formwork shall be close fitting to prevent leakage. Temporary

openings shall be provided, if necessary, for cleaning and inspection. The
arrangement shall allow for removal of formwork from the sides of members
without disturbing soffit formwork.

h) Where timber is used for the soffits of slabs, the boards shall be placed and laid
perfectly true with close joints to prevent the percolation of liquid or fines from the
concrete. Tongue and groove planks shall be used if specified. All requisite
bearer and struts shall be adjusted in position and placed where necessary on
bearers as specified in the case of beam forms.

i) Exposed formwork shall be used for surfaces of concrete, which will be exposed
to view or to liquids. It shall be constructed from material of sufficiently high
quality to produce a smooth denser concrete surface of uniform texture free of
blowholes and appearance without visible imprint of grain or steppings or ridges.
Where lined the same type of lining shall be used throughout any one structure.

j) If the use of metal-faced formwork is proposed details shall be submitted to the

Engineer for approval prior to use. Metal forms shall be insulated to prevent
excessive temperature fluctuations at the concrete surface.

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k) If movement or deflection of the formwork or loss of liquid occurs, and if the

Engineer so directs, the Contractor shall cut out and replace the concrete
supported by such formwork at his own expense.

l) Formwork, or an approved alternative, shall be used for upper inclined surfaces of

concrete where the slope is greater than 30° to the horizontal.

m) Formwork shall be designed so that splays, fillets, chamfers and projections are
cast as the work proceeds. The Drawings, particularly those prepared to small
scales, may not detail chamfers but unless specifically deleted all external angles
on exposed concrete shall have a 25 mm by 25 mm chamfer.

n) Before placing the concrete all extraneous matter shall be removed from the
interior of formwork. All faces of lined formwork against which concrete is to be
placed shall be carefully cleaned.

o) The surface temperature of the reinforcement and formwork shall not exceed the
temperature of the concrete at the time of placing.

p) The Contractor shall provide facilities for examination of the formwork after its
erection and before concrete is placed and shall give 24 hours notice to enable
the Engineer to examine the formwork if he so wishes. The Contractor shall place
concrete only after obtaining approval from the Engineer but this shall in no way
relieve the Contractor of any of his responsibilities under the Contract.

3.6.4 Type of Formwork

All concrete faces shall be left as struck with a fair face, true to line finish.

3.6.4.1 Job Mock-up

Prior to commencement of related formwork operations erect a job mock-up, to a

reasonable size including all items such a sheeting, stiffeners, soldiers, ties,
insulation layer etc. (and CPF liner where used) for the following types of formwork
and obtain approval before proceeding:

a) Columns

b) Walls, RAFT foundation

c) Slabs and beams

d) Staircases

e) Fair faced concrete (show method used to conceal tie holes)

3.6.4.2 Methods

a) Prior to commencing work, submit to the Engineer details of methods and

techniques proposed for the design and completion of formwork and the height of
each lift proposed for wall concrete.
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b) A Controlled Permeability Formwork (CPF) liner shall be used on the inside faces
of the formwork for all water retaining structures to produce a denser concrete
with a surface that is free of blowholes and other surface blemishes.

c) The CPF liner shall have a British Board of Agreement (BBA) certificate or other
similar independent third party certification from an approved authority.

d) The CPF liner shall have the following characteristics:

(i) Material: non-woven polypropylene, needle punched and thermally bonded

(ii) Weight : 250 g/m²

(iii) Thickness at 2kPa: 1.2mm

(iv) Pore size: < 30 microns

(v) Air permeability at 800 kPa : 100-500 l/ m²/sec

(vi) Tear strength (ASTM D1117) : Min: 125 N

e) The CPF liner shall be used up to a total of 3 uses.

f) Release agents shall not be used with the liner and any residual release agent
remaining on forms from previous use shall be removed.

g) The CPF liner shall be installed either by mechanical tensioning or gluing and
shall be used in accordance with the manufacturer’s technical guidelines.

3.6.5 Tolerances and Finishes of Concrete Surfaces

Unless tolerances for particular surfaces are specifically shown on the Drawings,
tolerances for the exposed surfaces shall be as follows:

1. Floor and roof slabs: The level of the surface at any point shall be within 5 mm
of the level derived from the drawings. There shall be no abrupt irregularities.

2. Walls: The position of the face at any point shall be within 10 mm of its position
derived from the drawings. There shall be no irregularity exceeding 3 mm in a 3
m template. The level at any point on the top of the wall shall be within 3 mm of
the value derived from the Drawings.

3. Beams and Columns: The position of each face at any point shall be within 3
mm of its position derived from the Drawings.

4. Measuring Flumes: Any point on the invert of the flume channel shall be within
2 mm of the level derived from the Drawings. The width of the throat at any
cross section shall be within 2 mm of the required width and the surfaces shall
be smooth.

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5. Weirs: Any point on a weir shall be within 2 mm of the level derived from the
Drawings and the surfaces shall be smooth.
Note: For the purpose of this clause, 'exposed surfaces' includes those with RTR or PVC liners.

3.6.6 Tolerances for Unexposed Surfaces

3.6.6.1 General

Tolerances are not specified but thicknesses shall not be less than shown on the
drawings.

3.6.6.2 Surface Finishes

a) Unless specifically detailed on the drawings, exposed concrete finishes shall

comply with the following:

(i) General: There shall be no abrupt irregularities or visible surface

imperfections.

(ii) Concrete Roads: Surfaces shall have a brushed or tamped finish with float
finished edges and arrissed angles.

(iii) External Walkways: Surfaces shall be float finished and then except for
margins at exposed edges, slightly roughened by brushing to produce an
even textured surface.

(iv) Concrete Floors and Tops of Walls: Surfaces shall be steel float finished to
be uniform and smooth.

b) The surfaces of walls and other exposed surfaces cast against formwork that will
be exposed to view or to liquids shall be rubbed down smooth in an approved
manner within three days after formwork has been removed. After inspection by
the Engineer any holes shall be filled with matching cement mortar.

3.6.7 Preparation of Formwork for Concreting

a) Immediately before the concrete is deposited, the formwork shall be thoroughly

cleaned out and freed from sawdust, shavings, wire cuttings, dust, sand, clay and
all other deleterious and extraneous materials.

b) Temporary openings shall be provided in the formwork to facilitate this work.

c) The inside surfaces of the formwork shall, immediately prior to final erection, be
installed the specified CPF liner in accordance with manufacturer’s guidelines.

d) The CPF liner shall be of approved type and shall be applied uniformly and the
quantities used shall be the minimum consistent with its purposes.

e) The Contractor shall ensure that all steel reinforcement and adjoining concrete
surfaces are kept free of all kinds of contaminations.
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f) All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.

3.6.8 Approval of Formwork before Concreting

a) The Contractor shall in all cases request the approval of the formwork by the
Engineer’s Representative in sufficient time to allow an inspection to be made and
shall not commence concreting until such approval is obtained.

b) The period between the Contractor’s request for approval and his intention to
commence concreting shall be not less than one clear normal working day and
the Engineer’s Representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.

c) Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

3.6.9 Removal of Formwork

All formworks shall be struck without jarring the concrete or subjecting the same to
sudden shock.

3.6.10 Formation of Holes for Fixing

a) The Contract may include for the formation of holes and pockets for the later
building in of holding down bolts, other fixing devices, services and structural
steelwork. Boxes for the formation of such holes shall be adequately supported
and preferably fixed rigidly to the main formwork.

b) All holes shall be formed in positions to be detailed for the various items of
machinery.

c) Where a group of holes has to be formed for a number of bolts for fixing one item,
the formers shall be securely fixed together before the concrete is poured around
them. The boxes shall be suitably protected to avoid extraneous matter falling
onto them.

3.7 BATCHING, TRANSPORTING, PLACING & COMPACTION OF CONCRETE

3.7.1 General

a) All concrete used on the Works shall be made at batching plants where quality
can be monitored and controlled.

b) Measurement of all the aggregates and cement shall be by weight. Allowance

shall be made for the water content or absorption of the aggregates as
appropriate.

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c) For this purpose the Contractor shall determine the moisture content of
aggregates at least twice a day during continuous concrete production using an
approved method.

d) The quantity of water for each batch shall be accurately measured by means of a
calibrated device. After the device has been set to discharge the given quantity of
water it shall not be altered without the consent of the Engineer. Concrete shall be
mixed with a machine of a type and size complying with the approved standard
and shall be used within 80 to 100% of its rated capacity unless otherwise
approved.

e) All plant and equipment used in mixing concrete shall be maintained in good
working order and shall be kept clean and free of hard or partially set concrete.

3.7.2 Ready Mixed Concrete

a) Ready mixed concrete shall be as defined in BS 8500-1:2006 batched off the site
and shall comply with all requirements of the Contract.

b) Concrete shall be transported in:

(i) a truck mixer or agitator; or

(ii) b non-agitating vehicle where permitted by the Engineer.

c) Where non-agitating vehicles are used, procedures shall be followed that have
been proven to minimise:

(i) segregation;

(ii) any change in entrained air content except for the case where the loss of air
has been taken into account (see BS 8500-1:2006, B.1)

(iii) loss of any constituent

(iv) ingress of foreign matter or water.

3.7.3 Time of Transport

a) Concrete shall be delivered and placed within 2 hours after the time of loading
where transported in truck mixers or agitators or within 1 hour after the time of
loading where non-agitating equipment is used, unless a shorter time is specified
or a longer time permitted by the concrete manufacturer/ specifier.

b) A longer time after loading can be appropriate in cool, humid weather or where
ggbs, or retarding admixtures have been used. A shorter time can be essential in
hot weather with cement-rich concretes, or where accelerating admixtures have
been used.

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3.7.4 Concrete Placement

a) Inspection: Before placing concrete, inspect and complete formwork installation,

reinforcing steel, and items to be embedded or cast in. Notify other crafts to
permit installation of their work; cooperate with other trades in setting such work.

b) General: Deposit concrete continuously or in layers of such thickness that no

concrete will be placed on concrete that has hardened sufficiently to cause the
formation of seams or places of weakness. If a section cannot be placed
continuously, provide construction joints as herein specified. Deposit concrete to
avoid segregation at its final location.

c) Temperature: The Contractor shall take measures to ensure under all

circumstances that the temperature at the time of placing does not exceed 30°C.
In the event that conditions become such that these requirements cannot be met,
concreting shall be suspended immediately and not resumed until the
requirements can be met again. Under such circumstances, additional
precautions should be taken to avoid the temperatures being exceeded on future
pours.

d) Protection: During concreting throughout the first stage of hardening, the concrete
shall be protected from the harmful effects of sunshine, drying winds, rain or
running water. Concrete shall not be subject to disturbance between 4 hours and
24 hours after compaction except with the agreement of the Engineer.

e) Placing concrete in Forms: Deposit concrete in forms in horizontal layers not

deeper than 500 mm and in a manner to avoid inclined construction joints. Where
placement consists of several layers, place each layer while preceding layer is
still plastic to avoid cold joints.

(i) Consolidate placed concrete by mechanical vibrating equipment

supplemented by hand-spading, rodding or tamping.

(ii) Do not use vibrators to transport concrete inside forms. Insert and withdraw
vibrators vertically at uniformly spaced locations not farther than visible
effectiveness of machine.

(iii) Place vibrators to rapidly penetrate placed layer and at least 150mm into
proceeding layer.

(iv) At each insertion limit duration of vibration to time necessary to consolidate

concrete and complete embedment of reinforcement and other embedded
items without causing segregation of mix.

f) Placing concrete of Raft Foundation & Roof Slabs: Deposit and consolidate
concrete slabs in a continuous operation, within the limits of construction joints,
until the placing of a panel or section is completed.

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(i) Consolidate concrete during placing operations so that concrete is

thoroughly worked around reinforcement and other embedded items and
into corners.

(ii) Bring slab surfaces to correct level with straightedge and strike of. Use bull
floats or darbies to smooth surface, free of humps or hollows. Do not disturb
slab surfaces prior to beginning finishing operations.

(iii) Maintain reinforcing in proper position during concrete placement.

g) Hot-weather placing: When hot weather conditions exist or rate of moisture

evaporation exceeds 1.0kg/ m² per hour, subject to the Engineer’s decision, that
would seriously impair quality and strength of concrete.

3.7.5 Compaction of Concrete

a) All concrete shall be compacted to produce a dense homogeneous mass. Unless

otherwise agreed by the Engineer, it shall be compacted with the assistance of
vibrators. Sufficient vibrators in serviceable condition shall be on site so that
spare equipment is available in the event of breakdown. A 50 mm diameter
internal vibrator shall be deemed capable of compacting 20 m³/hr. Internal
vibrators shall be capable of producing not less than 10,000 cycles per minute.

b) Vibration shall not be applied by way of the reinforcement. Where immersion

vibrators are used, contact with reinforcement and all inserts shall be avoided.

c) Concrete shall not be subject to vibration between 4 and 24 hours after placing.

d) Vibrators shall be so manipulated as to work the concrete thoroughly around the

reinforcement and embedded fixtures and into corners and angles of the forms.
Vibrators shall not be used as a means to cause concrete to flow or its position in
lieu of placing. The vibration at any point shall be of sufficient duration to
accomplish compaction. After initial set of the concrete, the forms shall not be
jarred and no strain shall be placed on the ends of projecting reinforcement.

e) Concrete when deposited shall have a temperature of not more than 30oC unless
otherwise specified. Concrete shall be compacted in its final position within 30
minutes of discharge from the mixer unless carried in purpose made agitators
operating continuously, when the time shall be within 1 hour of the introduction of
cement to the mix and within 30 minutes of discharge from the agitator.

f) Except where otherwise agreed by the Engineer, concrete shall be deposited in

horizontal layers to a compacted depth not exceeding 400 mm where internal
vibrators are used or 300 mm in all other cases.

g) Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 1m. When trunking or chutes are used they shall
be kept clean and used in such a way as to avoid segregation. Where steep
slopes are required for placing concrete with chutes, the chutes shall be equipped
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with baffle boards or be in short lengths that reverse the direction of the
movement. Chutes and the use of chutes must be approved by the Engineer. All
chutes shall be kept clean and free from coating of hardened concrete by
thoroughly flushing with water after each run. The water used for flushing shall be
discharged clear of the concrete already in place.

3.7.6 For underwater Concrete

a) Full details of the method proposed shall be submitted in advance to the Engineer
and his approval obtained before placing begins. Where the concrete is placed by
the tremie, its size and method of operation shall be in accordance with BS EN
1997-1:2004

b) “Foundations”. During and after concreting under water, pumping or dewatering

operations in the immediate vicinity shall be suspended until the Engineer permits
them to be continued.

c) Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement against
which concrete is to be placed shall be shielded against the direct rays of the sun
and shall be sprayed with water to prevent excessive absorption by the surfaces
of water from the fresh concrete.

d) A complete record shall be kept of the date, time, temperature and conditions of
placing the concrete in each portion by the Engineer at any time.

3.7.7 Placing of Concrete in Water (Tremie Concrete)

a) Tremie concrete shall be deposited in water only if specified on the drawings and
/ or directed by the Engineer and under the Engineer’s supervision.

b) Concrete to be deposited in water shall have the cement content increased by

25% at the Contractor’s expense.

c) Concrete shall be carefully placed in a compact mass in the space in which it is to

remain by means of tremie bottom dump bucket or other approved method that
does not permit the concrete to fall through the water without adequate protection.

d) The concrete shall not be disturbed after being deposited.

e) No concrete shall be placed in flowing water and forms which are not reasonably
watertight shall not be used for holding concrete deposited under water.

3.7.8 Concreting in High Temperatures

When concrete is to be manufactured, transported and placed in hot weather the

following limitations shall apply:

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a) The temperature of the concrete when placed shall not exceed 30oC nor shall
concrete be mixed or placed when the shade air temperature is 40oC or above, or
is expected to reach such a level during concreting.

b) For all concrete section the Contractor shall take precautions to limit the effects of
heat of hydration.

c) In general, the recommendations for “Hot Weather Concreting” contained in ACI

305:1977 shall be followed. The Contractor may, however, take any of the
following measures in order to control the temperature of concrete at the time of
placing:

(i) Effectively shade aggregate stockpiles, cement silos, water tanks and
concrete handling plant;

(ii) Paint all concrete handling plant white;

(iii) Run all concrete handling plant with flake ice to reduce the temperature of
the machinery before mixing / transporting concrete;

(iv) Add flake ice to the mixing water;

(v) Concrete at night

d) The following measures shall be taken:

(i) All forms, moulds, mixed and placed concrete shall be shaded from sunlight
and protected from any drying wind;

(ii) Transit time shall be restricted to a minimum to be agreed in advance

between the Engineer and Contractor, taking into account the use of
admixtures etc.

e) The size of concrete pours may be restricted if the Engineer decides that
shrinkage and other factors are a consideration for particular elements of the
construction.

f) For concrete sections 500 mm and greater in thickness, the Contractor shall
submit to the Engineer for approval detailed proposals of the measures to be
taken. These measures shall include but are not limited to control of concrete mix
constituents; curing water; formwork type; surface insulation. All submissions
shall be based on measured values of heat of hydration generated by the
proposed mix to meet the criteria set out below:

(i) Maximum temperature difference between the core and the surface of any
pour. Design target 15oC. Field maximum 20oC.

(ii) Maximum temperature difference between a new pour and a previous:

Design target 12oC. Field maximum 15oC

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(iii) Absolute maximum temperature anywhere in a pour. Design target 60oC.

Field maximum 70oC.

(iv) Instrumentation shall be installed in the works to verify compliance with the
above criteria. Temperature measurements shall be made by means of
thermocouples positioned in a line perpendicular to the concrete faces. The
thermo couples shall be fixed; at the concrete faces; at the centre of the
section; and at equal intervals of approximately 300 mm.

(v) Temperatures shall be measured and logged continuously from the start of
the pour until instructed to stop by the Engineer. The Contractor shall
submit to the Engineer for approval details of the proposed methods and
equipment for the measuring and logging of temperatures.

(vi) If temperature measurements exceed any of the criteria above then action
in accordance with the sub-section on defective concrete.

3.7.9 Concrete Curing and Protection

a) General: Protect freshly placed concrete from premature drying and excessive
cold or hot temperatures. In hot, dry, and windy weather, protect concrete from
rapid moisture loss before and during finishing operations with an evaporation-
control material.

b) Initial curing: Start initial curing as soon as free water has disappeared from
concrete surface after placing and finishing. Weather permitting, keep
continuously moist for not less than 7 days.

c) Curing Methods: Perform curing of concrete by curing and sealing compound, by

moist curing, by moisture-retaining cover curing, and by combinations thereof, as
herein specified, as approved by the Engineer.

d) Moisture Curing: Provide moisture curing by following methods.

(i) Keep concrete surface continuously wet by covering with water.

(ii) Use continuous water-fog spray.

(iii) Cover the concrete surface with specified absorptive cover e.g. hessians,
thoroughly saturate cover with water, and keep continuously wet.

(iv) Place absorptive cover to provide coverage of concrete surfaces and edges,
with 100mm lap over adjacent absorptive covers. Leave the cover for at
least a further 7 days following 7 days of curing.

e) Moisture Cover: Provide moisture-cover curing as follows:

(i) Cover the concrete surfaces with moisture-retaining cover for curing
concrete, placed in widest practicable width with sides and ends lapped at
least 75mm and sealed by waterproof tape or adhesive. Immediately repair
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any holes or tears during curing period using cover material and waterproof
tape.

(ii) Leave the cover for at least a further 7 days following 7 days of curing.

f) Curing and Sealing Compound: Provide curing and sealing compound to exposed
interior slabs and to exterior slabs, walks, and curbs as follows:

(i) Apply specified curing and sealing compound to concrete slabs as soon as
final finishing operations are complete (within 2 hours and after surface
water has disappeared). Apply uniformly in continuous operation by power
spray or roller in accordance with manufacturer's directions. Re-coat areas
subjected to heavy rainfall within 3 hours after initial application. Maintain
continuity of coating and repair damage during curing period.

(ii) Use membrane-curing compounds that will not affect bonding of the
concrete surfaces to be covered with finish materials applied directly to
concrete.

g) Curing Formed Surfaces: Cure formed concrete surfaces, including underside of

beams, supported slabs, and other similar surfaces, by moist curing with forms in
place for full curing period or until forms are removed. If forms are removed,
continue curing by methods specified above, as applicable.

h) Curing Unformed Surfaces: Cure unformed surfaces, such as slabs, floor topping,
and other flat surfaces, by addition of water providing or by application of
appropriate curing method.

(i) Within ten minutes of placing and compaction, the unformed surfaces of the
concrete shall be completely covered with white reflective polythene
sheeting with substantial close fitting taped laps.

(ii) The polythene sheeting may be raised a short distance above the concrete
so that it does not mark the surface.

(iii) At the edges of the pour, the polythene shall drape over the forms and it
shall be securely fixed to prevent billowing due to the wind.

(iv) Within three hours of placing and compaction the polythene shall be quickly
removed and replaced with wet hessian laid onto the concrete surface. The
polythene shall then be replaced and secured as above.

i) Final cure concrete surfaces shall be performed using one of the following
methods:

(i) liquid floor hardener or finish flooring by use of moisture retaining cover;

(ii) addition of water to concrete surface by fog spray;

(iii) addition of water by sprinkling.

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j) Potable Water for Curing: potable water shall only be used for curing and the
temperature of water shall not be lower than 10oC cooler than surface
temperature of the concrete at the time the water and concrete come in contact.

3.7.10 Concrete in Adverse Weather

a) No concreting shall take place in the open during storms or heavy rains.

b) Where such conditions are likely to occur the Contractor is to arrange for
adequate protection of the material, plant and formwork so that the work may
proceed under proper cover.

c) Where strong winds are likely to be experienced additional precautions to ensure

protection from driving rain and dust shall also be taken.

d) The Engineer may withhold approval of commencement of concreting until he is

satisfied that full and adequate arrangements have been made.

3.7.11 Batching of admixtures

a) Where air entrainment agents or other admixtures are specified or approved they
shall be added at the mixer.

b) Unless alternative methods to the recommendations of the admixture supplier are

approved the admixture shall be batched in solution in a portion of the mixing
water by means of a mechanical batcher which is capable of dispensing the agent
in quantities varying by not more than 5 per cent from the quantities required and
in such a manner as to ensure uniform distribution of the agent throughout the
batch during the time of mixing.

c) The capability of the apparatus to achieve the required dosing and mixing
requirement shall be demonstrated to the Engineer and the apparatus shall be
checked each day before concrete mixing commences.

3.7.12 Concreting at Night

Where approval has been given to carry out concreting operations at night, the
Contractor is to provide adequate lighting to all points where mixing, transportation
and placing of concrete are in progress.

3.7.13 Striking Formwork

a) The Engineer shall be informed in advance when the contractor intends to strike
any form work.

b) Formwork shall not be removed until the concrete temperature differentials

reached below 20C between surface and core temperature. Formwork shall not
be struck until the structure has attained sufficient strength to carry its own
weight, plus any constructional or other loads likely to come upon it, without
excessive deformation. Also the concrete shall have matured sufficiently to resist
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physical damage. Formwork shall be struck in such in a manner that no damage

shall result to the concrete.

c) Formwork shall not be struck except with the Engineer’s permission. The work of
striking or removing such moulds, shuttering or centering shall be conducted only
under the direct supervision of a competent foreman.

d) The method statements for each structure shall include proposals for the methods
and times for the striking of shutters. Table 3.21 showing the minimum intervals of
time between the placing of concrete and the striking of shuttering at 16C and
above but these periods may be varied by the Engineer if environmental
conditions make this permissible or desirable.

e) Method statements may include proposals for different periods by reference to

recognised standard publications on concreting practice. Where it is proposed to
remove soffit shuttering in advance of props the method statement shall clearly
indicate the sequence and means of dismantling the soffit with a view to
maintaining adequate support.

f) The Contractor shall be responsible for any injury to the work and any
consequential damage caused by or arising out of the removal of the formwork.
Any advice, permission or approval given by the Engineer relative to the removal
and striking of the formwork shall not relieve the Contractor from the responsibility
here defined.

Table 3.21 - Minimum Formwork Striking Times

Type of Formwork Ordinary & Sulphate Resisting

Portland Cement Concrete (Surface
temperature 16C and above)

Beam sides, columns and foundations 4 days

Walls & Floor slab 7 days or temp differential reached to

min 20C & below

Soffits to slabs (props left under) 7 days

Soffits to beams (props left under) 7 days

Props to slabs 14 days

Props to beams 14 days

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3.7.14 Re-use of Formwork

a) CPF Liner on formwork shall be a total of 3 uses.

b) Care should be taken, when re-using formwork, that its surface shall be smooth
and clean and that it shall be free from warping or other deformations.

c) Any formwork which has, in the opinion of the Engineer, deteriorated sufficiently
to render it unsuitable for the work shall be rejected and must be removed from
the Site within 48 hours or must be broken up at once.

d) New formwork with CPF Liner shall be provided at the Contractor’s expense.

3.8 GRANOLITHIC CONCRETE SCREEDS TO FLOORS, SURFACINGS, BENCHINGS

AND CHANNELS

a) Granolithic concrete screeds should preferably be placed and compacted within

three hours of casting the base in which case the base concrete shall be left
rough and the screed shall be spread and consolidated onto the whole of each
bay or structure.

b) Where this cannot be achieved the base concrete shall the cast with a rough
surface. Weak surface laitance and any other contaminating materials must be
completely removed and the coarse aggregate cleanly exposed. This surface
shall be thoroughly cleaned and then soaked overnight, any surplus water being
removed. The surface shall then be brushed with a 1:1 sand/cement grout and
the granolithic concrete screed applied.

c) The granolithic concrete shall be compacted and screeded to levels or falls with a
screeding board and wood float. Further trowelling shall be done with a steel
trowel after about two hours. The thickness of a surfacing where it is inclined at
45 or greater to the horizontal shall not exceed a nominal 15 mm and if this is
inadequate to complete the work the surface shall be left rough and keyed with a
trowel. A further surfacing coat shall be applied within 24 hours.

d) Screeds shall be cured as specified for exposed surfaces and shall be protected
from traffic or other loading for a period of at least 7 days.

e) Where benching and channels are to be protected by epoxy mortar or in situ GRP
lamination the final surface of the concrete shall be left rough.

3.8.2 Inspection of Concrete

The contractor shall not proceed with the surface finish or making good of concrete
surfaces until he has received the Engineer’s Representative’s permission to do so
and he shall not apply cement slurry or mortar or any other coating to the concrete
surfaces from which the shuttering has been struck until the concrete has been
inspected and approved by the Engineer’s Representative.

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3.8.3 Repairs to Concrete

The method of repairing and replacing defective concrete which the Contractor
proposes to adopt shall be submitted to the Engineer’s Representative for prior
approval and the repair shall be carried out in such manner as the Engineer may
direct or approve.

3.8.4 Supervision of Concrete Work

Throughout the progress of the concrete work the Contractor shall employ and
provide such supervision as is necessary to ensure.

a) the day to day control of the quality of the concrete and

b) the mixing, transporting, placing , compacting, curing and protection of the

concrete, and

c) the carrying out of all testing as specified herein and any further testing which the
Engineer’s Representative may require

3.8.5 Cracks in Concrete Structures

The filling of cracks will not be permitted unless approval is given by the Engineer in
writing. Where required by the Engineer the Contractor shall follow the repair
procedures recommended in CIRIA publication 2002.

3.8.6 Quality of Finish

a) The quality of concrete finish shall be as indicated on the Drawings, and shall not
be inferior to that described herein.

b) If any portion of the facework should prove unsatisfactory on removal of the

formwork it shall, without delay, be cut out and made good as directed. No
plastering of concrete surface shall be allowed. At the discretion of the Engineer,
board marks of minor discontinuities on exposed faces may be removed by
rubbing down with carborundum, and pinholes, small voids or minor porosity of
the surfaces, may be filled, by rubbing down with cement and sand mortar of the
same richness as in the concrete. Treatment shall be made immediately after
removing the formwork. The cement used shall consist of a mixture of white and
grey ordinary sulphate resisting cement mixed in such proportions that the colour
of the mortar matches that of the surrounding hardened concrete.

c) Such rectification shall be carried out as directed and shall in no way relieve the
Contractor from his obligation to cut out and reconstruct work if, in the opinion of
the Engineer, such rectification does not give the required standard of surface
finish. Any concrete, the surface of which has been treated without consent, shall
be liable to rejection.

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3.8.7 Classes of Finish Formed Surfaces

On formed surfaces the under listed classes of finish shall be used where ordered.

a) Class ‘A’ finish is of surfaces prominently exposed to view where good

appearance uniform colour and alignment are of special importance. To achieve
this finish, which shall be free of board marks, the formwork shall be faced with
plywood and CPF liner or equivalent material in large sheets. The sheets shall be
arranged in an approved, uniform pattern. Wherever possible, joints between
sheets shall be arranged to coincide with architectural features, or changes in
direction of the surface. All joints between panels shall be vertical and horizontal
unless otherwise directed. Suitable joints shall be provided between sheets to
maintain accurate alignment in the plane of the sheets. Un-faced wrought
boarding or standard steel panels will not be permitted for Class A finish.

b) Class ‘B’ finish is for surfaces which are permanently exposed to view but where
the highest standard of finish with a surface free of blow holes and after surface
blemishes. Forms to provide a class B finish shall be faced with CPF liner
wrought and thickness boards with square edges arranged in a uniform pattern.
Alternatively, plywood or metal panels with CPF liner may be used if they are free
from defects likely to detract from the general appearance of the finished surface.
Joints between boards and panels shall be such as to require no general filling of
surface pitting, but fine surface discoloration and other minor defects shall be
remedied by approved methods.

c) Class ‘C’ finish is for surfaces against which mass-fill concrete will be placed.
Formwork shall consist of sawn boards, sheet metal of any other material which
will prevent the loss of material from the concrete when it is vibrated.

3.8.8 Classes of Finish Unformed Surfaces

On unformed surfaces the under listed types of finish will be required.

3.8.8.1 Class U/A

a) Class U/A is a hard, smooth steel-trowel finish for surfaces of concrete paving,
tops of walls, copings and other members exposed to weathering, surfaces of
beds and slabs to receive thin flexible sheet, and tile paving bedded in adhesive,
and seating for bearing plates and the like where the metal is in direct contact
with the concrete.

b) Trowelling shall not commence until the moisture film has disappeared and the
concrete has hardened sufficiently to prevent excess laitance from being worked
to the surface. The surfaces shall be trowelled under firm pressure and left free
form trowel marks.

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3.8.8.2 Class U/B

a) Class U/B is a floated finish for surfaces of beds and slabs to receive mastic
paving or block or tile paving bedded in mastic, and for exposed surfaces of
paving where a hard smooth steel trowelled surface is not required.

b) Floating shall be done only after the concrete has hardened sufficiently, and may
be by hand or machine.

c) Care shall be taken that the concrete is worked no more than is necessary to
produce a uniform surface free from screed marks.

3.8.8.3 Class U/C

a) Class U/C is a screed finish for surfaces of roads or of blinding under foundations,
bed, slabs, bonded concrete topping or cement mortar beds to receive paving,
and on exposed surfaces of paving where a superior finish is not required.

b) The finishing also the first stage for finishes U/A and U/B. The finishing operations
shall consist of levelling and screeding the concrete to produce a uniform, plain or
ridged surface, surplus concrete being struck off by a straight edge immediately
after compaction.

3.8.9 Defective Concrete

a) Defective concrete shall be defined as one or more of the following:

(i) Not conforming to required levels, lines, details and elevations.

(ii) Defective in required concrete strengths.

(iii) Defective in appearance in ultimate exposed areas due to:

1. Improper placement or preparation of concrete formwork resulting in

bowed formwork.

2. Improper formwork joints.

3. Honey combing.

4. Damaged surfaces.

5. Surface cracks.

6. Exposed reinforcement.

7. Improperly placed snap on or cone ties

8. Unsatisfactory conditions for the performance of sandblasting work etc.

b) Defective concrete work must be reported to the Engineer.

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(i) No remedial work shall be performed without the prior agreement of the
Engineer, with respect to timing, method of repair, final acceptable standard
and appearance of completed repair work.

(ii) Surface cracks less that 0.20 mm width shall be ground out ‘V’ cut and filled
with epoxy mortar (5 mm wide ) or as recommended by the coating/lining
manufacturer unless otherwise directed by Engineer.

(iii) Cracks wider that 0.20 mm shall be fully resin injected as directed by the
Engineer.

c) The engineer will make detailed inspection and may instruct for additional test on
In-place Hardened concrete.

(i) When the routine cube test results indicate specified concrete strength and
other characteristic have not been attained in the structure.

(ii) Surface cracks observed.

(iii) Variation of cube strength observed from specified job mix with the
tolerance limits.

(iv) Reinforcement appears to be near to the surface. Faulty concrete works.

3.8.10 Concrete Surface Repairs

a) Plastic cracking: if plastic shrinkage cracking occurs, the construction affected

shall be rectified and the contractor shall take all necessary steps to prevent a
recurrence. Rectification method and results shall be subject to the approval of
the Engineer.

b) Random Drying Shrinkage Cracking and Plastic Settlement Cracking: if any

cracking of the concrete occurs in an uncontrolled manner the construction
affected shall be rectified and the Contractor shall take all necessary steps to
prevent a recurrence. Rectification method and results shall be subject to the
approval of the Engineer.

c) Patching Defective Areas: Repair and patch defective area with cement mortar
immediately after removal of forms, when acceptable to the Engineer.

(i) Cut out honeycomb, rock pockets, voids over 6 mm in any dimension, and
holes left by rods and bolts, down to solid concrete but in no case to a depth
of less than 25mm. Make edges of cuts perpendicular to the concrete
surface. Thoroughly clean, dampen with water, and brush-coat the area to
be patched with specified bonding agent. Place patching mortar before
bonding compound has dried.

(ii) For exposed-to-view surfaces, blend white Portland cement and standard
Portland cement so that, when dry, patching mortar will match colour
surrounding. Provide test areas at inconspicuous location to verify mixture
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and colour match before proceeding with patching. Compact mortar in place
and strike-off slightly higher than surrounding surface.

d) Repair of Formed Surfaces: Remove and replace concrete having defective

surfaces if defects cannot be repaired to satisfaction of the Engineer. Surface
defects, as such, include colour and texture irregularities, cracks, spalls, air
bubbles, honeycomb, rock pockets, fins and other projections on surface, and
stains and other discoloration that cannot be removed by cleaning. Flush out form
tie holes, fill with dry-pack mortar, or Precast cement cone plugs secured in place
with bonding agent.

e) Repair concealed formed surfaces, where possible, that contain defects that
affect the durability of concrete. If defects cannot be repaired, remove and replace
concrete.

f) Repair of unformed Surfaces: Test unformed surfaces, such as monolithic slabs,

for smoothness and verify surface plane to tolerances specified for each surface
and finish. Correct low and high areas as herein specified. Test unformed
surfaces sloped to drain for trueness of slope and smoothness by using a
template having required slope.

(i) Repair finished unformed surfaces that contain defects that affect durability
of concrete. Surface defects, as such, include crazing and cracks in excess
of 0.20mm wide or that penetrate to reinforcement or completely through
non-reinforced sections regardless of width, spalling, pop outs, honeycomb,
rock pockets, and other objectionable conditions.

(ii) Correct high areas in unformed surface by grinding after concrete has cured
at least 14 days.

(iii) Correct low areas in unformed surfaces during or immediately after

completion of surface finishing operations by cutting out low areas and
replacing with patching compound. Finish repaired areas to blend into
adjacent concrete. Propriety underpayment compounds may be used when
acceptable to the Engineer.

(iv) Repair defective areas, except random cracks and single holes not
exceeding 25mm in diameter, by cutting out and replacing with fresh
concrete. Remove defective areas to sound concrete with clean, square
cuts and expose reinforcing steel with at least 20mm clearance all around
bonding compound. Mix patching concrete of same materials to provide
concrete of same type or class as original concrete. Place, compact, and
finish to blend with adjacent finished concrete. Cure in same manner as
adjacent concrete.

g) Repair isolated random cracks and single holes not over 25mm in diameter by
dry-pack method. Groove top of cracks and cut out holes to sound concrete and
clean of dust, dirt, and loose particles. Dampen cleaned concrete surfaces and
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apply bonding compound. Mix dry-pack, consisting of one part Portland cement to
2/½ parts fine aggregate passing a No.16 mesh sieve, using only enough water
as required for handling and placing. Place dry-pack before bonding compound
has dried. Compact dry-pack mixture in place and finish to match adjacent
concrete. Keep patched area continuously moist for not less than 72 hours.

h) Perform structural repairs with prior approval of the Engineer for method and
procedure, using specified epoxy adhesive and mortar.

i) Notwithstanding the provisions specified in above clauses and irrespective of any

cause of cracks, all cracks wider than 0.2 mm in concrete structures, other than
water retaining or in contact with earth, shall be rectified at the Contractor’s own
cost and time by approved epoxy resin injection method. All cracks in structures
in contact with earth or retaining liquid shall be rectified as above irrespective of
width of cracks.

j) Repair methods not specified above may be used, subject to acceptance of the
Engineer.

3.9 JOINTS IN CONCRETE STRUCTURES

3.9.1 Construction Joints

3.9.1.1 Description

Construction joints are provided for convenience of construction and, in some

instances, to assist in the control of shrinkage cracking.

Where the positions of construction joints are not shown on the Drawings they may
be proposed by the Contractor to suit his methods of working.

Construction joints are required to give monolithic construction and to be leakproof.

a) Locate and install construction joints as indicated or, if not indicated, locate so as
not to impair strength and appearance of the structure, as acceptable to Engineer.

b) Provide keyways at least 40 mm deep in construction joints in walls and slabs and
between walls and footings. Accepted bulkheads designed for this purpose may
be used for slabs.

c) Place construction joints perpendicular to main reinforcement. Continue

reinforcement across construction joints except as otherwise indicated. Do not
continue reinforcement through sides of strip placements.

d) Where kickers are required they shall be placed integrally with the floor slab. This
may necessitate a special design for the formwork. Kickers shall have a height of
not less than 70 mm and not more than 170mm above the floor slab or splay.

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Concrete in kickers shall be of the same mix as the main member. The concrete
shall be vibrated into place and prepared as for other joints.

e) Joints in column and walls shall only be formed about 15mm above the soffits of
suspended floors, at floor levels, or at the tops of kickers which shall not be less
than 70 mm. There may be a joint between haunches or column capitals and the
column.

f) Vertical joints in walls generally shall not be spaced at intervals greater than 6m
and in no case shall be more than 10m. Where, however, a wall changes
direction by at least 60 degrees, the overall spacing of joints may be increased to
10 m subject to the length of pour in either leg of the wall being no more than 5m.
Where possible, joints shall be positioned at least 2m away from corners.

g) Use bonding agent on existing concrete surfaces that will be joined with fresh
concrete.

h) Water Stops: unless specified otherwise, provide PVC Water stops in construction
joints as indicated. Install water stops to form continuous diaphragm in each joint.
Make provisions to support and protect exposed water stops in accordance with
manufacturer’s printed instructions.

i) Isolation Joints in Slabs-on-Ground: Construct isolation joints in slabs-on-ground

at point of contact between slabs-on-ground and vertical surfaces, such as
column pedestals, foundation walls, grade beams, and elsewhere as indicated.

j) Contraction (Control) joints in Slabs-on-Ground: Construct contraction joints in

slabs-on-ground to form panels of patterns as shown. Use saw cuts 3 mm wide
by ¼ depth or inserts 6 mm side by ¼ of slab depth, unless otherwise indicated.

(i) Form contraction joints by inserting pre-moulded plastic, hardboard, or

fibreboard strip into fresh concrete until top surface of strip is flush with slab
surface. Tool slab edges round on each side of insert. After concrete has
cured, remove inserts and clean groove of loose debris.

(ii) Contraction joints in unexposed floor slabs may be formed by saw cuts as
soon as possible after slab finishing as may be safely done without
dislodging aggregate.

(iii) If joint pattern not shown, provide joints not exceeding 5 m in either direction
and located to confirm to bay spacing wherever possible (at column
centrelines, half bays, third bays).

(iv) Joint sealant material is specified in the architectural specifications.

(v) Contractor to submit shop drawing for contraction joints layout for approval
by the Engineer.

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k) No horizontal construction joints in beams, footings, pile caps and rafts shall be
permitted unless approved beforehand by the Engineer. Raft slab of 1.20m to 1.5
m can be cast into one go, without any horizontal joint. Casting can be made of
several pours. Maximum pour should not exceed 500mm in depth. At the sole
discretion of the Engineer, thicker raft slabs may be allowed to be cast with one
horizontal construction joint. Where rafts footings, pile caps etc are allowed to be
poured in two castings, then the horizontal construction joint must be prepared in
accordance with the following:

(i) Additional shear reinforcement to withstand horizontal interface shear shall

be calculated and provided by the Contractor at his own cost.

(ii) The concrete surface of the first pour is to be roughened to full amplitude of
approximately 5 mm. (broom finish).

(iii) Before the next pour, the contact surface is to be water-blasted to make the
surface clean and free of laitance. The clean concrete surface should be
approaching dryness and be free from surface moisture at the time new
concrete is placed on it.

(iv) The second concrete pour is to be carried out within 21 days after the first
pour. The concrete surface is to be kept saturated during the period
between the first and the second pour.

(v) All starter bars for columns and walls are to be brought down to the bottom
layer of the raft foundation reinforcement.

(vi) Only one horizontal joint shall be allowed in the depth of the raft, located
approximately at mid-depth.

l) Separation Strips: provide separate strips at locations as specified elsewhere.

Place concrete in the separation strips after concrete in adjacent areas has been
cured and has been in place for the duration noted on the drawings or specified
herein.

m) Settlement Joints: Place concrete in the settlement joints if specified elsewhere,

after the structure of the lowest tower has reached roof. Remove supports only
upon concrete has gained adequate strength.

3.9.2 Movement Joints

a) Movement joints are provided for expansion, contraction or flexibility. They are
detailed in the Specification and on the Drawings. All movement joints are
required to be leak proof.

b) Expansion and contraction joints shall be formed as detailed in this Specification

and on the Drawings. The Contractor shall ensure that there is no adhesion
between the two concrete faces of the joint and that debris does not enter the
joints.
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3.9.3 Expansion Joints

a) Expansion joints shall be constructed at positions shown on the Drawings or as

directed by the Engineer and shall be formed according to the instruction and
dimensions shown on the Drawings.

b) Type of joints, sealants, and on their selection & correct application shall be as
recommended in BS 6213:2000+A1:2010 .

c) Filled expansion joints shall be provided at every 6 m or as shown in the drawings

and /or directed by the Engineer for the kerb and concrete backing.

d) Any excavated surface for the concrete bedding should be watered and
compacted to a minimum 95% of optimum density.

3.9.4 Water Bars

3.9.4.1 General

a) Water bars shall be obtained from experienced manufacturers (minimum 10

years) and shall be the latest shapes and forms generally adopted in the industry.
Water bars shall comply with Table 3.22.

b) Technical back-up service during installation shall be provided by the

manufacturer at no additional cost to the employer.

3.9.4.2 Waterstop Across Joints in Concrete Structures

a) Seepage of water through any joints in a water retaining or water excluding

concrete structure shall be prevented by the use of PVC Waterstop or other
material as directed and approved by the engineer. They shall be placed centrally
as a water barrier across the designated joint in in-situ concrete structures and
cast centrally into the edges of adjacent concrete components.

b) Waterstop shall be used at all Expansion and Contraction joints in concrete

structures below water table. For a Construction Joint, requirement of a
Waterstop shall be indicated in the drawing. The Engineer may also require the
Contractor to provide Waterstop at any additional Construction Joint approved at
his request.

3.9.4.3 Material

a) Unless otherwise specified all Water stops shall be extruded from a high-grade
elastomeric polyvinyl chloride compound as basic resin and manufactured from
virgin materials necessary to meet the performance requirements of this
specification.

b) Comply with the requirements of BS 2782 or US Corps of Engineers specification

CRD C572-74.

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c) Suitable for storage, handling, installation and service within a range of 15C to
50C.

d) External water bar shall be the ribbed type to provide better watertight sealing
than dumbbells at floor, roof and kicker joints.

e) Intersection & Transition pieces shall be pre-formed factory moulded type and or
factory prefabricated type.

(i) Site jointing shall be limited to butt joints and shall be strictly in accordance
with the manufacture’s instruction.

(ii) Joints shall be heat sealed.

Table 3.22 – Physical properties of water bars

Property Test Method Minimum

Requirements

Tensile Strength ASTM D 638 15 N/m m²

Ultimate Elongation ASTM D 638 370%

Tear Resistance ASTM D 624 50 kN/m

Stiffness in Flexure ASTM D 747 4.14 N/m m²

Hardness, Shore A/15 ASTM D 2240 70 to 80

Water Absorption ASTM D 570 Max 0.3%

Tensile Strength after CRD – C 572 13.5 N/m m²

accelerated extraction

Elongation after CRD – C 572 300%

accelerated extraction

Specific Gravity ASTM D 792 Max 14%

Low temperature ASTM D 746 No failure at - 37C

Brittleness

Volatile Loss ASTM D 1203 Max 0.5%

Effect on Alkali after 7 CRD –C 572 Max + 0.25% /-

days
0.10% Max

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Property Test Method Minimum

Requirements

Weight change  5% Max

Hardness Change

f) Waterstop shall be extruded from high grade grey PVC Compound.

g) Flat Dumbbells plain web Waterstop shall be used for a Construction Joint while
for an Expansion Joint or a Contraction Joint, a centre bulb Waterstop shall be
used.

h) The width of the Waterstop shall depend upon the concrete thickness, the
aggregate size and the position of reinforcement. In general, the following shall be
taken as guide to select the width w of a Waterstop:

W < t, but w > (6a+j)

Where,

t = Concrete thickness

a = largest aggregate size

j = width of Expansion Joint

i) Care shall be taken to prevent damage to water bars. Water bars shall normally
include eyelets for fixing and shall not be nailed unless they incorporate a
reinforced outer nailing flange.

j) Water bars shall not be displaced during the placing of concrete, which shall be
fully compacted around them.

3.9.4.4 External Water stops

a) Base Slab Expansion Joints:

(i) Up to 250 mm wide with four ribs.

(ii) Centre bulb shall be:

1. 25 mm wide

2. Flat to accept a filler board

(iii) Height of ribs shall be 25mm

(iv) Shall have an outer nailing flange with a reinforced and profiled edge to
resist tear when fixed to shuttering with double headed nails.
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(v) Provide additional key when cast into the concrete.

b) Base Slab Construction and Contraction Joints:

(i) Up to 250 mm wide with four ribs

(ii) Height of ribs shall be 25 mm

(iii) Shall incorporate groutite fins in the central section.

(iv) Shall have an outer nailing flange with a reinforced and profiled edge to
resist tear when fixed to shuttering with double headed nails.

(v) Provide additional key when cast into the concrete.

c) Angle Guard

(i) Minimum 125 mm horizontally and vertically with four ribs.

(ii) Height of ribs shall be 25 mm.

(iii) Shall incorporate groutite fins in the central section.

(iv) Shall have an outer nailing flange with a reinforced and profiled edge to
resist tear when fixed to shuttering with double headed nails.

3.9.4.5 Internal Water stops

Wall and Roof Expansion Joints:

a) Up to 250 mm wide with four ribs.

b) Shall have a centre bulb accommodate movement.

c) Centre bulb shall be flat to accept a filler board.

d) Web shall be 10 mm thick with a thickened central section to transfer stresses to

the centre bulbs.

e) Shall have a brass reinforced eyeleted outer flange for secure fixing of the
Waterstop into position.

3.9.4.6 Self-Swelling Water stops to use in construction joints of minor structure like
inspection chamber.

a) Polymer based

b) Size 25 x 10 mm

c) Physical Properties: as per below.

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Physical properties of self-swelling water stops

Property Test Method Minimum Requirement

Elongation ASTM D 638 200%

Hydrostatic Pressure

Resistance 5 bar

Water migration at or none

through joint

d) Water bars shall be arranged so that there is a minimum distance if 25 mm from

the water bar to the reinforcement.

e) The Water stop shall be a high performance system forming a continuous network
as shown on the Contract drawings. Site jointing is to be limited to butt joints and
shall be performed strictly in accordance with the manufacturer’s instructions.

f) The ribs of the centrally placed water stop shall line up with the ribs of the
externally placed water stop. All jointing shall be carried out in strict accordance
with the manufacturer’s instructions using purpose made metal jigs and welding
equipment.

3.9.5 Bond Breakers

Bond breakers shall be polyethylene tape, closed cell expanded polyethylene foam in
flat strip or solid circular core section, or other approved material which is suitable for
preventing short or long term adhesion between the sealant and the base material of
the sealant groove.

3.9.6 Joint Fillers for Expansion Joints of Water Retaining Structures

a) The joint fillers are used as a support to the joint sealing compound to resist the
liquid pressure.

b) Unless otherwise shown on the Drawings joint fillers shall be non-absorbent,

semi-rigid, cellular polyethylene to the approved standard with the following
minimum characteristics: -

(i) Density 60 kg/cum

(ii) Maximum load to compress to 50 % of original thickness 0.15N/sq.mm

(iii) Recovery after compression 98%

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3.9.7 Expansion Joint Filler for Precast Units

a) Expansion joint filler shall be composed of approved durable non-extruding

fibrous material suitably impregnated to prevent deterioration. Sheet bitumen
fillers will not be accepted.

b) Performance strips of expansion joint filler shall be of such a nature as not to be

permanently deformed or broken by twisting, bending or other normal handling on
site. Samples shall be submitted for approval before ordering.

c) The vertical expansion joints in kerbs and parapets shall be formed with approved
vertical seal. Such vertical seal shall adhere to the vertical face sealed and shall
not flow under maximum local sun temperature not shall it be sticky to the touch.

(i) Expansion joints for Precast kerbs shall be at 6 m.

(ii) For flush kerbs cast in-situ, at 2 m max.

(iii) For Precast slabs, every 4 m min

3.9.8 Submittals for Sealants

3.9.8.1 Manufacturer’s Literature

The Contractor shall furnish the following information from the manufacturer

a) Published data or manufacture’s letter, clearly indicating that each product to be

furnished complies with these Specifications is recommended for the application
shown and is compatible with each other material in the joint system.

b) Complete instructions for handling, storage, mixing, priming, installation, curing

and protection for each type of sealant.

c) Test certificates for each type of joint sealant delivered to site.

3.9.8.2 Samples

a) Samples of each type of sealant: Provide samples 300 mm long installed between
two samples of the materials to be sealed, fully cured.

b) Samples will be reviewed by the Engineer for colour and texture only.

c) Compliance with all other requirements is the exclusive responsibility of the

Contractor.

3.9.8.3 Compliance with Performance Requirements

Not-withstanding the types of sealant specified herein, the Contractor shall in all
cases be responsible or providing sealant materials the best of their respective kinds,
compatible with adjoining materials and suitable for the purpose intended, all at no
additional expensive to the Employer.

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3.9.8.4 Guarantee

a) Guarantee stating that the sealant system installed will be watertight and free
from defects for a period of not less than ten (10) years other than sealant for
water retaining structures from date of Taking –Over of the Works.

b) In the event any defects occur within the period stipulated, the Contractor shall at
the convenience of the Employer, effect all repairs and replacements necessary
to remedy defects all to the complete satisfaction of the Engineer at no additional
cost to the Employer.

3.9.9 Environmental Conditions

a) The Contractor shall not proceed with the installation or application of sealant
during inclement weather unless all requirement and manufacturer’s instructions
can be complied with and unless the work can proceed in accordance with the
agreements of the pre-installation meeting.

b) The Contractor shall not proceed with the installation of sealant under extreme
temperature conditions which would cause joint openings to be at either
maximum or minimum width, nor when such extreme temperatures or heavy wind
loads are forecast during the period required for initial or normal cure of sealant.

c) Whenever possible, schedule the installation and cure of sealants during period of
relatively low temperatures (but well within manufacturer’s recommended range)
so that subsequent tensile stress upon the cured sealants will be minimised.

3.9.10 Pre-Installation Meeting

a) Prior to the installation of sealants, and at the Engineer’s direction, meet at the
project site to review the material selections, installation procedures and co-
ordination with other trades.

b) Meeting shall include the contractor, manufacturer’s representative, the Engineer

and representative of other trades or Sub-Contractors affected by the sealant
installation.

c) Examine sample applications to determine and record whether all parties agree
that the proposed installations are likely to perform as required.

3.9.11 Sample Application

a) Provide sample applications of sealants at locations designated by the Engineer.

b) Samples shall represent the primary types of materials, substrate surfaces, and
joint size. Exposure and other conditions to be encountered.

c) Preparation, priming, application and curing shall comply with manufacturer’s

recommendations and actual proposed methods.

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d) Schedule the applications with allowance for sufficient curing time, so that
samples may be examined and any necessary adjustments made at least one
week prior to date scheduled for commencing installation of the work.

e) Samples shall be visually examined for standing, dirt pickup, shrinkage, colour,
general workmanship and appearance.

f) Cut and pull the sealant from each sample joint to examine for internal bubbles or
voids, adhesion and general compatibility with substrate.

3.9.12 Delivery, Storage and Handling

3.9.12.1 Delivery

Deliver materials in manufacture’s unopened containers, fully identified with brand,

type, grade, class and all other qualifying information.

3.9.12.2 Storage

a) Storage materials in a dry location in such a manner as to prevent damage or

instruction of foreign matter.

b) Conspicuously mark “Rejected” on materials which have once been wet or

damaged and remove from the job site.

3.9.13 Materials - General

3.9.13.1 Product Variation

If more than one of the manufacturer’s products complies with the requirements for
any item specified herein, provide the specific product recommended by the
manufacturer for the particular condition of use in each case.

3.9.13.2 Manufacturers

a) Products and manufactures specified hereinafter are specified for the purpose of
establishing minimum quality standards.

b) Products equal in quality to, or better than those specified will be considered
acceptable to no additional cost to the Employer.

c) Decision of acceptability will rest with the Engineer.

d) Manufacturer shall operate a Quality System which is registered to ISO 9000

series or approved equal.

3.9.13.3 Compatibility

a) Provide only sealant and joint primers which are compatible with the joint surfaces
and backing or filler materials as stated in the manufacturer’s published data or as
certified by the manufacturer for each application.

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b) Confirm compatibility of sealant that may be in contact with each other.

3.9.13.4 Hardness

Determine the proper hardness or consistency of elastomeric sealants in consultation

with the manufacturer considering joint movement and exposure for the size of joint
shown.

3.9.13.5 Ranges of Hardness

In general provide sealants with the following ranges of hardness (fully cured sealant
at 24C):

Table 3.23

Exposure (Joints subject to) Shore A Hardness

Maximum movement, normal weather exposure 15 – 25

and abrasion.

Moderate movement, severe weather exposure 25 – 40

and moderate abrasion.

Minimum movement and severe abrasion 35

3.9.13.6 Modulus of Elasticity

a) In general, for elastomeric sealants, provide sealants having the lowest modulus
of elasticity which is consistent with the degree of exposure to wear and abrasion.

b) Any sealant exposed to traffic must have strength and modulus sufficiently high to
resist damage by traffic.

3.9.13.7 Colour

a) For fully concealed joints, provide the manufacturer’s standard colour of sealant
which has the best overall performance characteristics for the application shown.

b) For exposed joints provide the colour shown in the drg or if the colour is not
shown, provide the colour as follows:

The colour in each case will be selected by the Engineer from manufacturer’s
standard colours to match or blend with adjoining materials in a manner to be
determined by the Engineer.

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3.9.13.8 Manufacturer’s Representative

At the start of the installation, and periodically as work progresses, provide the
services of the manufacturer’s technical representative at the job site as often as
deemed necessary by the manufacturer to advice on all phases of this work at no
additional cost to the Employer.

3.9.14 Types of Area and application other than Water Retaining Structures

Table 3.24

Type Area of Application

1. One part elastomeric low 1. Exterior joints in masonry

modulus silicone rubber
sealant. 2. Around aluminium doors, window
frames
a. Conform to BS ISO
11600:2003+A1:2011 3. GRP materials

4. Glazing

2. One Part Elastomeric, high 1. Sanitary ware

modulus, Silicone Rubber
Sealant. 2. Kitchen units

a. Conform to BS ISO 3. Glazing

11600:2003+A1:2011 or

FS-TT-S-001543A

3. Two Part Polysulphide Joint 1. Ceramic tiles

Sealant

a. Resistant to corrosion and

chemicals

4. Two Part Polysulphide Sealant 1. Expansion and Contraction joints in

Concrete
a. Conform to BS EN ISO
11600:2003+A1:2011

5. Two Part Tar/Polysulphide 1. Expansion joints subject to heavy

Sealant traffic.

a. Non-bio degradable

6. Bitumen based sealant 1. Sealing and filling gaps on roofs

2. Pointing chases for water proofing

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Type Area of Application

a. Conform to BS 6920 membrane

7. Two Part Polysulphide sealant 1. Fuel and chemical spillage

with minimum 40% polymer area
content Type I

a. Conform to BS EN ISO
11600:2003+A1:2011

8. Sealant for fire rated structures 1. Pipe and cable penetration

a. Conform to BS EN ISO
11600:2003+A1:2011

3.9.14.1 Miscellaneous Materials

a) Joint Cleaners, Primers and Sealers

Products as recommended by the manufacturer of the sealant for each specific

joint surface and condition

b) Bond Breaker Tape

As specified

3.9.14.2 Execution

Acceptable Conditions

a) Examine the component surfaces and fillers of the joints to be sealed and the
conditions under which the work is to be done.

b) Do not proceed with the work until unsatisfactory conditions have been corrected
in a manner acceptable to the Engineer.

3.9.14.3 Preparation

a) Clean bonding joint surfaces to remove all traces of deleterious material such as
form oil, curing compounds and any surface laitance which might interfere with
bond or otherwise impair the work.

(i) Do not apply elastomeric sealants to joint surfaces previously painted or

treated with sealer, curing compound, water repellent or other coatings
unless a laboratory durability test of bond-cohesion has been performed
and successfully demonstrated that bond will be durable.

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(ii) Test method shall comply with procedures referenced as applicable to the
particular sealant.

b) Do not apply paint and other coatings or substances to surfaces adjoining joint
surfaces until sealants have been installed and are normally cured, so that
adhesion will not be impaired by migration of such substances onto the joint
surfaces.

c) Concrete and Masonry Joint Surfaces

Sealant manufacturer’s recommended primer shall be applied for sealing of

expansion and construction joints in concrete.

3.9.14.4 Installation

a) Comply with the manufacturer’s instructions for the use and installation of each
type of sealant, unless otherwise shown or specified.

b) Prime the sides of the joint with the relevant primer as recommended by the
sealant manufacturer:

(i) Avoid migration of primer or sealer onto adjoining surfaces and remove any
spillage promptly.

(ii) Apply sealant after applied surface becomes tack free but no more than 60
minutes.

c) Install bond breaker tape in joints as shown and wherever recommended by the
sealant manufacturer to prevent bond of the sealant to surfaces where such bond
might impair the performance of the sealant.

d) Do not puncture surface or skin of compressible rod type bond breaker.

e) Have the manufacture’s technical representative present when beginning the

installation of each major type of sealant.

f) Comply with manufacturer’s printed instructions and recommendations, except as

may be otherwise shown or except as may be otherwise directed (and recorded)
by the manufacturer’s representative.

g) Employ only tradesmen who are experienced in the use of the materials specified.

h) Unless otherwise specified all sealants shall be gun applied.

i) Use only the types of equipment recommended by the sealant manufacturer.

j) Apply compounds in continuous beads or rivets, filling joint from the bottom
without openings, voids or air pockets.

(i) Force compound to sides of joint so as carefully and thoroughly “wet”

opposite joint bond surfaces, forming equal areas of contact with sealant.
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(ii) Confine compounds to joint areas shown by use of masking tapes or other
precautions to prevent spilling and migration onto adjoining surfaces.

(iii) Apply compounds in concealed compression joints accurately so that

excess compound will not exude from the joint.

k) Apply sealants in the depth shown or, if none is shown, apply in accordance with
the manufactures recommendations.

l) Tool exposed surfaces so as to compress sealants to the profile shown or, if none
is shown, tool surface slightly concave except provide a slight wash on horizontal
joints where horizontal and vertical surfaces meet.

m) Against rough surfaces or in joints of uneven widths avoid appearance of excess

sealant by locating the sealant well back into wherever possible.

n) Remove excess sealant promptly as the work progresses and clean the adjoining
surfaces as may be necessary to eliminate any evidence of spillage.

o) If job progress or any other condition requires the installation of sealant at

temperature below those recommended by the manufacturer, consult the
manufacturer’s representative and establish the minimum provisions required to
ensure satisfactory work.

p) Record in writing the conditions under which such installations must proceed and
the provisions made to ensure satisfactory work.

3.9.14.5 Curing and Protection

a) Cure the sealants in accordance with the manufacturer’s instructions to obtain

maximum bond to surfaces, cohesive strength and durability at the earliest
possible date.

b) Protect the sealants during the remainder of the construction period, so that they
will be without any indication of deterioration of damage at the time completion of
the Works.

3.9.14.6 Performance Test

a) After curing exterior joints exposed to the weather, test for leaks by applying a
stream of water perpendicularly from a 19 mm hose at normal city water pressure.

b) Test approximately 5% of the exposed joint system where leakage could be

observed.

c) Conduct tests in the presence of the Engineer who will determine the actual
percentage of joints to be tested and the period of water flow exposure based on
any observed leakage.

d) Repair leaks and re-test as directed.

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3.9.15 Joint Sealing in water retaining Structures

a) BS 6213 :2000+A1:2010 provides guidance on types of construction sealant and

their selection and correct application. The Contractor shall provide a minimum 20
years guarantee for the service life of sealant proposed for the water retaining
structure. Selection of sealants for each joint shall take account of:

(i) Appropriate width/depth ratio of the joint

(ii) Material lifetime in the exposure condition concerned

(iii) Chemical resistance

(iv) Movement accommodation as a percentage of joint width

(v) Compatibility with adjacent materials

(vi) Ease of Replacement

(vii) Pot life in the local environment

(viii) Joint backing materials

b) Sealant slots to expansion, contraction and, where included, construction joints

shall be carefully constructed to the dimensions detailed on the Drawings or,
subject to approval of the Engineer to the manufacturer’s recommendations.
Jointing materials shall be capable of accommodating repeated movements
without permanent distortion and shall not be displaced by fluid pressure.

c) The Contractor shall take care to avoid spalling of concrete on the edges of slots.
Slots to expansion joints may be formed by installing joint filler to the concrete
surface and then using a special cutter to remove filler to the required depth.
Alternatively, and for contraction joints, slots may be formed by pre-formed PVC
or timber formers with sloping sides to assist removal.

d) Before placing sealants, the slots must be thoroughly cleaned and all laitance and
oil removed by an abrasive method. Immediately prior to sealing the slots, all
loose surface debris, sand and dust must be blown out using compressed air, and
the slots must be dry and free from collected rainwater etc. to ensure maximum
adhesion.

e) Sealants must in all cases be carefully selected as appropriate for their climatic
and environmental exposure and must, where appropriate, be resistant to bio-
degradation. The Contractor must supply to the Engineer copies of written
recommendations(s) and guarantee(s) from the manufacturer as to the suitability
of the product(s) for each individual structure and for the methods of installation.

f) Primers for use with joint sealants shall be compatible with, and obtained from the
same manufacturer as, the adjacent sealant. Primers shall have no harmful
effects on concrete.
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g) Where required by the Engineer masking tape shall be applied to protect the
concrete surface on either side of the joint priming and sealing operations. Such
masking tape must be carefully stripped away after joint sealing to leave neat
edges to the seal.

h) The recess to joints to be sealed with Polysulphide based sealant and shall not be
painted with bituminous products due to reactivity.

3.9.16 BOND BREAKING COMPOUND FOR DOWEL BARS

Bond breaking compound for dowel bars shall consist of a bitumen paint containing
66 per cent of 200 pen bitumen, blended hot with 14 per cent light creosote oil with
the addition, when cold, of 20 per cent solvent naphtha. It shall in no way retard or
otherwise affect the setting of concrete.

3.9.17 Expansion Joint Sealing Compound

3.9.17.1 General

a) The sealing compound shall be of an approved Polysulphide compound, non-

pouring grade for vertical application and pouring grade for horizontal application.

b) Expansion joints in contact with sewerage structures shall be a highly chemical

resistant two part polysulphide sealant with high polymer content conforming to
the requirements.

c) All joints Type I & III are to be treated with Hypalon Elastomer strip as specified in
Section 3.13 of this Specification Clause.

d) The sealants shall have high resistance to acid and alkalis and must be carefully
selected from Type I to III as appropriate for their climate and environmental
exposure.

3.9.17.2 Type I Joint Sealants

Type I Joint Sealants are those to be used for structures in contact with sewerage in
immersed condition (for expansion joints), which shall comply with the following
conditions:

a) Two part Polysulphide conforming to the requirements of BS EN ISO

11600:2003+A1:2011

b) Colour : Black

c) Hardness Shore ‘A’ (ASTM D2240) : Minimum 35

d) Movement Accommodation Factor : 20% 5

e) Polymer Content : min 40% (for sewage grade)

f) Elongation (ASTM D 638) : min: 200%

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g) Resistance to weathering, ultra-violet light, chemicals and biodegradation.

h) Ability to withstand repeated cycles of compression and expansion over a wide

temperature range.

i) Shall comply either the requirement as specified in “Sealants”.

j) Contractor must apply written recommendations and guarantees from the

manufacturers as to the suitability of the product for each individual structure and
the method of installation.

k) The Sealant shall be resistant to the sewage environment and

(i) shall have no harmful effects on concrete.

(ii) as recommended by the sealant manufacturer.

l) Resistant to 10% sulphuric acid @ 100 days: shall not show any deterioration
after the test in accordance with ASTM C581.

m) Type 1 sealants are to be covered with Hypalon sealing strips as specified in

Section 3.13

3.9.17.3 Type II - Joint Sealants

a) Type II sealants are to be used in structures not in contact with sewerage but
exposed to sunlight (for Expansion Joints).

b) Expansion joint sealants in other structures will be a two part polysulphide sealant
conforming to BS EN ISO 11600:2003+A1:2011 and US Federal Specification TT-
S-00227E.

c) The sealant will have the following properties.

1. Shore A hardness (TT-S-00227E): Min. 20

2. Movement Accommodation factor: 25%5
3. Elongation (ASTM D 638): Min. 350%
4. UV Resistance for 300 hours (ASTM G53) : No deterioration

3.9.17.4 Type III – Sealant for Sewage Tanks and other similar Structures (for Construction
Joints)

Epoxy modified polyurethane sealant conforming to the requirements.

This sealant shall have the following properties:

1. Shore A hardness (TT-S-00227E): 75%  10

2. Movement Accommodation factor: 10% 5
3. Elongation (ASTM D 638): Min. 50%
4. Resistance to 10% sulphuric acid @ 100 days: Shall not show any deterioration after
the test in accordance with ASTM C581.

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Type III sealants are to be covered with Hypalon sealing strips as

specified in Section 3.13 of this specification clause.
3.9.18 Properties of Sealant to fix GRP MH Liners

The sealant shall have the following properties:

Table 3.25: Properties of Sealant

Properties Requirements

Movement Accommodation Factor 10% 5

Cure Time @ 20C @35C

Initial: 24 hours 12 hours

Full: 3 days 2 days

Application temperature + 5C to 45C

Service temperature - 10C to 70C

Specific Gravity 1.31

Shore ‘A’ hardness 60-80

Chemical Resistance Good resistance to most common

mineral acids-alkalis, petroleum based
fuels and stream.

Resistant to 10% sulphuric acid @100 Shall not show any deterioration after
days tested in accordance with ASTM the test
C581

3.9.19 Dowel Bars

a) Dowel bars shall be straight, free from burred edges or other irregularities, and
shall have their sliding ends sawn.

b) The sliding half of each dowel bar shall be painted with a thin coat of bond
breaking compound, and the end of this half shall be provided with a close fitting
plastic or waterproof cardboard cap at least 100 mm long, the end 20 mm of
which shall be filled with a disc of joint filler or a pad of cotton waste.

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3.9.20 Bond Breaker Tape

a) Forced, non-absorbent polyethylene backing strip or equals

b) As recommended by the sealant manufacturer to prevent adherence of sealant to

backup material.

3.9.21 Sealing Strip Membrane Based On Hypalon-Elastomer

a) Hypalon elastometer strip with 2-part epoxy resin adhesive.

b) Shall allow considerable movements in more than one direction while maintaining
a high quality seal.

c) Strip width: 150 mm

d) Strip thickness: 2 mm

Table 3.26 – Sealing Strip Membrane – Physical Properties

Property Minimum Requirements

Strip Membrane:

Tensile Strength > 6 N/m m²

Peel Strength 4.5 N/m m²

Elongation at Break > 400%

Bending Test No Cracking at - 30C

Service Temperature -30C + 60C

Adhesive:

Density 1.7 kg/l

Pot life at 40C 25 min

Compressive Strength > 50 N/m m²

Bond Strength to Steel > 3 N/m m² (Concrete failure)

Final sealing strip system shall be able to accommodate movement which results in
the de-bonded area being extended up to 100% of the de-bonded width.

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3.9.22 Slip Membrane and Installation

3.9.22.1 Slip Membrane

a) The slip membrane shall be of low friction bearing strip to form a thin sliding joint
provided in two layers, each 1.5 mm thick.

b) The slip strips shall be manufactured from specially formulated polyethylene

resistant to most chemicals, solvents and weathering.

c) The bottom layer shall be bonded to substrate with high quality solvent borne
adhesive based on polychloroprene rubber.

d) Slip membrane shall have a coefficient of static friction of 0.15.

3.9.22.2 Installation of Slip Membrane

a) The roof slab of the reservoir is designed as a continuous flat slab.

b) Two layers of slip membrane shall be provided at the wall support to slab soffit.

3.10 REINFORCEMENT STEEL

3.10.1 General

a) This work shall consist of furnishing, fabricating and placing steel reinforcement
bars of the grade, type, quality, size, shape and quantity designated, all in
accordance with these Specifications and the details shown on the Drawings. The
epoxy coated reinforcement steel shall be used on the project.

b) The Contractor shall be responsible for furnishing reinforcing steel in sufficient

quantity and of the proper sizes, lengths and shapes shown on the Drawings for
any given structure.

3.10.2 Material Specifications

a) All reinforcement bars shall be of a deformed type in accordance with BS

4449:2005+A2:2009, except that plain bars may be used where specifically
indicated on the Drawings. Plain bars shall be in accordance with BS 4449
:2005+A2:2009.

b) All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars, Grade 500 (ribbed bars), unless otherwise
shown on the Drawings or specified by the Engineer.

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Table 3.27 - High Yield Steel Reinforcement Bars – Compliance Requirements

(Test Method BS4449:2005+A2:2009, Grade 500)

Bar Nominal Cross sectional Mass per metre , Test Results

Diameter area m² kg

6mm 28.3 0.222

8mm 50.3 0.395

10mm 78.5 0.617

12mm 113 0.888

16mm 201 1.58

20mm 314 2.47

25mm 491 3.85

32mm 804 6.31

40mm 1257 9.86

50mm 1963 15.4

Tolerances : The permissible deviation from nominal mass per metre shall not more
than +/- 4.5% on nominal diameters greater than 8 mm , and +/- 6% on nominal
diameters less than or equal to 8 mm .

Yield Stress (N/m Characteristic = 500

m²)
Minimum = 485

Maximum = 650

Tensile Stress As per BS

(N/m m²) 4449:2005+A2:2009

Elongation, % As per BS
(gauge length) 4449:2005+A2:2009

Bend Test As per BS

4449:2005+A2:2009

Rebend test As per BS

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Bar Nominal Cross sectional Mass per metre , Test Results

Diameter area m² kg

4449:2005+A2:2009

Chemical Analysis

Carbon %

As per BS
4449:2005+A2:2009
Phosphorous %

Sulphur %

c) Mild steel where specified or called for shall be either deformed or plain bars
complying with BS4449:2005+A2:2009 or any equivalent National Standard as
directed and approved by the Engineer.

d) Tying wire shall be No.18 gauge stainless steel wire or the equivalent BS
specification for tying wire and uPVC coated suitable for epoxy coated rebar.

e) Welded wire fabric shall be used as reinforcement for concrete where shown on
the Drawings and as directed. Welded wire fabric shall conform to the
requirements of BS 4483 ..

f) The Contractor shall be responsible for obtaining the Engineer’s approval to the
steel bars prior to coating commencing. A certificate of product conformity in
accordance with Clause 8 of BS4449:2005+A2:2009 shall be issued. Such
approval will in no way relieve the Contractor of his responsibilities under the
Contract.

Table 3.28 - Fusion Bonded Epoxy Coating Materials – Compliance

Requirements

Properties Requirement Results Test Methods

Finish & colour Light green (to be filled Manufacturer’s spec

by the
applicator)

Gel time Manufacturer’s spec (to be filled Manufacturer’s spec

by the @200oC

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Properties Requirement Results Test Methods

applicator)

Cure time Manufacturer’s spec (to be filled Manufacturer’s spec

by the @200oC (min. time to
applicator) quench)

Dry film thickness 7~12 mils ASTM A775/A775M

(175~300µ) ASTM G12

Continuity of coating 3 holidays/m ASTM A775/A775M

(67.5 volt DC holiday
detector)

Flexibility & No cracking ASTM A775/A775M

adhesion
No dis-bonding (180o bending)

Impact resistance No shattering, ASTM A775/A775M

cracking, bond loss
of coating ASTM DG 14 (80 in
lbs)

Abrasion resistance  100 mg ASTM A775/A775M

ASTM D4060

Cathodic dis-bond  4 mm (from the ASTM A775/A775M

edge)
ASTM G8
(1.5v*3%NaCl*24oC*1
68h)

g) Coating material shall be epoxy resin powders as specified in ASTM A775 for
coating of reinforcing bars.

(i) Epoxy resin powders which do not meet the above requirements must be
tested for the properties specified by an approved independent testing
laboratory and accepted by the Engineer prior to use.

(ii) Only fusion bonded epoxy coated reinforcing steel will be accepted.

(iii) No other means of epoxy coating will be approved.

h) Patching Material:

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(i) shall be furnished by the epoxy manufacturer

(ii) compatible with the coating

(iii) inert in concrete

(iv) suitable for repairs to the coated reinforcing bars to be made by the coating
applicator and the Contractor at the project site.

3.10.3 Testing of Reinforced Steel

3.10.3.1 Testing of Reinforced Steel (Uncoated)

a) Testing shall be carried out on uncoated steel bars in accordance with

BS4449:2005+A2:2009 unless otherwise specified here in and shall submit a
compliance statement in accordance with the summary sheet attached.

b) The following tests shall be carried out for each delivery of reinforcement.

(i) Cross-sectional area and mass

(ii) Deformation/bond characteristics of deformed bars

(iii) Tensile test

(iv) Yield stress

(v) Elongation

(vi) Bend test

(vii) Re-bend test

(viii) Chemical composition

(ix) Carbon equivalent value

c) Testing frequency shall be in accordance with BS4449:2005+A2:2009.

d) Test results for each bar size shall be submitted to the Engineer three (3) weeks
before concrete work commences on site.

e) Further tests may be called for when the source of supply of reinforcement
changes in which case the cost of such extra testing will be borne by the
Contractor.

f) When any test results do not confirm to the relevant standard, the reinforcement
steel shall be removed from the site and all costs resulting therefrom shall be
borne by the Contractor.

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3.10.3.2 Test on epoxy coated reinforcing bars

a) Adhesion and flexibility of the epoxy coating shall be evaluated on test bars
coated with each production lot.

b) Test bars shall be furnished extra

c) At least 1 percent of the length or 6 metres. Whichever is less, of each size of bar
to be coated shall be furnished as test bars.

d) Test bars may be in one length or multiple lengths as required to have one test
bar of each size with each production lot.

e) The flexibility of epoxy coated production bars shall be evaluated by bending 180
degrees (after rebound) around a mandrel of a diameter corresponding to size of
bar. Bend shall be made at a uniform rate and may take up to one minute to
complete. Bend test shall be conducted at room temperature 20 C - 30 C after
the specimen has been exposed to room temperature for a sufficient time to
ensure that it has reached thermal equilibrium.

3.10.4 Construction of Reinforcement

a) Steel reinforcing shall be stored on timber packing clear of the ground. The steel
bars shall be free from sharp deformations, rolled-in slivers, deep recesses or
surface faults/blemishes which could result in inefficient or inadequate coating.
When fixed in the work and immediately prior to concreting, steel reinforcing shall
be entirely free from loose mill scale, loose rust, oil, grease, paint, mould oil, and
all other deleterious and extraneous material. All hooks, bends, etc., unless
otherwise shown on the Drawings shall be to BS EN ISO 4066:2000 & BS
8666:2000.

b) Cut end of reinforcement is to be patched before any visible oxidation appears.

The patching material shall be furnished by the epoxy coating manufacturer.

c) Before ordering reinforcing steel, the Contractor shall prepare bar bending
schedules at his own cost and submit them to the Engineer for his approval. Bar
schedules shall show the weight of each bar, the total weight of each bar size and
the total weight of bars, and bending diagrams for bars in accordance with BS EN
ISO 3766:2003 & BS 8666:2005. Unless otherwise specified laps, hooks and bends
shall be to the minimum dimensions detailed in the approved standard .

d) The Contractor shall also provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of bar bending schedules or for the completion of the
Works.

e) The Engineer’s approval of the Contractor’s working drawings and bar bending
schedules shall in no way relieve the Contractor of responsibility for the
correctness of such drawings or schedules.
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f) Steel reinforcement shall be bent accurately to the shapes and dimensions shown
on the approved bar bending lists or drawings. Bars shall be bent round mandrels
of the requisite diameter.

g) Steel reinforcement shall be cut and bent in accordance with BS EN ISO 3766:2003
& BS 8666:2005. Cutting or bending by the application of heat is not permitted.
Where fabric reinforcement is required to be bent it shall be done cold, either
using a bending machine or swage blocks and hooks. Fabric reinforcement shall
be cut to cover the areas detailed plus the following laps:

(i) Rectangular mesh: 450 mm for longitudinal members; 75 mm for transverse

members.

(ii) Square mesh: 300 mm in each direction.

h) Welding of reinforcement shall only be permitted when approved in writing by the

Engineer. If such approval is given then the workmanship shall be in accordance
with BS EN 1011-2:2011 & BS EN 1011-1:1998. The Contractor shall submit full
technical details of his proposed procedures prior to seeking approval.

i) Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than four
times the nominal size of the bar.

j) Links, hoops, stirrups are generally to be bent round pins of the same diameter as
the bars they are to embrace. Where however, such bars are less in diameter
than twice the diameter of the link, the radius of the bend shall be equal to the
diameter of the link.

3.10.5 Placing Reinforcement

3.10.5.1 General

a) The number, size, form and position of all reinforcement shall, unless otherwise
directed or authorised by the Engineer, be strictly in accordance with the
Drawings.

b) Nothing shall be allowed to interfere with the disposition of the reinforcing bars.

c) Bars generally must be of the required lengths. Welding of the bars will not be
permitted.

d) Lapping of the bars other than the lap splices shown on the Drawings should be
avoided. The Engineer may approve certain lapping under special conditions. All
lapping should comply strictly with the BS/ASTM specifications, namely Article
1.5.6. Clause "c".

e) All intersecting bars shall be bound together with stainless steel wire with the
ends of the wire turned into the main body of the concrete.
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3.10.5.2 Maintaining Reinforcement in Position

a) Concrete cover blocks shall, unless otherwise directed, be used between the
reinforcement and the bottom and sides of the forms to ensure correct placing
and cover of the bars. The strength of such concrete cover blocks shall be not
less than that of the main concrete.

b) The reinforcement shall be assembled as dimensioned on the Drawings within

tolerances appropriate to the structure. It shall be firmly held in position by wire
ties and concrete blocks or other approved spacers designed to maintain the
correct clear cover of concrete over steel reinforcement. They shall be as small as
possible consistent with their purpose, and of a shape acceptable to the Engineer.
Minimum cover to reinforcement shall be as specified. The position of spacers
and their method of use shall be approved by the Engineer. No concrete or
reinforcement shall be cut in any way except by permission in writing from the
Engineer.

c) Concrete cover blocks shall be manufactured to the same specification as the

surrounding concrete. When tested in accordance with the approved standard the
water absorption shall not exceed 2% for samples up to the age of one month at
the time of test. Wire cast in the block for the purpose of tying it to uncoated
reinforcement shall be of stainless steel or epoxy coated wire and shall be rust
and contaminant free.

d) Spacers shall be of rust-proof material and shall not produce staining, or

otherwise be detrimental to the concrete or steel.

e) All chairs, spacers, tie-wires (including wire cast in blocks) or other devices used
to support or fasten epoxy coated reinforcement shall be made of or coated with a
dielectric material such as nylon, epoxy or plastic compatible with the coating of
the reinforcement.

f) Nothing shall be allowed to interfere with the disposition of any member of the
reinforcement and the Contractor shall take special precautions that it is not only
correctly placed, but remains undisturbed during the placing and setting of the
concrete, and that it has not been contaminated with release agent or any other
substance which will prevent the best possible bonding of steel and concrete.

g) With the approval of the Engineer mild steel reinforcement may be temporarily
bent aside at construction joints. This shall be done with care to a minimum
internal bending radius of 4 bar diameters and to avoid damage to the concrete
during bending and re straightening. The bending of high yield bars, epoxy coated
reinforcement and fabric reinforcement at construction joints is not permitted.

h) The greatest care shall be taken to prevent any displacement or bending of the
members of the reinforcement adjusted and temporarily fixed in position before
commencement of the concreting. Reinforcement temporarily left projecting from
the concrete at construction of other joints shall be adequately protected against
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displacement both during concreting and afterwards and shall not be bent out of
position unless agreed by the Engineer's Representative. During the concreting
competent steel fixer shall be in attendance to re-set any reinforcement
inadvertently displaced.

3.10.5.3 Approval of Reinforcement Before Concreting

a) The Contractor shall in all cases request the approval of the Steelwork by the
Engineer's Representative in sufficient time to allow an inspection to be made and
shall not commence concreting until such approval is obtained.

b) The period between the Contractor's request for approval and his intention to
commence concreting shall not be less than one clear normal working day and
the Engineer's Representative may require a longer period if, in his opinion, the
reinforcement is of such complexity as to require it.

c) Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

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GENERAL SPECIFICATIONS

SECTION 4

PIPES, PIPEWORK, MANHOLES AND CHAMBERS

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 4
PIPES, PIPEWORK, MANHOLES AND CHAMBERS

CONTENTS
4 PIPES, PIPEWORK, MANHOLES AND CHAMBERS ...................................................... 1
4.1 PIPE MATERIALS ....................................................................................................... 1
4.1.1 Pipe Classifications and Pressure Ratings .......................................................... 1
4.1.2 Joint Requirements and Limitations..................................................................... 1

4.2 RIGID PIPES................................................................................................................ 4

4.2.1 Reinforced Concrete Pipes.................................................................................. 4
4.2.2 Ductile Iron Pipes .............................................................................................. 13
4.2.3 Joints................................................................................................................. 17
4.2.4 Other Ferrous and Non-ferrous Pipes & Fittings ................................................ 25

4.3 THERMOPLASTIC PIPES ......................................................................................... 25

4.3.1 Unplasticised Polyvinyl Chloride Pipes and Fittings (uPVC) .............................. 25
4.3.2 POLYETHYLENE PIPES (HDPE) ..................................................................... 27

4.4 GRP PIPES & FITTINGS ........................................................................................... 38

4.4.1 Definitions and Requirements ........................................................................... 38
4.4.2 Glass Reinforced Plastic Pipe & Fittings (GRP) for use in Gravity and Pressure
Flow Systems.................................................................................................................. 40
4.4.3 Compulsory Requirements Particular to Pipes, Couplers and Joints ................. 44
4.4.4 Type Test for GRP Pipes and Joints ................................................................. 47
4.4.5 GRP Pipes and Fittings for Pumping Stations and Valve Chambers ................. 59
4.4.6 GRP Pipes and Fittings for Irrigation and Potable Water Distribution &
Transmission .................................................................................................................. 60

4.5 STORAGE AND HANDLING OF PIPES .................................................................... 72

4.5.1 General ............................................................................................................. 72
4.5.2 Glass Reinforced Plastic Pipes (GRP)............................................................... 72
4.5.3 Thermoplastic Pipes (uPVC) ............................................................................ 73
4.5.4 Reinforced Concrete Pipes (RCP) ..................................................................... 73
4.5.5 HDPE Pipes ...................................................................................................... 73

4.6 GRANULAR MATERIAL FOR PIPE BEDDING AND SURROUND ........................... 74

4.6.2 Stone for Land Drains ....................................................................................... 75
4.6.3 Compaction Fraction Test ................................................................................. 75

4.7 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION ........................... 76

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4.7.1 General ............................................................................................................. 76

4.7.2 Nominal Trench Width for Flexible Group ‘B’ Pipes ........................................... 76
4.7.3 Pipelines in Wide Trenches ............................................................................... 76
4.7.4 Pipe Laying and Jointing ................................................................................... 77
4.7.5 Pipelines in Concrete Cradles and Surrounds ................................................... 78
4.7.6 Pipelines on Granular Beds ............................................................................... 79
4.7.7 Placing Surrounds to Pipelines .......................................................................... 80
4.7.8 Group A Rigid Pipes Bedding, Surround Materials and the Trench Width ......... 80
4.7.9 Group B Pipe Materials ..................................................................................... 80
4.7.10 Compaction of Pipe Surrounds .......................................................................... 80
4.7.11 Pipelines below Permanent Groundwater Level ................................................ 81
4.7.12 Backfilling of Trenches - Pipelines/Structures .................................................... 81
4.7.13 Deflection Measurements on Group B Pipelines ............................................... 81
4.7.14 Deflection Measurements - GRP Pipes ............................................................. 82
4.7.15 Deflection Measurements - uPVC and other Plastic Pipes ................................ 82
4.7.16 Deflection Criteria on Group B Pipelines ........................................................... 83
4.7.17 Stanks to Pipelines in Granular Bedding ........................................................... 84
4.7.18 Thrust and Anchor Blocks to Pressure Pipelines ............................................... 84
4.7.19 Pipes Protruding from Structures, Concrete Surrounds and Anchor Blocks....... 84
4.7.20 Protection of Pipelines and Pipeline Component ............................................... 86

4.8 PIPEWORK WITHIN STRUCTURES ......................................................................... 96

4.9 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES ..................................... 96
4.9.1 General ............................................................................................................. 96
4.9.2 Construction of Manholes, Chambers, and Special Structures .......................... 96
4.9.3 Access Covers, Frames, and Grates ................................................................. 98

4.10 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS ................ 104
4.10.1 Repair Mortar for Metal Products..................................................................... 106
4.10.2 Approved List of Suppliers............................................................................... 106

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4 PIPES, PIPEWORK, MANHOLES AND CHAMBERS

4.1 PIPE MATERIALS

4.1.1 Pipe Classifications and Pressure Ratings

For structural purposes pipes shall be classified into two groups: -

Group A: Rigid pipes which do not depend on lateral support from the bedding and
trench sides for structural strength. Pipe materials include:

a) Stainless steel

b) Ductile Iron

c) Reinforced Concrete (RC)

Group B: Flexible pipes which depend on lateral support from the bedding and
trench sides for structural strength and to prevent distortion. Pipe materials include:

a) GRP (Glass Reinforced Plastic)

b) uPVC (Un-plasticised Polyvinyl Chloride)

c) HDPE (High Density Polyethylene)

d) PP (Polypropylene)

4.1.2 Joint Requirements and Limitations

Unless pipes are detailed with rigid joints or are specified differently all pipelines shall
be jointed with approved mechanical, flexible joints with elastomeric joint rings. The
whole joint assembly shall be compatible with the pipe construction and with the
specified performance of the completed pipeline.

4.1.2.1 Flexible Joints

Flexible joints shall be as a separate sleeve coupling and double spigot assembly
with two sealing rings.

Elastomeric joint sealing rings shall be manufactured to BSEN-681-1:1996 from

ethylene propylene rubber (EPDM) and shall have a hardness measured in
International Rubber Hardness Degrees (IRHD) compatible with the pipe material.

Deflection: The completed joint shall be capable of accepting the following ranges of
deformation when subjected to internal pressure without losing its seal at the
specified test pressure, without direct contact between spigot and socket/coupling
and without inducing stresses or strains in the pipe material beyond the safe working
limits.

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Table 4-1: Minimum Allowable Angular Deflection for Flexible Joints

Pipe Material Pipe Diameter (mm) Angular Deflection
(Degrees)

All materials (except up to 200 3

concrete and clay pipes)
Over 200 to 500 1.75

Over 500 to 1350 1

Over 1350 0.5

Straight draw: Not less than 10 mm or the following proportions of the length of the
longest pipe/unit at any joint:

- 1% for polyethylene pipes

- 0.5% for polypropylene
- 0.3% for GRP and uPVC pipes

In case of difference between this specification and the manufacturer’s specifications

then the most stringent requirements shall prevail.

Shear: Pipe materials which are listed in structural Group A shall be loaded to 10
times DN (mm) in Newton in accordance with BS EN-512:1995. Pipe materials which
are listed in structural Group B shall be subjected to a load of 17.5 N/mm of pipe
diameter in accordance with ASTM D-4161.

If the approved standard for a pipe material does not include a shear test for the
jointing system, this test shall be carried out in accordance with test procedure of
another appropriate pipe material standard.

4.1.2.2 Flanged Joints

Flanged pipes shall incorporate an annular gasket at the Joints and these gaskets
shall be manufactured to BS 1514-1:1997 from ethylene propylene rubber (EPDM)
3.0 mm thick and shall be dimensioned to full face of the pipe flange and to suit the
flange drillings. The hardness of the rubber (IRHD) shall be to the manufacturer's
recommendations to suit the pipe material but for pipe materials in Group A shall be
in the range 66 to 75.

4.1.2.3 Dismantling Joint and Flange Adaptor

a) Dismantling Joint

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This shall be used on GRP, ductile iron and stainless steel pipes and joints between
each of the materials as shown on the drawings. This shall provide flexibility at
installation stage of flanged pipework systems.

The dismantling joint is to comprise a flange adaptor, flange spigot piece and tie bars,
in a complete package and to allow a greater adjustment length allowance at the
installation stage. Adjustability is to be provided by the combination of a flange
adaptor and flanged spigot. Up to 50 mm of longitudinal adjustment (dependent upon
diameter) is to be available due to telescopic action of the spigot within the flange
adaptor. Once the final installation position is achieved bolt up procedures for the
flange adaptor and tie bars are to be applied.

The dismantling joint shall be fitted in accordance with the manufacturer’s

recommendation. Flanges shall be PN 10/16 rating.

(i) Steel for spigot and flange adaptor body in accordance with BS EN
10025:2004 Grade Fe 430 A

(ii) Rubber gasket to BSEN 681 – 1:1996 or to suit service.

(iii) Stainless steel for studs to BS 970: Part 1:1983 Grade 070 M20.

(iv) Stainless steel for tie bolts to BS 1506:1990: Table 1: Type 630-860

b) Flange Adaptor

This shall be used on GRP, ductile iron and stainless steel pipes to enable plain-
ended pipe to be connected either to flanged pipe or flanged valves or other fittings.
Flange adaptor to be provided with flat mating faces, suitable for bolting to raise
faces.

Flange Adaptors shall be of the restrained type where specified.

Flange adaptors to suit pressure rating of the flange PN16 or PN10 as specified.

The overall pressure rating of the assembled adaptor to be equal to that of the lower
rated component either pipe or flange.

Form of adaptor (straight sleeve, expanded sleeve or tapped flange) to be chosen as

per site requirements.

Material:

(i) For < 150 mm dia. body – ductile iron, end flange-malleable cast iron

(ii) For > 150 mm dia. body – ductile iron

(iii) For < 300mm dia. end flange – rolled steel.

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(iv) For > 300 mm dia. body – fabricated rolled steel, end flange – rolled steel.

4.1.2.4 Bolted Couplings

Bolted couplings shall be flexible couplings and shall be capable of withstanding the
pressure tests of the pipeline in which they are installed. They shall also be capable
of accommodating the deflections and movements specified for flange adaptors.

4.1.2.5 Nuts and Bolts

All bolts, nuts and washers shall be of stainless steel grade 316 S16 to BS 970: Part
1 or DIN 17440:4571 and shall remain unpainted. PTFE washers shall be fitted
beneath stainless steel washers for both bolt head and nut.

4.1.2.6 Shipping and Handling

All elastomeric joint sealing rings and gaskets for flanged pipes shall be supplied and
transported in light proof packaging so as to prevent damage due to ultra violet
radiation. The Contractor shall provide suitable storage facilities to prevent ultra violet
exposure until use.

4.2 RIGID PIPES

4.2.1 Reinforced Concrete Pipes

4.2.1.1 General

This section of the specification gives the requirements for Reinforced Concrete (RC)
pipeline materials and the installation and testing thereof in diameters 600mm and
above for use in gravity/low pressure systems.

4.2.1.2 Applicable Standards and Codes

RC pipes, fittings and accessories shall comply with the latest issue of the following
standards and other relevant standards noted elsewhere in this specification:

Standard Description

ASTM C76 Standard specification for reinforced concrete culvert, storm

drain and sewer pipe.

ASTM C361 Standard specification for reinforced concrete low head pressure
pipe.

ASTM D412 Standard test method for vulcanised rubber and thermoplastic
rubbers and thermoplastic elastomers- tension.

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Standard Description

BS 5911-1 Concrete pipes and ancillary concrete products. Specification for

unreinforced concrete pipes (including jacking pipes) with flexible
joints

BS EN 681 Elastomeric seals. Material requirements for pipe joint seals

used in water and drainage applications. Vulcanised rubber.

BS EN 1916 Concrete pipes and fittings, unreinforced, steel fibre and

reinforced

ISO 9000 Quality management systems.

4.2.1.3 Pipes and fittings

Reinforced concrete pipes and fittings with PVC internal lining shall be manufactured
to ASTM C76 class IV. Concrete for pipes and fittings shall be to the requirements of
Section 3 of the specification and shall be made using sulphate resisting cement type
V.

The entire interior surfaces of pipes and fittings shall be lined with a PVC or HDPE
lining to the product requirements as specified in the following text in this Section
of the specification.

a) Joints for reinforced concrete pipes

(i) All buried joints shall be spigot and socket type with EPDM rubber sealing
rings in accordance with ASTM C361 or BS EN 681. The sealing rings shall
be supplied by the pipe manufacturer.

(ii) The EPDM rubber sealing ring shall be of acceptable composition and must
be contained in a groove on the spigot end of each pipe to ensure proper
positioning and confinement in the annular space.

(iii) The sealing rings shall be extruded or moulded and cured in such a manner
that they will be dense, homogeneous and free from porosity, blisters,
pitting and other imperfections. The rings must be extruded or moulded with
smooth surfaces to the specified size within a tolerance of ±6 percent on
any dimension, measured at any cross-section. Joints in the ring shall be
vulcanised and not glued.

(iv) Joints shall be capable of withstanding a draw of 13mm over and above the
initial jointing allowance and remain watertight. The initial jointing allowance
is the gap between the spigot and the shoulder of the socket measured

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parallel to the centre line of the pipeline and must not be less than 6mm or
greater than 13mm or as recommended by the pipe manufacturer.

(v) For pipes up to and including 600mm nominal internal diameter joints shall
be capable of withstanding a deflection of not less than one and a half
degrees in any direction and remaining watertight. For pipes over 600mm
nominal internal diameter joints shall be capable of withstanding a deflection
of half degree in any direction and remaining watertight.

(vi) The pipe joints shall be capable of withstanding an external pressure

equivalent to 15m head of water without leakage in both the straight and
deflected positions.

(vii) Ensure that all pipes including cut lengths and all fittings before despatch
from the pipe manufacturer's works are indelibly marked as follows.

- The manufacturer's name, initials, or identification mark.

- The nominal internal diameter in mm.
- The length in m.
- Mark the classification i.e. pressure rating.
- The date of manufacture and batch number.
- A stamp to show that they meet the required inspection requirements and
hydraulic tests at the point of manufacturer.
- Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture delivery and testing of
that pipe.
- The angle of bends or branches.
- The manufacturing standard.
- The project or contract number.

b) Fabrication and fabrication tolerances

(i) Reinforced concrete pipes shall have a minimum nominal length of 2.5m
and a maximum length of 6m unless otherwise specified or for special
purposes such as curves or closures.

(ii) Use steel made forms with butt joints throughout when casting pipes.

- The surfaces of the forms adjacent to the pipe walls shall be smooth and
true.
- Forms shall be sufficiently tight with suitable gaskets provided at all form
joints to prevent leakage of mortar.
- The forms shall be braced and sufficiently stiff to withstand without
detrimental deformation all operations incidental to the placement and
compaction of concrete within the form.

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- The forms and end rings shall be constructed such that the pipe when
manufactured has circular and cylindrical inner surfaces and they can be
stripped from the pipe without damage to the pipe or its surfaces.
- Clean and oil the forms at the start of each continuous production.
Discard defective forms and end rings or adequately repair to the
satisfaction of the Engineer.

(iii) Accurately place reinforcement steel in the concrete wall. The minimum
concrete cover over reinforcement shall be 25mm. Permissible variations
shall be within the tolerances specified in ASTM C76 or BS 5911.

- Tie the reinforcement steel in the pipe barrel to the reinforcement steel in
the pipe joint. Fabricate the reinforcement as a rigid cage of bars or wire
fabric. Fabricate transverse reinforcement either as complete hoops,
welded or lapped, or as a continuous helix. When the transverse
reinforcement is formed as a cylindrical helix, finish off both ends of the
cage as a complete hoop.
- Use lapped or butt welded type splices.

(iv) Butt weld splice must develop the full strength of the bar. Submit for testing,
samples of welds proposed for use when required by the Engineer.

(v) Lap splice must extend 30 diameters when bars are being used for
reinforcement and 40 diameters when wire is being used.

- Use suitable devices to hold the cage of reinforcement in its circular

shape, and to maintain the cage in place within the forms during the
placing and consolidating of the concrete.
- Use sufficient longitudinal reinforcement to provide a rigid cage of
reinforcement. Providing enough longitudinal steel to provide a cage
sufficient to retain its shape and position in the forms during the
manufacturing process.

c) Internal Lining

(i) Line internally with a PVC or HDPE lining covering the entire interior of the
pipe.

(ii) Cast PVC or HDPE lining into the pipe at the time of manufacture of the
concrete pipe. Line the pipes entirely unless otherwise noted.

(iii) Cast sheets of PVC or HDPE lining as large as practicable to adequately fit
the intended use.

- Form large sheets by lapping basic size sheets a minimum of

13mm and fusing the sheets together in such manner as to produce a
continuous welded joint. Do not allow tears, cracks, or separation in the
laps.
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- Cast joint strips of 100mm, ±1 mm in width x 2mm minimum

thickness and bevel each edge prior to application.
- Cast welding strips of 25mm, ±2mm in width x 3mm minimum to 4mm
maximum thickness. Use bevelled edges for all welding and outside
corner strips at time of manufacture.
- Maintain all lining sheets, including locking extensions or studs, all joints
corner, and welding strips free of cracks, cleavages, or defects adversely
affecting the protective characteristics of the material. The Engineer may
authorise the repair of such defects by approved methods.
- Apply and secure lining to the forms. Inspect and approve the lining
application prior to the placement of reinforcing steel.
- Position lining so that the locking extensions are parallel with the axis of
the pipe.

(iv) For pipes up to and including 600 mm diameter form the lining around the
spigot and socket to extend to the outside of the joint ring. Hold the lining
accurately in position to provide finished surfaces to match the dimensions
of an equivalent unlined pipe with the gasket held in a containing groove on
the spigot face of the pipe.

(v) For pipes of 750mm diameter and larger set the lining flush with the inner
edge of the socket or spigot end of the pipe section. Extend the lining to
approximately 60mm beyond the opposite end for jointing after pipe laying.

d) Installation of PVC and HDPE lining

(i) All work for and in connection with the installation of the lining including any
accessories and welding of joints shall be carried out in strict conformity
with the manufacturer’s recommendations.

(ii) On completion the lining shall be continuous and free of holes in the lining
itself and in the joints.

(iii) The lining shall be in sheets made or cut to fit the forms to which it is to be
closely fitted and properly secured, using a minimum number of separate
pieces. Care shall be taken not to puncture the lining in any way.

(iv) Joints between adjacent sheets shall not be more than 3mm wide and shall
be sealed on the concrete side to prevent loss of grout during concreting.

(v) Concrete poured against the lining shall be compacted by suitable methods
in a careful manner so as not to damage the lining and produce a dense,
homogenous concrete securely anchoring the ribs or anchors into the
concrete. The Engineer shall reject any work if he considers that any part of
that work contains defective concrete and the work shall be removed and
reinstated at no cost.

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(vi) After pouring, the concrete shall be left to cure for a minimum of 48 hours
prior to striking the formwork. When removing formwork care shall be taken
to protect the lining from damage.

- Sharp instruments or tools shall not be used to pry formwork from the
lining.
- Any formwork materials that remain in the lining shall be removed and the
resulting holes clearly marked.
- Formwork tie holes shall be marked before ties are broken off and all
areas of abrasion or damage shall be marked.

(vii) All abraded areas in the lining shall be patched. Any one patched area shall
not exceed 0.25m2 or as directed by the Engineer.

- Patch shall be made of the same material as the parent lining.

- All surfaces shall be prepared and all patching work shall be carried out
in accordance with the manufacturer’s recommendations.

(viii) Unless otherwise shown on the drawings the lining shall be returned at least
100mm onto built in items such as manhole frames, gate guides and pipes
or to where the type of lining is changed or new work is built against existing
unlined concrete. At each return the lining shall be sealed to the adjacent
material with an approved adhesive system or if this is not acceptable an
alternative proposal shall be submitted to the Engineer for approval.

(ix) The lining at joints shall be free of all foreign matter and shall be clean and
dry before the joints are welded.

(x) All jointing materials shall be similar to that of the parent lining for
thickness, corrosion resistance and impermeability unless otherwise
approved by the Engineer.

(xi) Welded joints shall show no cracks or separations.

(xii) Welding strips which extend beyond the edge of the lining shall be tested as
follows:

- Welding strips shall extend 50mm beyond the edge of the lining to
provide a tab to which a 5kg pull will be applied.
- Force shall be applied normal to the face of the structure by means of a
spring balance.
- Lining adjacent to the welding strip shall be held against the
concrete during application of the force.
- The 5kg force shall be maintained if a weld failure develops until no
further separation occurs.
- Defective welds shall be retested after repairs have been made and
following successful testing the tabs shall be neatly trimmed away.

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(xiii) Hot joint compounds such as coal tar shall not come into contact with the
lining.

e) Field Jointing of Internal Lining

Field jointing of the internal lining shall be carried out as follows:

- Do not make field joint to the lining until the lined pipe has been backfilled
and pipe tests have been completed. Where groundwater is encountered,
do not make any field joint until pumping of the groundwater has been
discontinued and no visible leakage is evident at the joint. Ensure that
the lining at joints is free of foreign materials and is clean and dry before
joints are made.
- Hot joint compound shall not be brought in contact with the lining.
- Do not apply coating of any kind over any joint, corner, or welding strip,
except where non-skid coating is applied to lining surfaces.
- Do not apply adhesive to the surfaces of pipe joints, or the lining or the
joint strips.
- Ensure that the surface is clean to permit visual inspection and spark
testing. Physically test all welds with a nondestructive probing method.
The Engineer may request to test installed lining using a spark type
detector set at 20,000 volts. Properly repair and retest all areas of lining
failing to meet the field test.
- Use a spark detector approved by the Engineer when spark testing the
liner.
- Test each transverse welding strip, which extends to a lower edge of the
lining. Extend the welding strips below the lining providing a tab. Apply a
5kg pull normal to the face of the pipe by means of a spring balance.
Ensure that the lining adjoining the welding strip is held against the
concrete during application of the force. Maintain the 5kg pull if the weld
failure develops, until no further separation occurs. Retest defective
welds after repairs have been made. Trim neatly tabs after the welding
strip has passed inspection. Provide all test equipment required in the
manner recommended by the manufacturer and as described above.
The personnel provided to perform the testing shall be qualified.

f) External Epoxy Coating

(i) Coat exterior of pipe with an approved solvent free 2 component epoxy
system. All blowholes and surface defects must be filled with a two
component solvent free epoxy filler prior to top coating.

(ii) Pipe manufacturing shall be by vertically cast method or other

manufacturer's method as approved by the Engineer prior to pipe
fabrication.
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g) Application of Epoxy Coating

(i) Please refer to Section 7.2.2.1 (e) for the Application of Epoxy Coating.

h) Concreting

(i) Mix, transport, place, and test concrete in accordance with Section 3 of the
specification. Prevent separation of the concrete materials and the
displacement of reinforcement steel in the forms. Use external mechanical
vibrators in an approved manner to vibrate the concrete when placing in the
forms to avoid damage to the lining and produce a dense, homogeneous
concrete securely anchoring the locking extensions into the concrete. Use
the external vibrators particularly along the lower terminal edge of the
plastic lining.

(ii) If approved, use stiffeners along the locking extensions of the lining.
Withdraw the stiffeners completely during the placement of concrete in the
forms. Revibrate the concrete to consolidate the concrete in the void spaces
caused by the withdrawal of the stiffener.

(iii) Protect the lining from damage when removing forms. Do not use sharp
instruments to pry forms from the lining surfaces. When forms are
removed, pull out any nails that remain in the lining without tearing the
lining. Clearly mark the resulting holes. Mark form tie holes before ties are
snapped or broken off. Mark areas of serious abrasion of the lining.
Abraded areas shall be repaired in accordance with the requirements of
Section 3 of the specification.

i) Concrete Curing

(i) Concrete pipes and fittings. Provide adequate plant, piping, enclosures,
and other facilities for curing the pipe. Control the temperature and humidity
of the enclosures to keep the pipe surfaces moist at all times and maintain
the temperature continuously between limits described below. Apply one of
the methods of curing described below to the pipe, or any other method or
combination of methods that will give satisfactory results as approved by the
Engineer. Allow the pipe to be cured for a minimum 14 days so that the
concrete will develop the specified compressive strength at 28 days or less.

- Accelerated Curing. Place the pipe in a curing facility or otherwise

covered by a suitable enclosure that will allow proper circulation of moist
air or steam. Maintain the ambient temperature within the enclosure
between 15°C and 38°C by the introduction of heat until the initial set of
the concrete occurs. After a delay period of one to four hours, increase
the temperature at a rate not to exceed 2°C/hour, and thereafter,
maintain the temperature between 32°C and 66°C.
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- Water Curing. Apply water curing as soon as the concrete has set
sufficiently to prevent damage to the exposed concrete surfaces.
Maintain all exposed concrete surfaces moist by intermittent or
continuous water spraying for a minimum 14 days. Maintain the total
cure, consisting of the water cure and the ambient air cure sufficient to
produce the concrete strengths specified.
- Curing membranes shall not be used.

4.2.1.4 Quality Control Tests

The crushing strength of concrete pipes shall not be less than the values specified in
ASTM C76 or BS 5911 for the respective classes of pipes shown on the drawings.

Linings shall be tested for pin holes, using an approved electrical spark tester set at a
minimum of 20,000 volts. Holes in sheets shall be satisfactorily repaired and re-
tested prior to shipment to the pipe manufacturer.

The concrete pipes shall be substantially free from fracture, large or deep cracks and
surface roughness. The planes of the ends of the pipe shall be perpendicular to their
longitudinal axis.

Carry out inspection procedures and tests in accordance with BS 5911 or ASTM
C361.

Concrete pipes shall be rejected for any of the following reasons.

- Failure to pass the hydrostatic test.

- Transverse reinforcing steel found to be in excess of 6 mm out of
specified position after the pipe is moulded.
- Unauthorised application of any wash coat of cement or grout.
- Any crack showing two visible lines of separation for a continuous length
of 600mm or more, or an interrupted length of 900mm or more anywhere
in evidence, both inside and outside except where such cracks occur
during the external loading test.
- Exposure of any wires, and positioning spacers or chairs used to hold the
reinforcement cage in position, or steel reinforcement in any surface of
the pipe.
- Any shattering or flaking of concrete at cracks.
- Honeycombing on the exterior surfaces of the pipe exceeding 6 mm in
depth unless pointed with mortar or other approved material.
- Any crack having a width of 0.25mm or more throughout a continuous
length of 300mm or more.
- Any crack extending through the wall of the pipe and having a length in
excess of the wall thickness.
- When required by the Engineer, fill with cement grout any crack that is
0.25 mm wide or wider and is not a cause for rejection. Use neat cement

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grout composed of cement mixed with water to fluid consistency for

filling the cracks.
- A deficiency in the specified wall thickness of the pipe larger than
permissible. The deficiencies in wall thickness permitted herein do not
apply to gasket contact surfaces. Submit the tolerances of such contact
surfaces for approval by the Engineer.
- A variation from the specified internal diameter in excess of 1% of interior
surfaces which have been reworked after placing of the concrete. The
variation in internal diameter permitted herein does not apply to gasket
contact surface. Submit the tolerances of such contact surfaces for
approval by the Engineer.

4.2.2 Ductile Iron Pipes

4.2.2.1 General

This specification covers the general requirements for Ductile Iron (D.I.) pipes, fittings
and accessories including material specifications, internal lining, external coating,
joints, polyethylene sleeves etc. This specification sets the minimum acceptable
requirements. In case of difference between this specification and the specified
international standards then the most stringent requirements shall prevail.

4.2.2.2 Applicable Standards and Codes

DI pipes, fittings and accessories including coating and polyethylene sleeve shall
comply with the latest issue of the following standards and other relevant standards
noted elsewhere in this specification:

Standard Description

ISO 527 Plastics-Determination of tensile properties.

ISO 887 Plain washers for metric bolts screws and nuts.

ISO 974 Plastics-Determination of the brittleness temperature by impact.

ISO 2230 Vulcanised rubber-guide to storage.

ISO 2531/BS EN Ductile iron pipes, fittings, accessories and their joints for water
545 or gas applications.

BS EN Ductile iron pipes, fittings, accessories and their joints for

598:2007+A1:2009 sewage applications.

ISO 3506 Corrosion - resistant stainless steel fasteners.

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Standard Description

ISO 4014 Hexagon head bolts – Product grades A and B.

ISO 4032 Hexagon nuts, style 1 – Product grades A and B.

ISO 4179 Ductile iron pipes for pressure and non-pressure pipeline –
Centrifugal cement mortar lining – General requirements.

ISO 4587 Adhesives – Determination of tensile lap-shear strength of rigid-

to-rigid bonded assemblies.

ISO 4633 Rubber seals – Joint rings for water supply, drainage and
sewerage pipeline – Specification for materials.

ISO 6600 Ductile iron pipes, centrifugal cement mortar lining –

composition controls of freshly applied mortar.

ISO 6506-1 Metallic materials – Hardness testing – Brinell test – Part 1: Test
method.

ISO 6708 Pipe works components – Definition and selection of DN

ISO 7005-2 Metallic flanges – Part 2: Cast iron flanges

ISO 7268 Pipe components – Definition of nominal pressure.

ISO 7483 Dimensions of gaskets for use with flanges to ISO 7005.

ISO 8179-1 Ductile iron pipes – External coating – Part 1: Metallic zinc with
finishing layer.

ISO 8179-2 Ductile iron pipes – External coating – Part 2: Zinc rich paint
with finishing layer.

ISO 8180 Ductile iron pipes – Polyethylene sleeving.

ISO 8501-1 Preparation of Steel Substrates.

ISO 10804 Restrained joint systems for ductile iron pipelines – Part 1:
Design rules and type testing.

EN 1092-2 Circular flanges for pipes, valves, fittings and accessories, PN

designated – Part 2: Cast iron flanges.

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Standard Description

BS 146 Specification for Portland blast furnace cements. Cement.

Composition, specifications and conformity criteria for low early
BS EN 197-4:2004 strength blast furnace cements

BS 3416:1991 Specification for bitumen - based coatings.

BS 7079:2009 Specification for surface finish of blast-cleaned steel for

painting. General introduction to standards for preparation of
steel substrates before application of paints and related
products

BSEN 681:2000 Elastomeric Seals

BSEN 1563:2011 Founding Spheroidal graphite Cast iron

BSEN 10025:2004 Hot rolled products of non-alloy Structural Steels

DIN 30671 Thermoset plastics coatings for buried steel pipes

DIN 30672 Coatings of corrosion protection tapes and heat Shrinkable

material.

DIN 4226 Aggregates for concrete.

4.2.2.3 D.I. Material Characteristics

Ductile iron pipes, fittings and accessories shall meet the following requirements:

Material Characteristics Pipes Pipes not Centrifugally

Centrifugally Cast, Fittings and
Cast Accessories

Minimum tensile strength (MPa 420 420

Minimum yield strength (MPa) 300 300

Minimum elongation after fracture

(%)

DN 40 to DN 1000
10 5
DN 1100 to DN 2600

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7 5

Maximum Brinell hardness, (HB) 230 250

4.2.2.4 D.I. Pipes

All D.I. pipes supplied shall be truly circular, of uniform thickness and supplied in the
longest practicable length so as to minimise the number of joints.

Unless otherwise specified in the drawings or in the Particular Specification all pipes,
joints and fittings shall be suitable for the maximum pressure under which they will
operate (normal service pressure + surge pressure or the maximum site test pressure
whichever is greater) and shall sustain without damage or substantial leakage the
specified site hydrostatic test pressure.

The nominal iron wall thickness of pipes and fittings shall be in accordance with ISO
2531/EN 545 and calculated as a function of the nominal size, DN, by the following
formula, with a minimum of 6 mm for pipes and 7 mm for fittings:

e = K (0.5 + 0.001 DN)

Where:

e is the nominal wall thickness, in millimetres;

DN is the nominal diameter in millimetres;

K is a coefficient used for thickness class designation. It is selected form a series of

whole numbers: .8, 9, 10, 11, 12.

Unless otherwise specified in the Particular Specification all pipes used shall be class
K9 (K = 9).

All pipes shall be subject to Third Party Inspection during manufacturing.

The name of manufacturer, standard, nominal diameter (DN), type of socket, class
and date of manufacturing (month + year) shall be cast inside the socket. The
contract number shall be painted on the pipe.

Pipes shall be hydrostatically pressure tested for leak tightness and certified at the
manufacturer's plant prior to coating or lining for at least 10 seconds at the following
minimum internal test pressures:

(i) 50 bar for pipes DN 300 and smaller

(ii) 40 bar for pipes DN 350 through DN 600

(iii) 32 bar for pipes DN 700 through DN 1000

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(iv) 25 bar for pipes DN 1100 through DN 2000

(v) 18 bar for pipes DN 2200 through DN 2600

Unless otherwise all D.I. pipes supplied shall be of socket and spigot end.

It shall be the Contractor’s sole responsibility to order a percentage (minimum 2%) of

the total length per diameter of pipes as calibrated pipes, for the purpose of cutting
etc. These pipes shall be clearly marked and shall not be used for normal pipe laying
unless it becomes clear that they are not required for the purpose of cutting any
more. The percentage to be ordered shall give due regard to any changes in route
which may occur during the course of the work for whatever reason.

4.2.2.5 D.I. Fittings

All D.I. fittings supplied shall be truly circular of uniform thickness according to ISO
2531 and BS EN 545. For gravity sewer application it shall be made to BSEN 598.

All fittings shall be subject to Third Party Inspection during manufacturing.

Dimensions and nominal iron wall thickness of fittings shall be in accordance with the
ISO 2531/BS EN 545.

For fittings the thickness e is the nominal thickness corresponding to the main part of
the body. The actual thickness at any particular point shall be increased where
necessary to meet localised high stresses depending on the shape of the casting
(e.g. at internal radius of bends, at the branch body junction of tees, etc).

Name of manufacturer, standard, nominal diameter (DN), type of socket, class and
date of manufacturing (month + year) shall be cast inside the socket or on the barrel
of the fittings. The contract number shall be painted on the fitting.

Fittings shall be pressure tested for leak tightness and certified at the manufacturer's
plant prior to coating or lining. The test pressure shall be carried out for at least 10
seconds either with air at a pressure of 1 bar or with water at the pressure indicated
below:

- 25 bar for fittings DN 300 and smaller (for fittings with PN 10 flanges test
pressure shall be 16 bar)
- 16 bar for fittings DN 350 through DN 600
- 10 bar for fittings DN 700 and larger

4.2.3 Joints

4.2.3.1 Flexible Joints

Flexible joints shall be of spigot and socket "push-on" type suitable for angular
deflection any direction and capable of axial movement to compensate for thermal

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expansion or contraction and ground movement. All flexible joints for D.I. pipes and
fittings shall be designed in compliance with ISO 2531.

Joints may permit angular deflection to accommodate ground movements and to

negotiate large radius bends. The maximum angle deflection shall be as per the limits
given below and manufacturer's recommendations.

Nominal Diameter Maximum Deflection

80/150 5º

200/300 4º

400/500 3º

600/700 2º

800/1000 1½º

Rubber ring joints shall be of a type that will not deteriorate under local conditions
either during storage or during operation. The rubber gasket shall be of EPDM
elastomar or equivalent in accordance with ISO 4633 suitable for drinking water
supply.

Where mechanical type joints are specified, proposed and approved they shall be
supplied complete with approved gaskets, glands, hot dipped galvanized or cadmium
plated bolts, nuts and all other necessary accessories. Where retainer glands are
specified they shall be supplied with bolts and/or other necessary accessories.

a) Flanged Joints

Flange ended pipes and fittings shall only be used when connecting to valves or other
special fittings as approved by the Engineer

The flanges shall be raised faced and integrally cast or welded on. Screwed on
flanges or glued on flanges are not acceptable. Rotatable flanges may be used for
pipes and fittings up to DN 600.

The dimensions and drilling of the flanges shall be to ISO 7005-2 or BS EN 1092-2.
The pressure rating of the flanges shall be as given in the Data Sheet or Particular
Specification. Flanged joints shall be supplied complete with gaskets, hot dipped
galvanized or cadmium plated nuts, bolts and washers.

Rubber gaskets shall be EPDM elastomer or equivalent approved in accordance with

ISO 4633 suitable for drinking water supply. The gasket shall be minimum 3 mm thick
and shall be metal reinforced for pressure rating of 16 bar and higher. The
dimensions of the flange gaskets shall be to ISO 7483.

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The nuts, bolts, washers shall be of steel having minimum tensile strength of 800
N/mm2 hot dipped galvanised or cadmium plated. Nuts and bolts shall be suitable for
the pressure rating specified in the Particular Specification. Nuts and bolts shall be to
ISO 4014 and 4032 and washers to ISO 887.

b) Restrained Joints:

D.I. pipes and fittings with restrained coupling shall be utilised where pipelines have
to cross roads through existing ducts or in areas with restricted accessibility where
the use of concrete anchor blocks is prohibited, or as directed by the Engineer. The
CONTRACTOR shall submit with his bid full details of the type of restrained coupling
he proposes to use.

Whenever in the course of work the contractor intends to utilise restrained couplings
he shall obtain prior approval from the Engineer.

Calculation of the number of pipe lengths with restrained coupling required shall
follow the manufacturer's recommendation and shall be subject to approval by the
Engineer.

Restrained joints shall be designed to resist the axial thrust forces but maintaining
flexibility and angular deflection. Restrained joints shall be designed in accordance
with ISO 10804-1.

The joint shall be capable of withstanding the greater of the test pressure or the
service pressure + the surge pressure.

The type of restrained joint shall be subject to the approval.

The thrust resisting mechanism shall be separated from the sealing action of the
gasket and shall not be in contact with potable water in the pipeline.

4.2.3.2 Internal Lining to D.I. Pipes and Fittings

a) General

Unless otherwise specified in the Data Sheet or Particular Specification all D.I. pipes
and fittings shall be internally lined with sulphate resisting blast furnace slag cement
mortar in accordance with the following specification and shall be certified as suitable
for use with potable water by an internationally accepted organisation such as UK's
WRC (Water Research Centre).

The cement mortar lining for D.I. pipes and fittings shall be in accordance with ISO
4179.

The internal surface of the socket bell of all zinc/bitumen coated D.I. pipes and fittings
shall be painted with a non-toxic solvent-free two part epoxy coating applied to a
minimum dry film thickness (DFT) of 100 microns or equivalent corrosion protection
system to be approved by the Engineer. The thickness of the coating may be reduced
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only at the gasket locating ring to conform to manufacturer's recommended

tolerances.

b) Surface Preparation

Prior to cement lining application the inner surfaces of pipes and fittings shall be
cleaned of dirt, loose rust particles, grease, oil or any other material which could be
detrimental to good contact between the metal and the lining.

c) Cement

Cement to be used for the lining shall be with high alumina type. Alternatively
sulphate resisting blast furnace slag cement type complying with the requirement of
BS EN 197-4, obtained by grinding a mixture of 70 percent by weight of granulated
blast furnace slag, to be completed with Portland clinker and a maximum of 3.5
percent calcium sulphate.

d) Aggregates

Only clean, crushed natural mineral aggregates shall be used in accordance with the
requirement of the latest issue of the German DIN 4226 standards.

The distribution of grain sizes shall be:

(i) the amount of particles passing through a standard sieve with an aperture
size of 0.125 mm shall not be more than 10% by mass.

(ii) the amount of particles with a diameter up to 1/3 of the normal lining
thickness shall not be less than 50% by mass.

(iii) the maximum particle diameter shall not be greater than 1/2 of the normal
lining thickness. The amount of shall not exceed 5% by mass.

e) Additives

The use of cement additives is allowed, subject to the Engineer approval, provided
that they do not adversely affect the quality of the lining, and that of the transported
water. Additives shall not contain any elements which impart potable change in
colour, taste or odour or present a health hazard. Certificates of non-toxicity prepared
and signed by recognised, independent laboratories, shall be made available to the
Engineer.

f) Water

Water used for the mortar shall be of potable quality and shall not contain elements
which influence the hardening of the lining or the quality of the water flowing through
the finished pipes.

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g) Mortar

Mortar for the lining shall be composed of cement, sand and water. The mortar shall
be well mixed and of proper consistency to produce a dense homogenous lining that
will adhere firmly to the DI pipe or fitting surface.

Weight of cement and sand shall be accurate to + 3%. The water/cement ratio shall
not be more than 0.40. The minimum compressive strength of the mortar shall not be
lower than 50 W/mm2. The cement mortar shall not contain less than one part of
cement to 3.5 parts of aggregates by weight as per ISO 4179.

h) Method of Lining

Lining application and quality for finished surface shall be in accordance with ISO
4179. All pipes shall be lined by a centrifugal process. The consistency of the mortar
and the time and speed of spinning the pipe shall be so adjusted to minimise the
segregation of aggregates from the cement.

Fittings shall be lined by a spray method.

In all cases a smooth finish of the lining shall be obtained, entirely free from cavities
or visible air bubbles.

The lining shall be uniform and extend from the spigot end up to the beginning of the
socket cavity on the other side. The socket shall be left free of mortar.

No seal coat shall be applied to the cement lining unless otherwise instructed and
approved by the Engineer.

i) Curing

After application to pipes and fittings, the cement mortar shall be cured under
controlled conditions (minimum 48 hours, at more than 15°C and 75% relative
humidity).

Alternative methods of curing are subject to approval of the Engineer.

j) Repair of Defective and Damaged Areas of Lining

Defective or damaged areas of lining may, at the Engineer's discretion, be patched by

cutting out the defective or damaged lining to the metal so that the edges of the lining
not removed are perpendicular or slightly undercut. The cut out area shall then be
trawled with fresh mortar in the following composition:

- One part cement (by weight).

- One part sand.
- Water of potable quality, with non-toxic additive dispension of synthetic
materials subject to the Engineer's approval.

Thickness of lining
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Thickness of the cement mortar lining shall be as follows:

DN (mm) Lining Thickness (mm)

Normal Minimum Mean Minimum Value at

Value One Point

80 - 600 5.0 4.5 3.5

700 – 1200 6.0 5.5 4.5

1400 - 2000 9.0 8.0 7.0

2200 – 2600 12.0 10.0 7.0

N.B.: The above figures differ from ISO 4179.

k) Mechanical Properties:

The cement mortar lining shall have adequate resistance against compression and
bending action. Representative test pieces shall have the following minimum
properties after 28 days.

Water Cement Ratio of Compression Strength Bending Strength

Test piece N/mm2
N/mm2

0.45 40 5.0

0.40 45 5.5

0.35 50 6.0

l) Quality of Lining, Tests and Records

The lining shall be free from voids, ridges or corrugations that reduce the thickness of
the lining to less than the specified minimum thickness.

Lining shall have a smooth surface. There shall be no cavities or entrapped air,
similarly there shall be no evidence of differences between portions of lining.

Linings shall be placed so that there is no gap between the pipe barrel and the lining.
In some circumstances thicker linings may be required and these shall be stated in
the appropriate specification.

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If a lining is damaged it may be repaired on site using a one to one cement/sand

mortar mix (proportions by weight). Repairs shall cure for at least 72 hours.

Mortar lining may show evidence of cracking, crazing or debonding after delivery to
site. The following conditions may be accepted.

(i) Cracking - provided that the longitudinal length of a crack is not more than
600 mm, width of crack not more than 0.8 mm, circumferential cracks are
not more than 50% of the circumference.

(ii) Crazing - provided that individual cracks are less than the limits given in a),
crazing over an area not exceeding 25% of the lining area may be
acceptable.

(iii) Debonding - area of disbondment and radial displacement shall not exceed
the values given in EN 545.

The following tests and measurements shall be conducted, recorded and filed with
frequencies according to ISO 4179 and ISO 6600.

- Determination of lining thickness.

- Cross sectional sample.
- Water cement ratio.
- Aggregates.
- Bonding and compression strength.

m) Seal Coat internal over cement mortar lining

In order to minimise the leaching of cement by soft water a bituminous paint seal coat
shall be applied over cement mortar lining to a minimum thickness of 500 micron.

4.2.3.3 External Coating to D.I. Pipes and Fittings

a) The external coating to DI pipes shall be in accordance with BS EN 598 and BS

EN 545.

Pipes shall be supplied with the external coating type required to provide
adequate corrosion protection as follows.

(i) Type 1 = Zinc coating with minimum mass 200g/m2 with 100 micron
thickness bitumen or epoxy finishing layer

(ii) Type 2 = Type 1 coating with Polyethylene Sleeving

(iii) Type 3 = Alloy of zinc and aluminium coating with minimum mass 400
g/m2 with bitumen or epoxy finishing layer

(iv) Type 4 = Extruded polyethylene coating in accordance with to EN 14628

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Or Polyurethane coating with minimum thickness of 800 microns thick to EN

15189

Or Type 1 coating tape wrap with 55% overlap

Protection Type 1 Type 2 Type 3 Type 4

system

Resistivity above Y Y Y Y
2500 ohm.cm for
wet soils or
Resistivity above
1500 ohm.cm for
dry soils

Resistivity between N Y Y Y
1500 ohm.cm and
2500 ohm.cm for
wet soils
Resistivity between
750 ohm.cm and
1500 ohm.cm for
dry soils

Resistivity between N N Y Y
500 ohm.cm and
750 ohm.cm for dry
or wet soils

Resistivity below N N N Y
500 ohm.cm

Made up ground N N N Y
with material likely
to damage pipe

Contaminated land N N N Y

pH less than 5 N N N Y
Y = Suitable N = Unsuitable

For pipes in made ground with material likely to cause damage, an imported
embedment should be used for the pipeline.

Evidence of the long term performance of the above mentioned solution (e.g.
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tests and references) should be provided by the manufacturer.

As far as possible, PE sleevings and tape wraps should be factory applied.

All coatings are subject to the prior approval of the Engineer.

Where non-toxic coating is specified, certification shall be required from an

internationally recognised independent laboratory certifying that the material is safe
for potable water service. At the discretion of the Engineer all special coatings on
pipes and fittings shall be subjected to thickness checks and for holiday testing on
site in order to satisfy the Engineer that the coatings are within the specified limits
and that no pin holes are present.

The thickness of the coatings may be reduced only at the gasket locating ring to
conform to manufacturer's recommended fitting tolerance.

b) Vendor Documentation

The Contractor shall furnish the following vendor data as a minimum, with his bid:

- Catalogues/Brochures of the proposed manufacturer's.

- Dimensional details of pipes and fittings.
- Detailed material specifications.
- Manufacturer's drawings, showing fittings dimensions.
- Complete details of testing facilities available at manufacturer's works.
- Local (UAE) agent name and address.
- Outline of Quality Assurance Procedures in use.

Bids not accompanied by any of above-mentioned information/data shall be

considered incomplete, and liable to be rejected.

4.2.4 Other Ferrous and Non-ferrous Pipes & Fittings

Stainless steel pipe shall be as specified in the specification for mechanical work.

4.3 THERMOPLASTIC PIPES

4.3.1 Unplasticised Polyvinyl Chloride Pipes and Fittings (uPVC)

uPVC non-pressure pipes and fittings for underground drainage & sewerage
applications shall be manufactured and tested to BS EN 1401 – 1 : 2009 and for soil
and waste discharge pipe & fitting within the building structure shall be manufactured
and tested to BSEN 1329-1: 2000.

UPVC pressure pipes and fittings shall be PN 16 for pipes up to and including
160mmø and PN 12.5 bar rated pressure class for pipes above 160mmø suited to
service temperature up to 45°C manufactured and tested to BS EN ISO 1452 –2:
2009. The Pipe material of the Pressure Pipe shall have a minimum required strength
(MRS) of 25 Mpa as defined in BSEN 1452 – 1:2009. The density shall be between
1350 kg/m3 ≤ P ≤ 1460 kg/m3 when measured in accordance with ISO 1183. UPVC
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(P) pipes shall be tested after installation in accordance with the Pipe manufacturer’s
recommendation. The site test pressure shall be as specified in CL 6.2.3.

UPVC pipes shall be installed in accordance with the manufacturer’s guidelines. Both
gravity and pressure pipes shall be BSI kite marked and copies of kitemark license
including its schedule of items covered shall be provided to the engineer to satisfy the
third party quality assurances. The choice of wide or narrow trench condition, Pipe
surround & bedding material etc. shall be decided based on the native soil modulus
below the invert and spring line level of the pipe and the stiffness of the proposed
pipe. UPVC fittings shall be injection moulded factory made and kite mark certified
and shall conform to BS EN 1401-1 (for gravity fittings (G) and BSEN 1452: P2 & Part
3 for pressure fittings). Fabricated fitting may be permitted only for non-standard
fittings not shown in Pipe manufactures Technical Catalogue. Fabricated fitting shall
be PVC welded at joints and laminate with 3 mm thick GRP lamination external for
gravity fittings & 6mm for pressure fittings and shall comply with the quality control
test specified.

uPVC pipes shall be capable of withstanding ultraviolet degradation. A rodent

inhibitor shall be incorporated in the material of the pipe. Pipes shall be manufactured
with integral flexible rubber ring joints made to BSEN 681-1: 1996 EPDM type ‘D’
material and kite marked.

Construction and testing of drains and sewer pipes shall be as specified in BSEN
1610: 1998.

uPVC pipes for gravity pipelines shall be SN4 stiffness class and have a standard
dimension ratio, D :t (diameter to thickness), of between 35 and 45. The ring stiffness
of the pipes is to be tested in Dubai Central Lab. in accordance with ISO 9969: 1995
and comply with the requirements. From the installation point of view, SN8 class pipe
may be used if the pipe line is installed in accordance with BS EN 752 2008 or BS
5955-8:2001 in order to achieve the intended resistance to long-term deformation.

Any pipes exhibiting cracks, notches or deep scratches or other damage will be
condemned and shall not be incorporated into the permanent work under any
circumstances.

The minimum and the maximum burial depth of pipe shall be as per pipe
manufacturer’s recommendations. Evidence of type test and the quality control test
referred in the relevant standards for the pipes and fittings are to be provided to the
Engineer to satisfy the product prequalification.

4.3.1.1 uPVC Gravity Pipes for Land Drains

Pipes for slotted land drains/slotted carrier drains shall be uPVC pipes. Prior to
perforation, the basic pipe shall be manufactured to BS EN 1401-1, kite marked, and
shall comply with the requirements of Clause 4.3.1 of this specification relating to
uPVC pipes for non-pressure application. The slots shall be designed to give at least

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the minimum infiltration rates laid down in BS 5911: Part 114. The final configuration
of the slots shall be subject to approval by the Engineer.

The slots shall be cleanly machine cut and be not less than 3 mm or greater than 4
mm in width. The slots shall be in 180° segment of the pipe barrel in one or more
longitudinal rows, the slots in each row being spaced equidistantly. Where more than
one row of perforations is provided the slots shall be staggered. No slots shall be
nearer to the ends of the barrel than the spacing between two adjacent slots. The
spacing between slots in any row may vary up to ± 20 mm.

The minimum cross-sectional area of the perforations, at the inside surface of the
pipe barrel, shall be 2700 mm2 per metre run of pipe but shall not affect the structural
integrity of the pipe. Care must be exercised to prevent impact damage when placing
stone surround and during backfilling operations over the pipes.

4.3.1.2 uPVC Duct Pipes

uPVC Duct Pipes (Socket Spigot) shall be manufactured & tested to BS 3506:1969.
The class of pipe shall be Type ‘D’ having the specified properties given in the
standard.

4.3.2 POLYETHYLENE PIPES (HDPE)

4.3.2.1 Applicable Standards and Codes

All activities relating to this section of the specification shall comply with the following
or approved equal standards.

Standard Description

ASTM D638 Standard test method for tensile properties of plastics.

ASTM D790 Standard test methods for flexural properties of unreinforced and
reinforced plastics and electrical insulating materials.

ASTM D1238 Standard test method for melt flow rates of thermo- plastics by
extrusion plastometer.

ASTM D1505 Standard test method for density of plastics by the density-
gradient technique.

ASTM D1693 Standard test method for environmental stress-cracking of

ethylene plastics.

ASTM D2240 Standard test method for rubber property-Durometer hardness.

ASTM F1055 Standard specification for electrofusion type polyethylene fittings

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Standard Description

for outside diameter controlled polyethylene pipe and tubing.

BS EN 727 Plastics piping and ducting systems. Thermoplastics pipes and

fittings. Determination of Vicat softening temperature.

BS EN 728 Plastics piping and ducting systems. Polyolefin pipes and fittings.
Determination of oxidation induction time.

BS EN 744 Plastics piping and ducting systems. Thermoplastic pipes. Test

method for resistance to external blows by the round-the-clock
method.

BS EN 1053 Plastics piping systems. Thermoplastics piping systems for non-

pressure applications. Test methods for watertightness.

BS EN 1437 Plastics piping systems. Piping systems for underground drainage

and sewerage. Test method for resistance to combined
temperature cycling and external loading.

BS EN 12061 Plastic piping systems. Thermoplastics fittings. Test method for

impact resistance.

BS EN 12256 Plastic piping systems. Thermoplastic fittings. Test method for

mechanical strength or flexibility of fabricated fittings.

BS EN ISO 9967 Thermoplastics pipes. Determination of creep ratio

BS EN ISO Plastics. Determination of resistance to environmental stress

20088-3 cracking (ESC). Bent strip method.

DIN 8074 Polyethylene (PE) – Pipes PE63, PE80, PE100, PE-

HD.Dimensions

ISO 161 Thermoplastics pipes for the conveyance of fluids. Nominal

outside diameters and nominal pressures.

ISO 527 Plastics. Determination of tensile properties.

ISO 1133 Plastics. Determination of the melt mass-flow rate (MFR) and
the melt volume-flow rate (MVR) of thermoplastics

ISO 1167 Thermoplastics pipes, fittings and assemblies for the conveyance
of fluids. Determination of resistance to internal pressure

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Standard Description

ISO 1183-3 Plastics. Methods for determining the density of non-cellular

plastics. Gas pykonometer method

ISO 2505 Thermoplastics pipes. Longitudinal reversion

ISO 4427 Polyethylene (PE) Pipes for water supply. Specifications

ISO 6964 Polyolefin pipes and fittings. Determination of carbon black

content by clacination or pyrolysis Test method and basic
specification

ISO 9000 Quality management systems

ISO 11922 Thermoplastic pipes for the conveyance of fluids. Dimensions

and tolerances.

ISO 13479 Polyolefin pipes for conveyance of fluids – Determination of

resistance to crack propagation Test method for slow crack
growth on notched pipes

ISO 13967 Thermoplastics fittings. Determination of ring stiffness.

ISO 18553 Method for assessment of the degree of pigment or carbon black
dispersion in polyolefin pipes, fittings and compounds

WIS 4-24-01 Specification for mechanical fittings and joints for polyethylene
pipes for nominal sizes 90 to 1000.

4.3.2.2 HDPE Pipes and Fittings

Pipes and fittings shall be manufactured from polyethylene containing only those
antioxidants, UV stabilisers and pigments necessary for the manufacture of pipes
conforming to specification ISO 4427 and for its end use, including weldability when it
is possible. Minimum content of carbon black shall be 2,4%

All HDPE pipes and fittings shall be manufactured from material conforming to
polymer classification PE100 having a minimum required strength value (MRS) of
10MPa at 50 years and 20°C in accordance with ISO 4427. Design stress shall be
8MPa. Pipes shall have a standard dimension ratio (SDR, outside diameter/wall
thickness) of either 11 or 17 unless indicated otherwise by Engineer. Material shall be
procured from the manufacturer accepted to PE100+ Association

The pipes and fittings shall be homogeneous throughout and free of visible cracks,
holes, foreign inclusions, voids and other injurious defects.

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Butt fusion fittings shall be in accordance with ASTM D3261 and shall be
manufactured by injection moulding, a combination of extrusion and machining, or
fabricated from PE pipe conforming to this specification. Fabricated fittings shall be
manufactured using a Datalogger to record fusion pressure and temperature. Butt
fusion fittings shall have a pressure rating no less than that of the pipe. The fittings
shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions,
voids and other injurious defects.

Electrofusion fittings shall be manufactured from the same base resin as the pipe to
ASTM F1055 and shall have a pressure rating no less than that of the pipe.

Flanged and mechanical joint adaptors shall be manufactured to WIS 4-24-01 and
have a pressure rating no less than that of the pipe.

Pipes and fittings shall be fabricated to be capable of withstanding the working

pressures, test pressures and loadings specified.

Pipes and fittings must be designed to achieve a minimum working life of 50 years
under all applicable loadings, environmental and installation conditions.

Pipes and fittings shall be suitable for carrying raw sewage, treated sewage effluent,
surface water and potable water at temperatures up to 40°C as appropriate for the
particular application.

Nominal outside diameters of pipes and fittings shall conform to ISO 161 and the
tolerances on these diameters shall be in accordance with ISO 11922.

Only fittings supplied or recommended by the pipe manufacturer and approved by the
Engineer shall be used. Fittings shall be installed in accordance with the approved
method statement.

The pipe shall contain no recycled compounds.

The properties of the polymer, extruded pipe and fittings shall be as shown in Tables
below.

HDPE Resin Properties

Property Required Value Test Method Test Method

European ASTM

Density >940kg/m3 ISO 1183-3 D1505

Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238 4

index or rate (2.16) 4

Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238 5

index or rate (5.00) T

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Property Required Value Test Method Test Method

European ASTM

Melt mass flow >8g/10min ISO 1133 condition D1238 6

index or rate (21.6) G

Environmental >250hrs BS EN ISO 20088 D1693

stress crack
resistance (10%
stabiliser)

Resistance to >165hrs ISO 4427 DIN 8047 -

internal pressure

Oxidation induction >20mins BS EN 728 -

time (200°C)

Flexural creep >900MPa - D790

modulus

Shore D hardness >50 - D2240

(40°C)

Tensile strength at >20MPa ISO 527 D638

yield (50mm/min)

Elongation at break >600% ISO 527 -

Modulus of >1000MPa - -
elasticity

Charpy impact No break - -

Vicat softening >125°C BS EN 727 -

point

Thermal expansion <0.20mm/m/ C - -

(20-90°C)

Thermal <0.6W/mK - -
conductivity (20°C)

Carbon black >2.4 ISO 6964 -

content

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Property Required Value Test Method Test Method

European ASTM

Carbon black ≤60µm (grade 3) ISO 18533 -

dispersion

*- Maximum deviation of +/- 20% of the nominated value

HDPE Pipe Properties

Property Required Value Test Method Test Method

European ASTM

Density >940 kg/m3 ISO 1183-3 D1505

Melt mass flow 0.2 to 1.4/10min* ISO 1133 condition D1238 5

index or rate 1T
(5.00kg, 190°C)

Oven test Defects shall not ISO 12091 -

develop

Resistance to No failure or ISO 1167 ISO 4427 -

internal pressure defects
(20°C, water in
water, hoop stress
12.4MPa, 100hrs)1

Resistance to No failure or ISO 1167 ISO 4427 -

internal pressure defects
(80°C, water in
water, hoop stress
5.5MPa, 165hrs)1

Resistance to No failure or ISO 1167 ISO 4427 -

internal pressure defects
(80°C, water in
water, hoop stress
5.0MPa, 1000hrs)1

Creep ratio >900MPa BS EN ISO 9967 -

Longitudinal <3% ISO 2505 -

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Property Required Value Test Method Test Method

European ASTM

reversion (100°C)

Shore D hardness >50 - D2240

Tensile strength at >20MPa ISO 527 D638

yield (50mm/min)

Elongation at break >350% ISO 527 -

Ring flexibility Refer standard BS EN 1446 -

Impact strength TIR 10% BS EN 744 -

Ring stiffness To SN or SD BS EN ISO 9969 -

required

Quality Grade N ISO 11922 -

Thermal stability 20mins BS EN 728 -

(200°C)

Notch test (at 500 Refer Standard ISO 13479 -

hours)

Legend

1) Either on pipe or from sample pipe using same resin and process.

*- Change of MFR by processing +/- 20% of the compound value

HDPE Injection Moulded Fittings Properties

Property Required Value Test Method Test Method

European ASTM

Density >940kg/m3 ISO 1183-3 D1505

Melt mass flow 0.2 to 1.4g/10min* ISO 1133 condition D1238

index or rate 1T
(5.00kg, 190°C)

Stiffness As required ISO 13967 -

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Property Required Value Test Method Test Method

European ASTM

Impact Refer standard BS EN 12061 -

Mechanical Refer standard BS EN 12256

strength or flexibility

Thermal stability >20 mins BS EN 728 -

(200°C)

Resistance to No failure ISO 1167 ISO -

internal pressure 4427
(80°C, water in
water, hoop stress
5.5MPa, 165hrs)1

Resistance to No failure ISO 1167 ISO -

internal pressure 4427
(800C, water in
water, hoop stress
5.0MPa, 1000hrs)1

Water tightness No leakage EN 1053 -

Legend

1) For moulded materials use either an injection moulded or extruded pipe

from same materials.

*- Change of MFR by processing +/- 20% of the compound value

4.3.2.3 Jointing

a) Butt Fusion Jointing

Butt fusion jointing shall only be used to join pipes of the same PE material with
compatible MFR and with the same nominal wall thickness and outside diameter.
The following procedures shall serve as a general guide only. The Contractor shall
obtain detailed jointing instructions from the manufacturer who shall have a technical
representative available at the Engineer’s request during the jointing process.

- The butt fusion machine should be sited within a shelter and the ends of the
pipe being joined should be covered or plugged to prevent through drafts.
- Each component that is to be fused should be held in position in the purpose
built clamping jig. The lengths of pipe hanging outside the jig should be
supported by means of roller cradles.
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- The pipe ends should be faced so that the finished surfaces are perfectly
smooth free of visible ridges, valleys or other surface imperfections.
- The outside diameters of the pipe ends should match closely without the
offset exceeding 10%
- The pipe ends should be heated to the pipe manufacturer’s recommended
temperature and interfacial pressure. The Contractor should use a pyrometer
or other surface temperature measuring device to confirm and record the
actual surface temperature for each weld. Temperature indicating crayons
should not come into contact with the surface to be welded.
- After the pipe ends have been properly melted, the heater tool should be
removed within the specified time. The molten pipe ends should be brought
together and allowed to cool without disturbance to form the permanent weld.
The proper bead size and geometry specified for the pipe being welded
should be formed.

b) Saddle/Sidewall Jointing

Saddle /sidewall fusion jointing shall be accomplished by using a mechanical saddle

fusion machine that has been designed for this purpose to ensure proper alignment,
temperature and force control. The following procedures shall serve as a general
guide only. The Contractor shall obtain detailed jointing instructions from the
manufacturer who shall have a technical representative available at the Engineer’s
request during the jointing process.

- Any dirt or coating that might interfere with the proper operation of the saddle
fusion machine should be removed from the pipe and the surfaces of the pipe
and saddle roughened to expose fresh material and any reside brushed away.
- Test fit the saddle fusion machine to ensure that alignment and contact are as
they should be.
- Commence the fusion process and periodically verify the surface temperature
using a pyrometer or other surface temperature measuring device. If
temperature indicating crayons are used, they should not be used on a
surface which comes into contact with the surfaces to be welded.
- After the heating period, remove the heater plate and check for the correct
melt pattern on both the fitting and the pipe. Join the fitting to the pipe with the
prescribed fusion force.
- Cool the joint without disturbance until the melt has formed a permanent
weld. The joint should not be subjected to any external stresses until the
fusion joint has cooled.

c) Electrofusion Jointing

Electrofusion jointing involves heating the electrofusion joint internally, either by a

wire coil at the interface of the joint or by a conductive polymer. Heat is created by an
electric current passed to the conductive material in the fitting.

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- Ensure that the fitting is dimensionally appropriate for welding to the pipe.
Clean the pipe surface in the joint area. Cut the end of the pipe square. Mark
on the pipe surface the proper position of the fitting to be installed. Scrape the
surface of pipe area to be joined, removing all surface degradation and
contamination. Avoid contamination of the scraped pipe surfaces.
- Place the pipe and fitting in the clamping fixture to prevent movement of
the pipe or fitting.
- Connect the electrofusion control box to the fitting and to the power source.
Apply electric current to the fitting as specified in the manufacturer’s
instructions. Turn off the current when the proper time has elapsed to heat the
joint properly.
- Allow the joint to cool for the recommended time and remove the clamping
fixtures. Do not remove prematurely from the clamps as any strain on a joint
that has not fully cooled can be detrimental to joint performance.

d) Mechanical joints and fittings

Many types of mechanical connection styles and methods exist. The Contractor shall
submit suitable mechanical joints. All such joints shall be recommended and
acceptance tested by the manufacturer of the pipe. Where marked on the drawings
end-load resistant fittings of an approved type shall be used.

When tightening polyethylene flanges care shall be taken to produce an equal torque
load to the limits given by the manufacturer. A torque wrench shall be used. Since
polyethylene creeps under load it is essential that the bolts are re-tightened several
times prior to commissioning to minimise the risk of leakage.

All joint materials and gaskets shall be suitable for use in the prevailing climate, soil,
ground water, potable water and irrigation water conditions.

4.3.2.4 Quality Control Tests

The routine factory quality control tests listed below shall be carried out at the
required frequencies and records of all tests and inspections shall be maintained by
the manufacturer. The Engineer shall be provided with two copies of all test
certificates and reports.

- Quality testing of all raw materials to ensure that they comply with the relevant
specification.
- Control of processing parameters in terms of temperature, pressure, flow
rates, haul-off speed and energy input.
- Visual inspection of the pipes to check general appearance, dimensional
compliance and any indication of inclusions or processing flows in pipe barrels
and joining ends.
- Production short-term tests to identify any variations in the plant functioning.
- The following tests shall be performed in accordance with the relevant
standards in order to ensure the quality of the extruded pipes:
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 Melt mass-flow rate of raw material.

 Density of raw material.
 Carbon black content.
 Carbon black dispersion.
 Long-term stress crack resistance at 80°C.
 Long-term MRS at 20°C on the raw material (data not older that 24
months)
 Appearance.
 Long term hydrostatic test at 20°C. (100hrs test)
 Welding.
 Slow tear test
 Oxidation induction time value.
 Visual inspection of pipes.
 Dimensional check of pipes.
 Heat reversion of pipes.
 Hydrostatic creep strength tests of pipes.
 Bend test / reverse bend test

When conditioning is required for laboratory tests, condition the specimens in

accordance with the appropriate standard.

Tensile testing for pipe resin, pipes and welds shall be performed on an approved
tensilometer capable of delivering safely and accurately 120 % of the stress required
by the sample. The tensilometer shall be connected to a computerised system
capable of delivering information in data and graphical form. The information
required from tensile measurements are tensile strength at yield and peak and
elongation at yield and peak.

- Test specimens shall be milled to exact size using approved designated

milling machines. Each specimen shall be measured to an accuracy of 10
microns.
- The Contractor shall submit statistical analysis based on minimum sample
populations of 32. Cumulative analysis based on overall and on individual pipe
resin batch based data shall also be provided.
- Welded samples shall be visually examined after tensile testing for signs of
adequate bonding and ductile and brittle failure. Weld samples with greater
than 25 % brittle failure shall be rejected.
- Tensile graphs indicating brittle failure shall be considered as failures.

The selection of samples of pipe, resin and welds for testing shall be as directed by
the Engineer.

If the results of any test fail to meet the requirements of this specification, the test
shall be repeated once again. If, upon retest, failure occurs, the batch quantity of
product represented by the test shall be rejected.

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The Contractor shall conduct quality checks at the manufacturer’s premises to ensure
that the in-process manufacturing quality checks are being conducted correctly and at
the stated frequency. Test certificates relating to the batch shall be furnished to
the Engineer before acceptance of the delivery. The test certificates shall contain all
the details in the agreed format of reporting.

Marking shall be applied to the pipe in such a manner that it is legible after installation
and durable throughout the construction period. Each standard and random length of
pipe and every fitting shall be marked before despatch from the pipe manufacturer’s
works as required in ISO 4427 and as follows:

- The manufacturer’s name, initials, or trade mark.

- The dimensions nominal outside diameter X nominal wall thickness.
- The outside diameter tolerance.
- The designation of the pipe material.
- The nominal pressure.
- The pipe series.
- The date of manufacture and batch number.
- Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture, delivery and testing of that
pipe.
- The manufacturing standard.

4.4 GRP PIPES & FITTINGS

4.4.1 Definitions and Requirements

The following definitions are used in this specification.

GRP Pipe: A tubular product containing glass-fibre reinforcements embedded in or

surrounded by cured thermosetting resin with or without aggregate.

Aggregate: Siliceous sand conforming to ASTM C33, except the gradation

requirement need not apply.

E-glass: Low Alkali content glass fibre.

ECR-Glass: Form of glass fibre specially developed for acid resistance.

C-Glass: Alkali -Lime glass with added boron used for surface layer reinforcement.
(Good chemical resistance).

Reinforcement: Glass fibres used to provide strength and stiffness to a composite

material.

Resin: A polymer that has high molecular weight with no definite melting point used
as a basic material for plastics.

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Orthophthalic resin: A general purpose polyester resin of limited chemical and

temperature resistance.

Polyester resin: Type of thermo-set resin with two or more ester group.

Thermo-set Resin: Resin which hardens irreversibly by use of additives. Once cured,
a thermo-set resin cannot be re-melted and insoluble.

Epoxy resin: A polymer containing two or more three member rings, each consisting
of one oxygen and two carbon atoms. The polymer is cured by cross-linking with
amine or anhydride hardener, with or without heat, catalysts or both.

Vinyl ester resin: High performance corrosion-resistant epoxy based resin.

Lining: Integral internal reinforced lining of a GRP pipe, normally of high resin content
consisting of a 'barrier layer' and a 'surface layer'.

Roving: A collection of parallel glass strands or filaments with binder.

Chopped fibre: Continuous fibres cut into short lengths (3-50mm).

Resin-rich Lining: A corrosion resistant lining containing approximately 65-80% of

resin by weight applied to the interior surface of GRP pipe to protect the structural
wall from corrosion.

Laminate: A composite of cured resin and reinforcement.

Filament winding: General term for pipe manufacturing method using continuous
rovings as the reinforcement.

Helical winding: Filament winding manufacturing method where continuous rovings

are applied at 60 - 70 degree to axis of pipe mould.

Barrier-Layer: The resin -rich anti penetrant layer forming part of the internal
corrosion resistant pipe lining applied behind the interior liner of pipe.

Inner surface layer: Resin-rich layer forming part of the internal corrosion resistant
pipe lining.

Exterior surface layer: A filled or unfilled resin-rich layer (reinforced or unreinforced)

applied to the exterior surface of the pipe wall.

Barcol hardness: Measure of surface resin hardness, used to check the degree of
cure.

Cure: Conversion of liquid resin into solid.

Air inhibition: Failure of surface layer of resin cure because of contact with
atmosphere.

Stress: The force per unit cross section area.

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Strain: Dimensional change per unit of length resulted from applied force or load
measured in (mm/mm).

Strain corrosion: Brittle failure mode caused by exposure of a strained laminate to a

corrosive environment.

Stiffness: The resistance of a pipe to circumferential deflection in response to

external loading applied along one diametrical plane.

Pressure class: Maximum sustained pressure for which the pipe is designed.

Pipe stiffness: A measure of the force required to deflect the diameter of a pipe ring a
unit amount.

Stiffness class: The nominal stiffness of a specified pipe.

Creep: Deformation or strain that occurs over time when a material under
sustained stress. GRP is subject to creep at all temperatures when subjected to
stress.

Hydrostatic Design Basis (HDB): The long -term hydrostatic hoop strength of a
specific fibre glass pipe material as determined by hydrostatic pressure test and the
data extrapolated to 50 years to use the data in pipe design calculation.

Long-term strain corrosion (SCV): The long-term strain corrosion strength of a

specific fibre glass pipe in acidic & under strained condition determined by deflection
test and the data extrapolated to 50 years to use in pipe design calculation.

Long-term Stiffness (Creep): The long term stiffness retention and creep factor of a

GRP pipe (under wet condition) determined by constant failure strain (deflection) test
and the test data analysed and extrapolated to 50 years.

Long-term Ring bending strain: The long term bending strength (in normal water
under immersed condition) of a GRP pipe determined by constant failure strain
(deflection test) and the test data analysed and extrapolated to 50 years strain to use
the data in pipe design calculation.

Design factor (FS): A number equal or greater than 1.0 which takes into
consideration the variables and degree of safety involved in a design. Test data are
divided by the design factor to obtain design allowable values. Also called safety
factor.

4.4.2 Glass Reinforced Plastic Pipe & Fittings (GRP) for use in Gravity and Pressure
Flow Systems

Pipe manufacturers must be members of, or affiliated with, a quality control or

certification authority relevant to the pipes or fittings proposed for incorporation in the
works. ISO 9001 certification is required for pipe/fittings manufacturers.

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The following specifications are referenced as applicable:

Reference Description

BS EN 14364:2006 +A1:2008

BS EN 1796:2006 +A1:2008 Plastics piping systems for drainage and

sewerage with or without pressure. Glass-
reinforced thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Specifications
for pipes, fittings and joints

Plastics piping systems for water supply with or

without pressure. Glass-reinforced thermosetting
plastics (GRP) based on unsaturated polyester
resin (UP)

ASTM D3262:2004 Specification for fibreglass sewer pipes for use in

gravity flow systems for conveying sanitary
sewage

ASTM D3754:2004 Specification for fibreglass sewer and industrial

pressure pipes for use in pressure systems for
conveying sanitary sewerage and industrial
wastes

ASTM D3517:2004 Specification for fibreglass pressure pipes for

conveying water system.

AWWA C950:2001 Standard for fibreglass pressure pipes

AWWA M45 Fibreglass pipe design manual

The GRP pipes & fittings shall be certified in accordance to BS EN 14364, BS EN

1796, ASTM D-3262 & D 3754 (Certificate to be submitted for Engineer’s approval).
Certification must include the diameters of pipe to be supplied. Evidence of diameter
range is necessary.

GRP Pipe and fittings shall be manufactured in accordance with BS EN 14364, BS

EN 1796 and ASTM D-3262 for gravity application and BS EN 14364, BS EN 1796
and ASTM D-3754 for pressure application. GRP pipe and fittings shall be at least
adequate to achieve a minimum working life of 50 years under all applicable loading,
local environmental and installation conditions.

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The pipes and fittings shall be designed to withstand up to 5% long term deflection in
the installed conditions.

Both gravity & Pressure Pipes shall have a 50 years strain corrosion design
performance as per the latest editions of ASTM D3262/ASTM D 3754, AWWA C 950
for sewer pipes, but the mean value of the regression line at 50 years shall not be
less than 1 % strain. Evidence of third party approved regression test date must be
submitted.

The GRP pipes used for gravity applications shall comply with the minimum
requirements for 6 Bar pressure pipes as the pipe lines may be intended to operate
under surcharged conditions and not as gravity pipe lines.

The pipe shall also comply with the additional requirements to suit the prevailing
Local temperature and corrosive environment conditions specified.

4.4.2.1 Materials Specification

a) Resin

The resin used for the internal liner of the pipes and fittings shall be of an epoxy
based vinyl ester resin complying with BS EN 14364 and BS EN 1796 and shall have
a minimum elongation to break of 5% when fully cured.

The resin in the structural wall of the pipes and fittings shall be of unsaturated
Isophtalic polyester type incorporating styrene as the monomer and meeting the
requirements of BS 3532 Type B. The use of vinyl ester resin in the structural layer is
also permitted.

* No pigments in the liner or structure shall be added.

b) Glass

The internal and external layer shall be of "C" glass veil produced from a chemically
resistant glass durable in both acid and alkaline environment and shall have a surface
treatment compatible with the resin. All fibre reinforcement used shall be of high acid
resistant type "ECR/Advantex" ' comply with BS EN 14364 and BS EN 1796 and shall
have a surface treatment compatible with the resin. The reinforcements shall
generally comply with the standards listed below as appropriate.

References Description

BS 3691 Glass fibre roving for the reinforcement of polyester resin systems".

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BS 3496 Glass fibre chopped strand mat for the reinforcement of polyester
resin systems".

BS 3396 Woven glass fibre fabrics for plastic reinforcement".

BS 3749 Woven glass fibre roving fabrics for the reinforcement of polyester
resin systems".

Glass rovings used in the structural wall shall not exceed 2400 Tex.

c) Aggregates and Fillers

Aggregates if used, shall be minimum 98% pure Silica Sand as defined in BS EN

14364, BS EN 1796 and AWWA C950 and shall contain no impurities. The
aggregates shall only be used in the stiffening layer of the pipe wall, where it is
designed as part of the composite structure.

The final product shall meet the requirements of the specifications.

Silica sand aggregates as defined in BS EN 14364 and BS EN 1796 shall contain no

impurities. Fillers as defined in BS EN 14364 and BS EN 1796 shall not be used. The
silica sand content in the pipe wall shall not exceed 50% for the gravity pipes and
30% for the pressure pipes.

The resin shall be cured to reach hardness not less than 90% of the resin
manufacturer's recommended hardness.

A manufacturer's tolerance of ± 1 % shall be allowed on the nominal diameter of the

pipe. The pipes shall be supplied in standard lengths of 3, 6, 10 or 12 metres with a
tolerance of ± 25 mm. The deviation from straightness of the bore of the pipe shall not
exceed 0.3% of the effective length or 15.00 mm whichever is smaller and shall apply
when measured on site. Up to 10% of the pipes will be allowed in random lengths.

The ellipticity of any pipe when measured resting freely on the ground shall not be
more than 2% of the mean diameter at any point. No pipe known to have undergone
a deflection greater than 7% shall be incorporated into the Works.

The stiffness shall be minimum 5000 N/m2 for all pipes but for pipes to be used in
Pumping Station and valve chambers and for Irrigation &Water application the
stiffness shall be minimum 10,000 N/m2 and pipes for use in microtunnelling or similar
jacking operations the stiffness shall be minimum 50,000 N/m2 unless surrounded in
concrete. Please refer to Section 12 for the production of GRP pipes in jacking
operations.

GRP Pipes shall also be used in place of A.C. Pipes wherever applicable in storm
water drainage and Irrigation Pipes. The pipe laying procedures & the deflection
checks at Site etc. shall be the same as for sewer pipe. Pipe installation & Pipe
surround material shall be the same as specified for GRP Pipes & Fittings. The
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minimum / maximum burial depth shall be as recommended by the Pipe

manufacturer. Supporting design calculation shall be provided to the Engineer to
satisfy the installation condition.

The specific tangential initial stiffness shall be demonstrated by application of the

following equation:

Stiffness of the pipe = is defined as EI/D3

(STIS)

Where: E = bending modulus of pipe wall circumferentially (in N/m2).

I = second moment of area of pipe wall per Unit length (in m4/m)

D = mean diameter of the pipe in metres

4.4.3 Compulsory Requirements Particular to Pipes, Couplers and Joints

a) The Inner Layer

All pipes and fittings shall have a resin- rich liner internal to protect the glass in
structural laminate from long term degradation having a minimum thickness of 1.5mm
and maximum thickness of 2.5mm consisting of an inner most 0.25mm surface layer
reinforced with chemical resistant "C" glass impregnated with 90% resin. The
remainder of the 1.25 mm backup barrier layer shall consist of acid resistant (ECR/
ADVANTEX) chopped glass strands or powder bound chop strand mat and having a
glass content between 25 and 30% by weight. The lining materials selected should
provide a good impact and corrosion resistance.

b) The Structural Layer

The structural wall of the pipe shall be reinforced with closely spaced continuous fibre
glass (ECR/ADVANTEX) filament winding, chopped roving, Silica Sand all
impregnated with Isophtalic polyester resin. No dark pigments or resin fillers such as
Calcium Carbonate shall be used in the pipes or fittings. Fine silica sand containing
no impurities and complying with the requirements of BS EN 14364 and BS EN 1796
may be added in a core layer sandwich, between the pipe structural layers.

c) The Exterior Layer

The exterior resin rich layer of the pipe shall have a maximum thickness of 1 mm
reinforced with corrosion resistant glass (ECR/ ADVANTEX) and "C" glass veil
impregnated with isophthalic resin/vinyl ester resin. For protection against ultra violet
light degradation a translucent "UV" inhibitor should be included in the resin mix.

A black colouring pigment to suit the service identification of Storm water drain pipe
shall be added on external resin rich layer as instructed by Dubai Municipality.
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d) Fittings

All fittings such as bends, tees, junctions, reducers and the like shall conform to BS
EN 14364 and BS EN 1796. The construction of bends shall be swept or mitered. The
laminated joints used in the fabrication of fittings shall meet or exceed the required
design requirements of the piping system. All hand laminations or windings shall
utilize only one type of resin throughout.

e) Flanges

GRP flanges shall be flat faced and drilled to BS EN 1092 PN 10 or PN 16 drilling

pattern. Flanges shall be filament wound up to 1800mm and may be contact moulded
for larger sizes. GRP flange gasket shall be of a design, material and thickness as
recommended by the GRP fitting manufacturer. The use of epoxy resin in a flange
manufacture is permitted.

f) Joints (For buried pipes)

Except where otherwise detailed on the drawings, all pipes and joints shall be of
flexible type. Joints shall be of loose GRP machine made coupling having two rubber
rings gaskets. All joints shall be capable of withstanding the various tests specified for
the appropriate class of pipe.

Joints shall withstand while maintaining the specified test pressure at a deflection of
not less than the values specified in the BS EN 14364/ BS EN 1796/ ASTM D3262/
ASTM D4161.

Pipes used for adjustment and short length shall be ordered from the manufacturer.
Cutting and rejoining is only allowed when butt joints are used or a calibration
machine is available and approved by the manufacturer. No cutting on site is allowed
without manufacturer’s recommendation. The Rubber rings shall be meeting
kitemarked the requirements of the appropriate parts of BS EN 681-1 and be of the
EPDM formulation.

g) Joint Lubricants

For lubricants, use only a vegetable based soap available from the pipe
manufacturer. Never use petroleum product or automotive oils to lubricate the joint,
as they will damage the rubber rings.

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Pipes shall have a resistance to longitudinal tensile force per unit circumference as
under:

Nominal Diameter (mm) Initial Ultimate Resistance

(N/mm)

Up to 700 100

700 to 1,000 120

1, 000 to 1, 600 160

1,600 to 2,400 250

2,400 to 4,000 300

When subjected to a parallel plate loading test no evidence of crazing or cracking and
no structural failure with the deflection levels specified in AWWA C 950-Table 9. The
deflection criteria presented are based on a Maximum installed long term deflection of
5%. If the pipe sample fails to meet either or both requirements, the long term
allowable deflection must be reduced proportionally for the pipes represented by the
sample.

The jointing system shall be an approved coupling system. Where the system
involves separate reinforced plastic couplings of sockets formed by a lay-up process
subsequent to pipe production, the resins used shall be clear and non-pigmented to
permit visual examination within the laminate.

Where GRP laminate is cut, exposed ends shall be sealed with a suitable resin and
approved prior to incorporation into the Works. Where such cutting and sealing takes
place at site the resins used and the methods of storage, mixing, application and
curing shall be strictly to the manufacturer's recommendation. Before any such work
takes place the manufacturer's representative shall visit the site to demonstrate and
give clear procedural advice to the Contractor in the presence of the Engineer.

GRP pipe and fittings shall be as uniform as commercially practicable in colour,

opacity, density, and other physical properties.

GRP pipe and fittings shall be smooth and both the internal and external surfaces
shall be clean and free from delaminations, cracks, bubbles, pinholes, pits, blisters,
foreign inclusions and resin-starved areas that due to their nature, degree or extent
detrimentally affects the strength and serviceability of the pipe.

Unless authorized by the Engineer, repair will not be permitted on any pipes with
defects, as listed below and such pipes shall not be incorporated into the works:

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(i) A scratch of greater depth than 0.30 mm.

(ii) Cracks of any type on the inside of the pipe.

(iii) Cracks on the outside, longer than 200 mm circumferentially or 6mm

longitudinally.

(iv) Delaminations.

(v) Damaged ends including bubbles, cracks, voids, exposed reinforcement or

extraneous matter.

(vi) Internal protruding fibres.

(vii) More than 25% of the external area with protrusions of any sort.

(viii) Air voids and blisters exceeding 5 mm diameter or 1 mm in depth, greater

in area than 0.50% of internal or 1.00% of external surfaces.

(ix) Pitting to more than 5% of the internal or 10% of the external surface area
and individual pits more than 1 mm diameter or 0.5 mm in depth.

(x) Wrinkles more than 3% of the surface area and individual wrinkles more
than 2 mm deep.

4.4.4 Type Test for GRP Pipes and Joints

DM approved, NAMAS accredited independent third party laboratory witnessed Type

tests shall be carried out compulsory, on locally produced representative pipe
products in accordance with Table 4-2 to pre-qualify the products and to verify the
design input data given in the design calculations.

Table 4-2 Pre-qualification Tests

Sr. Qualification or Type Test Method Minimum Requirements
Tests

1 Long term (10,000 hrs) BS EN 14364 AND Extrapolated predicted

Chemical test ( strain BS EN 1796 OR failure strain at 50 yrs.
corrosion resistance) ASTM D3681 shall not be less than 1%.

2 Long term hydrostatic or ASTM D2992 / OR Hydrostatic strain at 50

pressure design basis BS EN 14364 AND yrs. shall not be less than
10,000 hrs test. (for BS EN 1796 0.66%
Pressure Pipe)

3 Long term specific ring BS EN 14364 AND 50 years-extrapolated

stiffness (creep factor) BS EN 1796 stiffness value shall not
under ring deflection Appendix L be lower than 70% of the

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Sr. Qualification or Type Test Method Minimum Requirements

Tests

(10,000 hrs test) initial stiffness.

4 Long term ring bending ASTM D 5365 50 years strain shall not
strain (sb) be less than 1.35%.

5 Impact resistance BS EN 14364 AND As specified in relevant

BS EN 1796 standard.
Appendix J

6 Joint water tightness. ASTM 4161/BS EN Requirements as

14364 AND BS EN specified in relevant
1796 standard.

7 UV exposure on GRP Manufacturers Not to show surface

Pipe (1 Year). Recommended test Deterioration due to UV
Method. effect.

8 Short time Hydraulic ASTM D 1598 / D (a) Withstand 3.5 times

failure pressure of pipes 1599 the rated working
and fittings (After the first pressure with no sign of
production). leakage or weep. (b)
Determine the failure
pressure by pipe bursting.

Note: (1) The above tests are to be repeated on locally made pipes when the
material type & compositions are changed during the production from the original type
test of the product.

Quality control tests on raw materials and final products shall be carried out as listed
below:

4.4.4.1 Quality Control Tests & Records

The manufacturer shall have maintained a record of all quality control tests for a
period of not less than 2 years and if requested, shall submit the data to the Engineer.

a) General Requirements

The pipe manufacturer must demonstrate the capability to produce pipes of

consistent properties and quality meeting the requirements of these specifications. A
detailed quality control/quality assurance program must be implemented at the
manufacturing facilities and all necessary test equipment to be operated by skilled
technicians. Calibration of test equipment shall be performed at least once a year.
Details of the pipe manufacturers QC/QA program, testing equipment, testing
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program shall be presented to the Engineer for review and approval prior to
commencement of pipe manufacture. The manufacturer's quality control scheme
shall be certified by a recognized independent authority to meet the requirements of
ISO 9001.

b) Reconfirmation of Strain Corrosion Regression Line

When a GRP piping product has an existing strain corrosion regression line, any
change in material, manufacturing process, construction or liner will necessitate a
Screening evaluation as described in CL 10.2, 10.3, 10.4, 10.6 & 11 of ASTM
D3681:96. The pipe samples for screening test shall be selected by the Engineer’s
representatives from locally produced pipes only.

Table 4-3 Minimum Design Parameters, Installation Conditions and the

Mandatory Requirements for GRP Pipe Intended to Carry Septic Sewage/ Sea
Water
Details Requirements

Minimum working pressure class of pipe 6 Bar

for gravity applications.

Ground water table level (assumed). Minimum 1 M below ground surface.

Minimum working Pressure class pipe 10 Bar

Category for Pressure applications.

Service operating temperature 50 °C

Installation depth ('H' Min. & 'H' Max.) H min : Not less than 1.5 m

H max : As shown on the drgs.

Stiffness Class Pipe (for gravity & Minimum 5000 N/m² for gravity & 10000
pressure) N/m2 for Pressure pipes

50 Years extrapolated stiffness retention (a) Not less than 3500 N/m² for 5000
value (end stiffness) of pipe. STIS class pipe (b) Not less than 7000
N/m² for 10,000 STIS class pipe.

50 Years extrapolated strain value Minimum 1 %

established by long-term strain corrosion
type test conducted on local made pipe Safety factor = 1.5
(G & P) and witnessed by 3rd party
independent lab.

Required minimum strain value by 1000 Strain percentage achieved shall not be

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Details Requirements

hrs control test on local made production lower than the type test result of GRP.
pipe.

50 Yrs extrapolated 'HDB' value Minimum 0.66%

established by long term type test
conducted on local made pipe (G& P) Safety factor = 1.8
and witnessed by 3rd party independent
lab.

Permitted maximum long-term deflection Not greater than 5%

at 50 years service life of pipe.

Shape factor input data (Df) for pipe Minimum 4.5 as given in AWWA M45
design manual for pipe zone embedment
material as gravel with compaction
moderate to light.

Back fill modulus E'b for pipe zone Minimum 20.7 MPa as given in AWWA
embedment. M45.manual.Crushed rock as pipe zone
embedment with moderate proctor

Live load assumption to use in pipe Four-lane road with truck centred in each
design. 3.7m wide lane as given in AWW A M45
manual.

Impact factor to use in pipe design As per A WW A M45 manual

recommendation.

Water hammer calculation Ditto

Materials in Pipe Laminate Structure

A Type of glass throughout the pipe ECR/ Advantex only

wall

B Type of resin to be used in Isophthalic polyester Resin type ‘B’

structural wall having minimum 3.0% elongation
property

C Type of resin to be used on resin- Epoxy based vinyl ester resin having
rich liner internal & external of pipe minimum 5% resin elongation property

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wall

D Aggregate & fillers Silica sand SiO2 > 98%

E C' Glass (for the internal liner and Chemical resistant ECR Type only
liner external of pipe)

Corrosion Resistant Lining inside the Pipe Wall

a Surface layer internal Nominal thickness 0.25mm

Glass content up to 10%

b Barrier layer behind the surface Minimum thickness 1.25mm

layer of pipe
Maximum thickness 2.25mm

Epoxy based V.E.Resin 60- 80%

ECR / Advantex Glass 20-40%

c Overall liner thickness internal Minimum 1.5mm

Maximum 2.5 mm

d Overall liner thickness external Minimum 0.5mm

Maximum 1.00 mm

e Sand content minimum/max Sand content in gravity pipe wall shall not
limitations be greater than 50% and 30% in pressure
pipe.

f Chopped Rovings Chopped rovings in pipe wall

minimum/max limitations minimum 7%.

The manufacturer shall carry out the quality control test listed below using the pipe
production sample selected and witnessed by the Engineer at the frequency stated.
The manufacturer shall maintain records of all tests and inspections and two copies
of all test certificates and reports shall be forwarded to the Engineer.

c) Raw Materials

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Checks shall be made on all raw materials to ensure that they comply with the
manufacturers stated values. All deliveries of resin shall be checked for consistency
of Viscosity and reactivity. Any resin deviation from the manufacturers published
figures shall not be used. Glass samples shall be checked for yield/tex, moisture and
size content. All deliveries of aggregate shall be checked for consistency of grading,
moisture content and purity. The pipe manufacturer should provide a copy of the
materials certificate of analysis for the material supplied together with in-house Q.C.
test reports stating that the material used in the pipe wall construction is conforming
in all respects to the relevant specification.

Table 4-4 Quality Control Tests on Final Product

1 Pipes & Fittings Test Method Minimum
Requirements

Hydrostatic – Pressure Test BS EN 14364/ BS

(Pressure & Gravity) EN 1796 / ASTM
D 3262 / ASTM
3754 / AWWA C
950

(1) 100% of pipes and (1) 2 x Rated

couplers. working pressure for
5 minutes.

(2) 1% of the pipes and (2) 2 x Rated

couplers working pressure for
4 hours.

2 Stiffness (for Gravity & Pressure)

1 in every 100 pipes
manufactured (minimum)

(a) At 5% deflection ASTM D2412 / BS a) 5000 / 10000

EN 14364/ BS EN N/m2 (minimum).
1796 ASTM D3262
/ D3754

(b) At level “A” (12% / 9%) b) No liner

crack
Deflection. For 5000 / 10000
STIS pipe.

(c) At level “B” (20% / 15% c) No structural

) Deflection for 5000 / 10000 failure
STIS pipe.

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(d) After level “A”. d) Continue to

deflect to the point
of liner cracking and
record.

3 Wall Thickness ASTM D3567 Manufactures

minimum quoted
(On 100% Pipes, Couplers and thickness given in
Fittings) the calculation for
the pipe design.

4 Hardness (On 100% of pipes, BS 4549: PI Minimum 90% of the

Couplers and fittings) using Appendix A or hardness value
Barcol impressor 934 – 1, on ASTM D2583 declared by the
liner resin manufacturer
but not less than 33
barcol readings
using barcol
impressor 934 – 1.

5 Loss on Ignition (1 in every 100 ASTM D2584 + / -5% of

pipes) manufactures
specified resin /
glass sand ratio.

6 Hoop Tensile Strength (1 in 100 ASTM D2290 / BS Requirements

pipes) EN 14364/ BS EN specified in table 10
1796 of ASTM D 3754 as
appropriate for the
pressure class or
AWWA C950 Table
10

7 Longitudinal Tensile Strength (1 BS EN 14364/ BS BS EN 1796 Table

in 100 pipes) in axial direction EN 1796 Appendix 13 / Table 13 of
A ASTM D3754

8 Fittings

(a) Visual inspection ASTM D2563 (a) Every

items
(b) Dimension ASTM D3567
(b) Every
(c) Pressure tests BS EN 14364 BS

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(d) Barcol hardness (Resin EN 1796 / AWWA items

cure) C 950
(c) 1 in
ASTM D2583 10flanged
items 2 x
WP for
60s.

(d) Every
item
minimum.

(a) Every items

(b) Every items

(c) 1 in
10flanged items 2 x
WP for 60s.

(d) Every item

minimum. Barcol
reading 33

9 Chemical Control Tests ASTM D3681 Strain level shall be

above 1%.
(100 & 1000 hours tests) on ASTM D3262
samples of manufactured pipes
during pipes supply for each BS EN 14364 BS
contract. EN 1796

Evidence from the manufacturer shall be provided of the satisfactory completion of

the ‘Strain Corrosion Control test’ on samples of pipe representative of those to be
supplied together with an assurance that the test result are in full compliance with the
requirements stated in Table 4.9 Item (9) above.

d) Visual Inspection

Each pipe and fittings shall be subjected to a complete schedule of inspection before
shipment and after offloading at site. All pipes and fittings shall be commercially free
of defects such as delaminations, bubbles, exposed or protruding fibre, cracks, air
voids, pits, or resin-starved areas that due to their nature, degree of extent
detrimentally affects the strength and serviceability of the pipe. The maximum
allowable visual defects of GRP pipe laminate parts shall be classified to type and

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level as given in ASTM D2563: Table 1. The acceptable quality level for the pipes
internal and external shall be the level 2 as specified in CL. 3.3 of the above
standard. Visual inspection report of the pipes, couplers and fittings in accordance
with the above standard are to be provided by the manufacturer. Joints surface shall
be free of dent and other surface irregularities that will affect the integrity of the joints.
Any repairs at site if approved by the Engineer shall be carried out by qualified and
skilled staff of the pipe manufacturer.

e) Design Calculations

The manufacturer shall design the pipes for a life of not less than 50 years and shall
submit calculations for initial and long term deflection with truck loads, buckling,
vacuum, pressure, class, and strain in accordance AWWA M45. (Chapter V).

For the purpose of design calculations only the bedding and back fill for pipes shall be
considered as crushed stones/gravel with slight compaction and the modulus of soil
reaction value shall be 20.7 Mpa as given in Table 5.5 of AWAWA M45. The
maximum calculated long term deflection shall not exceed 5%. Copies of the design
calculations shall be submitted to the Engineer for review and approval at the time of
material submission.

f) Shape Factor

The shape factor input data to be used in the design calculation shall be based on
dumped gravel with slight compaction and its appropriate value shall choose as given
in Table 5.1 of AWWA M45 Manual.

g) Safety Factor

The following safety factor shall apply:

AWWA M 45 Design Procedure

Pressure Rating > = 1.8

Ring Bending Strain or stress > = 1.5

Combined Strain or stress > = 1.5 and 1.8

Buckling> = 2.5

h) Inspection and Testing

(i) The manufacturer shall take adequate measures in the production of

products covered by this specification to assure compliance with the
requirements herein. An inspection and testing plan should be forwarded to
the Engineer for approval prior to start of manufacturer.

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(ii) Production and testing notice: When plant inspection is required by the
Engineer the manufacturer shall provide adequate advance notice of when
and where production and testing of ordered products will commence.

(iii) The Engineer shall have free access with reasonable advance notice to the
manufacturer's plant areas that are necessary to assure that the products
comply with all requirements herein.

i) Workmanship

GRP Pipes, fittings and joints shall be free from delaminations, bubbles and pinholes,
pits, blisters, dry spots, pimples, resin pockets, deep scratches, wormholes and deep
wrinkles.

All GRP Fittings shall be fabricated in the factory to ensure quality control (under no
circumstances fabrication of fittings be allowed on site by the contractor). Complex
fittings arrangements may be pre-assembled by the pipe manufacturer on the factory
such that the field joints are kept to a minimum.

j) Marking

Each pipe and fittings shall be legibly marked with the following information:

- Manufacturers name or trademark

- Manufacturing date and the applicable standard
- Manufacturing number
- Nominal diameter in mm
- Operating pressure in bar
- Pipe stiffness class
- Nominal laying length (for pipe only)
- Manufacturer's inspection mark
- Contract name and number
- Identification mark & the colour distinguishing the gravity & pressure pipe.

k) Submittal/Drawings

The following information shall be submitted to the engineer by the manufacturer.

(i) Resin, Glass reinforcement, aggregate, joint and gasket data, with material
manufacturer’s certificate of analysis.

(ii) Pipe supply specifications & installation manuals.

(iii) GRP manufacturers Pre-qualification

(iv) GRP Manufacturers Quality Control and Assurance Manual.

(v) GRP pipe data sheet in the standard format shown below.
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In addition to the above information, the following information shall be submitted

during the mobilisation period.

(i) Detailed Manufacturing process for pipe, joints and fittings.

(ii) Detailed drawing of pipe end and couplers including pipe spigot OD, home
line length, allowable tolerance, and allowable gap between pipes.

(iii) Complete design calculations and design requirements including pressure

class from HDB, working pressure and surge pressure using pressure class,
calculation of allowable deflection from ring bending, external loads, WC &
WL based on burial depth, predicted deflection, buckling etc.

(iv) Quality procedure

(v) Type test results and reports specified

(vi) Safety factor

(vii) Proposed inspection and testing programme.

Prior to start production the manufacturer shall submit to the Engineer dimensional
drawings of each fittings required for approval. The Engineer may require design
calculations, and samples for approval at no extra cost.

GRP PIPE DATA SHEET (FOR EACH DIAMETER / PRESSURE/SERVICE)

(To be provided to the engineer prior to start of pipe manufacturing)

Attributes Units

Design parameters :

Service (sewer/storm water) :

Nominal Diameter (DN) :

Pipe Manufacturing process :

Installation service :
(minimum/maximum depth
adopted)

Rated working pressure :

(PN)

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Joint type :

Maximum allowable vacuum :

Factory hydrotest pressure :

Length of each pipe :

Pipe Wall Structure

Nominal Wall Thickness :

a) Liner thickness :

b) Structure Wall thickness :

c) Outer Layer thickness :

Resin /glass type

Mechanical Properties

Design specific Tangential :

initial stiffness (STIS)

Design initial Longitudinal :

tensile strength

Design initial hoop tensile :

strength

Internal Pressure & External :

Load

Flexural Modulus :

Allowance design stress :

Calculation Method

Internal Pressure & External :

Load

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4.4.5 GRP Pipes and Fittings for Pumping Stations and Valve Chambers

The design of GRP pipe and fittings for pumping stations and valve chambers shall
incorporate all the requirements of these specifications except for the following over-
riding or supplemental stipulations.

GRP pipe and fittings inside pumping stations and chambers shall be designed for
use above ground with no thrust blocks and shall have sufficient axial strength to
resist end thrust, temperature and bending stresses.

GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m2 and a
minimum wall thickness of 10 mm.

The design working pressure for pipes and fittings shall be minimum 12 bar unless
otherwise specified and the service temperature shall be 50°C. A minimum surge
allowance of 40% above the working pressure shall be included in the design of pipes
and fittings. Copies of the design calculations shall be submitted to the Engineer for
approval. The basis of design shall be checked by conducting 'type' tests on
representative sample(s) of manufactured materials, in accordance with the
requirements of BS EN 14364 and BS EN 1796 or ASTM D-2992.

The wall of the pipes and fittings shall be made up of:

a) A resin-rich inner liner of 1.5 mm minimum thickness, consisting of ‘C’ glass veil,
and 'ECR/ADVANTEX' glass and impregnated with vinyl ester or epoxy resin.

b) The structural layer consisting of ‘ECR/ADVANTEX’ glass reinforcements

impregnated with vinyl ester or epoxy resin. Silica sand shall not be used.

c) An exterior resin-rich layer of 1.0 mm minimum thickness, reinforced with a ‘C’

glass veil and impregnated with vinyl ester or epoxy resin.

No dark pigments, sand or aggregate fillers shall be used for pipes and fittings. Ultra
Violet stabilizers shall be incorporated in the pipe and fitting construction.

GRP pipe and fittings for pumping station and valve chamber pipework shall have a
suitably designed restrained joint capable of withstanding the design operating
pressure with no leaks and without the use of thrust blocks.

The acceptable jointing system shall be GRP flanges. GRP flanges shall be machine
filament wound using 'ECR/ADVANTEX' glass fibre reinforcements and vinyl ester or
epoxy resin. Hand layed up flanges shall not be permitted. Flanges shall be drilled to
BS EN 1092 (metric units) type PN 10.

4.4.5.2 Factory Testing

The following tests shall be carried out on manufactured GRP pipe and fittings at the
intervals specified. Test methods shall be in accordance with BS EN 14364 and BS
EN 1796 or ASTM equivalent. Witnessing of factory testing by the Engineer’s
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Representative will be required prior to delivery of the material. Copies of the

Manufacturer's test reports shall be submitted to the Engineer after each
consignment of pipe or fittings delivered to the site.

All GRP standard pipe and pipe used for fitting fabrication shall be factory pressure
tested to 24 bar for pressure pipes and 12 bar for non-pressure pipes.

The following tests shall be conducted on all GRP pipe and fittings:

- Dimension measurements (Wall thickness, Diameter, Length)

- Visual inspection
- Barcol Hardness (Resin Cure)

Stiffness and resistance to structural damage as per Tensile strength by strip for GRP
pipes as per BS EN 14364 and BS EN 1796: App: #, 1990.

Mechanical property testing shall be conducted on 1% of GRP pipe and fittings

produced.

Other tests for quality assurance shall be carried out on representative sample(s) as
required by BS EN 14364 and BS EN 1796 or ASTM equivalent.

In addition to factory testing, the following tests shall be re-checked in Dubai Central
Laboratory and compare with manufacturer’s test results. The cost involved in this
test shall be paid by the contractor.

- Initial longitudinal unit tensile strength by a tensile strip test as per BS5480
Appendix A.
- Initial specific stiffness under ring deflection BS EN 14364 and BS EN 1796
Appendix H.

4.4.5.3 Installation

GRP pipe and fittings shall be installed in accordance with the manufacturer's written
instruction. A field representative of the manufacturer shall be made available as and
when required during the installation of the GRP pipe and fittings. All flanges shall be
tightened in accordance with the Manufacturer's written instructions using a torque
wrench.

4.4.6 GRP Pipes and Fittings for Irrigation and Potable Water Distribution &
Transmission

4.4.6.1 Scope

This specification covers the minimum requirements for the GRP piping for
aboveground and underground installations, intended to be used for potable and raw
water applications.

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The Manufacturer's design shall satisfy the minimum requirements set herein. This
specification includes the minimum requirements for design, manufacture,
workmanship, testing, inspection and installation of standard GRP pipe systems.

4.4.6.2 Manufacturers Pre-Qualification

All Pipes and fittings shall be certified in accordance with BS EN 14364 and BS EN
1796 / ASTM D3517. For the diameters intended for the supply, evidence of the
certified range to be submitted.

GRP pipe and fittings shall be manufactured by an established pipe Manufacturer in a

purpose-built facility for the production of such materials. The Manufacturer shall
have an approved Quality Management System complying with ISO 9001 for all
activities being undertaken during pipe design, manufacture and supply.

Manufacturer's Scope of Work

The GRP pipe system Manufacturer will be responsible for the following:

a) Manufacture and Supply of the GRP pipe, fittings, flanges, saddles for
instrumentation tapping and pipe closing (make-up) pieces. Manufacturer to also
supply the gaskets for use in flange connections and provide general
recommendations on associated equipment such as valves, expansion bellows,
nuts and bolts and other accessories.

b) Design of the GRP pipe system including Stress Analysis (Surge and Flexibility),
Support Location / Function Analysis and the Conceptual Support Design for the
given design and routing for all above ground applications. These Engineering /
Design analysis are to be implemented by the pipe manufacturer.

c) Inspection and testing at the Manufacturer's works in accordance with specified

requirements herein.

d) Marking of pipe for identification shall be as per Clause 4.4.4.1 .

e) Provision of a Site Staff (s) to assist during pipe installation.

Applicable Codes and Standards

The following internationally accepted standards are the minimum requirements for
the manufacture of GRP Pipe Systems and should be referenced throughout the
Project Specification where appropriate.

AWWA C950 Glass Fibre Reinforced Thermosetting Resin Pressure (Latest

Edition)

AWWA M45 Fibreglass Pipe Design

BS EN 14364 and Plastics piping systems for drainage and sewerage with or
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BS EN 1796 without pressure - Glass-reinforced thermosetting plastics (GRP)

Plastics piping systems for water supply with or without pressure

- Glass-reinforced thermosetting plastics (GRP)

ASTM D3517 Specification for Glass Fibre Reinforced Thermosetting Resin

Pressure Pipe for conveying water system

4.4.6.3 Product Description

a) General

Pipe shall be designed and manufactured by the glass filament winding process as
described by AWWA M45, ASTM D3517, BS EN 14364 and BS EN 1796. Accepted
manufacturing processes are the continuous filament winding or the helical filament
winding process. The filament wound pipe shall be made using a straight steel
mandrel.

The pipe shall be constructed so as to include internal and external corrosion barriers
of a composition suitable to resist the corrosive effects of the contained and
surrounding environments.

The inside diameter (ID) of the finished pipe is fixed by the mandrel outside diameter.
The outside diameter (OD) of the finished pipe is determined by the amount of
material that is wound on the mandrel.

The pipe shall be produced in one continuous piece with no joints.

The resins to be used shall be:

Polyester: Isophthalic Acid Grade (at least equal to the requirements of BS 3532

Type ‘B’).

(i) Liner

Pipe and Fittings shall have a smooth resin rich internal liner of 1 mm thickness with a
resin to glass ratio of 70: 30. This liner will be reinforced with "C" Glass.

No dark pigment or resin fillers, such as calcium carbonate shall be used.

(ii) Structural Wall

The structural wall of the pipe shall be reinforced with closely spaced continuous
fibreglass filament winding, chopped roving, all impregnated in thermosetting resin.
No dark pigments or resin fillers such as calcium carbonate shall be used.
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For underground applications, where stiffness is a critical factor for the GRP pipe
system, fine silica sand, complying with BS EN 14364 and BS EN 1796 requirements,
may be included.

(iii) External Layer

A resin-rich post-coat, identically constructed as the inner liner, must be applied to the
external surfaces of all of the GRP pipes. All external surfaces shall be able to resist
the anticipated corrosion imposed by the service and ambient conditions.
Approximate thickness of the external surface, shall be 0.5 mm.

No dark pigments or resin fillers such as calcium carbonate shall be used.

(iv) Reinforcing ribs

Where stiffener ribs are used to structurally reinforce the pipe wall, they must be
protected in the same manner as specified for the external surface, above.

b) Raw Materials

All materials and the manner and degree to which they are used during the
construction of all components required for the GRP pipe system described by this
specification shall be selected so they will resist the corrosive effects of both the
contained and surrounding environments.

All structural materials shall be new and free from all deleterious defects and
imperfections and only be used for production after having been controlled and
approved by the Manufacturer's Quality Department.

Testing and controlling shall be done according to the relevant methods, as described
in Clause 4.4.4.1.h) (Inspection and Testing) of this specification.

Glass Reinforcements shall be compatible with the impregnating resin used and
should be suitable for the service intended.

Resins used shall be a commercial high grade thermosetting isophtalic, resin as

specified under Clause 4.4.6.3.

No dark pigments shall be used in the GRP pipe or joints. No additives shall be used
except when required for viscosity control.

Fine silica sand can be used for underground applications of GRP pipes.

Pipes used for Potable Water Service: All GRP pipes and fittings conveying potable
water shall be certified and listed for potable water use by the Water Regulations
Advisory Scheme "WRAS" United Kingdom, in accordance with BS 6920.

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4.4.6.4 Requirements

a) Wall Thickness

The wall thickness required for each size/pressure class shall be established by the
manufacturer to meet the design requirements but in no case shall the wall thickness
be less than (0.010 x DN); where DN is the nominal pipe inside diameter. For ribbed
pipe, the minimum shell wall thickness shall be (0.005 x DN); where DN is the
nominal pipe inside diameter. The pipe working pressure class shall be based on the
Hydrostatic design basis (HDB) of the pipe with a design (service) factor of 0.5.

b) Length

GRP pipe shall be manufactured in standard laying lengths of not greater than 12
meters. Random short lengths, if supplied, shall not exceed 5% of the quantity
supplied of each size. The tolerance on the Manufacturer's declared laying length
shall not exceed ± 25 mm.

c) Diameters

Pipe shall be manufactured in standard metric sizes based on the pipe nominal
diameter in sizes 25 mm and larger. The actual inside diameter shall not vary from
the nominal inside diameter by, more than 1 % or 4 mm whichever is greater.

d) Stiffness

The pipe stiffness shall be determined by the Manufacturer to meet the design
requirement with particular regard to installation method, burial depths, deflection
limits, buckling and vacuum requirements, in accordance with AWWA M45. The pipe
initial specific stiffness (EI/D3) shall, in no case, be less than 10,000 N/m2, when
tested in accordance with ASTM D2412 or BS EN 14364 and BS EN 1796.

e) Beam Strength

GRP pipe shall meet the minimum longitudinal tensile strength requirements specified
in AWWA C950 for the appropriate operating pressure class.

The above requirements are intended to provide adequate strength for normal
handling and underground conditions. Pipe intended to withstand the end load
resulting from internal pressure at changes of direction or the beam load resulting
from above ground installation shall require higher longitudinal strengths and a
suitably designed, fully restrained, jointing system.

f) Hoop Tensile Strength

GRP pipe systems shall meet the minimum hoop tensile strength requirements
specified in AWWA C950 standard for the appropriate operating pressure class.

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However, the structural wall hoop tensile stress for pressure pipe shall not be less
than 120,000 kN/m2 when tested in accordance with AWWA C950 or BS EN 14364
AND BS EN 1796.

g) Hardness - Barcol (ASTM D 2583)

The laminated surface shall have Barcol hardness of at least 90% of resin
manufacturer's minimum specified hardness for the cured resin.

h) Joints

(i) Flexible Joints

Standard buried pipe with unrestrained joints shall be filament wound GRP coupling,
with confined rubber ring gaskets. Rubber rings shall be of natural rubber conforming
to BSEN 681–1 or ASTM F 477 for seawater service, and synthetic rubber for other
services. Neoprene rubber shall be used for oil contaminated services. Joints shall
allow for at least 0.75° deviation while remaining watertight at 1.5 times the pipe
operating pressure. The rubber rings shall be the sole element depended upon for
water tightness. This system will require thrust blocks at changes in direction to
accommodate thrust loads,

(ii) Rigid Joints

Flanges: GRP flanges where used shall be machine filament wound up to 1800mmø.
Contact moulded flanges may be used for sizes 2000mm and larger. Flanges shall be
manufactured with epoxy or vinyl ester resin. Flanges shall be flat faced with full or '0'
Ring type gaskets. Gasket material and design shall be as per the Manufacturer's
recommendations. The pipe Manufacturer shall provide the torqueing sequence and
maximum tightening torque as appropriate for each flange size and design and
should at least be present in a supervisory role during the torqueing of all flange
connections. Washers shall be used under all nuts and bolts heads with special
spacers to be used at flange to valve connections as required.

Flange drilling and rating shall be as specified on the drawings. Flanged joints shall
be tensile resistant for above ground service.

(iii) Reinforced Overlay Joints (butt & wrap)

Butt & Wrap joint where used only for site modification or repair shall consist of layers
of Glass fibre reinforcement impregnated with resin. The wall thickness, tensile and
axial strength of the reinforced overlay shall meet or exceed the design strength of
the adjoining pipe sections.

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Butt & Wrap joints on site shall be performed only by or under the supervision of the
pipe Manufacturer.

All of the joint types given in Clause 4.4.6.4 h) shall be designed to remain watertight
when tested after installation to 1.5 times the pipe line pressure for a minimum of one
(1) hour.

i) Workmanship

GRP pipe, fittings and joints shall be free from de-laminations, cracks, bubbles,
pinholes, pits, blisters, foreign inclusions and resin-starved areas that due to their
nature, degree or extent detrimentally affects the strength and serviceability of the
pipe. No glass fibre reinforcements shall penetrate the interior surface of the pipe
wall.

Joint sealing surfaces shall be free of dents, gouges, de-laminations, or other surface
irregularities that will affect the integrity of the joints.

GRP pipe, fittings and joints shall be as uniform as commercially practicable in colour,
capacity, density and other physical properties.

j) Fittings

GRP fittings such as bends, tees, junctions and reducers shall be equal or superior in
performance to the GRP pipe of the same diameter and pressure. All fittings shall
have a smooth internal surface with similar wall construction.

Standard fittings shall be filament wound or mode by mitered construction from

filament wound GRP pipes.

For GRP fittings, the deviation from the stated value of the angle of change of
direction of a bend, tee, junction etc. shall not exceed  1 de gre e .

The tolerance on the Manufacturer's declared length of fitting shall be  10 mm t

from the point of intersection to the end of the fitting or  10 m m on s

All GRP fittings shall be fabricated in the factory, by the pipe manufacturer, to ensure
Quality Control (Under no circumstance shall fabrication of fittings be allowed on site
by Contractor). Complex fittings arrangements may be pre-assembled by the pipe
Manufacturer in the factory such that field joints are kept to a minimum.

4.4.6.5 Design Parameters

Pipe shall meet the following minimum design requirements:

Operating Pressure (Pw) Minimum 12 bar or as specified

Surge Pressure (Ps) 40% of ‘Pw' unless otherwise specified.

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Vacuum (Pv) As specified.

Minimum Earth Cover 1 .0 m or as shown on drawings for

buried pipe.

Initial Installed Deflection for buried pipe 2.0% Min

Long term Installed Deflection for Buried 5.0% Max. (3.0% max for ribbed pipe
Pipe and 5% for solid wall pipe).

Service temperature As specified

Safety Factors > = 1.8

Pressure Rating > = 1.5

Ring Bending Strain (stress) > = 1.5

Combined Strain (stress) Buckling > = 2.5

The Contractor shall be responsible for implementing / installing the correct design for
each GRP pipe system.

Buried GRP pipe design shall be established in accordance with A WW A M45.

Support requirements for complex above ground piping systems shall be based on
computer flexibility analysis (static and dynamic) of the piping systems. Pipe
manufacturer’s Design calculations shall be submitted to the Engineer for review and
approval.

4.4.6.6 Inspection & Testing

The Manufacturer shall take adequate measures in the production of the products
covered by this specification to assure compliance with the requirements herein. An
Inspection and Testing plan (ITP) should be forwarded to the Engineer for approval.
Plant inspection by the Contractor’s or Engineers qualified personnel or the omission
of such inspections shall not relieve the Manufacturer of the responsibility to furnish
products complying with the requirements of the minimum manufacturing
requirements given herein.

Production and Testing Notice - When plant inspection is required by the Contractor
or Client the Manufacturer shall provide adequate advance notice of when and where
production and testing of ordered products will commence.

The Contractor and / or Client Inspector (s) shall have free access with reasonable
advance notice to the Manufacturer's plant areas that are necessary to assure that
products comply with all requirements herein.

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As a minimum the following tests shall be performed at the indicated intervals unless
otherwise agreed-upon, and shall form a part of the Manufacturers overall quality
control program.

The following test shall be conducted on every pipe;

- Visual Inspection
- Dimension Measurements
- Resin cure (Barcol Hardness)

The following tests shall be conducted on pipe samples at a frequency of not less
than one per 50 pipes (one lot) of the same Diameter and Pressure.

- Stiffness
- Hoop Tensile Strength
- Longitudinal Tensile Strength
- Loss on ignition (composition)

However, this sampling is not applicable for GRP pipe manufactured thru helical
winding process. The determination of strength properties may be treated as
qualification testing, provided the manufacturer declares the winding angle and
submits qualification test reports duly authenticated by third party.

Pipe hydrostatic pressure test shall be carried out on 100% of Pipes.

Test methods shall be in accordance with AWWA C950 and BS EN 14364 AND BS
EN 1796.

Copies of all test reports shall be submitted to the Client for each lot delivered to Site.

4.4.6.7 Marking

Each pipe and fitting shall be indelibly marked with the following information.

- Manufacturers Name or trademark

- Manufacturing date
- Manufacturing number
- Nominal diameter in mm
- Operating pressure in bar
- Nominal laying length in meter (for pipe only)
- Manufacturers Inspection mark
- Applicable standard complying the product.

4.4.6.8 Submittals

The following information shall be submitted by the manufacturer.

a) Pipe Data Sheet (s)

b) Detailed Resin Data

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c) Detailed Glass Reinforcement Data

d) Detailed Pipe Aggregate Data

e) Detailed Joint & Gasket Data

f) GRP Pipe Manufacturer's Pre-Qualification

g) Manufacturer's ISO 9001 Certification

In addition to the above information, the following shall be submitted during the
mobilization period:

a) Detailed manufacturing process for pipe, joints and fittings.

b) Detailed drawings for pipe ends, joints and fittings.

c) Complete pipe design calculations for each Diameter/Pressure.

d) Friction loss factors of pipes and fittings

e) Manufacturers Quality Control and Assurance Manual.

f) Proposed Inspection and Testing Program (ITP).

g) Pipe Manufacturers written handling, storage and installation instructions.

h) Proposed Hydrotest method statement

i) Proposed pipe transport procedures.

j) Qualification (Type) Test results and report for:

- Long term stiffness (Aging factors); for buried pipe only

- Long term hydrostatic Design Basis (HDB); for pressure pipe only

4.4.6.9 Installation (General Requirements)

- The Contractor shall submit the pipe Manufacturer's Installation Manual and
associated Data for engineer’s review. A site meeting to include the engineer,
the Contractor and Manufacturer is to occur within two weeks from Contract
Award to clarify any outstanding issues / questions on the given installation
procedures.
- GRP pipe shall be handled, stored, transported and installed in strict
accordance to the Manufacturer written instructions.
- The pipe installation procedures and practices chosen shall meet the design
requirements specified.
- No stacking of pipe larger than 1.8 m in diameter shall be allowed on site or
during transport.
- Reinforced concrete thrust blocks shall be used at all changes in direction,
size reduction / expansion, and other thrust locations underground for
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unrestrained pressure systems. Thrust blocks shall encase the entire GRP
fitting at the directional change and should be constructed to fully absorb all
thrust loads. Thrust block sizes may be reduced or eliminated by using an
axially restrained piping system utilising high axial strength GRP pipe and
fittings and a suitable restrained pipe joint design.
- Pipe deflection readings shall be taken and recorded on all buried pipe at
three meter intervals. Initial deflections shall not show a reduction in internal
vertical diameter as mentioned in Clause 4.7.13 of the specification.
- The Contractor shall employ on a full-time basis the services of field
representatives from the pipe manufacturer throughout the pipe off loading,
storage, installation and testing period.
- For standard buried unrestrained pipeline sections, a flexibly jointed short pipe
shall be incorporated outside rigid structures to provide pipeline flexibility
against differential settlement. A minimum of two (2) flexible joints on either
side of a rigid structure is required. The length of the short pipe shall be in
accordance with the manufacturer’s recommendation.

4.4.6.10 Onshore Buoyancy Considerations

Where the pipe is to be installed on-shore within water table level, proper
considerations have to be taken to prevent pipe flotation. In general, a minimum soil
cover equal to one pipe diameter should be kept above the, pipe crown to prevent
flotation.

GRP PIPE DATA SHEET (FOR EACH DIAMETER/PRESSURE/SERVICE)

(To be provided prior to start of pipe manufacturing)

Design Units
Parameters

Nominal : mm
Diameter

Pipe :
Manufacturing
Process
Service

Rated : Barg
Working
Pressure

Joint Type :

Maximum : Barg

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Allowable
Vacuum

Laying Length : m

Pipe Wall
structure

Nominal Wall : mm
Thickness

Inner Layer : mm
Thickness
Resin Type

Glass Type

Structural Thickness mm
Wall Resin
Type

Glass
Type

Outer Liner Thickness mm

Resin
Type
Glass
Type

Mechanical
Properties

Design Pa
Specific
Tangential
Initial
Stiffness

Design Initial MPa

Longitudinal
Tensile
Strength

Design Initial MPa

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Hoop Tensile
Strength

4.5 STORAGE AND HANDLING OF PIPES

4.5.1 General

Method Statements must be approved for the transportation, handling and storage of
pipes before any pipes are delivered to site. All pipes shall be handled and stored in
compliance with the manufacturer's recommendations subject to the following
limitations: - Pipes shall be transported, handled and stored with such packing and in
such a manner that damage does not occur and that contact is avoided with sharp
edges which may cause damage. During transit, pipes and fittings shall be well
secured and adequately supported along their length. At every point of loading or
unloading, all pipes or castings must be handled by approved lifting tackle unless
specified elsewhere. Unloading by rolling down planks or any other form of inclined
ramp will not be allowed. Pipes shall not be tipped or dropped. Pliable straps, slings
or rope shall be used to lift pipes, and steel cables or chains will not be used without
written permission. Nesting of pipes for transportation will be permitted provided
method statements demonstrate that effective precautions will be taken to protect
inner surfaces from damage. All pipes and fittings shall be thoroughly inspected on
arrival at site after off-loading and prior to installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other
damages, proposals for repairs shall be submitted in writing for the Engineer's
approval. If in the Engineer's opinion the nature of any damage is such that the
condition of a pipe has been impaired and cannot be repaired, the pipe concerned
shall not be incorporated in the Works. Suitably smooth and level storage areas
shall be provided at or near the site and made secure to prevent unauthorised
access. Pipes of different sizes and thickness shall be stocked separately.

4.5.2 Glass Reinforced Plastic Pipes (GRP)

When pipes are transported or stacked they shall be supported on cradles at least
100 mm wide, conforming to the shape of the pipe placed at not more than 3 metres
centres. Pipes must on no account be stacked directly on the ground but if individual
pipes are placed on the ground prior to laying care shall be taken to remove all rocks
and any potentially damaging debris. The number of layers in a stack shall not
exceed the following:

Internal Diameter of Pipes (mm) Maximum Number of Layers

Up to 500 5

500 to 700 3

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The end pipes in each row shall be strapped to the battens. Pipes shall not rest on
their sockets.

4.5.3 Thermoplastic Pipes (uPVC)

Pipes and fittings of plastic materials smaller than 300 mm diameter may be handled
manually and those equal or larger than 300 mm diameter shall be lifted using a
single fabric or large diameter rope sling. There shall be enough slack in the sling to
keep the hook at least 600 mm over the pipe. Use of wire rope chains and forklifts
shall not be permitted. Care shall be taken to prevent distortion of the pipes during
transportation, handling and storage. They shall be stacked either on bearing timbers
on a level surface staked to prevent movement, or in suitable racks. Not more than
two layers shall rest on the bottom layer, and for spigot and socket pipes, sockets
shall be at alternate ends so that no pressure comes on a socket. Bearing timbers
shall be spaced at not more than 1 metre and shall be wide enough to prevent
denting of the pipe wall. Sharp edges (e.g. of metal) shall be avoided. Similar care
shall be taken with pipes in transit. Where shaped battens are used, they shall be at
least 100 mm wide and not more than 1.5 meters apart. The end pipes in each row
shall be strapped to the battens. The pipe shall not be stacked any higher than five
(5) layers. All thermoplastic pipes shall be shaded/protected from direct sunlight
during handling, transportation, storage and laying. The Contractor shall ensure that
thermoplastic pipes do not come into contact with bituminous or other hydrocarbon
based materials.

4.5.4 Reinforced Concrete Pipes (RCP)

Store pipes and fittings on a flat level area and raise above the ground on timber
bearers so that the lowest point of any pipe or fitting is not less than 150mm above
the ground. Provide timber bearers at spacing recommended by the pipe
manufacturer.

All coated pipes must be protected from UV exposure during storage.

Store rubber joint rings in a well ventilated place, free from exposure to sunlight and
in their original packing until they are needed.

4.5.5 HDPE Pipes

Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or crated,
remain on the pallets or in their crates until required.

- Stack non-crated pipes to the approval of the Engineer.

- Stack pipes of different sizes and thickness separately.

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Do not allow stacked pipes to exceed 2m in height or as recommended by the

supplier whichever is the lesser.

Scratching or scoring of pipe surface to a depth greater or equal to 10% of wall

thickness shall constitute an automatic rejection of that pipe section.

4.6 GRANULAR MATERIAL FOR PIPE BEDDING AND SURROUND

Granular material for pipe bedding & Surround shall be free-draining, hard, clean,
chemically stable gravel or crushed stone and shall be graded in accordance with the
following table:-

Table 4.3a Grading of Granular Material for Pipe Bedding and Surround

Test sieve (mm) Percentage by Weight Passing Sieve

For pipe diameters up to For pipe diameters

600mm 400mm and above

63 - -

37.5 - -

20 - -

14 100 85-100

10 85-100 0-50

5 0-25 0-10

2.36 0-5 -

Notes:

a) For pipes 400 mm to 600 mm diameter, either grading is acceptable.

b) Total acid soluble content of the material when tested in accordance with BS1377
shall not exceed 0.3 percent by weight of sulphate expressed as SO3 (sulphur
trioxide).

c) The material shall have a Compaction Fraction value not exceeding 0.10.

d) For uPVC pipes only rounded aggregates will be permitted but for all other pipe
materials crushed aggregates may also be used.

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4.6.2 Stone for Land Drains

Stone for land drains shall be nominal single size 20 mm in accordance with the
following table or the manufacturer’s recommendations if different, and placed as
shown on the drawings.

Table 4.3b Grading of Stone for Land Drains

Test sieve (mm) Percentage by Weight

Passing Sieve

75 -

63 -

37.5 100

20 85-100

14 -

10 0-25

5 0-5

2.36 -

4.6.3 Compaction Fraction Test

The compaction fraction test shall be carried out in accordance with BS EN 752 APP:
D.

For testing pipe bedding material, a representative sample of about 40 kg shall be

heaped onto a clean surface and quartered to obtain approximately 10 kg. The
moisture content of the sample should not differ materially from that of the main body
of material, at the time of use in the trench. A 150 mm internal diameter open ended
cylinder 250 mm high, shall be placed on a firm flat surface and loosely filled, without
tamping, from the 10 kg sample. Any surplus material shall be struck off level with the
top of the cylinder. The area around the filled cylinder shall be cleared of all surplus
material and the cylinder then lifted clear of its contents and placed alongside the
material. Approximately one quarter of the material shall then be replaced into the
cylinder and compacted by tamping vigorously with a 40 mm diameter metal rammer
weighing about 1 kg until no further compaction can be obtained. This operation shall
then be repeated for each of the remaining quarters, tamping the final surface as
level as possible. The distance from the top of the cylinder to the surface of final

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layer shall then be measured and this value, divided by the height of the cylinder,
shall be taken as the Compaction Fraction.

4.7 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION

4.7.1 General

This section applies to conventional open-trench pipe works.

4.7.2 Nominal Trench Width for Flexible Group ‘B’ Pipes

Nominal trench widths for single pipelines shall be defined as 1.50 times the diameter
plus 500 mm, subject to a minimum trench width of 750 mm.

Nominal trench widths for two or more pipes in the same trench (laid in parallel with
similar invert levels) shall be defined as the sum of the internal diameters plus 450
mm between the pipes, plus 750 mm. Any excavation from the bottom of the trench
to 300 mm above the level of the crown of the pipe which exceeds the nominal widths
defined above shall be filled with concrete or the specified bedding materials as
directed on site. A detailed method statement shall be submitted by the Contractor
for agreement by the Engineer to demonstrate an understanding of the correct
method of laying GRP and other pipes.

4.7.3 Pipelines in Wide Trenches

No wide unsupported trenches shall be permitted, in general, within the area of the
Works and therefore all trenches should conform to the minimum trench widths stated
above and shall be supported with the use of approved trench sheeting or sheet
piles. However in exceptional circumstances wide trenches may be approved by the
Engineer in which cases the following shall apply: -

- Wide trenches shall be constructed to not less than the defined widths for
those categories of Group B flexible pipelines in granular bedding defined
below.
- Prior to commencing trench excavation in an area an assessment of the
Modulus of Deformation (E's) shall be made of the soils likely to be
encountered at springing level of the pipes. In non-cohesive soils, approved
static cone penetrometer tests shall be carried out prior to excavation. In
cohesive soils other approved methods shall be used to determine E's.
Alternatively, standard SPT & CPT tests may be required by the Engineer
prior to excavation to suite pipe manufacturer’s standard method of deflection
and trench widths. Tests shall be carried out in accordance with BS 5930 at
intervals to be determined on site which in variable ground conditions may be
to every pipe length and its cost shall be inclusive of trench excavation without
any extra cost.
- If the value of E’s determined from the results of such tests is greater than 2.5
MN/m2 then trench width is not critical. If less than 2.5 MN/m2 then trench
widths shall be constructed to the widths defined in the following table unless
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alternative means of increasing the passive resistance of the trench sides are
detailed or are proposed in method statements where economic or
environmental restrictions make wide trenches undesirable.

Table 4.4 Wide Trench Widths for Non-Cohesive Soils

Static Cone Modulus of Deformation Wide Trench Widths

Penetrometer Test E’s (MN/m2) (mm)
(kg/cm²)

8.5-7.7 2.50-2.25 2.5 x dia

7.7 - 6.1 2.25 - 1.80 3.0* dia.

6.1 – 3.1 1.80 - 0.90 4.0* dia.

3.1 0.90 5.0* dia.

Alternative solutions to wide trench conditions may be adopted including permanent

sheeting increasing stiffness of the pipes used or encasing with reinforced concrete
as agreed by the Engineer subject to Pipe manufacturer’s recommendations.

4.7.4 Pipe Laying and Jointing

Pipes and fittings shall be laid and jointed in accordance with all relevant
recommendations of the manufacturer. Any variations between the manufacturer’s
recommendations and this specification shall be highlighted in the Contractor’s
Method Statements and a ruling will be given with the Engineer’s agreement.

Pipes and fittings shall be checked for soundness and be thoroughly cleaned out
immediately prior to laying and jointing. The setting of the pipeline to the required
levels and alignment shall be carried out by approved procedure such as boning
between sight rails or the use of laser systems. Sight rails, if used, shall be at a
suitable height vertically above the line of pipes or immediately adjacent thereto, and
there shall, at no time, be less than three sight rails in position on each length of
pipelines under construction to any one gradient. Large diameter pipes, 1000 mm
diameter or greater, shall be individually set to level and line by instrument. For
pipelines laid in trenches and headings the permissible tolerances in line and level
unless otherwise specified shall be ± 3 mm in level and ± 12 mm from centerline
between manholes or access points. Also where a gravity pipeline or sewer is shown
as a straight line between manholes it will not be accepted as having passed the final
test unless a full circular light can be sighted through the bore of the pipe for the
length concerned.

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For pipeline jointing systems incorporating flexible jointing rings pipes shall be laid
with a gap between the end of the spigot and the base of the socket, or between
spigots. This gap shall be not less than 6 mm or greater than one third of the straight
draw test dimension specified in CL. 4.1.2.1 for the pipe joint or as recommended by
the pipe manufacturer, and it shall be achieved by approved means, such as marking
the outside of the pipe or using removable metal or hardwood feelers. The annular
space between the pipe and the socket at a flexible joint shall be sealed with an
approved joint sealant to prevent the ingress of loose material or concrete. Sealing
shall be done on completion of a satisfactory preliminary testing prior to concreting or
backfilling, but not prior to the test. For uPVC pipes solvent welded joints with parallel
sockets shall not be permitted unless made in the manufacturer's workshop.
Where flexible jointed pipes are laid to curves the angular displacement at any joint
as laid shall not exceed three quarters of the maximum recommended by the
manufacturer. Flanged pipes shall incorporate an annular gasket at the joints. The
gaskets shall cover the full face of the flange and shall have holes cut in the
corresponding to the bolt holes in the flanges. However, in pipes fixed vertically a
plain ring covering the flange between the bolt circle and the bore of the pipe may be
used. Gaskets shall be manufactured as specified in Clause 4.1.2.2. When flanged
joints are to be made the Contractor shall follow manufacturer’s guidelines for the
tightening of nuts and bolts. The Contractor shall make sure that all joints are made
strictly in accordance with the manufacturer’s instructions. Pressure pipelines shall
be secured at all changes in direction by concrete anchor blocks or other means of
restraint approved in advance by the Engineer. After laying a length of pipeline but
before preliminary testing is carried out, the pipeline shall be checked for level and
gradient on top of the pipes. If a pipe is not at the correct level, it shall be un-jointed
and removed, the bed shall be adjusted and the pipe shall be re-laid and rechecked
for line and level. After the joint has been made and the preliminary testing completed
the annular gap at a socket or collar outside the flexible jointing ring shall be closed
with fine grained clayey soil or cotton waste to prevent the entry of granular material.

Pipelines shall be temporarily capped when pipe laying ceases to prevent the ingress
of foreign matter. The Contractor shall ensure that the pipes remain clean and free
from obstructions, and if required by the Engineer, the pipelines shall be cleaned out
using approved methods and equipment which do not damage the internal lining of
the pipes and manholes.

4.7.5 Pipelines in Concrete Cradles and Surrounds

Where pipes are to be laid with a concrete cradle or surround they shall be supported
initially above the trench bottom on concrete setting blocks. The blocks shall either be
laid accurately to level and covered with damp-proof sheeting beneath the pipe barrel
or shall be provided with two hardwood wedges each to an approved pattern to
enable the pipe level to be adjusted. The blocks and wedges shall be of sufficient
size and strength to prevent settlement of the pipes during laying and at least two
concrete blocks shall be provided for each pipe. Concrete cradles and surrounds
shall be RCC with Class C40/20 SRC Concrete. The concrete shall be poured on one
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side of the pipe until it can be worked under the pipe along its full length to ensure
that no voids develop. The concrete shall then be brought up equally on both sides of
the pipe until the required level is reached. The length of pipeline laid in any one
operation before concreting the pipeline shall be that which in the opinion of the
Engineer permits accurate laying of the pipeline and concreting in an efficient and
proper manner. Approved measures appropriate to the pipe material shall be
provided to prevent flotation or other movement during placement or curing of the
concrete. Concrete cradles to pipes of all diameters and surrounds to pipes of one
metre diameter or less shall be poured in a single lift. Concrete surrounds to pipes
over one metre diameter shall normally be poured in two lifts, with a horizontal joint
not more than 100 mm below the crown of the pipe. Concrete cradles and surrounds
shall be interrupted over their full cross sectional area at each pipe joint, by shaped
expansion joint filler. The thickness of filler shall be 18 mm for pipe diameter less than
450, 36 mm for pipe diameter 450 to 1200 and 54 mm for pipe diameters greater than
1200. In spigot and socket pipelines the joints in the bed shall be at the face of each
socket. In all flexible joints the annulus of the pipe socket shall be sealed with an
approved sealant to prevent the concrete from entering the pipe joint. When support
to excavations is provided, building paper or an approved material shall be placed
against that support before concreting to facilitate withdrawal of the support.

4.7.6 Pipelines on Granular Beds

Where granular beddings to pipelines are detailed the minimum thickness of bedding
material beneath the pipe shall be:

- 150 mm (minimum 100 mm under sockets) for pipes not exceeding 300 mm
internal diameter.
- 200 mm (minimum 100 mm under sockets) for pipes exceeding 300 mm
internal diameter.

The time interval between placing bedding material on the trench formation and
commencing pipelaying shall be as short as is practicable. The bedding material
shall extend to the full width of the trench and shall be compacted in layers not
exceeding 200 mm. The bedding material shall be carefully compacted using a plate
vibrator or other approved equivalent mechanical method. Sufficient passes of a plate
vibrator or other approved mechanical method are required to achieve positive
deflection of flexible pipes to ensure that final deflections are within the specified
limits. Hand tamping or punning will only be permitted where insufficient space is
available to allow the use of mechanical plant.

Recesses shall be formed in the bedding to accommodate pipe joints while ensuring
continuous even support along the pipe length. Bedding material shall be prevented
form entering pipe joints. After the joint has been made bedding material shall be
carefully placed and hand compacted beneath the joint barrel to close any void left by
the recess.

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Where the formation of the trench is of silt or soft clay and is below the natural water
table a 150 mm thick layer of cement stabilised road base material shall be
substituted after removal of soft material directly above formation and carefully
compacted to 95% of its MDD/ OMC if directed on site. The specified bedding
material shall be used above the road base layer.

4.7.7 Placing Surrounds to Pipelines

In narrow trenches and where the Contractor's method of working involves the use of
trench sheets or other forms of trench support it is imperative that the trench supports
are carefully withdrawn to a point above the crown of the pipe as the backfill material
is placed to ensure that voids between surround and trench side will be eliminated.
Where the Contractor is instructed to leave trench supports in place, the tops shall be
burned or cut off.

4.7.8 Group A Rigid Pipes Bedding, Surround Materials and the Trench Width

Except where concrete surrounds are specified or shown on the drawings, either
granular bedding material or approved selected excavated granular material shall be
introduced at bed, surround the pipe and compacted until it has been brought up to at
least 100 - 150 mm above the crown of the pipe.

The nominal trench width for the pipelines of single, twin or multiple pipes in the same
trench shall be as shown in the drawing. The methods of selecting excavated
materials may include seiving either in bulk or above the trench. Wherever
practicable the placing and compaction of the surround material shall be carried out in
sequence with the removal of the trench supports. In particular trench sheets or
boards shall be raised clear of each layer prior to its compaction. The granular
material shall be enclosed in approved filter fabrics to prevent the migration of native
soil.

4.7.9 Group B Pipe Materials

Except where concrete surrounds are detailed Group B flexible pipelines shall be laid
with granular bedding and surround, as specified, to at least 300 mm above the
crown of the pipe.

4.7.10 Compaction of Pipe Surrounds

The granular material shall be carefully laid and compacted at the sides of pipes
according to one of the following methods for alternative types of compaction plant as
agreed with or directed by the Engineer.

Table 4.5 Alternative Methods for Compaction of Pipe Surrounds

Surround Max. Alternative Methods (Minimum Number of Passes of

Material Layer Compaction Plant)

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Thickness Hand Rammer Vibrating Plate 100 kg Power

Rammer

Gravel 200 2 2 2

Sand 150 3 4 4

The Contractor must demonstrate that alternative methods of compaction will provide
positive deflection of flexible pipes during installation.

4.7.11 Pipelines below Permanent Groundwater Level

For Group A and B pipelines located beneath the permanent groundwater level and
for all slotted pipes any granular bedding material or approved selected excavated
granular material forming granular bedding and surround shall be laid on and
enclosed within a geotextile filter fabric membrane.

4.7.12 Backfilling of Trenches - Pipelines/Structures

After completion of placement and compaction of the surrounds to the pipelines

backfilling of trenches for pipelines shall proceed using selected excavated materials
in accordance with the specifications for earthworks. The use of power rammers will
not be permitted over any pipe until the depth of fill above the crown of the pipe is at
least 300 mm. Services warning tapes shall be placed over the pipelines as specified
in Clause 4.7.20.5. The backfill requirements for trenches around structures shall be
the same as that for pipeline except that compaction by mechanical means shall
commence from the formation level (to the specified densities).

4.7.13 Deflection Measurements on Group B Pipelines

All Group B pipelines will be subjected to in-situ deflection measurements. Any

section of pipe failing to meet the deflection criteria shall have its surround material
recompacted, such procedure being repeated until the in-situ deflection is found to be
satisfactory. In the above paragraph deflection shall be considered as the maximum
difference between the measured in-situ diameter and the stated non-deflected
diameter on any axis divided by the non-deflected diameter.

For all pipes the horizontal and vertical deflections shall be measured at each end at
points 100 mm and 1.5 m away from the joint and at 3.0 m intervals thereafter, or as
directed by the Engineer. For pipe lengths of less than 3.0 m these deflections shall
be measured at each end at a point 100 mm away from the joint and at the mid-point.
For pipelines smaller than 600 mm diameter deflections shall be checked by pulling
through an approved cylindrical plug dimensioned to suit the permissible minimum
deflected diameter of the pipe. Alternately, a deflectometer of a form that can be
drawn through the pipeline and be capable of measuring diametric dimensions both

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vertically and horizontally may be used for deflection measurement of pipes of

diameter less than 600 mm. The deflectometer shall be calibrated for each diameter
regularly in the presence of the Engineer to maintain the accuracy of the instrument.
The device shall also provide a means of identifying where each deflection
measurement was taken along the length of a pipeline. This shall be in the form of
either a continuos printout or a visual display on a remote monitor. For pipes of 600
mm diameter and greater the device shall be in the form of a telescopic spring loaded
rod graduated for each diameter to show percentage deflections. The Contractor
shall tabulate the results of the measurements and copies shall be submitted to the
Engineer immediately after each set of measurements has been taken.

For pipeline of 1000 mm diameter and above the deflection measurements shall be
taken manually. Reading shall be taken at each pipe end on each side of a pipe joint,
at the quarter, mid and three quarter point of each pipe length and at any other joints
directed by the Engineer.

4.7.14 Deflection Measurements - GRP Pipes

The measurement shall be taken on at least three separate occasions:

a) After the pipe surround material has been placed and compacted to 300 mm
above the pipe crown.

b) On completion of all backfill material up to final ground level but before the
dewatering is removed. This measurement shall be taken at least two weeks
after the completion of backfilling.

c) Immediately prior to the issue of a Certificate of Completion. All pipes exposed

for recompaction and pipes replaced for any reason shall subsequently be subject
to the three deflection checks listed above. Deflection checks shall also be
carried out on adjacent pipes for 50 m either side of the recompacted or removed
pipes.

4.7.15 Deflection Measurements - uPVC and other Plastic Pipes

The measurement shall be taken on at least two separate occasions:

a) As soon as a pipeline has been installed, tested and the trench backfilled, but
before the dewatering is removed.

b) Immediately prior to the issue of a Certificate of Completion. If any of these tests

indicate that the deflection may exceed the permitted values of the pipe or pipes
shall be replaced. Any pipe removed for this reason shall be taken from site and
not incorporated in the permanent works. All pipes replaced for any reason shall
subsequently be subject to deflection checks as described above. Deflection
checks shall also be carried out on adjacent pipes for 20 m either side of the
removed pipes.

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4.7.16 Deflection Criteria on Group B Pipelines

Pipes will be regarded as damaged and shall be removed from the trench and
condemned of their in-situ deflection at any time exceeds the values stated in the
following Table:

Table 4. 6 Deflection Measurements on Group B Pipelines

Type of Pipe Deflection Criteria %

Material SDR After At least two Damaged and

Completion of weeks after not to be
Surround completing reused
Permissible the trench
range vertical backfill.
diameter Maximum
elongated only measured in
any plane

uPVC 10 - 15 0 – 1.0 1.0 2.25

uPVC 15 - 25 0 – 1.5 2.0 3.75

RP 30 - 40 0 – 1.5 2.0 4.50

RP 40 - 50 0 – 2.0 2.5 5.25

uPVC 25+ 0 – 2.0 2.5 5.0

RP 50+ 2.50 3.0 7.5

PP 15+ 2.50 3.0 7.0

HDPE 10+ 2.50 3.0 7.0

‘SDR’ is the Standard Dimension Ratio, which is the ratio of pipe external diameter
divided by pipe wall thickness.

The deflection percentage shall be calculated as:

(𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐼𝐼𝐼𝐼 − 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝐼𝐼𝐼𝐼 × 100) ÷ 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐼𝐼𝐼𝐼

Actual ID may be determined by measuring the diameter of a pipe not installed laying
loose on a plane surface.
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𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐼𝐼𝐼𝐼 = (𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 𝐼𝐼𝐼𝐼 + 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐼𝐼𝐼𝐼) ÷ 2

4.7.17 Stanks to Pipelines in Granular Bedding

Where pipes are laid on a granular bed or with a granular backfill, a stank, i.e. an
impermeable barrier, shall be provided across the full width of the trench and for the
complete depth of the bedding at intervals not exceeding 50 m, and generally mid-
way between manholes or chambers. The stank shall consist of:- Either a 300 mm
long plug of fine grained clayey soil or a 300 mm long plug of a mixture of sand and
bitumen consolidated in an approved manner. Or a mixture of sand and clay or the
local material known as sabkha compacted to form an impermeable barrier at least
one metre in length. Or a layer of thick polyethylene cut to fit around the pipe across
the full width of the trench and laid on the granular bedding material at its natural
repose angle. All methods must form an impermeable barrier. Bitumen shall not be
used for thermoplastic pipes.

4.7.18 Thrust and Anchor Blocks to Pressure Pipelines

Underground pressure pipelines shall be provided with concrete blocks as follows:-

Thrust/anchor blocks shall be provided at every installed bend, tee or angle branch.
Anchor/thrust blocks shall be provided on pipelines laid to gradients steeper than
1:20, up to 1:15 every third pipe shall be anchored, up to 1:10 every second pipe and
at 1:5 every pipe shall be anchored. Concrete shall extend to undisturbed ground on
thrust faces of thrust blocks and on both faces of anchor blocks. Where details are
not shown on the drawings the Contractor shall prepare proposals for thrust and
anchor blocks including calculations and submit them to the Engineer's
Representative for approval. Such approval shall not relieve the Contractor of his
responsibility for the adequacy of his proposals. Special details shall be shown on the
drawings or instructed at site where environmental or ground conditions dictate.

4.7.19 Pipes Protruding from Structures, Concrete Surrounds and Anchor Blocks

Unless otherwise detailed a pipeline at or below ground level protruding from a

structure shall have two flexible joints adjacent to the structure. A band of an
approved concrete encasement rubber shall wrap around the pipe prior to placement
of any concrete such that the rubber protrudes 25 mm from the concrete. The pipe
shall be laid so the distance to first exposed flexible joint and the distance between
first and second joint are as follows:-

Table 4.7 Requirements for Flexible Joints for Protruding Pipes

Pipe Diameter Maximum Distance between first and second

(mm) distance to first joint (mm)
joint (mm)
Min Max

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Up to 300 150 450 2.5* dia.

300 to 1000 300 1.5* dia. 2.5* dia.

above 1000 450 1.5* dia. 2.5* dia

In the case of Group B pipe materials, particular attention will be placed on elliptical
deflection conditions.

These joints will be required at surrounds and anchor blocks unless directed
otherwise on site.

a) Group A Pipe on Disturbed Ground

Between the structure and the first joint any disturbed ground below the pipe shall be
removed and replaced with Class C 40/20 concrete in the form of a cradle, all to the
direction of the Engineer. The cradle shall not extend beyond the first joint.

Beyond the first flexible joint within the excavated working space of the structure the
concrete fill shall be brought up 300 mm below the pipe invert only. Specified bedding
materials will then be used.

b) Group B Pipe on Disturbed Ground

Within the excavated working space for the structure disturbed ground below the pipe
shall be removed and replaced with Class C 40/20 concrete to within 300 mm of the
underside of the pipe. Specified bedding materials will then be used to support the
pipe. The width of the concrete backfill shall not be less than the nominal trench
widths except for any permanent shuttering against temporary trench supports to
facilitate removal of such trench supports after concreting. Where a flexible pipe
passes through a rigid concrete face to a structure or surround the pipe shall be
protected from stress concentration and possible fracture of the pipe at the concrete
face. A 10 mm thick neoprene or other approved synthetic rubber strip complies to
BS 4255 Gr: L or ASTM C864 shall be wrapped around and cemented to the pipe
unless special wall protection units are used. The neoprene will normally extend
through the width of a wall to a dry chamber or structure but will be limited to 150 mm
or 100 mm is exposed to liquid (groundwater or liquid inside the structure) a sealant
groove shall be formed if detailed and filled with an appropriate, approved, joint
sealant.

The neoprene rubber properties shall be as described below:

Properties Requirements

Specific Gravity 1.5 gm/cc

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Properties Requirements

Hardness 70+ / -5 shore – A

Tensile strength 35 kg / cm²

Elongation at break Min 250%

Abrasion resistance 450 mm³

Compression set 35%

Tear Resistance 12 kg/cm

Temperature range -20 / +100°C

Care shall be taken to ensure that the rubber strip is not displaced during concreting.
Where a pipeline protrudes from a concrete surround, no protection from stress
concentration will be required if the surround ends at a flexible joint leaving the next
pipe free. If the surround ends on a pipe barrel the specified protection will be
provided and, for pressure pipes only, the protruding pipe will be wrapped from the
edge of the neoprene strip along to the next flexible joint at which the concrete
surround is interrupted with an approved compressible material such as damp-proof
sheeting or building felt of minimum thickness 2 mm.

4.7.20 Protection of Pipelines and Pipeline Component

4.7.20.1 Pipelines

Protection of pipelines shall be in accordance with the manufacturer’s

recommendations which shall be included with submission details for agreement by
the Engineer. The minimum requirements are shown below:

C 40/20 SRC concrete protection slabs as detailed on the drawing shall be provided
over the uPVC pipelines under roads when cover to pipe is equal or less than 1.2 m
for a gravity line; and for pressure line at any depth. In case of GRP pipe crossing
under the road RCC concrete surround shall be provided as per drawing if the depth
of cover is less than 1.5 m.

4.7.20.2 Pipeline Components

All buried valves, couplings, flange adaptors, and other metal components shall be
encased to guard against corrosion. Other pipe joints, valves and similar items on
both buried and exposed pipelines shall be encased where specified or shown on the
drawings.

The encasing shall be by one of the following methods, as detailed.

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(i) Surrounding with Class C 40/20 concrete.

(ii) Enclosed by an approved hot-poured bitumen compound.

(iii) Wrapped with tape.

Method (ii) shall not be used with plastic pipes. The item to be encased shall first be
cleaned and its original surface treatment made good.

The surface shall be dry before encasing is carried out, which shall not be done
before the pipeline has been tested. The bitumen compound shall be cast in
purpose-built moulds in accordance with instructions issued by the supplier. The
protective wrapping tape shall be open-weave cotton or synthetic fibre or woven glass
fibre coated on both sides with an even coat of petrolatum (petroleum jelly) containing
a filler. The tape and paste shall be suitable for use in the prevailing climatic soils
pumped liquid and ground water conditions.

Before wrapping with tape the item to be encased shall be enclosed with an approved
mastic or inert putty-like filler which shall be moulded by hand so as to provide a
smooth surface for the tape. The tape shall be tightly spirally wrapped with 25 mm
overlaps so as to enclose the whole of the item and a minimum of 150 mm of pipe
length on each side. The enclosure shall be firmly pressed out to prevent air being
trapped under the wrapping.

4.7.20.3 Indicator Posts to Pressure Mains

Where pressure mains pass through open ground, not adjacent to roads, or where
the danger of accidental breakage by excavation is evident, the Engineer may instruct
the erection of indicator posts of an approved design. Details of the indicator post
construction and spacing shall be shown on the drawings or be directed by the
Engineer. The depth, location and size of the pressure main shall be detailed in
Arabic and English, to be an approved design, on an engraved plastic or non-
corrodible plate attached to the post. In addition at all air valve chambers, the
Contractor shall erect indicator signs on posts, to an approved design, at locations
described to him by the Engineer.

The words ‘Warning Gas on Entry’ together with an appropriate pictorial

representation shall be detailed.

4.7.20.4 Enclosing Granular or Stone Surround with Geotextile Filter Fabric

The granular bedding and surround to all slotted pipes and pipes laid below the
permanent groundwater level shall be enclosed within a geotextile filter fabric.

Filter fabric used for subsurface drainage works shall consist of long-chain of
synthetic polymer fibres. They shall be formed into network such that the filaments or
yarns retain dimensional stability relative to each other, including selvages.

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The Fabric stabilized against ultra-violet light, inert to commonly encounted chemicals
in the in-situ soil and water, and it shall confirm to the following requirements.

Table 4. 8 Requirements for Geotextile Fabric for Subsurface Drainage

Property Test Method Minimum required

CBR Puncture Resistance BS EN ISO 12236, DIN 1250 N (min average)

54307

Trapezoidal Tear ASTM D 4533 300 N

Resistance

Mean Flow Rate EN ISO 11058, BS EN 45 – 100 l/m2/s

ISO 12958

Apparent Opening Size EN ISO 12956, ASTM D 50 – 180 microns

4571

UV Degradation (Percent ASTM D 4355 70% strength retention

Retained Strength) after 150 hrs exposure

Mass Per unit Area BS EN ISO 9864 120 g/m2 (Minimum)

The fabric shall be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with surround to
the correct level the filter fabric shall be closed over the top of the surround by
forming a ‘lap’ of minimum width 500 mm. All membrane joints shall be overlapped a
minimum of 500mm.

Care shall be taken not to puncture or damage the membrane in any way during
installation during backfilling of the trench. Any fabric damaged or displaced before or
during installation or during placement of overlaying aggregate material shall be
replaced or overlaid to the satisfaction of the Engineer at the Contractor’s expense.

During period of shipment and storage, the fabric shall be maintained wrapped in a
heavy-duty protective covering and protected from direct sunlight, ultra rays and
temperatures greater than 70°C.

4.7.20.5 Underground Services Warning Tapes

Service protection tapes shall be installed above all sewage, drainage irrigation,
water, DEWA, fire fighting and gas pipelines and pressure mains constructed or
exposed under this contract excluding individual service connections. For pipelines
with the top of the pipe barrel more than 900 mm below finished surface level the

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tape shall be placed over the centreline of the pipeline at 600 mm below finished
surface level during backfilling and compaction operations. For pipelines with less
than 900 mm cover to the top of the pipe barrel the tape shall be placed over the
centreline of the pipe at 300 mm above the top of the pipe barrel during backfilling,
compaction and reinstatement operations. The tape shall be continuous over
pipelines and at joints between tapes from separate rolls the joint shall be lapped a
minimum of one metre.

Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions
at pH values of 2.5 to 11.0 inclusive. The tape shall be 150 mm wide and 250 micron
thick and produced as a strong 4 layer composite laminate consisting of: -

(i) 12 Micron polyester film top layer with reverse printing

(ii) 50 Micron pigmented polyethylene

(iii) 12 Micron detectable aluminium foil in between

(iv) 176 Micron bottom layer polyethylene.

(v) The thickness of the tape (250 micron / 1000 gauge) shall be measured in
accordance with BS 2782 : Part 6. Method 630 A.

The following properties shall be demonstrated by appropriate tests:

a) Physical properties (Average of 5 tests)

Tensile strength Longitudinal (MD):160 N (Minimum)

(BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)

Elongation (PE only)

(BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%

Tear strength MD : 640 gram force

BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum

Dart Impact

BS 2782 : P3 : 352F : 1996 1000 grams minimum

b) Chemical resistance

The tape shall remain legible and colour fast in all soil conditions at PH 2.5 – 11.0,
inclusive. The tape shall not show any adverse effect when in contact with the
sulphates, chlorides and other minerals present in sub soil and water, oil, 5% Acetic
Acid, 5% NaOH and Alcohol mix, if any.

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Chemicals Temperature Test Duration Test Method

Diesel Fuel 50°C 30 Days ANZ 4275.4:1995

pH –2.5 (1% H2SO4) 50°C 30 Days

pH –2.5 (with Hydrochloric 50°C 30 Days

Acid)

pH –11.0 (10% Conc. 50°C 30 Days

Sodium Hydroxide)

Saturated Sodium nitrate 50°C 30 Days

solution

Acid Soluble sulphate (with 22 ±2°C 30 Days

CaSO4)

Sea water 50°C 30 Days

Wastewater with hydrogen 22 ±2°C 7 Days

sulphide (30 ppm)

Ammonium Hydroxide (NH3) 50°C 15 Days

Ammonium Hydroxide (NH3) 22 ±2°C 30 Days

Note: After the chemical exposure of the supplied warning tape, the surface printing
should be intact without delamination and corrosion. Relevant independent lab test to
be conducted on supplied tape sample and comply with the requirements prior to the
use on site.

Detectablility after installation and back filling Text in Arabic and English indicating
the protected services lying below the tape shall be permanent ink bonded to resist
prolonged chemical attack by corrosive acids and alkalis with the message repeated
at a maximum interval of two metres. Tapes shall be colour coded as follows, with
black text as indicated. The sign and styles of the text shall be approved by the
Engineer.

Sewers Blue

CAUTION Sea Pipeline below

Sewers Yellow

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CAUTION Sewer below

Sewage pressure mains Yellow

CAUTION Sewerage pressure main below

Drains Yellow

CAUTION Drain below

Drainage pressure main Yellow

CAUTION Drainage pressure main below

Irrigation pressure mains Orange

CAUTION Irrigation pressure main below

Potable Water & As per DEWA Specification

electricity cable

Fire fighting As per Civil Defence Requirements

Gas Red Dangerous Sewer Gas

The Dubai Municipality logo shall be printed on the tape between the spaces of the
repeated messages. The Dubai Municipality logo and its colours shall be as shown
below.

Property Test Method Minimum required

CBR Puncture Resistance BS EN ISO 12236, 1250 N (min average)

DIN 54307

Trapezoidal Tear ASTM D 4533 300 N

Resistance

Mean Flow Rate EN ISO 11058, BS 45 – 100 l/m²/s

EN ISO 12958

Apparent Opening Size EN ISO 12956, ASTM 50 – 180 microns

D 4571

UV Degradation (Percent ASTM D 4355 70% strength retention

Retained Strength) after 150 hrs exposure

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Property Test Method Minimum required

Mass Per unit Area BS EN ISO 9864 120 g/m² (Minimum)

The fabric shall be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with surround to
the correct level the filter fabric shall be closed over the top of the surround by
forming a ‘lap’ of minimum width 500 mm. All membrane joints shall be overlapped a
minimum of 500mm.

Care shall be taken not to puncture or damage the membrane in any way during
installation during backfilling of the trench. Any fabric damaged or displaced before or
during installation or during placement of overlaying aggregate material shall be
replaced or overlaid to the satisfaction of the Engineer at the Contractor’s expense.

During period of shipment and storage, the fabric shall be maintained wrapped in a
heavy-duty protective covering and protected from direct sunlight, ultra rays and
temperatures greater than 70°C.

a) Underground Services Warning Tapes

Service protection tapes shall be installed above all sewage, drainage irrigation,
water, DEWA, fire fighting and gas pipelines and pressure mains constructed or
exposed under this contract excluding individual service connections.

For pipelines with the top of the pipe barrel more than 900 mm below finished surface
level the tape shall be placed over the centreline of the pipeline at 600 mm below
finished surface level during backfilling and compaction operations. For pipelines
with less than 900 mm cover to the top of the pipe barrel the tape shall be placed
over the centreline of the pipe at 300 mm above the top of the pipe barrel during
backfilling, compaction and reinstatement operations.

The tape shall be continuous over pipelines and at joints between tapes from
separate rolls the joint shall be lapped a minimum of one metre.

Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions
at pH values of 2.5 to 11.0 inclusive.

The tape shall be 150 mm wide and 250 micron thick and produced as a strong 4
layer composite laminate consisting of: -

(1) 12 Micron polyester film top layer with reverse printing

(2) 50 Micron pigmented polyethylene
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(3) 12 Micron detectable aluminium foil in between

(4) 176 Micron bottom layer polyethylene.
(5) The thickness of the tape (250 micron / 1000 gauge) shall be measured
in accordance with BS 2782 : Part 6. Method 630 A.
The following properties shall be demonstrated by appropriate tests:

a) Physical properties (Average of 5 tests)

Tensile strength Longitudinal (MD):160 N (Minimum)

(BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)

Elongation (PE only)

(BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%

Tear strength MD : 640 gram force

BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum

Dart Impact

BS 2782 : P3 : 352F : 1996 1000 grams minimum

b) Chemical resistance

The tape shall remain legible and colour fast in all soil conditions at pH 2.5 – 11.0,
inclusive. The tape shall not show any adverse effect when in contact with the
sulphates, chlorides and other minerals present in sub soil and water, oil, 5%
Acetic Acid, 5% NaOH and Alcohol mix, if any.

Table 4. 1

Chemicals Temperature Test Duration Test Method

Diesel Fuel 50oC 30 Days ANZ

4275.4:1995

PH –2.5 (1% H2SO4) 50oC 30 Days

PH –2.5(with Hydrochloric 50oC 30 Days

Acid)

PH –11.0(10% Conc. Sodium 50oC 30 Days

Hydroxide)

Saturated Sodium nitrate 50oC 30 Days

solution

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Chemicals Temperature Test Duration Test Method

Acid Soluble sulphate (with 22 ±2oC 30 Days

CaSO4)

Sea water 50oC 30 Days

Wastewater with hydrogen 22 ±2oC 7 Days

sulphide (30 ppm)

Ammonium Hydroxide (NH3) 50oC 15 Days

Ammonium Hydroxide (NH3) 22 ±2oC 30 Days

Note: After the chemical exposure of the supplied warning tape, the surface printing
should be intact without delamination and corrosion. Relevant independent lab test
to be conducted on supplied tape sample and comply with the requirements prior to
the use on site.

Detectablility after installation and back filling

Text in Arabic and English indicating the protected services lying below the tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive
acids and alkalis with the message repeated at a maximum interval of two metres.
Tapes shall be colour coded as follows, with black text as indicated. The sign and
styles of the text shall be approved by the Engineer.

Sewers : Blue

CAUTION : Sea Pipeline below

Sewers : Yellow
CAUTION : Sewer below

Sewage pressure mains : Yellow

CAUTION : Sewerage pressure main below

Drains : Yellow
CAUTION : Drain below

Drainage pressure main : Yellow

CAUTION : Drainage pressure main below

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Irrigation pressure mains : Orange

CAUTION : Irrigation pressure main below

Potable Water & electricity cable : As per DEWA Specification

Fire fighting : As per Civil Defence Requirements

Gas : Red

Dangerous Sewer Gas

The Dubai Municipality logo shall be printed on the tape between the spaces of the
repeated messages. The Dubai Municipality logo and its colours shall be as shown
below.

Green

white

dark brown

brown

black

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4.8 PIPEWORK WITHIN STRUCTURES

(i) Pipework shall be supplied to the general arrangements and limits indicated
on the Contract drawings and shall be supplied complete with all joint rings,
gaskets, washers to each side of a bolted joint, nuts, bolts, grease and any
other components necessary for the complete installation

(ii) The layout and design of the pipework shall be such as to facilitate its
erection and the dismantling of any section for maintenance of associated
plant by inclusion of approved mechanical coupling or flange adaptors.

(iii) Where a common delivery pipe is used, individual pump delivery branches
unless otherwise shown on the drawings shall be jointed to it in a horizontal
plane and angled to prevent sharp changes of flow direction.

(iv) Adequate supporting and anchoring arrangements for all pipes shall be
included which may take the form of straps, stays, tie bars or concrete
cradles. All pipe hangers and supports inside pumping stations and valve
chambers or other structures shall be of 320S17 stainless steel. All fixing
bolts shall be stainless steel grade 320S17.

(v) GRP pipes shall be provided with puddle flanges where they pass through
the walls of underground or water retaining structures.

(vi) Small bore pipework for sump pumps, vents, etc., may be an approved
plastic material.

(vii) All pipes connected to pressure vessels, pumps, etc., shall have flanged
connections.

(viii) All pipes shall be checked for alignment and mating of flanges and
connections before secured. Pipes shall not be sprung into position.

4.9 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES

4.9.1 General

The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the drawings and
herein specified.

Manholes, chambers, and special structures shall conform in shape, size,

dimensions, materials, and other respects to the details indicated on the drawings or
as ordered by the Engineer.

4.9.2 Construction of Manholes, Chambers, and Special Structures

All manholes, chambers, and special structures shall have reinforced-concrete bases
as detailed on the drawings. Manhole bases for storm-sewers less than 600 mm and

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bases for chambers may be precast or cast in place at the Contractor's option and as
approved by the Engineer. For precast reinforced concrete manhole bases, openings
for pipes shall be cast in the base at the required location during its manufacture.
Field cut openings will not be permitted. All other manhole and special structure
bases shall be cast in place as indicated on the drawings.

Manhole and chamber cover slabs shall be cast in place reinforced concrete as
marked on the drawings. The ductile iron frames and covers for manholes and
chambers shall be brought to grade by the number of courses of concrete blocks
shown on the drawings or as instructed by the Engineer and a reinforced concrete
frame into which the ductile iron frame is embedded.

Class C 40/20 concrete shall be cast to a minimum thickness of 150 mm around the
concrete blocks for rigidity or as detailed on the drawings.

The inverts shall conform accurately to the size of the adjoining pipes. Side inverts
shall be curved and main inverts (where direction changes) shall be laid out in
smooth curves of the longest possible radius which is tangential, within the manhole,
to the centerlines of adjoining pipelines all as indicated on the drawings and
instructed by the Engineer.

The ductile iron frames, grates and covers shall be to the Dubai Municipality standard
frame, grate and cover as indicated on the drawings and hereinafter specified in
Clause.

All benching and channel shall be formed with C35/10 concrete unless shown
otherwise on the drawings. GRP laminate (7 mm minimum) shall be applied to
benching and channel.

Manhole walls shall be plain Class C 30/20 SRC concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to give a fair
faced finish.

Internal surfaces of manholes and structures shall be protected with a reinforced

plastic liner in accordance with Clause or with an approved coating in accordance
with Clause as and where shown on the drawing and the external (buried) surfaces
shall be protected in accordance with Clause either with water-proof membrane with
protection board or with a brush-applied bituminous emulsion as indicated in the
drawing.

Pipes entering and leaving manholes, chambers and special structures shall be laid
soffit to soffit unless otherwise shown on the drawings. Details of pipelines entering
and leaving manholes, chambers, etc., shall be as specified for pipes protruding from
structures in accordance with Clause 4.7.19.

All construction joints to manholes, chambers and special structures shall be perfectly
watertight. Waterstop across joints in structures as specified in Clause 3.9.5 shall be

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provided where detailed on the drawings or as directed. Joints shall be fully

scabbled.

Manholes and chambers shall be completely constructed as the Works progress and
as each one is reached by the pipework. Frames and covers shall be placed
immediately after the completion of the manhole and chamber.

4.9.2.1 Road Gullies

Gullies shall comprise the gully grating and frame and the polypropylene gully pot, all
as shown on the drawing.

The gully pots shall be supplied with a fibre glass sand bucket with lifting handle, as
detailed on the drawing. The sand bucket shall have perforations in its upper part and
small holes 3 mm in diameter in its base. The total area of perforations shall not be
less than 20,000 sq. mm and the minimum diameter of each hole shall be 50 mm.
The depth of the bucket shall not be less than 750 mm.

The gully pot shall be surrounded by a minimum of 150 mm of concrete as shown on

the drawing.

The connecting pipe between the gully pot and the drain/manhole shall be 160 mm
dia. uPVC.

The connection into the drain pipe shall be made by means of an oblique junction.

4.9.3 Access Covers, Frames, and Grates

4.9.3.1 General

The Contractor shall furnish all ductile iron frames, grates, and covers conforming to
the details shown on the drawings, and as specified in Table 4.23 and 4.24.

The Contractor shall submit for approval detailed shop and working drawings of all
castings before fabrication. Such drawings shall be obtained from the supplier(s) he
chooses to select from the approved list of Dubai Municipality.

The castings shall be of good quality, strong, tough, even-grained ductile iron,
smooth, free from scale, lumps, blisters, sand holes, and defects of every nature
which would render them unfit for the service for which they are intended. Covers and
frames contact surfaces shall be machined and the compatible frames and cover
carefully marked to ensure correct covers and frames are matched on site.

If required by the Engineer, the Contractor shall obtain from the supplier/
manufacturer a guarantee that replacement component parts will be available for a
minimum period of 10 years from the issue date of the Completion Certificate.

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All covers, frames and grates shall be delivered to Dubai with a transit protective
packaging or wrapping. Any damage occurring to the approved coating system shall
be made good prior to installation.

One set of prising and lifting keys of approved design Tri –glide Cover lifting key and
MSG safety grid shall be supplied by the Contractor with each twenty manhole covers
and frames supplied.

Loop –handled & T – handled keys suitable to lift Type E600, D400, C250 and B125
covers shall also be supplied along with 20 covers.

4.9.3.2 Access Covers and Frames

All access covers and frames shall be of heavy duty construction complying with BS
EN124 and the requirements of the Dubai Municipality Standards. Access covers and
frames shall be sand tight (with the use of sealing plates where necessary) with
seating designed to be non-rocking unless detailed otherwise.

Double triangular and semi-circular covers must be loosely coupled by stainless steel
bolts with nuts provided with an approved method to render the nuts incapable of
both undue tightening or loosening.

Holes provided in non-ventilating covers for lifting keys shall be appropriately shaped
pockets which shall not penetrate through and there may be no projections above
cover level.

Both sides of covers and frames shall be protected with an approved epoxy coating
system appropriate to the Dubai environment. The coating system may be applied at
the place of manufacture or in Dubai under controlled application conditions approved
by the Engineer.

Covers for sewerage manholes and chambers shall also be provided with a
reinforced plastic sealing plate. The design of cover, frame and sealing plate shall be
such that no load can be transferred from the cover to the sealing plate. Access
covers shall be as follows: -

a) Sewerage

(i) Manhole covers shall be 600 mm x 600 mm square clear opening double
triangular heavy duty, embossed with the word 'Sewerage' in Arabic and
English.

(ii) Inspection chamber covers shall be single seal 600 mm x 600 mm square
clear opening heavy or medium duty, embossed with the word 'Sewerage' in
Arabic and English. Alternately, 600 mm x 600 mm square clear opening
double triangular covers may be used subject to approval by the Engineer.

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b) Storm/Land drainage Manhole covers shall be non-ventilated, 600 mm diameter

clear opening double semi-circular heavy duty with sealing plate, embossed with
the word 'Storm' in Arabic and English.

c) Fire Fighting

Manhole covers shall be 600 mm diameter clear opening, circular, embossed with the
word ‘FH’ in Arabic and English. They shall be heavy duty (11.50 tonne wheel load
or D400) where located in a road corridor. For other locations they shall be Type
C250 or B150.

d) Water Supply

Manhole and chamber covers shall be of clear opening as specified on the drawings,
embossed with the word ‘water’ in Arabic and English. They shall be heavy duty
(11.5 tonne wheel load or D400) where located in a road corridor, for other locations
they shall be Type C250 or B 150. Where air tight / gas tight covers are specified,
these shall be of bolted type (bolted down) with double seal.

e) Aluminium Covers

General

Aluminium covers shall be of the clear opening as shown in the drawing, fabricated
from anodised aluminium alloy chequer plate of thickness as specified. The cover
shall be suitable for exposed locations (ambient conditions) and shall not distort due
to temperature variations. Hinges shall be of heavy duty with adjustments to provide
a proper vermin proof protection. Covers shall be provided with padlocking facility.

(a) Hinged Aluminium Floor Access Covers for Interior and Exterior Applications

Aluminium floor access covers shall be designed for interior and exterior applications
where water tightness is not required. The frame shall be with an angle frame
construction with an integral anchor flange designed to cast into concrete. The cover
panel shall be diamond plate required with a flush aluminium drop handle and an
automatic hold open arm with red vinyl grip.

Materials Aluminium cover and frame, stainless steel hinges and

hardware

Cover 6 mm thick aluminium diamond plate reinforced for live load of

800 kg/m2 and 1500 kg/m2.

Frame Angle iron frame fabricated from aluminium extrusion with an

integral (25 mm) wide anchor flange.

Hinge Stainless steel but hinges with tamproof stainless steel blots &

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nuts.

Opening Device Automatic hold open arm with red vinyl grip allows door panel to
open 90 
control when closing door panel.

Latch Flush aluminium drop handle with staple for padlock.

Finish Mill finish with optional specified coating with sprayed aluminium

Cover opening As shown in the drawing

size

Standard size 600 x 600 to 1500 x 1500 mm

(b) Non-Hinged Aluminium Floor Access Covers for Interior Applications

Aluminium floor access cover is designed for interior applications where water-
tightening is not required. The cover shall be flush diamond plate door secured to the
frame with flat head screws and is completely removable.

Cover size from 200 x 200 mm to 610 x 610 mm

Material Aluminium

Cover 6 mm thick aluminium diamond plate reinforced for the live load
of 800 kg/cm2, recessed 3 mm for floor finish/concrete.

Frame 25 mm x 25 mm aluminium angle designed to be cast into

concrete. 40mm x 32 mm aluminium angle with mounting holes
in top flange.

Latch Door panel secured to frame with 32 x 25 mm flat head screws.

Finish Mill finish with optional specified coating with sprayed

aluminium.

f) Channel Grating

Standard channel grating shall be DI, D400, 225 mm x 750 mm in size single piece
with two bearer frames or extendable to cross the carriageway location where
required.

g) Pumping Stations & Associated Chambers where Specified

They shall be rectangular 600 mm x 750 mm or 600 mm x 900 mm or multiples of

these sizes, as detailed on the drawings with concrete infill and shall be heavy duty.
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Where ventilated covers are detailed the total area of ventilation shall not be less than
5 % of the minimum clear opening area and the covers shall be provided with suitable
protective sand traps which shall seat in the access cover frame.

c) Reinforced Plastic Sealing Plates to Access Covers

Reinforced plastic sealing plates to access covers shall be designed to provide a

push-fit, gas-tight seal with the cover frame. The sealing plate shall be in the form of a
plug with a flange to prevent the plate passing into the manhole. The seal shall be
achieved by means of an approved integral synthetic rubber gasket mechanically
locked into the periphery of the plate.

The rubber gasket shall have the following physical properties:

Properties Specifications Test Method

Hardness (Shore A) 75 ± 5 ASTM D 2240

Tensile Strength (Mpa) 10.5 min. ASTM D 412

Elongation Break % 200 Min ASTM D 412

Hardness Change 0 to + 10 ASTM D 573

Tensile change % 15 Max ASTM D 573

Elongation change % 40 Max ASTM D 573

Compression Set 22 hours 25% Max ASTM D 395

at 70°C

Low Temperature Should be flexible at -40°C ASTM D 2137

Flexibility

Ozone resistance 20% No cracks ASTM D 1149

stretch 40°C 100 PPM 96
hrs

Maximum working 140°C

temperature

The gasket shall be suitable for the service temperature range 0°C to 60°C and
possess good weathering and H2S resistance. Any lubricant used on the seal shall be
silicon based. The underside of the plate shall have a resin-rich finish and there shall
be no exposed fibres. Cut and/or drilled faces shall be sealed with resin.

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The plate shall have a minimum thickness of 5 mm and be capable of withstanding a

static load of 150 kg applied centrally over a 150 cm square surface area with a
deflection, measured at the centre of the plate, not exceeding 25 mm.

A minimum of four number reinforced plastic lifting handles shall be provided per
plate. They shall be of the same materials as the plate securely laminated to the plate
or fixed by stainless steel blind rivets.

The complete sealing plate including gasket shall be resistant to 10% sulphuric acid
at 50°C for 100 days.

d) Road Gulley Gratings and Frames

Road gully gratings and frames shall be of ductile iron construction made to BS
EN124 and have a minimum waterway of 900 sq. cm. The grating and frame shall be
of a non-rocking construction and shall be dimensioned as detailed on the drawing.

Gully gratings shall be of the raised kerb type complete with sand seal, road retaining
bar and a removable GRP debris bucket. The weir depth shall be a minimum of 165
mm and the frame and cover are to be protected with an approved epoxy coating
system applied in Dubai under controlled application conditions approved by the
Engineer. The clear opening size shall permit removal of the GRP grit sand bucket.

e) GRP Gulley Grating Over the GRP Bucket

Reinforced plastic gully grating shall be a rectangular perforated plate to the shape
shown on the drawing. The plate shall have a minimum thickness of 6mm and shall
be capable of withstanding a static load of 100kg applied centrally over a 150mm
square surface area without showing any breakage. The corners of the plate shall be
chamfered as shown on the drawing to fit in to the place. The grating shall be
manufactured by using Isophthalic resin and ‘E’ glass standard mat & woven rovings
for the of 6mm thick layers and top coating shall be with gel coat as per the
lamination requirements.

f) GRP Gully Pot With Bucket

GRP gully pot with bucket shall be manufactured by using Isopthalic resin reinforced
with ‘E’ glass chopped strand mat to a thickness of 4 mm as per Dubai Municipality
approved drawings.

g) GRP Toe Holes inside Deep Manholes

G.R.P Toe holes shall be manufactured using Epoxy based vinylester resin reinforced
with ‘ECR’ glass 7mm thick and two layers of ‘C’ Glass surface Tissue.

h) GRP Pre-fabricated Sleeve

The pre-fabricated GRP sleeves shall be as shown on the Drawing. The sleeves
materials and construction shall also be as specified in Clause 7.1.6.
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4.10 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS

Table 4. 10 Standards for Covers and Gratings for Storm/Land Drainage

Requirements Manhole Gully Gratings

In Road Out of Road Flush Upstand Pumping

Kerb Kerb Station
Access
Cover

Shape Double Double Square - Rectangular

Semi- Semicircular
Circular

Size of clear 600 dia. 600 dia Width weir dpt 600 x 750
opening Nom.450 165 600 x 900

Standard BS EN BS EN 124 BS EN 124 BS EN BS EN 124

124 124

Strength D400 C250 D400 D 400 D400

Material Ductile Ductile Iron Ductile Iron Ductile Ductile Iron

Iron Iron

Protective Epoxy Epoxy Epoxy Epoxy Epoxy

Coating

Ventilation No No - - No

Construction Solid Solid - - Concrete

Infill

Sealing Plate Yes Yes - - -

Inscriptions Storm Storm Storm Storm Storm

Tightness Yes Yes - - -

Rocking No No No - No

Locking No No No - Yes

Interchange- Yes Yes Yes Yes Yes

ability

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Requirements Manhole Gully Gratings

In Road Out of Road Flush Upstand Pumping

Kerb Kerb Station
Access
Cover

Other - - - GRP Special Keys

GRID

Suppliers 1-6 1-6 1-6 1-6 1, 2, 4

Table 4. 11 Standards for Covers and Gratings for Sewerage

Requirements Manhole House Pumping

connection station
In road Out of road chamber access
cover

Protective Coating Epoxy Epoxy Epoxy Epoxy

Ventilation No No No No

Construction Solid Solid Solid Concrete

Infill

Sealing Plate Yes Yes Yes -

Inscriptions Sewerage Sewerage Sewerage -

Tightness Yes Yes Yes -

Rocking No No No No

Locking No No No -

Interchangeability Yes Yes Yes Yes

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Requirements Manhole House Pumping

connection station
In road Out of road chamber access
cover

Other - - - Special Keys

Suppliers 1–6 1-6 1-6 1, 2, 4

4.10.1 Repair Mortar for Metal Products

The cold applied mortar shall be a two component repair and rebuilding material on
metal products. It shall be based on ceramic and steel reinforced system (similar to
the product of Belzona) suitable to repair broken metal parts and the casting defects
etc.

This material shall be non-corrodable and be resistant to broad range of chemicals

including acids and alkalis.

The mechanical strength of the cured product shall not be lower than the values given
below:

Compressive strength ASTM D 695 ≥800 kg/cm2

Flexural strength ASTM D 790 ≥575 kg/cm2

4.10.2 Approved List of Suppliers

1. ELKINGTON GATIC

2. PASSAVANT

3. PAM – SAINT – GOBAIN PIPE LINES

4. SELFOCK

5. GLYNWED BRICKHOUSE

6. HYDROTECH

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 5

BRICKWORK AND BLOCKWORK

DM/DNID Section 5 Brickwork and Blockwork Rev 00 June

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 5
BRICKWORK AND BLOCKWORK

CONTENTS
5 BRICKWORK AND BLOCKWORK .................................................................................. 1
5.1 GENERAL .................................................................................................................... 1
5.1.1 Scope .................................................................................................................. 1
5.1.2 Standards............................................................................................................ 1

5.2 SUBMITTALS .............................................................................................................. 1

5.2.1 Products And Materials Approval ........................................................................ 1
5.2.2 Method Statements ............................................................................................. 2
5.2.3 Drawings ............................................................................................................. 2
5.2.4 Samples .............................................................................................................. 2
5.2.5 Mock Up .............................................................................................................. 3

5.3 QUALITY CONTROL ................................................................................................... 3

5.4 DELIVERY, STORAGE AND HANDLING.................................................................... 3
5.5 REGULATORY REQUIREMENTS ............................................................................... 4
5.6 MATERIALS ................................................................................................................ 4
5.6.1 Concrete Bricks and Blocks................................................................................. 4
5.6.2 Bricks .................................................................................................................. 5
5.6.3 Sand for Mortar ................................................................................................... 6
5.6.4 Lime for Mortar .................................................................................................... 6

5.7 CONSTRUCTION ........................................................................................................ 6

5.7.1 General ............................................................................................................... 6
5.7.2 Engineering Brickwork ......................................................................................... 7
5.7.3 Blockwork ............................................................................................................ 7
5.7.4 Cement Mortar / Masonry Mortar......................................................................... 7
5.7.5 Cement Lime Mortar............................................................................................ 8
5.7.6 Cement Mortar Rendering ................................................................................... 8
5.7.7 Masonry Grout .................................................................................................... 8
5.7.8 Metal Ties, Anchors and Joint Reinforcement ..................................................... 9
5.7.9 Accessories ......................................................................................................... 9
5.7.10 Lintels................................................................................................................ 10

5.8 EXECUTION .............................................................................................................. 10

5.8.1 General ............................................................................................................. 10
5.8.2 Masonry Construction ....................................................................................... 11
5.8.3 Placing And Bonding ......................................................................................... 12
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5.8.4 Cavity Walls ...................................................................................................... 13

5.8.5 Reinforcement And Anchorage.......................................................................... 13
5.8.6 Grouting ............................................................................................................ 14
5.8.7 Joints................................................................................................................. 15
5.8.8 Masonry Flashings ............................................................................................ 16
5.8.9 Lintels................................................................................................................ 16
5.8.10 Built-In Work...................................................................................................... 16
5.8.11 Cleaning ............................................................................................................ 17

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5 BRICKWORK AND BLOCKWORK

5.1 GENERAL

5.1.1 Scope

This section of the specification gives the requirements for concrete masonry.

5.1.2 Standards

All activities relating to this section of the specification shall comply with the following
or approved equal standards.

BS 6398 Specification for bitumen damp proof courses for masonry.

BS EN 480 Admixtures for concrete mortar and grout

BS EN 771-2 Specification for masonry units. Aggregate concrete masonry

units (dense and Light weight aggregates)

BS EN 772-1 Methods of tests for masonry units. Determination of compressive

strength

BS EN 13139 Aggregates for mortar.

ISO 11600 Building Construction Jointing Products Classification and

requirements for sealants

5.2 SUBMITTALS

5.2.1 Products And Materials Approval

a. In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Information to be submitted
shall comprise but not necessarily be limited to:

(i) Manufacturer’s/supplier’s name.

(ii) Product name/description.

(iii) Manufacturer’s technical data.

(iv) Manufacturer’s certificates of compliance with this section of the

specification.

(v) Storage instructions.

(vi) Application instructions.

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(vii) Mix design for mortar and grout.

5.2.2 Method Statements

a) The Contractor shall submit method statements to the Engineer for approval 4
weeks in advance of commencing the site activity. These shall comprise but not
necessarily be limited to:

Method of mortar mixing, block placement, reinforcing, tooling and grouting for all
masonry works

5.2.3 Drawings

a) The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity. These shall comprise but not necessarily be limited
to:

(i) Details of anchors, inserts, joints, connections to adjoining work or

materials. Also include elevations indicating setting out and placement of all
joints, openings, cut outs, etc.

(ii) In addition to above submit drawings for fabrication, bending and

placement of reinforcement for concrete masonry work. Show bar
schedules, diagrams of bent bars, stirrup spacing, lateral ties and other
arrangements and assemblies as required for fabrication and placement of
reinforcement for concrete masonry work.

5.2.4 Samples

a) Representative samples, as agreed with the Engineer, must be submitted for at

least the following items at the same time as the particulars are submitted.

(i) Hollow concrete blocks.

(ii) Solid concrete blocks.

(iii) Masonry reinforcement.

(iv) Masonry anchors.

(v) Lintels.

(vi) Damp proof course.

(vii) Flashings.

(viii) Joint fillers and sealants.

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5.2.5 Mock Up

a) Prior to the construction of concrete masonry work provide a sample wall mock-
up for all types of concrete masonry work.

b) Construct a masonry wall into a panel sized 2m long by 1m high, which includes
mortar and accessories, reinforcing, wall openings, flashings, wall insulation, air
barrier, vapour barrier and indicating the proposed range of colour, texture and
workmanship expected in the completed work.

c) Locate as directed by the Engineer.

d) Provide each sample wall panel using materials, together with bond and joint
tooling, shown or specified for final work.

e) Obtain acceptance of visual qualities of each sample panel before proceeding

with the final work.

f) Retain each sample panel mock-up during construction period as a standard for
judging completed masonry work. Do not alter, move or destroy mock-up until
work is completed.

g) Mock up may remain as part of the permanent work.

5.3 QUALITY CONTROL

a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery.

b) Products and materials shall be from a manufacturer/supplier that operates a

quality system which is registered to ISO 9000 series or approved equal.

c) To allow the Engineer to inspect the Works the Contractor shall give the Engineer
a minimum of 24 hours’ notice of carrying out the following activities on site.

(i) Commencement of masonry work.

5.4 DELIVERY, STORAGE AND HANDLING

a) Delivery, storage and handling of products and materials shall be in accordance

with the manufacturer’s recommendations:

(i) Delivery, storage and handling shall at all times be performed in a manner
to avoid product damage.

(ii) Products shall be stored at site in an. environment as recommended by the

manufacturer.

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(iii) Deliver concrete masonry materials, other than bulk materials, to site in
manufacturer’s unopened containers, bundles, pallets or other standard
packaging devices, fully identified with name, type, grade, colour and size.

(iv) Protect all concrete masonry materials during shipment, storage and
construction against wetting and contamination with earth or other types of
materials.

(v) Take all necessary precautions to prevent all masonry materials from
chipping, cracking or other damage during transportation, unloading and
storage on site.

(vi) The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.

1. Any products damaged during delivery, storage and handling shall be

marked by the Contractor and set aside.

2. Proposals for repair of any damaged products shall be submitted in

writing to the Engineer for approval.

3. Any damaged products deemed unsuitable for repair by the Engineer

shall be removed from site and replaced.

5.5 REGULATORY REQUIREMENTS

Requirements for fire-rated or lateral support conditions are to be regulated in

compliance with local building codes and are not necessarily fully defined on the
drawings. Whenever a fire rating is shown for a wall, use concrete masonry in that
wall complying with the requirements established by the local governing authorities.

5.6 MATERIALS

5.6.1 Concrete Bricks and Blocks

a) Concrete bricks and blocks shall be constructed from C 40/10 concrete but the
coarse aggregate shall be 10 mm to 5 mm. The blocks shall be cast in clean oiled
moulds.

b) They shall be free from cracks, uniform in size, true to shape; free from
deleterious matter, clean, hard, impervious with smooth faces in appearance
similar to normal Class 40/10 concrete and with well-defined arises. The
constituent parts comprising the concrete of the blocks shall conform, unless
otherwise stated, to Section 3 of this specification.

c) Bricks and blocks shall not be incorporated into the Works until they have
matured under suitable conditions for 28 days. All concrete blocks shall comply
with the requirements of DM Local Order No. 44/90.

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d) Do not use blocks which have chips, cracks, voids, streaks, iron spots or other
substances which might stain exposed finished surfaces.

e) Obtain blocks from one manufacturer, cured by one process and of uniform
texture and colour, for each type required, for each continuous area and visually
related areas.

f) Concrete blocks generally are to be in accordance with BS EN 771-3. They shall

be factory produced under strictly controlled conditions.

g) Blocks shall be made using ordinary Portland cement (OPC) unless otherwise
directed by the Engineer.

h) Blocks for external and load bearing walls where indicated on the drawings shall
be 100% solid blocks with an average compressive strength after 28 days of
10N/mm2

The blocks shall be of the following sizes:

390mm x 190mm x 190mm

390mm x 190mm x 140mm

390mm x 190mm x 90mm

i) Blocks for internal partition walls where indicated on the drawings shall be hollow
blocks with an average compressive strength after 28 days of 6N/mm2

The blocks shall be of the following sizes:

400mm x 200mm x 200mm.

390mm x 190mm x 140mm.

390mm x 190mm x 90mm

Provide special shapes wherever shown and wherever required to build corners,
lintels, jambs, control joints and expansion joints in order to provide a complete
installation in accordance with the highest standard of workmanship.

j) Ten blocks shall be taken from every designated block section in each
consignment and tested in accordance with BS EN 772-1.

5.6.2 Bricks

a) Engineering bricks and special purpose bricks such as radial bricks, weir bricks,
copings and bull nosed bricks shall have an average compressive strength of at
least 69 N/mm2 and an average absorption not exceeding 4.5 percent by weight
measured by a standard boiling or vacuum method.

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b) Faces of engineering bricks to be exposed to the weather or liquids shall not be

wire cut.

c) Bricks for arches and circular work of 1.5 metres and less in diameter shall be
purpose made radial bricks.

5.6.3 Sand for Mortar

a) Aggregates shall consist of natural sand or crushed sand complying with BS EN

13139 and approved by the Engineer.

b) Sand for mortar shall comply with the following table:

Sieve Size Percentage by mass passing sieve

Rendering Brickwork/General
Purposes

5.00 mm 100 100

2.36 mm 90 100 90 100

1.18 mm 70 100 70 100

600 microns 40 80 40 100

300 microns 5 40 5 70

150 microns 0 10 0 15

5.6.4 Lime for Mortar

a) Lime for cement-lime and lime-sand mortar shall be the hydrated type to the
approved standard.

5.7 CONSTRUCTION

5.7.1 General

a) Bricks and blocks shall be properly stacked on level hard standing. Broken blocks
shall be removed from the site.

b) Bricks shall be adequately protected from inclement weather.

c) During hot and dry weather bricks and blocks shall be wetted as necessary and
the tops of walls shall be wetted before a course is laid

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d) All faces of brickwork or block work will be kept clean and no rubbing down of
exposed faces will be permitted.

e) Vertical faces of all bricks shall be well buttered before being laid and the whole
well grouted at each course.

f) Brickwork and block work should be built in a uniform man¬ner. Corners and
other advanced work should be raked back and not raised above the general
level more than 1.0 m at one lift.

g) All blocks shall be laid on even full beds of mortar; vertical faces of all blocks shall
be well buttered before being laid and the whole well grouted at each course.

h) The overall dimensions of four blocks laid in mortar shall not exceed by more than
25 mm the overall dimensions of the same blocks laid dry.

5.7.2 Engineering Brickwork

a) Unless otherwise specified or ordered all engineering brickwork shall be built in

English bond.

b) In all engineering brickwork the overall dimensions of four bricks laid in mortar
shall not exceed by more than 25 mm the overall dimensions of the same bricks
laid dry.

c) When concrete is to be faced with brickwork, header bricks shall be built into
every fourth course and at intervals of 2 bricks horizontally so as to project 1/2
brick into the concrete. Headers in successive courses shall be staggered.

5.7.3 Blockwork

All block work shall be built level, plumb and true to line with all perpends in line
vertically. Blockwork shall be built in stretcher bond and alternate courses shall be
bonded in at all junctions. All block work shall be set in gauged mortar as described
to the lengths, heights and thicknesses shown on the drawings. Fair and fair-faced
work shall be kept perfectly clean and no rubbing down of block work will be allowed.
Blockwork to be plastered shall have joints struck off flush and left rough.

5.7.4 Cement Mortar / Masonry Mortar

a) Mortar for precast concrete units, brickwork and block work shall be gauged in the
proportions of one part of cement to three parts of sand. Lime shall only be added
if specifically ordered.

b) Cement mortar shall be mixed on a clean surface in small quantities sufficient

only for 30 minutes work and shall not be remixed or worked up again after
setting or hardening; any mortar that has become set or hard shall be rejected
and removed from the site.

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c) Ingredients shall be measured in proper boxes and shall be turned over and
thoroughly mixed on a wooden platform.

d) The ingredients shall be accurately measured and mixed in a mechanical mixer

with a sufficient amount of water added to produce a workable consistency

e) If only small quantities are required the Engineer may permit mixing together dry
on a clean wooden stage until the mix is homogeneous in colour. Water shall then
be added in sufficient quantity to give no more than stiff workability. The whole
shall then be turned until perfectly mixed.

f) Where admixtures are permitted they shall be in accordance with the

requirements of BS EN 480 and be used strictly in accordance with the
manufacturer’s instructions.

5.7.5 Cement Lime Mortar

Cement lime (gauged) mortar shall consist of one part Portland Cement, one part of
lime and six parts of sand by volume (1:1:6). All materials shall be accurately gauged
using gauge boxes and shall be thoroughly mechanically mixed. Mortar that has
begun to set shall not be revived or re-used.

5.7.6 Cement Mortar Rendering

a) Cement mortar rendering shall consist of two or more coats; the undercoat shall
be 13 mm thickness and scored to form a key for the final coat which shall be not
less than 6 mm in thickness. The finished coat shall be worked with proper metal
floats, and the face left with an even and polished surface. The mortar for the
undercoat of the rendering shall be gauged in the proportion of one part of
cement to three parts of sand, and the finished coat shall be in the proportion of
one part of cement to two parts of sand.

b) For at least 24 hours before rendering is applied the concrete or brickwork face or
previous coat of rendering shall be thoroughly soaked with water, and the finished
rendering shall be watered at least four times a day and kept damp for a period of
a least fourteen days after completion. Not more than three days shall elapse
between the application of one coat and its being covered up with a second or
finishing coat. All arises shall be sharp and linear.

c) When rendering is to be applied to brickwork, the joints shall be raked and

cleaned out to a depth of 13 mm.

5.7.7 Masonry Grout

a) Masonry grout shall consist of cement, sand and lime in the proportions given as
below

Grout Type OPC Sand Lime

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Coarse 1 1.5 Coarse 2.5 Fine 0.5

Fine 1 2.5 Fine 0.5

b) Aggregates shall consist of natural sand or crushed sand complying with BS EN

13139 and approved by the Engineer. Fine aggregate shall all pass a 9.5mm
sieve and coarse aggregate shall all pass a 12.5mm sieve. Aggregate grading
shall be to the approval of the Engineer.

c) All grouts shall have a minimum compressive strength of 20N/mm2 at 28 days

d) The ingredients shall be mixed in a mechanical mixer with a sufficient amount of

water added to produce a workable consistency. The Engineer may permit hand
mixing if the required quantity is small.

e) Method of measuring materials shall be such that the specified proportions of the
grout materials can be controlled and accurately maintained to the satisfaction of
the Engineer.

f) Where admixtures are permitted they shall be in accordance with the

requirements of BS EN 480 and be used strictly in accordance with the
manufacturer’s instructions

5.7.8 Metal Ties, Anchors and Joint Reinforcement

a) Provide anchoring devices such as bolts, straps, bars and rods of the type and
size shown fabricated from not less than 1.6mm sheet metal or 9mm diameter
bars unless otherwise shown on the drawings. Anchoring devices shall be
fabricated from stainless steel grade A316 unless otherwise approved by the
Engineer.

b) Lateral support for wall heads shall be fabricated from 30mm X 6mm thick
stainless steel grade A316, flat on both sides unless otherwise approved by the
Engineer.

c) Blocks shall be restrained at vertical interfaces with concrete using stainless steel
grade A316 wall starters with integral ties for building in.

d) Wall ties shall be fabricated from stainless steel grade A316 unless otherwise
approved by the Engineer.

e) Reinforcement shall be high strength deformed bars complying with Section

03200 of the specification.

5.7.9 Accessories

a) Compressible joint filler shall be closed cell PVC, SBR or Neoprene, either solid
or tube type, of proper dimension to serve as back-up for joint sealant at face of

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concrete masonry. Filler shall be an approved material meeting the required fire
rating if applicable.

b) Preformed control joints shall comprise solid rubber key section joint filler, 60 to
80 Shore A Durometer hardness, designed to maintain lateral stability in a
masonry wall. Corner and tee accessories shall be provided and the joints heat
fused.

c) Do not use control joint filler at building expansion joints.

d) Joint sealants shall be a one part, elastomeric, low modulus, silicone rubber
sealant. Joint sealant shall be an approved material meeting the required fire
rating if applicable.

e) Cavity vents shall have aluminium grilles and be insect resistant.

f) Flashings shall be manufactured from stainless steel grade A316 unless

otherwise approved by the Engineer.

g) Damp proof course shall comply with BS 6398.

h) Masonry work cleaning solution shall be non-acidic, not harmful to concrete

masonry work or adjacent materials.

5.7.10 Lintels

a) Concrete for lintels shall only be made from approved materials, in approved mix
proportions and at approved facilities.

b) Galvanised steel lintels may be used subject to the approval of the Engineer and
the sizes shall be as recommended by the manufacturer.

5.8 EXECUTION

5.8.1 General

a) Prior to the start of each major type of masonry work, meet at site and review the
installation procedures and co-ordination with other work. Meetings shall include
Contractor, Engineer and major material manufacturers as well as others whose
work must be co-ordinated with the masonry work.

b) Examine all parts of the supporting structure and the conditions under which the
masonry work is to be installed, and notify the Engineer in writing of any
conditions detrimental to the proper and timely completion of the work. Do not
proceed with the installation of masonry work until satisfactory conditions have
been corrected in a manner acceptable to the Engineer.

c) Ensure co-ordination between masonry work and concrete work such that all
inserts and flashing reglets required for the proper installation of masonry work

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are correctly pre-installed. Co-ordinate the masonry work with other building
works such as installation of window and door anchors.

d) Cutting of blocks shall be undertaken using a motor driven saw designed to cut
blocks with clean sharp corners.

e) Cut and fit for chases, pipes, conduit, sleeves and any other items. Co-ordinate
with other sections of work to provide correct size, shape and location.

f) Obtain approval prior to cutting or fitting masonry work not indicated or where
appearance or strength of masonry work may be impaired.

g) Take all necessary precautions to keep mortar, blocks and other materials cool
and in particular:

(i) Do not mix mortar or lay units while shade temperature is above 40oC on a
rising thermometer or above 43oC on a falling thermometer.

(ii) Do not allow temperature of fresh mixed mortar to exceed 32oC. Take
suitable measures to ensure this.

(iii) Do not lay masonry units having a film of water on their surfaces.

(iv) The Contractor will be deemed to have allowed for all steps necessary for
compliance with the above.

(v) Place a recording thermometer at each location of unit masonry work during
its construction.

h) Protection during progress of work.

(i) Protect masonry with polythene sheeting from direct exposure to the wind
and sun for 48 hours after construction.

(ii) Protect partially completed masonry walls against weather when work is not
in progress, by covering top of walls with strong, waterproof, non-staining
membrane. Extend membrane at least 600mm down both sides of walls and
anchor securely in place ensuring that there is free airflow sufficient to
prevent heat build-up.

(iii) Wet curing by direct application of water shall not be allowed.

i) Protection of completed work.

(i) Keep completed walls clean and protect from staining. Use suitable corner
guards to protect the corners of exposed masonry walls.

5.8.2 Masonry Construction

a) Comply with the manufacturer's printed instructions and recommendations for the
installation of each type of masonry product, unless otherwise shown or specified.
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b) Form chases and recesses as shown and as may be required for the work of
other trades. In select instances the Contractor may be allowed to chase hollow
blocks if approved by the Engineer. Do not cut horizontal or diagonal chases in
load bearing work. Provide not less than 200mm of masonry between chase or
recess and jamb of openings and between adjacent chases and recesses.

c) Leave openings for equipment as shown or required to be installed at later date.

Complete masonry work after equipment is in place using materials identical with
those immediately adjacent to the opening.

d) Step back unfinished work for joining with new work, toothing will not be
permitted. Before new work is started clean exposed surfaces of set masonry, wet
units lightly and remove loose blocks and mortar prior to laying fresh masonry.

e) Do not build in concrete blocks until at least 28 days after manufacture and until
they are fully cured.

5.8.3 Placing And Bonding

a) All blocks shall be laid in stretcher bond solidly bedded and jointed in masonry
mortar number 2. All block work joints above damp-proof course level shall be
raked back to a depth of 10mm and shall be pointed up after completion unless
the wall face is to be rendered as specified herein. Pointing externally shall give a
slightly recessed joint by using a jointer having a diameter slightly larger than the
mortar joint width. Pointing internally shall be flush. All work below damp-proof
course level shall be finished flush as the work proceeds. Joints in block work to
receive plaster or rendering shall be raked back.

b) All joints shall be 10mm nominal thickness. Horizontal joints shall be level and
vertical joints shall be aligned with jambs and other features and plumbed as the
work proceeds.

c) Blockwork shall be carried up in a uniform manner no one portion being raised at

one time more than 1m above another. All perpends, quoins, reveals and the like
shall be kept strictly true and square and the whole properly bonded together.

d) Cut blocks shall only be used where required for bonding purposes or to facilitate
building in of other components.

e) During laying blocks an open joint not less than 15mm wide shall be left between
the ends of all concrete lintels whether precast or cast in situ and blocks adjacent
to these ends. These open joints shall be left as long as possible during
construction and not filled in until plastering or other works render such filling
necessary. All such joints shall be properly filled in before the completion of the
work.

f) Jambs of opening in hollow block walling shall be built in solid blocks.

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g) The Contractor shall ensure that the finished walls are not damaged by
subsequent operations.

h) Where block work is to be constructed adjacent to concrete surfaces it shall be

tied to the concrete structure using stainless steel anchors shot fired or expansion
bolted to the concrete and built in every other course of block work.

5.8.4 Cavity Walls

a) Cavity shall be maintained at the width shown on the drawings or as specified.

b) Cavity shall be kept clean by efficient means throughout the construction of the
walls and any accidental mortar droppings shall be prevented from adhering to
cavity faces of walls, wall ties, cavity trays or insulation.

c) Wall ties shall be bedded a minimum of 50mm into each skin of walling and
spaced at 600mm vertically and 800mm horizontally. Additional ties shall be
provided within 200mm of sides of openings and at 400mm vertical centres. All
ties shall slope downwards and outwards.

d) Build inner skin ahead of outer skin to receive cavity insulation and air/vapour
barrier adhesive.

5.8.5 Reinforcement And Anchorage

a) Provide horizontal joint reinforcement and vertical reinforcement in all masonry

walls, unless specifically noted or specified to be omitted.

b) Vertical reinforcement shall comprise one 12mm diameter bar at 1m centres and
grouted full height. Bars shall be lapped by a minimum of 500mm.

c) Horizontal reinforcement shall be provided as follows:

(i) Spaced at 600mm centres for interior walls and 400mm centres for exterior
walls unless otherwise shown or specified.

(ii) Lap reinforcement a minimum of 150mm at ends and do not bridge control
and expansion joints with reinforcement except at wall openings.

(iii) Use matching prefabricated T and L sections of reinforcement at corners

and wall intersections to provide continuity.

(iv) Centre reinforcement in wall to provide a minimum mortar cover of 15mm to

reinforcement.

(v) Place masonry joint reinforcement in first and second horizontal joints
above and below openings. Extend minimum 400mm each side of opening.

(vi) Place joint reinforcement continuous in first and second joint below top of
walls.

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(vii) Reinforce joint corners and intersections with strap anchors at 400mm
centres.

5.8.6 Grouting

a) Grout used for filling cavities shall conform to the requirements given in the
specifications.

b) Use fine grout for filling cavities less than 100mm in one direction and coarse
grout for filling cavities 100mm and greater in both directions. Mortar shall not be
used for filling cavities.

c) At the Contractor's option, use either low-lift or high-lift grouting techniques

subject to the following requirements.

(i) Place vertical reinforcing before grouting and either before or after laying
blocks, as required by job conditions.

(ii) Support vertical reinforcing at 1m centres.

(iii) Where individual bars are placed after laying masonry, place wire loops
extending into cells as masonry is laid and loosen before mortar sets.

(iv) After insertion of reinforcing bar, pull loops and bar to proper position and tie
free ends.

d) Prior to grouting, clean and inspect grout spaces and close cleanout holes.

(i) Remove dust, dirt, mortar droppings, loose pieces of masonry and other
foreign materials from grout spaces.

(ii) Clean reinforcing and adjust to proper position as required.

(iii) Clean top surface of structural members supporting masonry to ensure

bond.

(iv) After final cleaning and inspection, close cleanout holes and brace closures
as required to resist grout pressures.

e) Do not place grout until entire height of masonry to be grouted has attained
sufficient strength to resist displacement of masonry units and breaking of mortar
bond. Install shores and bracing if required, before starting grouting operations.

f) Limit grout pours to sections which can be completed in one working day with not
more than one hour interruption of pouring operation.

(i) Place pour in lifts which do not exceed 1.2m.

(ii) Allow not less than 30 minutes and not more than one hour between lifts of
a given pour.

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(iii) Rod or vibrate each grout lift during pouring operation.

g) When more than one pour is required to complete a given section of masonry,
extend reinforcing beyond masonry as required for splicing.

(i) Pour grout to within 40mm of top course of first pour.

(ii) After grouted masonry is cured, lay masonry units and place reinforcing for
second pour section before grouting.

(iii) Repeat sequence if more pours are required.

h) Low lift grouting.

(i) Place vertical reinforcing prior to laying of masonry. Extend above elevation
of maximum pour height as required to allow for splicing. Support in
position.

(ii) Lay masonry to maximum pour height. Do not exceed 1.2m in height.

(iii) Pour grout using container with spout or chute. Rod or vibrate grout during
placing. Place grout continuously and do not interrupt pouring of grout for
more than one hour. Terminate grout pours within 40mm of top course of
pour.

i) High lift grouting.

(i) Provide cleanout holes in first course at all vertical cells which are to be
filled with grout.

(ii) Use units with one face shell removed and provide temporary supports for
units above or use header units with concrete brick supports or cut
openings in one face shell.

(iii) Construct masonry to full height of maximum grout pour specified prior to
placing grout.

5.8.7 Joints

a) Control joints.

(i) Install control joints in masonry walls where shown on the drawings.

(ii) Rake out mortar in preparation for application of sealant.

b) Control joint spacing.

(i) If control joint locations are not shown, place joints vertically spaced at each
structural column or joint between bays of the building but in no case
spaced more than 9m.

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(ii) Place vertical joints at points of natural weakness in the masonry work
including the following locations:

1. At locations where masonry wall height changes by more than 20%.

2. Above expansion or control joints in the supporting structure.

3. Where end of masonry wall butts against supporting structure.

c) Control joint construction.

(i) Form continuous control joints 10mm wide and build-in 40mm wide x
200mm long galvanised mild steel flats minimum 1.6mm thick at each
alternate course.

5.8.8 Masonry Flashings

a) Extend flashings horizontally at foundation walls, above ledge or shelf angles and
lintels, under parapet caps, at bottom of walls and where instructed.

b) Turn flashing up minimum 200mm and bed into mortar joint of masonry or seal to
concrete or otherwise as required.

c) Lap end joints minimum 150mm and seal watertight.

d) Turn flashing, fold, and seal at corners, bends, and interruptions.

5.8.9 Lintels

a) Provide masonry lintels wherever shown, and wherever openings in the masonry
of more than 300mm are shown without structural steel or other supporting lintels.
Provide reinforcement as shown on the drawings or as directed by the Engineer.

b) Provide minimum lintel bearing at each jamb of 100mm for openings which do not
exceed 1.8m width.

c) Precast lintels, or form lintels in place with adequate temporary support.

d) Cure precast lintels thoroughly before handling and installing.

e) Allow cast in place lintels to attain specified strength before removing temporary
supports.

5.8.10 Built-In Work

a) As work progresses, install built-in door and window frames, anchor bolts, plates,
and other built-in items.

b) Install built-in items plumb and level.

c) Do not build in organic materials subject to deterioration.

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5.8.11 Cleaning

a) During the completion of masonry installation and the tooling of joints, enlarge
any voids or holes and completely fill with mortar. Point up all joints at corners,
openings and adjoining work to provide a uniform, neat appearance, properly
prepared for the application of sealant compounds and other work to follow.

b) All exposed work shall be cleaned without the use of acid. Cleaning shall not be
done until mortar is thoroughly set and hard.

(i) Before wetting wall, remove large particles of mortar by means of wood
scraper, or if necessary by means of chisel or wire brush.

(ii) Pre-soak the wall, saturating the masonry with clean water and flush off all
loose mortar and dirt.

(iii) Using a stiff fibre brush only, scrub down the wall with a solution of 0.25 litre
household detergent and 0.25 litre of tri-sodium phosphate dissolved in 4
litres of clean water.

(iv) Thoroughly wash off all cleaning solution, dirt and mortar crumbs using
clean pressurised water.

(v) If after this cleaning procedure is completed the wall or portion of the wall is
not clean in the judgment of the Engineer, clean with an acid solution by
means and methods acceptable to the Engineer. If cleaned with an acid
solution, metal lintels and other material shall be thoroughly protected.

c) Particular care shall be taken to prevent smearing mortar on surfaces of concrete

masonry. If mortar smearing occurs, it shall be removed while soft, when
possible, if dry and hard, it shall be removed by rubbing with a small piece of
concrete masonry. All mortar smears, drippings, etc., on exposed faces of
concrete masonry units shall be removed.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 6

INSPECTION AND TESTING OF

PIPELINES AND STRUCTURES

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 6
INSPECTION AND TESTING OF PIPELINES AND
STRUCTURES

CONTENTS
6 INSPECTION AND TESTING OF PIPELINES AND STRUCTURES ................................ 1
6.1 CLEANING AND INSPECTION OF PIPELINES .......................................................... 1
6.2 TESTING OF PIPELINES ............................................................................................ 1
6.2.1 General ............................................................................................................... 1
6.2.2 Testing of Non-Pressure/ Low Pressure Pipelines ............................................... 2
6.2.3 Testing of Pressure Pipelines .............................................................................. 4

6.3 TESTING OF VALVES................................................................................................. 7

6.4 TESTING OF WATER RETAINING STRUCTURES .................................................... 8

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6 INSPECTION AND TESTING OF PIPELINES AND STRUCTURES

6.1 CLEANING AND INSPECTION OF PIPELINES

a) The Contractor shall ensure during and after construction that the pipes remain
clean and free of all silt, mortar, debris and other obstructions, and if required by
the Engineer, the pipelines shall be cleaned out using approved methods and
equipment which do not damage the internal lining of the pipes and manholes.
When work is not in progress the open ends of the pipeline shall be securely
plugged with an approved watertight plug or stopper to prevent the ingress of
deleterious matter into pipelines.

b) After backfilling pipe trenches and completing chambers, hatch boxes, etc., and
before the trench surfaces are reinstated, the interior of pipelines shall be cleaned
of silt and debris by approved methods for inspection by the Engineer's
Representative as follows:

c) All newly constructed pipelines of 600 mm (nom.) internal diameter and smaller
shall have a loose plug passed through them to show that they are clear of
obstruction and free from deflection. The loose plug shall be dimensioned to suit
the permissible minimum deflected diameter of the pipe. Alternately, a
deflectometer capable of measuring diametric dimensions both vertically and
horizontally may be used.

d) All newly constructed pipelines greater than 600 mm (nom.) internal diameter will
after cleaning be inspected from the inside and the Contractor shall provide a
suitable trolley for this purpose.

e) All renovated or replaced pipeline shall after cleaning, be inspected from the
inside using CCTV inspection, as directed by the Engineer.

f) In addition gravity pipelines or sewers shown as straight lines between manholes

on the drawings shall be subjected to a light sighting test as detailed in the pipe
laying specification Clause.

g) Pipelines, manholes, chambers/structures will be inspected again before being

put in service or taking over (whichever is sooner) and if required by the
Engineer's Representative shall be cleaned again in whole or in part by suitable
means which may include, if directed, flushing with clean water.

6.2 TESTING OF PIPELINES

6.2.1 General

a) The Contractor shall make his own arrangements for the supply of water used for
testing and cleaning of pipelines which shall be obtained from a source approved
by the Engineer. All water required for testing and cleaning shall be provided by
the Contractor at his cost.

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b) Prior to commencement of flushing or testing, approval shall be obtained to the

methods and programme for testing and to the method of disposal of all fluids
used for flushing or testing purposes. Under no circumstances will permission be
given for the discharge of such fluids into the existing sewerage system.

c) If permission is given to use new or existing pipelines or culverts which are not
part of a live system, they shall be thoroughly cleaned of all silt and any resulting
damage made good after use.

d) If lagoons for the storage of such fluids are permitted, they must be suitably
protected with fencing and attended by day and night to prevent access by the
general public and will not be sited adjacent to buildings. Approved means of
preventing the formation of mosquito larvae on the surface of the lagoons shall be
employed.

e) Testing of pipelines shall in all cases be applied in the presence of the Engineer's
Representative. The Contractor shall notify the Engineer at least 48 hours in
advance of his intention to test a section of pipeline. The Contractor, at his own
expense, shall provide complete plant and all struts, thrust blocks, etc., as may be
necessary for effectively testing the pipelines to the specified pressures.

f) Pipelines shall be properly completed and supported before being put under test.
No testing will be permitted until seven days after thrust blocks and other holding
down works have been completed.

g) For both gravity and pressure pipelines only testing of new, renovated, or
replaced sections of pipelines and fittings will be required under the Contract, in
accordance with this Specification, unless detailed otherwise. Such testing will be
carried out before making final connections to the existing network. However
where tees or other fittings are inserted into existing pipelines and where lengths
of pipeline are replaced, no backfilling will be allowed at the tees or fittings or at
the joints between new and existing pipework until the pipeline has been returned
to service and a visual inspection of all such fittings and joints made at the
network pressure.

h) Should any inspection be unsatisfactory or any test fail the Contractor shall
replace defective pipes, leaking joints or otherwise reconstruct defective work as
instructed following which cleaning and testing will be repeated until the
Engineer's Representative certifies the pipeline to be satisfactory.

6.2.2 Testing of Non-Pressure/ Low Pressure Pipelines

a) Non pressure/ low pressure pipelines of all sizes shall be tested for joints by Air
test as specified in this section.

b) Non pressure/ low pressure pipelines of 900 mm nominal diameter or smaller

shall be given a preliminary air test when the pipeline is bedded and jointed

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before backfilling and a final water test after backfilling in the presence and to the
satisfaction of the Engineer.

c) Water tests will not normally be applied to non-pressure pipelines greater than
900 mm (nom.) internal diameter and acceptance of these pipelines will be
dependent on satisfactory visual test of the joint for infiltration of the pipes and
joints.

d) Unless otherwise instructed non-pressure pipelines shall be tested in sections

between manholes.

e) Air Test (Preliminary Test)

After a length of pipeline is bedded and jointed, and before backfilling, it shall be
given a preliminary test as detailed below:

1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.

2. Air shall be pumped in slowly to the pipe until a pressure of 100 mm

head of water is indicated on a manometer connected to the system.

3. After the internal pressure of 100 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.

4. Air may be added to restore the pressure to 100 mm.

5. During a further period of 5 minutes (without further pumping of air) the

pressure should not fall below 75 mm.

6. Release of the air pressure shall be carried out by removal of the

stopper at the end of the pipeline away from the manometer which will
remain connected. Failure to carry out the air pressure release in this
manner shall render the test invalid.

7. The Contractor will not be permitted to commence testing later than 4

hours after sunrise or earlier than 4 hours before sunset during the
summer period unless otherwise directed by the Engineer.

f) Water Test (Final Test)

After backfilling the length of pipeline under test, it shall be given the following final
test:

1. All branches and open ends shall be closed with suitable stoppers,
secured with longitudinal braces before testing commences.

2. Water shall be filled from the lowest point and air allowed to escape. No
entrapped air shall remain in the pipeline while testing.

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Drainage and Irrigation Department

3. An internal pressure equivalent to a head of water of depth to invert of

the pipeline plus 1.25 m, or 4 m head whichever is greater shall be
maintained for 30 minutes to allow for initial absorption of water.

4. After that, the test pressure shall be maintained for 60 minutes and
water added shall be measured.

5. Pipeline shall be treated as passed if water consumption in 60 minutes

does not exceed 7.5 litres per metre of diameter per 30 m of length of
pipeline under test.

g) Where in the opinion of the Engineer's Representative the above test is not
sufficiently indicative of water tightness by reason of high ground water levels the
test will not be applied. Acceptance of the pipelines will then depend on
satisfactory inspection or testing for infiltration as referred to below, and air test of
the pipeline in manhole lengths.

h) The Engineer may require any length of pipe suspected of being damaged to be
retested by the water test at any time during the contract period.

i) Infiltration Test

After completion of backfilling and restoration of normal subsoil conditions, all gravity
pipelines and manholes shall be examined for infiltration as follows:

1. All inlets to the system shall be closed sufficiently to prevent the

entrance of water.

2. Pumping of groundwater shall be discontinued for at least 3 days prior

to the test for infiltration.

3. The section of the pipeline under test, including manholes, shall be

accepted as satisfactory if the infiltration does not exceed 1.00 litre per
day per metre of pipeline per metre of nominal internal diameter.

j) Notwithstanding the satisfactory completion of the infiltration test, if there is any

discernible flow of water entering the pipeline at a point which can be located
either by visual or closed circuit television inspection, appropriate measures shall
be taken to stop such infiltration.

6.2.3 Testing of Pressure Pipelines

a) Pipelines shall be subjected to a preliminary air test as soon as a length of pipe

has been laid and before backfilling. Pressure pipelines shall then be given a
final test using water after they have been backfilled, cleaned and inspected.

b) Individual joint tests, by means of an approved joint testing apparatus, may be

used for pipes of 1200 mm diameter and above subject to the approval of the
Engineer.
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c) Each joint shall be individually water tested by means of an approved joint testing
apparatus at a pressure of 100kN/m2. The test will not be considered satisfactory
if the loss of pressure during a test period of 30 minutes exceeds 10kN/m2 as
indicated by an approved pressure gauge having a range of 0 – 150 kN/m2.

d) Preliminary pressure testing of pipelines may be carried out if so required by the

Engineer with partial backfill only and exposed joints, but the stability and safety
of the Works must be ensured at all times.

e) Each test shall be restricted to pipes of one class. Pipelines shall be tested in
sections not exceeding 500 metres or between valve positions. In addition the
whole pipeline shall be tested upon completion. Particular care must be taken to
isolate air valves, etc., not to apply higher pressure than specified at any point on
the pipelines and to ensure that the pipelines are adequately anchored before any
test is carried out.

f) Gauges used for testing pressure pipelines shall be capable of reading

increments of 0.1 metre head. Before any pressure gauge is used, the Contractor
shall arrange for it to be checked independently and a dated certificate of its
accuracy shall be provided to the Engineer. Calibration of pressure gauges shall
be carried out at regular intervals as required by the Engineer

g) Air Test (Preliminary Test)

As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary test:

1. The Contractor shall plug all pipe outlets with suitable plugs, and brace
each plug securely where needed.

2. Air shall be pumped in slowly to the pipe until a pressure of 300 mm

head of water is indicated on a manometer connected to the system.

3. After the internal pressure of 300 mm is obtained, two minutes shall be

allowed for the air temperature to stabilize within the pipe.

4. Air may be added to restore the pressure to 300 mm.

5. The test will not be satisfactory if the air pressure falls to less than 275
mm during a period of 5 minutes without further pumping of air.

h) Water Test (Final Test)

i) Pressure pipelines shall be given the following final test using water after they
have been backfilled, cleaned and inspected:

1. All the joints of the pipeline shall be left open for the purpose of
inspection for leakage if any, where practicable or instructed by the
Engineer.
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2. Pipe ends shall be closed with suitable stoppers, secured with

longitudinal braces/thrust block, before testing commences.

3. Water shall be filled slowly from the lowest points and air allowed to
escape through an air vent fixed for the purpose at the highest points of
the pipeline section under test. No entrapped air shall remain in the
pipeline while testing.

4. Pressure in the pipeline shall then be raised steadily up to and

maintained at the rated pressure for a period of 30 minutes to allow for
absorption and achieve conditions as stable as possible for testing.

5. If no leakage has been observed, pumping shall then be resumed and

the pressure slowly raised to the specified test pressure.

6. Unless specified elsewhere or directed otherwise by the Engineer. The

minimum site test pressure shall be:

a. Reinforced Concrete Pipeline =1.5 x Maximum working pressure

of pipe line (or) 9 bar pressure whichever is higher

b. GRP Pipe lines =1.5 x Maximum working pressure

of pipe line (or) 9 bar pressure whichever is higher.

c. HDPE & P.P Pipe lines = 1.5 x maximum working pressure

of pipe line minus the deration factor above 25°C temperature at the
time of testing.

d. UPVC Pipe line =1.5 x maximum working pressure

of the pipe line minus the deration factor above 25°C temperature at
the time of testing.

e. Stainless steel Pipeline =1.5 x maximum working pressure

of the pipe line

f. D.I. Pipelines =1.5 x maximum working pressure

class of the pipe line

Note: (1) Below noted graph shall be used to calculate the derating factor.
(applicable only for thermoplastic pipes) . This shall be verified from the
manufacturer’s data.

(2) The maximum working pressure of the Pipeline shall be as specified. Pipes shall
be tested at site after installation at test pressure.

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Figure 1: Graph of Derating Factor fT for Derating up to 45°C

7. Pressure in the pipeline shall be checked after a period of 60 minutes

and test pressure shall be restored by the use of the pump. The amount
of makeup water required to maintain the pressure shall be accurately
measured (to the nearest 1/8 litre).

8. Pipeline shall be deemed to have passed the test if all the following
conditions are satisfied:

a. No water is visible coming out of the pipe or joints at any point;

b. Amount of make-up water required does not exceed 1 litre per hour
per 100 mm diameter per kilometre of pipeline under test;

c. The loss of the pressure during the test period does not exceed
70KN per square metre.

6.3 TESTING OF VALVES

Valves and all pipelines appurtenances shall be hydraulically tested together with the
pipeline in which they are installed. Valves shall be tested for operation under working

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pressure and shall be adjusted so that they operate smoothly, seat properly and are
installed to tolerances recommended by the manufacturer.

6.4 TESTING OF WATER RETAINING STRUCTURES

a) All water retaining structures shall be visually inspected to confirm that there is no
infiltration. Where it is required by the Engineer, water retaining structures shall
be tested for water tightness.

b) The Water test for liquid retaining structures shall be tested as described below.

(i) ‘For a test of liquid retention, the structure should be cleaned and initially
filled to the normal maximum level with the specified liquid (usually water) at
a uniform rate of not greater than 2 m in 24 h. When first filled, the liquid
level should be maintained by the addition of further liquid for a stabilizing
period while absorption and autogenous healing take place. The stabilizing
period may be 7 days for a maximum design crack width of 0.1 mm or 21
days for 0.2 mm or greater. After the stabilizing period the level of the liquid
surface should be recorded at 24 h intervals for a test period of 7 days.
During this 7-day test period the total permissible drop in level, after
allowing for evaporation and rainfall, should not exceed 1/500th of the
average water depth of the full tank, 10 mm or another specified amount.
Notwithstanding the satisfactory completion of the test, any evidence of
seepage of the liquid to the outside faces of the liquid-retaining walls should
be assessed against the requirements of the specification. Any necessary
remedial treatment of the concrete, cracks, or joints should, where
practicable, be carried out from the liquid face. When a remedial lining is
applied to inhibit leakage at a crack it should have adequate flexibility and
have no reaction with the stored liquid. Should the structure not satisfy the
7-day test, then after the completion of the remedial work it should be
refilled and if necessary left for a further stabilizing period; a further test of 7
days’ duration should then be undertaken in accordance with this clause.’

(ii) Or otherwise specified by the Engineer.

c) The roofs of the liquid retaining structures shall be tested & shall comply as
described below.

(i) ‘The roofs of liquid-retaining structures should be watertight and should,

where practicable, be tested on completion by flooding the roof with water to
a minimum depth of 25 mm for 24 h or longer if so specified. Where it is
impracticable, because of roof falls or otherwise, to contain a 25 mm depth
of water, the roof should have water applied by a continuous hose or
sprinkler system to provide a sheet flow of water over the entire area of the
roof for not less than 6 h. In either case the roof should be considered
satisfactory if no leaks or damp patches show on the soffit. Should the
structure not satisfy either of these tests, then after the completion of the
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remedial work it should be retested in accordance with this clause. The roof
insulation and covering should be completed as soon as possible after
satisfactory testing.’

d) The test shall be carried out before any backfilling and before the application of
any internal and external concrete protection or roof membrane has taken place.
Any damages revealed as a result of such tests shall be made good to the
satisfaction of the Engineer.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 7

CORROSION PROTECTION AND SURFACE COATING

DM/DNID Section 7 Corrosion Protection and Surface Coating Rev 00 June

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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 General Specifications for Civil Works
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SECTION 7
CORROSION PROTECTION AND SURFACE COATING

CONTENTS
7 CORROSION PROTECTION AND SURFACE COATING ................................................ 1
7.1 MATERIALS .................................................................................................................. 1
7.1.1 Corrosive Environment and Corrosion Protection System ................................... 1
7.1.2 Paint ...................................................................................................................... 2
7.1.3 Impervious Tanking Membrane ............................................................................ 2
7.1.4 PVC Sheet Lining Materials .................................................................................. 2
7.1.5 Glass Reinforced Plastic Liners ............................................................................ 3
7.1.6 In-situ GRP Laminations ....................................................................................... 6
7.1.7 Epoxy Mortar for Manholes ................................................................................. 20
7.1.8 Rubberised Bitumen Emulsion ........................................................................... 21
7.1.9 Waterproof Paper ............................................................................................... 22
7.1.10 Protective Materials for Wrapping Pipeline Components ................................... 22
7.1.11 High Density Polyethylene Protection Sheet ...................................................... 22
7.1.12 Protective Coating with Cementitious Water Proof Coating................................ 22
7.1.13 Approved Paint Suppliers ................................................................................... 23
7.1.14 In-situ GRP Lamination with Grit bonding on final finish coat ............................. 24
7.1.15 Epoxy Coating .................................................................................................... 24

7.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO

CONCRETE ................................................................................................................. 25
7.2.1 General ............................................................................................................... 25
7.2.2 Water Proof Membranes/Liners/Roof Waterproofing and Protective Coatings... 25
7.2.3 GRP Prefabricated benching unit for Sewer Inspection Chambers .................... 39
7.2.4 Cutting and Sealing of Reinforced Liners ........................................................... 39
7.2.5 Protective Coatings to Concrete Works .............................................................. 40
7.2.6 Coating System for Ferrous, Non Ferrous Metals and Plastics .......................... 46

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7 CORROSION PROTECTION AND SURFACE COATING

7.1 MATERIALS

7.1.1 Corrosive Environment and Corrosion Protection System

Corrosion protection systems and surface coatings shall in all cases be suitable for
exposure to their contact with environmental conditions which may include any or all
of the following:

a) The average climatic conditions prevailing in the project area with particular
emphasis on temperature variations, high surface temperatures and high humidity.
The following table presents the average climatic conditions exist in Dubai:

Table 7.1 – Average Climatic Conditions in Dubai

Maximum Ambient Temperature 52ºC

Minimum Ambient Temperature 1ºC

Max. incident light intensity (energy) 50ºC

Light intensity (measured under the sun) approximately 50,000 Lux

Maximum metal temperature under the sun 85ºC

Min. Barometric Pressure 998 mb

Max. Barometric Pressure 1030 mb

Average Barometric Pressure 1015mb

Max. Ambient Humidity 100%

Min. Ambient Humidity 20%

Design Ambient Humidity 80%

Max. Design Wind Velocity 160 km/hr

Average yearly Rainfall 80 mm

i. The climate of Dubai is relatively mild from November to April, and hot from May
to October with high relative humidity.

ii. Under certain combinations of the above climatic conditions considerable

condensation may take place.

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iii. A considerable amount of salt is contained in the atmosphere, which together

with the extremely high ambient humidity can produce severe corrosion problems.

iv. Distribution of rainfall is irregular, and the precipitation amounts are normally of
no significance, but attention should be paid to the fact that sudden heavy rain falls in
a very short period of time can occur.

v. The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr and sandstorms and dust-
storms occur in the summer months.

b) Sea water with a pH value of 7 to 9 and maximum salinity upto 40,000 ppm.

c) Saline groundwater with high chloride or sulphate contents both below the water
table and in soil zones above the water table where capillary action and the presence
of oxygen may cause extremely severe conditions.

d) Windblown chlorides

e) Windblown abrasive sands

7.1.2 Paint

a) Protective and decorative paint systems including primers and undercoats shall
be obtained ready mixed for use. All containers of paints and other coating systems
shall show date of manufacture, shelf life and pot life where applicable. Paint shall be
applied as per Clauses in section 7.2.

b) The Contractor shall only be allowed to use paints which are delivered to the site
in sealed cans or drums bearing the name of the manufacturer and properly labelled.

c) Tints and shades of final coats shall be advised by the Engineer or his
Representative.

7.1.3 Impervious Tanking Membrane

Membrane used for tanking to concrete structures shall be impervious, self-adhesive

and covered with a release agent.

7.1.4 PVC Sheet Lining Materials

a) PVC sheet materials to be used for lining concrete structures and pipelines
internally shall be manufactured from polyvinyl chloride, plasticisers and pigments to
make permanently flexible sheets.

b) The colour of the sheet shall be approved on site.

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c) The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed
by extrusion to have on one side locking keys or ribs of either 'T' or diamond section
at centres not greater than 75 mm. It shall be capable of forming a continuous 100%
effective seal with the use of welding strips or other approved method and shall be
supplied with all materials and tools for making the joints.

d) The tensile strength of the material shall not be less than 17,000 kN/m2.

e) All weld strips, patches and other sheets used in the permanent fixing of the
ribbed sheet shall be of a material having the same composition as the ribbed sheet.

7.1.5 Glass Reinforced Plastic Liners

a) Glass Reinforced plastic liners to be used for lining water retaining structures,
pumping stations and manholes shall be manufactured to the dimensions given on
the Drawings, within the following tolerances:

1. The work size, which is defined as internal diameter as specified by the

manufacturer, shall be declared and shall not differ from the normal diameter by more
than ±1%.

A manufacturing tolerance on the work size of 10 mm will be allowed provided

that a tight fit is achieved between the liner and the slab liner.

2. Liners shall be supplied in lengths to suit requirements with a resin ¬rich finish to
internal surfaces.

3. Maximum thickness shall be 7 mm for required works as specified. Liners larger

than 2000 mm in diameter shall have a minimum wall thickness of 9 mm.

4. The out of squareness shall not be greater than 10 mm.

5. The deviation from straightness of the bore of the liner shall not exceed 20 mm.

b) Although the liners are not designed to be structural, they shall have a sufficient
stiffness to withstand:

1. Buckling or distortion in transit or storage.

2. A hydrostatic head of 8 metres without distortion damage, leakage or

permeation.

3. Grouting pressures.

c) Prior to grouting of the manhole liner at least 24 hours shall be allowed for
temperature equalization between the manhole structure and the reinforced plastic
liner.

d) The manufacturer shall provide shop drawings of the proposed top slab liners
prior to manufacture for approval.

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e) The manufacturer shall stipulate the maximum deflection of the slab liner
permitted without causing surface cracking to the gel coat. The Contractor must take
care not to exceed this limit, and any surface cracking that occurs will be repaired.

f) The construction methods employed shall be so as to ensure that a completely

water and gas tight seal is made preventing any exposure of the concrete surround to
the corrosive liquids and gases present, in the sewage.

g) In particular:

1. Glass Reinforced plastic liners shall be handled in the same manner as glass
reinforced plastic pipes. In addition, extra care shall be taken to avoid damage to the
liners which are not designed to carry loads.

2. The manufacturer shall visit the site to demonstrate to the Contractor in the
presence of the Engineer's Representative the methods of handling and lifting,
including formation of the joints between the chamber liners.

3. The Contractor is reminded that these liners are not designed to withstand
pressure exerted by the concrete during construction.

4. The design of GRP liners to provide a permanent internal shutter, to the concrete
structures shall be the responsibility of the liner manufacturer. The design should
however incorporate all the requirements of these Specifications.

5. The liner shall be designed to provide protection for concrete for 50 years from
the corrosive effects of raw sewage/ sea water or other liquid in temperature up to
50°C. The GRP liners shall be machine made filament wound and of similar material
(except sand filler) construction and manufacturing process as for the GRP pipe.

h) Chemical Requirements

The liner design shall qualify the chemical requirements specified in ASTM D3753.

1. Testing shall be performed in accordance with the chemical test method.

2. The log percentage property retention versus log of time data graph should be
extrapolated by a linear plot beyond the 12 months result to 10,000 hours. The
extrapolated data must assure retention of at least 50% of the initial properties.

i) Chemical Test Method

Testing procedures for measuring chemical resistance shall conform to ASTM C581
with the exceptions as noted below:

1. Test Laminate Construction: The basic test coupon shall be cut from a laminate
made in a manner consistent in every way with manhole construction.

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2. Test Intervals: Coupons shall be drawn and tested after 1 month, 3 months, 6
months, and 12 months immersion in each test medium. It may be advisable to
include extra coupons at the time of the initial immersion in the event it is necessary
to extend the test interval beyond 1 year to 10,000 hours.

3. Test Media: The test media shall represent as completely as equal to the actual
environment in the manhole service. In that respect, test medium shall be the material
as specified for chemical resistance for sewer manholes.

4. Test Temperature: The test temperature of test medium used in corrosion

resistance verification of manhole containing that medium (normally this shall be
50ºC).

5. Interpretation of Results: Laminate properties to be determined initially and after

each test period are flexural strength, flexural modulus (both as per ASTM D790) and
the Barcol hardness as per ASTM D2583) of both interior and exterior lamination. The
laminate should be fully cured before initial properties are obtained. Any effect up on
the immersion medium or laminate observed during visual inspection shall be noted.
The log percentage retention after immersion testing (verses initial) is to be plotted
against the log of immersion time in hours.

j) Quality Control Testing

The following test shall be carried out as detailed below:

1. Composition Test: A loss on ignition test shall be carried out once every 100m of
shaft produced. Conduct the test as per ASTM D2584 and determine the glass/resin
ratio. Controls on glass and resin content must be maintained for all manufacturing
process and for each portion of manhole fabrication. Record shall be maintained of
these control checks.

2. Barcol Hardness: Each manhole component part shall be tested in accordance

with ASTM D2583, standard method of test for Indentation Hardness of plastics by
means of a Barcol Impressor. The minimum acceptable value of cure shall not be
less than 90 percent of the resin manufacturers’ minimum value for the cured resin.

3. Thickness: Wall thickness of each manhole component part shall be checked

with a micrometer caliper gauge, or other suitable instrument to establish the actual
thickness.

4. Appearance (Interior and Exterior Surfaces): The following defects are not
permitted.

(a) Crazing (b) Delamination (c) Blisters (d) Fiber show (e) Surface pits and voids
directly beneath the surface of the laminate and on the surfaces (f) Dry spots (g)

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Pimples (h) Pit or pinhole (i) Resin pocket (j) Deep scratches (k) Impact cracks (l)
Fish eye (m) Worm holes (n) Deep wrinkles.

k) Certification

When requested, a certification shall be made on the basis of acceptance. This shall
consist of manufacturers test report accompanied by copy of test results, which the
GRP liner has been sampled, tested and inspected, in accordance with the previsions
of this specification and meets all requirements. Each certification shall be signed by
the manufacturer.

l) Cutting and Sealing of Reinforced Liners

1. Where the Contractor is required for any reason to cut reinforced plastic liners,
he shall seal the exposed ends with an approved resin before incorporating the cut
reinforced plastic in the work. No cut reinforced plastic shall be used until the resin
has cured.

2. The resin shall be as recommended by the manufacturer of the reinforced plastic

item and shall be pigmented so that the areas where it has been applied are easily
identifiable.

3. It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labeled as to its content and shelf life.

4. For flexible pipe materials a rubber protection strip shall be inserted between the
pipe barrel and the steel band.

7.1.6 In-situ GRP Laminations

a) General

This Clause shall cover all in-situ GRP lamination work to be carried out under the
Contract as corrosion protection. It shall include site work related to jointing of
prefabricated reinforced plastic components e.g. manhole liners, GRP pipe sleeves,
lamination work to benchings and channels, sealing of pipe entries, lamination work
to internal concrete faces of major concrete structures, pumping stations, valve
chambers, air valves and washout chambers etc as shown in the approved drawings.

b) Site Operatives for GRP Work

1. The In-situ GRP lamination work shall be carried out only by the DM approved
laminators. All lamination work must be carried out by skilled operators under the
supervision of a worker with a minimum of 10 years experience in in-situ lamination.

2. The Contractor shall only employ personnel who have received suitable training
and possess relevant experience in the execution of any in-situ GRP work, including

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lamination work and the cutting, sealing and jointing of reinforced plastic. Site
operatives for employment on this work shall be certified in writing by the supplier or
Contractor as trained to a satisfactory standard in application techniques.

3. Such personnel will be subject to approval by the Engineer prior to the

commencement of such work. Approval will include site trials to demonstrate
competence to undertake the work.

4. GRP Applicator’s Special Requirements

The company doing the GRP lamination work should have:

i. A Safety Manual ‘For Guide to Making a Laminate, Planning and Maintaining the
Work area’

ii. An automatic master and batch mixer with agitator

iii. A mobile storage (fire-proof) vehicle with steel container having AC, exhaust fan
inside for storing the resin and glass and the master batch resin mixer.

iv. Automatic resin discharge pump system and spray facilities to feed the resin
from master batch mixer into the laminated work area to achieve a uniform resin
mixing and dispensing during lamination period.

v. In-situ testing apparatus to carry out the following quality control tests.

– Barcol impressor Nr. 934-1 with sufficient numbers of calibrating shim.

– Digital elcometer thickness gauge with calibration shim

– Pull off adhesion tester with sufficient numbers of dolly.

– Holiday detection spark tester recommended by the resin manufacturer

– Relevant hammer for hammer test

vi. Safety arrangements to keep inflammable catalysts with fire hydrant in working
condition.

vii. Services of an efficient technician at site to mix the resin in desired proportion to
suit the variable working temperature condition at site.

viii. AC room facilities for bulk storage of resin drums and glass mat rolls in an
isolated place.

ix. first aid facilities and the services of a safety engineer at site.

x. Sufficient numbers of powerful exhaust fan at working area to clear out the
styrene gas.

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xi. Breathable air inlet facilities for the workers at site

xii. Safety harness for each labourer working on site.

c) Method Statement

1. All in-situ lamination must be carried out in accordance with an approved

detailed method statement. This shall include details of all materials to be used
together with the manufacturers’ names, addresses and specification sheets.
Particular details of procedures relative to separate categories of work as given
above shall be itemised separately.

2. If materials are to be stored on site then details shall be provided of the store in
which the materials are to be kept, the environmental controls which will be used to
ensure materials are stored in accordance with manufacturers’ recommendations and
the control and security arrangements necessary to prevent unauthorised tampering
with materials.

3. If materials are to be brought to site on a daily basis from the supplier’s central
store in site containers then details shall be provided of the type, size and
identification markings on each container to be used for this purpose. The Contractor
shall indicate the controls to be set-up to ensure that different resins and materials
are clearly identifiable at site. The method statement shall include forms to be
submitted to the Engineer which will be necessary to record the decanting of
materials from manufacturers containers to site.

d) Materials in GRP Lamination

Table 7.2 – Materials in GRP Lamination

1 Type of resin to prime Epoxy based vinyl ester resin having minimum 8%
the concrete surface elongation property
2 Type of glass (csm) Powder bound ECR/Advantex fiber glass ‘csm’
throughout the having excellent corrosion resistance to acids
lamination
3 Type of ‘C’ glass tissue ‘C’ glass of ECR type having excellent corrosion
for final layer resistant to acids
4 Recommended catalysts 1. BUTANOX LPT
to prepare resin at site 2. MEKP LA 3
5 Type of resin throughout Epoxy based vinyl ester
the lamination

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Table 7.3 Typical Room Temperature Clear Casting properties of VE Resin

Tests Epoxy Resin Epoxy Resin Method of Analysis

Primer

Tensile Strength MPa 81 70 ASTM D-638

Tensile elongation at 5 8 ,, D-638
yield%
Tensile modulus GPa 3.3 3.1 ,, D-638
Flexural strength MPa 124 135 ,, D-790
Flexural modulus GPa 3.1 3.2 ,, D-790
Compressive Strength 114 86 ,, D-695
MPa
Compressive Modulus 2.4 2.2 ,, D-695
GPa
Compressive deformation 6 6 ,, D-695
at yield%
Specific Gravity 1.12 1.13
Average coefficient of 65 70
expansion between 25
and 100ºC X10-6 cm
cmºC
Izod impact J/m 22 250 ,, D-256
Heat distortion temp ºC 102 80 ,, D-648
Barcol Hardness 35 40 Barcol impresser
model 934 -

Table 7.4 Typical Properties of Liquid Resins

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Property Epoxy Resin Epoxy Resin Primer

Styrene Level % 45 40
Brook field Viscosity MPa 500 350
at 25ºC
Flash point ºC Tag open 34 32
cup
Specific Gravity uncured at 1.04 1.04
25ºC
Acid number maximum 8.5 10
Storage stability (months) 6 3

Table 7.5 Physical Properties of ECR / Advantex Glass Fibres

Property Test Method Unit ECR/Advantex

Density ASTM D1505 g/cc 2.62
Refractive index Oil Immersion 1.560-1.562
Thermal linear ASTM D696 Ppm/C 6
expansion 0 -
300ºC
Softening point ASTM C338 ºC 916
Annealing point Parallel Plate ºC 736
Viscometry
Strain point Parallel Plate ºC 691
Viscometry

Table 7.6 ECR/Advantex Single Filament Tensile Properties

Property Test Method Unit ECR/Advantex

Tensile Strength ASTM D2101 MPa Kpsi 3100-3800 450-550
@23ºC
Elastic Modulus Sonic Method GPa MPsi 80-81 11.6 – 11.8
Elongation at the ASTM D2101 % 4.6
Breaking Load

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4. The method statement shall also provide details of the material build up or layup.
It shall state the number and type of layers of glass fibre reinforcement together with
the resin used to impregnate it. Proposed layup shall be not less than the
requirements detailed in this Clause.

5. The method statement shall also detail the Contractor’s safety proposals with
respect to this work to demonstrate compliance with his obligations under the
Contract, for each type of work location.

6. Surface preparation

i. The concrete surface must be fully cured and older than 4 weeks.

ii. Before commencing work surfaces must be cleaned down, suitably prepared and
allowed to dry. Under no circumstances must the laminate be applied in dirty, damp
or wet conditions.

iii. Once dry, no water should be allowed into the structure except that required for
safety reasons.

iv. Concrete surfaces must be clean, sound, dry and dust free. Any surface
laitance, loose or unsound concrete etc shall be removed. Surfaces must be entirely
free of oil, grease, paint, detergents, rust, biological or other surface contaminants.
Surfaces shall preferably be prepared by high pressure water jetting, pneumatic
scabbling, grinding or steel grit blasting, followed by thorough brushing with a clean
paint brush (used only for this purpose) or by washing to remove dust and remaining
particles and to provide an exposed aggregate finish to ensure a mechanical key to
the laminate. Diesel, oil and grease contaminants shall be removed and rinsed
thoroughly with water by steam cleaning, detergent scrubbing or the use of
proprietary degreaser. Effectiveness of decontamination may, on the instructions of
the Engineer, require to be assessed by a pull-off test. The hardened condition of the
concrete substrate is to be subjected to hammer test by tapping on concrete and
make sure any hollow sound is not produced. The defective concrete is to be
removed and make good and allow the surface to dry condition.

v. Prior to application, all active hydrostatic leaks must be stopped by the use of an
appropriate approved material specifically formulated to stop the ingress of water.

vi. Where the laminate will be in contact with the surface or edges of uPVC pipes or
existing GRP laminates, liners, pipe or fittings the contact surface shall first be
roughened by grinding or wire brushing. The contact surface for benching
lamination extending within GRP pipes shall be accurately feather ground from 0 to 7
mm over a length of 150 mm. All dust shall be removed as above.

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vii. Grinding shall be carried out to limits neatly defined by masking tape or other
approved means. Measures shall be taken to prevent damage to surfaces outside
such limits by the use of appropriate masking devices etc.

viii. On concrete surfaces of major structures, base slab wall and roof slab: -

ix. After completed two layers of GRP lamination work, SS 316 grade hilty nails are
to be shot into the concrete by the help of a shotgun at 60 cm intervals to achieve a
proper key in interlock between the concrete surface and the GRP lamination work.
Further layers of lamination work shall be continued after the nail fixing.

x. Particular care is needed in preparation to ensure that the correct laminate

thickness will be maintained over nosings to the arris between horizontal and vertical
parts of the benching, including removal of concrete as necessary.

xi. Following after obtaining engineer’s approval for the GRP materials a trial
lamination work to a size of 1.2M x 1.2M shall be carried out on concrete surfaces of
any one of the structures and conduct the followings Pre qualification test. These
trials shall be carried out using the approved type of materials, mixing procedures and
applications as will be used on the Contract.

Table 7.7 Trial Sample and Pre qualification Test on GRP Lamination Work

Sr. Test Test method Minimum Test Requirements

1 100 days acid ASTM C581 Test sample shall not show
immersion test @10% any defects as mentioned in
concentrated sulfuric relevant standard
acid at 50ºC
2 Flexural strength of ASTM D790 193 MPa
GRP laminate sample
3 Tensile strength of GRP ASTM D639 138 MPa
laminate sample
4 Pull off adhesion ASTM D 4541 Pulling strength shall be
strength of lamination greater than concrete
5 Resin / Glass ratio ASTM D 2584 60:40
6 Resin cure Barcol Impressor Minimum : 33 Barcol reading
934-1 in accordance with the
manufacturer’s test
procedure specified.
7 Thickness of Lamination Digital Elcometer Not less than the specified
thickness

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8 Holiday Detection Test 105 DC high voltage Air bubble / voids free
0-10 to 20 kV surface on final lamination
Holiday Detector
9 Surface Quality ASTM D 2563 Quality level ‘2’ as specified
in relevant standard
10 Acetone Sensitivity test Resin Tack free surface on GRP
manufacturer’s lamination
recommended test
11 Hollow sound detection Hammer test No hollow sound on
completed lamination work.
Note:
1. All relevant samples of GRP lamination test coupons are to be taken from the
test patch area and identified by the Engineer.
2. The tests are to be witnessed by the Engineer.
3. Testing apparatus required for in-situ tests is to be provided by the GRP
applicator.

xii. The acid immersion test will take 100 days duration and hence the applicator
shall provide a guarantee for the work until they get the relevant test results for the
GRP lamination work. The lamination work shall start at site on written confirmation
with the guarantee.

Table 7.8 Minimum Quality Control Test on Final GRP Lamination work

Sr. Test Test method Minimum Test Requirements

1 Barcol Hardness Resin Average 33 reading on
manufacturer’s Barcol Impressor @ 100% of
recommended test laminate area in accordance
method with test procedure specified
2 Thickness Digital elcometer Min. 3 tests on each
structure and shall achieve
the minimum thickness
specified.
3 Alarm type Spark test As stated in Spark Full surface area of each
tester catalogue structure. Locate the
defects if any & repair in
good condition
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4 Pull off adhesion test Pull off test in Minimum one test on each
accordance with major structure. Pull off
ASTM D4541 strength shall be greater
than the concrete strength
5 Resin glass ratio ASTM D 2584 One test on a sample taken
from any one of the
structure. The proportion
shall be 5% of the
specified value
6 Visual inspection ADTM D 2563 100% of the GRP laminated
area. Required Level-2 as
specified in the standard.

e) Test Procedure for Barcol Hardness Test Recommended by the Resin

Manufacturer

– Use Barcol impresser apparatus Nr. 934-1

– Take 10 – 12 readings on test patch area

– Reject the highest and lowest readings

– Take the average of the remaining 10 readings to get the barcol hardness value

1. Final approval for the GRP lamination work will be given by the Engineer only
after comply with the pre-qualification test specified.

2. Final approval for GRP work to proceed on site shall be subject to satisfactory
compliance test results observed at site.

3. Site Lamination

i. The following details of lamination apply to all work required under the Contract.

ii. Application shall be carried out in the cooler times of the day i.e. early morning or
late evening. Application shall not be carried out to surfaces exposed to direct
sunlight and high surface temperatures. Shade structures shall be provided as
necessary. Application shall not be carried out in conditions of windblown dust and
sand or during periods of high humidity.

iii. Before entering any chamber or standing on any surface which is to receive
lamination workers shall check their footwear to ensure that it is clean and will not
transfer contamination. Care shall be taken when passing materials down into
chambers etc. to avoid entry of contaminating materials.
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iv. Upon completion of mixing, materials shall be used immediately. During

lamination, work must cease immediately if the resin starts to gel and the work
completed to that point shall be allowed to cure before restarting.

v. No standing on or application of pressure to uncured laminates will be permitted

as this will result in squeezing out of resin producing defective areas of laminate
where the glass has not been fully wetted out.

vi. All surfaces to receive lamination shall be prepared as detailed above.

Lamination shall not be carried out to concrete surfaces until they have cured for at
least the minimum number of days recommended by the resin manufacturer since
casting of the concrete.

vii. All lamination to surfaces of prefabricated components shall be gradually

feathered away to a defined limit using masking tape or similar so that the final
appearance is neat without a sudden change in thickness or of appearance to the
completed job.

4. Lamination Build-up

i. A Primer coat of 75 to 125 micron catalysed vinyl ester resin shall be painted
over the area to be laminated. Whilst still wet one layer of ECR/Advantex glass shall
be applied over the area. Where it is necessary to make a joint in the reinforcement
then the reinforcement must overlap by a minimum of 25 mm. The reinforcement
shall then be rolled with a metal roller and then wet out with further resin until fully
wet. It shall then be carefully finally rolled with a metal roller to remove all air and
consolidate the laminate.

ii. Successive layers of ECR/Advantex glass shall be added and fully wetted-out
with epoxy based vinyl ester resin. Between applying each layer the laminate shall
be fully rolled using the metal roller to ensure that all the air is removed from all the
layers.

iii. Joints in reinforcement layers shall not lie directly above joints in layers below.

iv. This layer shall be allowed to fully cure. When fully dry the whole surface shall be
lightly abraded using a grinder with a 120 grit disc.

v. A coat of vinyl ester resin shall be applied over the area. Whilst still wet one layer
of ECR/Advantex glass chopped strand mat shall be applied. Further layers of ECR/
Advantex glass chopped strand mat shall be applied and fully wet out with epoxy
based vinyl ester resin and rolled with a metal roller.

vi. The final two layers of 'c' glass tissue shall then be applied and wet out with vinyl
ester resin. These layers shall not be rolled with a metal roller.

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vii. When the last layer has dried it shall be lightly sanded using 120 grade wet and
dry abrasive paper to remove any lumps or loose fibres. Any resin runs shall also be
removed making sure not to de-laminate the previous layers.

viii. A final layer of epoxy based vinyl ester resin incorporating a sealing agent
(paraffin wax) to ensure final and full cure shall then be applied over the whole
laminate and allowed to dry.

ix. In situ GRP lamination to concrete surfaces shall have the following composition,
as a minimum requirement.

Final finished GRP surface Finished GRP Surface with Paraffinated vinyl ester
resin flowcoat

2 x ECR, ‘C’ glass tissue impregnated with Epoxy

based vinyl ester resin
300 g/m2 ECR glass CSM impregnated with Epoxy
based vinyl ester resin
600 g/m2 ECR glass CSM impregnated with Epoxy
based vinyl ester resin
Minimum 7 mm thick GRP 600 g/m2 ECR glass CSM impregnated with Epoxy
Laminated Composite based vinyl ester resin
600 g/m2 ECR glass CSM impregnated with Epoxy
based vinyl ester resin
600 g/m2 ECR glass CSM impregnated with Epoxy
based vinyl ester resin
Concrete surface Vinyl ester Resin Prime Surface coat
x. In situ GRP lamination to the internal faces of brickwork corbelling shall have a
lesser composition as a minimum requirement as follows.

Final finished GRP surface Finished GRP Surface with Paraffinated

vinyl ester resin flowcoat

2 x ECR, ‘C’ glass tissue CSM impregnated

with Epoxy based vinyl ester resin

Minimum 3 mm thick GRP 300 g/m2 ECR glass CSM impregnated with

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Laminated Composite Epoxy based vinyl ester resin

300 g/m2 ECR glass CSM impregnated with Epoxy

based vinyl ester resin

300 g/m2 ECR glass CSM impregnated with Epoxy

based vinyl ester resin

Vinyl ester Resin Prime Surface coat

Concrete surface Concrete surface

5. Pipe Entries

i. The position of the centre of the required hole shall be accurately marked. This
includes holes to liners only where a boxout has been provided through the structural
wall. The prefabricated component and/or concrete wall shall be neatly cut by means
of a hole saw or diamond drill coring machine. The radius of the hole shall be not less
than the outer pipe radius plus 5 mm nor more than the outer pipe radius plus 15 mm.

ii. The surface of the liner shall be abraded to a distance of 100 mm from the cut
hole. The pipe to be fitted shall have its end and final 75 mm of barrel prepared to
receive lamination.

iii. The pipe shall be-fitted and securely fixed in position in accordance with an
approved Method Statement. It shall protrude at least 50 mm and not more than 100
mm past the face of the liner. The annular gap shall be filled with vinyl ester putty
which shall be neatly trimmed and allowed to cure.

iv. Lamination shall then be carried out to seal the pipe entry to the liner using ECR'
glass build-up to a minimum of 7 mm thickness but using vinyl ester resin only
throughout. Lamination shall be turned over the pipe end.

v. These requirements apply to all pipe entries including house connections, cable
ducts, air release pipework from pump casings, sump pump discharges, penstock
spindle sleeves, etc.

vi. These requirements apply to pipes built through both walls above benching level
and to pipes through walls into the benching. Sealing requirements where the pipes
penetrate the main structural wall are identical in both cases irrespective of whether
the pipe will later be covered by benching concrete.

vii. Should the material of the pipe built through the walls into the benching be
incompatible with in situ GRP lamination materials then the joint between the pipe

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and liner shall incorporate a prefabricated GRP pipe sleeve which shall be bonded to
the pipe outer diameter with a solvent free epoxy adhesive putty. In-situ GRP
benching lamination shall be bonded to the inner faces of the GRP pipe sleeve in
accordance with the above.

6. Cutting and Sealing of Reinforced Plastic

i. Where the manufacturer or Contractor is required for any reason to cut or drill
prefabricated reinforced plastic (GRP), including pipes, he shall completely seal the
exposed ends and edges with a coat of approved vinyl ester resin, before
incorporating the cut reinforced plastic into the Works. No cut reinforced plastic shall
be used until the sealing resin has fully cured.

ii. Resin used for sealing shall be delivered to site in sealed containers bearing the
name of the manufacturer and properly labeled as to its contents, storage
requirements and shelf life.

7. Safety Precautions

i. Proper ventilation and/or breathing apparatus shall be provided and all

necessary precautions shall be taken to ensure the safety of workers when in situ
GRP lamination materials are being used.

ii. Applicators shall also be made aware of the health risks involved in working with
these materials. Skin and eye contact should be prevented by the use of plastic or
rubber gloves, barrier creams, eye protection and protective clothing. Smoking will
not be permitted.

iii. Nothing in this Clause shall be deemed to limit the Contractor's more general
obligations under the Contract.

f) In-Situ GRP Lamination Requirements

Following Lamination Procedures and tests are to be conducted by the G.R.P

applicator.

1. To reduce air bubbles in the laminate relevant catalysts recommended by the

resin manufacturers only to be used. Catalyst manufacturer's technical catalogue to
be provided along with the material submission.

2. Samples of all materials to be used on sites are to be provided prior to start of

lamination work on site.

3. Resin and glass mat brought to the site are to be supplied in manufacturers
sealed drums, in packets with manufacturing date, compliance certificate and the
allowable pot life.

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4. Details of each constituent material and proof of supply throughout the work
period on site from the manufacturer is to be provided. Also provide test certificates
from the relevant material manufacturers for the materials used on site.

5. The lamination work is to be guaranteed for material and workmanship for a

period of 10 years from completion by the applicator and countersigned by the
manufacturer.

6. A Trial lamination is to be carried out in the presence of Engineer's

Representatives using proposed materials and the procedure, as specified, on a
concrete surface and arrange to conduct an initial pull off test, barcol hardness,
thickness and resin/glass ratio tests.

7. Lining of a concrete surface is to be carried out as per the manufacturers

recommended procedure.

8. Care must be exercised to ensure the correct balance of catalyst and accelerator
for optimum curing. Checking for complete cure to be carried out as per the
procedure recommended by the manufacturer.

9. The resin/glass ratio in the laminate, type of resin and glass and the sequence of
layers proposed are to be reported.

10. Final laminate thickness, loss on ignition, pull off adhesion, hardness tests etc are
to be conducted to prove compliance of the laminate with the contract requirement
and specification.

11. 100 days acid immersion test in 10 percent concentrated sulphuric acid solution
at 50 degree centigrade using final laminate samples ¬selected by the Consultant is
to be carried out. In-situ tests on the resin will be conducted during lamination work.

12. 2 layers of 'c' glass tissue of ECR type to be used on the final laminate.

13. Final wax topcoat resin formulation to be as per the procedure recommended by
the manufacturer.

14. Provide full details of safety measures that will be instituted during lamination
works for separate approval before starting any in-situ work. A full time supervisor
from the applicator's side must be on site.

15. Provide technical catalogue for all the type of resin, glass and surface tissue
proposed.

16. Minimum thickness of lamination shall be 7 mm and use only ECR glass epoxy
based vinyl ester resin approved by the Engineer.

17. No hollow sound on final laminate will be permitted.

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18. Lamination work is to be carried out in layer by layer and not to apply more than 3
layers in a day and allow the styrene gas to come out and enough curing time for
curing each layer.

19. Final approval shall be given following the acceptance of quality of the finished
works.

Material samples, safety procedures, material details, guarantee letter, name of

skilled workers and supervisors etc. are to be provided prior to starting the lamination
work on site.

7.1.7 Epoxy Mortar for Manholes

a) Where indicated on the drawings or specified to use epoxy mortar for benching
and channels in any manhole or any other structure such as chambers, pump station
wet-well, etc., they shall be formed to have a min. of 10 mm thickness of an approved
epoxy-resin mortar system.

b) The epoxy mortar system shall be a trowellable, two component epoxy resin
system consisting of a prefilled base and unfilled reactor which when mixed shall
produce a high strength, impermeable and chemically resistant mortar.

c) The epoxy mortar system shall have excellent chemical resistance to sodium
chloride and sulphuric acid (shall pass the relevant chemical resistance test), and
shall have high impact resistance. Typical properties are given in the following table:

Table 7.9 Properties of Two Component Epoxy Mortar

Property Test Method Limit

Sag at 10 mm thickness - None
Working Time ASTM C308 > 90 min. at 25°C
Full Cure at 25°C - 3 to 7 days
Setting Time at 25°C - 30 to 45 min.
Water Absorption ASTM C413 < 0.07 %
Compressive Strength BS 6319:Part 2 > 40 N/mm² at 25°C, 7
days cure
Flexural Strength BS 6319:Part 3 > 3 N/mm² at 25°C, 7
days cure
Tensile Strength BS 6319:Part 7 > 8 N/mm²

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Bond Strength BS 6319:Part 4 > 30 N/mm²

Density BS 6319:Part 1 1750 kg/m³

d) When placed on a concrete substrate the epoxy mortar system shall have an
adhesive strength of not less than the internal cohesive strength of concrete.

e) To achieve the necessary adhesion to the substrate an epoxy primer compatible

for use with the mortar and the substrate shall be applied.

f) The epoxy mortar or the primer where required, shall be suitable for application
onto a substrate with moisture content of 4% or less as measured by the "wet-check"
Moisture Meter or other instruments approved by the Engineer.

g) The pot-life of the mixed mortar shall not be less than one hour at the
temperature at the place of application at the time of mixing. The Engineer may
restrict application to such time as the ambient temperature is sufficiently low for the
specified pot-life to be ensured.

h) There shall be strict control of surface cleanliness between primer and epoxy
mortar and between coats of the same. Vacuum removal of dust and sand shall be
employed and water soluble contamination shall be removed as specified above.
Where dirt or dust has become trapped in the primed surface it shall be removed with
suitable abrasive paper. The surface being primed shall be free of visible moisture
throughout these operations.

i) The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a
maximum tolerance of +4 hours. Where this is exceeded the surfaces to be re-coated
shall be suitably abraded to remove gloss.

j) Mixing of the components shall be strictly in accordance with the Manufacturer's

recommendations and care shall be taken to avoid the entrainment of air in the
mixes.

k) Wet thickness gauge shall be used by the mortar applicators continually to check
that sufficient mortar is being applied to achieve the required dry thickness.

7.1.8 Rubberised Bitumen Emulsion

a) The bitumen emulsion shall be a cold applied thixotropic coating incorporating

liquid latex in the bitumen emulsion conforming to BS 8102. The latex content will be
a minimum 10% on the dried film and the solid content Min. 60%.

b) The coating shall be applied in two coats with a priming coat which will be made
by diluting the bitumen emulsion with max. 10% clean potable water or as
manufacturer’s recommendations.

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c) Two undiluted coats of the bitumen paint shall be applied @ 1.1 lit/m2 in two
coats. The total dry film thickness of the coating shall be Min. 0.50 mm.

d) The second coat will be applied at right angles of the first coat and only after the
coat has dried completely.

e) For concrete haunching at manhole and chamber covers and for 300 mm height
of concrete of structures above ground level, two coats of rubberised bituminous
emulsion system shall be applied. The second coat shall not be the same colour as
with the first.

f) The brush applied bituminous emulsion shall be used on location as given in the
approved drawings. The surface shall first be wire brushed and all dust and loose
scale removed. Both methods of protection shall totally enclose the substructure
within a water proof membrane of either polyethylene sheet or a waterproof building
paper as applicable to the limits shown on the drawings.

7.1.9 Waterproof Paper

Waterproof building paper shall be to the approved standard. For road works it shall
be Class ‘B’.

7.1.10 Protective Materials for Wrapping Pipeline Components

The protective materials for wrapping pipeline components shall comprise a rust
inhibiting compound for the bolts, a mastic or comparable filler which will not harden
for moulding over the assembly, and a waterproof tape for wrapping.

7.1.11 High Density Polyethylene Protection Sheet

The polyethylene sheet shall be of 1000 gauge (heavy duty) minimum thickness 250
microns.

7.1.12 Protective Coating with Cementitious Water Proof Coating

Concrete surface shall be protected with an approved elastomeric cementitious

waterproof coating as follows and where indicated on the drawings.

a) On the concrete blinding below perimeter and dividing wall base slabs.

b) The materials are required to provide excellent waterproofing and crack-bridging

properties, whilst providing protection against water abrasion.

c) The system shall be a high performance, elastomeric, cementitious coating

system specifically formulated to provide excellent resistance against aggressive
elements whilst retaining its chemical and physical properties through long term water
immersion.

d) The coating shall exhibit the following typical properties.

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Table 7.10 Typical Properties of Coatings

% Elongation Minimum 120%

Water vapour diffusion resistance SD 0.11 m @ 200 microns dft

Resistance to positive water pressure 7 bar DIN BSEN 12390

Resistance to negative water pressure 3 bar – Ditto-

Reduction in chloride ion penetration >99% (no penetration after 10 months

continuous testing)

Dynamic crack accommodation 1.8 mm

Abrasive resistance Wear index

e) The mixing and application of the elastomeric cementitious coating shall be

strictly in accordance with the manufacturer's instructions.

f) In preparation for the fairing coat and protective coating all existing surfaces shall
be free from existing coatings, oil, grease, loose particles, decayed matter, moss or
algae growth and general curing compounds. All surface contamination and surface
laitance must be removed through the use of high pressure water jetting or sweep
blasting.

g) Blow holes, prepared surface cracks and areas of substantial pitting shall' then
be filled with a proprietary polymer modified cementitious fairing coat as
recommended by the coating manufacturer.

h) The protective coating system shall be spray applied by a specialised applicator

approved and recommended by the coating manufacturer.

i) Where required by the Engineer, trial areas not exposed in the finished work
shall first be treated using the selected materials. These trial areas shall be carried
out using the type of materials, mixing procedures and applications as will be used on
the contract. These shall be approved by the Engineer before the Contractor
commences with the general work.

7.1.13 Approved Paint Suppliers

All paint suppliers shall be subject to approval. Suppliers shall demonstrate that their
paint systems have been successfully used in sewage environments similar to
conditions experienced and / or anticipated in Dubai.

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7.1.14 In-situ GRP Lamination with Grit bonding on final finish coat

This clause will cover all in-situ GRP Lamination work as specified in CL 7.1.6 and an
additional resin coat to be applied as final finish top coat sprinkled with non-metalic
mineral abrasive grit or sand to achieve a non-slip, non-abrasive surface finish.

7.1.15 Epoxy Coating

This clause will cover all in-situ Epoxy coating for the concrete surfaces as specified
such as water retaining structures, external surfaces of RC pipes and on the external
surfaces of Concrete Encased GRP Jacking pipes.

a) Epoxy coatings shall be solvent free, two component high build epoxies meeting
the requirements of Table below.

Table 7.11 Epoxy Coating Requirements

Property Requirement

Volume of solids 100%

Number of coats Minimum of 2

Dry film thickness Minimum of 250 microns per coat

Adhesion to concrete Minimum of 1.0 N/mm2

Colour Light grey or off white or as accepted by

the Engineer.

b) Coal tar epoxies shall not be used

c) Coating system shall have a proven track record of not less than 5 years in
Dubai or in similar environmental conditions prevailing in Dubai with regard to pot life,
useable life of freshly mixed components and curing.

d) Intermediate coats shall be tinted to facilitate inspection of coverage for each

coat.

e) UV resistant overcoating for external applications shall be as recommended by

the manufacturer.

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7.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE

7.2.1 General

Concrete structures shall be protected both internally and externally where indicated
on the Drawings and by the methods detailed.

7.2.2 Water Proof Membranes/Liners/Roof Waterproofing and Protective Coatings

a) All the protection systems shall be applied strictly in accordance with the
manufacturer’s instructions, two copies of which shall be included with the
Contractor’s application for the approval of the material, and when approved will be
deemed to be part of this specification unless stated otherwise.

b) The permissible rate of permeation of all protection systems shall not exceed
0.0027 per inch (ASTM, 1 per inch = 1 gramme of water per hour per square foot
(0.0929 m2) per mil (0.00254 mm) of thickness for a 1 inch (25.4 mm) difference in
Hg vapour pressure on each side of a membrane.

c) Coating shall not be applied at expansion, contraction or construction joints

which incorporate a sealant.

d) External and Internal Exposed Surfaces -

Where exposed surfaces of concrete structures are not protected by reinforced

plastic liners, the following systems given in the ‘Schedule of Tanking Membranes
and Protective Coating’ or as indicated on the drawings, where applicable, shall be
applied.

Table 7.12 Schedule of External Tanking Membrane on Concrete Surfaces of

underground Structures up to the Existing Finished Ground Level

System Description & Generic Type of Material

T1 Single coat solvented bitumen primer as

recommended by the tanking membrane
manufacturer

T2 Pre-fabricated self-adhesive SBS

modified bitumen membrane 1.5 mm thick
sandwiched between two layers of silicon
film having the specified properties

T3 Impervious self adhesive bituminous

water proofing membrane 2 mm thick
tropical grade, non-perforated, cross
laminated white polythene sheet top film
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with high impact and puncture and UV

resistance having the specified properties.

T4 Self-adhesive type 6 mm thick Asphaltic

protection board impregnated with tough
layer fibre glass reinforcement inside to
use under all raft foundation floor slab on
top of blinding layer.

T5 Self-adhesive type 3 mm thick bituminous

protection board with ‘UV’ resistant, 400
gm/m2 polyester fabric layer external
having specified properties.

T6 Termination end details of self-adhesive

membrane 2 mm thick + 3mm thick self-
adhesive protection board as shown in the
approved drawing

T7 Termination end details of composite 1.5

mm thick SBS modified membrane + 2mm
thick cross laminated membrane + 6 mm
thick self adhesive protection board as
shown in the approved drawing

T8 Termination details of membrane over

protruded built in pipes from the structure
as shown in the approved drawing.

T9 Termination details of membrane at

internal and external corners as shown in
the drawing

T10 Termination details of bitumen emulsion +

P.E. sheet as shown in the drawing.

Or alternatively

T11 3 mm thick two component spray in place

flexible 100% solid content Thermoplastic
(Tpu) Polyurathene / Polyurea Coating
System

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Note: The Contractor can choose either the

tanking membrane system T1 – T10 or
the 3mm thick polyurea coating without
any extra cost variation.

7.2.2.1 External Buried Surfaces

The external surfaces of major and minor concrete substructures shall be protected
or ‘tanked’ by the following methods which will be indicated on the Drawings.

a) External Waterproofing for Major Buried Structures

1. Water proofing for major structures shall be a three layer application.

i. Prime the concrete surface with solvent based bitumen primer as recommended
by the membrane manufacturer.

ii. The first layer shall be a 1.5 mm thick prefabricated layer of SBS modified
bitumen sandwiched between two layers of silicon film. The layer shall have 1200 %
elongation. The overlaps should be 15cm and should have 100% bitumen to bitumen
adhesion to ensure a seamless layer of rubberized bitumen. The layer should have
no reinforcements or top films which would affect the elongation and overlap
adhesion.

iii. The second layer shall be 2 mm thick an impervious bituminous waterproofing

membrane.

2. The membrane shall be tropical grade, non- perforated cross-laminated top film
with high strength, puncture and impact resistance and shall be chemically resistant
for protection against aggressive soils and contaminated ground water. The
membrane shall be white in colour to reduce the effect of UV and for easy
identification of damages if any on the membrane.

3. The cross laminated self-adhesive membrane shall comply with the following:

Table 7. 13 – Properties of Self-adhesive Membrane

Properties Test Method Typical Results

Tensile strength of ASTM D 638

membrane

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Longitudinal 3.8 N/mm width

Transverse 3.8 N/mm width

Top Surface High

Density Cross
Laminated PE Film
White

Tensile strength ASTM D 882

(Film)

Longitudinal 38 N/mm2

Transverse 38 N/mm2

Elongation of ASTM D 638

membrane

Longitudinal 230%

Transverse 180%

Tear Resistance ASTM D 1004

(film)

Longitudinal 280N/mm thickness

Transverse 280N/mm thickness

Puncture ASTM E154 220N /60mm deflection

Resistance

Adhesion to primed ASTM D 1000 2 N/mm width

substrate

-Ditto- self 2.4 N/mm width

Water absorption ASTM D 570

After 24 hours 0.14%

After 35 days 0.95%

Crack bridging Min 1 mm

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ability

Water resistance of BSEN 12390

Membrane 5 bar pressure No penetration

Cross laminated 5 bar pressure No penetration

Film (solvent
extracted from
membrane)

Self-adhesive ASTM D 36 102 C

softening point

4. The membrane shall be laid on the twin stick surface of the SBS bitumen layer
with the sticky side downwards and laid strictly in accordance with the manufacturer’s
instructions. The minimum overlap should be 150 mm side and end. The top silicon
release film of the twin stick membrane to be removed before the application of the
subsequent layer.

5. The corners and pipe joints shall be sealed with a 1.5 mm thick two side
adhesive bitumen tape. The tape shall comprise of a non-reinforced SBS modified
bitumen layer sandwiched between two layers of plastic release film. The bitumen
tape should have a minimum ultimate elongation of 1200%. The tape should be a
minimum of 300 mm width. The silicon release film on the top side should be
removed at the time of laying the waterproofing membrane. In the event adhesive
side of the tape gets contaminated with dust or other debris, the tape should be
removed with a heated scraper. The surface should then be primed again and the
tape re-applied. If the contamination is very minor and localised, the tape can be
repaired with heating it up with a hot air gun. A 40 mm x 40 mm corner fillet with
polysulphide sealant shall be made for all corners around the pipes to allow
movement.

6. Protection Board (6 mm & 3 mm thick)

The membrane has to be protected as the third layer with a 6 mm thick self-adhesive
asphaltic protection board impregnated with a tough layer of fibre glass and to be
used under all the raft foundation and 3 mm thick protection board for walls and sides
of raft foundation. The board should be weather, water and rot proof and should be
completely devoid of organic material. The edges of the protection board to be
sealed with a 50 mm self adhesive bitumen strips in order to avoid any back fill
material from entering into the system. The protection board shall comply with the
following properties.
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Table 7.14 Properties of Protection Board

Properties Test Method Typical Results

Thickness 6 mm & 3 mm

Chisel test BS 1142 pass

Heat resistance Ueatc Min 80C

All products in the waterproofing system to be sourced from the same manufacturer
who operates a certified ISO quality system. The membrane shall be applied strictly
in accordance with the manufacturer’s method statements.

Termination of the system shall be done at a height of 100 mm from the ground level.
A 40mm x 40mm groove to be cut and the membrane neatly tucked into the groove.
The groove shall be sealed with a polysulphide sealant. The self-adhesive protection
board should extend at least 50 mm above the groove and be sealed to the substrate
with an epoxy adhesive or a suitable system recommended by the membrane
manufacturer and approved by the Engineer. The cost of membrane is inclusive of
fixing and termination with approved sealant.

b) External Waterproofing for Minor Buried Structures such as Manholes,

Inspection Chambers etc.

1. The external surfaces of minor concrete substructures shall be protected or

tanked by the following method. The water proofing system shall be two layer
application. The 1st layer waterproofing membrane shall be a 2 mm thick bitumen
cross laminated self adhesive membrane and the 2nd layer shall be with a 3 mm thick
self adhesive membrane protection board with a tough geo-textile surfacing. The
membranes shall comply with the technical specifications as given in Cl. 7.2.2.1 (a).

2. The surface on which the waterproofing membrane is to be applied shall be

smooth and free of any sharp edges or protrusions. The surface should be primed
with an approved primer recommended by the membrane manufacturer.

3. Once the primer is completely cured, the membrane shall be laid on the surface.
The silicon release film is peeled off the sticky side and the membrane is to be
carefully laid on the surface. Care should be taken to minimize the entrapped air.
The minimum overlap should be 100 mm at side and end and minimum 200 mm at
the corners.

4. The corners and pipe joints shall be sealed with a 1.5 mm thick two side
adhesive bitumen tape. The tape shall comprise of a non-reinforced SBS modified
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bitumen layer sandwiched between two layers of plastic release film. The bitumen
tape should have a minimum ultimate elongation of 1500%. The tape shall be of
minimum 300 mm width. The silicon release film on the top side shall be removed at
the time of laying the waterproofing membrane. In the event adhesive side of the
tape gets contaminated with dust or other debris, the tape should be removed with a
heated scraper. The surface shall then be primed again and the tape re-applied. If
the contamination is very minor and localised, the tape can be repaired with heating it
up with a hot air gun.

5. Protection Board (3 mm thick)

The membrane shall be protected with a self-adhesive protection membrane

board with a tough, UV resistant, polyester surface. Staggered overlaps to be
ensured while application of protection membranes. The protection membrane shall
comply with the following properties.

Table 7. 15 – Protection Membrane Properties

Properties Test Method Typical Results

Thickness 3 mm

Puncture resistance ASTM E 154 1500 N

Tear resistance ASTM D 5147 500 N

Min: top surfacing weight of 350 gm/m²

fabric

Elongation of compound ASTM D 638 1500%

Any punctures on the membrane shall be repaired with an additional patch which
would extend at least 5 cm from the edges of the damage. The waterproofing
membrane shall be protected immediately with the protection membrane to avoid any
damages to the system because of ongoing site activities.

The end termination of the composite system shall be as shown in the approved
drawings or as recommended by the membrane manufacturer and approved by the
Engineer.

c) Brush Applied Bituminous Emulsion

1. The bitumen emulsion shall be cold applied thixotropic coating conforming to

ASTM D 1227 Type III Class 1. The coating shall have a solid content of Min 50%.
The coating shall be applied in two coats with a priming coat which will be made by
diluting the bitumen emulsion with max 20% clean potable water or as per
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manufacturer’s recommendations. Two undiluted coats of the bitumen paint shall be

applied @ 1.1 lit /m2 in two coats. The total Dry Film Thickness of the coating shall
be a minimum 0.5 mm.

2. The second coat shall be applied at right angles of the first coat and only after
the coat has dried completely.

3. The above coating system shall be protected with 1000 gauge polyethylene
sheet or building paper as specified for specific location to use.

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Table 7. 16

Application Procedure for Impervious Bituminous Tanking Membrane System (Clause 7.2.2 (1) (a) & (b) on Concrete Surfaces &
Structures (External) up to the Ground Level (For Major Structures)

Item Description and/or Application / Surface Shop Type of Coat No. of Description & generic type of Thick- Remarks
Location of work location preparation / site coats material ness

Microns

1. Buried concrete Blinding layer Levelled – 1000 guage One PE sheet 1000 guage as 250 To be placed
external surface in under raft formation Polyethylene layer specified on the
contact with soil and foundation sheet formation
groundwater for major (a) under the
structures; blinding blinding
under the raft
foundation
(b) over the Sweep – Primer One Rubberised bitumen emulsion 50 By brush
blinding blast System T1 coat application
Membrane One Self-adhesive type SBS modified 1.5 mm By hand
System T2 layer Bitumen non-reinforced thick application
membrane as specified
Membrane One Self-adhesive Bituminous 2 mm By Hand in
System T3 layer membrane cross laminated with thick staggered
white PE at top as specified Joints
Membrane One Self-adhesive type Bituminous 6 mm -Ditto-
System T4 layer Protection board. thick
2. Ditto – Raft (a) Raft Sweep – Primer One Solvented Bituminous Primer. 50 By brush
Foundation sides and foundation blast System T1 coat application
tank walls and roof base slab
slab in contact with sides and tank
ground soil / water walls
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Item Description and/or Application / Surface Shop Type of Coat No. of Description & generic type of Thick- Remarks
Location of work location preparation / site coats material ness

Microns

Membrane One Self adhesive type SBS modified 1.5 mm By hand

System T2 layer bitumen membrane (non thick application
reinforced) as specified.
One Self adhesive type bituminous 2 mm Fix in
System T3 layer membrane cross laminated with thick staggered
white PE at top as specified. joints
One Self adhesive type bituminous 3 mm Fix in
System T5 layer protection board with UV & thick staggered
puncture resistant fabric layer on joints.
top.
3. Ditto – for Minor Concrete Levelled – 1000 guage One PE sheet 1000 guage as 250 To be placed
Structures like blinding formation Polyethylene layer specified on the
manholes, chambers, (a) under the sheet formation
strip footing and its blinding
blinding layers.
(b) over the Sweep – Primer One Solvented bitumen primer as 50 By brush
blinding blast System T1 coat specified application
Membrane One Self-adhesive Bituminous 2 mm By hand
System T3 layer membrane cross laminated with thick application
white P.E. at top as specified
Membrane One Self-adhesive type bituminous 3 mm Fix in
System T5 layer protection board with polyester thick staggered
fabric at top as specified joints

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Item Description and/or Application / Surface Shop Type of Coat No. of Description & generic type of Thick- Remarks
Location of work location preparation / site coats material ness

Microns

4. Ditto – for wall, roof Manhole wall, Sweep – Primer One Solvented Bituminous Primer as 50 By brush
slab, the buildings roof slab Blast System T1 coat specified application
strip footing, and on
chambers below
ground
Membrane One Self adhesive type bituminous 2 mm By hand
System T3 layer membrane with cross laminated thick application
at top with white PE as specified
One Self adhesive type bituminous 3 mm Fix in
System T5 layer protection board with polyester thick staggered
fabric at top as specified joints

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Table 7. 17 [System – I, J, K, L, M & N] : TANKING MEMBRANE AND PROTECTIVE COATING TO CONCRETE Clause 7.2.5.1 [d
& e] SCHEDULE OF IN-SITU BITUMINOUS MEMBRANE/GRP/ COATING SYSTEM (FOR MINOR STRUCTURES)

STRUCTURE INTERNAL EXTERNAL

FLOOR WALL CEILING Base Slab/Strip footing Base slab sides, Wall
/foundation and Top of Cover Slab
1. Storm water Manholes Epoxy Resin mortar 300 micron thick 300 micron thick * System T1+
as specified in CL Epoxy coating system Epoxy coating P.E. sheet under the blinding * System T3 +
7.1.7 * System T5
*Rubberised Bitumen emulsion
System ‘K’ System ‘L’ System ‘L’ over the blinding + * System For each structure
T1+ * System T3
+ * System T5

2. Storm water chambers & Epoxy Resin mortar 300 micron thick 300 micron thick System M Rubberised emulsion
similar as specified in CL Epoxy coating system Epoxy coating Rubberised Bitumen emulsion + + P E Sheet
7.1.7 1000 gauge Polyethylene sheet

System ‘K’ System ‘L’ System ‘L’ System M

3. Building Strip footing, N/A N/A N/A *System T1 + -
compound wall foundation etc. *System T3 +
*System T5
4. Anchor blocks Protection N/A N/A N/A  P.E. sheet at formation
slab, concrete surround, & other  2 Coats Rubberised
similar burried concrete Bitumen emulsion over
concrete
 1 Layer P.E. sheet on top
System ‘M’
5. Above ground structures like System ‘D’ as System ‘D’ as N/A Same as item 1 above Ditto
Panel plinth (Exposed Surfaces) specified specified

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d) Alternative Proposal for Membrane Protection

3 mm thick two component spray in place flexible 100% solid content thermoplastic
(Tpu) polyurethane /Polyurea Coating System.

Table 7.18 Physical Data of Coating System

Physical Properties ASTM Test Value

Density (kg/m3) D - 1622 1121.3 (kg/m3)

Permeability (more 0.000 (metric/m2)

than 1 mm)

Hardness (Shore D – 2240 98

‘A’)

Abrasion D – 4060 0.001/1000 Cycles

Resistance (Taber)

Tensile Strength D - 2370 126.67

(kg/cm2)

Elongation (%) D – 2370 82.24% @ yield

Adhesion D - 4541 77 (kg cm2)

Tear Resistance Absolute Load 123.56 (N)

(N)

Colour FED STD 595B Black or other

Table 7.19 Resin Liquid Chemical Properties @24°C

Properties ASTM Test Value

Method

Viscosity (cps) D - 1638

Component ‘A’ 600 + 100

Component ‘B’ 1100 + 100

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Specific Gravity D - 1638

(gr/cc)
Component ‘A’ 1.15

Component ‘B’ 1.08

Mixing Ratio (A:B)

by volume
50:50

A Trial sample of the ‘Tpu’ coating is to be applied on any one of the concrete
structures external surfaces and the relevant sample is to be subjected to 100 days
acid immersion test in 10% concentrated sulphuric acid @ 50 C. This coating will be
acceptable only, if the chemical resistance of the “coating” fully comply with the
specification. The test shall be conducted in accordance ASTM C 581.

e) Application of Epoxy Coating

The material specifications and the area of uses of epoxy coatings shall be as per
clause 7.1.5. The epoxy coating shall be applied as per the followings:

1. Coatings shall be mixed and applied in strict accordance with the manufacture’s
recommendations.

2. Special attention shall be given to ensure that edges, corners, crevices and other
areas receive a film thickness at least equivalent to that of adjacent coated surfaces.

3. The penetrating solvent containing two component epoxy amine primer shall be
applied over the whole area to be coated by suitable nylon bristle brush or spray. The
primer shall soak into the concrete and shall not leave a resin rich layer on the
surface. Primers containing fillers or pigments shall not be used . A minimum of 24
hours shall lapse before filling the surface.

4. The surface of the primed concrete shall be scraped with an approved two
component solvent free epoxy filler supplied by the coating manufacturer. The filler
shall be squeezed into blowholes. The filler shall have the property of being resin rich
such that the finished surface shall look semi glossed when finished.

5. There shall be strict control of surface cleanliness between coats. Dust and sand
shall be used by vacuuming and any dust embedded in the coated surface shall be
removed with abrasive paper.

6. Two coats of a solvent free coating system as specified above shall be used .
Any thick runs or collections of coating shall be removed before they harden. Any
bowholes visible after each topcoat shall be filled and sealed.
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7. Wet film thickness shall be continually checked by the coating operators to verify
that sufficient coating is being applied to achieve the required dry film thickness.

8. Dry film thickness shall be checked for every 100m2 of coated surface.

9. Coated surfaces shall be visually inspected to ensure proper and complete

coverage has been obtained.

10. At least one adhesion test shall be conducted for every 100m2 of coated surface.
The resulting test specimens shall show no evidence of poor adhesion to the
substrate , residual laitance or intercoat adhesion weakness.

f) Waterproofing on Building’s Roof where thermal insulation is required.

The roofing system shall incorporate the materials and methodology specified in
Section 8 - Building Works.

7.2.3 GRP Prefabricated benching unit for Sewer Inspection Chambers

GRP prefabricated benching units shall be manufactured to the same process as

specified in CL. 7.1.6 for in-situ lamination but the work shall be carried out in
manufacturer’s yard with a wall thickness of 5 mm.

7.2.4 Cutting and Sealing of Reinforced Liners

a) Where the Contractor is required for any reason to cut reinforced plastic liners,
he shall seal the exposed ends with an approved resin before incorporating the cut
reinforced plastic in the work. No cut reinforced plastic shall be used until the resin
has cured.

b) The resin shall be as recommended by the manufacturer of the reinforced plastic

item and shall be pigmented so that the areas where it has been applied are easily
identifiable.

c) It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labelled as to its content and shelf life.

d) For flexible pipe materials a rubber protection strip shall be inserted between the
pipe barrel and the steel band.

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7.2.5 Protective Coatings to Concrete Works

7.2.5.1 Protective Coating on Concrete (Internal & External)

a) General Requirements

1. The coating system and the surface preparation shall be to the approved
standard and shall conform to the ‘schedule of surface preparation and protection
systems’ given below for concrete work.

2. The coating system proposed shall be applied by Client approved specialist

applicator.

Table 7-20 Surface Preparation on Concrete

System Description Surface Preparation

a) Sweep blasting The surface shall be sweep blasted with

non-metallic mineral abrasive to achieve
a minimum surface roughness of 100
micron on concrete or as recommended
by the paint manufacturer.

b) Surface Cleaning The concrete surface shall be cleaned to

remove dirt, oil, dust, laitance and all
other surface contaminations.

c) Epoxy binder / One coat 100 micron D.F.T two

sealer component polyamide epoxy based
transparent sealer coat shall be applied
by spray application to seal the porous
concrete substrate if any.

d) Filler One coat of alkali resistant acrylic based

filler 100 micron DFT shall be applied by
steel trowel or hand application to fill the
surface voids or as recommended by the
paint manufacturer.

b) Application of Field Coatings:

1. Coating shall be applied with a spraying equipment recommended by the

Manufacturer.

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i. Areas inaccessible to spray coating or rolling shall be coated by brushing or

other suitable means.

2. Give special attention to ensure that edges, corners, crevices, welds, bolts, and
other areas, as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.

3. Protective coating materials shall be applied in strict accordance with the

manufacturer’s printed instructions.

4. Prime coat shall be applied to clean surfaces:

i. Within a 4-hour period of the cleaning.

ii. Prior to deterioration or oxidation of the surface.

iii. In accordance with the manufacturer’s recommendations.

5. Coatings shall be applied in dry and dust-free environment.

i. No coating shall be applied during following conditions:

– When the surrounding air temperature, measured in the shade, is below 17 C

– To wet or damp surfaces.

– In rain, fog or mist or when the relative humidity exceeds 85%.

– When it is expected that the relative humidity will exceed 85% or that the air
temperature will drop below 5 C within 18 hours after the application of the coating
or paint.

– Dew or moisture condensation shall be anticipated.

– The cement laitance is removed with non-metallic mineral abrasive blasting

– Minimum specified surface roughness is achieved.

– Specified primer /sealer coat is applied.

– Filling the surface voids/cracks/and imperfections with approved epoxy filler.

ii. If the above conditions are prevalent, coating shall be delayed until surfaces are
dry.

iii. The day’s coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time prior
to the formation of moisture.

6. Care shall be exercised to avoid lapping, coating on adjacent surfaces.

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i. Coatings shall be sharply cut to lines.

ii. Finished coated surfaces shall be free from defects or blemishes.

iii. Drop cloths shall be used to protect floors, fixtures, and equipment.

iv. Care shall be exercised to prevent paint from being spattered onto surfaces from
which such paint cannot be removed.

v. Surfaces from which paint cannot be removed shall be painted or repainted as

required to produce a finish satisfactory to the Engineer.

vi. Apply second coat at right angles to first coat, ensuring pinholes are covered.

7. Surfaces inaccessible after assembly shall be coated before erection.

8. Touchup of surfaces shall be performed after installation.

9. Surfaces to be coated shall be clean and dry at the time of application.

10. Time of Coating:

i. Manufacturer’s recommended recoat time shall be complied with.

ii. Sufficient time shall be allowed to elapse between successive coats to permit
satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.

iii. No additional coating of any structure, equipment, or either item designated to be

painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment, or
other item.

11. Thickness of Coating:

i. Dry film thickness specified shall be achieved for each coat.

12. Clean up

– Concrete surfaces shall be visually inspected to ensure proper and complete

coverage has been attained.

– Upon completion of the work, staging, scaffolding, and containers shall be

removed from the site or destroyed in an approved manner.

– Coating spots, oil, or stains upon adjacent surfaces shall be removed.

13. Protective coating properties tests are to be conducted on the final coated
surface and shall comply with the requirements specified in Table 7 –22.

c) Schedule of Concrete Protection System

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1. For Major Structures Internal:

System - ‘A’ 7mm thick in-situ GRP lamination as specified in CL 7.1.6.

System- A - 1 7 mm thick in-situ GRP lamination with grit bonding on top of final
finish coat as specified in CL.7.1.14.

System - ‘B’ 1mm thick heavy duty glass flake vinylester resin based coating
250 micron each. Total D.F.T 4 x 250 microns + Approved Primer recommended by
the paint manufacturer.

System - ‘C’ 1mm thick Polysulphide modified Epoxy resin coating system
designed for superior adhesion, corrosion Protection, Chemical resistance &
waterproof coating 250 micron for each coat. Total D.F.T (4 x 250 micron) = 1 mm +
approved primer recommended by the paint manufacturer.

System - ‘D’ 0.5 mm thick solvent free 100% solid content polyamine based
Epoxy + Polyurethane resin coating.

Epoxy = 300 microns thick

Polyurethane = 200 microns thick

Total DFT = 500 microns + Approved Primer recommended by the paint

manufacturer.

System - ‘E’ Aggregate dressed (3 component) heavy duty, hard wearing,

solvent less Epoxy, anti slip deck coating minimum D.F.T = 3 mm. +75 micron high
build epoxy finish top coat with anti-fungi and antibacterial agents.

System - ‘F’ Fibre reinforced acid resistant, mineral based alkaline silicate
mortar minimum 6 mm thick with finish top coat for hard floor coating.

System - ‘G’ Double sided PVC lined membrane as specified in section

mechanical specification.

2. For Major Structures External Surfaces above Ground Exposed to Sunlight

System - ‘H’ Alkali Resistant Acrylic based anticarbonation coating + Sealer

coat + filler Coat

Epoxy binder / Sealer Coat – 100 microns thick.

Alkali Resistant Acrylic based filler 100 microns thick.

Alkali Resistant acrylic based anticarbonation coating – 100 x 3 coats = 300

microns thick.

d) For minor Structures (Internal Surfaces)

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System - ‘I’ 7mm thick in-situ GRP lamination over grano benching for sewer
MH’s as specified in CL 7.1.6.

System - ‘J’ 7mm thick Prefabricated GRP liner as specified in CL 7.1.5 for
sewer manholes.

System - ‘K’ Two component Epoxy mortar 10mm thick over grano benching of
storm water MH’s as specified in CL 7.1.7

System - ‘L’ Solvent free 100% solid content Polyamine based pure Epoxy 300
micron thick + primer, for storm water MH’s and Inspection chambers (sewer) etc.

e) For Minor Structures (External surfaces)

System - ‘M’ Rubberised bitumen emulsion + P.E sheet on top as specified in

7.1.8.

System - ‘N’ 5 mm thick GRP pre fabricated benching or in-situ lamination over
benching of inspection chambers (sewer) as specified in Clause 7.2.3.

Table: 7. 21 Schedules of Concrete Protection Details

Sr. Particular Protection Protection details

System

EXTERNAL PROTECTION FOR ALL MAJOR STRUCTURES

1 Below Ground Level

a. Below Blinding P.E 1000 gauge PE Sheet (250 micron thick)

b. Above Blinding (raft) System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T4 thick each & 6 mm thick protection board as
specified.

c. Walls outer surface System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T5 thick each with 3 mm thick protection board
on top as specified.

2 Above Ground Level System ‘H’ Approved sealer coat and filler coat and
Alkali resistant acrylic based anticarbonation
coating (300 micron) thick

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INTERNAL PROTECTION AND ROOFING DETAILS –

1 Stilling Tank, Pump Station,

Discharge chamber, Outfall

Floor, Wall, Roof System ‘D’ Approved primer recommended by the paint
manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint

2 Chemical Storage Area Bund System ‘A’ GRP Liner (7mm thick)

3 Potable Water Tank

Concrete Base floor and support System ‘D’ Approved primer recommended by the paint
wall manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint

4 Aeration Tanks

Floors, Walls & Ceiling, inlet/ System ‘B’ Approved primer recommended by the paint
Outlet channels manufacturer + 1 mm thick heavy duty glass
flake vinyl ester resin based coating.

Top Walkways System ‘E’ 3 mm thick heavy duty (3 component) non-

slip epoxy abrasion resistant deck coating +
high build 75 micron finish coat on top with
anti-fungi and anti-bacterial agents.

Valve chamber ( Waste activated System ‘L’ 300 micron pure epoxy paint ( Polyamine
Sludge) based) ( Solvent free 100% solid content)

5 FST Distribution / RAS Bellmouth

Chamber

All chambers walls / floors System ‘C’ Approved primer recommended by the paint
manufacturer + Polysulphide modified epoxy
resin coating 1mm thick

6 Gas Holders

Gas holders System ‘G’ Double sided PVC membrane as specified

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Table 7. 22 Test on Protective Coating of Concrete

Sr. Properties Test Method Minimum Requirements

1 Dry film thickness BS 3900 Specified thickness for each

coat

2 Discontinuity (holiday) National Association of 100% pin hole free

detection Corrosion Engineer’s
standard recommended
practice

3 Pull of adhesion strength ASTM D4541/ISO 4624 3.00 N/mm2 for epoxy coating

2.00 N/mm2 for anti

carbonation coating

Notes: (1) Freedom from pinhole shall be established by the use of a spark tester.

(2) Coating system should be resistant to:

(a) Sulphate and chloride ion penetration

(b) CO2 diffusion

(c) Bacterial and fungus growth

(d) Atmospheric temperature resistant

(e) Acids and alkalis of PH2 -14

(f) To accommodate shrinkage cracks appearing on concrete

substrate.

7.2.6 Coating System for Ferrous, Non Ferrous Metals and Plastics

7.2.6.1 GENERAL

a) DESCRIPTION

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Provide all labour, materials, equipment, services and accessories necessary to

furnish and install the coating system work of this Section, complete and functional as
indicated in Contract Documents and as specified herein.

1. Coatings for all ferrous, Non-ferrous surfaces, interior and exterior.

2. Submerged ferrous metal surfaces.

3. Structural and miscellaneous steel including tanks, hoppers and similar

equipment.

4. Equipment furnished without factory finished surfaces.

5. Exposed galvanized metal except handrails, grating, piping and checkered plate.

b) SUBMITTALS.

Manufacturer’s Data

1. Manufacturers current printed product description, materials safety and technical

data sheets for coating systems.

2. Detailed mixing, thinning and application instructions, minimum and maximum

application temperature, curing and drying times between coatings.

3. Instructions for surface preparation requirements, number and types of

Coats required for each surface.

4. Colour charts for each coating system.

5. Certifications from manufacturer verifying factory applied prime coatings are

compatible with the specified finish coatings.

6. Detailed maintenance manual including the following information:

i. Product name and number.

ii. Name, address and telephone number of manufacturer and local distributor.

iii. Detailed procedures for routine maintenance and cleaning.

iv. Detailed procedures for light repairs such as scratches and staining.

7. Abrasive:

i. Certified information of:

– Particle size distribution.

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– Dust generation at proposed operating pressure and distance.

– pH value.

– Soluble chloride content.

– Analysis for free silica.

– Trace toxic contaminants.

ii. Sample Panels

– Apply a complete coating system to a panel of the same material as that on

which the coating will be applied and submit for approval for each colour specified.

– Approved sample panels will be used for quality control in applying coating
systems.

iii. C. Certificates of Compliance.

iv. E. Inspection Reports.

v. F. Test Reports.

c) DELIVERY, STORAGE AND HANDLING

1. Delivery

i. Deliver materials in original, unopened packages and containers bearing

manufacturer's name and label including the following information:

– Name or title of material.

– Manufacturer's stock number and date of manufacture.

– Manufacturer's name.

– Contents by volume for major pigment and vehicle constituents.

– Thinning instructions where recommended.

– Application instructions.

– Colour code and name.

2. Storage

ii. Store materials on site in a suitable location, protected from exposure to extreme
weather.

iii. Keep area clean and accessible.

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iv. Restrict storage of coating materials and related equipment.

v. Keep temperature of storage area between 18 C and 32°C.

vi. Comply with Local Laws and Regulations.

vii. Cloth and Cotton wastes that might constitute of fire hazard shall be placed in
closed metal containers or destroyed at the end of each workday.

viii. Provide approved fire extinguishers in material storage area.

d) QUALITY ASSURANCE

1. Applicator Qualifications

i. Submit name and experience record of manufacturers recommended coating

applicator.

ii. Include list of utility or industrial installations painted, responsible officials,

architects, or engineers concerned with the project and the approximate contract
price.

2. Inspect surface and correct defects prior to application of each coat.

3. The protective coating systems specification, report on paint work progress and
the final report on corrosion protection should be provided by the applicator in the
formats (A), (B) and (C) given in this clause.

Form A – Form for a Protective Paint System Specification for New Work

(To be filled in for each constituent element of the structure by the applicator)

Project:

Name of Client:

Project: Protective paint system:

Location: ISO 12944-5 paint system No.

Constituent element: Environment:

Drawing No. / area: Required durability:

Position No.: Sheet No:

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Shop Application

Surface Preparation Grade:

Type of Prefabrication Primer (if used):

Paint manufacturer: Area:………..m2

Protective Paint Nominal dry Overcoating interval Drying time

System film at ….C (h)
thickness µm

Minimum (h) Maximum (h)

1st Coat

2nd Coat

3rd Coat

4th Coat

Total:

Site Application

Surface Preparation Grade:

Touch up:

Complete:

Paint Manufacturer: Area: ………..m2

Protective Paint Nominal dry Overcoating interval Drying time

System film at ….C (h)
thickness µm

Minimum (h) Maximum (h)

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1st Coat

2nd Coat

3rd Coat

4th Coat

Total:

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Form B – Form for a Report on Paint Work Progress and Application Conditions

(To be filled in by the coating applicator during the progress of work)

Project: Drawing No: Inspected by: Comments:

Location: Corrosion Protection Plan No:

Constituent Element: Position No:

Area:

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Date Time Type of work (i.e. Metho General Temp Temp Rel. Dew Blast Paint Colou Remarks Signatur
surface d used weather Air Struct/Constitue air poin cleaning batch r (eg. ISO e/
preparation, condition C nt element C humidity t C abrasive no. standard, initials
application of s % (material surface
priming coats, no.) prepar,
intermediate grade,
coats, top coats) irregularities

_______________ __________________ ___________________________ ________________________

_______________
(Place) (Date) (1st Signature) (2nd Signature) (3rd Signature)
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Form C – Form for Final Report on Corrosion Protection Work

(To be filled in by the applicator after the completion of the paint works)

Name of structure: Project No: Drawing No:

Protective paint system:

ISO 12944-5 paint system No. (if applicable)

1st Coat 2nd Coat 3rd Coat 4th Coat 5th Coat

Paint work contractor:

New work

Rust grade of steel surface (ISO 8501-1)

A .B .C .D

 Milling imperfections found

 Sharp edges and burrs removed
 Welding residues, including weld spatter,
not removed

Specified surface preparation grade (ISO 8501 –1 or ISO 8501-2):

Balst-cleaning  Sa2  Sa 2½  Sa 3

 PSa 2  PSa 2½  PSa 3

Flame cleaning  FI

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Hand and power tool  St2  St3

 PSt2  PSt3
Cleaning
 Pma
Machine abrading

Specified surface profile (ISO 8503-1):

Comparator G · Fine · Medium · Coarse ·

Comparator S · Fine · Medium · Coarse ·

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e) ENVIRONMENTAL CONDITIONS

1. Unless otherwise recommended by coating manufacturer, the ambient

temperature shall be between 7°C and 35°C when applying coatings other than
water-thinned epoxy.

2. Water-thinned coatings shall be applied only when ambient temperature is

between 10 C and 32°C.

3. Epoxy coatings will be applied only within the minimum and maximum
temperatures recommended by the coating manufacturer.

4. Coatings, except water-thinned types shall be applied only to' surfaces that are
completely free of moisture as determined by sight or touch.

5. Do not apply to surfaces which have visible frost or ice.

7.2.6.2 PRODUCTS

a) MANUFACTURER

1. Products and manufacturers specified hereinafter are specified for the purpose
of establishing minimum quality standards.

2. Products equal in quality to, or better than those specified will be considered
acceptable.

3. Decision of acceptability will rest with the Engineer.

4. Paint shall be from or approved supplier’s list specified.

5. Approved Paint Suppliers List:

i. Leigh’s Paints Sharjah

ii. Hempals Paints Dubai

iii. Sika Gulf BSC Dubai

iv. Polybit Industries Sharjah

v. Sigma Paints Dubai

vi. APS Dubai

vii. Fosroc Dubai

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viii. ICI Dulux Paints

b) GENERAL

1. No substitutions shall be considered that decrease:

i. Film thickness.

ii. Number of coats.

iii. Surface preparation.

iv. Performance criteria of the generic type of coating specified.

2. Furnish coatings and coating products under this Section from a single
manufacturer unless otherwise specified.

3. Compatibility

i. Compatible materials shall be used as primer and finish coats of systems.

ii. Compatible barrier coats may be used between factory-applied prime coats, or
finish coats on existing surfaces to be refinished and subsequent field coats with the
Engineer's approval.

4. Colours

i. Colors shall be as scheduled or selected by the Engineer.

ii. Prime and intermediate coats shall be tinted as approved by the Engineer to
facilitate inspection of coverage for each coat

c) HAZARDOUS MATERIALS RESTRICTIONS

Paints and painting practices shall comply with all applicable state and local
requirements limiting the emission of volatile organic compounds.

d) MATERIALS

1. Abrasive

i. Chose particle size, shape, and specific gravity to produce desired surface
profile for coating adhesion recommended by coating manufacturer. If not listed in
manufacturer's literature, provide for a 50 to 75 microns average profile.

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ii. pH value : Not less than 4 nor greater than 10 when

mixed in neutral water

iii. Soluble Chloride : None.

iv. Free Silica : To meet government regulations

v. Trace Toxic Contaminants : To meet government regulations

2. Colours as selected by Engineer from manufacturer's standards.

7.2.6.3 EXECUTION

a) WORKMANSHIP

1. Paint and coatings shall be applied so as to produce an even film of specified

thickness.

2. Edges, corners, crevices and joints shall receive special attention to ensure that
they have been thoroughly cleaned and that they receive an adequate thickness of
paint.

3. Finished surfaces shall be free from runs, drips, ridges, waves, laps, brush
marks and variations in colour, texture and finish.

4. Coverage shall be complete so that the addition of another coat of paint would
not increase the coverage.

5. Adjacent surfaces shall be protected by the use of drop cloths or other approved
precautionary measures.

b) ITEMS NOT TO BE COATED

1. Hardware, hardware accessories, nameplate data tags, machined surfaces and

similar items shall not be coated.

i. In contact with coated surfaces shall be removed or masked prior to surface

preparation and painting operations.

2. Following completion of coating of each piece, removed items shall be

reinstalled.

3. Removal and installation shall be done by workmen skilled in the trades involved.

c) PREPARATION

1. Surfaces to receive paint and protective coatings shall be cleaned as specified to

application of coating materials.

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2. Examine surfaces to be finished and correct surface defects before application of

any coating material.

3. Beginning the work of this section without reporting unsuitable conditions to the
Engineer constitutes acceptance of conditions.

4. Marred or abraded areas on shop-primed 'and factory-finished surfaces shall

receive touch-up restoration prior to any other coating applications.

d) SANDBLASTING

1. All sandblasting shall be done in strict accordance with the referenced

specifications of the Steel Structures Painting Council.

2. When items to be shop primed or shop primed and finish coated in the shop,
surface preparation shall be as specified in this Section.

3. The Engineer shall have the right to witness, inspect and reject any sandblasting
done in the shop.

4. When sandblasting is done in the field, care shall be taken to prevent damage to
structures and equipment.

i. Pumps, motors and other equipment shall be shielded, covered or protected to

prevent the entrance of sand.

ii. No sandblasting may begin before the Engineer inspects and approves the
protective measures.

5. Following surface preparations for metal surfaces to be painted or given coatings

shall form part of this Section:

i. White Metal Blast Cleaning (For very corrosive atmosphere).

– Removal of all visible rust, will scale, paint and foreign matter by blast
cleaning by wheel or nozzle (dry) using sand, grit or shot.

ii. Near-White Blast Cleaning (For high humidity, chemical atmosphere, or other
corrosive environment).

– Blast Cleaning nearly to White Metal Cleanliness, until at least 95 percent of

each element of surface area is free of all visible residues.

iii. Commercial Blast

– Blast cleaning until at least 67 percent of each element of surface area is free of
all visible residues.

iv. Brush- off Blast Cleaning

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– Blast cleaning of all except tightly adhering residues of mill scale rust and
coatings, exposing numerous evenly distributed flecks of underlying metal.

v. Solvent Cleaning

– Removal of oil, grease, dirt, soil, salts and other contaminants by cleaning with
solvent, vapour alkali, emulsion or steam.

6. Surface preparations shall be done to the satisfaction of the Engineer.

i. No painting or protective coating shall be applied before the Engineer has

inspected and approved the preparation.

7. After sandblasting, dust and spent sand shall be removed from the surfaces by
brushing or vacuum cleaning.

e) APPLICATION OF PROTECTIVE COATINGS

1. Shop Coating

i. Fabricated metalwork and equipment which requires coating may be shop

primed with specified primer.

ii. Any such work delivered to the job site with any other shop coat shall have this
coating removed and the specified coating applied in the field. Manufactured
equipment with approved corrosion-resistant factory finishes and galvanized finishes
shall be exempt from this requirement of stripping.

2. Field Coating

i. Except where in conflict with the manufacturer's printed instructions or where

otherwise specified herein, use choice of brush, roller, spray or airless spray
application.

– Any spray painting must first have the approval of the Engineer.

– Areas inaccessible to spray coating or rolling shall be coated by brushing or

other suitable means.

ii. Give special attention to ensure that edges, comers, crevices, welds, bolts and
other areas as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.

iii. All protective coating materials shall be applied in strict accordance with the
manufacturer's printed instructions.
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iv. Prime coat shall be applied to clean surfaces within a 4-hour period of the
cleaning and prior to deterioration or oxidation of the surface and in accordance with
the manufacturer's recommendations.

v. Coatings shall be applied in dry and dust-free environment:

vi. No coating or paint shall be applied during following conditions:

– When the surrounding air temperature, measured in the shade is below 15 C.

– To wet or damp surfaces.

– In rain, fog or mist, or when the relative humidity exceeds 85%.

– When it is expected that the relative humidity will exceed 85% or that the air
temperature will drop below 5°C within 18 hours after the application of the coating or
paint.

– Dew or moisture condensation shall be anticipated.

vii. If above conditions are prevalent, painting shall be delayed until surfaces are dry.

viii. The day's coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time prior
to the formation of moisture.

ix. Care shall be exercised to avoid lapping paint on adjacent surfaces:

– Coatings shall be sharply cut to lines.

– Finished coated surfaces shall be 'free from defects or blemishes.

– Drop cloths shall be used to protect floors, fixtures, and equipment.

– Care shall be exercised to prevent paint from being spattered onto surfaces from
which such paint cannot be removed.

– Surfaces from which paint cannot be removed shall be painted or repainted as

required to produce a finish satisfactory to the Engineer.

– Whenever two coats of a dark coloured paint are specified, the first coat shall
contain sufficient powdered aluminium to act as an indicator of proper coverage, or
the second coating shall be of a contrasting colour.

x. Surfaces inaccessible after assembly shall be coated before erection:

– a. No structural friction connections, high-strength bolts and nuts shall be painted

before erection.

– b. Areas damaged during erection shall be hand or power-tool cleaned and

recoated with prime coat.

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xi. Touch up of surfaces shall be performed after installation.

xii. All surfaces to be coated shall be clean and dry at the time of application.

3. Time of Coating

i. Manufacturer's recommended recoat time shall be complied with.

– Sufficient time shall be allowed to elapse between successive coats to permit

satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.

– No additional coating of any structure, equipment or other item designated to be

painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment or
other item.

ii. Piping shall not be finish coated until it has been pressure tested and approved.

4. Thickness of Coating

i. Dry film thickness specified shall be achieved and verified for each coat.

f) TESTING AND INSPECTION

1. Inspection Devices

i. Provide, until final acceptance of coating and' painting, inspection devices in

good working condition for detection of holidays and measurement of DFT of coatings
and paints. .

ii. Furnish U.S. Department of Commerce, National Bureau of Standards or

equivalent certified thickness calibration plates to test accuracy of DFT gauge and
certified instrumentation to test accuracy.

iii. Dry film thickness gauges shall be made available for the Engineer's use until
final acceptance of application.

iv. Holiday detection devices shall be operated in the presence of the Engineer.

v. Inspection devices shall be operated in accordance with the manufacturer's

instructions and when directed by the Engineer's representative.

2. Conduct DFT measurements and electrical inspection of the coated surfaces.

3. Recoat and repair as necessary for compliance with the specifications.

4. After repaired and recoated ferrous metals areas have cured, final inspection
tests shall be conducted by the Engineer.

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i. Coating thickness specified in mils on ferrous substrates shall be measured with

a nondestructive magnetic or digital type dry-film thickness gauge

ii. Discontinuities, voids and pinholes in the coatings will be determined with
nondestructive type electrical holiday detector.

iii. Epoxy coatings and thin film coatings shall be checked for discontinuities and
voids with a Iow-voltage detector of the wet-sponge type,

iv. Use a non-sudsing type wetting agent, which shall be added to the water prior to
wetting the sponge.

v. A high-voltage, low-current, spark type detector shall be used for electrical

inspection of coal tar enamel only.

vi. Tape-type coatings shall be inspected for holidays using a device designed for
use in detecting such flaws.

vii. Pinholes shall be marked, repaired in accordance with the manufacturer's printed
recommendations and retested.

viii. No pinholes or other irregularities will be permitted.

ix. Coatings not in compliance with the specifications will not be acceptable and
shall be replaced and reinspected at Contractor's expense until the requirements of
the specifications are met.

5. All gauges and detectors shall be provided with calibration by the Contractor
facilities subject to the approval of the Engineer.

6. Paint Properties tests are to be conducted on final coated surface and shall
comply with the following test.

7. Test on protective coating to metal works shall be as given in Table 7 – 24

Table 7.24 TEST ON PROTECTIVE COATINGS OF METAL WORKS

Sr. Properties Test Method Minimum Test Requirements

1. Dry film thickness BS 3900 Specified thickness for each

coat

2. Pull of adhesion ASTM D 4541 / ISO 4624 6N/mm2

strength

3. Discontinuity National Association of 100% pin hole free

corrosion Engineering standard
(Holiday recommended practice
detection)

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Sr. Properties Test Method Minimum Test Requirements

4. Abrasion ASTM D 4060 0.22gm weight loss in 1000

resistance cycles

5. Coating BS 3900 : PG8 RG5 Permeability–Nil

resistance to
cracking (bend Visible defects - Nil
test)

g) CLEANUP

1. Upon completion of the work staging, scaffolding and containers shall be

removed from the site or destroyed in an approved manner.

2. Paint spots, oil or stains upon adjacent surfaces shall be removed.

h) PAINT AND COATING SCHEDULE

1. General

i. The schedule here-in shall indicate the surface preparation and practice coating
system to be used.

ii. The list shall not be construed as a complete list of surfaces to be coated, but
rather as a guide as to the application of the various coating systems.

iii. All surfaces shall be painted except those specifically deleted herein.

iv. Where reference is made to ferrous metal in this schedule, it shall not include
stainless steel or galvanized metals except as specified in paragraph C - Paint
Schedule.

2. Painting Systems

i. On ferrous metal subject to corrosive moisture or atmosphere and condensation.

Typical examples include the screening facility and grit dewatering facility.

– Surface Preparation:

• All metal surfaces shall be sandblasted near White Blast Cleaning using proper
abrasive size to achieve 35 to 40 micron anchor pattern.

• Weld surface, edges and sharp corners shall be ground to a curve and all weld
splatter removed.

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– Coating:

• Shall be applied by airless spray or by brush for small areas.

• Coating Thickness:

Minimum Dry Film Component

Thickness
Primer 50 microns or as specified in Table 7-25
Intermediate Coat 200 microns or as specified in Table 7-25
Finish Coat 50 microns or as specified in Table 7-25
– Time Between Coatings:

• A minimum of 12 hours time is required before additional coats are applied to the
prime coat.

• Two hours for the intermediate coat

• Two hours for the finish coat

ii. On ferrous metals subject to normal indoor or outdoor exposure, except as

specified for buildings and not subject to chemical attack.

– Surface Preparation:

• All surfaces shall be free of dirt, dust, grease or other foreign matter before
coating.

• Surfaces shall be cleaned and, Brush off Blast Cleaning.

• Weld surfaces and rough edges shall be ground and weld splatter removed.

– Coating:

• Application shall be in strict conformance with the manufacturer's

recommendations.

• All sharp edges, nuts, bolts or other items difficult to coat shall receive a brush-
applied coat of the specified coating prior to application each coat.

• Coating Thickness:

Minimum Dry Component

Film Thickness

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50 micro as specified in
Primer
or Table 7 – 25

Intermediate Coat 200 microns as specified in

or Table 7 – 25

50 microns as specified in
Finish Coat
or Table 7 - 25

– Time Between Coatings

• As stated in B1 (d) above

iii. On ferrous metals submerged or intermittently submerged in water or corrosive

liquid. Typical examples include the primary settling tanks and aeration tanks.

– Surface Preparation:

• All metal surfaces shall be sandblasted with near White Blast Cleaning using
proper abrasive to achieve 50 to 75 microns anchor pattern.

• Weld surface, edges and sharp comers shall be ground to a curve and all weld
splatter removed and welds neutralized with thinner.

– Coating:

• Application shall be in strict conformance with the manufacturer's

recommendations.

• All sharp edges, nuts, bolts or other items difficult to coat shall receive a brush-
applied coat of the specified coating prior to application of each coat.

• Coating Thickness:

Minimum Dry Film Component

Thickness

50 microns as specified in
Primer
or Table 7 – 25

250 microns as specified in

Finish Coat
or Table 7 - 25

– Time between Coatings:

• As stated in B1 (d) above

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iv. For exterior galvanized steel including the operating platform, handrail, piping
etc.

– Surface Preparation:

• Galvanized surfaces shall be washed with solvent thinner as

recommended by the paint manufacturer.

• Use power tool cleaning to remove insoluble contaminants.

– Coating:

• Given in schedule of protection system for metal surface.

– Time Between Coatings:

• As stated in B1 (d) above

3. Paint Schedule

i. General

– The coating system to be used is specified here-in the schedule of protection

system for metal surface.

– All surfaces shall be painted except those specified in paragraph 1.01.

– The Engineer shall select the colours.

ii. Process Piping Colour Code

– As specified in “Mechanical Identification".

iii. Equipment Colour Code

– All plant and equipment shall be painted to the colours detailed below or
equivalent RAL colours unless otherwise instructed by the Engineer.

BS 4800 Colour Description

Baseplates and } 00 A 05 Light Grey

mounting stools
handrails, }
walkways & steel }
supporting
structures

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Screw pumps } 00 E 53 Black

} Light Green
Non Potable Water
Tanks

Coupling & Fly }

wheels
}
Drive Shafting
} 04 E 53 Red
Valve handwheels
}

Lifting equipment, }
including rails }
beams,Bogies,
gantry girders crab,
block and control
cabin

Pumps }
} 08 E 51 Mid Yellow
Gearboxes

Transformers } 18 E 51 Sky Blue

}
Control,
switchgear, }
distribution &
mimic panels

Motors } Mid Blue

} 18 E 53
Alternators
}

All other exposed

metalwork

Shafts and coupling } Self Colour

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guards }
Aluminium or GRP
hand railing

4. General Coating System

i. The following list shall indicate the coating system.

ii. Piping shall be defined as all pipe, valves, fittings, supports, operating systems
and guides.

iii. Mechanical equipment shall include all drives, motor control panels, and all other
electrical equipment requiring a protective coating.

iv. The colours of other surface shall be selected by the Engineer.

Item System Color

Pump Station Wet Wells andAs specified in

 Sewage and Sludge Treatmentschedule of protective
Equipment: coating on metal works

 All exposed mechanical equipment *

All submerged mechanical

 .. Black
equipment and piping

Pump Station Dry Wells and Motor

 Rooms:

All mechanical equipment and

 .. *
piping

 Offices/Store/Workshops: ..

 All exposed metal .. *

 Miscellaneous:

All miscellaneous interior exposed

 .. *
metal surfaces

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 All miscellaneous exterior exposed .. *

metal surfaces

 All submerged metal surfaces .. Black

Colour per equipment or pipe color code

schedules.

v. All structural steel shall be hot-dip Galvanised in accordance with BS729 and to
be painted as per the schedule of protection system after applied paint
manufacturer’s particulars recommended wash primer.

SCHEDULE OF SURFACE PREPARATIONS ON FERROUS & NONFERROUS

METALS & PLASTICS

System Description Surface Preparation

(a) Degreasing Shop cleaning to remove group 1

contaminants in accordance with the

approved standard.

(b) Blast Cleaning The surface shall be shot or grit

blasted to remove all rust, millscale,

in accordance with the approved
standard first quality finish for steel,
second quality finish for cast iron.
Blasting materials shall be free of
deleterious substances.

(c) Fettling The surface shall be cleaned to

remove all scale, rust, etc., by hand

cleaning using a powered wire brush
or other approved method.

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(d) Site cleaning Immediately before site painting all

dirt, oil or grease shall be removed

from the surface with white spirit or
other approved solvent.

(e) Wire wool or On site preparation to provide key

for Abrasive cloth primers and

undercoats.

(f) Polish and /or Shop treatment for aluminium.

Anodise

(g) Sweep Blast Site preparation for glavanized

areas.

(h) Spot Blast cleaning Welded spot shall be spot blast

cleaned to Sa 2½ to remove the

accumulated dirt & welding
resounds.

(i) Prickling (stainless steel) The passive layer on the welded

parts of stainless steel shall be

removed & restored by prickling the
metal in a tank and then treating it
with passivating solution.

(j) Electro Chemical Polishing Electrolyte bath to produce a

(Stainless steel) homogeneously

polished surface with a dirt repelling
effect.

SCHEDULE OF PROTECTIVE COATINGS ON FERROUS & NONFERROUS

METALS

System Description

P1 Zinc metallisation or zinc spray to the approved standard.

Or thicker metallic zinc coating

P2 Sealer primer to follow hot dip galvanising.

P3 Etch primer or wash Primer to follow zinc spray.

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P4 Micaceous Iron Oxide Paint containing not less than 80% iron

Oxide and not more than 5% anti-settling agent.

P5 Alkyd Resin base undercoat

P6 Alkyd Resin base gloss finish paint

P7 Zinc Chromate primer with 85% zinc on dry film

P8 Epoxy or Polyester prefabrication primer

P9 Epoxy Zinc phosphate submersible primer

P10 High build Polyamine based Epoxy or Polyester airless spray

coating

P11 Approved nylon, PVC or other synthetic dip or spray applied

coating.

P12 Hand wrapping with hydrocarbon paste, mastic, Denso PVC tape

and Insulation

P13 Polyurethane tie coat for non ferrous substrate

P14 Polyurethane based coating for ferrous and non-ferrous metal

P15 Acrylic urethane based finish coat

P16 High alumina fibre cement mortar lining to specified thickness.

P17 Air drying modified polysiloxane resin based coating to withstand

250C. temperature

P18 Fusion bonded Epoxy

P19 High build Epoxy aluminium primer/build coat.

P20 Vinyl ester based primer

P21 Glass flake vinyl ester

P22 Zinc Phosphate Primer Epoxy for ferrous substrate

P23 Modified Epoxy

P24 Epoxy high build MIO (for Galvanized)

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P25 Special Red oxide Primer for non-ferrous areas.

P26 Polyethylene Sleeve / Thermal Insulation

P27 Anti Slip Deck Coat (3mm thick)

P28 Sprayed aluminium

P29 High build Epoxy for Potable water resistant

Notes:(1) For manufactured items all cutting and drilling shall be completed before
application of any of the surface treatment specified.

(2) All paint systems shall achieve a minimum dry film thickness (dft) of 300 and a
maximum of 500 micron unless otherwise stated separately. The number of coatings
to achieve this thickness may vary according to method and time of application.

(3) Epoxy/polyester coatings must be applied by airless spray of electrostatic

charging of particles and stoving.

(4) Freedom from pin holes shall be established by a spark tester or such other
means recommended by the coating applicators/manufacturer. Such equipment shall
be provided and maintained by the contractor and be available at all times for the sole
use of the engineer.

(5) Hot dip Galvanizing shall be as specified.

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Table 7.25 SCHEDULES OF PROTECTION SYSTEMS ON FERROUS & NON- FERROUS METALS

[A] INTERNAL SURFACES

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
1.  Ductile Iron (a) Fully  Pipes (a) & (b) P1, P16, 10 4mm* 10 10 (d) & (e) P1 P1 4300
submerged & P10, P10 0 0 0 0 0
in Sewage fittings
or in
contact
with
 Cast Iron Sewage Ditto Ditto P1,P9,P10,P 50 " 350
vapours 10 10 10 10
0 0 0 P1 P1
 Carbon 0 0
Steel Ditto Ditto 50 " 350
P1,P9,P10,P
10 10 10 10
0 0 0
P1 P1
0 0
 Mild Steel Ditto Ditto P1,P9,P10,P 10 50 10 10 " P1 P1 350
10 0 0 0 0 0

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Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns

 Ductile Iron (b) Partially  Pipes P1,P16,P10, 10 4mm* 15 50 " P1 P1 4300

submerged & P15 0 0 0 5
in sewage Fitting
or in s
contact
with
sewage
vapours

 Cast Iron Ditto Ditto P1,P3, 10 50 15 50 " P1 P1 350

P10,P15 0 0 0 5
 Carbon Ditto Ditto
Steel P1,P3, 10 50 15 50 " P1 P1 350
P10,P15 0 0 0 5
 Mild Steel Ditto Ditto P1,P3, 10 50 15 50 " P1 P1 350
P10,P15 0 0 0 5

 Ductile Iron (c) Submerge  Pipes (a) & (b) P1,P16,P10, 10 4mm* 10 10 " 4300
d Potable & P10 0 0 0
/effluent Fitting
water

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Drainage and Irrigation Department

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
 Cast Iron Ditto Ditto P1,P9,P29,P 50 50 12 12 " 350
29 5 5
 Carbon Ditto Ditto
Steel P1,P9,P29,P 50 50 12 12 " 350
29 5 5
 Mild Steel Ditto Ditto P1,P9,P29,P 50 50 12 12 350
29 5 5

 Ductile Iron (d) Exposed to  Pipes (a) & (b) P22,P16,P10 50 4mm* 12 " P1 P1 4175
ambient & 5 0 0
conditions fitting

 Cast Iron Ditto Ditto P22,P29,P29 50 125 12 P2 P2 300

5 9 9
 Carbon Ditto Ditto
Steel P22,P29,P29 50 125 12 " P2 P2 300
5 9 9
 Mild Steel Ditto Ditto P22,P29,P29 50 125 12 " P2 P2 300
5 9 9

 Ductile Iron (e) Buried Pipes & (a) & (b) P22,P16,P10 10 4mm* 10 10 (d) & (e) P2 4300
under the Fittings ,P29 0 0 0 9
ground

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
 Cast Iron Ditto Ditto P9,P29,P29 50 125 12 Ditto P2 300
5 9
 Carbon Ditto Ditto
Steel P9,P29,P29 50 125 12 Ditto P2 300
5 9
 Mild Steel Ditto Ditto P9,P29,P29 50 125 12 Ditto P2 300
5 9

2. Stainless Steel  Exposed to  Hot No Coating

GR: ambient water Internal
316L/GR304 conditions pipes
 Buried
under the No Coating
ground Internal
3. Galvanised (a) Exposed to  Pipes
Metals ambient &
conditions fittings

 Ductile Iron Ditto P3,P22,P16, 10 50 4m 15 10 (g) P1 4310

P10, P15 m* 0 0 5
 Cast Iron Ditto P3,P22,P24, 10 50 15 10 " P1 310
P15 0 0 5

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
 Carbon Ditto "
Steel P3,P22,P24, 10 50 15 10 P1 310
P15 0 0 5
 Mild Steel Ditto P3,P22,P24, 10 50 15 10 " P1 310
P15 0 0 5
 Galvanised Ditto "
Iron P3,P22,P24, 10 50 15 10 P1 310
P15 0 0 5
(b) Buried
under
Ground
 Ductile Iron Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Cast Iron Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Carbon Ditto "
Steel P3,P22,P23, 10 75 12 10 P2 310
P23 5 0 3
 Mild Steel Ditto P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3
 Galvanised Ditto
Iron P3,P22,P23, 10 75 12 10 " P2 310
P23 5 0 3

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Preparation Shop Coatings Shop coating thickness Preparatio Site Coating Total
Application in Shop 1st,2nd,3rd,4th,5th in microns n on Site System Coating
thickness
including
Primer
1st 2nd 3rd 4th 5th 1st 2nd 3rd microns
4. Thermo  Pipes No Coating
Plastics & & required
Thermo Set fittings Internal
Plastics in
uPVC/GRP/
GRE
* 4 mm thick cement mortar lining

Table 7.25 SCHEDULES OF PROTECTION SYSTEMS ON FERROUS, NON- FERROUS METALS & PLASTICS

[B] EXTERNAL SURFACES

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
1. Ferrous Metals

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Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
 Ductile Iron (a) Fully  Mechanical (a) (b) & h P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
submerged Equipment 1 0 microns
in sewage  Pipe work
or in **
contact
with
sewage
vapours

 Carbon (a) (b) & h P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
Steel 1 0 microns
 Structural Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
Steel 1 0 microns
 Mild Steel Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
1 0 microns
 Cast Iron Ditto P20,P21,P2 50 750 75 (d) (e) (g) P20 P21 1550
1 0 microns

 Ditto (b) Exposed to *Mechanical (a) (b) & h P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
Ambient equipments , microns
Conditions P15
** Pipe works " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
, microns
P15

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
 Valves " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
, microns
P15

 Gratings " P22,P14,P1 75 250 25 (d) (e) (g) P14 P14 575
4 0 microns
 Handrails " P22,P4,P15 75 125 50 50 (d) (e) (g) P4 P15 300
,P15 microns
* Mechanical equipment shall include all drives, motor control Panel and all other electrical equipment requiring a Protective Coating.
** Pipe work shall include all Pipes, Valves, fittings, supports operating system and guides
 M.S.Pipe " P7,P3,P5,P 10 10 10 10 (e) (g) P5 P6 310
Protection 6 0 0 0 microns
Barrier
 Plat forms " P22,P14,P1 75 250 25 (d) (e) (g) P14 P14 575
4 0 microns
 MH & " P9,P10,P10 75 200 20 50 (d) (e) (g) P10 P15 525
PSTN , 0 microns
Covers P15
 Pipe work " P7,P17,P17 25 75 50 (d) (e) P17 150
to with microns
stand
temperature
up to 250C

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
 Ditto (c) Buried  Pipe works " P22,P23,P2 75 125 12 (d) (e) (g) P23 P23 P12 325
under the 3 5 microns
ground

2. Ditto Fully  Mechanical (a) (b) & h P9,P29,P29 12 125 12 (d) (e) (g) P29 P29 375
submerged in equipment 5 5 microns
effluent  Pipe works Ditto P9,P29,P29 125 (d) (e) (g) P29 P29
/Potable water 12 12 375
5 5 microns
3 Galvanised (a) Exposed to  Galvanised (g) P3,P24,P14 10 100 25 25 (d) (e) (g) P14 P14 610
Metals ambient steel , 0 0 microns
conditions gratings P14

 G.I (g) P3,P24,P24 10 100 25 25 (d) (e) (g) P14 P14 610
multispan , 0 0 microns
covers P14
 G.I Panel (g) P3,P24,P5, 10 100 10 10 P15 P15 310
support 24 0 0 microns
frames P15
 Galvanised (g) P3,P24,P24 10 100 10 50, (d) (e) (g) P15 P15 310
electric ,P15, 0 50 micron
light poles P15 (clear)

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Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
 G. I. Pipes (g) P3,P24,P24 10 100 10 50, (d) (e) (g) P12 P12 310
, 0 50 Insul microns
P15,P15 ation

(b) Buried G. I. pipes P3,P24,P23 10 100 10 10 (d) (e) (g) P23 P23 310
under , 0 0 microns
the ground P23

4. Non- Ferrous
metal.
Stainless steel (a) Fully  Pipe works (e) & g , P25,P21,P2 50 500 50 (e) (g) P21 P21 1050
GR 316L/304 submerged (h) (i)(j) 1 0 microns
in sewage
or in
contact
with
sewage
vapours

Ditto (b) Exposed to  Pipe works " P25,P15,P1 50 50 10 (e) (g) P15 P15 P12 200
ambient carrying hot 5 0 Ins microns
conditions water up to ulati
50C on

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 General Specifications for Civil Works
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Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
 Ditto above " P25,P28 50 100 (e) (g) P12 150
50C to Ins microns
120C ulati
on
 Covers & " P25,P14,P1 50 250 25 (e) (g) P14 P14 550
platforms 4 0 microns
 Handrails " No coating
external &
internal
(Natural
Finish)
Ditto (c) Fully  Mechanical " P25,P29,P2 50 125 12 (e) (g) P29 P29 300
submersed equipment 9 5 microns
in  Pipe works " 50 125 " " P29 P29
effluent/Pot P25,P29,P2 12 300
able water 9 5 microns

Ditto (d) Buried  Pipe works " P25,P23,P2 50 125 12 " " P23 P23 300
under the 3 5 microns
ground

5. Aluminium Exposed to  covers (g) & (f) P25,P15,P1 50 50 50 (d) (e) P15 P15 P12 150
ambient 5 Ins microns
conditions ulati
on

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
6. Thermo (a) Exposed to  pipe works (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Plastics ambient 5 microns
uPVC/P.P/ conditions
HDPE
(b) Buried
under the No Coating
ground Required

7 Thermo (a) Exposed to  Odour (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Setting ambient Control 5 microns
Plastics conditions GRP Duct
(GRP/GRE) Pipes &
fittings
GRP "  GRP Pipes (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
and fittings 5 microns
for water
distribution

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
GRP  GRP Non  Type ‘A’ (d) & (e) Cover
Slip cover on manufacture
pedestrian Odour rs
trafficable Control Unit recommend
covers ed
protective
coating
system
resistant to
corrosion ,
Non slip and
U.V
resistant
GRP  GRP Non  Type ‘B’ (d) & (e) Cover
Slip covers on manufacture
Pedestrian odour r’s
trafficable Control recommend
covers with Units ed
chequer protective
plate coating
wearing
surface

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
GRP  GRP  Tanks (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150
Chemical external & 5 microns
Storage related
tanks / fittings
GRP
potable
water
storage
tanks
GRE (b) Potable  Tanks pipes (d) & (e) P25,P15,P1 50 50 50 (d) (e) P15 P15 150micro
Water & Fittings 5 50 50 50 (d) (e) P15 P15 ns
Pipes external P25,P15,P1 150micro
exposed to surfaces 5 ns
ambient
conditions
for fire
fighting

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Sr. Substrate Environment Typical Application Preparation in Shop Coatings Preparation on site Shop Preparation on Site Site Coating System Total
Shop 1st,2nd,3rd,4th,5t coating thickness Coating
h Unit (microns) thickness
1st 2nd 3rd 4th 1st 2nd 3rd
Note: (1) Final Coat protective coating on exposed surfaces of all GRP, GRE items Multi Colour Shades for beautification purposes will be selected by Dubai
Municipality Architect / Engineer at site.
(2) All structural steel items are to be hot dip galvanised to a minimum thickness of 140 microns.
(3) Colour shades of the metal works should match with relevant structures concrete paint system or as decided by the Engineer/Architect.
(4) All buried ferrous and non ferrous metal painted pipes & fittings shall be protected further with any one of the Protection wrapping system specified
in CL.7.2.6.4 on top of Protective Coating specified.
(5) All S.S bolts, nuts & washers are to be removed from the fittings before to apply paints and rectified after painting.
(6) All S.S bolted fitting, burried under the ground shall be protected with approved insulation system specified.

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Drainage and Irrigation Department

7.2.6.4 Protective Wrapping Tapes and Sleeve on Buried Pipes and Fittings

Buried ferrous and stainless steel pipelines, joints, valves and other fittings shall be
protected either by wrapping with adhesive tape, synthetic resin or plastic tape or
plastic sleeves. When applying wrapping tape an overlap of at least half the width of
the tape for pipes up to 300 mm dia is required.

a) Adhesive Tape

Adhesive tape shall be either a synthetic fibre or glass cloth impregnated with a
mixture of petroleum jelly and neutral mineral filler. When used for above ground
pipes these tapes shall be protected by a bituminous tape.

b) Synthetic Resin or Plastic Tape

Synthetic Resin or Plastic Tape shall be PVC or black polyethylene strips 250 micron
thick with fabric core coated one side with a compact adhesive normally of synthetic
rubber base.

c) Two-Pack Taping

Two-pack taping system shall be woven glass tape or sheet form impregnated with a
two pack solventless composition of polyester or epoxy. The surface to be protected
should first be cleaned and primed to receive with two pack epoxy. It should then be
wrapped with glass cloth in tape form with polyester or epoxy. A thin coat of
impregnating tape and then reinforcing substrate are applied. Several layers are be
built up and the final layer shall be trowelled smooth. The coating should set to a
hard glass like protective coating which is impermeable to water

7.2.6.5 Plastic Sleeves

Plastic sleeve shall be a black colour high density polyethylene 250 micron thick
which shall be used as a protective sleeve on pipes. The sleeving is to be applied at
the time of laying the pipe and joints are taped with adhesive tape.

7.2.6.6 Hot Dip Galvanising

Hot dip galvanised coating on iron and steel articles shall be carried out in
accordance with the requirements of BS 729:1971. The minimum average coating
thickness shall be 140 microns (equivalent to 720-1000g/m2).The coating operation
shall consist of dipping the steel parts into a molten Zinc bath at a temperature of
450 C. After completion of the dipping further treatment comprising of degreasing,
pickling, rinsing, fluxing and drying shall be carried out separately.

7.2.6.7 Water Level Marking Paint

The paint shall be a thermoplastic non-toxic ‘WRAS APPROVED’ product suitable for
application by brush or airless spray, day light reflecting type acrylic paint with

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Drainage and Irrigation Department

fluorescent pigments which give intense colour impression and high visibility.
Suitable colour shades shall be as approved by the Engineer.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 8

BUILDING WORKS

DM/DNID Section 8 Building Works Rev 00 June

2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 8
BUILDING WORKS

CONTENTS
8 BUILDING WORKS............................................................................................................ 1
8.1 GENERAL...................................................................................................................... 1
8.2 CONCRETE ................................................................................................................... 1
8.2.1 Tolerance .............................................................................................................. 1
8.2.2 Concrete Finish ..................................................................................................... 1
8.2.3 Construction Bays ................................................................................................. 1
8.2.4 Small Precast Items .............................................................................................. 2
8.2.5 Cast in Fixings ...................................................................................................... 2
8.2.6 Timber Cast in Fixings .......................................................................................... 2

8.3 BRICKWORK AND BLOCKWORK .............................................................................. 2

8.3.1 Damp Proof Course .............................................................................................. 2
8.3.2 Wall Ties ............................................................................................................... 2
8.3.3 Door and Window Frame Ties .............................................................................. 3
8.3.4 Mastic ................................................................................................................... 3
8.3.5 Brickwork and Blockwork ...................................................................................... 3
8.3.6 Cement Mortar ...................................................................................................... 3
8.3.7 Pointing ................................................................................................................. 3
8.3.8 Hollow Walls ......................................................................................................... 3

8.4 ROOFING ...................................................................................................................... 3

8.4.1 Roof Screed .......................................................................................................... 3
8.4.2 Roof Primer ........................................................................................................... 4
8.4.3 Waterproofing Membrane ..................................................................................... 4
8.4.4 Roof Insulation ...................................................................................................... 4
8.4.5 Roof Surface ......................................................................................................... 4
8.4.6 Roof Decking ........................................................................................................ 4
8.4.7 Fascia Cladding .................................................................................................... 4

8.5 JOINERY ....................................................................................................................... 4

8.5.1 Timber-General ..................................................................................................... 4
8.5.2 Timber Sizes ......................................................................................................... 5
8.5.3 Hardwood ............................................................................................................. 5
8.5.4 Plywood ................................................................................................................ 5
8.5.5 Timber Fixing Accessories .................................................................................... 5

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Drainage and Irrigation Department

8.5.6 Timber Preservative .............................................................................................. 6

8.5.7 Ironmongery .......................................................................................................... 6
8.5.8 Workmanship ........................................................................................................ 6
8.5.9 Fabrication ............................................................................................................ 6
8.5.10 Storage ................................................................................................................. 6
8.5.11 Door Frames ......................................................................................................... 7
8.5.12 Doors .................................................................................................................... 7

8.6 METALWORK ............................................................................................................... 7

8.6.1 Aluminium ............................................................................................................. 7
8.6.2 Aluminium Louvers ............................................................................................... 7
8.6.3 Aluminium Windows ............................................................................................. 8
8.6.4 Ironmongery .......................................................................................................... 8

8.7 PLUMBING .................................................................................................................... 8

8.7.1 General ................................................................................................................. 8
8.7.2 Sanitary Fixtures ................................................................................................... 8
8.7.3 Copper Tubes ..................................................................................................... 11
8.7.4 Copper Fittings, Waste Pipes, Ball Valves etc. ................................................... 11
8.7.5 uPVC Pressure Pipes and Fittings ..................................................................... 11
8.7.6 Workmanship ...................................................................................................... 12
8.7.7 Pipe work ............................................................................................................ 12
8.7.8 Copper Tube Fixing ............................................................................................ 12
8.7.9 Waste Pipes ........................................................................................................ 12
8.7.10 Sleeves ............................................................................................................... 12
8.7.11 Testing ................................................................................................................ 12
8.7.12 Storage Tanks .................................................................................................... 13

8.8 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES ......................... 14
8.8.1 Cement ............................................................................................................... 14
8.8.2 Lime .................................................................................................................... 14
8.8.3 Sand ................................................................................................................... 14
8.8.4 Gypsum Plasters ................................................................................................ 14
8.8.5 Plaster Trims ....................................................................................................... 14
8.8.6 Metal Lathing ...................................................................................................... 14
8.8.7 Plasticizers .......................................................................................................... 14
8.8.8 Bonding Agents .................................................................................................. 14
8.8.9 Storage ............................................................................................................... 14
8.8.10 Floor Tiles ........................................................................................................... 15
8.8.11 Wall Tiles (Internal) ............................................................................................. 15
8.8.12 Wall Tiles (External) ............................................................................................ 15
8.8.13 Tile Adhesive ...................................................................................................... 16
8.8.14 Tile Grout ............................................................................................................ 16
8.8.15 Expansion Joints ................................................................................................. 16
8.8.16 Backgrounds ....................................................................................................... 16

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Drainage and Irrigation Department

8.8.17 Dissimilar Materials ............................................................................................. 16

8.8.18 Hacking ............................................................................................................... 16
8.8.19 Dubbing Out ........................................................................................................ 17
8.8.20 Splatterdash or Stipple Coat ............................................................................... 17
8.8.21 Internal Finishes-General ................................................................................... 17
8.8.22 Internal Render ................................................................................................... 17
8.8.23 Stucco ................................................................................................................. 17
8.8.24 External Render .................................................................................................. 17
8.8.25 Insitu Floor Finishes ............................................................................................ 18

8.9 GLAZING ..................................................................................................................... 20

8.9.1 Glass ................................................................................................................... 20
8.9.2 Glazing ................................................................................................................ 20
8.9.3 Bedding Compound ............................................................................................ 21
8.9.4 Proprietary Curtain Glazing ................................................................................ 21

8.10 PAINTING AND DECORATING .................................................................................. 21

8.10.1 Painting-General ................................................................................................. 21
8.10.2 Exterior Stain ...................................................................................................... 21
8.10.3 Stopping to Plaster ............................................................................................. 21
8.10.4 Steel Priming ...................................................................................................... 21
8.10.5 Oil Based Paint ................................................................................................... 22
8.10.6 Internal Finish to Walls ....................................................................................... 22
8.10.7 Ironmongery ........................................................................................................ 22
8.10.8 Workmanship ...................................................................................................... 22

8.11 Water Supply and Drainage ...................................................................................... 23

8.11.1 Water Supply System ......................................................................................... 23
8.11.2 Water Drainage System ...................................................................................... 32

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

8 BUILDING WORKS

8.1 GENERAL

a) This specification defines the general requirements for the building works.

b) No deviations or exceptions from this specification shall be permitted without the

written approval of the Engineer.

c) Compliance with this specification shall not relieve the Contractor of the
responsibility of furnishing specified material.

d) The Contractor shall co-ordinate, expedite and resolve any problems with the
manufacturer / supplier. The Contractor shall be responsible for ensuring that all
relevant information and documentation is passed on to the manufacturer /
supplier, to complete the work to the satisfaction of the Engineer.

e) The final responsibility for the satisfactory completion of the work shall lie with the
Contractor.

8.2 CONCRETE

8.2.1 Tolerance

Floor and roof slabs shall be level to a point within  5 mm of the level shown on the
drawings. Columns and beams shall have no irregularities exceeding 3 mm in a 3m
length. The position of the face of columns, beams and walls at any point shall be
within 5 mm of its position derived from the drawings.

8.2.2 Concrete Finish

All exposed concrete beams, columns and slab surface described as fair-faced shall
be Type f.f. as follows:

(i) Type f.f. shall be an as struck finish entirely free from honeycombing, stains,
pins, clippings, lining joint marks, nail and screw marks, raised grain marks,
air holes and surface defects and shall be uniform in colour tone and
surface texture with clean true faces and arises.

8.2.3 Construction Bays

The Contractor shall submit to the Engineer for his approval prior to concreting his
proposals for the sequence of placing concrete and the position of horizontal and
vertical construction joints.

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Drainage and Irrigation Department

8.2.4 Small Precast Items

a) Small precast items such as lintels, sills and padstones shall be built in as the
work proceeds and shall have a fair-faced Type f.f. finish where exposed to view
and hacked surfaces where plastered.

b) Lintels shall have a minimum bearing of 100 mm or larger if indicated on the

drawings and shall have inserts for fixing windows and/or doors cast in.

c) Sills shall be weathered and have a throat as described, if projecting, and shall
have inserts for fixing windows and/or doors cast in.

8.2.5 Cast in Fixings

Cast in fixings shall be securely fixed to formwork ready for casting and shall be true
to line in the positions shown on the drawings.

8.2.6 Timber Cast in Fixings

Timber cast in fixings shall be made from 38 mm x 38 mm dovetailed shaped

softwood battens pressure impregnated with preservative.

8.3 BRICKWORK AND BLOCKWORK

8.3.1 Damp Proof Course

a) Horizontal and vertical damp proof courses shall be hessian based lead cored
bituminous damp proof course weighing not less than 4.4 kg/m2 to accepted
standards and approved by the Engineer.

b) Horizontal damp proof courses shall be laid on an even level bed of fresh mortar
and shall be lapped for the full width of the sheet at corners and junctions.
Stepped damp proof courses shall be wide enough to be built in to both skins of
the wall and to cross the cavity in one piece.

c) Vertical damp proof courses shall be continuous and shall be the width of the
block closing the reveal.

d) Damp proof courses shall not be bridged with mortar.

8.3.2 Wall Ties

a) Wall ties shall be 18/8 stainless steel vertical twist type 200 mm long.

b) Wall ties shall be built in the mortar beds as the work proceeds and shall be
spaced at a maximum of 900 mm horizontally and 450 mm vertically and shall be
staggered. Each door and window opening shall have wall ties at each joint at
225 mm centres vertically.

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Drainage and Irrigation Department

8.3.3 Door and Window Frame Ties

As described for Joinery Fixing Accessories. Door and window frame ties shall be
fixed as described under Joinery Work.

8.3.4 Mastic

a) Mastic for pointing door and window frames shall be one part gun-grade
polysulphide mastic to accepted standards and approved by the Engineer.

b) Mastic seals to windows or door frames shall be neatly gun applied to clean, solid
and dry backgrounds in one operation. The mastic shall be a triangular seal
across the whole joint and any surplus shall be cleaned off when set.

8.3.5 Brickwork and Blockwork

Brickwork and blockwork shall be as specified in Section 5.

8.3.6 Cement Mortar

Cement Mortar shall be as specified in Section 5.

8.3.7 Pointing

All pointing shall be done as the work proceeds and shall be flush with face of
blockwork.

8.3.8 Hollow Walls

Hollow walls shall be constructed with an outer skin of blockwork and an inner skin of
blockwork leaving a cavity of the widths shown. The two walls shall be tied together
with wall ties as described and the cavity shall be kept and left clear of all droppings.
Openings shall be left at intervals in the blockwork at the bottom of the cavities and all
debris shall be cleared out and the openings bricked up on completion. Cavities shall
be closed at opening reveals with either brick or block to match the surrounding
material and a continuous vertical damp proof course shall be built in.

8.4 ROOFING

8.4.1 Roof Screed

Roof screed shall be laid to fall over the concrete roof slab and shall have a minimum
thickness of 35 mm and maximum thickness of 75 mm. The screed shall be
thoroughly mixed 1:4 cement/sharp sand mix with very little water added. The screed
shall be laid and compacted and shall be levelled off and finished with a steel trowel.
Precautions must be taken to prevent rapid or excessive drying out.

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Drainage and Irrigation Department

8.4.2 Roof Primer

Primer for concrete shall be suitable for use with the waterproofing membrane and
shall be applied in accordance with the manufacturer's instructions.

8.4.3 Waterproofing Membrane

a) Flexible waterproofing membrane for roofing shall be bitumen based to accepted

standards and approved by the Engineer.

b) Surfaces to receive the membrane shall be smooth, dry and free from dust. The
membrane shall be laid on a primed surface and in accordance with the
manufacturer's recommendations.

8.4.4 Roof Insulation

Roof insulation shall be 75 mm thick closed cell non-absorbent rigid polystyrene

insulation board. The insulation boards shall be placed immediately after the
membrane has been laid.

8.4.5 Roof Surface

Roof surface shall be 50 mm thick 450 mm x 450 mm precast concrete paving slabs
laid dry.

8.4.6 Roof Decking

The roof decking shall be aluminium profiled sandwich sheeting fixed to Metsec ‘Z’
section purlins all in accordance with the manufacturer’s instructions. The Contractor
shall provide working drawings and manufacturers literature for approval before
ordering the same.

8.4.7 Fascia Cladding

The fascia cladding shall be of single skin construction formed from profiled
aluminium sheeting with matching aluminium-profiled flashings. The Contractor shall
provide working drawings and manufacturer’s literature for approval before ordering
the same.

8.5 JOINERY

8.5.1 Timber-General

All joinery shall be manufactured from timber complying with BS EN 942. No joinery
component shall be made from any species of timber which is indicated in BS En 942
as being unsuitable for that purpose. Timber for joinery shall be air dried and the
moisture content be allowed to reduce until it reaches a level in equilibrium with local
conditions. It will be deemed to have reached equilibrium when the moisture content
is 12% + 2%. All timber shall be sound and free from any fungal or insect attack. No

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Drainage and Irrigation Department

timber is to be incorporated in the Works which has been used for formwork,
planking, strutting, scaffolding, or any other form of plant work

8.5.2 Timber Sizes

Timber shall be 3 mm less per wrought or finished face than the sawn size.

8.5.3 Hardwood

Hardwood for joinery shall be sound, well conditioned and seasoned Mahogany or
Meranti with an average density of 529 Kg/m3 and a moisture content of 12% + 2%.
Exposed surfaces of joinery shall comply with the following requirements.

Knots : Pin knots up to 6 mm diameter will be permitted.

Checks & Shakes: Checks up to 3 mm width and 300 mm long will be permitted.

Pitch Pockets : Not permitted unless cut out and filled.

Plugs and Inserts : Not permitted.

Joints and Lamination

Glue Lines : Not permitted.

Rate of Growth : Not fewer than 8 growth rings per 25 mm at any point on any
cross section.

Slope of Grain : Not greater than 1 in 8.

Species & Character : Same on all surfaces and matched as far as possible.

Pinholes : Permitted if filled.

A sample of each representative section for use in the work shall be previously
submitted for approval by the Engineer's Representative.

8.5.4 Plywood

Plywood shall be from a manufacturing source approved by the Engineer and shall
comply in all respects with the requirements of BS 6566.

8.5.5 Timber Fixing Accessories

a) Nails for fixing joinery shall be aluminium or sheradised mild steel.

b) Screws for fixing joinery shall be sheradised mild steel.

c) Bolts shall be stainless steel.

d) Adhesives for exterior use shall be synthetic resin types, weather and boil proof,
complying with the approved standard. Adhesives for interior use shall be

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Drainage and Irrigation Department

synthetic resin types, moisture resistant and moderately weather resistant,

complying with the approved standard.

e) Door frame and lining fixing cramps shall be of 25 mm wide x 14 swg thick x 250
mm girth stainless steel, one end turned up 50 mm and twice drilled and the end
fishtailed for building in.

f) Dowels for fixing door frames shall be 10 mm dia. x 100 mm long stainless steel.

8.5.6 Timber Preservative

Timber preservative shall be water repellent and protect the timber from all wood
destroying fungi and insects particularly termites. The preservative shall be applied in
accordance with the manufacturer's instructions including treatment to all ends,
notches and joints in treated timber out on site.

8.5.7 Ironmongery

Ironmongery shall be as shown on the drawings.

8.5.8 Workmanship

a) All exposed faces of joiners work shall have wrought faces.

b) All arises shall be rounded to a 1.5 mm minimum radius unless specified or drawn
to a greater radius.

c) Where the term 'framing or framed' is used it shall mean all halvings, dovetails,
tenons and hardwood pins and the best known means of putting this work
together.

8.5.9 Fabrication

a) All joinery is to be purpose made and constructed in workmanlike manner,

morticed and tenoned, dovetailed, tongued and grooved, glued, pinned, screwed,
etc., as best suited to the particular part. All mortice and tenon joints are to be
pinned with hardwood dowels or with brass pins in addition to wedging and
gluing. All joinery shall be put together with waterproof adhesive.

b) All carpenter's work shall be accurately set out and shall be framed together and
securely fixed in the best possible manner with properly made joints. All
necessary brads, nails and screws, etc., shall be provided to the approval of the
Engineer.

8.5.10 Storage

a) All joinery shall be protected from the weather during transit and shall be stored
under cover, clear of the ground in clean, dry ventilated conditions so as to
maintain the specified moisture content.

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Drainage and Irrigation Department

b) All framework shall be put together loosely and stored as described and shall not
be wedged and glued together until required for fixing.

8.5.11 Door Frames

External door frames shall be built in as work proceeds with fixing cramps as
described. The fixing cramps shall be screwed to the back of the frames at 450 mm
maximum centres with two serialised screws 25 mm long. The fishtail ends shall be
built in to the brickwork or blockwork mortar joints as the work proceeds.

8.5.12 Doors

a) External doors shall be hung on one and a half pairs of hinges unless otherwise
detailed, to give a maximum tolerance all round of 2 mm.

b) Panel doors shall be constructed in hardwood and shall comply with the
requirements of BS 459 and BS 4787.

c) Flush doors shall be solid cored, faced on both sides with 6 mm exterior marine
quality plywood with hardwood veneer to match panel doors and lipped with
hardwood. They shall be constructed in accordance with BS 4787.

d) Door sizes shall be as given in drawings and schedules.

e) Where shown on drawings doors shall have inset vision panels complete with
glazing to match adjacent windows.

f) Fire ratings for doors shall be minimum 2 hour in accordance with BS 476.

g) Door frames shall be screwed and plugged or cramped to brickwork or blockwork

to the satisfaction of the Engineer.

h) Where required on drawings proprietary plate glass double swing doors shall be
provided. Glazing shall match that for adjacent windows. Doors shall be installed
in accordance with manufacturer / supplier requirements.

i) No doors or frames shall be incorporated in the works without first obtaining the
Engineer approval of a sample.

8.6 METALWORK

8.6.1 Aluminium

Aluminium alloy sections for aluminium shall be type H59 TF box sections.

8.6.2 Aluminium Louvers

Aluminium louvers shall be made from NS 4 H3 aluminium and have a natural or

bronze anodised finish. Sizes to be as shown on the drawings.

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 General Specifications for Civil Works
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Drainage and Irrigation Department

8.6.3 Aluminium Windows

a) Aluminium windows shall be manufactured by an approved specialist window

manufacturer from extruded aluminium sections mechanically cleared and sealed.
Glazing to be fixed into opening with clip on aluminium beads and gasket sealed.

b) Finish to windows to be natural anodised 25 microns in thickness. Windows are to

be fixed into openings with stainless steel screws and sealed all round in mastic
bedding.

8.6.4 Ironmongery

a) Rates for supplying and fixing ironmongery shall include for all boring, cutting,
mortising, sinking, making good, replacing damaged screws, oiling, adjusting,
leaving in good working order and mastering all locks.

b) Screws shall be of suitable gauge and material for the purpose and shall match
the item to be fixed.

8.7 PLUMBING

8.7.1 General

a) The works covered under this contract include all the supply, installation testing
and delivery in good operating conditions of all the plumbing works as described
in these specifications and/or shown on the drawings.

b) The Contractor shall supply all the necessary components and accessories as
well as manpower, scaffolding, painting, etc., to provide a complete operational
system.

8.7.2 Sanitary Fixtures

a) Supply and install all sanitary fixtures as shown on the drawings and described in
the specifications.

b) Sanitary tapware and waste fittings for basins shall be in accordance with BS EN
274.

c) Vitreous china fixtures shall be of first quality with smooth glazed surfaces, free
from warp, cracks, discolorations or other imperfections.

d) Fixtures shall be set in a neat; finished and uniform manner making the
connection to all fixtures at right angles to the wall of concealed holding type,
unless otherwise directed by the Engineer. Fixtures are not to be set until so
directed by the Engineer.

e) Ample application of petroleum jelly shall be made to all surfaces of exposed

chromium plated piping, valves and fittings and stainless steel fixtures
immediately after installation.
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f) Concealed brackets, hangers and plates shall have a shop coat of paint.

g) Plastic piping systems for soil and waste discharge (low and high temperature)
within the building superstructure shall be uPVC as per BS EN 1329-1.

8.7.2.2 Wash Hand Basins (W.H.B)

a) Supply and install W.H.Bs wherever shown on the drawings. Each W.H.B shall
be white coloured vitreous china complete with its pedestal.

b) The lavatory shall be furnished with the following:

(i) • Wall supports.

(ii) • Wash hand basin mixer and tap unit.

(iii) • Chrome plated bottle trap with wall flange.

(iv) • Vitreous china shelf 560 mm of the same colour as the fixture.

(v) • Vitreous china soap holder.

(vi) • Chrome plated angle valves for hot and cold water supply complete with
copper tube and handle.

8.7.2.3 Showers

Showers shall be supplied and installed wherever shown on the drawings. Each
shower shall be white coloured vitreous china with complete accessories.

(i) Floor support and fixings.

(ii) Combined mixer and tap unit.

(iii) Concealed piped fixed shower head and spray rose.

(iv) Vitreous china soap holder.

(v) Metal shower rail and fixtures and curtain rings.

(vi) Shower curtain.

(vii) Chrome plated outlet with bottle trap (removable type).

8.7.2.4 European water closets

Water closets of this type shall be supplied and installed wherever shown on the
drawings. Each closet shall be white coloured with complete accessories. It shall be
of floor mounted type with floor outlets trap.

(i) Coloured seat and cover

(ii) Outlet connector with rubber sealing ring and fixing pins.
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(iii) 80 cm long chrome plated hose complete with angle valve, nozzle and
hook.

(iv) Chrome plated floor fixing screws and gaskets.

(v) Toilet paper holder.

(vi) All necessary fixing and accessories required for its installation, fixing and
connections to water supply and waste and its satisfactory operation.

8.7.2.5 Asian water closets

Water closets of this type shall be supplied and installed wherever shown on the
drawings. Each closet shall be white coloured with complete accessories. It shall be
of flush floor type with back outlet trap.

(i) 80 cm long chrome plated hose complete with angle valve, nozzle and
hook.

(ii) Toilet paper holder.

(iii) All necessary fixing and accessories required for installation, fixing and
connections to water supply and wastewater and its satisfactory operation.

8.7.2.6 Electric water heaters

a) Electric water heaters of capacities shown shall be supplied and installed

wherever shown on the drawing.

b) Electric water heaters shall be of the storage type, cylindrical shape white
enamelled, insulated and complete with the following:

(i) Electric heating element of capacity corresponding to the following

schedule:

Capacity Litres Capacity Watts

50 1000

(ii) • Chrome plated recessed type gate valves at the inlet and outlet.

(iii) • Non return valve at inlet.

(iv) • Thermometer. -Thermostat.

(v) • Electrical connection.

(vi) • Relief valve.

(vii) • Metallic supports and accessories required for its installation, connection,
support, fixing and its satisfactory operation.

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8.7.2.7 Air hand dryers

Electric powered automatic air hand dryers shall be supplied and installed wherever
shown on the drawings. Each unit shall be white enamelled, insulated and with
electric supply and local isolation switch and shall be in accordance with IEE
regulations. Units shall be supplied complete with fixings.

8.7.2.8 Towel holders

Proprietary industrial duty paper towel dispensers shall be supplied and installed
wherever shown on the drawings. All units shall be of a single type and size, and
shall be supplied complete with opening keys (2 No./Unit) and necessary fixings.

8.7.3 Copper Tubes

a) Copper tubes shall be half hard copper tube of accepted standard approved by
the Engineer.

b) All Hot and Cold water installations shall be made using copper pipes. Copper
pipes shall be of the seamless hard drawn type.

c) Pipes of appropriate types shall be used for underground and over ground
installation.

d) Soldered joints for tubing shall be made with approved fittings. Surface to be
soldered shall be cleaned bright. The joints shall be given a thin coating of
approved soldering flux and the tubing end inserted into the fitting as far as
possible.

8.7.4 Copper Fittings, Waste Pipes, Ball Valves etc.

a) All fittings shall be of an accepted standard approved by the Engineer and as

described on the drawings.

b) Fittings shall be of the same material and weight as the pipes and shall be
suitable for solder jointing pressure type. Heating and finishing of the joint shall
be done in accordance with the recommendations of the manufacturer/supplier of
the fittings, using solid string or wire solder composed of 50 percent lead for
inside and 95 percent tin and 5 percent antimony for underground.

8.7.5 uPVC Pressure Pipes and Fittings

a) uPVC pressure pipes and fittings for water supply shall be of an accepted
standard approved by the Engineer.

b) The pipe shall be homogenous throughout and free from visible cracks, holes,
foreign inclusions or other defects. The pipe shall be as uniform as commercially
practicable in colour, capacity, density and other physical properties.

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c) All fittings and accessories shall be of same material and quality as the pipe and
jointing shall be of the spigot and socket cemented type where solvent cement is
applied to both parts. After pushing the pipe into the socket the joint shall be
allowed to set for at least 10 hours.

8.7.6 Workmanship

The plumbing installation shall be carried out to the satisfaction and in accordance
with the Acts and By-laws of the Dubai Electricity and Water Authority.

8.7.7 Pipe work

All pipework shall be neatly executed in long lengths to avoid unnecessary jointing.
Horizontal pipes shall be fixed with a slight fall to prevent airlocks and to enable the
system to be easily drained down.

8.7.8 Copper Tube Fixing

a) Copper tube shall be fixed clear of walls and ceilings with two piece copper
spacing clips or with proprietary plastic pipe clips. Clips shall be at 1.20m
horizontally and 1.50m vertically for 15mm diameter pipes and at 1.80m and
2.40m respectively for 22mm and 28mm diameter pipes. Capillary joints shall be
neatly made with all surplus solder removed.

b) Screw threads on compression joints shall be wrapped with PTFE tape prior to
tightening.

8.7.9 Waste Pipes

uPVC waste pipes for sinks and urinals shall be fixed and jointed in accordance with
the manufacturer's instructions. Fixing clips shall be at 0.50m horizontally and 1.20 m
vertically and joints shall be by 'O' rings, seals or solvent cement. Care shall be taken
to allow for expansion in accordance with manufacturer's instructions.

8.7.10 Sleeves

uPVC sleeves shall be provided through walls and ceilings for pipes and shall be
internally 3 mm minimum larger than the pipes.

8.7.11 Testing

a) Soil and waste pipes shall be air tested for leaks to a pressure of 38 mm water
gauge, constant for three minutes.

b) Rainwater pipes shall be tested for leaks as above and gutters shall be tested by
filling with water to overflow level.

c) Testing shall be undertaken to hidden sections of pipework before they are built
in.

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d) All leaks found shall be rectified and retested.

8.7.12 Storage Tanks

a) GRP cold-water storage tanks shall be provided.

b) Water storage tanks shall be supplied, erected and connected in the position
indicated on the approved drawing and in accordance with the details provided.
The tank shall be under a shade.

c) The tank shall be of the size and capacity indicated on the drawing.

d) The capacity shall be without free board unless specifically indicated otherwise.
The tank shall be made of insulated GRP panels to suit the dimensions and
capacity indicated

e) The tank shall have connections as required by the Water Supply Authority
regulations positioned as required to conform to the regulations and shall include
the following:

(i) Mains cold water inlet to tank complete with ball valve as indicated
elsewhere and full way gate pattern isolating valve.

(ii) Cold Water down feed connection complete with full way gate pattern
isolating valve for parent service.

(iii) Overflow connection.

(iv) Drain connection complete with bronze gate valve having wheel handle,
non-rising stem, screwed bonnet, solid wedge type manufactured in
accordance with BS 19 arranged to drain from the bottom of the tank.

f) All tank connections shall be full bore of the sizes indicated on the drawings.

g) The outlet from the drain valve shall be run to the position indicated on the
drawing.

h) All tank overflows shall be run to the position indicated on the drawing.

i) The tank shall be provided with a lightweight dust lid complete with easily
removable 300 mm min. square flanged and bolted on access cover positioned
directly above the ball valve, and complete with mushroom cowled ventilator.

j) The tank shall be supported on RSJ's not less than 75 mm wide at 610 mm
centres in one direction only and in accordance with the manufacturer's
requirements.

k) On completion of installation the tank shall be filled and tested for a minimum
period of 2 hours. For a satisfactory test all joints shall remain watertight, no leaks
shall be detected, and no visible bulging of the tank walls shall occur. Should the

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test not prove satisfactory, all defects shall be repaired and the tank re-tested at
no cost to the contract.

8.8 PLASTERWORK & OTHER WALL, FLOOR & CEILING FINISHES

8.8.1 Cement

Cement shall be Portland Cement as described in Section 3.

8.8.2 Lime

Lime shall be the hydrated type to the approved standard.

8.8.3 Sand

Sand for plasterwork with gypsum plasters shall be suitable for use with the brand of
gypsum plaster used. Sand for rendering, internally and externally, and floor screeds
shall comply with requirements as specified in Section 5 .

8.8.4 Gypsum Plasters

Gypsum plaster shall be of an accepted standard approved by the Engineer.

8.8.5 Plaster Trims

Metal angle beads and plaster stops for plasterwork and plasterboard shall be
manufactured from galvanised mild steel.

8.8.6 Metal Lathing

Metal lathing shall be manufactured from galvanised mild steel having a minimum
shortway aperture of 6 mm.

8.8.7 Plasticizers

Plasticizers shall be an approved vinyl resin type and used in the manner and
proportions recommended by the manufacturer.

8.8.8 Bonding Agents

Bonding agents generally shall be an approved polyvinyl acetate (PVA) type and
used in the manner and proportions recommended by the manufacturer.

8.8.9 Storage

a) Plaster shall be stored in a building in dry condition on timber platforms and shall
be used within two months of manufacture.

b) Plasterboards shall be stored in a building in dry condition and shall be laid flat
and stacked on a sheet of polythene.

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8.8.10 Floor Tiles

a) Vitrified and fully vitrified floor tiles shall be as detailed on the drawings.

b) Floor tiling shall be laid with a proprietary tile adhesive (approved by the
Engineer) either directly onto a clean, dry and level concrete sub floor, or on a
cement/sand screed laid over the sub floor. The sub-floor surface shall be
scabbled to remove all surface laitance prior to tiling or screeding. The screed
shall be mixed semi dry by hand or in a pan mixer and shall be a 1:4
cement/sharp sand mix with just enough water to enable it to hold together when
squeezed in the hand. The sub floor shall be kept damp for 24 hours and the
screed shall be laid and well compacted to a thickness of 56mm and brought to
the required levels using a draw float. The finished floor screed shall be kept
damp for a period of 7 days prior to commencement of tiling. The tile adhesive
shall be spread evenly by steel trowel to a thickness of 3mm onto which the
clean, dry tiles shall be laid to give a 3mm minimum joint width. The tiles shall be
grouted with a proprietary and approved tile grout within a minimum period of 24
hours after laying.

8.8.11 Wall Tiles (Internal)

Coloured wall tiles shall be 152 x 152 x 5.5mm thick glazed tiles approved by the
Engineer.

8.8.12 Wall Tiles (External)

a) External wall tiles shall be as detailed on the drawings.

b) The concrete surface to receive tiling shall be prepared as follows:

(i) Concrete surface to be 100% keyed by either bush hammering, hacking or

water scabbling of smooth surface.

(ii) Concrete surface shall be thoroughly moistened and a concrete slurry mix
of one part cement to two parts of medium sharp sand applied as
splatterdash thrown onto concrete surface.

(iii) While the surface is wet apply 1:3.5 mix sand/cement render to a thickness
of 12mm in two coats to a plumb and level finish and with wood float finish.

c) The completed rendering is to be protected and allowed to dry slowly with

damping as necessary. After curing, the surface is to be allowed to dry completely
before the fixing of tiles.

d) Tiles shall be fixed with proprietary tile adhesive (approved by the Engineer). The
tiles are to be bedded strictly in accordance with the manufacturer's instructions
with 10mm joints between tiles.

e) At least 24 hours after fixing tiles are to be jointed using approved mortar.
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f) Movement joints are to be formed between tiles in positions shown on the

drawings to the full depth of the tiles, bedding and render. Joints are to be 10mm
wide and are to be filled to within 8mm of surface with inert filler and finished with
2 part polysulphide pointing in colour to match tile jointing.

8.8.13 Tile Adhesive

Tile adhesive for floor and wall tiling shall be as recommended by the Tile
Manufacturer and used in accordance with the adhesive manufacturer's instructions.

8.8.14 Tile Grout

Tile grout for floor or wall tiles shall be as recommended by the manufacturers of the
ceramic tiles and used in accordance with the manufacturer's instructions.

8.8.15 Expansion Joints

a) Expansion joints in floor and wall tiling shall be 6.5 mm wide Polyethylene backing
strip with 6.5 mm wide approved silicone sealant, gun applied on the face in
accordance with the manufacturer's instructions.

b) Expansion joints in floor tiling shall be at 6 m maximum centres in both directions

and around the perimeter of rooms, over structural joints and around machine
bases and holes in the floor. The joints shall be the full depth of the floor tiles,
bedding and screed x 6.5 mm minimum width. The joints shall be primed with two
coats of approved primer and when dry, filled up to within 6 mm of the tile finish
with polyethylene compressible foam strip. An approved joint sealant shall then
be gun applied and tooled to a slightly concave smooth even finish.

8.8.16 Backgrounds

All backgrounds shall be clean, dry, and free from efflorescence, paint, oil and dust
and adequately prepared to provide a good key. All loose, flaking and unsound
material shall be completely removed and all mortar joints shall be raked out, if
required, to a minimum depth of 10 mm. Concrete surfaces shall be well wetted five
minutes prior to plastering or rendering.

8.8.17 Dissimilar Materials

Joints between dissimilar materials such as blockwork and concrete shall be covered
with a 300 mm wide continuous strip of expanded metal lathing fixed to both sides
with masonry nails or plugs and screws at 200 mm centres.

8.8.18 Hacking

Concrete surfaces shall be well hacked to expose the aggregate thus providing a firm
coarse textured background.

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8.8.19 Dubbing Out

Dubbing out of all areas to receive plaster or render shall be in the same mix as the
subsequent coat, not exceeding 10 mm thickness in one application, and shall be
allowed to harden.

8.8.20 Splatterdash or Stipple Coat

Splatterdash or stipple coats shall consist of 1:1.5 cement/sharp sand mixed with
50% water/50% PVA bonding agent to form thick slurry. The mixture shall be
vigorously brushed onto the background and stippled to give a close textured key.
The resulting finish shall be kept damp to prevent rapid drying out and allowed to
harden for seven days minimum before subsequent coats are applied.

8.8.21 Internal Finishes-General

All internal finishes shall not commence until the building is watertight, including
glazing, and reasonably dried out.

8.8.22 Internal Render

Internal render shall be applied to concrete blocks as follows:

The render shall be two coat work comprising a stipple coat as described previously
and a finishing coat giving a maximum thickness of 12 mm. The mix shall be in the
proportion 1:1:6 cement/lime/sand. The render shall be kept damp for a minimum of
three days. All window and door openings must be closed to prevent through
draughts causing rapid drying out.

8.8.23 Stucco

A PVA copolymer based putty for concrete and plaster shall be applied, in
accordance with the manufacturer's instructions, to the surface of the internal render
after curing has taken place. The stucco shall only be applied in sufficient thickness to
seal the surface of the render and remove minor surface irregularities to give a
smooth surface ready to receive the decorative finish.

8.8.24 External Render

a) External render shall be applied to concrete, concrete blocks and clay bricks as
follows:

b) The render shall be three coat work comprising a stipple coat as described
previously, an undercoat and a finish coat giving a maximum thickness of 16 mm.
The mixes shall be in the proportions shown on the schedule of mixes. The
undercoat shall be level, true and of sufficient thickness to prevent the
background joints showing through and shall be kept damp for three days before
applying the final coat.

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c) Where shown on the drawings the final coat shall be approximately 5 mm thick
coloured Tyrolean open honeycombed texture machine applied render.

d) A key for the final coat shall be provided by combing the undercoat prior to setting
with wavy lines 20 mm apart and 5 mm deep. The final coat shall be 6 mm
minimum thickness and worked to a level and smooth finish with a wooden float
with clean, true and level arises. The whole shall be protected from rapid drying
out in hot, dry and windy weather.

Table 8.1:Schedule of Mixes for External Render

Mix Type Concrete, Concrete Blocks or Aerated Concrete Blocks of
Engineering Bricks Soft Clay Bricks

Undercoat Finish Undercoat Finish

Cement:Lime:Sand 1:1.5:4 to 4.5 1:1:5 to 6 1:2:8 to 9 1:2:8 to 9

Cement:Ready 1:4 to 4.5 1:5 to 6 1:8 to 9 1:8 to 9

Mixed Lime / Sand

Cement:Sand with 1:3 to 4 1:5 to 6 1:7 to 8 1:7 to 8

Plasticizers

8.8.25 Insitu Floor Finishes

8.8.25.1 Terrazzo finish

a) Cast in situ terrazzo flooring shall conform to BS 8204.

b) The size of terrazzo panels shall be as directed by the Engineer The sub-floor
shall be clean from dust, oil or grease and any other foreign matter and shall
provide a good mechanical key.

c) The screened bed shall be of a minimum thickness of 25 mm and the mix shall be
1 part cement to 1 part of fine aggregate and 2 parts of coarse aggregate by
volume. The amount of water added shall be the minimum necessary to give
sufficient plasticity for laying and compacting. The "green" concrete shall be
covered with sacks, polyethylene sheet, or tarpaulins, carefully lapped and
supported on a temporary framework.

d) Dividing strips shall be of ebonite 4 mm thick and shall be embedded to the full
depth of the screened bed and reach to the exact level of the finished floor.

e) The main body of the flooring shall not be less than 16 mm thick. The mix shall be
1 part of cement, pigmented in the approved colour shade, to 2½ parts of crushed
marble. The marble chipping shall be free from fines, dust, dirt or other impurities
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and shall be approved by the Engineer. The amount of water added shall be
sufficient to produce a plastic but not fluid mix.

f) The terrazzo finish shall stop 10 mm from the walls and covered skirtings shall be
added. They shall be of the same mix and rise to 100 mm above floor level.

8.8.25.2 Granolithic Flooring

a) Granolithic surfacing shall consist of 2½ parts of granite aggregate to one part

cement. The granite aggregate shall consist of clean chipping of 6 mm single
size in accordance with BS EN 12620, except that 100% shall pass the 10 mm
sieve and shall have sufficient fine sand to produce a mixture of satisfactory
workability. Aggregates shall be free from deleterious material in accordance with
the relevant clauses in the specification for concrete.

b) Normally the ratio of granite aggregate to sand is 2½:1. An approved hardener

shall be incorporated in the topping mix. The water/cement ratio shall be kept to a
minimum to provide a workable mix capable to being fully compacted.

8.8.25.3 Acid Resistant Floors

a) Where required by the drawings, rooms and enclosures liable to acid chemical
spillages shall be provided with acid resisting flooring.

b) Acid Resisting Asphalt, laid on a base coat shall be laid by a specialist sub-
contractor who must be approved by the Engineer, in accordance with BS 8204.

c) The asphalt shall be capable of withstanding dilute inorganic acids having a

specific gravity not exceeding 1.4 and temperature not exceeding 45ºC.

d) The finished thickness of the asphalt shall be 20 mm and shall be laid in two
coats over an impregnated flax felt to BS EN 13707 Type 4A (1) and weighing not
less than 15 kg per 23 metre roll.

e) The asphalt floor shall be finished with a true and even surface ready to receive
tile paving.

f) Acid resisting vitrified tiles and fittings to BS 6431/BS EN ISO 10545 shall be
99.7% acid proof to BS EN 14483.

g) Coved corner skirting shall be provided around the perimeter of the room. Tiles
shall be bedded, straight joint, set true and level, on cement/sand screed mix
(1:3), thickness 36 mm, joints to be 5 mm wide.

h) The tiles to be thoroughly pointed up with a suitable and approved epoxy resin
type cement. The recess at the top edge of the skirting shall be pointed similarly
and finished neatly with a slight weathering flush to the top of the skirting tile.

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i) Expansion joints 12 mm wide to full depth of tile and screed shall be formed
between the coved skirting and adjoining floor tiles and pointed up with a suitable
and approved flexible epoxy resin type cement.

8.8.25.4 Cleaning and Protection of Floors

All floor finishes shall be left in a clean and perfect condition, and all dirt, grease,
extrusions of bedding or other materials are to be carefully removed without
damaging the floor finish. The Contractor must protect all floors and skirtings from
damage after laying, using the most suitable and approved means for the type of floor
concerned. Any damage resulting from the floors not being properly protected shall
be made good to the satisfaction of the Engineer.

8.8.25.5 Finishes Generally

The quality of all final finishes shall be subject to the approval of the Engineer and
any remedial measures which he considers necessary, including the breaking out and
replacement of sub-standard areas, shall be carried out by the Contractor .

8.9 GLAZING

8.9.1 Glass

a) Glass for glazing shall be the best of its respective kind and free from blemishes
and imperfections. Glass shall be as shown on the drawings.

b) All glass shall comply with the requirements of BS 952-1 and shall be free from
specks, bubbles, smoke vanes, scratches and any other defects. All glass shall
be delivered in proper containers with manufacturer / supplier name, guarantee,
type of glass and thickness or weight of glass attached to the outside of the
containers.

c) All external glazing shall be laminated glass fabricated as factory sealed double
glazed units, and tinted to an approved shade and colour.

d) All glass surfaces shall be kept dry during transit and storage. Glass becoming
moist from condensation or other causes shall be thoroughly dried and aired.

8.9.2 Glazing

a) Only single and complete sheets of glass shall be used in each opening to be
glazed. No butt joints will be permitted.

b) All glass shall be cut accurately to the rebates and all glazier's work shall be
carried out in the best approved manner and in accordance with the requirements
of BS 6262.

c) All glass shall have clean cut edges. Wired glass shall be cut so that the wires
are parallel to the edges.

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d) The Contractor shall replace all cracked, scratched, damaged or defective glass
with new, and leave all glass sound and perfectly clear on completion.

8.9.3 Bedding Compound

a) The bedding compound for external glazing shall be an approved non setting
butyl rubber based proprietary compound and sufficiently elastic to allow for
thermal or other movement of the glass and timber, compatible with the approved
decorative wood stain.

b) The bedding compound shall show no sign of separation after bedding.

8.9.4 Proprietary Curtain Glazing

Where required by the drawings a proprietary curtain glazing system shall be used.
This shall be installed by suitably qualified personnel in strict accordance with system
manufacture / supplier recommendations.

8.10 PAINTING AND DECORATING

8.10.1 Painting-General

a) All primers, oil bound undercoats and finishes, emulsions and polyurethane
interior varnishes shall be used in strict accordance with the manufacturer's
recommendations and shall be obtained from an approved manufacturer.

b) Only fresh paint delivered to site in original sealed containers shall be used. Each
container shall be labelled with the manufacturer's name, contents, colour,
quantity, batch number and date and instruction on method of application.

8.10.2 Exterior Stain

Pigmented stain shall be PX 65 as manufactured by Sadolin's Ltd., and used in

accordance with their recommendations, or other equal and approved, two coats
before fixing and one coat after fixing.

8.10.3 Stopping to Plaster

Plaster shall be clean and dry and free from loose material. Holes and cracks shall be
cut back and solidly filled, allowed to dry and rubbed down smooth.

8.10.4 Steel Priming

Mild steel shall be blast cleaned and primed with two coats of primer within four hours
of cleaning.

Galvanised mild steel shall be degreased with white spirit and primed with two coats
of primer.

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8.10.5 Oil Based Paint

Interior primed softwood and all primed mild steel shall be painted with two
undercoats and one gloss or semi-matt finish coat of oil-based paint to give a smooth,
even and solid finish, all as instructed. Each coat shall dry overnight before applying
further coats.

8.10.6 Internal Finish to Walls

The paint finish to internal walls shall be PVA copolymer matt emulsion paint or as
detailed on the drawings.

8.10.7 Ironmongery

All fixed ironmongery except hinges shall be removed before painting and refixed on
completion.

8.10.8 Workmanship

a) All painting shall be carefully executed with clean brushes and in the best manner
and applied strictly in accordance with the manufacturer's instructions.

b) All paints, stains and varnishes shall be well stirred before use and thinned only in
accordance with the manufacturer's recommendations.

c) Painting of exterior work shall not be carried out in wet, dusty or foggy weather
and interior work shall not proceed in dusty conditions.

d) All woodwork shall be prepared to a fine clean finish by scraping or sanding all
made dust free immediately before painting and coating.

8.10.8.2 Painting of Metalwork

a) Steelwork delivered to the Site unprimed shall be cleaned of impurities, shot

blasted, scraped or wire brushed to remove rust to the approval of the Engineer,
and painted with one coat of priming paint applied by brush.

b) Steelwork delivered to the Site primed shall be cleaned of impurities and damage
to the priming paint repaired to the approval of the Engineer.

c) Galvanized metal work to be painted shall be cleaned of impurities. Where rusting

has occurred the rust shall be removed by wire brushing and made good with an
approved rust inhibitor. The surface shall be coated with a mordant solution,
washed with clean water and painted with two coats of priming paint applied by
brush and one finishing coat of paint applied by brush.

d) Metalwork which is exposed shall be prepared and primed as above and shall be
painted with two undercoats and one finishing coat applied by brush.

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8.10.8.3 Painting of Concrete, Blockwork and Plaster

a) Concrete, blockwork and plaster surfaces to be painted or decorated shall have

all cracks cut out and made good to the satisfaction of the Engineer. The surface
shall be completely dry and shall be brushed free of impurities immediately prior
to the commencement of painting work.

b) Efflorescence shall be completely removed by rubbing down with dry coarse

cloths followed by wiping down with damp cloths and allowed to dry. All surfaces
shall be rubbed down with damp cloths and allowed to dry. All surfaces shall be
rubbed down with fine glass paper and brushed free of dust before applying any
forms of decoration.

c) Concrete blockwork and plastered surfaces which are to receive paint shall be
given one thin coat of oil putty and allowed to dry for at least two days. The
surfaces shall then be rubbed down with fine sand paper and given second thin
coat of oil putty and when completely set shall be rubbed down again with fine
glass paper before applying the primary coat of paint.

d) Emulsion of chlorinated rubber paint shall be applied by brush or roller and shall
consist of a mist coat and three coats of interior quality paint internally and a mist
coat and three coats of exterior quality paint externally.

e) Oil paint shall be applied by brush or roller and shall consist of a priming coat, two
undercoats and one finishing coat of paint.

f) Plastic resin paint shall be applied strictly in accordance with manufacturer/

supplier’s instructions.

8.10.8.4 Painting of Woodwork

Holes, cracks, knots and other defects in the surfaces of woodwork to be finished with
paint or varnish, shall be treated so as to ensure a smooth appearance of the coating.

8.11 WATER SUPPLY AND DRAINAGE

8.11.1 Water Supply System

The water supply system consists of three sub-systems as follows:

i. Potable Water Supply System

ii. Sanitary Water Supply System

iii. Hot Water Supply System

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8.11.1.1 General Requirements

Except for minor modifications, all fittings shall be standard manufactured products
commercially available for a minimum of two years after the scheduled completion
date of construction works.

All fittings shall be suitable for service and operating conditions as identified within
this specification.

All pipes and fittings shall be suitable for the fluid temperature between 10 °C and 35
°C.

The minimum design life of various components shall be as below:

- Civil, Structural & Piping – 50 years

- Mechanical – 25 years

- Electrical, Instrumentation & Controls – 10 years

All fittings shall be capable of satisfactory operation at the working pressure of the
pipeline into which it is installed, plus any surge.

All parts and components shall be designed and built for operation at normal flows
without seizure, cavitation, excessive vibration or strain and requiring only that degree
of maintenance generally accepted as normal for the specific type of equipment.

All parts and components shall be designed and built for interchangeability so that
replacement parts may be installed without additional fitting or machining.

8.11.1.2 Technical Requirements

1. General

Detailed design of water supply system shall be provided at the proposed facilities as
specified on the drawings and in Particular Specifications. The Contractor shall
submit the shop drawings of the water supply system to Engineer approval before
commencing the work at site.

2. Installation of Pipes and Ducts

All pipe work shall be installed by skilled and experienced personnel.

The Water Supply Systems shall be installed accurately in straight lines with
proprietary fittings used at any change in direction or level. All socketted pipes shall
be laid with the sockets facing upstream. All pipes shall be fully supported at the
intervals and using mounting in strict accordance with the recommendations of the
pipe material manufacturer.

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Immediately prior to laying, all pipes and fittings shall be examined carefully to ensure
that they are sound. No damaged or defective items shall be used. Any part length
used shall be cut squarely and cleanly at the end.

All pipes shall be clean before installation and jointing. All Water Supply Systems
shall include bends, tapers, junctions and other special pipes of a particular pattern
as required.

When pipes pass through walls, floors or ceilings they shall be sleeved and sealed.
All concealed pipes within walls, ceilings or floors shall be run within protective
conduit.

Pipes which are laid, or built into walls and manholes, but not immediately connected
up, shall be fitted with suitable temporary stoppers or seals, and the position of such
pipes shall be clearly defined by means of stakes or training wires properly marked or
labelled.

Before the commencement and for the smooth progress of the pipework installation,
the Concrator shall coordinate and finalize the routes, ground/invert levels, positions
of the manholes etc. with Engineer.

All the changes in the design shall be subject to the approval of Engineer.

3. Pipe Bedding and Surrounding Material

Pipe bedding and surrounding material shall be well rounded not angular.

When the as dug material is suitable, the bottom of the trench shall be trimmed and
loosened to form the bed otherwise the trench shall be excavated to a depth below
the invert level to allow for the thickness of bedding material. No sharp material shall
be in contact with the supply pipe.

When as dug material is not suitable, imported granular material as per BS EN 12620
shall be used.

All surround and backfill materials up to 300 mm above the pipe shall be loose laid
and hand compacted only.

If the as dug material contains stones larger than 40 mm the bedding material must
be extended 150 mm above the circumference of the pipe. Alternatively, the backfill
can be graded to eliminate stones exceeding 40 mm and this selected backfill used
for the first 300 mm above the circumference of the pipe. The remainder of the trench
may be backfilled with suitable excavated material.

4. Inspection Chambers, Valve Chambers and Pits

All water supply related concrete and steel structures shall be carried out in
accordance with the relevant specifications.

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All chambers and pits shall be constructed of reinforced concrete or of solid concrete
blocks to the internal dimensions laid out in BS 5834. Chambers and Pits shall be
designed for the vehicular or other loading to which they will be subjected.

Foundations to chambers and pits shall be of concrete complying with the relevant
clauses of the Concrete Specification and shall finish flush with the chambers and pit
sides unless specifically otherwise required.

Concrete block walls shall be bedded and jointed in cement and sand 1:4 mortar and
the joints on the internal faces raked out to form a key for rendering. Walls shall be
constructed in stretcher bond.

The internal surfaces of concrete block walls shall be rendered with cement and sand
1:2 mortar 10mm thick and the rendering shall be finished with a smooth and even
surface.

The ends of all pipes shall be neatly built into the blockwork and finished flush with
mortar. Where subsequent pipework is to be installed adequate free end is to be left
for later coupling.

Where the depth of invert of chambers exceeds one metre below the finished ground
level, stainless steel grade 316 steps as specified in BS EN 13101 shall be built in at
vertical intervals of 300mm, with alternate steps in line vertically and at 225mm centre
to centre horizontally.

Entry to deep chambers (> 2500 mm) shall be by means of one or more caged
vertical GRP ladders.

Chamber covers and frames shall be coated cast-iron complying with BS EN 124
approved or equal and shall be designed for the loading category to which they will
be subjected. The CONTRACTOR shall bed and haunch frames in cement and sand
1:3 mortar and seal covers with thick grease. Two sets of keys shall be delivered to
the Engineer for each pattern of cover supplied.

8.11.1.3 Potable Water System

The Potable Water Supply System shall be provided at proposed facilities as

specified on the drawings and in Particular Specifications.

The Potable Water Supply System also delivers water for service within buildings.

8.11.1.4 Sanitary Water Supply

a) The Sanitary Water Supply System is required to supply cold water to non-
potable consumers within the plant building and other buildings.

b) To ensure that no back contamination of the potable supply occurs, all sanitary
water is to be supplied from high level break tanks and cisterns fed from the
potable water system.
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8.11.1.5 Hot Water Supply

a) The Hot Water Supply System is required to provide Hot Water to non potable
consumers within buildings.

b) Hot water is to be supplied from local water heater tanks located at convenient
proximity to the consumers. Fed from the high level break tanks and cisterns
each system shall be in consequence a low pressure system although for design,
installation and test purposes shall conform to the same requirements as those
for the potable water supply system.

8.11.1.6 Materials

a) General

All materials to be supplied and installed in accordance with this specification shall be
subject to Engineer’s approval. The materials of all pipes, fittings, valves and
equipment supplied for the project shall be new and of first class quality, free from
scale, lamination, inherent corrosion and any other defects. Pipes, fittings, valves and
equipment shall be manufactured, inspected and tested in accordance with the
relevant British Standards and Codes of Practice, and shall be suitable for service
under the stated pressures and temperatures. All component materials for
incorporating into the water supply system shall be procured with BSI certification.

All materials to be incorporated in the work shall be handled and stored strictly in
accordance with the recommendations of the manufacturer.

b) Cold Potable Water Supply Pipework

1. Pipes and Fittings

Cold water pipes less than 3" diameter shall be of one of the following options
throughout:

- u-PVC pipes and fittings shall comply with BS EN 1452.

- Polyethylene pipes shall comply with BS EN 12201. Fittings to be of either

compatible thermoplastics to BS 7291 or Brassware to BS EN 12167/BS EN 1254.

- Copper pipes to BS EN 1057 with fittings to BS EN 12165/BS EN 1254.

Cold Water pipes of 3" diameter or greater shall be of one of the following options
throughout.

- GRP Pipes and Fittings to BS EN 1796.

- uPVC pipes and fittings to BS EN 1452.

- DI pipes and fittings to ISO 2531 BS EN 545.

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The CONTRACTOR shall perform the detail design for each supply system using one
of the above material options. The CONTRACTOR's complete detail design including
calculations, detail drawings and samples shall be submitted for ENGINEER’s
approval.

c) Sanitary Water Supply Pipework

1. Pipes and Fittings

Pipes and Fittings for Sanitary Water Supply System shall be provided in accordance
with the materials options as specified in respect of Cold Potable Water Supply
System above.

d) Hot Water Supply Pipework

1. General

All Hot Water Supply System pipes shall be in copper and shall be provided with
readymade plastic cover.

2. Pipes and Fittings

Pipes and Fittings shall be provided in accordance with the following:

- Above ground copper pipes shall conform to BS EN 1057 related table and shall
have joints and fittings of copper alloy to BS EN 12165 or BS 1254.

- Below ground copper pipes shall conform to BS EN 1057 and shall have joints
and fittings of gun metal to BS EN 1982.

3. Thermal Insulation

All exposed Hot Water Supply System pipes and fittings shall have thermal insulation.
Hot Water Supply Pipes and Fittings buried within walls ceilings or floors shall be
surrounded with fine grade vermiculite mixture.

e) Thermal Insulation & Weather Protection

1. Thermal Insulation

Minimum thickness of thermal insulation shall be as follows:

- Pipes up to 1½" diameter - 15 mm

- Pipes 1½" to 2½" diameter - 32 mm

- Pipes 3" diameter and above - 50 mm.

2. Weather Protection

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All pipes and fittings exposed to the effects of weather shall be thermally insulated as
above and provided with an approved white abrasion resistant weather proof coating
system.

f) Stop Valves, Stopcocks and Fittings

Stop valves less than 3" diameter shall be of the medium pattern type with female
ends and manufactured and tested in accordance with the requirements of BS 1010.

- The stop valve shall withstand a test pressure of 16 bar without leakage.

- The valve shall close in a clockwise direction.

Stop valves of 3" diameter or greater shall be approved standard stainless steel ball
valves complete with flanges as per project specifications.

1. Ferrules (with combined stopcock)

The ferrule combined with stopcocks shall be of hot pressed brass to BS EN 12165
with heavy gauge, swivel balancing, screw down type. ½" square head for closing
and opening with female ends. The spindle shall be of high tensile manganese
bronze to BS EN 12167. Threads shall be B.S.P in accordance with BS EN 10226-1.

2. Compression fittings

Where pipe joints and equipment couplings are made using compression fittings,
these shall be threaded B.S.P in accordance with BS EN 10226-1. Inserts shall be of
copper and male and female fittings shall be chamfered to suit assemblage and to
avoid crossing of threads.

Suitable change pieces and adaptors shall be used where required for coupling of
individual items of equipment not available with B.S.P threads.

g) Flexible Hose Assemblies

All flexible hose assemblies shall comply with BS 6501 and shall be of a type suitable
of withstanding the same pressure as the piping to which they are attached.
Assemblies shall be proprietary items and shall have compatible couplings with both
the pipe system and the individual consumer to which they are attached.

h) Water Filter Units

In-line water filter units shall be provided immediately upstream of each potable water
supply system consumer. Each filter unit shall be proprietary item capable of
withstanding the same pressure as the piping to which it is connected, shall be wall
mounted of canister type with removable porous unglazed ceramic filter element and
shall be protected by a stopcock at its inlet side. Filter units shall be supplied
complete with all fittings and fixings. Complete units shall be capable of delivering
water to meet the quality provisions of BS 6920.

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i) Cold Water Cisterns & Break Tanks

Cold Water Cisterns shall be provided in accordance with BS 7181 for up to 500 litre
size. Cisterns provided for holding of potable water shall be of a suitable grade and
materials to meet the provisions of water quality required under BS 6920. Cisterns
provided for holding of sanitary water only shall be of either GRP construction in
compliance with BS EN 13280 or of polyolefin construction in compliance with BS
4213.

Where storage requirements as per design exceed 500 litres, storage shall be in
approved covered segmented galvanised steel Break Tanks. Tanks shall be suitably
jointed, coated, lined and insulated using materials to meet the provisions of water
quality required under BS 6920.

j) Water Heater Cylinders

Water Heater Cylinders shall be in strict compliance with the requirements BS 853.

Cylinders shall be of double walled pre insulated type and of 50 litres minimum
capacity for each consumer location.

8.11.1.7 INSPECTION TESTING & COMMISSIONING

a) Civil Works

The following items shall be subject to field inspection in respect of setting out,
excavation, concrete works including reinforcement, protective membranes and
linings, inserts fixings and supports, backfilling and finishes, covers and frames and
access provisions:

- All manholes, inspection and valve chambers and pits

- All pipe trenches, road crossings, sleeves and ducts.

b) Pipe Works

As a minimum the following acceptance tests shall be performed at site:

- Visual inspection of all materials and fabrications installed

- Dimensional check

- Hydrostatic pressure test and leak test

- Impact resistance check.

c) Testing

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(i) The Contractor shall test all water supply systems pipelines, joints and
fittings prior to surrounding, backfilling, building in to walls & floors or other
concealment.

(ii) All tests shall be performed in convenient sections for each system in the
presence and to the satisfaction of the Engineer by experienced personnel.

(iii) All costs in providing personnel, apparatus, equipment and temporary works
for testing shall be borne by the Contractor.

(iv) Prior to the commencement of testing the system shall be thoroughly

cleaned by flushing with potable quality water to ensure no foreign matter
remains within the pipe.

(v) During the filling operation care must be taken to ensure that there is no
entrapped air in the system. The test pressure shall be applied gradually by
means of a suitable pump connected to the pipe in a manner satisfactory to
the Engineer. The pressure test shall be in accordance with BS EN 850.

(vi) All gauges used shall be new and shall be accompanied by the valid
respective calibration and test certificates. Gauges used for testing
pressure pipelines shall either be circular type, not less than 200 mm
diameter, calibrated in metres head water, or shall have a digital indicator
capable of reading increments of 0.1 m head.

(vii) The pipes shall then be filled and allowed to stand for a period of 24 hours
before testing to achieve conditions as stable as possible for testing.

(viii) The pressure in the pipeline shall then be raised steadily until the specified
test pressure is reached in the lowest part of the section and the pressure in
the pipeline shall be checked after a period of 60 minutes and test pressure
shall be restored by pumping and the loss measured by drawing off water
from the pipeline till the pressure is reached again. During the test all
exposed pipes, joints, fittings, valves etc. shall be carefully examined, and
any joint or item showing signs of leakage shall be rejected. All sections or
items rejected shall be removed and replaced by the Contractor at his own
expense, and the test shall be repeated to the satisfaction of the Engineer.

d) Commissioning

(i) Prior to final handover each supply system shall be drained of test water,
flushed, refilled and disinfected in accordance with the requirements of
AWWA C 651 or as directed by and to the satisfaction of the Engineer.
Pipes shall be flushed with sufficiently high velocities to remove any
sediment or debris. The flushing velocity shall be not less than 1 m/s. The
time required for flushing shall be at least the time necessary to discharge
three times the contents of the section being flushed.

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(ii) Flushing water shall be discharged via temporary discharge hoses to either
the surface water drainage system, if commissioned, or to mobile tanker for
disposal.

(iii) All costs associated with providing experienced personnel, apparatus,

equipment, consumables and temporary works for flushing and disinfecting
shall be borne by the Contractor.

8.11.2 Water Drainage System

8.11.2.1 General Requirements

Except for minor modifications, all fittings shall be standard manufactured products
commercially available for a minimum of two years after the scheduled completion
date of construction works.

All fittings shall be suitable for service and operating conditions as identified within
this specification.

All pipes and fittings shall be suitable for the fluid temperature between 10 °C and 35
°C.

The minimum design life of various components shall be as below:

- Civil, Structural & Piping – 50 years

- Mechanical – 25 years

- Electrical, Instrumentation & Controls – 10 years

All fittings shall be capable of satisfactory operation at the working pressure of the
pipeline into which it is installed, plus any surge.

All parts and components shall be designed and built for operation at normal flows
without seizure, cavitation, excessive vibration or strain and requiring only that degree
of maintenance generally accepted as normal for the specific type of equipment.

All parts and components shall be designed and built for interchangeability so that
replacement parts may be installed without additional fitting or machining.

8.11.2.2 Technical Requirements

a) General

Detailed design of water drainage system shall be provided at the proposed facilities
as specified on the drawings and in Particular Specifications. The Contractor shall
submit the shop drawings of the water drainage system to Engineer approval before
commencing the work at site.

b) Installation of Pipes and Ducts

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All pipe work shall be installed by skilled and experienced personnel.

The drains shall be accurately laid in straight lines and to self-cleansing gradients.
Pipes shall be laid singly and the level of each pipe shall be tested in an approved
manner using sight rails erected at manholes and at intermediate positions as
necessary. Pipes shall be laid with the sockets facing upstream.

Immediately prior to laying, all pipes and fittings shall be examined carefully to ensure
that they are sound. No damaged or defective pipes shall be used. Any part length
used shall be cut squarely and cleanly at the end. All pipes shall be clean before
laying and jointing.

All service systems shall include bends, tapers, junctions and other special pipes of a
particular pattern as required.

When pipes pass through walls a flexible joint is to be fitted, situated as close as
possible to the outside face and permitting a minimum deflection between adjacent
pipes of 3°. The length of the next pipe ( rocker pipe) away from the structure shall
be as follow: for 150mm to 600mm nominal diameter pipes the length should be
0.6m, for nominal diameter over 600mm to 750mm pipes the length should be 1m
and for over 750mm nominal diameter pipes the length should be 1.25m.

Pipes which are laid, or built into walls and manholes, but not immediately connected
up, shall be fitted with suitable temporary stoppers or seals, and the position of such
pipes shall be clearly defined by means of stakes or training wires properly marked or
labelled.

Wherever the depth of cover to the pipe laid under a road or driveway is less than
1.20 m, a concrete cover slab spanning the trench width shall be provided.

Before the commencement and for the smooth progress of the pipeline work, the
Contractor shall coordinate and finalise the routes, ground/invert levels, positions of
the manholes etc. with the Engineer.

All changes in the design shall be subject to the approval of the Engineer.

c) Pipe Bedding and Surrounding Material

Pipe bedding and surrounding material shall be well rounded not angular.

When the as dug material is suitable, the bottom of the trench shall be trimmed and
loosened to form the bed otherwise the trench shall be excavated to a depth below
the invert level to allow for the thickness of bedding material.

When as dug material is not suitable, imported granular material as per BS EN 12620
shall be used.

If the as dug material contains stones larger than 40 mm the bedding material must
be extended 100 mm above the circumference of the pipe. Alternatively, the backfill
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can be graded to eliminate stones exceeding 40 mm and this selected backfill used
for the first 300 mm above the circumference of the pipe.

d) Manholes, Sump Pits and Inspection Chambers

These shall be constructed as per the specifications given in clause 4.9.2 ‘

Construction of Manholes , chambers and Special structure’ of Section 4 .

e) Gully Gratings and Frames

Gullies shall consist of a concrete pit with cover.

Gully gratings and frames shall comply with the requirements of BS EN 124 (Grade
A) or equal with straight bars. The Contractor shall bed and haunch frames in
cement and sand 1:3 mortar.

The finish of steel components shall be given 2 coats of black coal tar epoxy paint
with a minimum thickness of 250 microns.

f) Continuous Trench Soakaways

Continuous trench soakaways shall be constructed as per design. The filter

membrane provided for the soakaway surround shall be geotextile of appropriate
gauge. The Contractor shall take every care to avoid damage to the membrane. In
the event of damage to the membrane during construction, the Contractor shall make
good the damage with a minimum lap of 500 mm all to be carried out at the
Contractor ‘s expense.

g) Local Soakaways

Local soakaways shall be provided at locations determined by the Engineer and to

details as approved by him and shall be similar to the soakaway to be provided at the
septic tank.

h) Joints

All joints shall have adequate strength which shall be demonstrated by the
Contractor.

Pipe joints shall be fully flexible and capable of bearing the same pressure that can
be borne by the pipes. Prior to importing any pipes, fittings or jointing rings to the site,
the Contractor shall submit a works test certificate from the manufacturer, as to their
conformity with the Specification, for the approval of the Engineer.

The Contractor shall ensure that there is adequate suitable equipment on site to
enable the works to be carried out to the specified standard, as approved by the
Engineer.

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i) Valve Pits

All below ground valve pits and chambers shall have their invert laid to fall towards
collection sumps to allow pump out of accumulated rain water etc.

8.11.2.3 Surface Water Drainage

a) General

Surface water drainage is required to collect and direct rain water from apron and
paving areas and roof run-offs and will also be required to dispose of external
washdown.

b) System Characteristics

The surface to be drained shall be laid to fall at a minimum slope of 1:250 generally.
The collected rainwater, wash water is to be drained by means of surface falls only
towards local soakaways at appropriate locations.

Roof run-offs to be collected by means of gullies, hoppers & downpipes discharging

to grade level local soakaways at appropriate locations.

All roads, aprons and paving shall be delineated by kerbs and laid to fall towards
soakaways. Parking area to be similarly drained towards soakaways.

c) Areas Contributing Surface Water Drainage

The following areas contribute to the Surface Water Drainage:

- Roof of Pump Station & other Ancillary Buildings

- Electrical Substation and Control Building

- Paving Around the Building

- Roads & Aprons within the Plot

- Parking and Approach Road

- Other areas as applicable

Unpaved areas are to be terraced and gravel (size 20 mm – average) finished to

allow insitu soakaway of rain water or washwater.

d) Surface Water Drain Manhole

Manholes shall be provided as shown on the drawings or as required by the detail

design of the Contractor.

e) Road Gully

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Road gullies are to be provided with silt trap, heavy duty manhole, ductile iron grating
non rocking cover with frame and retaining bar as per the drawings. Road gullies
shall be provided as indicated on the Surface Water System layouts or as required by
the detail design of the Contractor.

f) Road Curb Gully

Road curb gullies are to be provided with silt trap, standard ductile iron cover and
frame with retaining bar as per the layouts and ocontractor’s drawings. Road curb
gullies are to be provided as indicated in the Surface Water System layouts or as
required by the detail design of the Contractor.

g) Roof Drain Pipe

Roof drain pipes shall be provided as indicated in the individual building details and
the storm water drain system layout or as required by the details of the Contractor.
The roof drain pipes shall be provided with an inlet hopper, support brackets, stack
and a splay end terminating 150mm above local paving level and directing water
away from the building towards local soakaways as per the drawings.

8.11.2.4 Foul Water Drainage

a) General

The Foul Water Drainage System is required to collect the foul wastewater from the
buildings. The toilets, sinks, showers and kitchens are to be connected and routed to
a septic tank and local soakaway or connected to the main drainage of the pumping
station. The scope of this work shall include all septic tank/soakaway pits and foul
drainage system pipework.

b) System Characteristics

The Foul Waste from Toilets, Washrooms and Kitchens shall be collected in the foul
drainage manholes & subsequently routed to the septic tank & soakaway pits. The
system is to be suitably trapped & externally vented. The Foul Water System is to be
laid to fall at a minimum slope of 1:100 generally.

c) Areas Connected to Foul Water System

The following sources shall be considered for the Foul Water System:

- Toilets

- Kitchens

- Washroom sinks and showers

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Note: Chemical storage & other industrial sinks shall be routed separately through
contaminated water drainage system.

d) Piping Requirements

(i) Pipes and Fittings

All pipes & fittings to be used on the project shall comply with the requirements of the
latest relevant British/other standards approved by Engineer.

The pipes and fitting for pipe diameter sizes up to 300 mm shall be of uPVC
conforming to BS 4660 and BS 5955. The joint sealing rings shall conform to BS EN
681-1. Products to be procured with BSI certification. The dimension & pressure
rating of the pipes shall be in accordance with ISO 161/1.

The pipes and fittings for pipe sizes equal to or greater than 300 mm shall be GRP
pipes. Requirements as per BS EN 14364 and BS EN 1796 are to be followed for the
pipes & pipe fittings. The pressure rating of the pipes shall be a minimum of 10 bar.

(ii) Jointing Systems

The surface preparation to consist of the minimum following steps:

- Surface to be jointed are to be cleared of glass fibre and to be ensured to be free

of grease, humidity or dust.

- Surface to be ground, external layer of resin to be taken off and first glass fibre
uncovered.

- Surface to be rubbed with an emery cloth and cleaned with a volatile solvent so
as to remove all traces of grease, dust & humidity.

- (No gluing shall be undertaken during sand storm or rainfall).

The minimum requirements for adhesive are as follows:

- Adhesives shall be compatible with the resin and shall not be of a type affected
by hydrocarbon or inorganic contaminants that may be present.

- Type of adhesive shall be submitted by the Contractor for Engineer approval.

- Adhesives shall have two components, cold polymerization type. The two
components will be maintained within allowable temperature and mixed to form a
homogenous mixture just before application to the prepared joint.

- The joints shall have adequate strength and this shall be demonstrated by the
Contractor.

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Pipe joints shall be fully flexible and capable of bearing the same pressure that can
be borne by the pipes. Prior to importing any pipes, fittings or joining rings to the site,
the Contractor shall submit a works test certificate from the manufacturer, as to their
conformity with the specification, for the approval of the Engineer.

The Contractor shall ensure that there is adequate suitable equipment on site to
enable the works to be carried out to the specified standard, as approved by the
Engineer.

For the uPVC piping, the following minimum steps are to be taken while making a
joint:

- Proper alignment of the two pipes to be ensured.

- The surfaces to be joined are to be thoroughly prepared using sandpaper.

- Surfaces to be cleaned with solvent.

- Even layer of cement is to be applied.

- Joint to be made.

It should be ensured that the joint is held together for the required drying time based
on ambient conditions. A minimum of 24 hrs. is required before pressure testing.

The joint shall be fully flexible and capable of bearing the same pressure as the
pipes. The joint strength shall be demonstrated by the Contractor .

e) Foul Water Drain Manholes

Manholes shall be provided as shown on approved Foul Water System Layouts or as

required by the detailed design of the Contractor. The details of the manholes are to
be as per drawings.

f) Soakaways

(i) Soakaways shall be constructed using precast/cast in-situ concrete

manhole rings to designated dimensions and depths.

(ii) The concrete in the rings may be made using moderate sulphate resistant
portland cement in accordance with ASTM C 150 designation type II.
However Type of cement is to be verified as per relevant soil condition.

(iii) The bottom ring shall be founded on an in situ concrete base, to the
approval of the Engineer.

(iv) The soakaway shall be surrounded by granular material which shall in fill
the whole void between the soakaway and the undisturbed ground around
the excavation. The granular material shall be laid and tamped by hand in

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300mm layers and shall be clean, crushed rock to the approval of the
Engineer and shall be 20-40mm nominal size with little or no fines.

(v) Manhole covers and frames shall be coated cast-iron complying with BS EN
124 or approved equal and shall be designed for the loading category to
which they will be subjected. The Contractor shall bed and haunch frames
in cement sand 1: 3 mortar and seal covers with thick grease. Two sets of
keys shall be delivered to the Engineer for each pattern of cover supplied.

(vi) Filter fabric material lining to soakaway excavation shall be Geotextile of

approved gauge & make. Placing and lapping sheets to be in accordance
with manufacturer/supplier's recommendations.

(vii) All pipes and fittings shall be assembled strictly in accordance with the
written instructions of the manufacturer/supplier and to the satisfaction of
the Engineer.

g) Continuous Trench Soakaways

Continuous trench soakaways shall be constructed at the location and to the details
as shown on the drawings. The Contractor shall take every care to avoid damage to
filter membrane. In the event of damage to the membrane during construction, the
Contractor shall make good the damage with a minimum lap of 500 mm all to be
carried out at the Contractor's expense.

h) Floor Drains

(i) All floor drains shall be supplied and installed at the locations and to the
details shown on the drawings and as specified herein.

(ii) Each floor drain shall be of heavy duty uPVC with "S" or "P" trap complete
with chrome plated heavy duty, 200 x 200mm, bronze strainer. The strainer
shall be screwed to the body of the drain. All floor drains shall have chrome
plated removable covers to their strainers or heavy duty aluminium cover.

i) Clean Outs

(i) All clean outs shall be supplied and installed at the locations and to the
details shown on the Drawings and wherever specified herein.

(ii) Each clean-out shall be of the same material and dimensions as the pipe to
be cleaned, and shall be placed in walls, slabs or floors as required for ease
of operation.

(iii) Where cleanouts terminate in floors, a bronze cleanout tile 200 x 200mm,
with screwed and sealed cover shall be provided. Tile and cover shall be
chrome plated.

j) Vent Caps
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Vent caps shall be supplied and installed on all waste, soil and vent stacks at the
locations and to the details shown on the drawings and in accordance with this
specification.

Each vent cap shall be of uPVC and shall be solvent cemented onto the waste, vent
and soil stack.

k) Septic Tank

(i) This shall be a rectangular chamber of concrete built underground and to

dimension and depth as shown on the approved drawings.

(ii) The base, walls and roof shall be of reinforced concrete construction.
Concrete shall be to grade C40.

(iii) The floor of the tank shall slope 1 in 30 towards one side or centre to
facilitate cleaning of sludge and the manhole shall be located directly over
this.

(iv) Initially the septic tank shall be filled with water to its outlet level before
sewage is allowed to enter the tank.

(v) A small quantity of decaying organic matter should preferably be put into the
septic tank to start the initial reaction.

8.11.2.5 Contaminated Water Drainage

a) General

The Contaminated Water drainage system is required to collect specific discharges of

predominantly contaminated water together with floor spillages within the buildings
and other contaminant spillages. Flow rates, salinity, other contaminant levels and
temperatures of the contaminated drainage shall be determined.

Sources of possible spillage are to be routed via tundishes and hard piped systems
above-ground as detailed by the Contractor‘s piping/mechanical department,
discharging to suitable lined reinforced concrete gullies and trenches from where the
contaminated material shall be routed to the main drain sump outwit the building from
where it shall be pumped to outfall remote from the plant.

b) Areas Connected to Contaminated Sump Pits

The following areas are to be served by the contaminated water drainage system:

- Pump Station

- Workshop
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- Battery Room

- Others as applicable

c) Piping Requirements

For details of all pipes and fittings refer to the Piping Requirements Section above.

d) Floor Gullies, Drain Trenches and Cut-Off Drain Channels

Refer to Section 8.11.2.4 h generally.

Linings, covers and frames shall be suitably chemical resistant.

e) Clean Outs

Refer to Section 8.11.2.4 i generally.

Linings, covers and frames shall be suitably chemical resistant.

f) Tundishes

Tundishes and their hard piping systems shall be provided at locations and to details
as determined by the Contractor's detailed design and shall be subject to the
approval of the Engineer.

g) Industrial Sinks

Industrial sinks shall be provided at the locations and to the details shown on the
drawings and shall drain to the contaminated water drainage system.

8.11.2.6 INSPECTION TESTING & COMMISSIONING

a) Inspection Requirements

(i) Civil Works

The following items shall be subject to field inspection in respect of setting out,
excavation, concrete works including reinforcement, protective membranes and
linings, benching and inserts rack filling and finishes, covers and frames, handrailing
and access provisions:

Manholes, Inspection Chambers, Septic Tank, Soakaway Pits, Drain Sump, Floor
Gullies, Drain Trenches, Cut off Drain Channels.

(ii) GRE/ GRP Pipes and Pipe Fittings

As a minimum the following acceptance tests shall be performed at site:

- Visual inspection

- Dimension check

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- Curing

- Glass content

- Hydrostatic pressure test

- Impact resistance test

uPVC Pipes & Pipe Fittings

The minimum number and type of acceptance tests at site is to be as per BS 5955:
Part 6.

b) Testing

(i) The Contractor shall test all drainage pipelines, joints and fittings before
carrying out haunching of pipe surrounds or backfilling trenches. The tests
shall be carried out between two manholes in the presence and to the
satisfaction of the Engineer.

1. Water shall be introduced into the pipes to be tested,so that air is

expelled, and the pipes filled with water so that the highest point in the
line shall be subject to a pressure of 1.5 metre water head. The line
shall be considered acceptable if no leakage is visible from pipes,
connections or fittings and if the above water head in a testing pipe of
75 mm diameter is not reduced by more than 15mm per minute for each
30 metre length of pipe. The Contractor shall, after filling the pipes,
allow some time before conducting the test in order to allow the pipes
their first natural saturation with water for the elastic characteristics and
the relatively high thermal expansion of the uPVC piping. If any damage
is noticed in the pipeline the Contractor shall repair such damage to the
approval of the Engineer.

2. If in the opinion of the Engineer any damage has occurred to the

pipelines during the processes of pouring concrete or backfilling, he
shall have the right to order retesting of the doubtful part. If a second
testing proves that the pipe is not serviceable, then the Contractor shall
locate the damage, make it good and carry out retesting until meeting
Engineer approval.

3. The Engineer may instruct the Contractor to carry out tests to the
manholes to establish their water tightness, prior to backfilling around
manholes, and any damage revealed by such tests shall be made good.

4. The Contractor shall provide all necessary testing equipment and shall
carry out such other tests as may be required by the Engineer. Ground
water shall not be used for the purpose of testing.
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c) Commissioning

(i) All traps and flooded systems shall be charged and periodically refilled until
final handover. During commissioning flows shall be confirmed for all major
runs.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 9

METALS AND PLASTICS

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 9
METALS AND PLASTICS

CONTENTS
9 METALS AND PLASTICS ................................................................................................. 1
9.1 GENERAL...................................................................................................................... 1
9.1.1 Description ............................................................................................................ 1
9.1.2 Qualification .......................................................................................................... 1
9.1.3 Submittals ............................................................................................................. 1
9.1.4 Delivery, Storage and Handling ............................................................................ 2
9.1.5 Products ................................................................................................................ 2
9.1.6 Materials ............................................................................................................... 3

9.2 METAL AND PLASTIC PRODUCTS ............................................................................ 5

9.2.1 Ladders ................................................................................................................. 5
9.2.2 Ship Ladders......................................................................................................... 7
9.2.3 Staircase Assemblies ........................................................................................... 8
9.2.4 Handrailing ............................................................................................................ 9
9.2.5 Gratings .............................................................................................................. 10
9.2.6 Chequered Plate Flooring ................................................................................... 11
9.2.7 Construction Castings ......................................................................................... 12
9.2.8 Steel Lintels ........................................................................................................ 13
9.2.9 Recess Infill Duct Covers .................................................................................... 13
9.2.10 Shade Canopies ................................................................................................. 13
9.2.11 Miscellaneous Trim ............................................................................................. 13
9.2.12 Edge Angles and Seating Angles ....................................................................... 14
9.2.13 Installation ........................................................................................................... 14
9.2.14 Fabrication .......................................................................................................... 14
9.2.15 Painting ............................................................................................................... 16

9.3 STRUCTURAL STEEL ................................................................................................ 18

9.3.1 Description .......................................................................................................... 18
9.3.2 Qualifications ...................................................................................................... 18
9.3.3 Submittals ........................................................................................................... 18
9.3.4 Testing ................................................................................................................ 20
9.3.5 Substitutions ....................................................................................................... 22
9.3.6 Delivery, Storage & Handling .............................................................................. 23
9.3.7 Steel Parameters ................................................................................................ 23
9.3.8 Bolts & Nuts ........................................................................................................ 23
9.3.9 Structural Tubing ................................................................................................ 24
9.3.10 Welding Electrodes ............................................................................................. 24
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9.3.11 Paint .................................................................................................................... 24

9.3.12 Quality Control .................................................................................................... 25
9.3.13 Bench marks ....................................................................................................... 26
9.3.14 Erection ............................................................................................................... 26
9.3.15 Erection Tolerance .............................................................................................. 27
9.3.16 Connections ........................................................................................................ 27
9.3.17 Setting Bases and Bearing Plates ...................................................................... 28
9.3.18 Weld Testing Schedule ....................................................................................... 29
9.3.19 Survey ................................................................................................................. 29

9.4 STAINLESS STEEL .................................................................................................... 30

9.4.1 General ............................................................................................................... 30
9.4.2 Alternative Grades of Stainless Steel ................................................................. 30
9.4.3 Stainless Steel Products ..................................................................................... 34

9.5 ALUMINUM.................................................................................................................. 40
9.5.1 General ............................................................................................................... 40
9.5.2 Material ............................................................................................................... 40
9.5.3 Aluminium Products ............................................................................................ 40

9.6 GRP MOULDED GRATING AND GRP PULTRUDED SUPPORTS ........................... 44

9.6.1 General ............................................................................................................... 44
9.6.2 Construction ........................................................................................................ 45
9.6.3 Quality Control .................................................................................................... 46
9.6.4 Design Criteria: ................................................................................................... 48
9.6.5 Submittals ........................................................................................................... 49
9.6.6 Pultruded Supports ............................................................................................. 49
9.6.7 Structural Design Basis ...................................................................................... 49

9.7 GRP PULTRUDED LADDER ...................................................................................... 52

9.7.1 General ............................................................................................................... 52
9.7.2 Manufacturing Process ....................................................................................... 53
9.7.3 Construction ........................................................................................................ 53
9.7.4 Design / Standard ............................................................................................... 54
9.7.5 Submittals ........................................................................................................... 55

9.8 GRP PULTRUDED HANDRAILS ................................................................................ 55

9.8.1 General ............................................................................................................... 55
9.8.2 Manufacturing Process ....................................................................................... 55
9.8.3 Construction ........................................................................................................ 56
9.8.4 UV Protection ...................................................................................................... 56
9.8.5 Design / Standard ............................................................................................... 57
9.8.6 Submittals ........................................................................................................... 57
9.8.7 Mock -Up ............................................................................................................ 57
9.8.8 Delivery, Storage & Handling .............................................................................. 57
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9.8.9 Project Conditions ............................................................................................... 57

9.8.10 Fabrication .......................................................................................................... 58
9.8.11 Installation ........................................................................................................... 58

9.9 Glass Reinforced, Hot Pressed, SMC (Sheet Moulding Compound)

Potable Water Tank .................................................................................................... 58
9.9.2 General ............................................................................................................... 59
9.9.3 Construction ........................................................................................................ 60
9.9.4 Quality Control .................................................................................................... 64
9.9.5 Inlet, Outlet & Over Flow Pipes ........................................................................... 64
9.9.6 Drain Pipe ........................................................................................................... 64
9.9.7 Approval of Local / International Health Authorities ............................................ 64
9.9.8 Guarantee Certificates ........................................................................................ 65
9.9.9 GRP Baffles ........................................................................................................ 66

9.10 GLASS REINFORCED PLASTIC TANKS FOR CHEMICAL STORAGE ................... 67

9.10.1 General ............................................................................................................... 67
9.10.2 Products .............................................................................................................. 70

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9 METALS AND PLASTICS

9.1 GENERAL

9.1.1 Description

The work included in this Section comprises furnishing all labour, equipment,
appliances and materials and performing all operations in connection with metal
fabrication work.

Metal fabrication work is defined as including any items shown on the Drawings
and/or specified herein, fabricated from aluminium, steel, stainless steel and iron
shapes, plates, bars, pipes tubes, casting and roll-formed shapes which are not a part
of an overall system specified in any other Section of this Specification.

9.1.2 Qualification

a) Employ only experienced tradesmen for both fabrication and installation, who are
capable of producing work of the highest standards of quality in the industry.

9.1.3 Submittals

a) Manufacturer’s Literature

(i) Manufacturer’s specifications, load tables, dimensions diagrams, anchor

details and installation instructions for products to be used in the
manufacture of metal fabrications, including paint products.

b) Shop Drawings

(i) Shop drawings for the fabrication and erection of all assemblies of metal
fabrication work which are not completely shown by manufacturer’s data
sheets.

(ii) Include plans and elevations at not less than 1:10 scale, and include details
of sections and connections at not less than 1:4 scale.

(iii) Show anchorage and accessory items.

(iv) Give location, type, size and extent of welding and bolted connections and
clearly distinguish between shop and field connections.

(v) Prior to submittal co-ordinate shop drawings with related trades to ensure
proper mating of assemblies.

(vi) Detailed drawings shall show material type, thickness, grade/class,

dimensions, and construction scheme.

(vii) The submittal shall include catalogue pages, erection description,

manufacturer data/instructions and templates.

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c) Test Reports

(i) Furnish certified physical and chemical mill test reports for materials used
for major structural members.

d) Samples

(i) Handrail and railing assembly to show joints, bends, toeplate, posts and
anchorage.

(ii) Stair treads and safety nosings, 200 mm long.

(iii) Grating, support angles and plates, 200 x 200 mm.

(iv) Fasteners and anchoring devices.

(v) G.I & S.S cover samples.

9.1.4 Delivery, Storage and Handling

a) Store on blocking so that no metal touches the ground and water cannot collect
on them.

b) Protect from bending under own weight or superimposed loads.

9.1.5 Products

a) Products and manufacturers specified herein-after are specified for the purpose of
establishing minimum quality standards.

b) Structural steel fabrication and erection shall be performed by an organization

experienced in work of equivalent magnitude.

c) Contractor shall verify all measurements and shall take all field measurements
necessary before fabrication.

d) Contractor shall be responsible for correctness of detailing, fabrication, and for

the correct fitting of structural members.

e) Substitution of sections of modification of connection details, or both, will not be

accepted by the Engineer.

f) Connections fully designed and detailed on the Contract Drawings shall be

furnished as shown.

g) Members and connections, for any part of the structure, not shown on the
Contract Drawings shall be the Contractor’s responsibility.

(i) Such connections shall be considered standard and designed and detailed
in accordance with AISC M016.
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h) Welding shall be in accordance with AWS D1.1.

i) All anchor bolts shall be stainless steel in accordance with paragraph 9.1.6.C

(i) All other bolts, nuts washers and screws shall be 316L stainless steel
except where they are used with aluminium members.

j) The following materials shall be isolated from each other by bituminous paint,
PVC tape or neoprene gaskets as directed by the Engineer at no additional cost
to the Employer.

(i) Galvanized steel and stainless steel

(ii) Galvanized steel and aluminium

(iii) Aluminium and Concrete

9.1.6 Materials

a) Steel

Steel work shall be to the appropriate standard and where specified or details shall be
hot dipped galvanised at the place of manufacturer.

(i) Structural Steel : BS 4, Grade 43A or ASTM A36,

Grade 36,minimum thickness 4 mm

(ii) Steel pipe : ASTM A53, Types E or S,Grade B

(iii) Structural Tubing : ASTM A500, Grade B

(iv) Steel Forgings : ASTM A668

(v) Electrodes for welding steel : AWS A5.1, E70 series

b) Iron

(i) Ductile iron : ASTM A536/BSEN 545

(ii) Gray Cast iron : ASTM A48

(iii) Malleable iron : ASTM A47, A197

c) Stainless Steel

Stainless steel shall conform to ASTM A167 and ASTM A276 and the alloy types
shall be as follows:

(i) Plates and basins : Grade 316L or 317L

(ii) Anchor bolts, bolts, nuts, washers and screws: Grade 316L

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1. Yield Strength : min. 270 N/mm2

2. Tensile Strength : min. 480 N/mm2

(iii) Electrodes for welding stainless steel.

1. Use electrodes and techniques per AWS 5.0 series specifications and
as recommended in the International Nickel Co. publication ‘Welded
Austenitic Chromium – Nickel Stainless Steel Techniques and
Properties’.

d) Aluminium

(i) Rolled shapes and extrusion :ASTM B308 or B221

(ii) Castings :ASTM B26

(iii) Aluminium angles, beams, pipes, plates and channels :Alloy 6061 –
T6

(iv) Aluminum weir plates and baffles :Alloy 6061 – T6

(v) Aluminium bolts :ASTM F468,alloy2024 T4

(vi) Aluminium nuts :ASTM F467,alloy2024 T4

(vii) Electrodes for welding aluminium :AWS D1.2, filler alloy 4043 or 5356

(viii) Alloys specified

1. Aluminium alloys shall be selected as having properties appropriate to

the duty of unit, the method of fabrication and environmental conditions.

2. In general alloys of the following ISO designations shall be used:

a. For castings For Wrought items

b. A1 Sil Mg or AlSil2 Al Mg 4.5 min or Al Sil Mg Mn

3. Alternative alloys may be proposed by the contractor if the manufacturer

considers its properties more appropriate to the applications of the
environmental or physical conditions.

e) Galvanizing

(i) Iron and Steel

1. Galvanising shall be done in accordance with ASTM A123 or BS EN

ISO 3834 with an average coating weight of 720-1000gm/m2.

(ii) Touch-up material for galvanized coatings

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1. Galvanising coatings marred or damaged during erection or fabrication

shall be repaired in accordance with the coating manufacturer’s
instructions.

f) Post Drilled Adhesive/Resin Anchors

(i) Meet or exceed ICBO requirements.

(ii) Shall be Grade 316L stainless steel HVA anchors by Hilti or approved
equal.

(iii) Mechanical type anchors will not be permitted.

g) Headed Studs

(i) Conform to ASTM A108

(ii) Yield Strength : min. 345 N/mm2

(iii) Tensile Strength : min. 414 N/mm2

h) Deformed Bar Anchors

(i) Conform to ASTM A496

(ii) Tensile Strength : min. 550 N/mm2

(iii) Yield Strength : min. 482 N/mm2

i) Washers

(i) Same materials and alloy as found in accompanying bolts and nuts.

(ii) Provide two washers per each nut and bolt.

(iii) Provide neoprene pad between dissimilar metals.

j) Painting

(i) As specified in Section 8.

9.2 METAL AND PLASTIC PRODUCTS

9.2.1 Ladders

a) Material

(i) Stainless Steel Grade 316L or

(ii) Aluminium, Grade 6082 (HE – 30) to BS EN 755-3 as indicated.

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b) Stringers

(i) Minimum 65 x 10 mm flat or 38 mm OD tube with a thickness of 3.25mm.

c) Rungs

(i) Solid, min 20 mm diameter

(ii) Shall be at 250 mm centres

(iii) Minimum 380 mm wide between stringers

(iv) Minimum 200 mm from adjacent wall.

(v) Non slip tread pattern.

(vi) Capable of withstanding a point load of 5000 N applied at the centre close
to one end.

d) Brackets

(i) Fixing brackets shall be at max 2000 mm centres.

(ii) Capable of withstanding shear pull-out load of 5000 N.

e) Safety cages shall be provided when the distance between landings exceeds
2200mm.

(i) Cage construction shall be as follows:

1. Flat Hoops : min. 50 x 8 mm with a min internal diameter of 760

mm

2. Vertical Flats : min 40 x 4 mm

3. Hoops shall be at max 750 mm centres, supported by a minimum of 3

vertical straps at equal centres inside the hoops.

4. First hoop shall be 2400 mm above lowest platform.

5. Each hoop shall be able to withstand both a tangential point load of 740
N and a vertical point load of 1200 N applied at any point on the hoop.

6. All connections shall be constructed from same material as ladder.

f) A rest platform shall be provided if the height of the ladder is more than 6Metres
and shall be equipped with one or more platform.

(i) Size : min 840 x 840 mm

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(ii) Handrail : min 1000 mm high

(iii) Landing shall be provided at every 6m.

g) Construction

(i) Top of ladder shall extend 1000mm above the upper access level where
required.

(ii) Fully welded type.

(iii) All welds to be full penetration welds.

h) Ladder accessories

(i) Telescoping tubular section that automatically locks into place when fully
extended.

(ii) Accessories shall be constructed from same material as ladder.

(iii) Corrosion-resistant spring.

(iv) Factory assembled with all hardware necessary for mounting to ladder
where indicated on the Drawings.

9.2.2 Ship Ladders

a) Material

(i) Stainless Steel Grade 316L or

(ii) Aluminium as indicated

b) Design

(i) Construct to fit openings shown on the Drawings.

(ii) Provide minimum rake angle practical between 65° and 75°.

(iii) Provide same load carrying capabilities as specified for staircase

assemblies.

(iv) Provide 42 mm diameter handrailing on both sides of ladder. Make

continuous with handrailing at upper platform or landing.

(v) Use maximum stair width practical between 450 mm and 550 mm.

(vi) Fix the ladder base to the concrete floor as required.

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(vii) Fabricate and design components in accordance with NAAMM Metal Stairs
manual and BS 5395.

c) Treads/Stringers/Hardware

(i) As specified for staircase assemblies.

9.2.3 Staircase Assemblies

a) Material

(i) Stainless steel Grade 316L or

(ii) Aluminium as indicated.

b) Design

(i) Construct to the overall sizes detailed on the Drawings.

(ii) Provide minimum rake angle practical between 30° and 50°.

(iii) Capable of carrying 4.5 kN concentrated, moving load or 5 kN/m2 uniform

live load, whichever is higher.

(iv) Stringers shall be of adequate size to support treads/landing gratings.

c) Stringers

(i) Size for design live loads as well as treads, handrail and other fixed loads.

(ii) Use RS channel sections unless other sections are approved by the
Engineer.

(iii) Minimum width between stringers shall be 1000 mm.

d) Treads

(i) Use open type

(ii) Non Slip tread

(iii) Bull nose edge for strength

(iv) Provide end plated or shelf angles as necessary. Drill for bolting between
stringers.

e) Landings

(i) Provide landing not exceeding 16 rises (15 treads).

(ii) Width > 750mm.

(iii) Capable of supporting a minimum loading of 5 kN/m.

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(iv) Landing panels shall match the stair treads.

f) Handrailing

(i) All open sides of staircases and landing shall be protected by handrail.

(ii) Height from the nose of the tread to top of rail shall be between 840 mm to
1000 mm on the stairs and min 1000 mm from the floor to top rail on
landings.

(iii) Size and load carrying capabilities shall be as specified for handrails.

g) Hardware

(i) Use Grade 316L stainless steel hardware throughout.

(ii) Protect all hardware against corrosion.

h) Fabricate and design stair components in accordance with NAAMM Metal Stairs
Manual.

9.2.4 Handrailing

a) Comply with ANSI A 12.1 and ANSI A58.1/ BS EN ISO 14122.

b) Material

(i) Stainless Steel Grade 316L or

(ii) Aluminium, Grade 6082 (HE 30) to BS EN 755-3 as indicated.

c) Posts

(i) Outside diameter : 60 mm tube

(ii) Wall thickness : 4mm

(iii) Ball : 90mm

d) Rails

(i) Outside diameter : 48mm

(ii) Wall thickness : 4mm

(iii) Capable of withstanding a 1.0kN load applied at any point or 740 N/m along
the rail whichever is higher at the level of top rail.
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(iv) Curves shall be bent to a radius of not less then 100mm.

(v) Horizontal rail shall be 1000 mm high with an intermediate rail at 500 mm
high.

e) Provide hand rails on walls at stairs and similar locations as required by ANSI A
12.1.

f) Where shown or required removable sections and toe plates shall be provided.

g) Connections to concrete masonry/concrete surfaces shall be secured with

accurately positioned anchor bolts.

(i) Protect all hardware against corrosion.

h) Safety Chains

(i) 12.5 mm link

(ii) Grade 316L Stainless steel

9.2.5 Gratings

a) Material

(i) Aluminium

(ii) Galvanized Steel

(iii) Stainless Steel

b) Design

(i) Size to fit openings shown on Drawings.

(ii) Use alloy 6063-T6.

(iii) Minimum depth 38mm.

(iv) Minimum rectangular bar size 5 mm thick.

(v) Minimum 1 bar flange width 6 mm.

(vi) Live load:

1. not less than 10 kN/m2.

2. maximum 6 mm deflection at a live load of 5 kN/m2.

(vii) Cross bars welded, swaged, or pressure locked to bearing bars.

(viii) Serrated edge on top of bars.

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(ix) Standard mill finish.

(x) Provide openings at joint between individual grating sections.

1. reinforce openings to provide required load carrying and band with 100
mm high toe plate.

(xi) Use 316 stainless steel hardware (clips and bolts)

c) Unless otherwise specified or shown on the Drawings, the grating material,

fabrication, installation, and banding shall be in compliance with the National
Association of Architectural Metal Manufacturers’ ‘Metal Bar Grating Manual’ as
applicable.

(i) Banding is required at all openings and the perimeter of all grating.

d) Bar gratings shall be neatly and accurately cut to the configuration necessary to
clear structural members and pipes and to permit removal of the grating.

e) Gratings shall have bolted anchorage with a minimum 4 bolts per panel using
stainless steel fastners.

(i) The bolts shall be supplied with neoprene washers.

(ii) Aluminium grating in contact with steel members of concrete shall be

isolated with an approved material.

9.2.6 Chequered Plate Flooring

a) Conform to ASTM B632.

b) Material

(i) Aluminium, type 6061 – T6.

(ii) Galvanized steel conform to BSEN 10025-1 / BS EN 10025-2

c) Design

(i) Capable of withstanding a load of 5 kN/m2 with maximum deflection of 1/300

of span under a superimposed live load of 2.5 kN/m2.

(ii) Diamond pattern

d) Plate Sections

(i) Maximum 1000 mm wide

(ii) Minimum 6 mm thick

e) Provide joints at centre of all openings unless shown otherwise.

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(i) Reinforce joints and openings with additional angles to provide required
load carrying capacity.

f) Unless shown otherwise, frame for openings for aluminium checkered plate.

(i) Aluminium angles of minimum size 40 mm x 40 mm x 6 mm having 8 mm

dia x 150 mm long anchor bolts spaced at maximum of 600 mm along each
side with not less than two anchor bolts per side.

(ii) Drill and tap frame to receive 8 mm dia aluminium cap screws at not more
than 600mm centres with not less than two screws per side.

9.2.7 Construction Castings

a) General

(i) Conform to Employers standard patterns an designs

(ii) Pre-fabricated ductile or cast iron construction conforming to ASTM

(iii) A 48 or A536.

(iv) Design for AASHTO HS – 20 wheel loading for indicated span.

(v) Machine horizontal mating surfaces.

b) Storm Water Gutter

(i) Heavy duty, ductile iron, single piece construction complete with Bearer
bars.

(ii) Conform to BSEN 124, Class D400 loading.

(iii) Gutter clear opening 240 mm or as shown on the Drawings.

c) Channel Grating

(i) Heavy duty, ductile iron, single piece construction complete with Bearer
bars.

(ii) Conform to BSEN 124, Class D400 loading

(iii) Cover clear opening 300mm or as shown on the Drawings. Or Polymer

concrete monoblock gratings conforming to DIN EN 1433 Class D400
loading.

d) Solid Top, Channel Covers

(i) Heavy duty, ductile iron construction

(ii) Conform to BSEN 124, Class D400 loading

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(iii) Cover clear opening 300mm or as shown on the Drawings.

9.2.8 Steel Lintels

a) Conform to BS EN 845 : Part 2

b) Steel lintels shall be provided for openings as noted on the drawings, for openings
left in masonry work for ducts, and for similar items where openings are not steel
framed.

c) Lintels, unless otherwise shown, shall be fabricated from galvanised steel

conforming to BS EN 10346:2009.

d) Size as scheduled or the width of the opening plus at least 200 mm where not
scheduled, bearing on supports at each end.

9.2.9 Recess Infill Duct Covers

a) Covers shall be of Grade 316L stainless steel with Grade 35 concrete infilling
where specified.

b) Shall be capable of supporting a 5000 kg wheel load.

c) Covers shall, preferably, be single span but multi-span with Grade 316L stainless
steel intermediate beams are acceptable on larger openings.

d) Covers and frames shall have edging strips and keyhole extensions of barass for
floor finishes when provided in floors inside buildings.

9.2.10 Shade Canopies

a) Fabricate canopies from Structural Steel cantilevered frames, Hollow Steel Box
Section Rails and Purlins where shown on Drawings.

b) Fix steel framework to concrete substrate with requisite fixing devices.

c) Provide all trim as required.

d) Shop prime the complete assembly prior to erection.

9.2.11 Miscellaneous Trim

a) Provide shapes and sizes as required for the profiles shown.

b) Except as otherwise noted, fabricate units from structural steel shapes, plates and
steel bars, with continuously welded joints and smooth exposed edges.

c) Use concealed field splices wherever possible.

d) Provide cutouts, fittings and anchorages as required for co-ordination of assembly

and installation with other work.

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9.2.12 Edge Angles and Seating Angles

a) Provide edge angles or seating angles of size as shown on the Drawings with
welded on strap anchors 600 mm on centres.

b) Install angles in as long lengths as possible.

c) Mitre and weld corners and provide splice plates for alignment between sections.

9.2.13 Installation

a) Set metal fabrication work accurately in location, alignment and elevation, plumb,
level, true and free of rack, measured from established lines and levels.

b) Anchor securely as shown or as required for the intended use, using concealed
anchors wherever possible.

(i) Fastenings to wooden plugs will not be permitted.

(ii) Drill holes for bolts to the exact diameter of the bolt, using a rotary drill for
concrete and a percussion drill for masonry.

c) Where pipe sleeves are used to support miscellaneous ironwork, anchor sleeves
securely to supporting concrete or structure to provide rigid support.

d) Pipe sleeves shall be of galvanized steel of size shown and adequate to meet the
requirements.

(i) Fit exposed connections accurately together to form tight hairline joints.

(ii) Weld connections which are not to be left as exposed joints, but cannot be
shop welded because of shipping size limitations.

(iii) Grind joints smooth and touch up shop paint coat.

(iv) Do not weld, cut or abrade the surfaces of exterior units which have been
hot-dip galvanized after fabrication, and are intended for bolted or screwed
field connections.

e) Deliver items which are to be built into the work of other sections in time so as not
to delay the progress of work.

f) Leave work exposed to view clean, smooth and neatly finished.

9.2.14 Fabrication

a) For the manufacture of metal fabrications which will be exposed to view, use only
materials which are smooth and free of surface blemishes including pitting, seam
marks, roller marks, rolled trade names and roughness.

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(i) Remove such blemishes by grinding, or by welding and grinding, prior to

cleaning, treating and application of finishes including zinc coatings.

b) Use materials of the size and thickness shown, of the required size and thickness
to produce adequate strength and durability in the finished product for the
intended use.

(i) Work to the dimensions shown or approved on shop drawings, using proven
details and fabrication and support.

(ii) Use the type of materials specified for the various components of work.

c) From exposed work due to line and level with accurate angles and surfaces and
straight sharp edges.

(i) Ease exposed edges to a radius of approximately 1 mm unless otherwise

shown.

(ii) Form bent metal corners to the smallest radius possible without causing
grain separation or otherwise impairing the work.

d) Verify dimensions by accurate field measurement before fabrication wherever

work adjoins other work that precedes it in construction.

(i) Allow for trimming and fitting of metal fabrication work wherever the taking
of field measurements before fabrication might delay the work.

(ii) On shop drawings, note which dimensions have been verified by field
measurement.

e) Weld corners and seams continuously and in accordance with the

recommendations of AWS.

(i) Grind exposed welds smooth and flush, to match and blend with adjoining
surfaces.

f) Form exposed connections with hairline joints which are flush and smooth, using
concealed fastners wherever possible.

(i) Use exposed fastners of the type shown, or if not shown, use Philips flat-
head (countersunk) screws or bolts.

(ii) All screws or bolts will be Grade 316L stainless steel.

g) Pre-drill bolt and/or screw holes as shown and as required for attachment of metal
fabrication work and for the attachment of adjacent materials.

h) Furnish inserts and anchoring devices which must be set in concrete or built into
masonry for the installation of metal fabrication work.

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(i) Co-ordinate delivery of such devices with other work so as to avoid any
delay. See Concrete and Masonry Sections of these Specifications for
installation of such inserts and anchoring devices.

i) Provide for anchorage of the type shown, co-ordinated with the supporting
structure and the construction program.

(i) Fabricate and space anchoring devices as required to provide adequate

support.

j) Cut, reinforce, drill and tap metal fabrication work as may be required to receive
finish hardware and similar items of work.

k) Use hot-rolled steel bar for work fabricated from bar stock, except where shown
or specified to be fabricated from cold-finished or cold rolled stock.

l) Pre-assemble work at shop to the greatest extent possible, so as to minimize field

splicing of fabricated units at the project site.

(i) Disassemble units only to the extent necessary to comply with shipping
limitations.

(ii) Mark units clearly for reassembly and proper installation.

m) Where shown as galvanized, complete the shop fabrication prior to application of

the coating.

(i) Remove mill scale and rust, clean and pickle the units as required for
coating.

(ii) Apply hot-dip zinc coating of 0.72-1.000 kg/m2 in accordance with ASTM A
123.

9.2.15 Painting

a) General

(i) Primers selected shall be compatible with finish paints.

(ii) Refer ‘Coating System for Ferrous Metals’ for finish paint material and
applications.

(iii) Clean, treat and paint metal fabrications work in the shop prior to delivery to
the project site, except for work which has been hot-dip galvanized after
fabrication.

(iv) Include all surfaces, inside and out, whether exposed or concealed in the
construction.

b) Aluminium

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(i) Mill finished unless scheduled or otherwise specified or, if approved,

finished in manufacturer’s standard.

1. Coat surfaces in contact with dissimilar materials as specified here in.

c) Fully Concealed Items

(i) Clean steel and wrought iron work by ‘Solvent Cleaning’ method specified
followed by ‘Hand Tool Cleaning’ to remove loose mill scale and rust by
methods specified.

(ii) Apply paint as per ‘Coating system for Ferrous Metals’.

d) Exposed Interior Items

(i) Clean and paint work which is not accessible to foot traffic, floor cleaning
operations or hand contact, as specified, except that mill scale and rust
which would result in visible roughness must be removed and the surfaces
must be made smooth before painting.

(ii) Apply the following cleaning, treatment and painting to interior work which is
exposed (or partially exposed), and is subject to foot traffic, floor cleaning
operations or hand contact by the building occupants.

1. Clean by ‘Solvent Cleaning’ method followed by ‘Hand Tool Cleaning’ or

‘Power Tool Cleaning’ method to remove loose mill scale and rust.

a. ‘Pickle’ by methods specified to remove all remaining mill scale and

rust.

b. Grind rough surface as necessary to provide smooth metal surfaces.

c. Tool cleaning and pickling may be omitted from fabricated cold-

rolled or cold-finished stock and from castings, provided the surfaces
are not heavily rusted.

2. Apply pre-treatment to inhibit corrosion and improve paint adhesion, by

methods specified for ‘Cold Phosphate’ treatment.

3. Apply prime coat or metal primer paint as soon as possible after pre-
treatment.

a. Provide a smooth coat, with uniform dry film thickness of 50 microns.

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9.3 STRUCTURAL STEEL

9.3.1 Description

The work covered by this section comprises all plant, labour equipment, appliances
and materials and performing all operations in connection with Structural Steelwork.

9.3.2 Qualifications

a) Structural steel fabrication and erection shall be performed by an organization

experienced in structural steel of work of equivalent magnitude with minimum 5
years documented experience.

(i) Contractor shall verify all measurements and shall take all field
measurements necessary before fabrications.

(ii) Contractors shall be responsible for correctness of detailing, fabrication and

for the correct fitting of structural members.

(iii) Substitution of sections or modifications of connections details, or both will

not be accepted by the Engineer.

(iv) Connections fully designed and detailed on the Contract Drawings shall be
furnished as shown.

(v) Members and connections, for any part of the structure, not shown on the
Contract Drawings shall be the Contractor’s responsibility.

1. Such connections shall be considered standard and designed and

detailed in accordance with BS 5950: Part 1 and BS EN 1993-1-1 & BS
EN 1993-1-3.

2. Welding shall be in accordance with AWS D1.1.

3. High-strength bolting shall be in accordance with the AICS S329.

(vi) Welders qualified to ASME IX and utilizing a previously qualified Welding

Procedure would not require further qualification to weld structural steel.

9.3.3 Submittals

a) Shop Drawings

(i) Shop drawings including structural calculations prepared by a qualified

structural engineer for all structural steel components and their connections,
all in accordance with the requirements of the Contract Documents showing
the following:

1. Shop fabrication drawings which show type of material.

a. Size and weight of members.

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b. Other information necessary for the fabrications of each members.

c. Information for shop assembly of members of the structure.

2. Drawings shall include the type, size, locations and extent of all welds
and bolts.

3. Drawings shall clearly distinguish between shop and field, bolts and
welds.

4. Field assembly and erection drawings which show all field assembly
prior to erection and after erection.

5. Drawings shall indicate all details, schedule, procedures and diagrams

showing field assembly and sequence of erection.

6. Information shall indicate locations of shoring and how shoring is

stabilized and controlled.

7. Drawings shall indicate elevations of shored points and splice locations.

8. Procedures shall indicate step by step erection sequences including

intermediate surveys and allowances for temperature.

9. Diagram shall indicate erection equipment, size and weight and

additional elements which may be required to support or stabilize
elements during erection.

(ii) Written procedures for fabrication of the steel work.

1. Procedures shall describe the complete welding process including

machine, current, voltage, preheat, filler metal, welding system (manual,
semi – automatic or automatic), positions of welding, number of passes
for each weld size, preparation of surfaces prior to welding etc.

2. These procedures shall indicate the Contractor’s quality control

measures, monitoring and repair procedures.

(iii) Contractor shall be responsible for the arrangement of all joints and their
load carrying capacities.

1. Connection may or may not be shown on the Contract Drawings.

2. All details along with the calculations to Engineer’ prior to fabrication.

b) Manufacturer’s Literature

(i) Manufacturer’s specifications and installation instructions for the following

products, including laboratory test reports and such other data to show
compliance with these Specifications (including specified standards):

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1. Structural steel, (each type) including certified copies of mill reports

covering:

a. Chemical and physical properties,

b. Country and rolling mill of origin,

c. Statement indicating that the steel is new billet steel.

d. Testing has been performed in accordance with ASTM standards.

2. High strength bolts (each type) including nuts and washers.

3. Welding electrodes (each type).

4. Shop coat primer paint, field touch-up paint, and color samples of all
paint to be used.

5. Epoxy paint.

6. Bearing materials and assembles.

c) Testing Reports

1. The following reports shall be submitted in triplicate directly to the

Engineer by the Testing Laboratory, with copy to the Contractor.

a. Shop Welders Certifications.

b. Field Welders Certifications.

c. Magnetic particle tests.

d. Ultra-Sonic tests.

e. High strength bolted connection tests.

9.3.4 Testing

a) Contractor shall engage, at his own expense, an independent certified Testing

Laboratory approved by the Engineer.

(i) To inspect high strength bolted connections and welds.

(ii) To perform all test reports to Engineer as herein specified.

b) Contractors shall submit evidence regarding qualification of the proposed Testing

Laboratory.

c) The Contractor shall provide the Testing Laboratory with the following:

(i) A complete set of shop fabrication and erection drawings.

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(ii) Cutting lists order sheets, material bills, shipping bills and mill test reports.

(iii) Provide certified copies of mill test reports of:

1. Bolts, nuts, and washers.

2. Names and locations of mills and shops.

3. Analyses of chemical and physical properties.

(iv) Information as to time and place of all rolling and shipment of materials to
shops.

(v) Representative sample pieces requested for testing.

(vi) Full and ample means and assistance for testing all material.

(vii) Proper facilities, including scaffolding, temporary work platforms, hoisting

facilities, etc., for inspection of the work in the mills, shop and field.

d) Bolted connections shall be inspected by the Testing Laboratory in accordance

with AISC Specifications for “Structural Joints Using ASTM A325-83, ASTM
A325M-83 and ASTM A490-83A or ASTM A490-82.

e) Welding should be inspected and tested by a Testing Laboratory approved by the

Engineer during fabrication and erection of structural steel as follows:

(i) Certify all welders in accordance with AWS and make inspections and tests
as required.

1. Record types and locations of all defects found in the work, and
measures required and performed to correct such defects.

(ii) In addition to visual inspection of all welds, magnetic particle and ultra –
sonic inspection shall be made of all welds indicated on the Drawings.

1. Magnetic particle inspection shall be made on the root pass and finished
welds.

(iii) The method of magnetic particle inspection shall be in accordance with

ASTM E109. Any type of crack or zone of incomplete fusion or penetration
will not be acceptable.

(iv) Ultra-sonic inspection shall be performed in accordance with AWS D1.1.

f) Each bolting crew and welder shall be assigned an identifying symbol or mark.

(i) All shops and field connections shall be so identified so that the inspector
can refer back to the crew or person making the connection.

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g) Testing laboratories shall be responsible for conducting and interpreting the tests,
shall state in each report:

(i) Whether or not the test specimens conform to all requirements of the
Contract Documents.

(ii) Any deviations therefrom.

h) Access to places where the material for this Contract is being fabricated or
produced shall be provided to Engineer and the Testing Laboratory for the
purpose of inspections and testing.

i) Engineer and the Testing Laboratory may inspect structural steel at the plant
before shipment.

(i) The Engineer reserves the right to reject any material, at any time before
final acceptance, which does not conform to all requirements of the
Drawings and Specifications.

j) The Testing Laboratory shall perform specified tests and submit reports directly to
the Engineer.

(i) Corrective measures, including additional and more complete testing, which
may results from these tests shall be the contractor’s responsibility.

(ii) All cost of testing shall be the expense of the Contractor.

k) Contractor shall coordinate and allow for necessary time for the testing laboratory
to complete all testing and inspections prior to shop painting.

l) The Testing Laboratory shall prepare test specimen from steel samples cut from
delivered material and shall conduct tension tests in accordance with ASTM.

(i) Contractor shall mill order 1.0 meter extra length for the members noted on
the Drawings to provide the steel for testing.

9.3.5 Substitutions

a) Contractor shall fabricate and erect the structural steelwork as shown on the
Drawings and Specifications.

b) Details all fabrication and construction shall be submitted to Engineer for

approval.

c) All changes and modifications require that the Contractor shall guarantee in
writing, with guarantee signed by a principal officer of the company, that the
equipment offered will provide comparable or superior features as the equipment
specified including the following:

(i) Performance;

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(ii) Quality;

(iii) Material of construction.

d) Cost of any changes incidental to the installation of the alternate equipment such
as electrical wiring, relocation of piping, engineering supervision, ductwork,
building configuration and design, shall be at the expense of the Contractor with
no additional expense to the Employer.

e) If after installation to the alternate installation does not perform in accordance with
the specifications or other deficiencies are noted, the Employer will require the
modification or replacement of such equipment to meet the specifications at no
additional expense to the Employer.

9.3.6 Delivery, Storage & Handling

a) Do not handle structural steel until paint has thoroughly dried.

b) Care shall be exercised to avoid abrasions and other damage.

c) Stack material above ground out of mud and dirt and provide for proper drainage.

d) Protect from damage or soiling by adjacent construction operations.

e) Provide suitable separators to avoid individual items from coming into contact.

f) Do not deliver material to the project site until the proposed method and
sequence of erection has been reviewed by the Engineer.

g) Method and sequence shall be planned so as to avoid delay or damage to the

work of other trades.

h) Storage of fabricated steel at the job site shall be the responsibility of the
Contractor.

i) Material stored at the job site shall not exceed design load on existing newly-
constructed structures so that members will not be distorted or otherwise
damaged and shall be protected against corrosion or deterioration.

9.3.7 Steel Parameters

a) All structural steel shall conform to BS 4: Part 1 and BS EN 10210-2/BSEN

10067/BSEN 10056-1, Grade 43A or ASTM A 36, Grade 36

b) Minimum yield stress : 245 N/mm2 unless noted otherwise.

c) Minimum thickness shall be 4 mm unless noted otherwise.

9.3.8 Bolts & Nuts

a) All bolts, nuts and washers shall be Grade 316 L stainless steel.

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b) Provide two washers per each nut and bolt.

9.3.9 Structural Tubing

a) All structural tubing shall conform to ASTM A 500, Grade B, Seamless, yield
strength 317 N/mm2.

9.3.10 Welding Electrodes

a) All welding structures shall be E70XX and shall comply with the provisions of
AWS Specifications A5.1, A5.5, A5.17, A5.18, A5.20.

b) All weld not specified shall be continuous fillet welds using not less than the
minimum size based on thickness of the thicker part jointed.

Thickness Minimum weld size

12 mm 4 mm

Over 12 mm to 20 mm 6 mm

Over 20 mm to 40 mm 8 mm

Over 40 mm to 50 mm 10 mm

9.3.11 Paint

a) As specified in “Coating System for Ferrous Metal”.

b) Use spray application for painting

(i) Minimum thickness shall be maintained on all corners, edges and ends of
pieces.

(ii) Surface to be painted shall dry and above 20C.

(iii) Temperature of the air shall be 50C.

(iv) Do not paint outdoors in rainy and dusty weather.

(v) Paint surface within 4 hours sandblasting.

(vi) Allow paint at least 24 hours drying time in good weather before recoating.

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9.3.12 Quality Control

a) Testing and inspection of structural steel will be performed by an independent

structural steel testing agency engaged by the Contractor, at his own expense
and approved by the Engineer.

(i) Provide the testing agency with the following:

1. A complete set of accepted documents under paragraph 1.03 in –

“Submittals”.

2. Cutting lists, order sheets, material bills and shipping bills.

3. Information as to time and place of all rollings and shipment of materials

to shops.

4. Certification of chemical composition with each shipment of bolts and

fasteners to the project site.

5. Representative sample pieces as requested by the testing agency.

6. Full and ample means and assistance for testing all material.

7. Proper facilities, including scaffolding, temporary work platforms, etc.,

for inspection of the work in the mills, shop and field.

b) The Inspector will perform his duties in such way that fabrication and erection are
not unnecessarily delayed or impeded, and as follows:

(i) The inspector will make all tests and inspections as required by “Structural
Welding Code.”

(ii) The edges material to be welded will be ultrasonically examined for

evidence of laminations, inclusion or other discontinuous.

1. The extent to which such defect will be permitted and the extent of
repair permitted shall be determined by the Inspector and made in
accordance with ASTM A6, Paragraph 9.

2. Repairs made by welding shall be done in compliance with the

requirements of AWS D1.1 and the accepted welding procedures.

(iii) The root layer of all multiple pass welds and the backside of groove welds
are made from both sides, after back gouging or chipping, will be examined
by magnetic particle inspection (or dye penetration if magnetic particle
inspection is not feasible).

(iv) The technique of radiographic inspection will be in accordance with the

requirements of AWS D1.1.

1. A double film technique will be used.

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2. One copy of each film will be sent to the Engineer, the other will be
retained by the inspector.

(v) Where the inspections reveals defects, the extent of inspection will be
increased as much as necessary to ensure that:

1. Full extent of the defects in a joint has been found.

2. Same defects are not present in welds made on similar parts or under
similar circumstances.

(vi) Work that is not acceptable will be designated by “Repair” or “reject”, as

applicable.

(vii) Shop welds will be inspected in the shop before the work is painted or
approved for shipment.

(viii) the inspector will maintain a daily record of the work he has inspected and
its disposition.

1. Reports of tests will be made on form prescribed in AWS D1.1.

2. One copy of each of the reports will be submitted to the Engineer on a

weekly basis.

(ix) The inspector will make all tests and inspections of high strength bolt
connections as required by AISC S314.

9.3.13 Bench marks

a) Contractor shall employ the services of a qualified surveyor who shall:

(i) Establish permanent bench marks.

1. Field check all elevations of concrete on which structural steel is to be

placed.

2. Locations of anchor bolts.

(ii) Reports discrepancies to the engineer.

(iii) Obtain the engineer’s approval before the work proceeds

9.3.14 Erection

a) Contractor shall be responsible for the accurate setting and levelling of all bearing
plated or setting plates.

(i) Bearing plates shall be levelled on steel wedges or shims or as otherwise

detailed.

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(ii) Bearing and setting plates shall be grouted as specified. All shims to have
50mm grout coat.

b) Furnish templates for accurate setting of all anchor bolts.

(i) Furnish shim plates or developed fills required to obtain proper fit and
alignment.

c) Oxygen cutting of structural steel for “fitting-up” purpose shall not be done except
with the prior approval of the Engineer.

(i) The use of an oxygen cutting torch for correcting fabrications errors will not
be permitted.

9.3.15 Erection Tolerance

a) The Contractor shall be responsible for the correct fitting of all structural members
and for the elevation and alignment of the finished structure.

(i) Any adjustments necessary in the steel work because of discrepancies in

elevations and alignment shall be responsibility of the Contractor.

b) Unless otherwise noted, the structure shall be levelled and plumbed to accuracy
of 1 to 1000, but not to exceed 12 mm.

(i) The actual centerlines of truss chords shall not vary from theoretical
centerlines by more than 12 mm at any point.

(ii) The difference between offset to the actual centerlines of truss chords at
adjacent panel points shall not exceed 3mm.

(iii) All levelling and plumbing shall be done based on the mean operating
temperature of the structure.

(iv) Allowance shall be made for the difference in temperature at time of

erection and the mean temperature at which the structure will be when
completed and in service.

c) All measurements relating to the above shall be on the theoretical centerlines of

the members.

9.3.16 Connections

a) Welding or bolting shall not be performed until all stiffening components of the
structure have been properly aligned.

b) Drift pins shall not be used to enlarge holes in primary members.

(i) Holes that must be enlarged to admit bolts shall be reamed.

(ii) Burning and drifting will not be permitted.

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c) When high strength bolts or high strength bearing bolts are used, the AISC
specifications shall apply including values as noted therein, and installation with
torque wrenches.

(i) In using manual torque wrenches, the required torque can be read from the
wrench dial.

(ii) Care should be taken that the wrench is properly calibrated.

(iii) Nuts shall be in motion when torque is measured.

(iv) In using power wrenches, the recommendations of the wrench manufacturer

shall be followed.

(v) Use hardened washer under bolt head or nut whichever is turned in
tightening, unless the specified standards require hardened washer both
head and nut.

d) All bolts shall be kept in dry storage until needed for installation.

(i) A325 bolts 28mm and 32mm diameter and A490 bolts 25 mm diameter and
over shall have Johnson’s Stick Wax No. 140 applied to their threads before
being assembled in the work.

(ii) 2. If bolts have been left out and have become rusty before use, they shall
be rejected and shall not be used until they have been cleaned and waxed
with Johnson’s Stick Wax No. 140.

e) Welded and bolted connections shall be comply with BS 5950: Part 1, BS EN

1993-1-1 / BS EN 1993-1-3 and AICS S 329 and tested in accordance with the
requirements of paragraph 1.04 Testing.

9.3.17 Setting Bases and Bearing Plates

a) Clean concrete and masonry bearing surfaces of bond-reducing materials and

roughen to improve bond to surface.

(i) Clean the bottom surface of base and bearing plates.

b) Set loose and attached baseplates and bearing plates for structural members on
wedges or other adjusting devices.

c) Tighten the anchor bolts after the supported members have been positioned and
plumbed.

(i) Do not remove wedges or shims, but if protruding, cut off flush with edge of
the base or bearing plate prior to packing with grout.

d) Pack grout solidly between bearing using surfaces and bases or plates to ensure
that no voids remain.

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(i) Finish exposed surfaces, protect installed materials, and allow to cure in
strict compliance with the manufacturer’s instructions, or as otherwise
required.

9.3.18 Weld Testing Schedule

Weld Location Length of Weld Type of Weld Test ASTM Test

to be Tested
Specification

Other stress 300 mm in 3 m Fillet M.P.* E709

Carrying Welds
300mm (min. Groove U.T. E164
test)

Flange Splice 100% Groove U.T. E94 – Shop

(Full
Penetration) E164 – Field
(Weld only)

Web Splice Top 100% Groove U.T. E94 – Shop

Bottom-33% E164 – Field

Middle-34%

Bearing 300 mm in 1.2 m Fillet M.P* E709

Stiffener to web
300mm(min.test)

Misc. 300 mm in3 m Fillet M.P.* E709

Secondary (min. test)
Members
Tension Zones

Compression Visual only

Zones

*Only for fields welds E165, liquid penetrant test may be substituted

9.3.19 Survey

a) Make an accurate survey of actual locations of steel members immediately upon

the completion of erection of steel but before removal of shoring.

b) Promptly submit same to the Engineer.

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c) Should locations very beyond the allowable tolerances, necessary corrective

measures and procedures shall be performed with approval of the Engineer.

d) Survey the final erected structural steel after release of shoring but prior to final
removal of shoring elements and prior to the start of any other work.

e) Report any discrepancies from Contract requirements to the Engineer.

9.4 STAINLESS STEEL

9.4.1 General

Stainless steel shall have the following composition with mechanical properties to the
appropriate approved standard.

Table 9.4 Stainless Steel Composition

Element Percentage Chemical Composition

Fabrication Technique

Welded Cold

% minimum %maximum % minimum % maximum

Carbon - 0.03 - 0.07

Silicon 0.20 1.00 0.20 1.00

Manganese 0.50 2.00 0.50 2.00

Nickel 11.00 14.00 10.00 13.00

Chromium 16.50 18.50 16.50 18.50

Molybdenum 2.25 3.00 2.25 3.00

Sulphur - 0.03 - 0.03

Phosphorous - 0.045 - 0.045

9.4.2 Alternative Grades of Stainless Steel

Alternative, higher grade, stainless steel may be proposed by the Contractor if the
manufacturer considers its properties more appropriate to the environmental or
physical conditions. Higher grade stainless steels shall conform with the parameters

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given in tables 9.2, 9.3 and 9.4 for austenitic, ferritic and martenstic stainless steels
groups respectively.

Table 9.4 Austenitic Stainless Steels

BS AISI Forms Main Major Tensile Service

1449 * Characteristics Constituents Strength Temperature
% N/mm2 °C

301 301 Plate High cold work C CR Ni 0.15 max 540 800
S12 Precision hardening Rate, 16-18 6-8 (Softened to
Strip moderate 1240 (full
formability hand)

302 302 Precision Weldable with C Cr Ni 0.08max 510 800

S17 strip good formability 17-19 8- (Softened)
and general 11
corrosion
resistance

304 304 Plate Good C Cr Ni 0.06 max 510 800

S15 weldability, 17.5 –19 (Softened)
form-ability and 9-11
general
corrosion
resistance

304 304 Precision Excellent C Cr Ni 0.06 max 510 800

S16 strip drawability, 17.5 –19 Softened)
good weldability 9-11
and general
corrosion
resistance

304 304L Plate Weldable and C Cr Ni 0.03 max 490 800

S12 Precision resistance to 17.5 – 19 (Softened)
Strip sensitisation, 9-12
good corrosion
and oxidation
resistance

305 305 Precision Good C Cr Ni 0.1max 460 800

S19 Strip formability and 17-19 11- (Softened)
general 13
corrosion
resistance

309 309 Plate Excellent C Cr Ni 0.15 max 540 1050

S24 oxidation 22 –25 (Softened)
resistance, 13-16

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BS AISI Forms Main Major Tensile Service

1449 * Characteristics Constituents Strength Temperature
% N/mm2 °C

Weldable

310 310 Plate Excellent C Cr Ni 0.15 max 540 1100

S24 oxidation 23-26 19- (Softened)
resistance, low 22
magnetic
permeability,
Weldable

315 - Precision Highly corrosion C Cr Ni Mo 0.07 max 540 800

S16 Strip resistant 16.5 – (Softened)
Weldable 18.5 10-
13 1.25 –
1.75

316 316 Plate Highly corrosion C Cr Ni Mo 0.07 max 540 800

S16 Precision resistant, and 16.5 – (Softened)
strip Weldable 18.5 9-11
1.25 –
1.75

316 316L Plate Highly corrosion C Cr Ni Mo 0.03 max 480 800

S12 Precision resistant, 16-5 – (Softened)
Strip Weldable and 18.5 11-
resistant to 14 2.25 –
sensitisation 3.0

317 317 Plate Extremely high C Cr Ni Mo 0.06 max 540 800

S16 corrosion 17.5 – (Softened)
resistant, 19.5 12-
Weldable 15 3-4

317 317L Plate Extremely high C Cr Ni Mo 0.03 max 490 800

S12 corrosion 17.5-19.5 (Softened)
resistant, 14-17 3-4
Weldable,
resistant to
sensitisation

320 - Plate, Highly corrosion C Cr Ni Mo 0.08 max 540 800

S17 Precision resistant, 16.5 – (Softened)
Strip Weldable and 18.5 11-
resistant to 14 4 x C-
sensitisation 0.6 2.25 –
3.0

321 321 Plate, Weldable and C Cr Ni Ti 0.08 max 510 800

S12 Precision resistant to 17-19 9- (Softened)
Strip sensitisation. 12 5 x C-

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BS AISI Forms Main Major Tensile Service

1449 * Characteristics Constituents Strength Temperature
% N/mm2 °C

Good corrosion 0.70

and oxidation
resistance

347 347 Plate, Weldable and C Cr Ni 0.08 max 510 800

S17 Precision resistant to 17-19 9- (Softened)
Strip sensitisation. 12
Highly resistant
to hot
concentrated
nitric acid

*The equivalent EN grades shall be applicable.

Table 9.4 Ferritic Stainless Steels

BS AISI Forms Main Major Tensile Service

1449 * Characteristics Constituents Strength Temperature
% N/mm2 °C

403 403 Plate, Weldable, Heat C Cr Ni 0.08 max 420 750

S17 Precision resistance and 12-14 (Softened)
Strip moderate 0.5max
corrosion
resistance

405 405 Plate, Weldable, Heat C Cr Ni A1 0.08 max 420 750

S17 Precision resistance and 12-14 Softened)
Strip moderate 0.5max -
corrosion 0.3
resistance

409 409 Precision Weldable, Heat C Cr Ni Ti 0.09 max 420 750

S17 Strip resistance and 10.5 – (Softened)
moderate 12.5 0.7
corrosion max 5 x C
resistance min- 0.7
Max

430 430 Plate, Fairly good C CR Ni 0.1 max 430 800

S15 Precision general 16-18 0.5 (Softened)
Strip corrosion max
resistance.
Formable

434 434 Precision Good C Cr Ni Mo 0.1 Max 420 800

resistance to 16-18 0.5

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S19 Strip atmospheric Max 0.9 – (Softened)

corrosion. 1.3
Formable

*The equivalent EN grades shall be applicable.

Table 9.4 Martenstic Stainless Steels

BS AISI Forms Main Major Tensile Service

1449* Characteristics Constituents Strength Temperature
% N/mm2 °C

410 410 Precision Hardenable. C Cr Ni 0.09 – H and T 750

S21 Strip Heat resistant 0.15 11.5 550/700
and Moderate – 12.3 1.0
corrosion max
resistance

420 420 Precision Hardenable. C Cr Ni 0.28 – H 540 mm -

S45 Strip Heat resistant 0.36 12.0
and Moderate – 14.0 1.0
corrosion max
resistance

*The equivalent EN grades shall be applicable.

9.4.3 Stainless Steel Products

9.4.3.1 General

Stainless steel products must be of grade 316, any welded items to be manufactured
from grade 316 low carbon material, including welding wire. Any materials produced
in mill finish to have marks removed after fabrication by wire brushing or using a
solution of acid paste (pickled and passivated) or electropolishing.

9.4.3.2 Handrails

Handrails for walkways, platforms and stairs etc. will generally come under the
category of General Duty with a loading requirement of 0.36kN/m or Heavy duty with
a loading requirement of 0.74kN/m as defined in BS 6180/BSEN ISO 14122-2010.
The location to use each products and its sizes shall be as shown in the drawing.

a) Handrail for General Duty (0.36kN/m)

Handrails and standards shall be of stainless steel grade 316 L complying with the
requirements of BS 5395:Part 3: 1985, having top and intermediate rails. Handrails
shall be constructed from 60 mm o/d tube (minimum 4mm wall thickness) complete
with all bends and internal joints. Handrail joints to be of the internal ferrule type
secured with M8 stainless steel grub screws. Joints to be concealed within balls of
standards. Handrails shall be supported by ball type tubular handrail standards,
spaced at not greater than 1800mm centres standards shall be constructed from 42.4
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mm/OD tubular shanks and fitted with 75 mm diameter balls drilled through of the
above described handrails and fitted with M8 grub screws to secure handrail.
Standards to have welded on round base plates (minimum 135mm x 12mm thick)
drilled for 3 nos holes at 100 pcd to be fitted with M12 resin anchor bolts having
stainless steel studs. Handrails to platforms, walkways and landings to be 1100mm
high and between 900mm and 1000mm above the pitch line on the stairs.

Finish: Handrails to be brush polished, pickled clean or electropolished with satin

finish.

b) Handrail for Heavy Duty (0.74kN/m)

Handrails and standards shall be of stainless steel grade 316L complying with the
requirements of BS 5395: Part 3 : 1985, having top and intermediate rails. Handrails
shall be constructed from 75 mm o/d tube (minimum 4mm wall thickness) complete
with all bends and internal joints. Handrail joints to be of the internal ferrule type
secured with M8 stainless steel grub screws. Joints to be concealed within balls of
standards. Handrails shall be supported by ball type tubular handrail standards,
spaced at not greater than 1500mm centres. Standards shall be constructed from 50
mm o/d tubular shanks and be fitted with 90mm diameter balls drilled through or the
above described handrails and fitted with M8 grub screws to secure handrail.
Standards to have welded on round base plates (minimum 150 mm & 12mm thick)
drilled for 3 nos. holes at 100 pcd to be fitted with M12 resin anchor bolts having
stainless steel studs. Handrails to platforms, walkways and landings to be 1100mm
high and between 900mm and 1000mm above the pitch line on the stairs.

9.4.3.3 Toe Plates

Toe plates shall be provided to all platforms and walkways and shall be a minimum of
100mm high x 6 mm thick secured to handrail standards with a clamp plate and 2
nos. M8 ‘U’ bolts. All joints in toe plates shall be made secure with 100mm square x
6mm thick joint plates and 4 no. M8 pan head stainless steel bolts. All joints in toe
plates shall be made secure with 100mm square x 6 mm thick joints plates and 4 nos.
M8 pan head stainless steel bolts. All corners shall be complete with clear
connections, again of bolted construction. Toe plates are not required to the slope of
stairs.

Finish: Toe plates and fittings to be brush polished, pickled clean or electropolished.

9.4.3.4 Ladders (Fixed Vertical or near Vertical)

All ladder sizes shall be as shown in the drawing. All access ladders shall be
fabricated from stainless steel grade 316L, complying with the requirements of BSEN
ISO 14122-2001 (BS 5395:Pt 3 : 1985 ), having flat stringers and solid round rungs.
Ladders shall be constructed from minimum 65mm x 10mm flat stringers, spaced
380mm apart (400mm overall width), fitted with 20mm diameter solid rungs at 250mm
centres of all welded construction. Fixing stays shall be provided at centres not

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greater than 2.3m. Inclined ladders should be set at 75 or steeper. Landing where
required shall not be less than 840 mm square with handrails and toe plates to
protect open sides. Ladders rising more than 2.2 m should be fitted with a safety
cage. Handholds shall be provided to all ladders. Ladders rising above the floor level
to which they give access shall be fitted with hand holds where access is to one side
for a walk through access. The latter shall be fitted with safety chains or drop bars.
Where ladders terminate below the floor level to which they give access (manhole
type) they shall be fitted with handhold. Safety cages shall be constructed from 50mm
x 8mm flat hoops, complete with 3 vertical straps. Hoops shall be provided at centres
not greater then 750mm and shall be of bolted construction, M10 countersunk type.
Ladders tops shall be extended above floor level acting as handhold where required.
Pumping stations, tanks and deep manholes shall have ladder with top type
retractable handhold. For open top ladders single height or full height hinged gates
shall also be provided if required.

9.4.3.5 Step Ladders

Step ladders shall be of stainless steel grade 316 and shall comply with the design
requirement of BSEN ISO 14122-2001 (BS5395: Pt3: 1985), constructed from
130mm x 10mm flat stringers 550mm apart, cleated top and bottom for fixing and
fitted with open type treads, complete with end plates welded on and twice drilled at
each end for fixing to the stringers with M10 bolts. A single line handrail shall be
provided on each side of the step ladder, constructed from 60mm o/d x 4mm tube
supported by single ball tubular standards. Handrails shall be opened out at the top to
a minimum of 610mm and shall be turned to form continuity with the platform
handrail. At the lower end the handrails should be returned to the stringers.

Step ladders shall have untreated mill finish (weld as laid), pickled clean or
electropolished.

9.4.3.6 Safety Chains on Platforms

Safety chains shall be of 12.5mm diameter long link swivel eye, with ‘S’ hook and ‘D’
shackle each end as shown in the drawing made from grade 316 stainless steel,
bright finish.

9.4.3.7 Open Type Flooring

Open type flooring shall be of stainless steel grade 316L complying with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985 and BS4592: Pt 1 2006),
Suitable for a super imposed loading of 5kN/m.sq. The flooring shall be rectangular
pattern type constructed from main span bars designed to suit the loading and made
up of suitable size panels for ease of handling and complete with welded on nosing
bars. The mass of any individual panel shall not exceed 40kg. Where floor panels are
supported on structural members, adjustable type fixing clips or shot fired fixings shall
be provided with a minimum of 2 clips per panel, securing each corner with 2
additional clips for end panel covers. Where floor panels are contained within angle
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curbing, fixing clips are not required. Where angle curbing is provided, this shall
complete with bent flat lugs welded on for grouting into the surrounding concrete at
maximum 900mm centres and at a maximum of 150mm from each end or corner.
Flooring shall be of such depth to ensure that deflection does not exceed span/200 or
10mm whichever is lesser when fully loaded. Support beams of grade 316 stainless
steel shall be provided, including all cleats and fixing bolts to facilitate easy removal
where necessary. Fixing clips shall be stainless steel grade 316 material. Where cut
outs are required in flooring around pipe work or other obstructions, a continuous
nosing bar shall be fully welded to all load bearing bars around the cut out. The
clearance around the obstruction shall not exceed 30mm.

Flooring shall be untreated mill finish (welds as laid), pickled clean or electropolished.

9.4.3.8 Solid Floor Plates

Solid floor plates shall be Durbar pattern stainless steel grade 316L and shall comply
with the requirements of BSEN ISO 14122-2001 (BS 5395: Pt 3: 1985). Floor plates
shall have a minimum 6mm base thickness, be provided with lifting holes and
secured with M10 stainless steel countersunk head screws. Where floor plates have
concrete surrounds they shall be provided with stainless steel flat curbing. The 6mm
flat base providing a 25mm wide seating. Bent flat lugs shall be welded on to the
underside at 900mm maximum centres and at 150mm from corners or ends for
grouting into the surrounding concrete. Where necessary intermediate stainless steel
supports shall be provided and shall include all necessary cleats and fixing bolts to
enable removal when required. Where cut outs are required around pipe work or
other obstruction, these shall be neatly cut with all rough and sharp edges ground
smooth. Clearance between the floor plates and obstructions shall not exceed 30mm.
Floor plates shall be designed for a uniformally distributed loading of 5kN/m.sq. and
deflection shall not exceed span /200 or 10mm whichever is the lesser, when fully
loaded.

Flooring shall be untreated mill finish (weld as laid), pickled clean or electropolished.

9.4.3.9 Staircase

Staircases shall be of stainless grade 316L, S 31complying with the requirement of

BSEN ISO 14122-2001 (BS 5395: Pt 3: 1985). Staircases shall have a rake not
exceeding 38 degrees and shall have a width of between 800mm and 1 metre.
Handrails shall be provided on both sides and shall be continuous with walkway and
platform handrails. Stairs shall be fitted with open type stainless steel treads shall be
fitted with sight bars and have end plates welded on and twice drilled for M12
stainless steel fixing bolts for attaching to the stair stringers. The going of each tread
shall be 250mm and the maximum rise shall be 190mm. The stair stringers shall be of
minimum 180 x 10mm flat section stainless steel and shall be cleated top and bottom
for fixing. Stringers at the bottom of the staircase shall not extend more than 50mm
beyond the lowest tread. Stairs shall have no more than 16 risers or less than 3.
Where staircases are to be fitted with solid treads these shall be constructed from
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floor plates with a flanged nosing and end plates for bolting to the stair stringers.
Where stairs have a rise exceeding 3040mm, intermediate landings shall be
introduced. A staircase shall be designed for a uniformly distributed loading of
5kN/m.sq.

Finishes: Stair case – Natural untreated mill finish (weld as laid), pickled clean or
electropolished. Handrails – Brush polished, pickled clean or electropolished.

9.4.3.10 Step Irons

Step irons shall be of stainless steel as described below.

Stainless steel irons shall be fabricated from 25 mm diameter solid bar twice bent to
form a ‘U’ shaped width 375 mm with two legs 350 mm long, the ends of the bar shall
be ragged and built 175 mm into the concrete wall. The tread of the rung shall be
stamped or otherwise roughened.

9.4.3.11 Stainless Steel Clamping Systems

Stainless steel band for fixing uPVC saddles to AC pipes or similar rigid pipes shall
comply with the requirements and be resistant to environment corrosion and
electrolytic action. Standard band 19 mm wide shall be utilised with the edges of the
band rounded for ease of handling.

Clamping shall be by ‘standard’ buckles. Buckles shall be manufactured from the

same material as the standard band and have the same corrosion resistance.

9.4.3.12 Saftey Chains and Fittings for Manholes

Safety chains to guard railing shall be supplied by the guard railing manufacturer to
the dimensions shown on the Drawings.

Safety chains shall be fitted in manholes across the entries to all outlet pipes
exceeding 600mm diameter and shall be manufactured in stainless steel Grade 316
S16 capable of withstanding continuous exposure to the severe corrosive conditions
occurring in sewers or drains carrying septic sewage and groundwater.

The suitability of the chain and fittings for use in aggressive environment shall be
verified by immersing an approved length of chain together with fittings in a 20%
concentration of sulphuric acid at 35 C for 90 days. At the end of this period, neither
the chain not the fittings shall display any visible loss of material. The chain shall then
be subjected to a static tensile load of 1.5KN for 15 minutes. It shall not show any
deformation or visible strain.

The anchorages for the safety chains shall be of stainless steel Grade 316 S16.

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9.4.3.13 Nuts, Screws, Washers and Bolts

Nuts, screws, washers and bolts shall be of such material to resist environmental
corrosion and electrolytic action with mating metals.

Unless an alternative is specifically approved, stainless steel items shall be supplied

for all dismantleable items.

Zinc coated items 10mm diameter and larger shall have the nuts cut oversize and
shall be spun galvanised (or equivalent). Smaller zinc coated items shall be
electroplated.

Black hexagonal bolts, screws and nuts shall be to a grade with a tensile strength of
400 N/mm2.

Bright (high tensile) items to a grade with a tensile strength of 800 N/mm2 may be
used instead of black items.

The items shall have coarse metric threads.

Bolting for pipes and fittings shall comply with the approved standard. Spheroidal
graphite iron bolts for use with ductile iron pipes and fittings shall have a tensile
strength of 500 N/mm2.

9.4.3.14 Stainless Steel Weir Plates

The weir plates shall be stainless steel grade 316L with 10mm thick plates as shown
in the Drawings.

9.4.3.15 Stainless Steel Baffle Plate

The Baffle Plate shall be with Steel grade 316L and comply with the design
requirements as shown in the approved drawing.

9.4.3.16 Certification

The product manufacturer has to provide a compliance certification that the stainless
steel items supplied fully comply with the relevant standard requirements with
supporting test reports of materials, chemical composition, load/deflection,
concentrated & uniformly distributed load tests carried out on each unit.

9.4.3.17 List of Approved Product Supplier

a) European Platform Systems – UK International

b) Standard Fabrications – Dubai

c) Al shabia Engineering Ltd - Sharjah

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9.5 ALUMINUM

9.5.1 General

The following specification relates to aluminium equipment based on current British

and European Standards.

9.5.2 Material

All aluminium alloy must be marine grade 6082 to BS EN 755-3, fully heat treated
T.6. condition, except that T.4 condition shall be used for the upper and lower tubular
horizontal handrails. (Note: handrail tube T.4 condition is more ductile and allows
bends to be formed). Material certificates shall be required to demonstrate conformity.

9.5.2.1 Precautions Against Electrolytic Action

Precautions should be taken in damp or moist conditions to avoid electrolytic action

between dissimilar metals, particularly with aluminium. The good corrosion resistance
of aluminium and its alloys is attributable to the protective oxide film which forms on
the metal surface spontaneously on exposure to air. The protective film is relatively
inert and forms naturally. After fairly rapid initial formation of the oxide film, very little
further action occurs. Such behaviour is consistent for practically all external freely
exposed conditions and for all internal or shielded conditions, except where extremes
of acidity or alkalinity can develop. Aluminium is in general considered maintenance
free. However, in damp or wet conditions aluminium can be adversely affected by
being allowed to come into direct contact with dissimilar metals and some building
materials including concrete.

Protection, in general can be provided by painting the contact surface of the

aluminium with 2 coats of bituminous paint. Bolts used for fastening in adverse
conditions should be provided with plastic ferrules and washers for the bolt shank and
under the bolt head and nut.

Unprotected ‘mill finish’ aluminium is highly weather resistant and lasts for many
years even in an exposed environment. Where it is desirable to provide added
protection, anodising the metals to BS 1615 grade AA25 can be considered.
Anodising is an electrolytic process in which the natural oxide layer that is always
present on aluminium is thickened.

9.5.3 Aluminium Products

9.5.3.1 Handrails

Handrails for walkways, platforms and stairs within BSEN ISO 14122-2001 will
generally come under the category of ‘General Duty’ with a loading requirement of
0.3kN/m or heavy duty with a loading requirement of 0.7kN/m.

a) Handrail for General Duty (0.36kN/m)

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Handrails and standards shall be of aluminium alloy grade 6082 (T.6. condition for
handrail standards and T.4. condition for handrails), complying with the requirements
of BSEN ISO 14122-2001 (BS 5395:Pt 3: 1985), having top and intermediate rails at
550mm centres. Handrails shall be constructed from 60 o/d tube (minimum 6.3mm
wall thickness), complete with all bends and internal joints. Handrail joints to be of the
internal ferrule type. Handrails shall be supported by tubular type handrail standards
spaced at not greater than 2000mm centres. Standards shall be constructed from
50.8mm o/d tube (minimum 6.35mm wall thickness) and be fitted with a die cast top
tee and a high duty die cast aluminium (LM25) base, secured to shank with 2 no. M8
stainless steel grub screws. Bases shall be purpose made (minimum 170mm x 90mm
x 15mm thick) twice drilled for 2 no. M12 resin anchor bolts, having stainless steel
studs grade 316. Handrail standards to be fitted with stainless steel grub screws to
screw to secure handrails in position. Handrails to platforms, walkways and landings
to be 1100m high and between 900mm and 1000 mm above the pitch line on the
stairs.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

b) Handrail for Heavy Duty (0.74 kN/m)

Handrails and standards shall be of aluminium alloy grade 6082 (T.6 condition for
handrail standards and T.4 condition for handrails), complying with the requirements
of BSEN ISO 14122 /2001 (BS 5395:Pt 3 : 1985), having top and intermediate rails at
550mm centres. Handrails shall be constructed from 75 mm o/d tube (minimum 6.25
mm wall thickness), complete with all bends and internal joints. Handrail joints to be
of the internal ferrule type. Handrails shall be supported by tubular type handrail
standards spaced at not greater then 1500mm centres. Standards shall be
constructed from 50 mm o/d tube (minimum 6.35 mm wall thickness) and be fitted
with a die cast top tee and a high duty die cast aluminium (LM25) base secured to
shank with 2 no. M8 stainless steel grub screws. Bases shall be purpose made
(minimum 170mm x 90mm x 15mm thick) twice drilled for 2 no. M12 resin anchor
bolts, having stainless steel grade 316. Handrail standards to be fitted with stainless
steel grub screws handrails in position. Handrails to platforms, walkways and
landings to be 1100 high and between 900mm and 1000mm above the pitch line on
the stairs.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.2 Toe Plates

Toe plates shall provided to all platforms and walkways and shall be of extruded
section minimum height 160mm. Toe plates shall be secured to handrail standards
with clamp plate and strap, to avoid any distortion along its length. All joints in toe
plates shall be made secure with 3mm thick joint plate. All corners shall be complete
with cleat connections, again of bolted construction using grade 316 stainless steel
fixings.

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Finish: natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.3 Ladders (Fixed Vertical or Near Vertical)

Access ladders fabricated from aluminium alloy grade 6082 T.6 shall comply with the
requirements of BSEN ISO 14122-2001 (BS5395:Pt 3: 1985). Ladders shall be
constructed from minimum 65 mm x 10mm stringers, spaced 380mm apart, fitted with
20mm diameter solid or tubular rungs at 250mm centres of all welded/ riveted
construction. Fixing stays shall be provided at centres not greater than 1.8m. Ladders
rising more than 2.2m should be fitted with a safety cage. Handholds shall be
provided to all ladders. Ladders rising above the floor level to which they give access
shall be fitted with safety chains. Where ladders terminate below floor level to which
they give access (manhole type) they shall be fitted with retractable handholds.
Safety cages shall be constructed from 50mm x 8 mm flat hoops, complete with 3
vertical straps. Hoops shall be provided at centres not greater than 750mm and shall
be of bolted constructions, bolts to be M10 stainless steel countersunk type or have
dome heads on the inside of safety cages.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.4 Step Ladders

Step ladder shall be of aluminium alloy grade 6082 T.6 and shall conform with the
design requirements of BSEN ISO 14122-2001 (BS 5395:Pt 3: 1985), constructed
from 130mm x 10mm flat stringers 550mm apart, cleated top and bottom for fixing
and fitted with open type aluminium alloy treads, (or solid treads type), complete with
end plates welded on and twice drilled at each end for fixing to the stringers with M10
stainless steel bolts. A single line handrail shall be provided on each side of the step
ladder, having 50.8 mm o/d x 6.3 mm tubular shanks and purpose made high duty
cast aluminium side palm bases, secured to the step ladder with 2 nos. M12 stainless
steel bolts. Handrails shall be opened out at the top a minimum of 610mm and shall
be turned to form continuity with the platform handrail.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.5 Open Type Flooring

Open type flooring shall be of aluminium alloy grade 6082 T6 Deck type having 24%
open area, complying with the requirements of BSEN ISO 14122 – 2001 (BS 5395:Pt
3: 1985), suitable for a super imposed loading of 5kN/m.sq. in accordance with the
requirements of BS4592. The flooring shall be of a reinforced extruded section with
integral inverted ‘T’ section stiffening webs, made up into suitable size panels for
ease of handling and complete with welded on nosing bars. The mass of any
individual panel shall not exceed 40kg. Where floor panels are supported on
structural members, adjustable type fixing clips shall be provided with a minimum of 4
clips per panel, securing each corner. Where floor panels are contained with angle
curbing, fixing clips are not required. Where angle curbing is provided, this shall be

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complete with purpose made lugs. Curbing shall provide adequate seating for the
flooring and should match the depth of the floor plate for which it is provided. Floor
plates shall be of a depth to ensure that deflection does not exceed span/200 or
10mm whichever is lower, when fully loaded. All necessary intermediate support
beams shall be provided, including all necessary cleates and fixing bolts to facilitate
easy removal where necessary. Fixing clips shall be aluminium alloy with M8 nickel
head stainless steel fixing screws, spring washer & nut.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.6 Solid Floor Plates

Solid floor plates shall be aluminium alloy grade 6082T6 and shall comply with the
requirements of BSEN ISO 14122-2001 (BS5395: Pt 3: 1985). suitable for a super
imposed loading of 5 kN/m.sq. Floor plates shall be of a reinforced extruded section
with integral inverted ‘T’ section stiffening webs. The floor plates shall be supplied in
suitable size panels for ease of handling and complete with welded on nosing bars.
The mass of any individual panel shall not exceed 40kg. Where floor plates are
supported on structural members, adjustable type fixing clips shall be provided with a
minimum of 4 clips per panel securing each corner. Fixing clips shall be aluminium
alloy with M8 nickel head stainless steel fixing screws. Where floor panels are
contained within angle curbing, fixing clips are not required. Where angle curbing is
provided this shall be complete with purpose made lugs. Curbing shall provide
adequate seating for the flooring and should match the depth of the floor plate for
which it is provided. Floor plates shall be of a depth to ensure that deflection does not
exceed span/200 or 10mm whichever is the lower, when fully loaded. All necessary
intermediate support beams shall be provided, including all cleats and fixing bolts to
facilitate easy removal where necessary. Where cut outs are required in flooring
around pipework or other obstructions, a continuous nosing bar shall be welded to all
load baring bars around the cut out. The clearance around the obstruction shall not
exceed 30mm.

Finish: Natural untreated mill finish, powder coated or anodised AA25.

9.5.3.7 Staircases

Staircases shall be of a aluminium alloy grade 6082 T6, complying with the
requirements of BSEN ISO 14122-2001 (BS 5395: Pt 3 : 1985). Staircases shall have
a rake not exceeding 38 degrees and shall have a width of 800mm or 1 metre as
shown on drawings. Handrails shall be provided on both sides and shall be
continuous with toeplate to horizontal areas (not stringers). Stairs shall be fitted with
open type aluminium alloy treads which shall be complete with end plates welded on
and each twice drilled for M12 stainless steel fixing bolts for attaching to the stair
stingers. The going of each tread shall be 250mm and the maximum rise shall be
190mm. The stair stringers shall be of minimum 180 x 10 mm flat section aluminium
alloy and shall be cleated top and bottom for fixing, stringers at the bottom of the
staircase shall not extend more than 50mm beyond the lowest tread. Stairs shall have
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no more than 16 rises or not less than 3. Where stairs have a rise exceeding
3040mm, intermediate landings shall be introduced. Staircases shall be designed for
a uniform distributed loading of 5kN/m.sq.

Finish: Natural untreated mill finish, powder coated or anodised grade AA25.

9.5.3.8 Heat Treatment of Aluminium Alloys Specified.

Material grade 6082 to BSEN 755.

Heat-treated to T4 (H30TB) and T6 (H30TF) condition to BSEN ISO 515.

9.6 GRP MOULDED GRATING AND GRP PULTRUDED SUPPORTS

9.6.1 General

a) GRP grating types shall be open or solid top, slip resistant where indicated in the
drawings.

b) All finished surfaces of GRP items and fabrications shall be resin rich, free or
voids and without dry spots, cracks, or un-reinforced areas. All fiberglass shall be
well covered with resin to protect against their exposure due to wear and
weathering.

c) All GRP products shall be mechanically secured using holddown clamps and
pannel connections of GR: 316L SS for all grating pannel sections. A minimum of
4 per panel shall be provided.

d) The submittal must be along with the relevant product catalogues / descriptive
literature stating manufacturing process, materials, mill certificates of accessories
and instructions on construction or erection manual, handling.

e) Shop drawing shall be indicated with mesh size, design load parameters,
dimensions, materials, clearances, tolerances, support details, integration of
piping components and anchorage, etc.

f) Manufacturing process shall be open heat moulded, Continuous glass fibres are
placed in the mould in alternating layers and completely wetted out with resin.
This continuous process produces an integral, one piece construction which
provides excellent corrosion resistance as well as bi-directional strength. When
the weaving process is completed, the mould is heated to cure the panel. The
mould will receive the grit before the part is cured. After curing the part is
extracted from the mould.

g) Grating shall be suitable for 100% humidity and > 50C temperature, corrosion
proof, UV stabilized.

h) Sealing: All shop fabricated and field fabricated grating cuts shall be coated with
a resin compatable to grating resin to provide maximum corrosion resistance.

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i) The Grating shall be free, as commercially possible, from visual defects such as
foreign inclusions, delamination, blisters, resin burns, air bubbles and pits.

j) Colour of Grating shall be safety yellow pigmented Grey or Green or Orange.

k) After moulding, no dry glass fibres shall be visible on any surface or bearing bars
or cross bars. All bars shall be smooth and uniform with no evidence of fiber
orientation irregularities, interlaminar voids, resin rich or resin starved areas.

l) Moulded grating to be designed to exhibit a minimum of class 1 flame spread

rating less < 25, when tested in accordance with ASTM E-84 flame spread rating
tunnel Test.

m) All openings shall be edge banded.

n) Grating designated as “solid top” shall include a seamless GRP sheet of minimum
thickness 5 mm permanently attached to the bars.

o) Top surface of all open and solid panels shall have a non- skid grit affixed by
baked epoxy resin.

p) Moulded grating must be designed with superior slip resistant grit top. The grits
must be embedded to the surface before the heating process, which Sprayed
type grit is not allowed.

9.6.2 Construction

a) Glass Content:

Moulded grating is manufactured using a proprietary method enabling a higher

percentage of glass roving to be introduced into the grating. The grating must contain
a 30-35% glass. The corrosion resistance of fiberglass grating is provided by the
resin and the stiffness is provided by the glass. Percentage of glass (by weight) shall
not exceed 40% so as to achieve maximum corrosion resistance, and as required to
maintain the structural requirements of the contract.

b) Resin Selection:

The resin selection is paramount in determining the corrosion resistance of the

finished product. VEFR-25 is a premium vinylester resin with a flame spread rating
less than 25. It provides the most chemical resistant moulded product offered in the
industry. Designed to withstand the harshest chemical environments over a
broadrange of acids and caustics, it shall be primarily used in petrochemical,
wastewater, where the grating is subject to frequent and direct contact with harsh
chemicals.

c) Mesh Selection: shall be as Table 9-5.

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Type of Grating Application Specification

Powergrid 38 x 25 x Service and Maintenance Mesh 25 x 150 , depth 38 mm,

150 RM platforms for light, medium Load bar thickness 9.3 mm,
duty equipment, load bar centres 25, open area
Accessories, tools. 56%, Approx. Weight 22.4
kgs/m2.

Powergrid 60 x 38 Service and Maintenance Mesh 38 x 38, depth 60 mm,

SM platforms for heavy-duty load bar thickness 11, load bar
equipment, Accessories, centres 38 mm, open area
tools, Machinery, etc. 58%, Approx. weight
50.4kgs/m².

(i) FIRE RETARDANT

Manufacturer is required to test and provide certification of ASTM E84 test on grating
panels from independent testing laboratory. The data performed only on the base
resin shall not be acceptable.

(ii) INSTALLATION

1. Sub-contractor shall install gratings in accordance with the

manufacturer’s assembly drawings. Lock grating panels securely in
place with hold-down fasteners.

2. Field cut and drill fiberglass reinforced plastic products with carbide or
diamond tipped bits and blades. Seal cut or drilled surfaces in
accordance with manufacturer’s instructions.

3. Install items specified as indicated and in accordance with

manufacturer’s instructions.

(iii) TOLERANCES

1. The grating tolerance to side of trench is 6 mm,

2. The grating tolerance to wall 10mm.

3. The grating tolerance between panels is 0 mm to 6 mm.

4. The minimum support width is 38mm.

5. The cutting tolerance is +0 mm, - 6mm.

9.6.3 Quality Control

a) All testing and inspection costs if required, shall be born by the contractor.

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b) The following min Test reports to be provided by the manufacturer / supplier for
Engineer’s review:

Table 9-6: Minimum Tests Reports to be provided

Sr. Tests on Properties Standard Limits

1. Uniform load testing NSI/ASCE/ACMA Minimum design

FGM-2003 requests

2. Concentrated load testing ANSI/ASCE/ACM "

AFGM 2003

3. Concentrated line load testing ANSI/ASCE/ACM A "

FGM 2003

4. Barcol hardness ASTM D 2583 > 33

5. Visual inspection ASTM D 2563 Level 1

6. Acid immersion test in 10% ASTM C 581 Shall not show any
Concentrated sulphuric acid for deterioration after
100 days the test.

7. Glass content ASTM D 2584 >30%

Type of Grating Application Specification

Powergrid 38 x 25 x 152 Stair Treads Mesh 25 x 152, depth 38

RM with double bearing mm, load bar thickness
bars at 150 intervals and 6.4, load bar centres 25,
non- skid nosing open Area 56%, weight 23
kgs/m2

Powergrid 38 x 25 x 150 Service and Maintenance Mesh 25 x 150 , depth 43

RM, Covered plate platforms in odour control mm, load bar thickness 9.3
surface area mm. Load bar centres 25 ,
closed top surface,

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Approx. Weight 30 kgs/m2

9.6.4 Design Criteria:

a) The criteria of the FRP products including connections shall be in accordance

with governing building codes and generally accepted standards in the FRP
industry.

b) Gratings: Design live loads of the FRP gratings for walkway applications shall be
500 kgs/m2 uniformly distributed load with a maximum deflection of 6 mm or L/120
at the centre of a simple span or a concentrated load of 750 kgs with a maximum
deflections of 6.25 mm at the centre of a simple beam.

c) Stair Treads: Stair treads shall be designed for a uniform load of 500 kgs/m2 at
the centre of a simple span OR a 450 kgs/m of width line load at the centre of the
tread.

d) LOAD DEFINITIONS:

(i) Dead load:

All structural materials, floors and various permanent elements forming part of the
platform shall be considered as dead loads.

(ii) Live Load:

The design imposed loading shall be as per Table 9-7:

Floor Area Usage Distributed load Kgs/m2 Concentrated load Kgs

Maintenance , and storage 500 750

Area

Heavy equipment, loading 1500 2250

and offloading area, where
forklift is used.

e) DEFLECTION:

Floor Area Usage Max allowable deflection

Maintenance , and storage area L/120

Heavy equipment, loading and offloading L/120

area, where forklifts used

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9.6.5 Submittals

a) Submit manufacturer’s shop drawings of all fabricated gratings clearly showing

Materials sizes, types, styles, part or catalogue numbers, complete details for the
fabrication of and erection of components including, but not limited to, location,
lengths, type and sizes of fasteners, clip angles, members sizes and connection
details.

b) Submit the manufacturer’s published literature including structural design data,

Structural properties data, grating load/deflection tables, corrosion resistance
tables, certificate compliance, test reports as applicable and design calculation
manual for pultruded supporting system.

c) Submit sample pieces of each item specified herein, manufactured by the method
used in the work and as quality and colour.

9.6.6 Pultruded Supports

a) A pultruded fiberglass structural shape is comprised of reinforcing fibres and

resin. The fibre reinforcement provides the structural stiffness, and the resin
provides the resistance to the environment, be it ultraviolet resistance, chemical
resistance, impact resistance. Resins typically contains fillers to assist in
achieving an intended performance characteristic.

b) Reinforced fibres consist of continuous strand mat and continuous stand roving.
Typical structural shapes contain from 45% - 75% fibre reinforcement by weight.

c) Since pultrusion is a low pressure process, fiberglass reinforcement normally

appear close to the surface of the product. This can affect the corrosion
resistance. Surface veils must be added to the laminate construction, and when
used, displaces the reinforcement from the surface of the profile, creating a resin
rich surface.

d) Vinylester resin possess excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly
corrosive environment.

e) Fiberglass will undergo some decay and change of appearance due to prolonged
exposure to outdoor weathering. UV stabiliser will retard the effect of weathering.
UV Stabilised urethane coating shall provide for U.V protection with minimal
change in appearance.

9.6.7 Structural Design Basis

a) Effect of Temperature

When designing fiberglass structures that will be subjected to high heat exposure, the
manufacturer is cautioned to consider the effect of temperature as it relates to the
allowable stresses and to the modulus of elasticity. The result of higher temperatures
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on structural fiberglass is a reduction in modulus of elasticity and thus a lowering of

the allowable stresses. The table below provides the retention of modulus of
elasticity.

Temperature Retention of Modulus of Elasticity

37° C 100%

51° C 95%

Temperature Retention of Ultimate Stress

37°C 90%

51°C 80%

b) Safety Factors

Safety factors are defined as the ratio of the ultimate stress to the allowable stress.
Safety factor (S.F) = Ultimate Stress (U.S) / Allowable Stress (A.S)

The safety factors are chosen to prevent “first deformation of the part”. First
deformation is defined as the first visible deformation including local flange or web
buckling, twisting, crushing, etc.

The recommended design safety factors are:

Loading Type Recommended Safety Factors

Flexural members, beam 2.5

Compression members, column 3.0

Tension members 4.0

Beam Shear 3.0

Connections 4.0

MODULUS

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Modulus of Elasticity 1.0

Shear Modulus 1.0

(i) DEFLECTION

As a minimum, all live load deflections of all beams should be limited such that the
deflection over length ratio (∆ / L) does not exceed 1/150. For Cantilevered beams,
the deflection ratio should be limited to 1/100.

The deflection of a fiberglass beam is actually comprised of two components:

 Flexural deflection
 Shear deflection

The shear deflection will and add an additional 10-15% to the deflection.

In short beams subjected to high concentrated loads, shear stress may govern the
beam selection as opposed to the flexural stress.

(ii) FLEXURAL BEAM MEMBERS

Flexural members have two primary failure modes due to bending:

1. Failure due to pure bending stress, i.e. Compression flange crushing or

tension flange breaking and

2. Failure due to global buckling, i.e. lateral torsional buckling. Proper

design of flexural members required that both of these failures modes
be investigated in the design process. Allowable stresses will be
reduced significantly if the proper bracing scheme is not used. The use
of intermediate beams at the appropriate spacing along the bending
member shall be used to eliminate buckling concerns.

(iii) COMPRESSION COLUMN MEMBERS

The column failure can be categorized into two modes: bearing failure and local/
global instability. The short column generally fail in bearing deformation or local
buckling mode. The long columns generally fail in the global buckling mode. Short
columns with I section fail to due to combination of axial load and bending moment.

Table: 9 -8 Determine the effective length coefficient, k-value

Sr. End connections Recommended K - Value

1. Pinned - Pinned 1.00

2. Fixed - Fixed 0.65

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3. Pinned - Fixed 0.80

4. Fixed - Translation Fixed 0.80

5. Fixed - Translation Free 1.20

6. Pinned - Translation Fixed 2.00

(iv) CONNECTION

1. Fiberglass structures are typically designed to be removable, thus all

connections are to be bolted.

2. All connections are to be designed using a safety Factor of 4.0.

3. All bolting hardware used should be SS 316 stainless steel.

4. When designing bolted connections, there are four engineering checks

to be performed,

5. Using the reaction load at the joint:

a. Check of beam shear on net throat area of a clip angle, S.F = 4.0

b. Check of beam shear on the web areas of the beams, S.F = 4.0.

c. Check of bolt bearing on the web of the beams, S.F = 4.0

d. Check of bolt shear, web of beams through bolt, S.F = 4.0.

Note: The shear factor for a beam analysis performed at a location other than
the connection is 3.0.

9.7 GRP PULTRUDED LADDER

9.7.1 General

a) All finished surfaces of GRP Ladder items and fabrications shall be resin rich, free
of voids and without dry spots, cracks, or un—reinforced areas. All fibreglass shall
be well covered with resin to protect against their exposure due to wear and
weathering.

b) All GRP products shall be mechanically secured using fixings manufactured from
SS316.

c) The submittal must be along with the relevant product catalogues / descriptive
literature stating manufacturing process, materials, mill certificates of accessories
and instructions on construction, handling.

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d) Shop drawing shall be indicated with size, design load parameters, dimensions,
materials, clearance, tolerances, support details, etc….

e) Manufacturing process of side rail, rungs is pultrusion process. Cage hoops, and
wall bracket shall produced by open moulded hand lay up method.

f) Ladder shall be suitable for 100% humidity and > 50 C temperature, corrosion
proof, UV stabilized.

g) Sealing: all shop fabricated and field fabricated ladder cuts shall be coated with a
resin comparable to ladder resin to provide maximum corrosion resistance.

h) The ladder shall be free, as commercially possible, from visual defects such as
foreign inclusions, delamination, blisters, resin burns, air bubbles and pits.

i) Colour ladder shall be safety yellow pigmented.

9.7.2 Manufacturing Process

Pultruded fibreglass ladder is comprised of reinforcing fibres and resin. The fibre
reinforcement provides the structural stiffness, and the resin provides the resistance
to the environment, be it ultra-violet resistance, chemical resistance. Resins typically
contain fillers to assist in achieving an intended performance characteristic.

Reinforced fibres consist of continuous strand mat and continuous stand roving.
Typical structural shapes contain from 45% - 75% fibre reinforcement by weight.

Since pultrusion is a low pressure process, fibreglass reinforcement normally appear

close to the surface of the product. This can affect the corrosion resistance two layers
of surfaces veils must be added to the laminate construction, and when used,
displaces the reinforcement from the surface of the profile, creating a resin rich
surface.

Vinylester resin possesses excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly corrosive
environment.

9.7.3 Construction

The ladder side rail shall be 54 mm square with a wall thickness of 6 mm. the rungs
shall be 32 mm diameter Pultruded structural shapes, continuously fluted to provide a
non-slip surface. Rungs that are gritted as secondary operation shall not be
permitted. Rungs are to be capable of withstanding a pointed load of 500 N applied at
the centre of rug. Ladder wall and floor mount shall be fabricated from hand lay up or
Pultruded angles 10mm minimum thickness.

The ladder cage vertical bars shall be 50mm wide x 15 mm Pultruded channel
shapes to offer protection to workers from exposed hardware.

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Type SS 316 stainless steel bolts shall be provided for attaching ladder cage vertical
bars to hoops, ladders hoops to brackets, ladder cage brackets to the ladder and wall
brackets to the ladder.

All rungs shall be both mechanically attached to the ladder with stainless steel rivets
and chemically bonded with epoxy.

9.7.4 Design / Standard

The ladder shall meet the following min requirement of OSHA code, section 1910.27
and project requirement:

a) The minimum design live load shall be a single concentrated load of 300 kgs.

b) The distance between rungs shall not exceed 300mm and the minimum clear
distance between side rails shall be 450 mm.

c) The safety cage is required on ladders of more than 6 m to a maximum unbroken

length of 9m.

d) The safety cage to extend minimum 1050 mm above top of landing.

e) The safety cage to begin minimum 2100 m to maximum 2400 mm above base of
ladder (floor).

f) The safety cage shall not extend less than 675 mm not more than 700mm from
the centreline of the rungs of the ladder. Cage shall not be less then 675 mm in
width.

g) The distance between hoop cages shall be max 850 mm.

h) The wall mounting brackets shall be spaced at max. 1800 mm.

i) Vertical bars shall be located at a maximum spacing of 40 degrees around

circumference of the cage; this will give a maximum spacing of approximately 138
mm centre to centre.

j) In certain locations, where safety is a major concern, the safety cage shall have a
fibreglass net manufactured by pultrusion process instead of vertical bars,
average thickened 3 mm, green or yellow colour, fixed on the GRP Cage hoops,
to provide extra safety for technicians.

k) When supported horizontally over a span on 1.0 meter with the climbing
uppermost and with a load of 1000N applied at the centre of the span , the ladder
shall:

(i) Not deflect more than 15mm at the point of application of the load.

(ii) Show no permanent deflection after removal of the load.

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9.7.5 Submittals

a) Submit manufacture’s shop drawings of all fabricated ladder clearly showing

Material sizes, types, part or catalogue numbers, complete details for the
fabrication of components including, but not limited to, lengths, type and sizes of
fasteners, clip angles, members sizes and connection details.

b) Submit the manufactures published literature including structural design data,

corrosion resistance tables, test reports as applicable, raw material data sheet.

c) Submit sample ladder, safety cage of each item specified herein, manufactured
by the method used in the work and as quality and colour.

9.8 GRP PULTRUDED HANDRAILS

9.8.1 General

a) All finished surfaces of GRP handrail items and fabrications shall be resin rich,
free of voids and without dry spots, cracks, or un-reinforced areas. All fibreglass
shall be well covered with resin to protect against their exposure due to wear and
weathering.

b) All GRP products shall be mechanically secured fixing using SS316.

c) The submittal must be along with the relevant product catalogues / descriptive
literature stating manufacturing process, materials, mill certificates of accessories
and instructions on construction, handling.

d) Shop drawing shall be indicated with size, design load parameters, dimensions,
materials, clearance, tolerances, support details, etc…

9.8.2 Manufacturing Process

Pultruded fibreglass handrail is comprised of reinforcing fibres and resin. The fibre
reinforcement provides the structural stiffness, and the resin provides the resistance
to the environment, be it ultra-violet resistance, chemical resistance. Resins typically
contains fillers to assist in achieving an intended performance characteristic.

Reinforced fibres consist of continuous strand mat. Typical structural shapes contain
from 45% - 75% fibre reinforcement by weight.

Since pultrusion is a low pressure process, fibreglass reinforcement normally appear

close to the surface of the product. This can affect the corrosion resistance two layers
of surfaces veils must be added to the laminate construction, and when used,
displaces the reinforcement from the surface of the profile, creating a resin rich
surface.

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Vinylester resin possesses excellent corrosion resistance, as well as better

performance characteristics at elevated temperatures. It is used in highly corrosive
environment.

9.8.3 Construction

a) The Handrail post/rail connection is to be fabricated such that the rail is unbroken
and continuous through the post without the use of packs and splices.

b) The bottom rail is to be installed through the post at a prepared hole made to fit
the outside dimensions of the rail.

c) The top rail is to fit into a machined “U” shaped pocket formed into top of the post
such that the rail is located at the centre of the post. All exposed corners are to be
chamfered and rounded to eliminate sharp edges.

d) The top rail and middle rail size is 44 x 44, the post size is 54 x 54 mm.

e) The rails are to be joined to the post through a combination of bonding and
riveting. No sharp protruding edges to remain after assembly of the handrails.

f) The handrail must have a vertical height of 1100mm from upper surface or as
shown in the Drawing.

g) The stair handrail must have a vertical height of 850 mm from the upper surface
of the top rail to the face of the riser at the forward edge of the tread.

h) Spacing of the posts should not exceed 1.5 m. For inclined handrail, the spacing
of the posts shall be maximum 1.2 m.

i) The middle rail must be approximately halfway between the top rail and the floor.

j) All Fasteners shapes used in handrail are to be SS 316.

k) Kicker plate shall be securely fastened in place with no more than 6.4 mm
clearance above the walking surface. Kicker plate size shall be 100mm, 3 mm
thick, W shape or M shape.

l) All shop fabricated cuts are to be coated with vinyl ester resin to provide
maximum corrosion resistance. Field cuts are to be similar coated in accordance
with manufacturer’s recommendations.

9.8.4 UV Protection

For outdoor exposure, the optimum method of maintaining surface appearance is to

apply a coating to the surface. UV stabilized Urethane coating must be applied to the
handrail in order to provide protection with minimal change in appearance.

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9.8.5 Design / Standard

The complete handrail installation shall meet the following loads requirements of
OSHA standard, section 1910.23 with a safety factor of minimum 2. The handrail
system must withstand the following structural loads.

a) Concentrated load : 890 N applied in any direction at the top rail.

b) Uniform load of 75kg/m applied horizontally.

c) Concentrated and uniform loads shall not be applied simultaneously.

9.8.6 Submittals

a) Submit manufacturer’s shop drawings of all fabricated handrail clearly showing

Layout. Profiles and products components, including anchorage, accessories.
Include details showing plans, elevations, sections, details of components.

b) Submit the manufacturer’s published literature including Corrosion resistance

tables of resin, test reports as applicable, raw material data sheet of (vinylester
Resin, fire retardant additives, UV inhibitor additives, UV urethane coating,
Surface veil)

c) Submit sample handrail 0.5m each item specified herein, manufactured by the
method used in the work and as quality and colour.

9.8.7 Mock -Up

Mock-up: install at project site a job mock up, assembled handrail 2.5 m long, using
manufacturer approved installation methods. Maintain mock-up during construction
for workmanship comparison.

9.8.8 Delivery, Storage & Handling

a) Ordering: Comply with manufacturer’s ordering instruction and led time

requirements to avoid construction delays.

b) Delivery: Deliver materials with identification labels intact.

c) Storage & Protection: store materials protected from exposure to harmful weather
conditions, at temperature and humidity conditions recommended by
manufacturer.

9.8.9 Project Conditions

a) Field Measurement: manufacturer to verify actual measurements and opening by

field measurement before fabrication; show recorded measurement on shop
drawings. Co-ordinate field measurements and fabrication schedule with
construction progress to avoid construction delays.

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9.8.10 Fabrication

Fabricate handrails and railing systems to comply with requirements indicated for
design, dimensions, details, finish and member sizes.

a) Fabricated at supplier /Dealer’s workshop in UAE, and if practical preamble rail

sections prior to transporting to job site. Fabrication includes but not limited to,
cutting, routing and drilling components in accordance but not limited to, cutting,
routing and drilling components in accordance with engineering drawings.

b) Brackets, flanges, fittings and Anchors: Provide manufacturer’s standard

brackets, mounts and anchors for assembly and mounting of rail system.

9.8.11 Installation

a) Ensure mounting surface and substructure are structurally capable of supporting

railing system and application loads.

b) During installation, FRP components shall be carefully handled and stored to

avoid contact with abrasive surfaces.

c) Install handrail as indicated on the drawings provided.

d) List of Approved Supplier for Grating, handrail, Ladder:

(i) Leadertech, UAE

(ii) Top Glass, Italy

(iii) Strong well, USA

9.9 GLASS REINFORCED, HOT PRESSED, SMC (SHEET MOULDING COMPOUND)

POTABLE WATER TANK

This specification shall apply to the tanks assembled by the Hot pressed Sheet
Moulding Compound (SMC) panels, manufactured from fibre-glass reinforced
polyester compound, filler, unsaturated polyester resin, pressurised and moulded by
hydraulic process where used for

(i) Potable water storage

(ii) Treated Effluent water storage

(iii) Irrigation water storage

Applicable Standards: BSEN 13280, ASTM 3841

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9.9.2 General

a) The Product manufacturer shall submit the relevant product

catalogues/descriptive literature stating manufacturing process, material, mill
certificates of accessories, and instructions on construction or erection manual,
handling, periodic inspection and maintenance.

b) The tank capacity shall be as shown in the approved drawing. The product
manufacturer’s Shop drawing shall indicate the capacity as given above, and the
tank type, design load parameters, dimensions, materials, fabrication details,
clearance, field jointing, tolerances, support details, integration of piping
components, anchorage, partition etc.

c) The panel specification sectional design according to tank size and application
flexibility shall be submitted for the approval of the Engineer. These panels shall
be non- toxic, hygienic for water storage and ultra violet protection against algae
growth.

d) The panel thickness to be designed based on (FEM) Finite Element Method study
with a safety factor 6times the actual hydrostatic water pressure according to
BSEN 13280 and the relevant design calculation shall be submitted for engineer’s
review.

e) Tank material shall be virgin reinforced fiber-glass mat ‘E’ type comply with BSEN
3691/BSEN 14118/BS 3396/BS 3749 standards, the mixed filler and unsaturated
polyester resin comply with BS 3532 Type-B & BSEN 14364/BSEN 1796.

f) The tank shall be suitable for 100% humidity and > 50°C Water temperature,
corrosion proof, UV stabilized, non-toxic, non-staining, smooth inner surface &
algae resistant.

g) The colour of tank panels and components shall be light Grey, pigmented as such
to reduce the heat absorption. The process shall be hot press using SMC
material. Different process like RTM/cold press shall not be acceptable.

h) The SMC Panel structure shall be double skin with foam material heat insulation
type (25 mm Polyurethane, density 40 kgs/m3 with thermoplastic vacuum
moulded cover for top, side panels, and bottom).

i) The tank should be opaque to help reduce evaporation of disinfectant and inhibit
algae growth. Maximum measured light transmission value inside a closure cover
tank shall not exceed 0.05%.

j) Tank exterior frames, pipe fittings, fasteners, supports, etc shall protected against
weather conditions.

k) Interior strengthening reinforcing steel shall be with stainless steel pipe section
min dia 32 mm grade 444 (carbon content < 0.025).

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l) Tank shall be erected above ground with General arrangements shown in the
approved drawing and a clear access of not less than 1m all around.

m) Flexible connectors shall be used to avoid stress & vibration transfer to the water
tanks.

n) Manufacturer’s instructions and guidelines concerning storage of tank parts and

accessories general site conditions of tank location, erection method, usage and
operation of the water tanks shall be strictly observed.

o) The water level indicator shall be as recommended by tank manufacturer.

p) Manufacturer’s representative certified and experienced bodies shall fix the tank.

q) The manufacturer must be a member of, or affiliated with quality control or

certification authority, relevant to GRP tanks & fittings proposed for incorporation
in the works. ISO 9001 certification is required for the tank manufacturer.

9.9.3 Construction

a) The tank body shall be configured to quadrilateral panel assembling type and
secure assemblage space and maintenance space around the tank. The Wall
Panel configuration shall be as follows: 1 x 1.5m and 1 x 2 m panels shall be used
at the top part, while 1x1 m panels shall be used at the lower part of the wall.

Example: 2.5m High tank: 1 x 1 (bottom) + 1 x 1.5 (top)

4.0m High tank: 1 x 1 (bottom), 2 nos + 1 x 2 (top)

b) External and internal reinforcing parts section shall be capable to withstand the
expected load such as water pressure, wind load, live load, etc.

c) Tank roof panel top supporting metal reinforcements shall be installed outside to
avoid the chlorine gas corrosion.

d) Internal / external Reinforcing parts: Internal Reinforcement shall be used at the

lower part of the tank (MATERIAL SUS 444, NO WELDING, SECTION PIPE DIA
32 MM MIN), while the upper part (Large panels 1.5 M, 2 M) must be externally
reinforced with top external stays, vertical external frame and bottom external
bracket due to the following reason: “Chlorine from disinfectant generates rust on
upper part of internal reinforcement material (SS) which are not under water, say
1.5 m section below the ceiling”.

e) Tank accessories, structural reinforcing / frames, fasteners and components shall

be as given in Table 9-9 & 9-10.

Table 9-9 GRP HOT PRESSED SECTIONAL (PANEL) WATER TANKS

Sr. Physical Characteristics Standard Values

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1. Specific Gravity ASTM D 792 1.8

2. Tensile Strength (Longitudinal ASTM D 638;BS (1000 Kg/cm2 ±

Transversal) 2782; ASTM D 15%)
2841

3. Flexural Strength ASTM D 790; BS (1900 Kg/ cm2 ±

2782; ASTM D 15%)
3841; BS 5734

4. Impact Strength ASTM D 256;BS (59 kgf.cm/cm2)

2782; BS5734

5. Water Absorption ASTM D 570; BS Not greater than

EN 13280 0.10%

6. Glass Content ASTM D 2584; BS More than 30%

2782

7. Light Transmission < 0.05%

8. Coefficient Of Thermal Expansion ASTM D 696 1.7 x 105 /°C

9. Thermal Conductivity 0.15 kcal/m/hr/°C

10. Barcol Hardness ASTM D 2583; BS >40

2782

11. Cavity Less than 1%

12. Toxicity BS 6920 Nil

13. Micro- Biological Growth BS 6920 Nil

14. Ultra –Violet Resistance Stabilised /

resistant

15. Opacity BS 2782 / BS EN 0.02

ISO 7686

Contents of the panel tank

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Components Standard Items

Tank Panel Hot pressed SMC- grey colour

Material SMC Suitable for storing drinking water

Nuts, Bolts, Washers S/S grade 316L in contact with liquid

water

Sealant / Gasket PVC foam

External Reinforcement

Internal Reinforcement Structural steel hot dipped galvanised

S/S grade 444 angle stays, tie angles or

tie rods

External Ladder Stainless steel 316 grade L

Internal Ladder Stainless steel grade 444

Roof Support 75mm diamter Pipes S.S grade 444

Level Indicator (optional) Mechanical float switch/clear tube/or

painting

Steel Skid Hot dip galvanised & epoxy coated

structural steel channels

Finishing Smooth internal and external finish

Tie Rods S/S 316L rods diameter 12 mm

Resistance Water temperature upto 50 C

Properties of Insulation (Polyurethane)

Density 38 to 40 Kg/m3

Thermal Conductivity 0.018 to 0.020 kcal/m/hr/C

Closed cells 90 to 95 %

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Operation Temperature + 80 C

Insulation Thickness 25 mm

Light transmission 0.00%

Table 9 –10 Panel Tank Accessories

Accessories / Fasteners Material Corrosion Protection

External

Base frame, Wall panel Structural Steel channel Hot dip galvanised and
joints, (Frames, Flanges sections epoxy & Polyurethane
bars, and Roof stays) coated.

External Ladder Stainless steel grade 316L -

Roof access Manholes, GRP , SMC Hinge :Stainless steel

Min. 900 mm dia, clear grade 316L
opening. Equipped with
locking device.

Bolts, nuts, washers SS 316L -

Fittings Copper alloy / PVC Specified Coating &

Insulation

Ventilation hole, ABS Material with PE UV protection

Screen

Internal

Corner frames, stays, Tie Stainless Steel G 444 -

rods etc.

Roof support (pipe 75mm Stainless steel -

Ø)

Ladder Stainless steel G:444

Bolts, nuts, washers SS 316L -

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9.9.4 Quality Control

a) The manufacturer / Supplier shall take necessary measures to satisfy the client
that water tank supplied for use within its domain meets the requirements
detailed. This shall be repeatedly done every five years or as and when called by
the owner during guarantee period.

b) Tanks shall be erected, tested and commissioned for use by the manufacturer/
Local Agent under the supervision of engineer’s representatives.

c) The manufacturer / local agent shall carry out periodic inspection of tank algae
growth and remedial measures.

d) Whenever composition or manufacturing process of particular component part is

changed or modified, the affected component part shall have to be tested in the
presence of Engineer.

e) All testing and inspection costs shall be borne by the contractor.

f) The GRP hot pressed water tank shall comply the requirements of British
Standard BS EN 13280/ ASTM D3841.

g) The tank operating atmospheric pressure shall be tested under ‘tank full’ condition
for water tightness and structural soundness. Water tank shall be subject to a
standing leak test for 24 hours, during which time all joints shall be carefully
examined. Noticed defects shall be rectified immediately and the test to be
repeated.

h) In house QA/QC records: (mill certificate for SS 444 accessories and SMC) shall
be provided along with tank supply to the site.

i) Upon the completion of the erection, tank shall be cleaned and disinfected by the
contractor, as per the manufacturer’s guideline.

9.9.5 Inlet, Outlet & Over Flow Pipes

UPVC material (socket / flange type). Overflow pipe shall be placed in same level of
inlet pipe. Outlet pipes shall be kept level at least 10cm above the tank bottom.

9.9.6 Drain Pipe

Drainpipe shall be fixed at bottom most level of the tank.

9.9.7 Approval of Local / International Health Authorities

a) The tank manufactured shall be certified by International Authority to meet the

requirements of BS 6920 for products approved for potable water usage. The
following certificates to be provided for engineer’s review and approval.

(i) WRAS (UK) approval up to 50 C

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(ii) FDA (USA) approval for SMC material

b) Potable water tank must comply with BS EN 13280 requirements. The following
test reports by Independent Authority is to be provided by the manufacturer for
Engineers review, during submittal stage:

(i) Permanent compressive strain test.

(ii) Sunlight transmission test

(iii) Physical properties test (tensile, Bending, Elastic modulus, Barcol hardness,
Water absorption)

(iv) Leakage test

(v) Deflection test

(vi) Metal toxicity test of Stainless steel in contact with water.

(vii) Test of Sealing gasket in accordance with Japanese Food Sanitation Law

(viii) Opacity Test to BSEN ISO 7686

(ix) Testing of GRP for use in contact with water intended for human
consumption.

c) A guarantee of fitness for storing, effluent water shall be obtained from concerned
local government agencies (Municipality & Town planning / Environment & Health
Section), and a copy provided to the Engineer. Certificate should cover
accessories and component parts of the Water tank in question.

9.9.8 Guarantee Certificates

Manufacturer, importer or supplier of the water tank shall provide a certificate of

guarantee, against manufacturing and erection defects covering a period of minimum
ten (10) years from the date of erection. During the guarantee period, tank
component parts and accessories found deteriorated, defective shall be replaced by
the manufacturer at his cost.

FOLLOWING ENGINEERING CALCULATIONS TO BE SUBMITTED FOR

ENGINEER’S REVIEW AND APPROVAL:

 STRUCTURAL DESIGN
 HYDROSTATIC PRESSURE
 WIND LOADING
 SEISMIC LOADING
 MAINTENANCE ACCESS
LOADING
a) List of Approved Supplier

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 LG HITANK - South Korea

 BALMORAL - UK
 AC PLASTIC - UK

9.9.9 GRP Baffles

a) Material

(i) Fibreglass reinforced polyester resin composite laminate shall exhibit the
following minimum properties:

Property Test Method Minimum Requirement

Impact Notched , Izod ASTM D 256 13.5 Nm

Heat Distortion ASTM D 384 79°C

Water Absorption after 24 ASTM D 570 Max 0.20%

hours

Tensile Strength ASTM D 638 62 MPa

Thermal Expansion ASTM D 696 10.5 x 10-6 mm/mm/°F

Flexural Strength ASTM D 790 110 Mpa

Flexural Modulus ASTM D 790 6 Gpa

Barcol Hardness ASTM D 2583 40

(ii) “ECR” glass fiber and vinylester Epoxy resin shall be used in full laminate.

(iii) Perform hardness tests on the resin-rich surfaces of the test samples.

(iv) Prepare test coupons in accordance with appropriate ASTM test method.

(v) The manufacturer shall maintain a continious quality control program and
upon request shall furnish certified test results of the physical properties.

(vi) Laminate shall be 75 mm thick and shall contain a gel-coat on each surface
a minimum of 20 mils thick.

b) Components

(i) The Baffle System component shall be as shown in the Drawing.

1. Each segment shall be moulded using gel-coated exterior surfaces,

vinyl resin and fibreglass reinforcement (ECR “C” glass).
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9.10 GLASS REINFORCED PLASTIC TANKS FOR CHEMICAL STORAGE

9.10.1 General

9.10.1.1 Scope of Work

Furnish all labour, materials, equipment, and incidentals required to install, field test,
complete and make ready for service vertical, flat bottom, seamless, fiberglass tanks
for chemical storage and make-up, as shown on the Drawings and as specified
herein.

9.10.1.2 Related Work

a) Field painting external as specified in protective coating schedule or pigmented

coating recommended by the manufacturer.

b) Chemical feed pumps are as shown in the drawing.

c) Instrumentation is as shown in the drawing.

d) Piping, valves and appurtenances and pipe hangers and supports are shown in
the drawings.

e) Process mixers are as shown in the drawing.

f) The chemical compatibility of the liner internal proposed shall be based on the
process fluid storing inside.

g) The size and capacity of the tank shall be as shown in the drawing.

h) The geometry and supports of the tank shall be as shown in the drawing.

9.10.1.3 Submittals

a) Submit to the Engineer the shop drawings showing details of construction and
erection as follows:

(i) The type and category of tanks shall be related to the three categories given
in Table 2 of BS4994: 1987 to suit the various chemicals storing inside.

(ii) The chemicals storing inside the tanks are Ferric chloride, caustic &
Polymer.

(iii) Dimensions of tank, fittings and attachments.

(iv) Wall thickness (shell, head and base).

(v) Location of fittings, attachments and joints.

(vi) Width and thickness of joint overlays.

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(vii) Resin used and complete description of chemical resistance for all materials
that will come in contact with material stored.

(viii) Weight of tanks and fittings.

(ix) Statement that fabrication is in accordance with these Specifications.

(x) Complete structural calculations for each tank, including all accessories and
tank supported appurtenances to be furnished by others.

(xi) Description of fabrication method.

(xii) Laminate samples.

(xiii) Description of hold-downs.

(xiv) Description of nozzles showing details of construction and attachment to

tank.

(xv) Instructions for handling, storage and installation of tanks.

(xvi) Installation list of tanks with similar applications.

b) Samples

Representative laminate samples of both the filament wound cylindrical shell and the
heads shall be furnished. These samples shall be from plant production and shall be
representative of actual construction, workmanship, appearance and surface
hardness of tanks to be furnished. The Engineer may reject any tank which does not
meet the standard of the representative samples.

c) In the event that it is impossible to conform to certain details of the specifications

due to different manufacturing techniques, describe completely all non-
conforming aspects.

d) Drawings shall be approved by the Engineer prior to start of fabrication. Approval

of Drawings by the Engineer shall not release the Contractor of responsibility of
compliance with specifications. All proposed changes in specifications shall be
stated in writing. No fabrication may start prior to approval of proposed changes
by the Engineer.

e) Submit shop inspection and test records as specified herein.

9.10.1.4 Reference Standards

a) American Society for Testing and Materials (ASTM).

(i) ASTM D3299- Standard Specifications for Filament-Wound Glass-Fiber¬

Reinforced Thermo set Resin Chemical-Resistant Tanks.

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(ii) BS 4994:1987 Design and construction of vessels and tanks in reinforced

plastics.

(iii) BS 476-7.

(iv) ASTM C 581

(v) ASTM C 582

(vi) ASTM D 4097

b) Occupational Safety and Health Administration (OSHA).

9.10.1.5 Quality Assurance

a) Tanks shall be constructed by a single manufacturer that has at least 10 years

prior experience in construction of fiberglass tanks for similar applications.

b) Should equipment which differs from these Specifications or as shown on the

Drawings be offered and determined equal to that specified and shown, such
equipment shall be acceptable only on the basis that any revisions to the design
and/or construction of the structure, piping, appurtenant equipment, etc., required
to accommodate such a substitution shall be made at no additional cost to the
client and be as approved by the Engineer.

9.10.1.6 System Description

a) The tanks shall be constructed of fiberglass reinforced polyester with chemical

resistant backing layer internal and shall be vertical, cylindrical, flat bottom,
furnished with all accessories as specified herein.

b) Tank accessories and fittings shall be of the sizes and arrangement as detailed
on the Drawings.

9.10.1.7 Delivery, Storage and Handling

a) The Contractor shall require the manufacturer to assume responsibility for

packaging to prevent damage to the tanks during normal transit and handling.

b) Flange faces shall be protected from damage. All openings are to be securely
covered to prevent entrance of dirt, water and debris.

c) Tanks shall be mounted on skids or protective framework so constructed as to

provide for easy handling for fork truck or similar device and be provided with
lifting lugs, cleats, etc. to permit handling by crane, nozzles manholes, or other
fittings shall not be used for lifting.

d) Tanks shipped horizontally shall be supported by cradles supporting 120 degrees

of the tank circumference.

e) Instructions shall be provided for unloading and installation of the tanks.

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9.10.2 Products

9.10.2.1 General

a) The use of manufacturer's name and model or catalogue number is for the
purpose of establishing the standard of quality and general configuration desired.

b) Like items of materials, equipment shall be the end products of one manufacturer
in order to provide standardization for appearance, operation, maintenance, spare
parts and manufacturer's service.

c) Hold-down devices shall be provided by the manufacturer.

9.10.2.2 Materials

a) Resins used for the tanks shall be a commercial-grade corrosion-resistant thermo

set, fully tested and acceptable for the service conditions. Resins shall not contain
fillers, pigments, dyes, or colourants. A chemotropic agent that does not interfere
with either visual inspection of laminate quality or with corrosion resistance of
laminate, may be used.

b) Clear ultraviolet absorbers shall be used in final resin coats.

9.10.2.3 GRP Tanks

a) The GRP tanks shall be manufactured strictly in accordance with the specified
standards.

b) The GRP tanks shall be constructed using the filament winding process and shall
be capable of storing the chemicals specified above at service temperatures in
excess of 82°C. The manufacturer shall be responsible for the design and
structural integrity of the tanks. All glass reinforcement used shall be 'ECR' type
only.

c) The type of chemical barrier to be used shall be agreed between the

manufacturer and the Engineer prior to manufacture the tank where a thermo set
lining is used it shall be as specified in CL 7 & 8 of BS 4994: 1987.

d) All parts shall be designed and proportioned as to have lateral strength and
stiffness, to especially adapted for the work to be done. Ample room and facilities
shall be provided for access.

e) Tanks shall be non-insulated suitable for vertical installation in an enclosed

thermally controlled or outdoor environment as specified. Tanks shall be designed
so that no external bracing, ribs, hoops, or support wires are required. Top of tank
must be capable of supporting weight of maintenance personnel.

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f) There shall be no vertical joints (in axial direction) in the cylindrical shell. The
entire thickness of the cylindrical shell (inner surface, interior layer and exterior
layer) shall be built up prior to removal of the shell from the mandrel.

g) The longitudinal strength of the cylindrical shell shall be at least 25 percent of the
hoop strength.

h) Regardless of the theoretical design requirements, the minimum total laminate

thickness of the filament wound tank shall NOT BE LESS THAN 10mm with
stiffeners external. The tank wall thickness shall be designed by the manufacturer
in accordance with BS 4994/ ASTM D 3299 and relevant calculations shall be
provided for engineer’s review.

i) Where a tank is intended to contain flammable fluids the external surface layers
shall be modified so as to have a surface spread of flame characteristic which at
least complies with class 1 requirements of BS 476-7.

j) The knuckle radius of the top and bottom heads shall be a minimum of 40-mm.

k) Heads may be fabricated integrally with the shell or may be fabricated separately.
Heads fabricated separately shall be moulded with an integral skirt. The minimum
skirt length shall be l00-mm. The entire head including knuckle radius and skirt
shall be fabricated in one piece.

l) Tanks shall be completely fabricated in the shop. No field assembly is permitted.

m) All surfaces exposed to chemicals shall be resin rich with "c" glass and the
thickness of this inner most layer shall be a minimum of 0.5mm.

n) A backing layer of 2mm thick normally containing a minimum of 1.2 kg/sq.m

"CSM" between 25% - 33% glass content by mass with epoxy based vinyl ester
resin.

o) The heat distortion temperature of the fully cured resin system used for the GRP
laminate shall not be less than 20 degree C higher than the design temperature of
the tank when determined as described in BS 2782 method 121A.

p) The exterior layer of laminate shall consists two layers of "C" glass resin rich outer
liner and the minimum thickness shall be 1 mm.

q) The structural layers shall be with ECR glass and ISO resin and no sand filler
Shall be used. The laminate shall consist of Hoop glass, CSM, glass cloth &
woven roving as necessary. External ribs shall be used to meet the stiffness
requirements not less than 10,000 N/SQ.M.

r) No paints or pigmented, coloured or dyed resins shall be used on the outside

surface of the tank.

s) The tanks shall be made with machine made shaft liner.

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t) Tanks specified herein to require interior baffles shall be sized and oriented within
the tank as recommended by the mixer manufacturer. Tank baffles shall be of
GRP attached to the tank walls by Gusseted Brackets, at the locations
recommended by the mixer manufacturer.

u) Accessories

(i) The fibreglass tanks shall be equipped with the accessories as shown on
the drawings.

(ii) Each tank shall have an identification label laminated to the exterior surface
which shall indicate manufacturers name, address, model number, and date
of manufacture, capacity, design temperature and the pressure operating
and vacuum.

v) Installation

The contractor shall install the tanks in accordance with the drawings and the
manufacturer's instructions.

w) Compliance

The manufacturer shall provide a compliance statement for the products supplied in
accordance with relevant standards given in 9.10.1.4.

Test Requirements

(i) Degree of cure of the laminate by Barcol hardness in accordance with

ASTM D 2584.

(ii) Chemical resistance of the resin in accordance with ASTM C581

(iii) Wall thickness in accordance with ASTM D 3567.

(iv) The glass content of the inner liner and the interior layer combined in
accordance with STM D 2584.

(v) The surface spread of flame characteristic in accordance with BS 476-7. All
test result should comply with the relevant standard requirements.

x) Field Testing

After installation the tank shall be field tested by filling with water. The tank & fittings
shall hold water without loss, evidence of weeping or capillary action for a period of
24 hrs prior to acceptance.

y) Guarantee

The finished product shall be guaranteed for a minimum of 50 years design life.

z) Inspection
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Drainage and Irrigation Department

Should any defects become evident during inspection, testing or within the guarantee
period the contractor shall repair or replace the tank or fitting as approved by the
Engineer.

aa) Additional Labelling

All tanks shall be labelled with the name of relevant liquid content proposed,
operating and safety instructions and other warning if necessary.

DM/DNID Section 9 Metals and Plastics Rev 00 June Page 73 of 73

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 10

SAFETY PROCEDURES

DM/DNID Section 10 Safety Procedures Rev 00 June

2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 10 Safety Procedures Rev 00 June Page i of ii

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 10
SAFETY PROCEDURES

CONTENTS
10 SAFETY PROCEDURES ................................................................................................... 1
10.1 GENERAL...................................................................................................................... 1
10.2 FAMILIARISATION WITH SAFETY PROBLEMS......................................................... 1
10.3 SAFETY OFFICER ........................................................................................................ 1
10.4 SAFE WORKING CONDITIONS AT THE SITE ............................................................ 2
10.5 SAFETY EQUIPMENT................................................................................................... 3
10.6 USE OF ROADS & HIGHWAYS ................................................................................... 4
10.7 SAFETY PROCEDURES............................................................................................... 5
10.7.1 General ................................................................................................................. 5
10.7.2 Atmosphere Monitoring ......................................................................................... 6
10.7.3 Atmosphere Ventilation ......................................................................................... 6
10.7.4 Safety Harness ..................................................................................................... 7
10.7.5 Emergency Breathing Apparatus .......................................................................... 7
10.7.6 Active Confined Space Entry ................................................................................ 7
10.7.7 Washing Facilities ................................................................................................. 7
10.7.8 Communication ..................................................................................................... 7
10.7.9 Lighting ................................................................................................................. 7

10.8 TRAFFIC CONTROL ..................................................................................................... 8

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 General Specifications for Civil Works
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Drainage and Irrigation Department

10 SAFETY PROCEDURES

10.1 GENERAL

a) The Contractor shall be responsible for the safety of personnel and the public
during the contract period and compliance with safety requirements stated herein
shall not relieve the Contractor of his responsibility or liability under the Contract.

b) Prior to the commencement of the Works, the Contractor shall submit a safety
policy for the Contract detailing all proposed specific safety arrangements for the
agreement of the Engineer. This shall include but not be limited to the
requirements set out in this section.

c) If at any time safety requirements are not being met by the Contractor, the
Engineer shall have the right to instruct the Contractor on the necessary safety
provisions and the Contractor shall comply with such instructions forthwith.

d) The Contractor shall notify the Engineer immediately of any accident that occurs
whether on or off site in which the Contractor is directly involved which results in
any injury to any person whether directly concerned with the site or whether a
third party. Such initial notification may be verbal and shall be followed by a
written comprehensive report within 24 hours of the accident.

e) Particular problems of health and safety may arise with respect to microtunnelling
/ pipe jacking non-destructive methods of trenchless construction employed for
new pipeline construction or for pipeline replacement or manhole renovation. In
this respect the Contractor must ensure that adequate precautions and
satisfactory working practices are adopted in the execution of such Works to
protect the health and safety of all personnel engaged in executing the Works and
in their supervision.

10.2 FAMILIARISATION WITH SAFETY PROBLEMS

The Contractor shall make himself familiar with the condition of the site before
tendering in order to assess the nature of safety problems he is likely to encounter
and the safety requirements.

10.3 SAFETY OFFICER

a) The Contractor shall appoint a Safety Officer who shall be responsible for all
aspects of safety. He shall be conversant with and experienced in all general civil
engineering construction and sewer safety techniques and emergency
procedures, and shall be on site at all times operatives are working. He shall
enforce and supervise the safety procedures at all places of works and make sure
that adequate safety equipment, required under Clause 10.5, is available in good
working condition and at all places of works at the time works are on-going.

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b) The Safety Officer shall also be responsible for organizing, implementing and
maintaining any road closures, traffic diversions, removal of parked cars causing
an obstruction, etc., in adequate time to ensure compliance with the Contract
programme.

10.4 SAFE WORKING CONDITIONS AT THE SITE

a) The Contractor shall provide Method Statements detailing proposed safe methods
of work with the Tender. The Contractor is specifically required to provide method
statements/risk assessments for the following activities, but not limited to;

(i) Work in Excavations including shoring, dewatering

(ii) Work in the vicinity of Underground Services

(iii) Use of Excavators & Micro-tunnelling Machines

(iv) Working in the vicinity of Overhead Services

(v) Working adjacent to active Roadways

(vi) Manual Handling

(vii) Use of Scaffolding

(viii) Demolition Work

(ix) Working with Sewage/Hazardous substances

(x) Pit Excavations

(xi) Borehole Drilling

(xii) Entry into Confined Spaces

(xiii) Working at Heights

b) The methods should generally follow the recommendations of the following

publications:

(i) Code of Construction Safety Practice as published by the Dubai

Municipality.

(ii) Administrative Order No. 330 in connection with Safety Manual of Dubai
Municipality.

(iii) Health and Safety Guideline No. 2, Safe Working in Sewers and at Sewage
Works as published in the United Kingdom.

c) Accident procedures and emergency procedures shall be fully detailed.

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d) No persons shall be allowed to enter a confined space until the safe methods of
work have been agreed upon and fully implemented to the satisfaction of the
Engineer.

10.5 SAFETY EQUIPMENT

a) The Contractor shall make sure, prior to commencement of works on site that
adequate safety equipment, apparatus and devices are available, and that as a
minimum the following equipment and devices are available at each entry point to
a confined space:

Sr. Type of equipment No. required

1 Safety harness and ropes 2

2 Lifting frame and tackle for safety harness 1

3 Gas detector (suitable for H2S) 2

4 Approved mechanical air blower and power supply 1

5 Emergency breathing apparatus 2

6 Atmosphere monitoring device, capable of monitoring

oxygen levels, and levels of toxic and flammable gas 1

7 Washing facilities with disinfectants, toiletries As required

8 Communication facilities As required

9 Lighting (explosion proof) As required

10 Fire Extinguishers As required

b) All personnel working on, visiting or inspecting any part of the Works shall be
provided with and be required to wear appropriate protective clothing or
apparatus. This may include:-

(i) Safety helmets, coats, gloves, footwear, goggles, ear muffs, breathing
apparatus and any other protective apparel or any other equipment deemed
necessary by the Engineer.

(ii) Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle,
used in the Works shall be thoroughly examined by a competent person at
least once every 6 months and shall be test loaded to 150% of the safe
working load and shall then be tagged with the safe working load and the
date of successful testing by an authorised testing authority.

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Drainage and Irrigation Department

c) All parts and working gear whether fixed or movable, including the anchoring and
fixing appliances of every crane and lifting machine shall be of good construction,
sound material, and adequate strength and shall be properly maintained. All
parts and gear shall be examined at least once every twelve months.

d) A register of all such equipment and examinations shall be kept up to date by the
Contractor and be available for inspection by the Engineer.

10.6 USE OF ROADS & HIGHWAYS

a) The Contractor shall provide a Traffic Control Plan and give four weeks notice in
writing to the Employer of his intention to commence Works on any public road
(which shall include unmade rights of way) or highway.

b) The closure of public roads or highways will not be permitted without the written
permission of Dubai Municipality, the Dubai Traffic Police, Roads and Transport
Authority (RTA) any other relevant Authority and the Employer.

c) The Contractor shall submit five no. copies of his proposals for diverting traffic,
indicating positions of all signs, cones, lights and anything else which may be
necessary. The Contractor shall comply with any specifications for traffic
diversion, including surfacing requirements, safety and control laid down by the
Authorities and shall be responsible for continuous maintenance. Where a
temporary diversion of the public road or highway is approved which will be
utilized by public traffic then the route shall have an asphalt surface.

d) No Works will be permitted on a public highway verge, central reservation or

garden without the signed approval of the respective Authorities copies of which
must be handed to the Employer before such Works commence.

e) The Contractor's Works shall be arranged so that use of the roads or highways
affected by the Works shall be restored to the public with the minimum of delay.
Laying of the pipelines, backfilling, testing of the pipelines, temporary
reinstatement and clearance of the Site shall follow closely behind excavation
and, unless written permission is obtained, the Contractor shall not occupy more
than a 100 meters length of highway at any one location at any time.

f) The Work shall be carried out in such a manner as to cause minimum

interference with the public use of highways, footpaths and other thoroughfares,
and only such Plant, Materials, tools, etc., as from time to time required for
immediate use, shall be deposited thereon. Storage depots, offices, etc., shall be
sited elsewhere.

g) The Contractor shall maintain those parts of the roads or highways, etc., not
temporarily occupied by the Works in a clean, passable and safe state.

h) Suitable temporary roads shall be provided by the Contractor to allow access to

all Sections of the Works at all times. Suitable precautions will be taken to prevent
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Drainage and Irrigation Department

misuse of site roads by the general public. The Contractor shall be responsible for
reinstating these areas to their original condition after completion of the Works.

10.7 SAFETY PROCEDURES

10.7.1 General

a) All excavation shall be adequately supported against collapse and provided with
protective safety barriers and appropriate warning signs and bunting.

b) Suitable and sufficient scaffolds shall be provided and properly maintained for all
work that cannot safely be carried out from the ground or from part of the
structure or from a ladder. Every scaffold shall be of good construction, of
suitable and sound material and of adequate strength for the purpose for which it
is used. Unless designed as an independent structure, every scaffold shall be
rigidly connected to a part of the structure which is of sufficient strength to afford
safe support. Protective headgear shall always be worn.

c) All manufacturer’s instructions and recommendations for the use, application,

erection or construction of any material or item of equipment or plant shall be
followed precisely.

d) Special care shall be taken to protect all employees when using power tools or
materials which will produce a fine dust and in particular all asbestos based
products. The operator should stand upwind of the operation and wear an
approved respirator and goggles. Wherever possible overalls should be worn and
should consist of 60% polyester fibre and 40% cotton.

e) Transportation of any material by the Contractor shall be in suitable vehicles

which when loaded does not cause spillage and all loads shall be suitably
secured. The Engineer shall have the right to instruct the withdrawal from the site
of any vehicle which does not comply with these requirements or any of the Dubai
or UAE traffic regulations and laws.

f) The Contractor shall adopt the safety procedures as proposed by him as per
Clause 10.4 for entry into a manhole or other confined space. However, the
following safety procedures are outlined as a guide only. The Contractor shall,
where appropriate, use these procedures in addition to his proposed procedures
while entering into a manhole or a confined space. Also included is additional
information on safety procedures for manhole entry in Appendix 3 contained in
these Specifications for his guidance and use where appropriate.

g) It shall be explicitly understood that safety is the responsibility of the Contractor

and use of any of these procedures as outlined under this clause or in Appendix 3
shall not relieve him of any of his contractual responsibilities.

h) The manhole or confined space shall be thoroughly vented by mechanical air

blower prior to entry.
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i) A full gas check is to be undertaken prior to entry. If the level of toxic or explosive
gases is above the safe level (maximum acceptable for hydrogen sulphide is 10
ppm) or the level of oxygen is below a safe level (18%) then entry is not permitted
without the use of full breathing apparatus.

j) All persons entering a manhole or a confined space shall wear a safety harness
properly rigged to the lifting frame.

k) The mechanical air blower shall be kept close by the manhole or confined space
which has been entered.

l) The hydrogen sulphide level in the manhole or confined space shall be

continuously monitored. If the level rises above 10 ppm then the manhole or
confined space shall be evacuated immediately.

m) At least two people shall be available close to the point of entry to operate the air
blower and lifting tackle in the event of an emergency and who shall note the
location of the nearest telephone in working order and the telephone number of
the nearest hospital before entry is permitted.

n) No smoking shall be permitted and ‘no spark’ tools shall be used.

10.7.2 Atmosphere Monitoring

a) When any person is in a confined space, the atmosphere at the work place and at
the base of the access manhole or pit shall be continuously monitored by a
Monitoring Device to detect oxygen deficiency, flammable gas and toxic gases.
The monitoring equipment shall be designed to be lowered into the work place or
access manhole and shall not depend on a sample draw tube from the surface.
The monitoring equipment shall be the first piece of equipment to be lowered into
the place of work and shall be the last piece of equipment removed.

b) The Contractor shall provide, maintain and calibrate the approved monitoring
equipment in accordance with the manufacturer's instructions. The Contractor
shall provide adequate numbers of monitoring devices to fully cover all proposed
work places and open manholes or access pits with adequate spare devices,
parts and batteries as needed to ensure complete monitoring of all sites of work
at all times throughout the construction period. No entry into a confined space
shall be allowed until the monitoring devices have been properly placed at the
work place or access site and the readings indicate that the atmosphere is safe.
Operatives are to be fully trained in the use of the monitoring equipment and in
the necessary response to alarm conditions.

10.7.3 Atmosphere Ventilation

Before any person is allowed to enter a confined space, the atmosphere shall be
adequately ventilated. As a minimum, both ends of the sewer section or work place
shall be opened to the atmosphere either by removing the manhole covers or through
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Drainage and Irrigation Department

open access pits. Positive ventilation shall be provided at all times when a person is
in a confined space, even if the atmosphere monitoring equipment indicates that the
atmosphere is safe for access.

10.7.4 Safety Harness

Each person entering a confined space shall wear a harness at all times. The
harness shall be designed such that it will enable an unconscious person to be lifted
to the surface in a vertical posture.

10.7.5 Emergency Breathing Apparatus

Each person in a confined space shall have emergency breathing apparatus available
and ready for use within the confined space. The breathing apparatus shall have a
minimum capacity of 2 litres and a working pressure of 200 bar and shall be tested
daily, prior to starting work.

10.7.6 Active Confined Space Entry

Before any person is allowed to enter a confined space that is in active service, the
Contractor shall ascertain the schedule of sewage flows which can be anticipated
over the duration of the work. This shall include average and peak gravity sewage
flows and the discharge flows from all upstream pumping stations. Should the
combined gravity and pumped flows exceed safe working conditions at the work
place, then the Contractor shall prepare a plan for the control and diversion of flows
around or away from the work place. The method of flow diversion shall be as
approved by the Engineer and by the Dubai Municipality. A "permit to work" system
shall be employed for work on sewers where incoming flows (from pumping or
diversion) are controlled by people remote from the work site.

10.7.7 Washing Facilities

Every work place where persons are entering a confined space shall be provided with
facilities for washing.

10.7.8 Communication

The Contractor shall provide a means of communication, appropriate to the safe

system of work, between ground level and any work place within the confined space.

10.7.9 Lighting

When permanent works are being constructed or inspected, the confined space shall
be adequately lit. The lighting apparatus shall operate at a voltage not exceeding 50
Volts. The circuit shall be protected against overload. No transformers, switches,
fuses, contact breakers, etc., shall be taken into the confined space. Bulbs shall be
protected against damage.

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Drainage and Irrigation Department

10.8 TRAFFIC CONTROL

a) Prior to initiating any work at a site, the Contractor shall prepare, for the approval
of the Engineer, a plan for the diversion and control of traffic around the work site.
The approved traffic control plan shall be submitted to Roads & Transport
Authority and Dubai Traffic Police for review. Work at the Site may not commence
until the traffic control plan has been approved by the Roads & Transport
Authority and Dubai Traffic Police.

b) The traffic control plan shall include a street plan of the work site showing all
traffic lanes and building access drives that will be affected by the work. The
proposed system of traffic diversions and the manner of control shall be clearly
illustrated, including the location and types of traffic cones, warning signs and
warning lights to be used. The plan should indicate the anticipated schedule of
works for which traffic must be diverted. Road diversions and road signs shall
conform to Clause 1.3.5 and to Appendix 1 contained in the Specifications.

c) The traffic control plan shall take into consideration the requirements of the work
crew for access to the work site, for positioning and parking of vehicles needed
for the work and for the temporary storage of equipment and materials.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 11

PIPELINES RENOVATION, REPLACEMENT AND

ABANDONMENT

DM/DNID Section 11 Pipelines Renovation, Replacement and Rev 00 June

Abandonment
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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 11 Pipelines Renovation, Replacement and Rev 00 June Page i of iii
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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 11
PIPELINES RENOVATION, REPLACEMENT AND
ABANDONMENT

CONTENTS
11 PIPELINES RENOVATION, REPLACEMENT AND ABANDONMENT ............................ 1
11.1 GENERAL...................................................................................................................... 1
11.1.1 Renovation, Replacement and Abandonment Works ........................................... 1
11.1.2 Use of Approved Specialist Firms / Sub-Contractors ........................................... 1
11.1.3 Health and Safety ................................................................................................. 2
11.1.4 Materials ............................................................................................................... 2
11.1.5 Diversion of Sewage Flows .................................................................................. 6
11.1.6 Flow Control .......................................................................................................... 6
11.1.7 Maintaining Clean Conditions ............................................................................... 7
11.1.8 Sewer Pre-Renovation Surveys ............................................................................ 7
11.1.9 Cleaning of Sewers ............................................................................................... 7
11.1.10 Traffic Control and Diversion ................................................................................ 8
11.1.11 Manhole Connections ........................................................................................... 8
11.1.12 House Connections .............................................................................................. 8

11.2 PIPELINE RENOVATION - SLIPLINING ...................................................................... 9

11.2.1 General ................................................................................................................. 9
11.2.2 Slip-Lining Execution ............................................................................................ 9
11.2.3 Grouting .............................................................................................................. 10

11.3 PIPELINE RENOVATION - DEFORMED PIPE LINING .............................................. 11

11.3.1 General ............................................................................................................... 11
11.3.2 Materials - HDPE or HPPE Pipe ......................................................................... 12
11.3.3 Further Site work Preparation ............................................................................. 12
11.3.4 Pipeline Obstructions .......................................................................................... 12
11.3.5 Sewer Lining Execution ...................................................................................... 13
11.3.6 Guarantee ........................................................................................................... 14
11.3.7 Finishing to Manholes ......................................................................................... 14

11.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING ....................................... 15

11.4.1 General ............................................................................................................... 15
11.4.2 Materials ............................................................................................................. 16
11.4.3 Inversion Type Resin System ............................................................................. 17
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11.4.4 Tests ................................................................................................................... 17

11.4.5 Soft Lining Design ............................................................................................... 18
11.4.6 Sewer Lining Execution ...................................................................................... 19
11.4.7 Guarantee ........................................................................................................... 21
11.4.8 Finishing to Manholes ......................................................................................... 21

11.5 PIPELINE REPLACEMENT - PIPE BURSTING ......................................................... 22

11.5.1 General ............................................................................................................... 22
11.5.2 Pipe Bursting - Execution ................................................................................... 23
11.5.3 Finishing to Manholes ......................................................................................... 24
11.5.4 Obstructions ........................................................................................................ 24

11.6 PIPELINE ABANDONMENT ....................................................................................... 25

11.6.1 General ............................................................................................................... 25
11.6.2 Grout and Grouting for Abandoned Pipeline ....................................................... 25

11.7 SEWER CLEANING AND CCTV SURVEY ................................................................. 25

11.7.1 General ............................................................................................................... 25
11.7.2 Sewer Cleaning .................................................................................................. 26
11.7.3 Survey and Operational Equipment .................................................................... 27
11.7.4 Performance of Survey ....................................................................................... 28
11.7.5 Survey Data Reporting ....................................................................................... 30
11.7.6 Drawings ............................................................................................................. 30
11.7.7 Metric Measurement ........................................................................................... 30
11.7.8 Photographs ....................................................................................................... 31
11.7.9 Equipment Standards ......................................................................................... 31
11.7.10 Quality Control .................................................................................................... 33

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 General Specifications for Civil Works
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Drainage and Irrigation Department

11 PIPELINES RENOVATION, REPLACEMENT AND ABANDONMENT

11.1 GENERAL

11.1.1 Renovation, Replacement and Abandonment Works

The Contractor shall provide the labour, material and equipment and perform the
work necessary to renovate, replace or abandon the sewers indicated on the Contract
Drawings and as directed by the Engineer.

Where downsizing has been indicated the renovation of existing sewers or rising
mains shall be undertaken using slip-lining technology. Alternatively subject to the
approval of the Engineer and prior to mobilization to the works site, renovation of the
pipeline may be by using either a deformed pipe lining system or an inversion type
soft lining system.

Where up-sizing or replacement has been indicated the existing pipeline may be
replaced using conventional open cut methods or where such methods are
unacceptable or impractical, a non-disruptive method using pipe bursting techniques
shall be adopted.

All renovation or replacement operations shall be conducted from within existing

manholes without long lead in trenches unless otherwise approved by the Engineer.
The selection of insertion and reception locations shall be such as to minimize
disruption of normal traffic and inconvenience to the public.

Design calculations and method statement for each method proposed shall be
submitted to the Engineer at least 35 days prior to the intended date of
commencement of the work on site.

The Contractor shall inspect each location for proposed pipeline renovation to confirm
or determine the following:

1) The length and size of pipeline to be renovated.

2) The access available to the pipeline at either manholes or chambers.

3) The location of existing services together with any additional services not shown
on the drawings.

4) The number of house connections to the pipeline and their location.

Where there is infiltration of groundwater at pipe joints, cracks and other defects, the
infiltration shall be sealed off prior to the installation of any lining. The materials and
method of sealing shall be submitted to the Engineer for approval.

11.1.2 Use of Approved Specialist Firms / Sub-Contractors

The Contractor shall engage specialist Firms / Sub-Contractors to carry out / execute
each of the specialized category of works such as:
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a) Pipeline Renovation - Slip lining, deformed pipe lining, and soft lining.

b) Pipeline Replacement - Pipe bursting

All specialist Firms/Sub-Contractors are subject to approval for each aspect of work
on this project in the field of their respective specialization. Only those companies that
can demonstrate successful experience on projects similar to that required for this
work (scope, size, conditions, and program) shall be proposed by the Contractor for
consideration and approval. Companies proposed for approval shall demonstrate the
necessary registration as a contractor licensed to work in Dubai either directly or
through a legal association with a registered contractor.

11.1.3 Health and Safety

The contractor shall provide and agree with the Engineer a written statement detailing
safe systems of work (see clause 10.4 & 10.7 ‘Safety Procedures’ of the General
Specification).

The Contractor shall provide and maintain on site suitable and sufficient safety
equipment and the necessary personnel trained in its use, for the safety and
protection of employees, the general public and systems and property of Dubai
Municipality.

The Contractor is responsible for the safety of all personnel as well as for the safety
of the public during the performance of the work and is responsible for maintaining
safe conditions in and around the work area. This is specified in more detail in
Section 10.

11.1.4 Materials

11.1.4.1 Polyethylene and uPVC Pipe

a) General

uPVC sewer lining pipe shall comply with the provisions of clause 4.3.1 of this
specification.

Polyethylene (HDPE or HPPE) sewer lining pipe shall comply with the relevant
provisions of Clause 4.3.2 of this specification.

Short length sections shall be used for slip lining and pipe bursting technique
between manholes where no long lead in trenches is permitted.

The short sections shall be of such a length as to enable insertion from within the
smallest diameter manhole in the applicable sections of the sewerage system.

Winching forces on PE and uPVC pipes during jointing and installation processes
shall be restricted so as not to exceed the maximum permissible short term tensile
stress specified by the pipe manufacturer at the appropriate temperature.

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b) Storage, Handling and Transport

uPVC, HDPE or HPPE pipe shall be stored, handled and transported generally as
specified in clause 4.5.3 & 4.5.5 for Thermoplastic / HDPE pipes .

Black polyethylene pipe may be stored either under cover or in the open. Natural
polyethylene pipe, however, shall be stored under cover and protected from direct
sunlight.

Straight lengths shall be stored on horizontal racks giving continuous support to

prevent the pipe taking on a permanent set.

If, due to unsatisfactory storage or handling, a pipe is damaged or kinked, the

damaged portion shall be cut out completely

Transport vehicles shall be provided with a flat bed free from nails or other projections
which might cause damage to the pipe by abrasion.

All lining pipes shall be inspected before being taken into store and again before
being taken underground for infiltration.

c) Jointing

Short section pipes shall be capable of jointing by fusion welding techniques or,
alternatively, by mechanical type joints including screw type joints or snap on locking
connectors. Details of jointing systems shall be provided to the Engineer prior to
procurement of the pipe.

Linings shall be cut using methods approved by the Engineer. Precautions shall be
taken to avoid delaminating or spalling.

Jointing - Butt Fusion Welding

The Contractor shall supply the Engineer with the pipe manufacturers welding
instructions.

Welding shall be undertaken in clean conditions and an appropriate cover shall be

provided to prevent rain or airborne particles from contaminating the pipe faces
prepared for welding. If necessary, the pipe ends shall be plugged or covered to
prevent internal cooling. Only electric heating plates shall be used for butt fusion
welding.

Pipe jointing shall conform to the pipe manufacturers recommended procedures. The
weld bead is to be checked to ensure that it is uniform in shape, smooth in
appearance and bead width conform to the manufacturers allowable limits. The bead
height shall not be greater than half the bead width.

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Any unacceptable weld, and at least 250mm length of pipe on either side of that weld,
shall be cut off and discarded.

Internal and external weld beads shall be removed to a minimum protrusion of 1mm
from the pipe wall after the outside of the joint has cooled to 35°C or below.

Welds shall be sampled, as directed by the Engineer, and shall meet the
requirements of PE tensile weld test.

Jointing - Mechanical Type

The Contractor shall use either Snap Lock, Clear line or other approved mechanical
joint system and shall satisfy himself that loads applied during the slip lining operation
are within the accepted limits for the joint as provided by the manufacturer. The joint
shall be capable of withstanding the grouting pressure or the standard pipeline water
or air test, whichever is greater.

The Contractor shall provide calculations of the loads expected during installation and
during service and the manufacturers recommended allowable loads to the Engineer
prior to purchase of the pipe.

11.1.4.2 Annulus Grout

a) General

Cement for annulus grout mixes shall be sulphate resisting Portland cement
complying with the provisions of BS 4027. The use of pfa with sulphate resisting
cement shall not be permitted.

Sand for annulus grout mixes shall meet the relevant requirements of BS 882 or BS
1200.

Admixtures for annulus grout mixes shall meet the relevant requirements of BS 5075,
but shall not be used without the written approval of the Engineer.

Any admixture shall be measured using a proprietary dispenser and shall be mixed
with the full amount of water required for each batch and the combined water /
admixture mixed with the dry constituents.

Admixtures shall be stored and used strictly in accordance with the manufacturer’s
instructions.

Mixing water for annulus grout mixes shall be of potable quality.

Full details of the proposed grout mix shall be submitted to the Engineer for approval.

Trial mixes of the grout type proposed shall be undertaken to establish the properties
of the grout. The following properties shall be determined and the results shall form
the control values for quality control purposes.

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1) Density using the Baroid Mud Balance or similar approved equipment.

2) Workability using either the Concrete Flow Trough or the Marsh Cone with 10mm
orifice.

3) Compressive strength. Grout cubes shall be prepared and tested as follows :-

Cube moulds shall be 100mm or 70.7mm with all joints sealed to prevent leakage.
Moulds shall be overfilled and air bubbles removed by lightly tapping the mould. After
leaving for 30-60 minutes, the excess grout shall be struck off and the moulds
covered with plastic sheeting. Moulds shall be stored at 20°C± 5°C for 24 hours or
until the grout has attained sufficient strength to allow the cube to be stripped from
the mould whichever is the greater.

The cubes shall be removed from the moulds, marked and stored in water at a
temperature of 20° C± 1°C until tested. The Contractor shall test the grout cubes at
28 days after casting. Grout cubes shall have a minimum compressive strength of
3N/mm2

4) Bleeding. The amount of bleed water shall be determined by filling a 100mm

diameter container to a depth of 100mm with grout, covering to avoid evaporation and
removing the bleed water after 3 hours. The amount of bleed water shall be
expressed as the percentage ratio of the volume of bleed water to the original grout
sample volume.

5) The percentage by volume of bleed water after 3 hours shall not exceed 5
percent (5%).

b) Grouting

Grout shall be injected from the downstream end of the renovated sewer.

A minimum of two air vents shall be provided. Vent holes shall be plugged when all
air, water and contaminated or watery grout has been released. The pressure shall
be continuously monitored by a suitable gauge fitted at the injection nozzle. The
injection pressure shall not exceed 50kN/m2. The gauge shall have a full-scale
reading of not more than 200 kN/m2.

Means of immediate communication between the nozzle operator and the pump
operator shall be maintained during the grouting and a means of rapidly stopping the
grout flow shall be provided.

The quantity of grout injected at each injection point and the maximum pressure at
the nozzle at each injection point shall be recorded and the records made available to
the Engineer.

The grout shall be mixed in the proportions specified in Clause 3.2.8 for Class G3
cement grout.

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The dry constituents shall be thoroughly mixed using the minimum quantity of water
to ensure the necessary fluidity and to render it capable of penetrating the work. All
grout is to be used within one hour of mixing.

Sulphate resisting cement shall not be used as a constituent of grouts containing pfa

Immediately after each grouting operation, the Contractor shall inspect the pipeline
and clean out any excess grout. All excess grout shall be disposed of in a manner
acceptable to the Engineer such that it does not contaminate any sewer or
watercourse.

Unacceptable grout and any grout wash water shall be disposed of by the Contractor
in a manner acceptable to the Engineer such that it shall not contaminate any sewer
or watercourse.

The Contractor shall make three (3) grout cubes from samples taken from every 5m3
of grout or after every 50 meters of grouted pipe, whichever is the smaller, as detailed
in the previous section.

The density and workability of every batch shall be determined. The density shall not
differ by more than 5 percent from the specified density. The workability shall not
differ by more than 125mm or 5 seconds (through or Cone test respectively) from the
specified workability.

11.1.5 Diversion of Sewage Flows

The Contractor shall provide the equipment, materials and labour necessary to divert
flows around the work site during the lining operation. The pipe section to be lined
shall be isolated from sewage flow by plugging or blocking the line in the upstream
and downstream manholes.

The flow diversion system shall be designed and installed in such a manner as to
minimize disruption of traffic and inconvenience to the public. The Contractor shall
submit his proposed diversion details to the Engineer for approval prior to mobilizing
onto the site.

11.1.6 Flow Control

The Contractor shall use flow control methods and procedures as required to ensure
the safety or personnel and to facilitate completion of the work. Control measures
shall include plugging or blocking of the sewage flow or bypass pumping where
appropriate. The Contractor shall provide, operate and maintain all equipment
needed to properly control flows during the work.

Where the flow is to be blocked or plugged temporarily, the equipment shall remain in
place until the work has been completed and inspected. It is to be removed in such a
manner that permits sewage flow to gradually return to normal without surge,
surcharging or causing other disturbances downstream.

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The Contractor shall provide, operate and maintain a bypass system to conduct
sewer flows around the work area when flow cannot be controlled by blocking or
plugging or when it is necessary to maintain system sewer flow around the work area.

The bypass system is to be of sufficient capacity to handle existing normal sewer

flows plus any additional flow, which may occur during a rain event should the work
take place during the rainy season.

Flow control and bypassing methods and procedures must result in minimum
inconvenience and disturbances to the public, and prevent damage to public and
private property due to flooding, surge or excessive surcharging.

11.1.7 Maintaining Clean Conditions

As noted elsewhere in this Section, the Contractor shall maintain clear conditions in
and around the work area at all times. All material removed from the manholes shall
be taken from the site immediately and disposed of in a safe and approved manner.
Removed material and debris shall not be stored at the work area. The manner and
location of disposal of material shall be approved by the Engineer and employer prior
to the commencement of work.

Construction material and equipment shall be brought to the work area only as
needed and shall be stored on site in a safe and proper manner. The Contractors
equipment and material at the work site shall result in minimum inconvenience and
disturbance to the public.

During the performance of the work, the Contractor shall ensure that no removed
materials or debris, nor any construction material or equipment is permitted to enter
the sewerage system. The Contractor shall provide suitable screening and other
means of trapping and blocking as required in the downstream manhole to prevent
material from passing downstream.

The screened, trapped or blocked material shall be promptly removed from the
manholes by suitable means, placed in suitable containers, removed from the site
and disposed of properly.

11.1.8 Sewer Pre-Renovation Surveys

The existing sewer shall be CCTV surveyed prior to any renovation or repair work.
Refer to Section 11.7 for CCTV survey requirements.

11.1.9 Cleaning of Sewers

All deposits of debris that are likely to jeopardize the performance of the lining
operation or of the finished pipe lining shall be removed. This may include, but not be
limited to sand, grease accumulations, construction rubble and other debris in the
sewers as well as root and other hard protrusions. Cleaning shall be carried out by
approved methods.

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All debris removed from the sewer shall be disposed of in a safe manner. The method
and location of disposal shall be submitted to the Engineer for approval prior to
beginning cleaning operations. The Contractor shall take all precautions to prevent
debris from being carried downstream of the work place. Refer to Section 11.7 for
Sewer Cleaning Requirements

11.1.10 Traffic Control and Diversion

The Contractor shall submit his plans for the diversions of traffic around the site of the
work to the Dubai Municipality and the Dubai Traffic Police for approval prior to
mobilizing on site. The Contractor shall provide all traffic barricades, lights, signs and
all other equipment or personnel necessary to control traffic safely around the work
site. For road-diversions and road-signs refer to Appendix 1 and Appendix 4, Part 3 of
3 of the Specifications.

11.1.11 Manhole Connections

Where a renovated or replacement sewer connects to a manhole the channels and

benching shall be modified in accordance with Section 12.2 ‘Manhole Renovation to
suit the new pipe sizes and / or arrangements.

The design and installation shall be such as to ensure that groundwater is not
permitted to enter the sewer or manhole.

Compatibility between materials for sewer renovation or replacement works and

manhole materials shall be ensured.

11.1.12 House Connections

House connection work including the re-routing of existing house connections is not
shown on the drawings.

All house connection work shall be designed by the Contractor and approved by the
Engineer. This design work shall include a full survey and investigation for each
individual house connection together with drawings and calculations for submission to
the engineer for approval.

House connections to existing manholes that will be abandoned shall be re-routed to

the most suitable alternative new or existing manholes.

Where the main sewers to be renovated or replaced have house connections directly
connected to the sewer by a “Y” connection, the existing house connections shall be
abandoned and replace with new house connections and transition chambers, if
necessary. The new house connections shall be constructed connecting to the
nearest existing manhole or house connection chamber. House connections and
chambers shall conform in shape, size, dimensions, materials and other aspects to
the details indicated on the Contract Drawings or as ordered by the Engineer.

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House connection works shall be carried out in accordance with Section 4 of the
Specification.

11.2 PIPELINE RENOVATION - SLIPLINING

11.2.1 General

The renovation of existing sewers or rising mains where down-sizing has been
indicated shall be undertaken using slip-lining technology, The slip-lining pipe is to be
manufactured from unplasticised polyvinyl chloride (uPVC), high density polyethylene
(HDPE) or high performance polyethylene (HPPE). The annular space between the
existing pipe and the new slip-lined pipe shall be filled with grout.

The slip lining work shall include, but not be limited to the following operations.

1) Initial sewer cleaning prior to CCTV Survey

2) Initial CCTV survey and logging

3) Submission by Contractor to Engineer of proposed slip lining method based on

the initial CCTV survey and minimum disruption.

4) Full sewer cleaning prior to slip lining.

5) Slip lining

6) Grouting

7) Manhole Refurbishment as per clause 11.1.11

8) Testing of slip lined pipe

9) Temporary blocking off and over pumping and diverting of all contributing flow as
required during operations (1) through (8) above.

10) proving pig down the length to be relined to confirm the minimum annulus size.

11.2.2 Slip-Lining Execution

Slip-lining shall use uPVC, HDPE or HPPE pipe lining.

Immediately prior to installation of the pipe lining, the Contractor shall pass a proving
pig down the length to be relined to confirm the minimum annulus size.

The proving pig shall have solid ends of sufficient rigidity and length to be
representative of the proposed lining system.

The pipe lining shall be installed by winching (or other approved method) the
assembled pipe through the existing sewer. Details of the proposed method of
winching must be submitted to the Engineer for approval at least seven (7) days
before the proposed insertion date.

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The joints shall be watertight during winching of the pipes and in their final positions.

The joints shall be designed to withstand the external pressure applied to the joint
during annulus grouting and to prevent any leakage of grout into the liner pipe.

The winch shall be fitted with a direct reading load gauge to measure the winching
load. At the end of each days winching, the Contractor shall provide the Engineer with
copies of the forces recorded in winching or each approved method at the start of any
pull and during the pull at increments of 20 meters of winching distance and at any
restart after temporary stops.

The Contractor shall supply sufficient cable in one continuous length so that the pull
may be continuous between approved winching points.

The winch cable and cable drum must be provided with safety cage and supports so
that it may be operated safely without injury to persons and property.

The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.

A nose cone shall be fixed to the first pipe to be inserted and shall be fitted with a
swivel attachment to reduce the twist transmission between the winch cable and nose
cone.

Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.

Linings shall be cut using methods as recommend by the manufacturer or approved

by the Engineer. Precautions shall be taken to avoid de-lamination or spilling.

11.2.3 Grouting

The annular space between the existing sewer pipe and the newly installed lining is to
be filled with cementitious grout as per clause 11.1.4.2. The Contractor shall take all
necessary precautions to ensure continuous operations between manholes or drive
pits and that any delay due to blockage or mechanical breakdown is minimized so as
not to affect the performance of the placed grout.

The selection of the grout material and the method for grouting the annular space
shall be such as to prevent the flotation of the pipe during the grouting operation. As
a minimum, the newly installed pipe lining, shall be capped and filled with water.

11.2.3.1 Treatment of End of Lining

At the upstream end of the lining, the existing invert is to be broken out and the lining
lay on a suitable mortar bed so that the inverts are level. At all other points, the
existing sewer shall be suitably prepared and a smooth transition made with suitable
mortar.
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Where existing benching and channels require modification to suit the new pipe sizes
and arrangements, then prior to sewer lining being carried out, the manhole shall be
thoroughly cleaned; the existing benching and channels scrabbled. All loose scale
aggregate and dust removed and any large holes filled with 3:1 sand cement mortar.

The channel invert and sides shall be broken out to a depth sufficient to permit a
minimum of 10mm thickness of epoxy mortar or 7mm thickness of GRP laminate to
be applied in accordance with Section 7 of this specification after completion of the
renovation works.

Alternatively, with the approval of the Engineer, the benching and channel may be
broken out and reconstructed with Class 30/20 concrete to profiles suitable for the
new pipe sizes and arrangements and which will enable application of the minimum
thickness of laminate as detailed in Section 7 of this specification .

11.3 PIPELINE RENOVATION - DEFORMED PIPE LINING

11.3.1 General

Where downsizing has been indicated on the Drawings and where the existing pipe is
not suffering from excessive deformation, the Contractor may propose to renovate the
existing sewer using deformed pipe lining systems. In such instances, the Contractor
must indicate which line he proposes to renovate using deformed pipelining
techniques and obtain approval from the Engineer prior to mobilizing labour, materials
and equipment to the work site.

The deformed pipe lining works shall include but not be limited to the following
operations:

1) Initial sewer cleaning prior to CCTV survey.

2) Initial CCTV survey

3) Submission by Contractor to Engineer of proposed deformed pipe lining process

to be used based on the initial CCTV survey.

4) Preparation of manhole per clause 11.3.7

5) Full sewer cleaning prior to deformed pipe sewer lining.

6) Deformed pipe sewer lining

7) Testing of lined pipes.

8) Final jetting and CCTV survey

9) Temporary blocking off, over pumping and diverting of all contributing flows as
required during operations (1) to (8) above.

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11.3.2 Materials - HDPE or HPPE Pipe

Pipeline renovation by deformed pipe techniques shall use high-density polyethylene

(HDPE) or high performance polyethylene (HPPE) pipe as specified in Section 4 of
these specifications.

The HDPE or HPPE pipe shall be supplied in coils or on reels as recommended and
provided by the manufacturer.

11.3.3 Further Site work Preparation

The Contractor shall obtain the field measurements of the existing pipe profiles at the
accessible points such as manholes.

In addition to vertical and horizontal measurements of the pipe diameters, the

Contractor shall obtain measurements of the inner circumference of the pipe. From
the inner circumference measurements a round pipe theoretical outer diameter shall
be computed and compared to measured diameters. The horizontal and vertical
diameters measured shall be used by the Contractor to make necessary decisions
about the overall conditions for the new pipe cross sections.

The Contractor will make a determination concerning the lower and upper ranges of
the pipe’s diameters. The Contractor shall use the circumferences measured from
inside the pipe as a governing measure while the two perpendicular diameters will be
used as supporting measurements. The Contractor shall compare the inside
circumference of the pipe with the outside circumference for the liner pipe. By
subtracting one from the other, the Contractor will determine what matching pipe
should be selected for the work.

The Contractor shall ensure that the replacement pipe shall match the existing pipe to
provide a tight fit after the deformed pipe has been reverted to its full size.

The pipe shall be determined and ordered in the cold state and the Engineer shall
approve the size requirements for the pipe using the methods described above.

11.3.4 Pipeline Obstructions

The Contractor shall repair or remove from the pipeline all obstructions (e.g.
sediments, protruding service laterals and collapsed pipe sections), that can prohibit
insertion of the pipe. A high speed rotating hydraulic cutter shall be used to cut
protruding service laterals, offset joints, roots, barnacles, concrete or other
obstructions. The cut will be made flush with the wall of the pipe to be restored and
the debris will be flushed down the pipe to the downstream manhole. If an obstruction
cannot be removed by conventional methods and/or mechanical equipment remotely
controlled, then the Contractor shall, by excavation, remove or repair the obstruction.
Such excavation shall be considered as separate measurement item and must be
approved in writing before commencement. The difficult or special cases shall be

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evaluated by the Engineer and Contractor prior to excavation. All loosened material
must be removed at the downstream manhole.

The pipeline shall also be checked immediately before lining for the presence of
collapses occurring subsequent to cleaning by passing sewer rods between
manholes, shafts or chambers. If a collapse is detected its position shall be
determined and an additional shaft shall be excavated if the debris cannot be
removed.

Where a collapse has occurred subsequent to cleaning the cost of excavation to clear
the blockage shall be paid at the appropriate billed rates.

If deformed pipe lining is delayed for a period in excess of 7 days after cleaning and
initial inspection the pipeline shall be reinspected. The cost of this work will be borne
by the Contractor if he is responsible for the delay as determined by the Engineer.

11.3.5 Sewer Lining Execution

All blocking off of sewers and house connections and over pumping shall be carried
out to the approval of the Engineer.

11.3.5.1 Pipe Insertion

The pipe reel or coil shall be positioned at the upstream manhole. The pipe will be
installed by pulling it, through the pipe to be restored, directly from the reel or coil,
through the upstream manhole in one single section without any excavation.

The pipe shall be winched through the existing pipe with due care to avoid snagging
or damage to the manholes. Guides or rollers shall be fitted within the manholes to
avoid the risk of snagging.

If it is necessary to reclaim the pipe from its position in the pipeline, this should be
done immediately the decision is made. Preferred methods are vacuum collapsing
the pipe or mechanically pulling the pipe, if the friction is not prohibitively high.
Excavation should be used as a last resort in the process of recovering the pipe.

11.3.5.2 Manifold Installation

Processing manifolds to enable head and steam to revert the deformed pipe shall be
fixed at each end of the pipe.

11.3.5.3 Processing the Pipe

The Contractor shall install temperature and pressure measuring devices at the
upstream and downstream manholes. The temperatures sensors shall be fixed as far
as possible inside the pipe at the inlet and outlet points.

A steam heat source, operated in conjunction with the pressure, such as is generated
from the steam generator, shall be utilized to supply steam to the pipe during the

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processing period. The steam generating equipment shall have a capacity of not less
than 102°C (215°F) nor more than 177°C (350°F). This capacity should be sufficient
to reach a downstream manhole. These measurements will be gauged at the
upstream manhole. The internal pressure range, which will be used in the pipe’s
processing, will not be less than 1.36 bars (20 psi) or more than 1.70 bars (25 psi) for
normal processing. The equipment must have the capacity to provide at least this
quoted pressure range.

11.3.5.4 Cooling Process

After the pipe has been fully processed or it has reverted to its circular shape
pressurized air shall replace steam at a gradual rate. Further cooling shall be carried
out using water.

11.3.5.5 Finishing Work

The pipe shall be cut flush at the inlet and outlet prior in the manhole by using the
rotary cutter.

11.3.5.6 Equipment General Specifications

Steam rated pressure and temperature gauges to be fitted to the steam generator
and processing gauge stations and manifold shall be at least 125mm in diameter and
shall be clearly readable at a distance of 2 metres. All such gauges shall have the
capacity to measure from 10 to 260°C.

The remote steam gauges shall be attached to the downstream processing gauge
station.

The high pressure steam hoses and fittings shall be rated for 200 psi or higher
working steam pressure.

The pulling winch shall be equipped with a tension gauge, capable of running at
constant and controlled speed. The operator must have the ability to increase or
decrease the pulling speed. The Contractor will prepare computations for approval by
the Engineer of the size of the winch necessary for a particular job.

11.3.6 Guarantee

The Contractor must provide a 10 year guarantee for the deformed pipe sewer lining.

11.3.7 Finishing to Manholes

A. Prior to deformed pipe lining work being carried out, the manholes shall be
thoroughly cleaned, the existing benching and channels scrabbled and all loose
scale, aggregate and dust removed and any large holes filled with a 3:1 sand cement
mortar. The invert and sides of the main channel shall be broken out to a minimum
depth of 10mm with a chase 75mm x 15mm deep being formed in the sides of the
main channel just before springer level. A layer of epoxy mortar 10mm thick shall be
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formed in the main channel up to springer level to give a uniform fall across the
manhole.

B. On completion of the deformed pipe sewer lining process and removal of

equipment, the lining pipe shall be neatly cut and trimmed to suit the benching profile
in each manhole. The free edge of the cut liner shall be dressed with epoxy mortar
into the performed chase in the channel sides and a 10mm minimum thickness of
epoxy mortar or 7mm thickness of GRP laminate shall be applied to the whole of the
benching and exposed channel and over the free edge of the cut pipe as specified in
Section 7 of these specifications.

C. At the point of entry of the lining pipe to a manhole the lining pipe is to be cut at
the crown 25mm from the inside of the manhole finish and the junction between the
pipe and manhole lining is to be sealed with a compatible material giving a similar
degree of protection to the manhole liner.

D. In manholes where two dissimilar lining pipe section adjoin, the channel between
the lining pipes shall be broken out to a depth to allow 10mm minimum thickness of
epoxy mortar or 7mm minimum thickness of GRP laminate to be applied between the
lining pipes, and a 75mm wide 15mm deep chase shall be formed around the channel
into which the bonding edge of the lining pipe shall be dressed with epoxy mortar or
GRP laminate. The entire channel shall then be applied with a minimum of 10mm of
Epoxy Mortar or GRP laminate as per Section 7 of these specification .

11.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING

11.4.1 General

Where down sizing has been indicated on the drawings and where the existing pipe is
not suffering from excessive deformation, the Contractor may propose to renovate the
existing sewer using inversion type soft lining techniques. In such instances, the
Contractor must indicate which lines he proposes to renovate using inversion lining
techniques and obtain approval from the Engineer prior to mobilizing labour, materials
and equipment to the work site.

The inversion sewer lining works shall include, but not be limited to the following
operations:

1) Initial sewer cleaning prior to CCTV survey

2) Initial CCTV survey.

3) Submission by Contractor to Engineer of proposed liner design based on the

initial CCTV survey.

4) Full sewer cleaning prior to lining.

5) Inversion sewer lining

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6) Testing of soft lined pipes

7) Manhole refurbishment as per clause 11.4.8

8) Final jetting and CCTV Survey

9) Temporary blocking off and over pumping and diverting of all contributing flows
as required during operations (1) to (8) above.

11.4.2 Materials

The inversion type soft lining pipe material shall be of the following types: -

1) A composite tube, consisting of one or more layers of polyester or acrylic needle

felt with an integral external coating of polyurethane, polyethylene, PVC or nylon,
impregnated with an approved thermosetting resin, which, after inversion into a pipe,
will bed against the pipe wall with the coating on the inside.

2) On or more layers of a continuous glass fibre reinforcement impregnated with an

approved thermosetting resin, which, after inversion into a pipe will bed against the
pipe wall.

For the purposes of this project, only soft lining systems which provide structural
strength liners capable of resisting ground and traffic or groundwater loadings as
necessary upon curing will be considered. The resin system and the lining thickness
shall be selected to meet the chemical resistance and structural requirements for the
lining.

A trial section must be carried out and test performed as detailed in clause 10.4.3 to
prove the Contractor’s proposed resin, handling technique, and the amount of resin
required.

The Contractor must supply the Engineer with full details of recommended usage,
curing method, pot times, life, mechanical properties and chemical resistance or the
resin he proposes to use.

The Contractor must provide evidence that the proposed resin or polyethylene
material will have strength, stability and resistance to corrosion in an environment
which may comprise any combination of the following factors for a design life of 50
years: -

1) Immersion in septic sewage at up to 35°C.

2) Exposure to hydrogen sulphide gas derived from septic sewage to temperatures

up to 35°C

3) Immersion in saline water at temperatures up to 35°C

4) Deposits of free sulphur on exposed surfaces

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5) Exposure to 10% sulphuric acid at up to 35°C

Note: For items 1 through 3, refer to the 100-day ASTM test C581.

A preliner shall be used to prevent migration of resin into connections. The preliner
shall be composed of a polymeric membrane and may be integral with the in-situ
tube. This form of construction will be used in all applications of inversion type lining
systems.

11.4.3 Inversion Type Resin System

The inversion type soft lining systems shall use a resin system using an isophthalic
polyester resin or a proven alternative with equivalent or higher performance
characteristics than the isophthalic polyester resins. The resin systems may contain
only those additives approved by and only up to the limits defined by the resin
manufacturer to control viscosity and pot life.

The thermosetting resin system shall cure with a minimum of volumetric shrinkage
and shall have viscosities suitable for good impregnation and defined processing
characteristics at ambient temperatures between 20-50°C (Middle Eastern and
tropical conditions must be accommodated).

The resin system shall cure under water and must also cure in the presence of tar
residues and dirt in the pipelines. The resin system shall not be affected by sun
radiation usually prevailing when inverting the impregnated felt tube.

In addition to the requirements of BS3532 the heat distortion temperature of castings

of fully cured resin (as opposed to felt/resin matrix) when determined in accordance
with BS2782: Method 121A, shall be not less than 20 C above the expected
maximum service temperature of the lining.

11.4.4 Tests

The Contractor shall, when directed, periodically provide results of tests carried out
on the cured in-situ lining material by an approved testing laboratory. These tests are
to confirm the physical properties of the cured in-situ lining material. Tests shall be
carried out in accordance with Appendix 2 of this Specification. The properties to be
tested are given below: -

• Flexural modulus

• Flexural strength at first break

• Tensile strength

• Compressive strength

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The Contractor will be required to initiate with an approved testing laboratory a test to
substantiate the 50 year creep modulus of the In-situ form material at the working
temperature in the pipe.

11.4.5 Soft Lining Design

Following the initial CCTV survey the contractor shall supply calculations to
demonstrate the ability of the in-situ pipe to withstand design loading. These
calculations shall be comprehensive and should not be based on empirical
relationships found by the Contractor. They shall be based on a design life of 50
years. They shall cover all pipe diameters noted in the contract documents.

The liner shall be designed assuming no adhesion between the cured liner and the
walls of the existing pipe.

Approval by the Engineer of the use of any particular in-situ pipe thickness shall not
release the Contractor from his obligations under the Contract.

11.4.5.1 Liner Thickness Design

The liners for soft lining shall be designed as structural liners i.e. as chemically
protective liners with structural capability to withstand continuous inside and outside
pressure at an elevated temperature of up to 50°C.

The following parameters shall be reviewed from CCTV survey record for evaluation
of the existing sewer as to its soundness structurally.

1) Infiltration of ground water accompanying soil, bedding material through joints,

open joints, breaks and missing sections.

2) Degree of corrosion due to corrosive effluent and corrosive environment.

3) Overall condition of the sewer - any visible cracks, protrusion of rubber rings at
open joints, intrusion of the tree roots etc.

The finished cured liner thickness design shall be based on: -

1) Loading criteria such as ground and water pressures, highway loading.

Note: Water pressure shall be assumed to be from ground level. Highway loading
shall be assumed from Sewer Rehabilitation Manual

2) A Standard Dimensional Ration (SDR) as shown:

Nominal inner pipe diameter (mm)SDR

250 35 – 40

300 40 – 50

350 40 – 50
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400 40 – 50

500 40 – 50

750 50 – 60

1000 40 – 55

Note:

For pipes less than dia 250mm, the liner (cured) thickness shall be minimum 4mm,
but shall not exceed 6mm.

11.4.5.2 Liner Tube Fabrication

The lining bag or tube shall consist of one or more layers of needle interlocked
polyester felt or woven glass fibre and shall be fabricated to provide the required
length and thickness of in-situ pipe and shall be of a diameter such that on inversion it
expands to fit the profile of the pipe to be renovated. The required thickness of liner
tube may be achieved by fabrication in successive layers each formed by sewing or
flame bonding. Where the liners thickness is built-up using more than one layer of
polyester felt, the joints in the felt shall be offset to prevent excessive thickening on
the completed lining. The thickness of the finished pipe shall be at least minimum
specified and may be up to 15% greater, except where felt layers overlap in which
case it may exceed this value. The outer layer shall be made from coated felt and a
covering strip shall be bonded over the flame bonded or sewn seams. The diameter
of the tube shall allow for any variation in the diameter of the pipe to be lined such
that voids or wrinkles do not occur in the finishing lining.

11.4.6 Sewer Lining Execution

All blocking off of sewers and house connections and over pumping shall be carried
out to the approval of the Engineer.

Pipe connections (if any) protruding into the sewers to be renovated shall be cut off
neatly using an approved cutting technique

11.4.6.1 Equipment

The Contractor shall provide the expertise, personnel and equipment necessary to
perform in-situ soft lining of sewer pipes. The Contractor shall be responsible for the
provision, transport, storage, insertion and curing of the pipe lining as specified. The
Contractor shall supply all equipment, tools, materials and labour required to
efficiently perform the soft lining work within the specified schedule.

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11.4.6.2 Impregnation

The liner tube shall be laid flat and a vacuum applied by means of a vacuum pump
and the resin injected. The resin shall be impregnated evenly throughout by means of
rollers. Both ends of the in-situ tube shall then be sealed. The volume of resin shall
be such that on completion of inversion and curing the specified in-situ pipe thickness
is achieved.

Immediately after impregnation the liner tube shall be placed in storage at or below a
maximum temperature recommended by the resin manufacturer and approved by the
Engineer and this temperature shall be maintained until the inversion procedure
commences on site using ice and cold storage vehicles as necessary. The maximum
time of storage after impregnation shall be as recommended by the resin
manufacturer and approved by the Engineer.

11.4.6.3 Transport and Storage

The lining system materials shall be transported to the site under controlled
environmental conditions according to the manufacturer’s recommendations.

The lining manufacturer shall be familiar with the changes in viscosity, gel time, etc.,
which may occur during transport and storage of the resin, especially in the climatic
conditions in the U.A.E., and shall make appropriate allowances in the lining
manufacturing process. Resin stored in original, unopened containers shall not be
used after the resin manufacturers stated keeping period.

11.4.6.4 Inversion and Curing

The lining shall be inverted into the prepared pipeline using the unheated water or
compressed air. The medium used for the insertion should be as cool as possible
considering the climatic conditions in the U.A.E. and may require timing the insertion
during the night time hours and providing means for keeping the insertion water cool.

Equipment shall be such that there is adequate head to ensure proper inversion of
the in-situ tube.

The in-situ tube shall be clamped around the inversion ring or elbow and inverted into
the pipe. Water or compressed air shall be pumped into the in-situ tube at a rate such
that inversion proceeds under an adequate head.

A water hose with discharge holes along its length, or a draw rope for subsequently
pulling in light cure lamps shall be attached to the in-situ tube rope end so that on
completion of the inversion it shall occupy the full length of pipe being renovated.

On completion of inversion, curing shall be effected by the application of heat or by

the application of ultra violet light of the correct wavelength and intensity.

Heat shall be applied by means of circulating the water contained in the in-situ pipe
through a boiler and the water hose until the optimum curing temperature is attained
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throughout the length of the pipe being renovated. The rate of temperature rise and
fall shall not exceed 10 C/min. The optimum curing temperature is to be as
recommended by the manufacturer and approved by the Engineer. The water
temperature shall be automatically controlled. The resin temperature shall be
monitored using thermocouples on the inner and outer faces of the lining installed
where applicable. The boiler inlet and outlet water temperature shall be recorded.
During cure, the curing reactions become exothermic which may show up on the
temperature monitor as a peak. The curing temperature shall be maintained until the
exothermic reaction is witnessed, indicating a properly cured liner.

Ultra violet light shall be applied by drawing suitable lamps along the length of the in-
situ tube at a rate compatible with the resin system. For all installations the curing
parameters required must be agreed with the resin manufacturer and approved by
the Engineer.

After curing, the water in the in-situ pipe shall be released provided that the
temperature of the water is within 10°C of ambient and provided always that this
temperature is within the safe permissible limits of temperature to allow the
Contractors employees to carry out this work in safety. The curing water must be
allowed to cool naturally and the full inversion head must be maintained throughout
cooling.

In the event that local repairs to the in-situ pipe are required the Contractor shall
submit proposals for such repairs to the Engineer. The Contract shall however take
all necessary steps and precautions to obviate the need for such repairs during
manufacture and installation of the liner.

11.4.7 Guarantee

The Contractor must provide a 10-year guarantee for the in-situ sewer lining. The
Contractor should note, however, that the design life of the lining should be 50 years
as stated in clause 11.4.1

11.4.8 Finishing to Manholes

A. Prior to in-situ lining work being carried out, the manholes shall be thoroughly
cleaned, the existing benching and channels scrabbled and all loose scale, aggregate
and dust removed and any large holes filled with a 3:1 sand cement mortar. The
invert and sides of the main channel shall be broken out to a minimum depth of
10mm with a chase 75mm x 15mm deep being formed in the sides of the main
channel just above springer level. A layer of epoxy mortar 10mm thick shall be
formed in the main channel up to springer level to give a uniform fall across the
manhole.

B. On completion on the in-situ sewer lining process and removal of inversion

equipment, the in-situ pipe shall be neatly cut and trimmed to suit the benching profile
in each manhole. The free edge of the cut in-situ liner shall be dressed with epoxy

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mortar into the preformed chase in the channel; sides and a 10mm minimum
thickness of epoxy mortar or a 7mm minimum thickness of GRP laminate shall be
applied to the whole of the benching and exposed channel and over the free edge of
the cut in-situ pipe as specified in Section 7 of this specification .

C. At the point of entry of the in-situ pipe to a manhole the in-situ pipe is to be cut at
the crown 25mm from the inside of the manhole finish and the junction between the
in-situ pipe and manhole lining is to be sealed with a compatible material giving a
similar degree of protection to the manhole liner.

D. In manholes where two dissimilar in-situ pipe sections adjoin, the channel
between the in-situ pipes shall be broken out to a depth to allow a 10mm minimum
thickness of epoxy mortar or 7mm minimum thickness of GRP laminate to be applied
between the in-situ pipes, and a 75mm wide 15mm deep chase shall be formed
around the channel into which the bonding edge of the in-situ pie shall be dressed
with epoxy mortar of GRP laminate. The entire channel shall then be applied with a
minimum of 10mm of epoxy mortar or 7mm of GRP laminate as per Section 7 of this
specification.

11.5 PIPELINE REPLACEMENT - PIPE BURSTING

11.5.1 General

The Contractor shall select a suitable pipe bursting method and equipment to perform
the specified pipe upsizing and replacement. The Contractor shall specify the method
and equipment to be used in his tender submittal.

Pipe bursting operation shall be conducted from within existing manholes without long
lead in trenches unless otherwise approve by the Engineer. The selection of drive
and reception locations shall be such as to minimize disruption of normal traffic and
inconvenience to the public.

The Contractor’s design shall include for all dewatering or other ground water and soil
support systems, necessary to prevent any adjacent ground from being adversely
affected during and after pipe bursting activities.

The pipeline replacement by pipe bursting works shall include, but not be limited to
the following operations:

1) Initial sewer cleaning prior to CCTV survey.

2) Initial CCTV survey

3) Submission by contractor to Engineer of proposed pipe bursting technique based

on the initial CCTV survey.

4) Full sewer cleaning prior to pipe bursting.

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5) Preparations of manholes prior to pipe bursting

6) Pipe replacement by pipe bursting

7) Testing of new pipes.

8) Manhole refurbishment per clause 11.5.3

9) Final jetting and CCTV survey

10) Temporary blocking off and over pumping and diverting of all contributing flows
are required during operations (1) to (9) above.

11.5.2 Pipe Bursting - Execution

The details of the method of pipe replacement to be used shall be submitted by the
Contractor to the Engineer in the form of a detailed method statement for approval
prior to mobilization to the site. The details shall include but not be limited to the
method of pipe bursting, method of jointing and if necessary, debeading the pipe
internally and externally, the location of driving and reception pits and the necessary
temporary works.

Pipe bursting shall use HDPE or PPE pipe. HDPE or PPE pipe shall be installed by
winching (or other approved method) the pipe bursting assembly and jointed pipe
through the existing sewers. Details of the proposed method of winching must be
submitted to the Engineer for approval at least 7 days before the work is intended to
be performed.

The winch shall be fitted with a direct reading load gauge to measure the winching
load. At the end of each working day, the Contractor shall provide the Engineer with
copies of the winching forces recorded for each approved method at the start of any
pull and during the pull at increments of 20 meters of winching distance and at any
restart after temporary stops.

The Contractor shall supply sufficient cable in one continuous length so that the pull
may be continuous between approved winching points.

The winch cable and cable drum must be provided with safety cage and supports so
that it may be operated safely without injury to person and property.

The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.

The pipe bursting assembly shall be fixed to the first pipe to be inserted and shall be
fitted with a swivel attachment to reduce the twist transmission between the winch
cable and nose cone.

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Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.

Cutting of Linings

Linings shall be cut using the methods approved by the Engineer. Precautions shall
be taken to avoid delaminations or spalling.

11.5.3 Finishing to Manholes

A. Prior to pipe bursting work being carried out, the manholes shall be thoroughly
cleaned, the existing benching and channels scrabbled, and all loose scale,
aggregate and dust removed and any large holes filled with a 3:1 sand cement
mortar. The invert and side of the main channel shall be broken out to accommodate
the outer dimensions of the new pipe to be installed plus a minimum additional 10mm
depth. A layer of epoxy mortar 10mm thick shall be formed in the main channel up to
springer level to give a uniform fall across the manhole.

B. Prior to pipe bursting work being carried out, the existing pipe penetrations
through the manhole wall shall be broken out to accommodate the outer dimensions
of the new pipe to be installed. The Contractor shall prevent groundwater flow into the
manhole by the use of hydrophilic gel injection around the existing pipe penetrations
or by dewatering around the manhole, or by such other method as shall be approved
by the Engineer.

C. On completion of the pipe bursting process, and removal of the equipment, the
new pipe shall be neatly cut and trimmed to suit the benching profile in each
manhole. A 10mm minimum thickness of epoxy mortar or a 7mm minimum thickness
of GRP laminate shall be applied to the whole of the benching and exposed channel
and over the free edge of the new pipe as specified in Section 7 of this specification.

D. At the point of entry of the new pipe into a manhole, the new pipe is to be cut at
the crown 25mm from the inside of the manhole finish and the junction between the
new pipe and the manhole lining is to be sealed with a compatible material giving a
similar degree of protection to the manhole liner.

11.5.4 Obstructions

The contractor may encounter section of existing pipe where a concrete surround has
been used. In these situations, the pipe bursting technique may not be capable of
fracturing the pipe and concrete surround. The Contractor shall endeavour to identify
the possible locations of such obstructions through review of Dubai Municipality
records and discussions with Municipality personnel.

Where obstructions are known to exist, or where such obstructions are encountered
during the execution of pipe replacement work, the Contractor shall excavate at the
site and remove the obstruction. Following completion of the pipe replacement

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through the affected section, the Contractor shall place pipe bedding and backfill and
complete reinstatement of pavements.

11.6 PIPELINE ABANDONMENT

11.6.1 General

The Contractor shall clean and fill by the method of continuous grout injection, the
asbestos cement sewer pipelines to be abandoned as indicated on the Contracts
Drawing(s) and as specified herein. uPVC pipes to be abandoned will be fully cleaned
as per Section 11.7 and left in place. The abandonment works must be scheduled
and co-ordinate with the renovation of existing sewers and construction of new
sewers so as to avoid conflicts between work crews, to facilitate rapid completion of
the work, and to limit disturbances to the area.

11.6.2 Grout and Grouting for Abandoned Pipeline

Grout for abandoned pipeline shall be as the annulus grout specified in clause
11.1.4.2

The asbestos cement sewers to be abandoned will be fully cleaned as specified in

Section 11.7 immediately prior to grouting.

11.7 SEWER CLEANING AND CCTV SURVEY

11.7.1 General

The Contractor, where required to conduct a closed-circuit television survey (CCTV)

of sewers, shall perform a series of surveys as detailed below:

11.7.1.1 Extent of the Survey

The Contractor shall conduct an initial CCTV survey and logging on all existing
gravity sewers within the project area prior to the renovation and replacement of any
line. A (Post Renovation) survey shall be conducted on completion of renovation and
replacement operations all as described herein.

Initial Survey/Condition Survey

An initial survey shall be carried out on all pipelines to be renovated or replaced or as

otherwise required by the works. This survey shall be carried out as soon as possible
to check the condition of the pipe and to confirm proposed method of replacement.
This survey shall be carried out in addition to the survey immediately prior to
renovation/replacement whilst the sewer is operating under actual flow conditions.
The maximum flow in the pipe should be not more than 10%.

A light source shall be placed at the other end of the line to be surveyed to verify the
alignment of the pipe. The light may be removed once observed by the camera, the

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location in the pipe length from which the light is first observed shall be recorded.

Pre-Renovation Survey

Immediately prior to the renovation of any pipe, a CCTV survey (Pre-Renovation

Survey) shall be conducted.

Post Renovation Survey

As soon as practical after the renovation/replacement of the pipe a CCTV Survey

(Post Renovation Survey) shall be carried out.

11.7.2 Sewer Cleaning

All sewers including manholes prior to rehabilitation, renovation, replacement or

abandonment shall be cleaned as per the requirements of this section.

a) Prior to beginning the CCTV survey in any section of sewer, the Contractor shall
have the sewer section including manholes thoroughly cleaned and prepared for the
survey. The Contractor shall provide all necessary vehicles, equipment, materials and
labour, in proper condition and in sufficient numbers, to carry out the cleaning of the
sewers and manholes in a timely and expeditious manner.

The Contractor shall arrange for the disposal of all material and debris in a safe
manner, as approved by the Engineer and the relevant authorities.

b) Sewer and manhole cleaning shall be carried out mainly by water jetting.

Water jetting shall be carried out using purpose built jetting tankers. Jetting tankers
shall be equipped with at least 150m of suitable 25mm diameter hose with jetting
heads. The water pressure at the jetting head shall be variable between 100 bars and
170 bars. The minimum flow rate at 100 bars will be 2.5 l/s.

The hose shall be mounted on a power operated drum reel having variable speed
and direction controls. The hose system shall incorporate a suitable method of
meterage indication. A calibrated hose is an acceptable method for measuring
meterage. The hose must be equipped with a variety of nozzles, including rear jets
only (15½ to 30½), rear plus forward jets, and rear plus side jets or other
configuration to ensure adequate cleaning of the pipelines.

Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.

c) Along with water jetting, sewer and manhole cleaning shall include the following :

i. blocking off sewer lengths and over pumping where required

ii. bucket and winch dredging where required

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iii. flushing from downstream manhole only using potable water. Debris and sand
jetted or dredged from the sewers shall be collected by silt traps or screens installed
in the downstream manhole.

iv. removal and disposal of all collected debris and sand.

v. wire brushing of manholes

vi. such other methods and works as may be required to clean the sewers and
manholes to a satisfac¬tory standard.

d) Initial sewer cleaning, prior to the initial CCTV survey, shall be carried out in such
a manner as to avoid damage to the sewers, which are likely to be in poor structural
condition. Jetting pressure will be limited to 100 bars for initial cleaning.

During initial cleaning sewers must be cleaned to a standard such that an effective
CCTV survey of their structure can be carried out. Manholes shall be similarly
cleaned to permit visual surveys.

e) Full cleaning shall be performed prior to lining or abandonment of sewers and

manholes and will include all operations necessary to remove all grease, slime and
loose material from the pipes and manholes.

Sewers and manholes must be cleaned to a standard such that the sewer lining can
be effectively in¬stalled.

Where the initial CCTV survey indicates that the sewers are in poor structural
condition jetting pres¬sure will be limited to 100 bars. Care must be taken, generally,
to avoid damage to the sewers. Any sewer collapses caused by jetting shall be
rectified by the Contractor immediately at his cost.

11.7.3 Survey and Operational Equipment

The surveying equipment shall be capable of surveying a section of sewer up to 350

meters in length where entry to the sewer may be obtained at each end, up to 30
meters by rodding. Where entry is at one end of the section only, the equipment shall
be capable of survey¬ing a section of sewer up to 150 meters in length using a self-
propelled unit.

The Contractor shall maintain this equipment in full working order and shall satisfy the
Engineer at the beginning of each working shift that all items of equip¬ment have
been provided and are in full working order.

Each survey unit shall contain a means of transporting the CCTV camera in a stable
condition through the sewer under inspection. Such equipment shall ensure that the
CCTV camera position is maintained on or near to the central axis of the sewer.

Where the CCTV camera is towed by winch and bond through the sewer, all winches
shall be stable with either lock¬able or ratcheted drums. All bonds shall be steel or of
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an equally non-elastic material to ensure the smooth and steady progress of the
CCTV camera. All winches shall be inherently stable under loaded conditions.

Each survey unit shall carry sufficient numbers of guides and rollers such that, when
surveying, all bonds are supported away from pipe and manhole structures and all
CCTV cables and/or lines used to measure the cameras location within the sewer are
maintained in a taut man¬ner and set at right angles, where possible, to run through
or over the measuring equipment.

Each unit shall carry a range of flow control equipment, as opposed to over pumping
equipment, for use in control¬ling flow during the survey. A minimum of one item of
each size of equipment ranging from 150 mm to 450 mm diameter inclusive shall be
carried.

11.7.4 Performance of Survey

11.7.4.1 Camera Position

The camera lens shall be positioned centrally within the sewer, looking along the axis
of the sewer. A position¬ing tolerance of ± 10 % of the vertical sewer dimension shall
be allowed.

11.7.4.2 Camera Speed

The speed of the camera in the sewer shall be limited to 0.1m/s for sewers of
diameter less than 200 mm, 0.15 m/s for sewers of 200 mm diameter up to 315 mm
diameter, and 0.20 m/s for sewers exceeding 315 mm in diameter. The camera shall
be stopped whenever defects are being noted or photographed.

11.7.4.3 Linear Measurement

The CCTV monitor display shall incorporate an automati¬cally updated record, in

meters and tenths of a meter, of the linear measurement of the camera position from
the cable calibration point.

The Contractor shall use a suitable metering device, which enables the cable length
to be accurately measured, with a tolerance of ± 1% or 0.3m, whichever is greater.
The Contractor shall demonstrate that this tolerance is being complied with using one
or both of the following methods:

i. - use of a cable calibration device, or

ii. - use of a tape measurement of the surface between manholes.

If the Contractor fails to meet the standard of ac¬curacy, the Engineer shall instruct
the Contractor to provide a new metering device and may, at his discre¬tion, instruct
in writing, the Contractor to resurvey those lengths of sewer first inspected with the
original metering device.

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11.7.4.4 Data Display, Video Recording and Start of Survey

At the start of each sewer length being surveyed, the length of sewer from zero
chainage up to the cable calibration point shall be recorded and reported in or¬der to
obtain a full record of the sewer length.

The meter reading entered on to the data display at the cable calibration point must
allow for the distance from the start of the survey to the cable calibration point such
that the meterage at the start of the survey is zero. In the case of a survey through a
manhole where a new header sheet is required, the meterage shall be set at zero
with the camera focused on the outgoing pipe entrance.

The camera operator shall ensure that the metreage counter starts to register
immediately the camera moves.

At the start of each manhole length, a data generator shall electronically generate
and clearly display on the viewing monitor and video recording a record of data in
alpha-numeric form containing the following minimum in¬formation:

Automatic update of the camera's metreage position in the sewer line from adjusted
zero,

i. Sewer dimensions,

ii. Sewer use,

iii. Manhole reference numbers,

iv. Date of survey,

v. Road name and planning area number,

vi. Direction of survey, and

vii. Time of start of survey.

The size and position of the data display shall be such as not to interfere with the
main subject of the picture.

Once the survey of the manhole length is under way, the following minimum data
shall be continuously displayed:

i. Automatic update of the cameras metreage position in the sewer line from
adjusted zero,

ii. Sewer dimensions,

iii. Manhole reference number, and

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iv. Direction of survey.

Correct adjustment of the recording apparatus and monitor shall be demonstrated by

use of the test tape or other device approved by the Engineer. Satisfactory
performance of the camera shall then be demonstrated by the recording of the
appropriate test device at the commencement of each day for a minimum period of 30
seconds.

The test device(s) shall be provided on site at all times to enable practical
demonstration of compliance with the requirements of this section.

All video cassette tapes shall be supplied by the Con¬tractor and shall be best quality
high grade (HG) new and unused prior to the recording and shall be of a Video Home
Systems (VHS) format.

11.7.5 Survey Data Reporting

The Contractor shall record and present the survey data in a format acceptable to the
Engineer. The report should generally be in accordance with the format presented in
the WAA/WRC "Manual of Sewer Condition Classification" 2nd Edition, published
1988.

The Contractor shall supply the various numbers of copies and types of report for
each item listed, within the time period stated in the schedule for each section of
sewer.

Reports submitted by the Contractor shall be prepared by a qualified, trained and

certified Operator. The Operator shall be a signatory to each report.

11.7.6 Drawings

One clean set of drawings showing manhole reference numbers which coincide with
the reporting format and tapes, shall be returned to the Engineer at the comple¬tion
of each section of the survey and shall be clearly annotated to show any significant
errors noted in the course of the survey. Such errors shall be brought to the attention
of the Engineer during the survey.

11.7.7 Metric Measurement

All dimensions shall be metric. For the purpose of metrication, inch sizes shall be
converted on the basis of 1 inch = 25.4 mm. Measurement shall be on nominal
diameter dimensions quoted to the nearest mm.

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11.7.8 Photographs

The Contractor shall provide colour photographs. The photographs shall be durable
and shall be approximately 89 mm X 125 mm. Photographs should be high resolution
and computer generated by the CCTV system and printed on photographic quality
paper.

Photographs shall be taken of the internal condition of the sewers at the following
locations:

i. All defective junctions and connections,

ii. At defects including cracks, fractures, broken pipes, deformations, collapsed

pipes and severe joint displacement,

iii. For continuous defects, at the beginning and end of the defect,

iv. Wherever else the Engineer may direct.

Where photographs are not otherwise required, general condition photographs shall
be taken of each manhole length.

The photographs must clearly and accurately show what is displayed on the monitor,
which shall be in proper adjustment.

Photographs must be clearly identified in relation to the location, survey direction,

metreage, photograph number and date when the photograph was taken. The
annotation shall be clearly visible and in contrast to its background, shall have a
figure size no greater than 5 mm and shall be type printed. The annotation shall be so
positioned so as not to interfere with the subject of the photograph.

The photographs shall be supplied in suitable A4 sized plastic holders and bound in
ring binders or lever arch files. The photographs shall be presented in chronologi¬cal
order and each file shall contain a contents page providing clear cross-referencing to
the report.

11.7.9 Equipment Standards

11.7.9.1 Picture Quality

The Contractor will provide a colour CCTV system.

The electronic systems, television camera and monitor shall be of such quality as to
enable the following to be achieved:

Shades of Grey. The grey scale shall show equal changes in brightness ranging from
black to white with a minimum of five clearly recognizable stages.

Colour. With the monitor control adjusted for correct saturation, the six colours plus
black and white shall be clearly resolved with the primary and complementary colours

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in order of decreasing luminance. The grey scale shall appear in contrasting shades
of grey with no tint.

Linearity. The background grid shall show squares of equal size, without convergence
or divergence over the whole of the picture. The centre circle should appear round
and have the correct height to width relationships within a tolerance of ± 5 percent.

Resolution. The live picture must be clearly visible with no interference and must be
capable of registering a minimum number of TV lines per picture height lines. In the
case of a tube camera, 350 lines, and in the case of a CCD type camera, 250 lines.

Colour constancy. To ensure the camera shall provide similar results when used with
its own illumination source, the lighting shall be fixed in intensity prior to commencing
the Survey. In order to ensure colour constancy, generally no variation in illumination
shall take place during the Survey.

The Contractor shall note that the Engineer may periodically check both the live and
video picture colour consistency against the colour bar. Any differences will
necessitate re-survey of these new length affected at the Contractor's expense.

11.7.9.2 Video Playback

Video playback shall be capable of a resolution of a minimum of 250 lines recorded at

standard VHS speed.

11.7.9.3 Focus, Iris and Illumination Adjustment

The camera shall have pan and tilt facilities with zoom; capable of 360° rotation. The
adjustment of focus and iris shall allow optimum picture quality to be achieved and be
remotely operated. The adjustment of focus and iris shall be suitable for conducting a
360° rotational joint survey for a minimum pipe diameter of 150 mm. The range shall
extend to infinity. The distance along the sewer in focus from the initial point of
observation shall be a minimum of twice the vertical height of the sewer.

The illumination shall be such as to allow an even distribution of the light around the
sewer perimeter without loss of contrast, flare out of picture or shadowing.

11.7.9.4 Equipment Testing

All equipment used shall be factory calibrated and conduct a self-test on start-up. The
self-test should confirm all aspects of picture quality and general operation. In the
event of calibration discrepancies, the Contractor shall resurvey all affected lines at
his own expense.

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11.7.10 Quality Control

11.7.10.1 Contractor's Quality Control Procedure

The Contractor shall operate a quality control system, to be approved by the

Engineer, which will effectively gauge the accuracy and consistency of the survey
report produced by the operator from the monitor picture.

The system shall be such that the accuracy of reporting shall be a function
particularly of:

i. the number of faults not recorded (omissions),

ii. the correctness of the coding and classification of each fault recorded.

The Engineer shall be entitled to audit periodically the control system and be present
when assessments are being computed.

When requested by the Engineer in writing the Contractor shall forward to the
Engineer sufficient details and information for this audit assessment.

If any report fails to achieve the specified percentages for a particular sewer length,
the Engineer shall require the Contractor to re-code and re-submit the report. If the
accuracy check fails, the Contractor shall repeat the full quality control check on 10
surveys, 5 surveys either side of the survey which has failed. If any further failures
are found to be outside the tolerances laid down in clause 11.7.10.5 within these
additional checks, the process shall be repeated until the acceptable standard has
been reached. Any reports that have failed shall be re-coded by another Water
Training qualified surveyor and submitted to the Engineer to replace those in his
possession.

11.7.10.2 Random Selection

Quality selection shall be achieved by using two parameters:

i. Population: the anticipated number of surveys carried out by one surveyor over a
period of time.

ii. Sample size: the number of surveys required to be checked to satisfy the quality
control validity.

The sample surveys for quality control shall be selected by the use of computer
generated random numbers (ERNI) or other such equivalent method and shall be 5%
of the total population. Each surveyor shall have a different set of random numbers,
which are sorted into chronologi¬cal order, and are renewed once the population size
has been reached. The random numbers shall not be disclosed to the surveyor until
they have been used up.

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11.7.10.3 Survey Extraction

On site the surveyor shall log the information on the surveys and the "in-office" staff
shall then count through the surveys that have taken place and copy those reports
that coincide with the random numbers.

A copy of the relevant section of video tape shall also be made.

Information on the new tape and its contents shall be entered on a survey selection
log.

11.7.10.4 Checking

Header information - All header information shall be checked to ensure that left and
right justified entries are correctly entered, alpha or numeric symbols are correctly
used and all compulsory boxes filled in. The percentages of accurate entries shall be
ascertained and any that fall below the value stated in clause 11.7.10.5 shall be
rejected. All decimal percentage points shall be rounded down to the nearest whole
number.

Detail information - Each error/omission shall be treated on an equal basis whether or

not it is a minor or major error or omission. During the checking each error/omission
shall be highlighted on the report from which the following totals shall be calculated
for each survey report:

i. the number of actual entries that should have been made.

ii. the number of actual errors/omissions made.

These totals shall be entered on the right of the survey report being checked.
Individual column totals shall also be calculated and entered on to the survey
accuracy log.

The accuracy of each survey shall be arrived at by taking the number of actual
errors/omissions away from the number of actual entries that should have been made
and dividing the result by the number of actual entries that should have been made
and multiplying by 100 to create a percentage.

Note:

The Contractor shall have the option to employ quality control methods other than
those outlined in clauses 11.7.10.2 through 11.7.10.4 of this specification with the
approval of the Engineer.

11.7.10.5 Accuracy for Quality Control

The minimum level of accuracy to be obtained under the quality control procedure
shall be as follows:-

Standard for this Contract

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i. Header accuracy 95%

ii. Detail accuracy 85%

iii. lowest acceptable tolerance 75%

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 12

MANHOLE RENOVATION & ABANDONMENT AND

PUMP STATION AND RISING MAIN ABANDONMENT

DM/DNID Section 12 Manhole Renovation & Abandonment and Rev 00 June

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 12
MANHOLE RENOVATION & ABANDONMENT AND
PUMP STATION AND RISING MAIN ABANDONMENT

CONTENTS
12 MANHOLE RENOVATION & ABANDONMENT AND PUMP STATION AND
RISING MAIN ABANDONMENT........................................................................................ 1
12.1 GENERAL...................................................................................................................... 1
12.1.1 Flow Control .......................................................................................................... 1
12.1.2 Maintaining Clean Conditions ............................................................................... 1
12.1.3 Safety .................................................................................................................... 2

12.2 MANHOLE RENOVATION ............................................................................................ 2

12.2.1 General ................................................................................................................. 2
12.2.2 Cleaning of Manholes ........................................................................................... 3
12.2.3 Inspection of Manholes ......................................................................................... 3
12.2.4 Manhole Inspection Report ................................................................................... 5
12.2.5 Manhole Renovation ............................................................................................. 5
12.2.6 Covers and Frames .............................................................................................. 5
12.2.7 Corbelling .............................................................................................................. 7
12.2.8 Concrete Access Shaft, Top Slab and Barrel ....................................................... 7

12.3 MANHOLE ABANDONMENT ..................................................................................... 10

12.3.1 General ............................................................................................................... 10
12.3.2 Manhole Abandonment ....................................................................................... 10

12.4 PUMPING STATION AND RISING MAIN ABANDONMENT ...................................... 11

12.4.1 General ............................................................................................................... 11
12.4.2 Pumping Station and Rising Main Abandonment ............................................... 11

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12 MANHOLE RENOVATION & ABANDONMENT AND PUMP STATION AND RISING

MAIN ABANDONMENT

12.1 GENERAL

12.1.1 Flow Control

The Contractor shall use flow control methods and procedures as required to ensure
the safety of personnel and to facilitate completion of the work. Control measures
shall include plugging or blocking of the sewage flow or bypass pumping where
appropriate. The Contractor shall provide, operate and maintain all equipment
needed to properly control flows during the work including standby equipment in case
of plant failure.

Where the flow is to be blocked or plugged temporarily, the equipment shall remain in
place until the work has been completed and inspected. It is to be removed in such a
manner that permits sewage flow to gradually return to normal without surge,
surcharging or causing other disturbances downstream.

The Contractor shall provide, operate and maintain a bypass system to conduct
sewer flows around the work area when flow cannot be controlled by blocking or
plugging or when it is necessary to maintain system sewer flow around the work area.

The bypass system is to be of sufficient capacity to handle existing normal sewers

flows plus any additional flow which may occur during a rain event should the work
take place during the rainy season.

Flow control and bypassing methods and procedures must result in minimum
inconvenience and disturbances to the public, and prevent damage to public and
private property due to flooding, surge or excessive surcharging.

12.1.2 Maintaining Clean Conditions

The Contractor shall maintain clean conditions in and around the work area at all
times. All material removed from the manholes and pump stations shall be taken
from the site immediately and disposed of in a safe and approved manner. Removed
material and debris shall not be stored at the work area. The manner and location of
disposal of material shall be approved by the Engineer and Employer prior to the
commencement of work.

Construction material and equipment shall be brought to the work area only as
needed and shall be stored on site in a safe and proper manner. The Contractors
equipment and material at the work site shall result in minimum inconvenience and
disturbance to the public.

During the performance of the work, the Contractor shall ensure that no removed
material or debris, nor any construction material or equipment is permitted to enter
the sewerage system. The Contractor shall provide a suitable screening and other

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means of trapping and blocking as required in the downstream manhole to prevent

material from passing downstream.

The screened, trapped or blocked material shall be promptly removed from the
manhole by suitable means, placed in containers, removed from the site and
disposed of in an approved manner.

12.1.3 Safety

The Contractor is responsible for the safety of all personnel as well as for the safety
of the public during the performance of the work and is responsible for maintaining
safe conditions in and around the work area. This is specified in more detail in
Section 10 under “Safety Procedures”.

The Contractor shall provide and agree with the Engineer a written statement
detailing safe systems of work and shall provide and maintain on site suitable and
sufficient safety equipment and the necessary personnel trained in its use, for the
safety and protection of employees, the general public and systems and property of
Dubai Municipality.

12.2 MANHOLE RENOVATION

12.2.1 General

The extent of renovation works shall be as indicated on the drawings and as

determined by the Engineer during the Contract Period from the manhole condition
survey.

The Contractor shall provide all labour, materials and equipment and perform the
works necessary to renovate existing manhole as shown on the drawings or in the
specification or as directed by the Engineer.

A work method description and a proposed programme of manhole renovation works

shall be submitted to the Engineer for approval by the Contractor not less than 14
days prior to the commencement of renovation works.

The manhole condition survey shall be preceded by manhole cleaning which should
be co-ordinated with the sewer cleaning works to be conducted prior to the CCTV
surveys as specified in Section 11.7.

The manufacturer’s instructions on application and safety procedures for all

equipment and materials shall be strictly followed, and where it is deemed necessary
by the Engineer the whole or any part of the application shall be carried out or
supervised by specialists.

The Contractor shall provide the Employer with a written guarantee for the materials
and performance of the manhole renovation works for a minimum period of ten years
commencing on the date of completion of renovation works.

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All manhole renovation works shall be carried out by in-situ lamination methods
unless otherwise instructed.

To minimize disruption to vehicular traffic no manhole cover slabs shall be removed

to undertake the work unless such cover slab is determined to be structurally
unsound by the Engineer.

The Contractor shall keep accurate records of the location and nature of works
carried out to each manhole.

12.2.2 Cleaning of Manholes

Prior to commencing the detailed inspection of any manhole, the manhole shall be
visually inspected for evidence of any accumulations of sand, grease or debris which
may impede the progress or thoroughness of the detailed inspection.

Any accumulations of sand, grease or other debris shall be cleaned from all surfaces
of the manhole prior to commencing the detailed inspection. Manhole walls benching,
corbelling and roof slab shall be cleaned by means of water jetting. Where absolutely
necessary steam may be used to remove obstinate grease and other deposits where
the use of steam is permitted, adequate precautions to protect the operative and
general public from air borne pollution shall be observed. In general, the use of such
methods shall be kept to a minimum. Where directed, additives for cleaning and
disinfecting shall be used.

No sand, grease and other debris in the manhole shall be allowed into the
downstream portions of the sewerage system and shall be removed immediately from
the site. The removed material shall be disposed of in a safe manner and as
approved by the Engineer.

12.2.3 Inspection of Manholes

The Contractor shall prepare a manhole inspection program and submit the proposed
program to the Engineer for approval prior to commencing work. The submittal shall
indicate the methods and procedures to be used to evaluate the condition of the
manholes, equipment to be used, the reporting forms to be used to record the results
of the inspection, and the schedule of work. The work schedule must be coordinated
with the schedule of work for the CCTV surveys.

At a minimum, the Contractor shall evaluate the manhole condition against the
following parameters for each manhole:

1) The type and condition of the existing manhole cover and frame. The cover and
frame should conform to the DM standard type and be free from corrosion and
damage. The cover shall also be checked as to its proper seating in the frame so as
to prevent rocking under traffic and to its level relative to the surrounding surface
when in road or footpath.

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2) The presence of and condition of the GRP sealing plate.

3) The condition of the brick corbelling courses under the manhole frame. The
bricks shall be checked for evidence of damage from corrosion and should be
structurally sound. The mortar should be in good condition and the bricks should be
properly seated.

4) The condition of the interior face of the concrete access shaft, barrel and roof
slab. The concrete shall be inspected for evidence of corrosion, pitting, spalling and
loss of material. Exposed reinforcing steel in the top of slab should be noted. Any
evidence of leakage, as indicated either by an active leak or by staining on the interior
face of the concrete, shall be noted.

5) The structural soundness of the concrete access shaft, manhole barrel walls and
roof slab. The structural soundness shall be tested by non-destructive means from
inside the manhole. The testing methods shall be as approved by the Engineer but
shall include :-

Core (100mm dia) strength, BS 1881: P. 1 core per every 10 sq. meter (If the core
120 strength is less than 1.12 times the
required compressive strength additional
cores will be taken).

Water absorption of concrete BS 1881: P. 1 test per every 10 sq. meters.

122

Sulphate content of concrete, BS 1881: - do -

P.124

Cement content in concrete, BS 1881: 1 test per every 10 sq. meters

P.124

Chloride content of concrete, BS 1881: - do -

P.124

Alkali content in concrete, BS 1881: - do -

P.124

Determination of concrete cover depth

Determination of reduction in steel cross

sectional area

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6) The material and condition of the existing liner where present in the shaft and
barrel of the manhole.

7) The type and condition of any fittings inside the manhole including manhole
ladders, manhole steps or rungs, flap valves, safety chains or any other
appurtenance. The report shall note the type of fittings, their number, material of
construction, their location in the manhole, their condition and the manner of their
installation in the manhole.

8) The condition of the benching. The benching shall be inspected for evidence of
corrosion, pitting and loss of material as well as any physical damage. The invert
shall be checked for uniformity and for the smooth transition form the upstream to
downstream pipe and from any branch into the mainline.

9) The pipe entrances and exists to the manhole shall be inspected for damage to
both the manhole wall and to the pipe material.

12.2.4 Manhole Inspection Report

The Contractor shall submit the results of the manhole inspections to the Engineer for
review. The report shall include notes on the visual inspection of the manhole
parameters listed in preceding Clause 12.2.3 “Inspection of Manholes” and any
drawings or sketches necessary to adequately convey the results of the inspection to
the Engineer. The report text shall be clearly legible and typewritten in a format
previously agreed upon with the Engineer.

An inspection report shall be submitted for each manhole as work progresses within
48 hours of completion of the inspection on that manhole or as otherwise agreed
upon with the Engineer.

The Engineer will review the manhole inspection reports and determine the action to
be taken for each manhole; the actions to be recommended include renovation of the
manhole, either wholly or in part, complete replacement of the manhole or no action.

12.2.5 Manhole Renovation

The Contractor shall renovate existing manholes as shown on the contract drawings
and where directed by the Engineer. The renovation work must be scheduled and
coordinated with the renovation or rehabilitation of the existing sewer pipeline so as to
avoid conflicts between work crews, facilitate rapid completion of the work and to limit
the disturbance to the area.

12.2.6 Covers and Frames

Where the manhole cover and frame are found not to conform to the DM standard
type (refer to Clause 4.10 headed “DM Standards for Covers and Gratings”), or if
either the existing cover or the frame are found to be corroded or otherwise damaged,
the Engineer will direct the Contractor to remove the existing cover and frame, which

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shall be taken from the site and disposed of as directed by the Engineer. The
Contractor shall immediately install a new cover and frame conforming to the DM
standards.

Manholes covers and frames which are in the opinion of the Engineer in serviceable
condition, but are not in accordance with current Dubai Municipality requirements,
shall be removed and transported to the Dubai Municipality Drainage Section store.
New covers and frame complying with DM standards shall be installed by the
Contractor.

Where in the opinion of the Engineer, the existing manhole cover and frame may be
retained and of the DM Standard type, then refurbishment of the cover and frame
shall comprise the following :-

1) Removal of the cover followed by cleaning and sand blasting to remove all
grease, rust and scale.

2) Painting of the cover in accordance with the requirements of Clause 4.10 “DM
Standards for Covers and Gratings” appropriate for sewerage environment.

3) Where in the opinion of the Engineer the frame can be removed, items 1. and 2,
shall also apply to the frame.

4) Where the frame is to be left in place, all exposed parts shall be thoroughly
cleaned to remove all grease, rust and scale and then painted in accordance with the
requirements of clause 4.10 “DM Standards for Covers and Gratings” appropriate for
sewerage environment.

5) If there is an existing GRP sealing plate and this is in a damaged condition the
Contractor shall provide and install a new and identical GRP sealing plate to replace
the damaged unit and to suit the cover and frame in which it is to be installed.

6) If there is no existing GRP sealing plate, the Contractor shall provide and install
a new GRP sealing plate to suit the cover and frame in which it is to be installed. The
Contractor shall submit detailed drawings of each type of GRP sealing plate to
demonstrate how it will fit each type of existing cover and frame.

The new or rehabilitated manhole covers and frames shall be set with the tops
conforming to the finished grade of pavement or ground surface unless otherwise
indicated, specified or directed by the Engineer. The manhole frame shall be set
concentric with the top of the manhole access shaft and cantered over the opening.
The frame shall be set in specified mortar all around and on top of the bottom frame
flange. The mortar shall be smoothly finished and provided with a sloping, rounded
surface all as shown in the drawings.

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12.2.7 Corbelling

Depending on the extent of the damage, if any, to the brick or block corbelling, the
Engineer may direct the Contractor to replace individual bricks or block work, to point
up deteriorated or missing mortar or to replace the entire brick or block corbelling.

Where necessary due to differences between manhole cover and surrounding

surfaces the Engineer may direct the Contractor to replace the entire brick or block
corbelling.

12.2.8 Concrete Access Shaft, Top Slab and Barrel

a) Leak Sealing

Any visible leaks or areas showing evidence of leakage shall be sealed as directed by
the Engineer.

The Contractor shall carefully drill a hole from the interior of the manhole through the
thickness of the wall at each leakage point. Suitable approved non-shrink grout or
sealing material shall be injected through the hole into the surrounding soil to form a
permanent seal from outside of the leaking area. The Contractor shall select and use
suitable equipment to provide an effective watertight seal and ensure that the
grouting pressures do not damage the manhole structures.

When the injection of the sealing grout is complete, the equipment shall be removed
and any sealing material cleaned from the inside surfaces of the hole in the manhole
wall. After the leak sealing operations are complete and the sealing grout has
achieved its set, the manhole shall be inspected in the presence of the Engineer. If
the leak sealing operations are successful and to the satisfaction of the Engineer, the
hole shall then be filled with an approved sewage resistant epoxy mortar.

b) In-Situ Lining

The Contractor shall form an approved in-situ laminated GRP liner to cover the
internal surfaces of the access shaft if applicable, the manhole top slab, the
underside of the roof slab and the barrel walls. The liner shall be by hand application
of an approved resin and glass fibre reinforcing mix onto the prepared surfaces. All
GRP linings shall be in accordance with Section 7.1.6 “In-Situ Laminations”.

The Contractor shall engage personnel with proven expertise in the field of
application of the lining material onto existing surfaces and shall utilize equipment
appropriate to the work and for the conditions under which the work shall be
performed.

All manholes shall be adequately ventilated or otherwise made safe to work without
breathing equipment.

Prior to forming the liner, the interior surfaces shall be thoroughly cleaned as per
Clause 12.2 and all interior appurtenances removed. The cleaned surfaces shall then
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be scabbled using a pneumatic needle hammer or similar to prepare the surfaces for
bonding with the liner material and to ensure that any remaining unsound material is
removed.

Any voids left after the removal of interior appurtenances or from the scabbling
operation shall be filled with an approved epoxy mortar. The final surface of the
internal walls shall be made uniform and to conform to the original contour and levels.

c) Preformed Liner

Where cover slab replacement is necessitated by structural deterioration of the

member or for renovation of the manhole barrel, the Contractor shall install an
approved preformed GRP liner to cover the internal surfaces of the barrel walls. (All
GRP linings shall be in accordance with Section 7.1.5).The diameter of the liner for
the barrel walls shall be 100-150mm less than the existing wall. The liner shall be
formed with spacers to maintain a constant annulus between the liner and the
concrete wall.

Where cover slab replacement involves removal of the access shaft construction of
any replacement shaft shall incorporate a preformed liner with concrete surround, all
as indicated on the drawings.

The preformed liner for the cover slab shall be as shown on the drawings or as
directed by the Engineer.

All manholes shall be ventilated or otherwise made safe to work without breathing
equipment.

Prior to installing the liner, the interior surfaces shall be thoroughly cleaned as per
Clause 12.2 and all interior appurtenances removed. The cleaned surfaces shall then
be scrabbled using a pneumatic needle hammer or similar to prepare the surfaces for
bonding with the liner material and to ensure that any remaining unsound material is
removed.

Any voids left after the removal of interior appurtenances or from the scrabbling
operation shall be filled with an approved epoxy mortar.

A rebate shall be prepared in the benching to receive the GRP liner. The rebate shall
be prepared along the perimeter of the manhole where the benching meets the
manhole wall. The rebate shall measure 100mm deep by 100mm wide at the top and
90mm wide at the bottom.

After insertion of the liner, the rebate remaining between the liner and the existing
wall face shall initially be sealed with grout and allowed to set. In addition, the rebate
in the benching shall be filled with cement mortar.

After sealing the base of the liner the remaining annulus between the liner and the
existing wall face shall be filled with approved non-shrink grout, care being taken not

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to deform or disturb the liner due to excessive or uneven pressures. Upon completion
of the grouting the rebate shall be filled with cement mortar and the surface of the
benching shall be repaired .

After the benching has been repaired a 25mm wide and 35mm deep rebate shall be
formed along at the perimeter between the liner and the benching, as detailed in the
drawings for new manholes.

The joint between the wall lining and the cover slab lining shall be sealed effectively
by an approved method.

d) Benching and Channel

The existing benching and channel are to be removed to a sufficient depth to conform
to the new pipe size with an allowance for a 10mm thick epoxy mortar or 7mm GRP
laminate liner. Any material below the required level that is unsound shall also be
removed until sound material is reached. The resulting depression shall be brought to
the proper level and contour using an approved epoxy mortar mix. The benching and
channel surfaces shall be thoroughly cleaned and scrabbled using a pneumatic
needle hammer or similar.

After the benching and channel have been brought to the proper level and contour
and the liner has been installed, an epoxy mortar or GRP laminate liner as specified
in Clause 7.1.7 and 7.1.5 shall be applied to all surfaces of the benching and
channel.

Where epoxy mortar is used a rebate shall be prepared in the benching as specified
to form a satisfactory joint to the internal lining. The material removed from the
benching and channel for resurfacing and from the benching for preparation of the
rebate shall be immediately removed from the manhole and disposed of in a safe and
approved manner and location. Under no circumstances shall debris be allowed into
the downstream sections of the sewer.

The rebate shall be tightly packed with approved sealant which shall be pouring
grade polysulphide suitable for cold application. It shall comply with the requirements
of BS 4254 (amended) and/or USFS TT-S-227 or DIN 18550:1973.

Prior to application of the sealant the rebate shall be made clean, dry and free from
dirt, dust and loose material. The sealant shall be applied and finished strictly as per
the manufacturer’s instructions.

Where in-situ GRP lamination is used, a 50 x 50 mm fillet shall be formed using vinyl
ester paste along the perimeter of the benching at the wall lining. The lamination to
the benching shall be extended to form a 100mm wide overlap to the wall lining
above the chamfer.

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Any holes required in the liner for pipework shall be carefully cut to the outside
diameter of the pipe. A 25mm x 25mm rebate shall be formed in the concrete around
the pipe and this shall be sealed with an approved sealant.

The sealant shall be durable, resistant to microbiological attack, contact with sewage
and sewage gases, weathering and immersion. The rebate shall be primed with
appropriate primer prior to application of the sealant. The sealant shall be applied
strictly in accordance with the manufacturer’s instructions.

12.3 MANHOLE ABANDONMENT

12.3.1 General

The Contractor shall provide the labour, materials and equipment and perform the
work necessary to abandon existing manholes as indicated on the Contract Drawings
and as specified herein. The abandonment work shall be scheduled and co-ordinated
with the renovation of existing sewers and construction of new sewers so as to avoid
conflicts between works crews, facilitate a rapid completion of the work and to limit
the disturbance to the area. Manhole abandonment may commence only after
pipeline abandonment work has been completed at any manhole.

12.3.2 Manhole Abandonment

Covers, frames, all brick or block corbelling together with concrete haunching, shall
be removed from the manholes to be abandoned. All brick and block corbelling and
concrete debris shall be removed from the site and disposed of in a manner approved
by the Engineer.

Where the manhole covers and frames are found not to conform to the DM Standard
type (refer to Clause 4.10), or if either the existing covers or frames are found to be
corroded or otherwise damaged, the Engineer will direct the Contractor to remove the
existing covers and frames from the site and dispose of in an approved manner.

Where the existing manhole covers and frames are found to be in good condition, of
the DM Standard type and are approved by the Engineer, the covers and frames shall
be rehabilitated in accordance with Clause 12.2.6 and delivered to DM stores.

After removal of the cover, frame and corbelling and any undesirable material from
within the manhole, the manhole shaft/barrel walls shall be broken-out to a depth of
1.5m below finished ground level. All undesirable material and concrete rubble shall
be removed or disposed of in a manner approved by the Engineer. After approval by
the Engineer, the Contractor shall fill the entire remaining volume of the manhole
concrete barrel and access shaft, and the excavated area with an approved well
graded natural sand or gravel as specified for Structural Filling in Section 2. Structural
filling is required within road corridors and/or wherever a structure is to be supported
on the fill and where settlement is required to be minimal.

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Where the abandonment of manholes involves the disruption of existing road

surfaces, pavement or tiled areas the affected surfaces shall be reinstated as
specified in Appendix 1 and Appendix 4 of the Specification.

12.4 PUMPING STATION AND RISING MAIN ABANDONMENT

12.4.1 General

The Contractor shall provide all labour, materials and equipment and perform the
work necessary to abandon existing pumping stations as indicated on the Contract
Drawings and as specified herein. The abandonment work shall be scheduled and
co-ordinated with the renovation of existing sewers and construction of new sewers
so as to avoid conflicts between work crews, facilitate a rapid completion of the work
and to minimize disturbances to the area.

Where existing pumping stations are to be demolished, the Contractor shall give
Dubai Municipality Sanitary Sewers Maintenance Team a minimum of two weeks
notice of the intent to commence demolition in order that the Municipality can arrange
for removal of all mechanical and electrical equipment by their personnel and
establish isolation of the power supply to ensure the whole area is safe.

Pumping station abandonment may commence only after pipeline abandonment work
has been completed in the pumping stations catchment area.

12.4.2 Pumping Station and Rising Main Abandonment

The work shall include, but not be limited to, the following:

i. Demolition of kiosk, plinth, wet wall and valve chamber top slab and walls to a
depth of at least 1.5 meters.

ii. Flushing and grouting of rising main

iii. Filling of wet well, valve chamber and excavated area, and

iv. Reinstatement, where necessary.

Access hatches, manhole covers and frames shall be removed from the pumping
station structures to be abandoned. Where the hatches, covers and frames are found
not to conform to the DM Standard type (refer to Clause 4.10), or if either the existing
covers or frames are found to be corroded or otherwise damaged, the Engineer will
direct the Contractor to remove the existing covers and frames from the site and
dispose of in an approved manner.

Where the existing access hatches, covers and frames are found to be in an
acceptable condition, of the DM standard type and are approved by the Engineer, the
covers and frames shall be rehabilitated in accordance with Clause 12.2.6 and
delivered to DM stores.

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The kiosk plinth, top slab and walls of the valve chamber and wet well shall be
removed to a minimum depth of 1.5 meters below ground surface. All concrete and
other material shall be removed from the site and disposed of in a manner approved
by the Engineer.

The Contractor shall flush the rising main with clean water. All flushing water shall be
collected at the discharge end of the rising main to be abandoned and disposed of in
a manner approved by the Engineer. If the rising main is within 1.5 meters from the
surface, the pipe shall be removed for a distance of at least 0.5 meters from the
exterior wall of the valve chamber and then to the next pipe joint. After flushing of the
rising main and if required, after removal of any pipe lengths, the rising main shall be
permanently filled with cement grout all as specified in Section 11.6

The Contractor shall prepare the inlet sewer length for abandonment as provided in
Section 11.6. All sewer lengths from the proposed abandoned pumping station to the
first manhole to remain in service are to be abandoned.

The Contractor will inspect and remove any undesirable material from the pumping
station structures. After approval by the Engineer, the Contractor shall fill the entire
volume of the structures and the excavated area with an approved well graded
natural sand or gravel as specified for Structural Fill in Section 2. Structural filling is
required within road corridors and/or wherever a structure is to be supported on the
fill and where settlement is required to be minimal.

Where the abandonment of pumping station involves the disruption of existing road
surfaces, pavement or tiled areas, the affected surfaces shall be reinstated as
specified in Appendix 1 and Appendix 4, of the Specification.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 13

PILES AND PILING

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 General Specifications for Civil Works
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Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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 General Specifications for Civil Works
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SECTION 13
PILES AND PILING

CONTENTS
13 PILES AND PILING............................................................................................................ 1
13.1 SCOPE........................................................................................................................... 1
13.2 GENERAL...................................................................................................................... 1
13.2.1 Related Specifications .......................................................................................... 1
13.2.2 Record of Condition of Existing Structures ........................................................... 2
13.2.3 Record of Existing Services .................................................................................. 2
13.2.4 Specialised Contractors ........................................................................................ 2

13.3 MATERIALS .................................................................................................................. 2

13.3.1 Permanent Casings .............................................................................................. 2
13.3.2 Temporary Casings .............................................................................................. 2
13.3.3 Concrete for Piling ................................................................................................ 3
13.3.4 Reinforcement ...................................................................................................... 3
13.3.5 Execution of Work ................................................................................................. 3
13.3.6 Pile Head Protection / Water Proofing System ..................................................... 4

13.4 DESIGN ......................................................................................................................... 5

13.4.1 Design Criteria ...................................................................................................... 5
13.4.2 Spacing ................................................................................................................. 5
13.4.3 Submittals ............................................................................................................. 6

13.5 WORKMANSHIP ........................................................................................................... 6

13.5.1 Substandard Work ................................................................................................ 6
13.5.2 Obstruction or Changes in Condition .................................................................... 6
13.5.3 Handling ................................................................................................................ 6
13.5.4 Lengthening of Piles ............................................................................................. 7
13.5.5 Pile Location Identification .................................................................................... 7
13.5.6 Setting Out and Tolerances .................................................................................. 7
13.5.7 Piling Records ....................................................................................................... 8

13.6 TESTING OF CONCRETE ............................................................................................ 8

13.7 LOAD TESTING OF PILES ........................................................................................... 8
13.7.1 General ................................................................................................................. 8
13.7.2 Negative Skin Friction ......................................................................................... 10
13.7.3 Preliminary Pile Tests ......................................................................................... 10

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13.7.4 Working Pile Tests .............................................................................................. 11

13.7.5 Test Failure Criteria ............................................................................................ 12
13.7.6 Fluctuating Load Tests ....................................................................................... 12
13.7.7 Completion of a Test ........................................................................................... 12

13.8 PILE INTEGRITY TESTING ........................................................................................ 13

13.9 CALLIPER LOGGING OF PILE BORE ....................................................................... 13
13.10 DYNAMIC PILE TESTING ........................................................................................... 14
13.11 TEST REPORTS.......................................................................................................... 15
13.12 AS-BUILT DRAWINGS ............................................................................................... 16

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13 PILES AND PILING

13.1 SCOPE

a) This Specification deals with the general requirements for the materials, design,
workmanship and testing of bored piles of all types. Generally cast insitu (bored)
piles with temporary casing method will be allowed. The type of equipment
adopted shall be selected with consideration of any noise regulations imposed by
the Local Authorities/ Employer.

b) The Contractor shall visit the site to familiarise with the site conditions and
existing services in locations where the piling works has to be carried out and
accordingly make allowance in the price.

13.2 GENERAL

13.2.1 Related Specifications

a) The piling works are to be carried out in accordance with the Institution of Civil
Engineers Specification for Piling and Embedded Retaining Walls (SPERW,
1996). The piles are to be constructed by bored and cast in place techniques. Pile
tests will be required to confirm the design assumptions made and the load
settlement characteristics of the piles.

b) The Contractor shall perform the works with reference to the following codes of
practice

BS 1377 Methods of Test for Soils for Civil Engineering Purposes.

BS 1881 Methods of Testing Concrete.

BS 5930 Code of Practice for Site Investigations.

BS EN 1997-1 Foundations.

CP 2011 Safety Precautions in the Construction of Large Diameter

Boreholes for Piling and other Purposes.

BS EN 1992-1-1 The Structural Use of Concrete.

BS 5950 Structural Use of Steelwork

BS 8102 Code of Practice for the Protection of Structures against

Water from the Ground

CIRIA R144 Integrity Testing in Piling Practice

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13.2.2 Record of Condition of Existing Structures

a) Prior to commencing work the Contractor shall examine and note all existing
cracks or other damage in adjacent structures and bring them to the attention of
the Engineer. This survey shall be submitted to the engineer in report form prior to
the commencement of the works. The report shall include a record of size and
location of all cracks.

b) These surveys shall be carried out by a qualified structural engineer at the Piling
Contractor's expense.

c) It is the responsibility of the Contractor to ensure that no damage occurs to

existing structures, roads or services for the duration of the piling works.

d) If during execution of the work, damage is, or is likely to be caused to any part of
adjacent buildings including finishes etc. and any equipment etc. within the
building the Contractor shall submit his proposal for avoidance of such damage to
the Engineer.

13.2.3 Record of Existing Services

Prior to commencing work, records of drains, cables, piles and other services shall be
made by the Contractor, to ensure that no piles or piling equipment causes damage
to these services. The Contractor is liable for any damage to services occasioned by
or arising out of his work on site.

13.2.4 Specialised Contractors

The works shall be carried out by a specialised piling contractor, well experienced in
the types of piling being specified, and suitably staffed and equipped to carry out such
work in the United Arab Emirates in accordance with this specification.

13.3 MATERIALS

13.3.1 Permanent Casings

For soils in areas classified as category 5 according to BRE Digest 363, permanent
casings shall be provided. The permanent casing length shall be 2.0m below ground
surface. Should the ground water table be at 2.5m below ground level, casing will be
extended to become 3.0m below finished ground surface. This procedure shall be
applicable for areas not affected by tidal effects. For areas affected by tidal effects,
casings shall project 0.5m below the lowest water level anticipated. Permanent
casings shall be of steel, thickness not less than10 mm External surface to be coated
with 2 coats of coal tar epoxy with an overall thickness no less than 300 micron.

13.3.2 Temporary Casings

a) Temporary casings shall be free from significant distortions. They shall be of

uniform cross-section throughout each continuous length. During concreting they
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shall be free from internal projections, debris and encrusted concrete which might
prevent the proper functioning of the pile, or formation of a monolithic pile shaft
free of defects.

b) For temporary casing, a method statement shall be submitted to the Engineer for
approval.

13.3.3 Concrete for Piling

a) Cement to be used shall be selected according to the recommendations of the

soil Investigation Report.

b) The minimum grade of concrete for all piles shaft be C60.

c) Maximum Free WCR shall be 0.35.

d) The minimum cementicious content shall not be less than 400 kg/m³ and the
maximum specified cement content in any mix shall not exceed 475 kg/m³.
Concrete design mix shall be submitted to the Engineer for approval.

e) Concrete is to be placed by a tremie under water the slump shall be 175mm +/-
25mm (Type C) for each pile. Concreting shall be a continuous operation and no
(cold) joint shall be permitted.

f) Certificates and test cube results for the materials and the concrete shall be
supplied to the Engineer for Approval.

13.3.4 Reinforcement

Reinforcement anchorage lengths shall be considered as tension anchorages. The

reinforcement shall be stored to ensure it is clean and free from debris at all times.

13.3.5 Execution of Work

a) Cast insitu (bored) piles with temporary/permanent steel casing will be permitted
for execution. Casing shall extend to a minimum of one metre below the solid
strata of soil as shown in the soil investigation report. Immediately after drilling,
the reinforcement shall be placed and the pile cast. Tremie pipe shall be used for
concrete casting. The internal diameter of the tremie pipe shall not be less than
150mm and it shall extend to the bottom of the pile prior to commencement of
concreting. A minimum embedment of 3.00 m in the concrete shall be maintained
so as to ensure that no mud or debris enters the pile. Concreting shall continue
until sound uncontaminated concrete is present at ground level. The hopper and
tremie shall be fully charged at all times.

b) During withdrawal of temporary casings a sufficient head of wet concrete shall be

maintained within them to prevent the inflow of ground water or collapse of
unstable soil. Excavation around the piles to assist in the extraction of temporary
lining tubes will not be permitted. The level of the concrete after removal of each
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temporary casing length shall be recorded. Temporary casing shall be removed

by vibration.

c) The Contractor shall not cause any damage to previously cast piles and shall
avoid excessive plant manoeuvres in their vicinity. As soon as a pile is cast it shall
be protected in such a way as to prevent plant moving adjacent to it.

d) As a guide and at the discretion of the Engineer no item of plant or equipment

shall be allowed to pass within 5 pile diameters from the outside face of the pile
until a period of not less than 3 days after completion of concreting has elapsed.

e) The concrete cover to the reinforcement shall be uniform and be a minimum of

75mm; the method used to maintain such cover requires the Engineer's approval.

f) The stability of reinforcement cages shall be achieved by means of helical

binding, the diameter and pitch of which shall be subject to the approval of the
Engineer. The helical binding shall fit closely around the main bars and be bound
to them by approved wire the ends of which shall be turned to the interior of the
pile.

g) Only concrete cover blocks shall be used for all piles. The concrete grade of
cover blocks shall be the same as the concrete grade in the piles.

h) To facilitate the breaking-down of the piles, de-bonding sleeves shall be used to

prevent the bonding of the reinforcing steel and the concrete for all reinforcement
above a level of 50 millimetres above the theoretical pile cut off point in every pile.

i) Unless detailed otherwise reinforcement shall be extended a minimum of 50 times

the maximum bar diameter above the cut-off level shown on the drawings and in
any event shall meet the minimum anchorage requirement for the contractors
design.

j) Where joints in main reinforcement occur they shall be such that the full strength
of the bar is effective across the joint and shall be staggered.

13.3.6 Pile Head Protection / Water Proofing System

The Pile Head Protection / Water Proofing System shall be applied in the following
manner:

(i) Fix a swelling vinyleaster based gasket, stretched until taught and wrapped
around the pile head so the two ends overlap and are then stapled;

(ii) Pour shrinkage compensated, high strength (60 N/mm2), very low
permeability micro concrete (DIN-1048) or cementitious grouting with the
necessary curing as recommended by the manufacturer;

(iii) Fix the water proofing membrane over the blinding concrete and extend it
50mm on pile perimeter (round edge).
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13.4 DESIGN

13.4.1 Design Criteria

The following minimum design criteria a), b), c) and d) shall be met for the tension
pile design;

13.4.1.1 Stability Check - Uplift of Soil Block for Tension Piles

As a minimum the following minimum requirement shall be met:

Working Tension load as specified x Y f < Uplift resisting load mobilized by pile
below pile cut-off level, adjusted by partial safety factors as per Section A.4 in Annex
A of BS-EN /1997-1:2004 (EC 7)*.

*As per BS-EN 1997-1:2004 (EC 7), Section A4., favourable dead weight resisting
uplift shall be multiplied by 0.9. Unfavourable buoyancy forces (within the block mass)
which reduce resistance to uplift shall be multiplied by 1.0.

The value of the factor Yf above shall be applied as set out below for each pile type

13.4.1.2 Stability Check - Single Pile/Soil Skin Friction Failure

As at minimum, the following criteria shall be met;

`Working Tension/Compression Load < Design Ultimate Skin Friction

Capacity divided by a minimum factor of safety of 2.5

13.4.1.3 Corrosion Resistance (0.2 mm Crack Width Limitation)

Tension piles shall be reinforced to ensure maximum crack widths shall be limited to
0.2 mm arising from loads not less than the working tension loads as specified on the
drawings for each pile type. Design calculations shall meet all the requirements of BS
EN 1992-3:2006.

13.4.1.4 Structural Failure of Pile - Ultimate Tensile and Compression Resistance

The piles shall be designed to have an ultimate capacity greater than the specified
working loads (in both tension and compression) multiplied by 1.5 for all pile types.

13.4.2 Spacing

Friction piles shall not be placed closer than 2.5 x diameters centre to centre. With
piles deriving their resistance from end bearing, the spacing centre to centre should
not be less than twice the least width of the pile. For piles having enlarged bases
careful consideration shall be made of interaction effects between the bases.

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13.4.3 Submittals

The contractor shall submit for the Engineer’s approval full details and design
calculations of his proposals for the piled foundations based on the preliminary design
accepted at Tender stage. They will include the following information:

a) The cross-sectional dimensions and length of pile constructed to carry the

specified loadings. Also, as appropriate, the details of the shape and plan of any
under ream.

b) The anticipated proportion of the working load carried in shaft friction and in end-
bearing together with the estimated factors of safety on shaft, base and total
overall.

c) Details of reduction in pile capacity due to group action.

d) The minimum spacing of piles in groups.

e) Reinforcement quantities and method of maintaining specified cover.

f) The properties and application of "slip" compounds, designed to reduce the

effects of negative skin friction where applicable.

g) Confirmation of all codes of practice used.

h) Confirmation of all factors of safety adopted.

Any additional soil investigations considered necessary by the Contractor to enable

him to design the piles in accordance with the Specification shall be carried out at the
Contractor's own expenses.

13.5 WORKMANSHIP

13.5.1 Substandard Work

Any pile which fails to comply with the Specification or the Drawings, in any respect,
shall be repaired, replaced or its load carrying capacity downrated as appropriate. In
extreme cases this may involve the redesign of the pile cap and modification of the
foundations as necessary at the Contractor's own expense.

13.5.2 Obstruction or Changes in Condition

The Contractor shall inform the Engineer immediately when unforeseen underground
obstructions are encountered and shall not resume work until approval to continue
has been obtained. If the nature of the strata should vary significantly from that
indicated in the site investigation report, the Engineer should be notified immediately.

13.5.3 Handling

The Contractor shall take all necessary precautions against damage to piles or
components when manufacturing, unloading, transporting, storing, handling, pitching,
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boring piles and piles damaged or distorted to the extent that their function is
impaired will be rejected.

13.5.4 Lengthening of Piles

When lengthening a cast in place pile, the head shall be cut off square to sound
concrete; all loose particles shall be removed by wire brushing, followed by washing
with water. For lap or splice joints sufficient link bars shall be provided to resist
eccentric forces.

13.5.5 Pile Location Identification

The Contractor shall be responsible for identifying the location of and providing safety
measure for all partly formed or complete piles. In the event of the top of the pile
being below the surroundings ground surface all bars protruding above the level of
finish ground shall be coated with cement slurry and then the remaining void shall be
backfilled with granular material to the ground surface and the location marked by a
brightly coloured peg, or other approved system of identification.

13.5.6 Setting Out and Tolerances

a) The main setting out lines shall be approved by the Engineer before any piling
(excluding test piling) is commenced. These setting out lines shall be marked by
suitable metal plates set in 300mm x 300mm concrete plinths and inscribed with
the exact setting out lines.

b) The proposed location of setting out lines must be marked on Contractor's

drawings and approved by the Engineer before work commences on site.

c) The required accuracy of setting out shall be as +/- 6mm for main setting out lines
and +/- 30mm for centre lines of pile groups.

d) The maximum tolerance from the plan position shown on the drawing at the cut~
level of any vertical pile shall be 75mm or 1/6 of the pile diameter whichever is the
smaller. Vertical piles shall be not more than 1 % out of the true vertical. The
maximum tolerance from the plan position on the drawing at the cut-off level of
any raking pile shall be 150mm or 1/3 of the pile diameter whichever is the
smaller. The axis of raking piles shall not deviate more than from the specified
rake and direction thereof.

e) The maximum pile diameter should be no greater than the specified diameter plus
5%. The minimum pile diameter shall not be less than the specified diameter.

f) An enlarged base mechanically formed shall be not smaller than the dimensions
specified and shall be concentric with the pile shaft to within a tolerance of 10% of
the shaft diameter. The sloping surface of the frustum forming the enlargement
shall make an angle to the horizontal of not less than 55 degrees.

g) The vertical cut~ tolerance for breaking down the piles shall be +/- 15rnm.
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13.5.7 Piling Records

a) From the commencement of work, the Contractor shall record, for each pile
constructed, all data relevant to the pile type. Information to be recorded is
specified in clause 1.11 of the ICE SPERW (1996). The records shall be
maintained continuously and shall be available to the Engineer at all times.

b) The Contractor shall supply one copy of the pile record to the Engineer within 24
hours of the completion of any pile. A further two copies for each pile shall be
supplied within seven days of the completion of the pile.

13.6 TESTING OF CONCRETE

Slump tests shall be taken at a frequency required by the Engineer, but shall be not
less than one test for every three piles. Each set of test cubes taken shall be
supplemented by a slump test on the same batch of concrete

13.7 LOAD TESTING OF PILES

13.7.1 General

a) Testing shall be carried out in accordance with the Institute of Civil Engineers
publication Specification for Piling and Embedded Retaining Walls, referred to as
ICE:5PERW below.

b) Cross-hole sonic testing shall be carried out for each pile which is subject to a
preliminary pile test in addition to those specified below for the working piles.

c) As a minimum, the following testing regime for working piles shall be used for
each pile type specified on the pile layout drawings;

(i) Integrity testing: 100% of piles

(ii) Sonic Coring (Cross-hole sonic testing): 15% of piles

(iii) Dynamic load test on working pile: 5% of piles

(iv) Static load compression test on working pile: 1 % of piles with a minimum of
two tests for each pile

(v) Static load tension test on working pile: 1 % of piles with a minimum of two
tests for each pile

d) Static test loads shall be applied to the pile head by jacking against kentledge,
reaction piles or anchorages. Where kentledge is used the Contractor shall satisfy
the Engineer as to the accuracy of the weight which shall be at least 10% more
than the maximum load to be applied in the case of vertical piles or be such that
the component of the kentledge measured along the axis of a raking pile is at
least 10% more than the maximum axial load to be applied. Where reaction piles
or anchorages are used, the centre to centre spacing between the test pile and
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the reaction piles or anchorages shall not be less than 3 times the diameter of the
test or tension pile or 2000mm whichever is the greater. Should the base of the
anchor piles extend below the test pile the minimum spacing shall be increased to
fives times the pile diameter.

e) Before commencing the piled foundations the Contractor shall construct the
preliminary test piles solely for testing purposes. The Contractor shall provide one
compression test and one tension test for the pile types as stated above and as
indicated on the drawings.

f) Permanent piles should not be used for jacking during testing.

g) The Contractor shall arrange his work programme to accommodate all tests.

h) Before commencing any tests the Contractor shall submit to the Engineer, for his
approval, full details of his proposals including the datum beam arrangements and
the location of reaction piles or kentledge supports.

i) Notwithstanding the Engineer's approval, the Contractor shall be responsible for

the ability of the teat set-up to apply safely the required load and to measure this
load and the resulting settlement 10 accuracies of +/. 2% and +/. 0.05mm
respectively. The Contractor's arrangements shall include details for protecting all
gauges and other testing equipment from weather or other conditions likely to
affect their performance.

j) The load shall be measured by means of a proving ring or other approved system
and also by a pressure gauge included in the hydraulic system. Load cells shall
be used during testing. The Contractor shall satisfy the Engineer that the
measuring devices are calibrated to an accuracy of +/. 2%.

k) The settlement shall be measured by at least three extensometer dial gauges

mounted on an independent rigid datum frame, which shall be supported at points
at least five diameters from either the test pile or the kentledge perimeter where
kentledge is used. The accuracy of the gauges shall be checked against a master
gauge which shall be supplied by the Contractor for use by the Engineer.

l) The master gauge should be certified by an approved laboratory to be accurate to

+/- 0.5%.

m) During the course of a test, level observations shall be taken on the test pile, the
datum frame and kentledge stack, reaction piles or anchorages.

n) The pile test shall be continuous day and night and the Contractor shall provide
technically qualified supervision throughout its duration and shall ensure that the
jacks maintain the correct pressure.

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o) Within 24 hours of the completion of each pile test the Contractor shall submit to
the Engineer copies of the following graphs for the complete test including
recovery and allowing for any movements of the datum beam:

(i) Load -Settlement

(ii) Load -Time

(iii) Settlement -Time

p) When the Engineer considers the results of test on a particular pile unsatisfactory
three further piles will be tested as directed by the Engineer.

q) If satisfactory results cannot be obtained from these further tests the Contractor
shall agree with the Engineer to the modifications which shall be made to the pile
design or to the additional piles which may be required to carry the specified
loads.

13.7.2 Negative Skin Friction

a) When a component of loading due to negative skin friction has been indicated by
the Engineer, the Contractor shall give full consideration of this in relation to test
loading. In evaluating the necessary reactions to the test pile it shall be
considered that at the time of test positive friction occurs and this positive friction
shall be equal in magnitude to the negative skin friction. Thus the test load
applied at any multiple of the structural working load, at or in excess of the
structural working load, shall be further increased by a loading equivalent to twice
the negative skin friction in order to negate the positive friction and simulate the
long term negative skin friction. For loading less than the structural working load,
the additional load applied for negative skin friction effects shall be in proportion
to the fraction of the structural working load under consideration.

b) A relaxation of the above procedure may be allowed by the Engineer on the basis
of preliminary pile tests. The Engineer will then stipulate the revised testing loads.

13.7.3 Preliminary Pile Tests

a) Such tests shall be carried out to verify the design assumptions and to check the
sufficiency of the piling system before any working piles are constructed. The
Contractor shall give the Engineer at least 48 hours notice of the commencement
of construction of any preliminary pile which is to be test loaded.

b) Each preliminary test pile shall be constructed in a manner similar to that to be

used for the construction of the working piles, using similar equipment and
materials. Any variations will only be permitted with the prior approval of the
Engineer.

c) A full record of the strata passed through for preliminary test piles shall be kept.
Preliminary pile tests shall be carried out in two stages as follows:
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(i) Stage 1:

The maximum test load shall comprise the Design Verification Load (DVL) plus 50%
of the Specified Working Load (SWL). The DVL shall be the SWL plus any additional
load resulting from any change in design conditions at the time the test is undertaken.
The proof load test procedure as defined in Clause 10.13.1 of the ICE SPERW shall
be followed and the loads shall initially be applied in increments not exceeding 25%
of the DVL Displacement readings shall be taken every 15 minutes after application
of the load increment until two consecutive readings show that the displacement has
ceased. When the test load reaches the DVL the displacement readings shall
continue until it is established that no further displacement has occurred over a 15
minute period. The DVL shall then be maintained for a further 24 hours, with
displacement readings taken every 2 hours.

(ii) Stage 2:

The extended proof load test procedure as defined in Clause 10.13.2 of the ICE
SPERW shall be then be followed and load shall then be increased in eight equal
increments of 25%SWL up to DVL plus 200% of the SWL, the same procedure being
followed as stipulated for the beginning of the test. The maximum load shall be
maintained for 24 hours or as directed by the Engineer after all displacement has
ceased, and readings shall be taken every 2 hours during this period.

d) The load shall then be reduced in five approximately equal stages to zero load.
The final recovery level reading shall be taken at least 12 hours after the pile is
completely unloaded.

e) The records shall be taken jointly by the Engineer and the Contractor, and the
Contractor shall present the Test Results in accordance with Appendix C.

13.7.4 Working Pile Tests

a) Such tests will be required on a statistical number of working piles selected by the
Engineer as a test ot the uniformity of the ground conditions and of the
workmanship and materials used.

b) The maximum test load shall comprise the Design Verification Load (DVL) plus
50% of the Specified Working Load (SWL). The DVL shall be the SWL plus any
additional load resulting from any change in design conditions at the time the test
is undertaken. The proof load test procedure as defined in Clause 10.13.1 of the
ICE SPERW shall be followed.

c) Where working piles have deep cut-off levels, the Engineer may require
measures to be taken to eliminate shaft friction between the cut-off level and the
ground level; alternatively friction over this length shall be allOlN8d for in the
evaluation of the test results.

d) Requirements of ICE:SPERW Clause 10.13.3 shall be met for tension piles.

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13.7.5 Test Failure Criteria

a) Any pile which fails before the proof load mentioned on the drawings is reached
shall be condemned by the Engineer.

b) A pile will deem to have failed the test if anyone of the following criteria is
satisfied:

(i) The net settlement of the pile at working load, including allowance for
negative skin friction as necessary, exceeds 1% of the pile diameter.

(ii) The total penetration of the pile base reaches 100k of the nominal diameter.

(iii) The slope of the net settlement exceeds 0.25mm per 10KN of test load.

c) If any preliminary or working pile fails the test, the cost of the additional test shall
be borne by the Contractor who shall replace the pile(s) with additional piles at his
own expenses.

13.7.6 Fluctuating Load Tests

The Engineer may require the load on a test pile to be cycled several times between
the working and proof loads. In the event the pile shall be unloaded and reloaded
between those two loads in less than ten minutes except that shock loads shall not be
allowed. Both loads shall be maintained for one hour until settlement (or recovery)
has ceased.

13.7.7 Completion of a Test

a) On completion of a test all equipment and measuring devices shall be dismantled,

checked and either stored so that they are available for use In further tests or
removed from the Site as specified.

b) Kentledge and its supporting structure shall be removed from the test and stored
so that they are available for use in further tests or removed from the Site as
specified.

c) On completion of a preliminary pile test, the pile cap, if formed in concrete, shall
be broken off and the resulting material disposed of off the Site. If the pile cap is
made of steel it shall be cut off and stored so that it is available for use in further
tests or removed from the Site as specified. The pile head shall be made good or
extended to the cut-off level. The reacting piles and ground anchors shall be cut-
off below ground level as indicated by the Engineer, removed from the Site and
the ground made good with approved material as specified.

d) On completion of a test on a working pile, the test pile cap, if in concrete, shall be
stripped and left in a state ready for incorporation in the Permanent Works and
the resulting material disposed of off the Site. If the pile cap is made of steel it

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shall be cut-off and stored so that it is available for use in further tests or removed
from the Site as specified.

e) On completion of a working pile test, temporary piles and ground anchors shall be
removed, cut-off or, if approved, incorporated in the Permanent Works.

13.8 PILE INTEGRITY TESTING

a) Tests shall be carried out on all working piles to determine their integrity. The
Contractor shall state in his tender which method he proposes to use. Before
commencing any tests the Contractor shall submit to the Engineer for his
approval, full details of his proposals together with details of any specialist sub-
contractor he elects to carry out the work.

b) Sonic integrity testing and interpretation is to be carried out in accordance with

Section 9.1 of the Institution of Civil Engineers' Specification for Piling and
Embedded Retaining Walls, CIRIA Report CP28 - The role of integrity testing and
other non-destructive testing in the evaluation of piled foundations and CIRIA
Report 144 - Integrity testing in piling practice.

c) All piles shall be tested by the sonic echo method. The age of the piles shall not
be less than 7 days and not more than 20 days at the time of testing.

d) Sonic logging shall be carried out on 15% of the total number of piles. The
number of ducts placed shall be sufficient for the pile diameter used.

e) Non-destructive integrity testing and cross hole sonic logging shall be carried out
on every preliminary and working test pile constructed, prior to and post
undertaking the load test. Sonic and cross hole sonic logging and interpretation is
to be carried out in accordance with Section 9.1 of the ICE' SPE RW. CIRIA
Report CP28 and CIRIA R144.

f) Within 48 hours of completion of the tests the Contractor shall submit to the
Engineer a full report showing clearly all test results together with their
interpretation.

g) When the test results of one or several piles are not, in the opinion of the
Engineer, satisfactory, the Contractor shall submit proposals for any remedial
work to be agreed by the Engineer.

13.9 CALLIPER LOGGING OF PILE BORE

a) Calliper logging of the entire length shall be carried out at a rate of 1 for every 10
piles constructed per rig and for all preliminary and working test piles. A
mechanical calliper having a minimum of three arms shall be used to carry out
logging in accordance with ASTM. The calliper to be used shall be calibrated not
more than 3 months prior to its use for this project and shall have a resolution not
less than 2mm of the measured bore diameter.

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b) The Contractor shall submit a hard copy of the log to the Engineer within 24 hours
of the measurement having taken place.

c) The bore shall be considered unacceptable if any part of the bore has a diameter
less than the specified diameter of the pile.

13.10 DYNAMIC PILE TESTING

a) The Contractor shall dynamically test all preliminary piles and 5% of the total
number of working piles.

b) The Engineer will consider the dynamic load tests being undertaken on the
preliminary compressive load test piles provided the Contractor can prove that the
test will not have any detrimental effects on the static load test. If the Contractor is
unable to prove this to the satisfaction of the Engineer then additional piles should
be constructed for the dynamic load tests.

c) Should a pile that is to be used for a preliminary static load test be damaged
whilst being dynamically tested then the Contractor shall install an identical
replacement at his own expense.

d) The age of the piles shall not be less than 7 days at the time of testing.

e) The permanent penetration per blow and temporary compression of the pile and
soil system shall be measured independently of the instruments being used to
record the dynamic test data from a fixed reference point unaffected by piling
operations.

f) Piles shall be integrity tested, prior to and post dynamic load testing.

g) The procedure adopted shall be in accordance with the guidance given in ASTM
D4945. Analyses shall be according to the CASE Method and CAPWAP analysis.

h) Stain transducers and accelerometers are to be mounted in pairs and

diametrically opposite to each other on the original pile at a minimum distance of
1.5 times the pile diameter below the top.

i) The pile driving analyzer along with the strain and accelerometer transducers
must have current calibration certificates, copies shall be provided to the Engineer
prior to the dynamic testing commencing.

j) The hammer and other equipment used shall be capable of delivering an impact
force sufficient to mobilize the equivalent specified dynamic test load without
damaging the pile.

k) The Contractor is to demonstrate and provide calculations to prove the hammer

proposed has sufficient weight to mobilize the toe of the pile, the pile having to
move 2.5mm per blow. Either a wave equation analysis based on the GRLWEAP
program or drivability study if it is not possible to prove by calculation. The
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Contractor is to ensure that there is adequate reinforcement so that at least 150%

of the working load can be achieved without exceeding the allowable tensile
stress.

l) The preparation of the pile head shall involve the trimming of the head, cleaning
and building up the pile using materials the same as or giving equal performance
characteristics of the concrete used to form the pile. The impact surface shall be
flat and at right angles to the pile axis.

m) Pile reinforcement is to be as per Contractor's design and as approved by the

Engineer.

n) The interpretation of the tests shall be carried out by competent and experienced
persons to be approved by the Engineer. The Contractor shall give all available
details of the ground conditions, pile dimensions and construction method to the
specialist firm in order to facilitate interpretation of the tests.

o) Initial results shall be provided to the Engineer within 24 hours of completion of

the test. These shall include:

(i) Maximum force applied to the pile head

(ii) Maximum pile head velocity

(iii) Maximum energy imparted to the pile

p) Twelve copies of the full report shall be provided to the Engineer within 7 days of
completion of the testing.

q) Fix the water proofing membrane over blinding concrete and extend it 50mm on
pile perimeter (round edge).

13.11 TEST REPORTS

Reports on Pile testing shall be submitted to the Engineer following completion of all
tests and shall include but not be limited to the following information:

(i) Layout of Piles

(ii) Pile identification, length, diameter, etc.

(iii) soil investigation log;

(iv) test equipment and description

(v) graphs of load and settlement / heave versus load;

(vi) graphs of settlement / heave versus load;

(vii) remarks concerning any unusual occurrences during the testing of the pile;

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(viii) test report on integrity testing of the piles shall include clear sample
diagrams of acceptable signals for comparison purposes as well as graphs
indicating defects or doubts on integrity of the piles.

13.12 AS-BUILT DRAWINGS

As-built drawings showing pile coordinates and the reinforcement details for pile,
design loads, test results shall be prepared and submitted to the Engineer for
approval at least two weeks prior to final inspection.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 14

MICROTUNNELLING AND PIPE JACKING

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 14
MICROTUNNELLING AND PIPE JACKING

CONTENTS
14 MICROTUNNELLING AND PIPE JACKING ..................................................................... 1
14.1 GENERAL...................................................................................................................... 1
14.1.1 Scope .................................................................................................................... 1
14.1.2 Applicable Standards / References ...................................................................... 1
14.1.3 Definitions ............................................................................................................. 3
14.1.4 Submittals ............................................................................................................. 4

14.2 EQUIPMENT and PIPE MATERIALS ......................................................................... 16

14.2.1 Equipment ........................................................................................................... 16
14.2.2 Pipe Materials ..................................................................................................... 19
14.2.3 Joint Packing ...................................................................................................... 26
14.2.4 Joint Seal ............................................................................................................ 26
14.2.5 Dewatering Equipment ....................................................................................... 26

14.3 EXECUTION ................................................................................................................ 27

14.3.1 General ............................................................................................................... 27
14.3.2 Examination ........................................................................................................ 27
14.3.3 Cavity Grouting ................................................................................................... 27
14.3.4 Shafts, Jacking and receiving Pits ...................................................................... 28
14.3.5 Tunnelling / Pipe Installation ............................................................................... 31
14.3.6 Constructions Shift Records ............................................................................... 34
14.3.7 TBM Real Time Monitoring ................................................................................. 34
14.3.8 Guidance and Control System ............................................................................ 35
14.3.9 Drilling Fluid Tests .............................................................................................. 35
14.3.10 Grouting .............................................................................................................. 36
14.3.11 Tolerances .......................................................................................................... 37
14.3.12 Dewatering .......................................................................................................... 38
14.3.13 Slurry Separation Plant ....................................................................................... 40
14.3.14 Protection of existing Structures and Services ................................................... 40
14.3.15 Monitoring Ground Surface Movement ............................................................... 41
14.3.16 Pipe Testing ........................................................................................................ 42

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14 MICROTUNNELLING AND PIPE JACKING

14.1 GENERAL

The following Specifications are for the Microtunnelling and Pipejacking requirements.
The Contractor shall perform non-disruptive techniques in accordance with the
provisions of this Section.

14.1.1 Scope

The Contractor’s scope includes , but is not limited to , providing all labour, tools,
materials, equipment and incidentals required to design and complete the installation
of pipelines using micro-tunnelling or pipe jacking methods as and where indicated on
the Drawings and as specified, including surveying, instrumentation and dewatering.
The Contractor shall be responsible for the design of the Temporary Works,
Permanent Works, jacking pipe and for the selection of the tunnel boring machine
and the tunnel construction systems.

14.1.2 Applicable Standards / References

All activities related to this section of the specifications shall comply with the
followings or approved equivalent standards:

AASHTO HS20 44+100%-Surcharge loading.

BS 1377 Methods of test for soils for civil engineering purposes.

BS 5228-1 Code of practice for basic information and procedures for

noise control.

BS 5228-2 Guide for noise control legislation for construction and

demolition , including road construction and maintenance.

BS 5911-1 Concrete pipes and ancillary concrete products. Specification

for unreinforced concrete pipes ( including jacking pipes) with
flexibe joints.

BS 5930 Code of practice for site investigations.

BS 6164 Code of practice for safety in tunnelling in the construction

industry.

BS EN 681-1 Elastomeric seals. Material requirements for pipe joint seals

used in water and drainage applications.

BS EN 1916 Concrete pipes and fittings , unreinforced , steel fibre and

reinforced.

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ISO 9000 Quality management systems.

BS EN 12620:2002 Aggregates for Concrete.

BS EN 12889:2000 Trenchless construction and testing of drains and sewers.

BS EN 206-1:2000 Concrete. Specification, performance, production and

conformity.

BS EN 14364:2006 Plastic piping systems for drainage and sewerage with or

without pressure. Glass reinforced thermosetting plastics
(GRP) based on unsaturated polyester resin (UP).
Specifications for pipes, fittings and joints’

BS EN 14364:2006 Plastics piping systems for non-pressure drainage and

sewerage. Glass-reinforced thermosetting plastics (GRP)
based on unsaturated polyester resin (UP). Fitness for
purpose of the joints.

BS6164: 2011 Code of Practice for Safety in Tunnelling in the Construction

Industry.

ASTM D4161-01 Standard Specification for "Fiberglass" (Glass-Fiber-

Reinforced Thermosetting-Resin) Pipe Joints Using Flexible
Elastomeric Seals’.

ASTM D638 Standard test methods for tensile properties of plastics.

ASTM D 6783 Standard Specification for Polymer Concrete Pipe.

ASTM C 579 Standard test method for compressive strength of chemical

resistant mortars, grouts, monolithic surfacing and polymer
concretes.

DIN 54815-1 Pipes made of filled polyester resin moulding materials -

Dimensions, material and marking.

DIN 54815-2 Pipes made of filled polyester resin moulding materials -

Requirements and testing.

British Tunnel Society: Model specifications for Tunneling’

2001.“Specification for Tunnelling 3rd Edition”: The British
Tunnelling Society and The Institution of Civil Engineers:
Thomas Telford Ltd 2010.

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CIRIA C577 Guide to the construction of reinforced concrete in the

Arabian Peninsula.

Pipe Jacking Association, UK.

Guide to best Practice for installation of pipe Jacks and

Microtunnel (Concrete Pipe Association and the Pipe Jacking
Association, UK - 1995)

An Introduction to Pipe jacking and Microtunneling design.

Dubai Municipality – Guidelines and Requirements for

Planning and Design of Non Disruptive Road Crossings.

14.1.3 Definitions

The following definitions shall apply to words and phrases utilised in this Section:

a) “Pipe Jack” is defined as a pipeline constructed by thrusting specially designed

pipes or other permanent lining of preformed units progressively into the ground
by means of jacks or similar equipment while excavation proceeds at the leading
edge.

b) The use of the term ‘‘tunnelling’’ herein refers to excavation and installation of
pipe by either pipejacking or microtunnelling methods, or other similar trenchless
method. The term ‘tunnel’ shall be taken to mean the installed pipeline, whether
during or after the completion of the installation.

c) “Pipejacking” is a trenchless technology of installing underground pipelines

(between 900mm and 3500mm in diameter) by means of jacking specially
designed pipes through the ground from a jacking pit or shaft. The excavation is
achieved by using a shield at the forward end of the pipeline. Unless otherwise
approved by the Engineer, all shields shall be capable of providing continuous
support to the face by slurry or earth pressure balance methods.

d) “Microtunnelling” is a trenchless technology for construction of pipelines (between

200mmm and <900mm in diameter). It is a remotely-controlled, guided,
pipejacking process that provides continuous support to the face (via a full-face
micro-TBM) without requiring personnel entry into the tunnel.

e) “Tunnel Boring Machine (TBM)” refers to the mechanised cutting unit, shield and
ancillary equipment, whether it is for microtunnelling or pipejacking applications.

f) “Face Control” refers to complete mechanical support of the excavated face at all
times.

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g) “Earth Pressure Balance” refers to pressure applied to the cutting face equals the
pressure of the earth against the cutting face.

h) “Drill String” refers to a series of joined individual pipes which is used to advance
the excavation equipment.

i) “Annular Space”: The void between the outside diameter of the installed casing
pipe and the outer limits of the bore being excavated for the casing pipe. The
annular space also refers to the space between the casing pipe and the smaller
diameter carrier pipe installed within the casing.

j) “Hydraulic Fracturing”: Shall mean fractures produced by pressurised drilling

fluids or grout in weak or unconsolidated areas of the soil matrix resulting in
excessive fluid loss or upwelling of fluid to the surface.

14.1.4 Submittals

14.1.4.1 Products and Material Approvals

The Contractor shall submit information for all products and materials used in the
Works to the Engineer for approval in advance of their use in accordance with the
contract programme allowing for ordering and approval times. Information to be
submitted shall comprise but not necessarily be limited to:

a) The manufacturers design calculations, complete and detailed specification and

test results of the proposed pipes and fittings required for the Works including
manufacturer’s certificates of compliance in accordance with specifications.
Information shall be given for every diameter in each class of pipe.

b) Should any details of the pipes and fittings be altered in any way during
manufacture from those proposed and approved by the Engineer, submit for the
Engineer’s approval the revised details and test results.

c) Submit to the Engineer the results of all quality control tests carried out on the
manufactured pipes and fittings as soon as practicable after testing and in any
case not later than the time of delivery of the relevant pipes and fittings to the site.

d) Pipe manufacturer’s guarantee that the pipe and its materials are suitable for its
Intended use.

e) Joint materials and gaskets.

f) Concrete protection systems.

g) Provide from the manufacturer a certificate of the bentonite powder showing the
properties of each consignment delivered to the site. Ensure that this certificate is
available to the Engineer on request. The properties to be given by the
manufacturer are the apparent viscosity range in pascal seconds and the gel
strength range in pascals for solids in water.
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h) The Contractor shall submit a schedule for the submission of working drawings
and specifications for review. This schedule shall be agreed with the Engineer.

i) The Contractor shall submit a detailed schedule of manufacture/supply of TBMs,

back-up plant and equipment including delivery dates and testing dates. The
Contractor shall update progress on a weekly basis and comment on future
necessary action to maintain delivery date.

j) Within 8 weeks after the Commencement Date, the Contractor shall provide all
details of the TBMs and back-up equipment, including all items specified herein.

k) The Contractor shall demonstrate that the TBM manufacturer has manufactured
at least three TBMs of similar type, size, and complexity, used in successfully
completed similar size projects.

l) The Contractor shall submit to the Engineer information on all proposed drilling
fluids, additives, lubricants and conditioning agents. Submittals must include
material safety data sheets on each material along with a description of where the
material will be used and its purpose in the construction process. All drilling fluids
and lubricants shall be bio-degradable.

m) Prior to the commencement of the Works the Contractor shall submit calculations
showing the estimated maximum jacking force for each drive. The calculations
shall take into consideration the frictional characteristics of the ground and the
pipe material, the type of lubricant, the depth and the diameter of the pipe and the
required length of the drive.

n) Prior to commencement of works, the Contractor shall design the pipes for
adequate strength for NDM (non-disruptive method) works considering ground
characteristics and jacking force, etc. Contractor shall submit the design
calculations for Engineer’s approval.

o) The Contractor shall submit the details, method statements and specifications for
the final pipe systems selected for construction, for approval of the Engineer.
These shall include: pipe materials; collar and joint systems; corrosion protection
lining; grouting; intermediate jacking stations and locations in drives; break in/out
from shafts, soft eyes and seals.

p) The Contractor shall prepare a Gas Characterisation Programme, detailing the

methods and frequencies for monitoring of hazardous gases.

14.1.4.2 Submittals for Dewatering

a) The following submittals shall be forwarded to the Engineer for approval a

minimum of 6 weeks before any work referred to in the submittals is scheduled to
commence.

b) Water Control Plan:

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(i) The Contractor shall submit a Water Control Plan (WCP).

(ii) The WCP shall include, as a minimum, descriptions of proposed

groundwater and surface water control facilities including, but not limited to,
equipment; installation, operation, and removal methods; standby
equipment and power supply, silt removal facilities, pollution control
facilities, discharge locations to be utilized.

(iii) The WCP shall contain provisions for measuring discharge flow from the
dewatering system, a program for measuring groundwater level during
dewatering system operations, and a program for sampling and testing
ground water quality.

(iv) The Contractor shall be required to submit full details to demonstrate that
settlement due to dewatering operations will not exceed the allowable
amounts specified for settlement due to microtunnelling or pipe jacking
operations. The Contractor shall also demonstrate that all buildings,
structures and services within the zone affected by the dewatering
operations shall not be affected by the dewatering. The Contractor shall
submit full details of the numbers and locations of piezometers required to
monitor the extent and magnitude of the drawdown caused by the
dewatering, and of settlement points and other instrumentation to verify that
the settlements are being maintained within allowable tolerances. The
Contractor shall also provide full details of how to monitor both the rate of
abstraction of water from all the wells and the quality of the water
abstracted.

(v) The WCP shall include projected pumping rates based on information
established in the Geotechnical Data Report, Geotechnical Interpretative
Report, and Geotechnical Assessment Report for the project. The WCP
shall also include projected drawdown curves, recharge rates, and other
hydro-geologic information and calculations developed to support the
proposed dewatering systems and methods.

c) Shop Drawings:

(i) The Contractor shall submit shop drawings showing locations, dimensions,
and relationships of elements of each dewatering system. The submittal
shall include design calculations demonstrating adequacy of proposed
dewatering or isolation systems and water wells and their components. The
Contractor shall provide manufacturer's literature describing installation,
operation, and maintenance procedures for all components of the
dewatering system and water wells.

(ii) The Contractor shall provide installation records of all components of the
dewatering systems proposed in the WCP including drawings showing the
installed location of each component of the dewatering system installed.
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d) Quality Control Submittals: The Contractor shall submit weekly to the Engineer,
tabulated water level elevations recorded daily in observation wells and
piezometers.

14.1.4.3 Method Statements

The contractor shall submit method statements to the Engineer for approval 4 weeks
in advance of commencing the site activity in accordance with specifications. These
shall compromise but not necessarily limited to:

a) Geotechnical investigation report to include all information related to geotechnical

and geophysical investigation undertaken and recommendations for tunnelling
technique to be adopted , excavation support, and soil stabilisation if required
including grouting of cavities if any.

(i) Geotechnical Design Report, which:

1. May be separated into the different elements (based on geographic

location and type of pipejacking or microtunnelling);

2. Includes any additional geotechnical investigations and testing (factual

data) undertaken by the Contractor post award;

3. Summarises the anticipated ground conditions for each work shaft and
pipeline drive;

4. Presents the basis for the selection of particular TBM’s and cutter face
arrangements;

5. Presents the basis of design for all work shafts;

6. Presents the requirements and basis of design for all dewatering and
ground improvement;

7. Includes estimates of ground surface movements associated with the

excavations and pipeline construction

8. Presents geotechnical risks and mitigations applicable to the works.

b) List of all equipment and resources and programme of work showing allocation of
equipment and resources.

c) No work shall commence on shaft excavation and support activities until the
following method statement submissions have been approved by the Engineer:

(i) Shaft excavation and support: Shaft excavation method(s) and methods of
installing shaft support system(s) for temporary work shafts (6 weeks).

(ii) Authority approvals: Plan identifying the requirements of and for obtaining
approvals from all relevant agencies and authorities (4 weeks).

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d) Typical shift performance report.

e) Detailed step by step procedure describing how work will be carried out in
particular how the different aspects of pipe jacking are monitored , such as
angular deflection , jacking pressures , face pressures , packers etc. and then
managed so that the interjacks are installed as required , deflection controlled and
jacking pressures minimised.

f) Submit independently authenticated test results to demonstrate that the joint

packing complies with the specification. Include a graph of the stress/strain
relationship over the range of conditions which will be encountered during the
works.

g) Method of excavation and removal.

h) Methodology for correcting line and level.

i) Support of existing services and adjacent structures.

j) Safety arrangements for compliance with safety requirements.

k) Arrangement for dealing with ground water, taking due regard to controlling the
loss of material and preventing settlement around pits/shafts, pipe/pit interfaces
and tunnel face.

l) Dealing with different ground conditions.

m) Locking pipe in position during insertion of the next pipe.

n) Sealing working shafts and reception pits during exiting and entering of pipe.

o) Control of over break.

p) Grouting of cavities where applicable.

q) Grout mix design and method of grouting.

r) Details describing the measures to be taken to avoid the development and

transfer of grout shrinkage or expansion stresses to the pipe and to avoid any
adverse chemical reaction between the pipe and the concrete, grout or other
materials comprising the pipeline.

s) Handling and fixing of the inner line pipe in the case of tunnelling with oversize
casing pipes.

t) Reuse/dumping of cuttings and slurry.

u) Layout of monitoring points for detection of surface movement.

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14.1.4.4 Drawings and Calculations

The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the specification. These shall
comprise but not necessarily be limited to:

a) Working drawings showing on plan and section the method of supporting

excavations.

b) The location of all pits/shafts including those indicated as permanent works in the
design drawings, having due regard to existing services, minimising disruption to
traffic and pedestrian movements and achieving the required system layouts, as
shown on the tender drawings.

c) Foot print plans showing the working site areas at the thrust and reception
pits/shafts, control room, pipe storage area, craneage area, slurry tank, generator
etc.

d) Plan showing proposed traffic and pedestrian diversion proposals around all
pits/shafts.

e) No work shall commence on shaft excavation and support activities until the
following submissions have been approved by the Engineer.

(i) General arrangement drawing of pipejack/microtunnel jacking sites and

reception shaft sites showing layout of all temporary and permanent works,
including site offices, stores, etc (6 weeks).

(ii) Design submittals including calculations demonstrating that the design of

the shaft support system will adequately support the shaft excavation
throughout all stages of construction and until the shaft is either backfilled or
a permanent lining or structure is installed within the shaft (10 weeks)

(iii) Preliminary design drawings for temporary work shafts (10 weeks).

f) Details of entry and exit pipe seals and seal rings in pits/shafts.

g) Longitudinal profiles from thrust to reception pits/shafts showing location of pipe

joints, location of existing services and surface levels.

h) Calculations for thrust and reception pits/shafts which shall be designed to resist
external soil and water pressure and stresses resulting from the jacking machine.

i) Calculations justifying allowable deflections at joints to limit damage to the joint

from eccentric loading under drive and sealing limits and to ensure a completed
pipeline with no visible leaks and within infiltration allowances.

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j) Pipe calculations showing capability of pipe to resist jacking and friction forces in
the axial direction and earth, AASHTO HS20 traffic, and surcharge loadings in the
vertical direction.

k) Calculations for friction loads, face loads, interjacks, jacking pressures etc. for
the complete system, including thrust walls, which demonstrate how the pipes
will be installed with no damage.

l) Calculations giving predicted settlements along and adjacent to route of

pipeline.

14.1.4.5 Quality Control

a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or Material prior to delivery in
accordance with the specification.

b) Products and materials shall be from a manufacturer/supplier who operates a

quality system which is registered to ISO 9000 series or approved equal.

c) To allow the Engineer to inspect the Works the contractor shall give the Engineer
a minimum of a 24 hour notice of carrying out the following activities on site.

(i) Geotechnical investigation.

(ii) Construction of thrust and reception pits / shafts.

(iii) Undertaking each stage of NDM work.

d) Ensure instrumentation is calibrated for each drive. Provide a valid calibration

certificate. Ensure that the certificate is available to the Engineer upon request.

e) The designer shall be an approved qualified Engineer experienced in the design

of this work or similar.

f) The installer shall be an approved company with specialised personnel in

performing the work with minimum 5 years experience in the application of non
disruptive method of pipeline construction of projects of similar size.

(i) All operators in the employment of the Contractor and his sub- contractor
shall be skilled and have a minimum 12 months experience in their
respective trades and in particular in operating a machine similar to the
machine used by the Contractor. Operators shall be subject to a
probationary period of three months.

(ii) Curriculum Vitae of key personnel and operators shall be submitted for
approval by the Engineer and interviews may be taken at the discretion of
the Engineer.

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(iii) The supervising operator who will perform the work for the Contract duration
shall have a minimum of 5 years of experience of similar works.

g) Approval for method statements and to carry out the work shall be obtained from
the Engineer and the concerned authorities including RTA and Works Department
as appropriate prior to excavation.

14.1.4.6 Delivery, Storage and Handling

a) Delivery, storage and handling of products and materials shall be in accordance

with the manufacturer's recommendations and the following provisions.

(i) 1. Delivery storage and handling shall at all times be performed in a manner
to avoid product damage and be in accordance with the manufacturer’s
recommendations.

(ii) 2. Pipes and fittings shall not come in contact with any sharp
projections that may cause damage to the pipes and fittings during
transportation loading and unloading. Ensure that pipes and fittings are well
secured during transit and adequately supported along their length. Cover
pipes and fittings of plastic materials during transportation. Do not allow
pipe to overhang the end of a vehicle during transportation.

(iii) 3. Ensure that pipes and fittings are lifted using nylon or large
diameter rope slings positioned at a quarter of the pipe length from each
end. Do not allow the use of wire rope chains or unpadded forks or clamps
on forklifts to lift pipes.

(iv) 4. Store pipes and fittings on a flat level area and follow
manufacturer’s storing requirements.

(v) 5. Stack non-crated pipes to the approval of the Engineer.

1. Stack pipes of different sizes and thickness separately.

2. Do not allow stacked pipes to exceed 2m in height or as

recommended by the supplier whichever is the lesser.

(vi) Store GRP pipes and fittings under opaque cover and out of direct sunlight
at all times. Maintain a free flow of air around the pipes at all times.

(vii) Coated and cured RC pipes shall be protected from UV exposure during
storage if required by coating manufacturer.

(viii) Store joint materials and gaskets in a well ventilated place free from
exposure to sunlight and in their original packing until they are needed.

(ix) The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.

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1. Any products damaged during delivery, storage and handling shall be

marked by the Contractor and set aside.

2. Proposals for repair of any damaged products shall be submitted in

writing to the Engineer for approval.

3. Any damaged products deemed unsuitable for repair by the Engineer

shall be removed from site and replaced.

b) Store the lubrication material in a manner recommended by the

supplier/manufacturer.

14.1.4.7 Safety

a) Adopt safe working practices for tunnelling in accordance with

provisions of BS 6164 and BS 5228: Parts 1 & 2.

b) Allow only authorised personnel access to the site.

c) Provide a Safety Officer, suitably experienced in tunnelling operations and with

adequate authority to control and implement safe working practices.

d) Provide and maintain suitable arrangements at site for personnel including:

(i) Telephone service.

(ii) Telecommunication equipment between the control room and the working
crew.

(iii) Approved gas detectors.

(iv) First aid kit.

(v) Emergency escape or breathing apparatus sets.

(vi) Transport.

e) Provide a separate cage type ladder for each pit/shaft.

f) Fence the shafts/pits on all sides with close steel panels of a minimum 1.8m in
height equipped with orange safety warning lights. Join the panels, maximum
space between the panels is 100mm, by steel rods supported on concrete blocks.

g) Provide adequate lighting and ventilation to the shafts/pits. Except where

otherwise necessary, electricity shall be 110 volts from a centre tapped to earth
(CTE) supply and up to 220 volts with use of ELCB protection.

h) Provide an air-conditioned control room at the thrust pit/shaft with sufficient space
for a desk and chair for one inspector.

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14.1.4.8 Investigation Requirements

a) Obtain existing utility information, and excavate trial pits to locate and confirm
services at pit/shaft locations and along the proposed tunnelling route as
necessary. Obtain approval of utility authorities and relevant Department prior to
the commencement of work.

b) Carry out all geotechnical site investigation including ground water level
monitoring, as considered necessary and as minimum at the proposed pits/shafts
locations and along the proposed tunnelling route as necessary.

c) Carry out a geophysical survey on a 10 metres wide strip along the proposed
tunnelling route covering a depth range between ground level and up to 5
metres below the invert of the proposed tunnel. The objective of this survey
is to detect any cavities or broken or collapsed subsurface strata, so that any
such cavities or strata can be treated to allow tunnel construction. The general
requirements and specification for the geophysical survey are as follows:

(i) The survey shall be applicable to depths greater than 15m from existing
ground level to invert of pipe.

(ii) The survey shall provide information on both lateral and vertical extent of
subsurface conditions together with the identification and classification of
the geophysical materials in the subsurface sequence within the targeted
depth of investigation. The information provided is to include details on
likely size, depth and character of the features interpreted.

(iii) The geophysical survey and all associated works shall only be carried out
by specialist companies approved by the Dubai Municipality.

(iv) Before commencement of the survey, the Contractor shall submit the
anticipated calibration work required to fully assess and interpret the
geophysical survey, and confirm his acceptance that the objectives of the
survey are achievable.

(v) The geophysical survey technique to be used is that of resistivity imaging,

and shall be generally conducted as follows:

1. Establish benchmarks and topographically survey and inspect routes for

interference.

2. Undertake data acquisition and assess the data quality.

3. Provide the preliminary resistivity section and preliminary interpretation

result and undertake drilling of boreholes required for the calibration of
the resistivity results.

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4. Provide precise interpretation of resistivity anomalies, supplement

interpretation with physical evidences, drilling of boreholes, borehole
logs and core photographs.

5. Provide a survey report with the final interpreted sections, colour scale
of sections should be standardised.

6. The location of anomalies/cavities shall be marked and flagged by the

Contractor at the exact location indicated by co-ordinates Easting and
Northing.

(vi) One borehole in accordance with BS 5930 and BS 1377 for each 50 survey
stations is included in the scope of geophysical survey in order to be used
by the Contractor for calibration/interpretation of the survey results. Each
borehole shall incorporate SPT at 1m intervals, groundwater level, rotary
drilled coring of solid strata and photographs of cores.

(vii) All basic data recording, preliminary and final interpretation and borehole
records shall be included in the NDM design report.

d) Notwithstanding the general requirements of Clause 14.1.4.8 above, soil

conditions and ground conditions shall constitute the Contractors risk and the
Contractor shall undertake such investigation as necessary to establish the sub
surface conditions at no extra cost to Dubai Municipality.

14.1.4.9 Design Requirements

a) The Contractor is responsible for the design of all pipes including all joints, the
thrust and reception pits/shafts including supports and thrust wall, the size of the
pits/shafts to suit his method of construction and for the design of the jacking
system in general.

b) Ensure that the design of the thrust wall and any other associated Temporary
Works is such as to prevent damage to any part of the Permanent Works or any
immediately adjacent service or structure.

c) Design thrust and reception pits/shafts to allow the safe operation of the plant,
equipment and handling of the materials and to withstand all loading imposed by
ground pressure, superimposed loads from surface structures and maximum
proposed thrust force.

d) Design pipes to withstand the maximum axial thrust with a factor of safety of 4
based on the full effective area and the ultimate compressive strength of the pipe
material. For reinforced concrete pipes, use the full effective area at the joint.

e) Where GRP or similar material pipes with concrete surround are proposed, the
concrete surround shall be designed to withstand the maximum jacking force. The

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design shall also ensure that the GRP or similar material pipe is not subjected to
any forces during installation.

f) Design pipe joints in conjunction with resilient packing that avoids projections
which could obstruct the travel of the pipe. Ensure that the joints will be
watertight under axial loading and at the permissible deflection of the pipes.

g) Design joints for concrete pipes such that with an angular deflection of 10 degree.

(i) The areas available for transmitting the maximum permitted thrust force will
be sufficient to ensure that there will be no pressure at any point greater
than the maximum permissible pressure.

(ii) There will be no damage to the pipe or loss of structural strength.

(iii) There will be no ingress or egress of water or lubricant under the maximum
operational or test pressures.

(iv) There will be no ingress of soil/groundwater onto the bearing surfaces.

h) Design shall take account of the behaviour of the pipe joint at the maximum
permitted angular deflection of 1º with the maximum permissible bearing stress in
conjunction with the stress/strain relationship obtained from the packing
compression tests and maximum jacking loads.

i) Where it is proposed to construct certain section within larger diameter pipes and
grout the annular space:

(i) Ensure that the difference between the external face of the inner pipe and
the internal face of the outer pipe is not less than 150mm and no more than
250mm unless otherwise approved by the Engineer.

(ii) The external pipe/sleeve may be of steel with full circumferential weld or
reinforced concrete pipe. In either case, the casing pipe and the grout shall
be regarded as sacrificial and the inner pipe shall be designed as a stand
alone pipe, capable of withstanding installation and grouting forces and soil,
traffic and groundwater loads. Where pipe-brackets, spider clamps, are
used, rubber packers shall be placed between the steel brackets and pipe.

j) Limit the dimensions of drive and reception pits/shafts to the minimum required to
construct the permanent works or to construct the pits/shafts, whichever is larger.

k) Determine the excavated dimensions of the drive and reception pits/shafts as

required to suit the site conditions. Minimum pit/shaft dimensions shall be used at
all locations where utilities, roads or trees exist adjacent to the required pit/shaft
locations.

l) Where it is proposed to use a tail tunnel as the reaction surface the maximum
permitted thrust force is not to exceed the lesser of the following.
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(i) The maximum permissible thrust force.

(ii) 50% of the sum of the maximum forces recorded at the rigs used to
construct the tail tunnel if the overbreak has not been grouted up.

(iii) If the overbreak to the tail tunnel has been grouted up, 100% of the sum of
the maximum forces recorded at the rigs used to construct the tail tunnel.

m) Any tail tunnel which has been used as a reaction surface shall pass the specified
water tightness test at a time not less than 14 days after the load has been
removed.

n) Lubricant fluid holes shall be threaded to enable plugs to be screwed into the
socket and withstand the external pressure. Non-return valves shall be fitted
where opening a hole would permit ground loss.

o) Confirm the tunnelling route is clear from cavities or obstructions or recommend

and design for grouting of cavities and/or dealing with obstructions.

14.1.4.10 Use of Approved Specialist Firms/Sub Contractors

The Contractor shall engage specialist Firms/Sub-Contractors to carry out/execute

work for Micro-tunnelling / Pipe jacking on this project. All specialist Firms/Sub-
Contractors are subject to approval for each aspect of work on this project in the field
of their respective specialisation. Only those companies that can demonstrate
successful experience on projects similar to that required for this work (scope, size,
condition, and programme) shall be proposed by the Contractor for consideration and
approval. Companies proposed for approval shall demonstrate the necessary
registration as a contractor licensed to work in Dubai either directly or through a legal
association with a registered Contractor.

14.2 EQUIPMENT AND PIPE MATERIALS

14.2.1 Equipment

The Contractor shall use only NDM (Non-disruptive Method) equipment that is
appropriate for the intended installation, site and ground conditions, length of drive,
and other relevant factors and can meet the contents of these specifications to the
satisfaction of the Engineer. It is envisaged that the NDM equipment will have the
following capabilities but the final choice of equipment will be the responsibility of the
Contractor to the approval of the Engineer.

14.2.1.1 Tunnel Boring Machines (TBMs)

a) The Contractor shall provide, install, maintain and remove on completion TBMs
suitable for excavation in the ground conditions as described in the Contract
documents.

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b) The proposed TBM manufacturers shall be recognised commercial TBM

manufacturers with no less than 5 years of successful experience in the design
and manufacture of the type of TBMs proposed by the Contractor.

c) All TBMs for internal pipeline diameters greater than 1200mm shall be new or
newly refurbished/rebuilt, with all major components tested and guaranteed by the
TBM manufacturer. TBMs for pipelines between 600mm and 1200mm diameter
shall have a maximum of three thousand working hours, and shall have newly
retooled and refurbished cutterheads, and be supported by documentary
evidence of service history. TBMs/moles/drilling equipment for pipelines less than
600mm diameter shall have a maximum of five thousand working hours, and shall
have newly retooled and refurbished cutterheads, and be supported by
documentary evidence of service history.

d) All TBMs provided must be capable of satisfactory performance in the anticipated

ground conditions presented in the Volume 5.

e) The design of the TBM shield shall include an articulated joint as required to
ensure construction of the pipe jack/ microtunnel to the theoretical alignment as
shown on the Contract drawings.

f) The Contractor shall provide a TBM Guidance and Control System with laser
theodolite. This shall be a commercially manufactured system.

g) The TBM shall have a proven system for monitoring the presence of hazardous or
explosive gases. Systems shall be arranged with adjustable limits and shall have
a first level warning signal and a second level with automatic shut-off of
equipment. Gases to be monitored shall be methane, hydrogen sulphide, oxygen,
carbon dioxide and carbon monoxide.

h) The TBM shall be designed to withstand all the jacking loads as well as the full
overburden pressure and hydrostatic pressure.

i) The TBM shall be capable of fully supporting the face during both excavation and
shutdown periods, and shall have the capability of exerting a continuous,
controllable stabilizing pressure at the face as required to prevent loss of ground
and groundwater inflows.

j) Only TBM synthetic oils HFDU (biodegradable, fire resistant polyesters) shall be
used. All oils must be approved by the TBM manufacturer.

k) In addition to above, TBM should also comply with the following requirements:

(i) Steerable and incorporating hydraulic rams to move the articulated head.

(ii) Designed to ensure no rotation or rolling during installation.

(iii) Remote controlled and can transmit information such as jacking force, face
pressure, length, roll, pitch, steering attitude, temperature, valves open or
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closed, cutter torque, rate of progress, slurry pressure, slurry flow, earth
face pressure to a microprocessor console on the surface from where the
system is operated.

(iv) Incorporates meters and gauges to measure the slurry flow and
pressures.

(v) Capable of operating under groundwater conditions as necessary with a

hydrostatic balance not less than 3m head of water.

(vi) Fitted with a calibrated laser target, robustly constructed and rigidly
secured.

(vii) Guidance system shall be laser or an approved equivalent for the control of
tunnel alignment. The guidance system shall be mounted independently of
the thrust wall or machine jacking rig or anything else that may move during
operations.

14.2.1.2 Thrust System

a) The rig shall distribute the thrust to the pipes via a thrust ring and packing. The
jacks shall apply the thrust to the thrust ring by means of a symmetrical
distribution. Interjack stations shall be used where frictional resistance or other
causes would otherwise result in unacceptable thrust forces.

b) If used, spacer blocks shall be true and free from any distortions.

c) All thrust rings shall be true and free from any distortions and sufficiently stiff so
as to transfer the load from the jacks uniformly to the packing.

d) Other than at the shield, each group of jacks shall be interconnected to ensure
that an evenly distributed load is applied to the thrust ring.

e) Fitted with automatic thrust recording equipment monitoring load cells

incorporated in each jack together with a pressure metering device.

14.2.1.3 Tunnelling Shields for Pipejacking

a) Where considered necessary, the Contractor shall provide and maintain a shield
suitable for excavating in the ground conditions as envisaged by him and in
accordance with his chosen method of excavation.

b) In determining the type of shield and method of excavation to be used, the

Contractor shall take account of the need to ensure that the face of the
excavation is adequately secured at all times such that ground loss is kept to a
minimum and is controlled to prevent excessive ground loss. The shield shall be
removed on completion of the tunnelling operation.

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c) Rotating excavating heads fitted to shields shall be capable of rotating clockwise

and counter-clockwise.

d) The shield shall be equipped with steering jacks and such heads, ploughs and
copy cutters as may be required for adjusting the alignment of the pipes.

e) Multiple lubricant injection points shall be provided within the shield in order to
provide immediate ground support when necessary.

f) In case of manual excavation, the shield should be pushed into the soil. The
excavation should be limited to the soil falling inside the sleeve. No excavation
should protrude outside the shield face.

14.2.2 Pipe Materials

a) Acceptable pipe materials for microtunnelling and pipejacking applications include

the following, subject to approval by the Engineer :

(i) Concrete Encased GRP Jacking Pipe (CEGRP)

(ii) GRP Jacking Pipe (GRPJP)

b) It is a requirement that CEGRP and GRPJP be standard jacking pipes, certified

by European or US accreditation authorities.

c) Only one type of pipe shall be used for the project.

d) The manufacturer of the pipe materials must demonstrate a 10-year recent history
of successful installations in similar corrosive environments.

e) Warranty

(i) The manufacturer and the Contractor shall jointly guarantee the completed
pipe system, including any protective coatings and linings, to be free from
defects in materials and workmanship for a period of 10 years from the date
of completion of the Works.

(ii) The Contractor shall furnish the Employer with the manufacturer’s
guarantee and warranty certificates for all materials and components used.

(iii) If the protective coating and lining system are found to be defective during
the warranty period, the manufacturer and Contractor shall replace and/or
repair the protective coating and lining system to the satisfaction of the
Engineer at no cost to the Employer.

f) The pipe and any fittings must be manufactured within six months of the Contract
commencement date.

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g) Before delivery the manufacturer shall submit a written “Certificate of Compliance”

that the pipe to be supplied meets all applicable BS, European and ASTM
Standards as referred to in the Specification.

14.2.2.2 Concrete Encased GRP Jacking Pipe – minimum requirement

a) General

(i) Contractor shall design the GRP pipe stiffness for reinforced concrete
encased GRP Jacking pipe as per the requirement given below or on the
recommendation of manufacturer depending on pipe diameter and site
conditions (soils, installation, compaction, loads etc.) in compliance to the
performance requirements and warranty conditions specified in this
document:

1. Minimum acceptable pipe stiffness for GRP pipe shall be 10,000N/m²

(SN 10,000).

(ii) Minimum concrete strength shall be grade C50, unless otherwise approved
by the Engineer.

(iii) The manufacturer of the pipe materials and pipes must demonstrate a 10-
year recent history of successful installations in similar corrosive
environments.

(iv) Warranty

1. The manufacturer and the contractor shall jointly guarantee the

completed pipe system, including any protective coatings and linings , to
be free from defects in materials and workmanship for a period of 60
years from the date of completion of the works.

2. The Contractor shall furnish the Employer with the manufacturer’s

guarantee and warranty certificates for all materials and components
used.

3. If the protective coating and lining system are found to be defective

during the warranty period, the manufacturer and Contractor shall
replace and/or repair the protective coating and lining system to the
satisfaction of the Engineer at no cost to the Employer and restart the
guarantee.

4. All pipe jointing systems and seals shall withstand a minimum external
water pressure of 1.5 bar. One joint in 100 shall be tested at the
manufacturer’s works.

5. All pipe jointing systems and seals shall withstand a minimum internal
water pressure of 2 bar. One joint in 100 shall be tested at the
manufacturer’s works.
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(v) The pipe and any fittings must be manufactured within six months of the
Contract commencement date.

(vi) Before delivery, the manufacturer shall ensure that factory acceptance test
(FAT) has been undertaken and a factory acceptance certificate (FAC) shall
be submitted.

(vii) Before delivery, the manufacturer shall submit a written “Certificate of

Compliance” that the pipe to be supplied meets all applicable BS, European
and ASTM Standards as referred to in the Specification.

b) Concrete Encased GRP Jacking Pipe

(i) Concrete Encased GRP Jacking Pipe design and performance requirement
includes:

1. Demonstration of the design and installation procedure ensures that the

reinforced concrete encasement takes the maximum jacking load. The
design shall ensure that the GRP pipe is not subjected to any forces
arising from the jacking installation.

2. Provision of UAE and Middle East case histories regarding the particular
pipe and joint system, ground conditions, drive lengths, water tightness
tests, and as-built tolerances and conditions.

3. Ensure that the manufacturer provides angular tolerances on installation

specific to this pipe system, supported by calculations justifying the
proposed tolerances.

4. A pipe system design demonstrating that the GRP coupling is adequate

to achieve the structural, durability and watertightness requirements up
to the end of the design life of 60 years, when installed at the limit of the
angular tolerance between pipes.

5. A pipe system design demonstrating that the encasement in concrete

results in no adverse chemical or physical effects to the GRP pipe.

(ii) Unless superseded by clauses herein, the requirements of ’Section 4-

Pipes, Pipework ,Manholes and Chambers’ apply.

(iii) Resin Systems: The manufacturer shall use only resin systems with a
proven history of performance in this particular application. The historical
data shall have been acquired from a composite material of similar
construction and composition as the proposed product.

(iv) Additives: Resin additives, such as curing agents, pigments, dyes, fillers,
thixotropic agents, etc., when used, shall not detrimentally effect the
performance of the product.

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(v) The inner liner of the pipes exposed to sea water /sewer flow shall be
manufactured using a vinylester resin with a 50% elongation (minimum)
when tested in accordance with ASTM D638/ ASTM C581. The interior
surface shall provide crack resistance and abrasion resistance. The exterior
surface of the pipes shall be comprised of a layer which provides UV
protection to the exterior.

(vi) Joints: Unless otherwise specified, the pipe shall be field connected with
fibreglass sleeve couplings that utilize elastomeric sealing gaskets as the
sole means to maintain joint water tightness. The joints must meet the
performance requirements of ASTM D4161.

(vii) Concrete encased GRP Jacking pipe shall be protected externally with an
epoxy coating as per Specifications 7.1.15 & 7.2.2.1(e).

c) Other Requirements

(i) Collars

1. Collars for butt-jointed pipes shall be designed for the specified design
life, and shall be manufactured from the following:

 Steel alloys having a minimum Pitting Resistance Equivalent Number

(PREN) >40.
 GRP: Joints utilising GRP sleeve couplings must meet the
performance requirements of ASTM D4161 or BS EN 1636-5:2001.
 Other material having equal or better performance than Steel Alloy or
GRP, subject to approval of the Engineer.

2. Collars shall be cast integrally with and securely anchored to the pipes
but shall not be attached to reinforcement or associated spacers.

(ii) Bentonite and grout holes

1. Bentonite injection holes shall be provided according to the tunnel

boring machine manufacturer’s recommendation. A minimum of three
holes at equal circumferential spacing shall be formed through every
third pipe.

2. Pipes may incorporate lifting holes and fixing holes for securing
temporary apparatus, all holes shall be threaded to enable plugs,
approved by the Engineer, to be screwed into the sockets to withstand
the external water pressure. On completion of the tunnel and following
grouting of the voids around the pipe all holes shall be filled with a non-
shrink cement mortar to a mix approved by the Engineer.

(iii) Packing

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1. Joint packing material when subjected to the maximum permitted

bearing pressure shall have under dry conditions:

 A restoration after 1 hour of at least 65% of the original thickness.

 A compression of at least 50% of the original thickness.
Independently authenticated test results to demonstrate that the
packing complies with the specification shall be submitted and shall
include a graph of the stress/strain relationship over the range of
conditions which will be encountered during the Works.

2. The material used for packing to withstand all imposed loading applied
during the installation of all pipes for each completed length without
showing signs of deterioration or distress.

3. Packers shall be made of Medium Density Fibreboard (MDF) or any

material of similar mechanical properties, subject to Engineer’s
approval. For MDF packers a thickness between 15 and 19mm and
bending strength of at least 20 N/mm2 are required.

(iv) Pipe Joint Sealing System

1. Pipe joints shall be designed to be watertight against both the external

water pressure head and any internal pressure, depending on the depth
and intended use of the pipeline. The integrity of the joint water-
tightness shall be guaranteed in writing by the manufacturer for the
approval of the Engineer.

2. Sealing rings shall be manufactured using an EPDM ring(s) complying

with BS EN 681-1:1996 and guaranteed to perform satisfactorily for the
whole design life.

3. All sealing rings shall have physical and chemical properties, including
hardness (measured in International Rubber Hardness Degrees-IRHD),
compatible with the pipe material. Sealing rings shall be stored in a
clean, cool condition out of direct sunlight and without being deformed.
Sealing rings for use with thermoplastic pipes shall contain no
component which can react with the material of the pipes.

(v) Lubrication and Conditioning Agents

1. It is envisaged that lubricating fluid shall be one of the following but the
final choice of fluid will be the responsibility of the Contractor to the
approval of the Engineer. Lubricating fluid shall generally be a polymer
or bentonite based slurry lubrication material. In suitable ground
conditions water alone may be used. For clay soils, non-aqueous
lubricants shall be used.

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2. The material used for lubrication shall be stored and mixed in a manner
recommended by the Supplier.

3. It is the responsibility of the Contractor to assess and allow for the

chemical effects, if any, of gypsum or high salinity ground and
groundwater, and/or any contaminated ground encountered, on his
proposed slurry and lubrication fluids and any additives.

4. Inert fillers such as limestone or sand may be added but no other

materials. Where inert fillers are proposed the sub-Contractor shall
submit the material type to the Engineer, for approval.

5. The term soil conditioning refers to the use of suitable additives

(conditioning agents) in various proportions to alter the soil properties of
the excavated spoil such as foams, polymers, slurries. The Contractor
shall seek compliance with both safety-in-use and disposal regulations.
All conditioners shall be inert and bio-degradable.

(vi) Contact Grouting

1. Overbreak grouting Portland cement and water determined by

geotechnical data and as directed by the Engineer, nominal strength
shall be of at least 20N/mm². Admixtures shall be used only if tests
have shown to the satisfaction of the Engineer that their use improves
the properties of the grout, e.g. by increasing workability or slightly
expanding the grout.

2. As annular space filling a low strength grout or foam concrete shall be

used and placed at low pressures. The density of the mix shall be in the
range of 900 to 1200kg/m³ and the free water/cement not greater than
0.6.

3. Cavities grouting Portland cement, Portland cement/sand or Portland

cement/bentonite mortars shall be determined based on ground
investigation data.

4. Grout shall be cementitious, containing between 2% and 4% bentonite

with a 7-day unconfined compressive strength of at least 3MPa per BS
EN 206-1:2000 and shrinkage less than 5%. Add sand to the mix for
voids larger than 50mm.

14.2.2.3 GRP Jacking Pipes – Minimum requirement

a) Unless superseded by clauses herein, the requirements of ’Section 4- Pipes,

Pipework, Manholes and Chambers’ shall apply.

b) Acceptable standard jacking pipe product shall be as per vendor list.

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c) This sub-clause relates to solid wall jacking pipe, not a composite e.g. concrete
encased GRP.

d) Pipes manufactured by a centrifugal casting process are preferred.

e) Pipes shall have an interior acid resistant liner. The inner liner shall have a
minimum thickness of 1.5 mm, consisting of ‘C’ glass veil backed with chopped
strand glass all impregnated with vinylester resin.

f) Resin Systems: The manufacturer shall use only resin systems with a proven
history of performance in this particular application. The historical data shall have
been acquired from a composite material of similar construction and composition
as the proposed product.

g) Glass Reinforcements: The reinforcing glass fibres used to manufacture the

structural wall shall be of highest quality commercial grade E-glass filaments with
binder and sizing compatible with impregnating resins.

h) Silica Sand: Sand shall be minimum 98% silica with a maximum moisture content
of 0.2%.

i) Additives: Resin additives, such as curing agents, pigments, dyes, fillers,

thixotropic agents, etc., when used, shall not detrimentally effect the performance
of the product.

j) Pipes: Manufacture pipe by the centrifugal casting process to result in a dense,

nonporous, corrosion-resistant, consistent composite structure. The interior
surface of the pipes exposed to sewer flow shall be manufactured using a resin
with a 50% elongation (minimum) when tested in accordance with ASTM D638.
The interior surface shall provide crack resistance and abrasion resistance. The
exterior surface of the pipes shall be comprised of a sand and resin layer which
provides UV protection to the exterior.

k) Joints: Unless otherwise specified, the pipe shall be field connected with
fibreglass sleeve couplings or bell-spigot joints that utilize elastomeric sealing
gaskets as the sole means to maintain joint water tightness. The joints must meet
the performance requirements of ASTM D4161. The joint shall have
approximately the same O.D. as the pipe, so when the pipes are assembled, the
joints are essentially flush with the pipe outside surface. Joints at tie-ins, when
needed, may utilize gasket sealed closure couplings.

l) Wall Thickness: The minimum wall thickness, measured at the bottom of the
spigot gasket groove where the wall cross-section has been reduced, is
determined from the maximum jacking load. Minimum factor of safety against
jacking force is 2.5 based on straight alignment.

m) End Squareness: Pipe ends shall be square to the pipe axis with a maximum
tolerance of 1.5mm.
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n) Pipes: Pipes shall be manufactured and tested in accordance with ASTM D3262.

o) Joints: Joints shall meet the requirements of ASTM D4161.

p) Stiffness: The stiffness of the pipe should be suitable to site conditions & be
approved by the Engineer. Stiffness test should be carried out in accordance with
ASTM D2412 .

q) Strain Corrosion: The extrapolated 50-year strain corrosion value shall not be less
than 0.9% as determined in accordance with ASTM D3681 and ASTM D3262.

14.2.3 Joint Packing

a) Joint packing material when subjected to the maximum permitted bearing

pressure shall have under dry conditions:

(i) A restoration after 1 hour of at least 65% of the original thickness.

(ii) A compression of at least 50% of the original thickness. Independently

authenticated test results to demonstrate that the packing complies with the
specification shall be submitted and shall include a graph of the stress/strain
relationship over the range of conditions which will be encountered during
the Works.

b) The material used for packing shall be suitable to withstand all imposed loading
applied during the installation of all pipes for each completed length without
showing signs of deterioration or distress.

14.2.4 Joint Seal

The joint seal shall comprise one or more elastomeric rings complying with BS EN
681-1.

14.2.5 Dewatering Equipment

a) Dewatering equipment may include the use of or the combination of well pumps,
eductors, deep wells, well-points, monitoring wells, temporary pipelines for water
disposal, temporary hose, manifolds, rock or gravel placement, containment
basins, sediment traps, settling tanks, cut-off or curtain walls, and/or other means.
Standby pumping equipment including self-contained emergency power
generators shall be maintained on Site at all times.

b) The Contractor shall install Piezometers at locations, intervals or spacing as

recommended by the dewatering system designer; however, if dewatering
beneath shaft invert is used for shafts, the Contractor shall provide a minimum of
two observation wells or piezometers per shaft, equidistant between adjacent
dewatering wells, well points, eductors, or similar equipment. Piezometers shall
be installed to a depth allowing confirmation that water level is 1.5 metres below
the bottom of the shaft excavation.
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c) Sump pumps in the shaft invert or any other excavations shall not be an
acceptable means of dewatering. Sump pumps will be allowed in emergency
situations only to remove small quantities of accumulated stormwater run-off.
Discharge of any sump pump shall be subject to all the provisions of dewatering
permits and the Construction Environmental Management Plan (CEMP).

14.3 EXECUTION

14.3.1 General

a) Confine surface operations to pits/shafts and the area immediately adjacent to

pits/shafts. Keep the working area to the minimum practicable for the proper
construction of the works.

b) Contractor shall take any measures necessary to prevent damage or deterioration

of the soil reaction face during the construction of the temporary and permanent
works from whatever possible cause, such as ingress of water, softening,
corrosive soil or loss of fines from a granular soil.

14.3.2 Examination

a) Contractor shall obtain existing utility information, and execute trial pits to locate
and confirm services at pit/shaft locations and elsewhere as required.

b) Pre construction photographs and pre construction grid survey of surface levels
along the length of the proposed tunnel shall be taken by the Contractor.

14.3.3 Cavity Grouting

a) In case cavities have been confirmed to exist along the tunnelling route by
geophysical survey, such cavities shall be grouted.

b) Grouting of existing cavities where required shall be carried out by means of

drilling and pressure grouting of cement, cement/sand or cement/bentonite mortar
to fill in the cavities and open fissures. This work shall be designed, carried out
and tested by a specialised Contractor to a method statement approved by the
Engineer.

c) Boreholes shall be drilled vertically to the required depth below existing ground
levels. Grouting shall be completed from the base of the boreholes up to ground
levels. Verification boreholes shall be drilled, water pressure tested and grouted
to assess the effectiveness of the treatment.

d) Drilling shall be executed using rotary drilling methods with a casing advancer
system to prevent borehole collapse in unconsolidated materials. Borehole
diameter shall be a minimum of 100mm.

e) Grouting shall be carried out in stages in accordance with the approved method
statement. Inflatable packs shall be used as necessary to isolate areas requiring
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grouting and to enable pressure grouting. Grout shall be pumped through flexible
hoses or steel pipes to the grout holes location. Grouting pressure shall be
regulated up to a maximum of 2 bar unless ground conditions dictate otherwise.
Grout shall be introduced to the grout hole via a tremmie pipe placed at the base
of the borehole. The tremmie pipe shall not be removed until 100% grout is
observed and maintained at the grout holes surface.

14.3.4 Shafts, Jacking and receiving Pits

a) The Contractor shall design, construct, maintain and backfill on completion all
temporary work shafts. Where a permanent structure like Manholes, Vortex
Chamber, or other permanent ancillary structure is built wholly or partially within a
temporary work shaft, the Contractor’s rates for the temporary shaft and the
permanent structure(s) shall fully take into account the method of construction of
both temporary and permanent works.

b) Pits/Shafts

(i) It is envisaged that pits/shafts will be constructed as follows but the final
design will be the responsibility of the Contractor to the approval of the
Engineer.

(ii) The Contractor shall select between using inter-locked sheet pile cofferdam,
secant piling or reinforced concrete caisson as the most appropriate for the
site conditions and for the soil profile.

(iii) All the joints between caisson rings shall be sealed with joint sealant and
the caisson grouted from outside in order to make it watertight.

(iv) Interlocked steel sheet piles shall be braced by suitable steel framing
welded to the sheet piles. No struts shall be used for bracing. The first set
of bracing shall be 0.5m from the ground surface.

(v) The pit bottom shall be sealed with a concrete plug, which shall be placed
underwater and designed to resist water uplift as well as forces from the
jacking equipment to be installed in the pit.

(vi) A reinforced concrete wall shall be provided in the thrust pit to resist the
jacking force. A properly braced concrete wall shall be provided in the thrust
and reception pits in order to install the exit and entry rings.

(vii) If a portion of the pit is to be constructed in rock, then this portion may be
unsupported provided the rock layer is strong enough to safely resist all the
expected forces and stresses. Contractor shall prove this by testing and
calculation. Special precautions shall be taken to seal the interface between
the caisson or sheet piles and the rock so that it is water and soil tight.
Rock faces should also be treated if necessary to make them watertight.

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(viii) Maintain the pits/shafts dry prior to commencing and throughout tunnelling
works. Dealing with groundwater shall be carried out carefully and slowly.
Provide standby facilities.

(ix) Thrust wall shall be:

1. Perpendicular to the proposed line of thrust.

2. Sufficient to accept repeatedly the maximum permitted thrust force

without undue movement and without thrusting directly off any part of
the permanent works comprising any shaft, chamber or pumping station
unless this is specifically designed to withstand the thrust reaction.

3. Not joined to the jacking rig base.

4. Any void between the soil face used to provide a reaction to the thrust
force and the thrust wall filled completely with grout or concrete.

5. The design of the thrust wall and any associated temporary works shall
be such as to prevent damage to any part of the Permanent Works.

(x) Provide entry and exit sealing rings to ensure a watertight joint around the
pipe at all times.

c) Shaft Support System

(i) Excavation support systems shall be designed by an experienced engineer

with Equivalent Qualifications. Contractor shall be responsible for all
support systems.

(ii) Excavation support system shall be designed to support ground and

groundwater loads, utility loads, traffic and construction loads, and all other
applicable surcharge to prevent damage to or minimise movement of
existing buildings, structures and services. The Contractor shall ensure that
the groundwater regime surrounding the shaft is not affected by the
construction of the shaft unless the Contractor can adequately demonstrate
that a temporary drawdown of the water table around the shaft will not
cause any damage and or settlement to nearby buildings, structures and
services.

(iii) Excavation support systems shall be designed to be compatible with the

geological conditions described in the Volume 5, and as updated or
supplemented and approved based on the results of the Contractors
additional Geotechnical Explorations, Testing and Evaluation Programmes.

(iv) Excavation support systems shall be designed for control of water,

maintaining bottom stability and protection of subgrade.

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(v) The size, type, and design of the shaft excavation support system are the
Contractor’s responsibility, and are subject to review and approval by the
Engineer. The Contractor shall assume full responsibility for the design,
construction, and safety of the shaft support system.

(vi) The system of support may consist of the following alternatives:

1. Bored pile walls (e.g. secant or tangential);

2. Sheet pile walls

3. Precast ring or segment caissons;

4. Slurry/diaphragm walls;

5. Drilled shafts with temporary casings;

6. Other alternatives;

7. With the exception of ring caissons, walls may be secured in place with
bracing members such as ring beams, struts or tieback anchors.

(vii) Each support member shall be designed to support the maximum loads that
may occur during construction.

(viii) The bottom of the support system shall be carried to an adequate depth
below the main excavation to minimise lateral and vertical ground
movements. Where additional excavation is carried below the main
excavation, a means to control movement of the main excavation supports
shall be provided.

(ix) The shaft shall be sized and the excavation support system designed to
allow the required free space for the safe movement of workers,
Contractor’s Equipment, and materials in and out of the shafts.

(x) If the proposed shaft support system includes tieback anchors, the
Contractor shall provide the geotechnical profile for which each anchor is
intended, the design load for the full depth of the excavation, the maximum
design and proof loads, and the criteria proposed for deformations under
proof loads. Any such anchors must be indicated on Contractor’s
applications for permits or Notices of Intent.

(xi) If removal is required wholly or in part, such removal shall be performed in a

manner that shall not disturb or damage adjacent structures, construction,
or utilities. Fill voids immediately with lean concrete or approved compacted
backfill.

(xii) The Contractor’s designs and method statements for temporary work shafts
shall include as a minimum the following:

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1. Details, arrangement, and method of assembly of the support system.

2. Method of preloading and bracing.

3. Ground reinforcement details.

4. Load test procedures.

5. Grouting materials and methods.

6. Loads for various stages of bracing removal and concrete placement.

7. Anticipated construction equipment loads.

8. Maximum design load to be carried by the various member systems and

preloads.

9. Depths below the ground surface to which the proposed support system
will be installed.

10. Maximum theoretical deflections of the support members and

surrounding ground

11. Special attention shall be applied in design and construction to ensuring

that the resultant settlement caused by the excavation of shafts is within
the limits specified in Section 16.

d) Invert Slab

(i) The invert slab at each excavation shall be designed to protect the
excavation invert in accordance with these minimum design criteria:

1. Capable of resisting maximum hydrostatic uplift recommended in the

GIR, with a minimum safety factor of 1.5, either with or without a
groundwater/pressure relief system. Reliance on pumping alone is not
acceptable. Pump or power failure shall not result in unsafe hydraulic
gradients, exceeding capacity of filters or excessive loads and
deformation of shoring.

2. Capable of supporting such combined dead and live loads as are

required by the Contractor’s means and methods.

14.3.5 Tunnelling / Pipe Installation

a) Tunnelling:

(i) Before any particular tunnelling commences, provide sufficient pipes, and, if
required, provide intermediate jacking station assemblies to ensure
continuous operation.

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(ii) Carry out the tunnel construction using the recommended accepted method
to the satisfaction of the Engineer and to meet the contents of these
specifications.

(iii) Limit the thrust force to the maximum permissible as determined and based
on submitted and approved calculations.

(iv) Excavation rate not to exceed the horizontal drive rate throughout the
operation.

(v) Prevent both subsidence and heave during all stages of the setting up,
tunnelling operation and dismantling.

(vi) Remove slurry/excavated soil mixture properly from the excavation, settle in
a stilling basin and remove from the site to a suitable location. Avoid stock
piling on site.

(vii) Maintain tunnel face support for balancing full earth pressure and
groundwater pressures.

(viii) Tunnelling operation shall be run continuously between drive and

reception pits/shafts.

(ix) Cuttings spoil removal and cutter face operation not permitted when the
pipe thrust is not being carried out.

(x) Fill the annular overbore voids around the outside of the pipe to avoid
collapse and upward migration of the void prior to permanent grouting.
Avoid drilling fluid injection overpressure.

(xi) Casing and carrier pipes: place and join carrier pipe sections individually
within the sleeve or mount on guide rails or trolleys in such a manner as to
transmit the pulling/pushing forces through the carriage and not
through the pipe.

b) Pipe Installation:

(i) All pipes shall be installed in accordance with the manufacturer’s installation
instructions.

(ii) If the Contractor’s design requires that pipe jacking operations be driven in
a downhill direction then the Contractor shall submit to the Engineer his
proposals for ensuring the security of his operations against flooding of the
tunnel.

(iii) TBM operation shall be capable of maintaining ground control at the face to
complete the work without exceeding the ground movement limits specified
in Section 16 ‘Protection of Existing Structures and Services’.

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(iv) Earth Pressure Balance Machines shall be operated in closed mode.

(v) Each pipe must be inspected for damage before installation and approved
for use by the Engineer. Pipe ends must be undamaged without any signs
of dirt or chipping. Defective packings and sealing rings must be discarded
before installation and joint sleeves must not show any dents, damage or
distortion.

(vi) The angular deviations between pipe faces can cause severe localisation of
stress and should be avoided. The angular deviation at each face shall not
exceed 0.15 degrees with a maximum total of 0.30 degrees.

(vii) Pipes should be straight and uniformly dimensioned, have squared ends
and have joints that are designed to allow for efficient load transfer from
pipe to pipe.

(viii) The jacking frame, jacks and steering head should be aligned along the
planned line and grade and shall be square and true to the thrust wall to
minimise eccentric loading. Steering corrections should be made gradually
to minimise abrupt misalignment angles between two pipes resulting in
eccentric loads.

(ix) Overcut around the circumference of the tunnel shield should be designed
to allow steering corrections to be made and lubricant to be injected to
completely coat the pipe exterior but the overcut should not be greater than
20mm on the radius of the skin of the shield.

(x) The jacking frame and the capacity of the jacks shall be designed by the
contractor to ensure uninterrupted operation of the works. Calculations shall
be submitted to the Engineer for his information.

(xi) The TBM and associated equipment must be capable of monitoring slurry
pressures. Regular inspection of the ground surface and existing
stormwater and sewer pipelines near underground slurry injection locations
is required to ensure that hydrofracture and loss of slurry is prevented and
managed.

(xii) Intermediate Jacking Stations: If the jacking force, after applying a safety
factor of 1.5, exceeds 75% of the maximum working load for the pipe, the
use of intermediate jacking stations is required. The Contractor shall notify
the Engineer in writing of his intent to install an intermediate jacking station.

(xiii) The Contractor shall take a sample from either the separation plant (slurry)
or muck skip (EPB) once per day for each drive. Each sample shall be
minimum 1 litre in volume. The sample shall be bagged, sealed and
labelled with: Contract #, Drive/Line #, Date, Chainage. Samples shall be
stored in a secure building out of direct sunlight, and available for inspection
by the Engineer from the day following the sampling.
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14.3.6 Constructions Shift Records

Construction shift records shall be submitted to the Engineer and shall include :

a) Extent and causes of any delays.

b) Face logs of the as-dug strata.

c) Machine performance (advance rates, slurry flow rates, jacking thrust loads,
machine torque measurements).

d) Computer output: grade and roll of MTBM, Torque and RPM of the cutterhead ,
instantaneous jacking rate and total distance jacking rate, indication of steering
direction, volume of the slurry in both the supply and the return side of the slurry
loop, and indication of the pressure of the slurry in the slurry chamber. All
parameters should be logged in real time and over distances.

e) Line and level of the lead pipe on completion of the installation of each pipe
during the shift.

f) Records of mucking out and muck deliveries to disposal site, ticketed and
stamped at the disposal site.

g) Copies of the shift records shall be submitted daily to the Engineer.

14.3.7 TBM Real Time Monitoring

a) Continuous data monitoring and logging of TBM performance shall be submitted

to the Engineer in real (instantaneous) time for the duration of TBM excavation.
Data collection shall be accomplished by automatic electronic continuous
recording systems. Data to be collected shall include the following:

(i) For every jacking shove or stroke, the date, time and station at start of
shove; duration of shove; type of soil; cutter head revs; drive speed;
average drive motor current or hydraulic pressure; power consumption;
thrust/propel cylinder pressure; number of operating motors; mode of
operation and cutterhead chamber pressure; jacking pressure; interjack
pressures; lubrication and grout volumes and pressures.

(ii) Slurry line pressure, flow, density, viscosity.

(iii) Gas monitoring and alarm.

(iv) Excavated volume against theoretical volume for the actual advance. The
system shall incorporate an audio visual alarm with preset alert limits in the
TBM operator cabin to warn of potential over-excavation.

(v) TBM orientation and deflection from line, level and grade, roll, and other
information provided by automatic data acquisition systems.

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b) The data acquisition system supplied to the Engineer’s office shall allow the
Engineer to study and print out real time and historical data for each TBM and
guidance system via a dedicated computer and backup computer. There shall be
one dedicated data acquisition system per TBM to be installed in the Engineer’s
office.

c) Should the TBM guidance system not be part of the TBM data acquisition
program, an additional dedicated guidance system computer is required to
duplicate the data acquisition system’s scope. Alternatives which require the
closure of the data acquisition program to view the guidance system are not
acceptable although separate windows running the data/guidance programs
simultaneously maybe acceptable, subject to the Engineers approval.

d) The data and guidance systems in each office are to be linked to the network
printers at the corresponding Engineers office.

14.3.8 Guidance and Control System

a) The setting of the laser and target and the alignment of the tunnel relative to the
laser beam shall be accurate and checked constantly.

b) Where pipeline diameter allows, manual checking of line and level shall be carried
out by conventional theodolite and level techniques.

c) If the deviation exceeds the specified tolerance, work shall cease immediately
and the Engineer informed forthwith. The Contractor shall submit proposals to
rectify the deviation and work shall only recommence on the written instruction of
the Engineer.

d) The alignment shall be determined by a surface survey. Care should be taken in

the transfer of the survey to the shaft bases. The guidance is achieved by using a
self-levelling Laser transit unit.

e) The Laser shall be mounted independently of the thrust wall so that minor
deflections of the wall would not result in inaccurate readings.

14.3.9 Drilling Fluid Tests

Contractor shall carry out control tests on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be measured
daily as a check on the quality of the suspension being formed. The measuring
device shall be calibrated to read to within 0.005 g/ml. Tests to determine density,
viscosity, shear strength and pH value shall be applied to bentonite supplied to the
pipe bore. For average soil conditions the results shall generally be within the
ranges in Table 14.1 below.

Table 14.1 – Bentonite Suspension Properties

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Property Test Method Range of Results

Density Mud density balance Less than 1.10g/ml

Viscosity Marsh cone method 30 to 90s

Fann viscometer less than 0.020Pa-s
Shear strength Shearometer 1.4 to 10Pa
10 minute gel strength Fann viscometer 4 to 40Pa

pH pH indicator paper strips or 9.5 to 12

electrical pH meter

Notes to Table 14.1

1) Where the Fann viscometer is specified, the fluid sample should be screened by
a 300 µm sieve before testing.

2) The Contractor shall propose the frequency of testing bentonite slurry and the
method and procedure of sampling for approval before the commencement of work.
The frequency may subsequently be varied as required, depending on the
consistency of the results obtained, subject to approval.

3) Carry out tests until a consistent working pattern has been established, account
being taken of the mixing process, any blending of freshly mixed bentonite
suspension and previously used bentonite suspension, and any process which may
be used to remove impurities from previously used bentonite suspension. When the
results show consistent behaviour, the tests for shear strength and pH value may be
discontinued, and tests to determine density and viscosity shall be carried out as
agreed with the Engineer. In the event of a change in the established working
pattern, tests for shear strength and pH value shall be reintroduced for a period if
required.

14.3.10 Grouting

a) Upon completion of a section the grout should be pumped through all lubrication
holes. The pressure and quantity of grout injected shall be calculated by the
Contractor and approved by the Engineer.

b) Commence grouting at the lower holes systematically working from one end of
the pipejack to the other. Where injection holes can be opened without loss of
ground, pump grout through the lower injection holes until it emerges from the
upper holes.

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c) Monitor grouting progress continuously to ensure no heave.

d) Protect the carrier pipe and joints from the possible adverse physical or chemical
effect of grout. Wrap compressible material around the carrier pipe if required.

e) Install a free venting standpipe of not less than 100mm diameter on the grout
injection feed to restrict grouting pressures to a maximum of 1 bar.

f) Plug lubrication holes watertight on completion and make good pipe lining or
coating. Maintain the pressure of the lubricant when it is to be replaced by grout.

g) Grouting (external to pipe):

(i) Immediately following the jacking operation the Contractor shall pressure
grout the jacked section to fill all voids existing outside of the pipe. Grouting
shall be from the interior of the pipe through grouting holes as specified.

(ii) System of standard pipe, fittings, hose, and special grouting outlets
embedded in the pipe walls shall be provided by the Contractor. Care shall
be taken to ensure that all parts of the system are maintained free from dirt.
Grout composed of cement, sand, other Engineer approved compound and
water shall be forced under pressure into the grouting connections at the
invert and shall proceed until grout begins to flow from upper connections.
Connections shall then be made to those holes and the operation continued
to completion.

(iii) Apparatus for mixing and placing grout shall be of a type approved by the
Engineer and shall be capable of mixing effectively and stirring the grout
and then forcing it into the grout connections in a continuous uninterrupted
flow.

(iv) After grouting is completed, pressure shall be maintained by means of stop

cocks, or other suitable devices until the grout has set sufficiently. After the
grout is set, grout holes shall be completely filled with dense concrete and
finished neatly without evidence of voids or projections.

(v) For pipes with concrete protection liners, grouting shall be carried out and
the Contractor shall ensure that the pipeline is watertight before proceeding
with the jointing of the linings of the pipes and the patching of the lining over
the filled grout holes. Grout holes patching shall be carried out using same
lining material.

14.3.11 Tolerances

a) Lateral deviation of any part of the pipeline shall be not more than ±50mm.

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b) Level deviation of any part of the pipeline shall be not more than ±20mm for pipe
diameter up to 1800mm and ±50mm for pipe diameter above 1800mm.

c) Maximum lipping between the edges of adjacent pipes shall be not more than
±5mm.

d) Ground movement shall be limited to the following:

(i) Ground or roadway surface above the pipe centreline 5mm (unless the
Roads Authorities requirement is more stringent).

(ii) Adjacent structures 3mm.

e) There shall be no pipeline backfall at any point.

f) Any pipe which is not laid in its correct position must be adjusted to obtain its
correct position

14.3.12 Dewatering

a) The Contractor shall carry out work specified in this Section including design,
installation, operation, maintenance, and removal of ground dewatering systems
for shafts and trenches, and establishment of a groundwater level monitoring
programme.

b) Dewatering shall only be employed as a form of ground treatment/ground

improvement after obtaining the Engineer’s approval in writing. To obtain the
Engineer’s approval, the Contractor shall demonstrate to the satisfaction of the
Engineer that dewatering operations at each proposed location shall not cause
any damage to existing building, structures and services and/or shall not cause
unacceptable surface settlement either in the short term or long term. The
Contractor shall be also required to demonstrate that the ground water regime
after decommissioning of the dewatering system shall not be permanently
affected by the dewatering, e.g. a permanent drawdown of the water table in the
area surrounding the dewatering well(s), migration of contaminants into the area,
etc.

c) The Contractor shall be solely responsible for the design, installation, operation
and maintenance of the sumps and dewatering systems under this Contract, and
shall provide all labour, materials, and equipment so as to lower and maintain the
groundwater table to the level necessary to allow safe excavation, construction of
structures, installation of pipes, structures and appurtenances, and backfilling of
excavations to be carried out under dry conditions. Care shall be taken to prevent
migration of natural soils and softening of the bottom of excavations due to
formation of “quick” conditions and/or “boils.”

d) The Contractor shall dispose of water from dewatering operations so as not to

cause injury or damage to adjacent property and shall at all times remain in

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compliance with Construction Environmental Management Plan (CEMP)

requirements .

e) The Contractor shall provide, install, operate, and maintain dewatering systems of
sufficient size and capacity to permit excavation and subsequent construction in
dry conditions. Unless otherwise approved by the Engineer, the dewatering
system shall lower and maintain groundwater at a level that will allow safe
excavation while complying with specified settlement limits. Excavations shall be
maintained continuously free of water, regardless of source, and until excavation
is backfilled to final grade.

f) System redundancy shall be provided as required to keep excavations free of

water in event of failure of well point, pump, eductor, or other component.

g) The Contractor shall provide 100 percent emergency pump and power backup
with automatic start-up and switchover in event of electrical power failure.

h) The Contractor shall provide supplemental ditches and sumps only as necessary
to collect water from local seeps.

i) The Contractor shall provide competent workmen and supervision for the
operation of the pumping equipment. Workmen shall be available 24 hours a day
during dewatering to perform emergency maintenance on system components.

j) The Contractor shall grade the site such that at all times, site grading shall
promote drainage and surface runoff shall be diverted from excavations. Water
entering the excavation from surface runoff shall be collected in shallow ditches
around the perimeter of the excavation, drained to sumps, and be pumped or
drained by gravity from the excavation to maintain a bottom free from standing
water. The Contractor shall provide berms, ditches, temporary piping that spans
the excavation, or other means to protect excavations from erosion due to surface
water runoff or stream flooding.

k) The Contractor shall conduct the dewatering in such a manner as to preserve the
undisturbed bearing capacity of the subgrade soils at proposed bottom of
excavation.

l) If foundation soils are disturbed or loosened by the upward seepage of water or

an uncontrolled flow of water, the contractor shall excavate the affected areas and
replace the materials with geotextile and drain rock in accordance with the
provisions of Section 2, Site Clearance and Earthwork, at no additional cost to the
Employer.

m) The Contractor shall maintain the water level a minimum of 1.5m below the
bottom of shaft excavation, where groundwater occurs during excavation,
construction, backfilling, and up to acceptance of work in such a manner to
guarantee the stability of the excavation invert against boiling or quick conditions.

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n) The Contractor shall prevent flotation of pipe or other work by maintaining a

positive and continuous removal of water. The Contractor shall be fully and solely
responsible and liable for all damages which may result from failure to adequately
keep excavations dewatered.

o) Wells used to dewater excavations shall be adequately spaced to provide the

necessary dewatering and shall be sand packed and/or filtered by other means
used to prevent pumping of fine sands or silt-size soil particles from the
subsurface. The Contractor shall maintain a continual check to ensure that the
subsurface soil is not being removed by the dewatering operation.

p) Settlement: The Contractor shall repair without additional cost to DM any damage
caused by dewatering.

q) Disposal of water: Water from ground dewatering operations is subject to the

following:

(i) The Contractor shall dispose of water from the Work in a suitable manner
without damage to adjacent property. Contractor shall be responsible for
obtaining any and all permit that may be necessary to dispose of water. No
water shall be drained into work built or under construction without prior
written authorization of the Engineer. Water shall be filtered using a method
to remove sand and fine-sized soil particles before disposal into any
drainage system.

(ii) All dewatering water shall be desilted through adequately sized desilting
tanks, plate clarifier systems or other systems as may be necessary, prior to
discharge.

(iii) The release of groundwater to its static level shall be performed in such a
manner as to maintain the undisturbed state of the natural foundation soils,
prevent disturbance of compacted backfill and prevent flotation or
movement of structures, pipelines, and sewers

14.3.13 Slurry Separation Plant

The excavated material from the face cut, crushed and mixed with the slurry shall be
separated and the water recycled or disposed of at a location agreed by the
Engineer. Cleaning of the slurry shall be achieved by using either:

a) Settling tanks, where the tank is cleaned by an excavator or grab, the water is
recycled and the solid material is disposed off the site; or

b) Separation plant, where a separate unit of screens and cyclones continuously

removes the solids and recirculates the slurry for further use or disposal.

14.3.14 Protection of existing Structures and Services

Protection of existing structures and services shall be carried out as per Section 16.
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14.3.15 Monitoring Ground Surface Movement

Monitoring ground Surface movement shall be carried as outlined in Section 15.

a) The Contractor shall continuously monitor the ground surface adjacent to

structures and buried utilities and shall control activities such as excavation,
tunnelling and dewatering to prevent movement and or damage to existing
structures.

b) Install movement points and monitor prior to any excavation associated with the
pipeline.

c) Determine the optimum location for points to monitor existing structures to the
approval of the Engineer.

d) Provide monitoring points within the existing structures and on the road surface to
the approval of the Engineer. Generally, monitoring points along the road surface
shall be located along the pipe centreline on each side. The distance for the
location of the monitoring points along the same line shall be calculated to fall
within the HS 20 wheel loads in each lane. Points on existing structures shall
be located approximately 500mm above the ground surface. Location of
settlement points in the vicinity of the pits/shafts will be agreed with the Engineer.

e) Monitor all points with reference to benchmarks located outside the area of
influence of the Works. Monitoring shall demonstrate repeatability to 3mm.

f) Obtain the elevations of monitoring points as described below.

(i) For monitoring points within 20m of the heading, after each advance
of 5m.

(ii) For monitoring points greater than 20m but less than 100m away from the
heading, daily.

The monitoring point elevations shall be reported to the Engineer within 24 hours
during the course of construction of the pipeline and related pits/shafts.

g) Should surface movement occur greater than the specified limits, at any location
affected by the Works, the Engineer may require modification of the method or
sequence of the work or a shutdown of the work to make appropriate changes in
the construction operation. Changes required to keep surface movement within
the specified acceptable limits shall be made solely at the Contractor’s expense.

h) Upon completion of the pipeline, continue to monitor point elevations during the
maintenance period as required by the relevant authority, record findings and
report to the Engineer on a monthly basis. If the specified limits are exceeded,
report immediately and submit a proposal to rectify the road surface and prevent
further settlement.

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14.3.16 Pipe Testing

Unless superseded by clauses herein, the requirements of ‘Section 4- Pipes,

Pipework, Manholes and Chambers’ apply.

a) Conduct infiltration test upon completion of the permanent construction of the

tunnel to verify the joints are water tight. The infiltration test shall be carried out
after dewatering is stopped and the groundwater has attained normal levels. In
the case of lined concrete pipes the leakage tests shall be carried out after
installation and before the liners of the successive pipes are joined and sealed.
After joining and sealing of the liners, there shall be no evidence of a build-up of
groundwater pressure at the joints of the concrete pipe.

b) Man entry pipelines shall be visually inspected only. Any leaks to be

repaired/stopped.

c) Infiltration or pipe deflection is not permitted in sections of pipelines underneath

roads, paved areas and services.

d) In the event of the works failing the test, for whatever reason, the Contractor shall
take such remedial action as is necessary to correct the deficiencies, subject to
the Engineer’s approval of any methods proposed. The works shall be re-tested
until such time as the works pass the test.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 15

GEOTECHNICAL INSTRUMENTATION & MONITORING

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DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

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SECTION 15
GEOTECHNICAL INSTRUMENTATION & MONITORING

CONTENTS
15 GEOTECHNICAL INSTRUMENTATION & MONITORING ............................................... 1
15.1 GENERAL...................................................................................................................... 1
15.1.1 Scope .................................................................................................................... 1
15.1.2 Submittals ............................................................................................................. 1
15.1.3 Quality Control ...................................................................................................... 1

15.2 MATERIAL..................................................................................................................... 2
15.2.1 Grout Mix .............................................................................................................. 2

15.3 EXECUTION .................................................................................................................. 2

15.3.1 General ................................................................................................................. 2
15.3.2 Installation ............................................................................................................. 5
15.3.3 Monitoring Frequency ......................................................................................... 10
15.3.4 Protection, Maintenance and Repair .................................................................. 11
15.3.5 Removal .............................................................................................................. 11
15.3.6 Drawings ............................................................................................................. 12

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15 GEOTECHNICAL INSTRUMENTATION & MONITORING

15.1 GENERAL

15.1.1 Scope

The work specified in this Section includes furnishing, installing, and monitoring
geotechnical instrumentation for the following:

a) All buildings, structures and services likely to be affected by the Works.

b) Performance of pipejack/microtunnelling equipment.

c) Pipeline ovality sections at selected locations for pipelines of 900mm diameter or

greater.

d) All shafts and excavations deeper than 5 m unless stated otherwise.

15.1.2 Submittals

The following documents shall be prepared by the Contractor and submitted to the
Engineer:

a) Method Statements: Submit a detailed instrumentation monitoring programme in

a written method statement to the Engineer for approval within 10 weeks from the
Commencement Date. It should include installation procedures, instrument types,
locations, monitoring procedures, monitoring frequency, and all requirements
imposed by the parties responsible for monitoring the affected structures.

b) Drawings: Submit planned depths, planned locations, and detail drawings for all
required and proposed instrumentation.

15.1.3 Quality Control

a) Qualifications: Engage a professional and independent geotechnical

instrumentation and monitoring firm, acceptable to the Engineer to carry out the
instrumentation and monitoring programme. The responsible person shall be a
Civil Engineer with a minimum of 5 years’ experience in geotechnical
instrumentation and monitoring.

b) Survey Methods and Survey Control:

(i) Establish deep cased bench marks from the approved datum for use in
instrumentation monitoring.

(ii) Establish the elevations of deep cased bench marks by running level
circuits started and closed at the specified bench mark and as follows:

1. Establish turning points so that foresights and backsights are

approximately equal. Foresights and backsights shall be less than 60 m.

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2. Turning points shall consist of well defined surface points of solid

objects or masonry nails driven into pavement.

3. Each error of closure shall be less than 3 mm. If any error of closure is
greater than 3 mm, re-survey the circuit.

4. Prove the established elevations of deep cased bench marks by running

at least three separate and complete level circuits which yield consistent
results. Re-survey all level circuits until correct and repeatable
elevations are obtained.

(iii) Determine initial locations and elevations of all monitoring points,

instruments, and bench marks by optical surveying techniques.

(iv) Provide initial readings of building settlement points by conducting at least

three separate and complete sets of optical survey readings on each
instrument which yield consistent results.

15.2 MATERIAL

15.2.1 Grout Mix

Bentonite grout shall comply with requirements of Table 15.1 below unless otherwise
approved by the Engineer.

Details of cement grout mixes and placement methods shall be submitted to the
Engineer approval prior to incorporation into the Works.

Table 15.1: Bentonite Grout Mix

Materials Weight Ratio by Weight

Portland cement 50 kg 1

Bentonite 13.2 kg 0.3

Water 125 litres 2.5

15.3 EXECUTION

15.3.1 General

a) Commence the monitoring programme as soon as possible after the Date of

Commencement and at least 4 weeks before construction work is scheduled to
start. Determine the present on-going rate of intrinsic settlement or subsurface
ground movement, background vibration levels, etc., at the site during this period
for the purpose of differentiation while the Works are in progress.

b) The monitoring programme shall include the installation of settlement observation

points, inclinometers, vibration monitoring equipment, extensometers,
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piezometers, and water level observation wells as specified below. Provide

additional monitoring stations, devices, and procedures if deemed necessary or if
directed by the Engineer during the progress of the Works. The Contractor may
propose additional or alternative instrumentation not listed herein.

c) Performance Monitoring of pipejacked/microtunnelled pipelines:

(i) Monitor TBM performance at selected locations within a minimum of four

monitoring zones, at least two of which shall be located on the conveyance
pipe line. The entire length of a monitoring zone shall be 16 m or less.
Install from the ground surface within each monitoring zone a series of
settlement observation points above the pipeline crown and transverse to
the centreline to determine the shape and depth of the longitudinal and
transverse settlement troughs. Install within each monitoring zone, a
minimum of 21 settlement points, including seven points at each of three
perpendicular pipeline cross-sections.

(ii) Install within each of the monitoring zones described above at least one
piezometer, four inclinometers, and three multiple point borehole
extensometers. Install the deepest extensometer a maximum of 0.5 m
vertically above the pipeline crown.

(iii) Install surface settlement points every 100 m along the pipeline centreline
and deep extensometers about every 500 m along the pipeline centreline.

(iv) Install in any building within the zone of influence of bored tunnel one
levelling settlement point every 25m along the building perimeter or at least
one point at each corner, at least one tilt meter and crack meters as
required based on actual condition. On other structures within the zone of
influence, above mentioned instruments to be installed, so as to adequately
monitor their behaviour during tunnelling works, at locations approved by
the Engineer.

d) Performance Monitoring of Shafts and Open-Cut Excavations:

(i) For shafts with excavated diameters of 4m or greater or deeper than 5m,
internal convergence points, strain gauges on lateral support elements,
surface settlement points, one inclinometer, one piezometer and building
settlement monitoring points shall constitute a minimum monitoring plan.

(ii) For shafts with excavated diameters greater than 6m diameter, include in
the monitoring plan, the same instrumentation as described in d) 1. above in
this section plus two additional inclinometers.

(iii) The monitoring points for any given shaft shall be of sufficient spacing and
density to determine the displacements around the shaft and at affected
structures.

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(iv) Install piezometers in order to properly define the extent, if any, of

groundwater drawdown.

(v) Install borehole extensometers between any structure with shallow

foundations or sensitive pipelines at higher elevations at the following
locations.

1. Within the zone of influence of any dewatering

2. In areas of mixed face conditions

(vi) Install convergence points at pipeline/shaft junctions immediately after

installation of the initial ground support systems at the approved locations.

(vii) Install in any building within the zone of influence of a shaft one levelling
settlement point every 25m along the building perimeter or at least one point
at each corner, at least one tilt meter and crack meters as required based
on actual condition. On other structures within the zone of influence, above
mentioned instruments to be installed, so as to adequately monitor their
behaviour during shaft construction works, at locations approved by the
Engineer

e) Notify the Engineer in the event that any of the approved instrumentation
locations are inaccessible and propose alternative monitoring locations, subject to
the Engineer’s approval and the parties responsible for the affected structures.
Where settlement observation points are inaccessible, propose an indirect
measurement or alternative form of measurement.

f) At a minimum, monitor displacements and vibration levels of any structure or any

ground surface that is adjacent to a shaft, open excavation, or pipeline where
predicted displacements exceed 5 mm, predicted induced settlement slopes
exceed 1/500, or where subjected to greater than 50 mm/sec peak particle
velocity (PPV) construction vibration levels.

g) Design all deformation monitoring instrumentation for ground settlements, heaves

or deformations which may occur. Replace or reset any instrumentation that
exceeds 85 percent of its design value.

h) Rates shall allow for carrying out the monitoring programme as specified,
including any additional stations, devices and procedures as directed by the
Engineer.

i) Use survey methods for instrument reading as specified for survey control.

j) Keep a continuous boring log of drilling observations including soil types, water
levels, and drilling difficulties encountered during drilling. Submit a boring log
template for the Engineer’s approval. Submit a completed boring log to the

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Engineer at the completion of installation work for each water level observation
well and piezometer.

15.3.2 Installation

a) Deep Cased Bench Marks:

(i) Drive outer casing vertically to refusal. Drill ahead of outer casing as
required for penetration into dense soil or weathered/fractured rock.

(ii) Seat the outer casing within firm ground. Drill below the outer casing to the
depth shown. Blow out soil and/or rock fragments from the drilled hole with
compressed air of sufficient pressure introduced at the bottom of the drill
hole.

(iii) Place cement grout in the drilled hole. Seat the inner bench mark pipe
within the cement grout.

(iv) Install centring devices between the inner bench mark pipe and outer
casing.

(v) Weld the stainless steel ball reading point to the top end of the bench mark
pipe.

(vi) Install lockable protective boxes over the top end of outer casing.

b) Near Surface Settlement Points:

(i) Flexible Pavement: Use survey masonry nails, with nail head flush with
pavement surface, suitable for use with levelling rod.

(ii) Rigid Pavement/Sidewalk: Install as shown on the drawing in Clause 15.3.6

of this Specification. Drive steel pipe to the depth shown using a coupling
and nipple as a striking surface. Remove coupling and install pipe cap with
read point.

(iii) Unimproved Areas: Install as shown on the drawing in Clause 15.3.6 of this
Specification. Install monument enclosure and cover as shown.

c) Building Settlement Monitoring Points: Install as shown on the drawing in Clause

15.3.7 of this Specification or in accordance with the manufacturer's
recommended procedures. Remove drilling debris from the drilled hole by air or
other suitable means.

d) Ground Inclinometers:

(i) Install inclinometer casing as shown on the drawing in Clause 15.3.6of this
Specification and in accordance with the manufacturer's recommended
procedures. Advance and clean the boring by rotary wash boring methods.

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Stabilise the borehole with temporary casing or drilling mud. Remove

temporary casing after installing inclinometer casing.

(ii) Place protective cap on bottom of inclinometer casing and seal with solvent
cement to provide a waterproof seal.

(iii) Assemble additional sections of inclinometer casing using appropriate

couplings and lower the sections into the hole. Fully extend telescoping
coupling and ensure that seals are watertight.

(iv) Add clean water to inside of inclinometer casing to facilitate lowering

inclinometer casing through water or drilling mud in the borehole.

(v) Position inclinometer casing so that the orthogonal grooves are parallel and
perpendicular to the shaft wall or pipeline.

(vi) Grout the annulus between the inclinometer casing and the borehole. Place
grout with a detachable flexible tremie pipe or grout pipe attached to the
bottom of the inclinometer casing. Ensure an intimate soil/grout contact.

(vii) Immediately after grouting, jet and flush inclinometer casing with clean
water.

(viii) Lower a dummy probe into inclinometer casing in two directions to ensure
that all four grooves are free of obstructions over their entire length.

(ix) Install lockable monument cover and enclosure over the top end of the
inclinometer casing as shown on the drawing in Clause 15.3.6 of this
Specification.

e) Vibrating-Wire Strain Gauges:

(i) Install strain gauges on steel struts or ring beams in accordance with the
manufacturer's recommended procedures.

(ii) Waterproof the strain gauges, cables, and cable connections using
recommended procedures.

(iii) Tack-weld bolts to strut web and secure protective channel covers to strut.
Wrench-tighten nuts. Attach steel and plates to channel by welding across
long dimensions of channel. Provide hole in end plate of cover to allow
passage of flexible conduit.

(iv) Protect cables from damage and lead them to an accessible platform within
the excavation where readings can be made. Terminate cables in
enclosures with panel boards.

f) Extensometers:

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 General Specifications for Civil Works
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Drainage and Irrigation Department

(i) Install extensometers as shown on the drawing in Clause 15.3.6 of this

Specification or in accordance with the manufacturer's recommended
procedures.

(ii) Drill holes to adequate depths. Avoid over drilling. Do not use drilling mud,
oil, or other materials in the hole which will adversely affect the bond
between soil, rock, grout, and extensometer anchors.

(iii) Grout extensometer anchors, attached extensometer rods, and protective

tubing within the borehole. Grout from the buried end of the borehole until
the borehole is filled. Do not interrupt grouting until the installation is
complete. Ensure an intimate ground/grout contact.

(iv) Terminate the top of extensometer rods and the top of the protective tubing
within the extensometer reference head guide sleeves.

(v) Clearly and permanently identify on extensometer reference head the

instrument identification number for each extensometer anchor and
connecting extensometer rod.

g) Crackmeters:

(i) Install crackmeters in accordance with the manufacturer's recommended

procedures, and as approved by the Engineer.

(ii) Wherever crack displacement after installation exceeds the crackmeter

displacement measuring range in one or more directions, dismount, reset,
and reinstall the crackmeter in the same location or approved alternate
location. No crackmeter shall be reset without prior approval by the
Engineer.

h) Tilt Meter

(i) Install tilt plates in accordance with the manufacturer's recommended

procedures and as approved by the engineer. Install tilt plates on buildings
and structures indicated in the approved plans. Monitor change in tilt of
building and structures using portable tiltmeter and readout unit cum
datalogger.

i) Water Level Observation Wells:

(i) Prior to construction operations, install observation wells. Install observation

wells at the locations and depths shown on the approved plans.

(ii) For each installation, drill hole using water as the drilling fluid. Support the
hole by using a hollow stem auger or by installing temporary casing. The
minimum diameter of the hole shall be 125 mm.

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

(iii) At the completion of drilling, flush the drilled hole with clean water to remove
drilling fluid.

(iv) Place a minimum of 100 cm filter sand in the bottom of the hole. Then insert
the well screen and riser pipe assembly into the hole. Fill the annulus
between the well assembly and the wall of the hole with filter sand to within
1 m of the top of the hole, withdrawing the hollow stem auger or temporary
casing as the sand is placed, to prevent caving of the hole around the filter
sand or riser pipe.

(v) Fill the top 1 m of the hole with lean concrete or similar.

(vi) Develop well by flushing out the installed riser pipe with clean water.

(vii) Survey the piezometer to document its exact location and collar elevation.
Fit the top of the riser pipe with a vented screw plug. Install the monument
enclosure and cover as shown.

(viii) Prepare a well installation log in a format approved by the Engineer.

(ix) Replace at no additional cost and within 48 hours any piezometer that is
damaged or destroyed.

j) Standard Piezometers:

(i) Prior to construction operations, install standpipe piezometers. Install

standpipe piezometers at the locations and depths shown on the approved
plans.

(ii) For each installation, drill a 125 mm (minimum) diameter hole using water
as the drilling fluid. Support the hole by using a hollow stem auger or by
installing temporary casing.

(iii) At the completion of drilling, flush the drilled hole with clean water to remove
drilling fluid.

(iv) Place a minimum of 30 cm of filter sand below the planned piezometer tip
depth. Insert the piezometer tip and riser pipe assembly into the hole. Fill
the annulus between the piezometer assembly and the wall of the hole with
filter sand to a minimum of 120 cm above the piezometer tip of the porous
piezometer top.

(v) Check that the required level of filter sand was placed in the hole by using a
measuring device, subject to the Engineer’s approval.

(vi) Place bentonite pellets in the annulus and tamp in place to produce a
bentonite seal a minimum of 50 cm thick above the top of the filter sand.
Provide a reliable apparatus, subject to the Engineer’s approval, for tamping
the pellets. Check the depth of the bentonite using the approved measuring
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Drainage and Irrigation Department

device specified above to ensure that the required seal thickness has been
achieved.

(vii) Fill the remaining annulus with bentonite grout.

(viii) Develop the piezometer by flushing out the installed riser pipe with clean
water.

(ix) Survey the piezometer to document its exact location and collar elevation.
Fit the top of the riser pipe with a vented screw plug. Install the monument
enclosure and cover as shown.

(x) Prepare a well installation log in a format approved by the Engineer.

(xi) Replace at no additional cost and within 48 hours any standpipe piezometer
that is damaged or destroyed.

k) Electric Vibrating-Wire Piezometers:

(i) Install electric vibrating-wire piezometers as shown on the drawing in

Clause 15.3.7 of this Specification or in accordance with the manufacturer's
recommended procedures. The location and depth of installation shall be as
per approved plan.

(ii) For each installation, drill hole using water as the drilling fluid. Support the
hole by using a hollow stem auger or by installing temporary casing.

(iii) After drilling is completed, flush hole with clean water to remove drilling
fluid.

(iv) Place a minimum of 300 mm of filter sand in the bottom of the hole.
Encapsulate a piezometer sensor in a canvas bag filled with filter sand.
Lower the encapsulated piezometer sensor and signal cable into the hole.
Fill the borehole annulus around and above the piezometer sensor with filter
sand to a minimum of 150 mm above the top of the piezometer sensor.

(v) Check that the required level of filter sand was placed in the hole by using a
measuring device, subject to the Engineer’s approval.

(vi) Place bentonite pellets in the borehole annulus and tamp in place to
produce a bentonite seal a minimum of 1 m thick above the top of the filter
sand. Provide a reliable apparatus, subject to the Engineer’s approval, for
tamping the pellets. Check the depth of the bentonite using the approved
measuring device specified above to ensure that the required seal thickness
has been achieved.

(vii) Simultaneously withdraw casing and fill the borehole annulus with bentonite
grout to the bottom of the next sensor's filter sand zone or, if no more
sensors are to be installed, to within 1 m of the top of hole.
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Drainage and Irrigation Department

(viii) After the grout above the final sensor has taken an initial set, fill the top 1 m
of the hole with bentonite grout and set the monument enclosure and
lockable cover in place at a level flush with the surrounding ground surface.
Provide approved signal cable insulation protection in monument enclosure.
Provide terminal caps and plugs for each sensor cable. Clearly and
permanently tag cable ends to indicate the sensor to which each is
connected.

(ix) Demonstrate at key intervals throughout installation that each installed

sensor is properly functioning by connecting sensors to the approved
readout unit. Prior to demobilizing installation equipment and crews,
demonstrate in the Engineer's presence that each piezometer sensor is
functioning properly by connecting sensors to the approved readout unit.
Immediately replace, at no additional cost, any non-functioning sensor with
an instrument installed in an adjacent borehole.

(x) Survey the piezometer to establish its installed location and monument
cover elevation.

(xi) Replace at no additional cost and within 48 hours any electric vibrating-wire
piezometer that is damaged or destroyed

15.3.2.2 Vibrating Monitoring

a) Monitor all structures that are subjected to continuous or transient construction-

induced ground vibrations greater than 15mm/sec and 50 mm/sec PPV for un-
reinforced/light framed structure and reinforced/framed structure respectively.

b) Select a seismic monitoring readout unit, subject to the Engineer’s approval, to

monitor vibrations at structures. At a minimum, the readout unit shall have three
seismic channels with a triaxial transducer. The triaxial transducer shall utilize
three high output/low distortion geophones, a permanent photographic record of
the particle velocity in each of the three axes, a flat frequency response from 4 to
200 Hz, input range of 2 to 500 mm/sec, and a vibration resolution equal to 0.025
mm/sec.

c) Structures having background PPVs greater than 50 mm/sec due to external

disturbances such as adjacent manufacturing facilities, shall be brought to the
Engineer’s attention. Modify the monitoring plan for these structures and submit to
the Engineer for approval.

15.3.3 Monitoring Frequency

a) Measure and record daily, displacements from appropriate instruments located

within a 30 m horizontal distance in any direction from a microtunnel/pipejack
drive face. Thereafter, measure and record weekly until three consecutive
readings show no detectable movements. Thereafter, measure and record
monthly until 6 weeks after the pipeline installation is completed within 300 m of a
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Drainage and Irrigation Department

given monitoring point. Measure and record groundwater levels within the same
distance and frequency as displacement monitoring.

b) Measure and record displacements from appropriate instruments required by

section 15.3.1 d) of this specification every 2 m of shaft excavation depth or four
times a week, whichever frequency is greater, until final grade is reached.
Thereafter, read weekly until three consecutive readings show no detectable
movements. Thereafter, read monthly until 6 weeks after all final lining and
permanent support walls have been installed and all planned recoverable
temporary support elements have been removed. Measure and record
groundwater levels at the same frequency as displacement monitoring.

c) Take readings more frequently than that specified above at no additional cost, if
the Engineer determines that such additional monitoring is warranted by actual
construction conditions.

15.3.4 Protection, Maintenance and Repair

a) Protect and maintain in good working condition all monitoring instruments and
devices throughout the Contract period. If in the opinion of the Engineer, any
instrument or device is not functioning properly or accurately, replace immediately
and at no additional cost.

b) All monument enclosures shall be lockable and keyed alike.

c) Protect and maintain all instrument systems. Maintenance shall include draining
or flushing monument enclosures and repairing damaged or missing components
of systems. Repair or replace damaged or missing instrumentation within five
days and at no additional cost

15.3.5 Removal

a) Instrumentation shall not be demolished, abandoned, removed, disposed of, or

rendered inaccessible without prior approval from the Engineer.

b) Remove instrumentation prior to final acceptance of the work or when directed by

the Engineer.

c) Remove and dispose of terminal boxes and covers.

d) Grout all remaining open portions of the boreholes and inclinometer casings,
backfill the area, patch pavement or surface, and restore to the Engineer's
satisfaction.

e) Remove reference points and paint marks on buildings and patch any holes or
spills on walls resulting from reference point removal

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

15.3.6 Drawings

a) Deep Cased Benchmark

Lockable protective cover

Survey pin
G.L.

75
Concrete
(500x500) mm

1
2" GI pipe socket

1
2" GI pipe, od-~22 mm.
15 m

PVC socket

PVC pipe, od-50 mm.

Cement-bentonite grout

Coupler

Anchor, Ø25x1000 mm.

Concrete

Ø100 mm

b) New Surface Settlement Point for Flexible /Rigid Pavement/Sidewalk

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Ø100
2
1

80

Epoxy fill

Pavement
or Tarmac

Base soil

Ø10

Item Description

1 Plastic Tapered Disc

2 Retaining nail

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

c) New Surface Settlement Points for Unimproved Areas

500x500

Lockable protective cover

Angle Survey pin, Matl. : AISI-304
G.L. frame

75
35
Soil

Sand

1000
Extension rod,
Matl. : M. S., Ø16

PVC pipe
(OD-48, ID-37)

Surrounding soil

Concrete, Cement :
sand : gravel (1:2:4)
Grouting plate
(M S - 100x100x5)

d) Building Settlement Monitoring Point

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

e) Ground Inclinometer

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

500x500
Lockable
Angle protective cover
frame Top cap
G.L.
200

125
500

Niche

Concrete

Fixed coupling

Grout

Casing

Bottom cap

Bore hole Ø125

f) Vibrating-Wire Strain Gauges

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

g) Crack Meter

HILTI : HPS 1 55x2.5

Acrylic plate
Red cursor
Crack

Screws
30.0

0
1 2 3 4 5
Ø5.0

30.0

Scale
30.0

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

h) Tilt Plate

(to be monitored using portable tiltmeter)

Item Description

1 Tilt plate

2 Impact Anchor

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

i) Extensometer

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Ø100

Wrapped in 14
a plastic bag
19 2
15,16
17,18 V 3
13
24 & G
25 8.b 1

B
7 9
15 17
8.a
6
PLAN (without cover)
16

Ø160

5
18

A
22

10
11 1 23
12
Ø82

Displacement A B 20
50 mm 248 200
100 mm 378 240

Item Description
1 Anchor
3
2 Connecting rod
3 Vent tube 4
4 Grout tube
5 Flanged housing Cable tie
6 Adaptor
7 Guide plate
8.a Grub screw, M4x5 2
8.b Grub screw, M4x8
9 Allen head screw, M5x12
10 Rubber bush Grout
11 Washer
1
12 Hollow bolt
13 Spacer
14 Reference plate
15 Reference button
Link plate Ø76
16
17 Sensor tightening nut
18 Sensor lock nut
19 Cover
20 Displacement sensor
21 Expandable anchor
22 Nipple with chuck nut
23 Junction box assembly

j) Electric Vibrating Piezometer

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Lockable protective cover (250x250)

G.L.
Cavity
(250x250
x150 depth)

Concrete
Terminal box
for observing data

Sand cement grout

5000

500

Bentonite seal

Sensor cable
1000
10000

V W piezometer

Saturated clean sand

Sand cement grout

500

Bentonite seal

Sensor cable
1000

V W piezometer

Saturated clean sand

300

Borehole Ø100
Note : All dimensions in mm.

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 16

PROTECTION OF EXISTING STRUCTURES AND SERVICES

DM/DNID Section 16 Protection of Existing Structures & Services Rev 00 June 2016
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page i of ii
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 16
PROTECTION OF EXISTING STRUCTURES
AND SERVICES

CONTENTS

16.............PROTECTION OF EXISTING STRUCTURES AND SERVICES 1

16.1 GENERAL .............................................................................................................. 1
16.1.1 Scope .................................................................................................................. 1
16.1.2 Submittals............................................................................................................ 1
16.1.3 Quality Control..................................................................................................... 1
16.2 EXECUTION ........................................................................................................... 2
16.2.1 General................................................................................................................ 2
16.2.2 Performance Requirements ................................................................................ 2
16.2.3 Preliminary Assessment and Preliminary Assessment Report ........................... 2
16.2.4 Detailed Assessment and Final Assessment Report .......................................... 3

DM/DNID Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page ii of ii
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

16 PROTECTION OF EXISTING STRUCTURES AND SERVICES

16.1 GENERAL

16.1.1 Scope

a) This section of the Specification contains the performance requirements of

the Works as they relate to impacts on existing structures and services and
contains the requirements for:
1. Assessing the effect of the deep excavation/ micro tunnelling Works on
existing structures and utilities.
2. Identifying which structures and utilities to monitor and instrument during
construction.
3. Evaluating the appropriate protection measures needed to prevent
damage or to reduce damage risk to structures and utilities.
b) All structures within the zone of influence of the pipeline construction are to
be considered.

16.1.2 Submittals

The following documents shall be prepared by the Contractor and submitted to the
Engineer:

 A preliminary report entitled, “Preliminary Report: Assessment of

Construction Impacts on Structures,” duly endorsed by a Registered
Professional Engineer or Chartered Engineer or Engineer with equivalent
qualifications shall be submitted to the Engineer by the Contractor within 8
weeks of the Commencement Date.
 A draft report entitled, “Draft Final Report: Assessment of Construction
Impacts on Structures,” shall be submitted to the Engineer 30 days prior to
the commencement of any excavation and shall be approved by the Engineer
before issuance as the final report.
 A final report entitled, “Final Report: Assessment of Construction Impacts on
Structures,” duly endorsed by a Registered Professional Engineer or
Chartered Engineer or Engineer with equivalent qualifications shall be
submitted to the Engineer and shall be unchanged from the approved draft
report, except for minor editorial changes.

16.1.3 Quality Control

The Contractor shall engage an independent specialist firm with not less than 10
years of professional experience in similar work to carry out the construction impact
assessment work.

DM/DNID Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page 1 of 5
 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

16.2 EXECUTION

16.2.1 General

Should changes to the pipeline alignment result in more than a 5 metre horizontal
shift, the Contractor shall re-assess the construction effects for all structures and
services within the zone of influence of the re-aligned section.

16.2.2 Performance Requirements

a) Contractor shall design both temporary and permanent works to ensure that
ground movements are kept to an absolute minimum. Proven techniques
and good workmanship are required to restrict ground loss that would lead to
ground movement.
b) Contractor shall select and operate construction equipment in a manner such
that damage to structures from vibrations is negligible.
c) Construct all pipelines and shafts using equipment and materials that are
able to quickly and adequately support the ground and that are able to
minimise and positively control the inflow of water. Exercise care to ensure
that a minimum of over excavation takes place.
d) Contractor shall meet the local regulatory requirement of maximum permitted
surface settlement during microtunnelling operation.
e) Initiate remedial measures when settlement reaches 60 percent of the
maximum permitted settlements. The Engineer may require remedial
measures when settlement reaches less than 60 percent of the maximum
permitted settlement if the rate of settlement is higher than predicted in the
assessment report.
f) The Contractor shall first discuss with the Engineer and then consult with and
advise the owner of any structure identified in the report, “Final Report:
Assessment of Construction Impacts on Structures,” of the risk and level of
damage expected. If required by the owner, the Contractor shall reach
agreement with the owner of the respective structures about the level of
protection and monitoring required and submit all the details to the Engineer.
Employer/ Engineer will assist Contractor in reaching such agreement with
the owner.

16.2.3 Preliminary Assessment and Preliminary Assessment Report

a) The Contractor shall carry out a preliminary assessment of the anticipated

displacements induced by the Works, the effects of those displacements, and
the effects of construction vibrations shall be carried out for all structures in
the vicinity of the Works.
b) A Preliminary Report shall be prepared presenting ground displacements
may be estimated by empirical methods. Empirical calculations for TBM
excavations shall assume a minimum face loss percentage equal to 0.25
percent and 0.5 percent considering average settlement and worst case
settlement scenario.
c) The report entitled, “Preliminary Report: Assessment of Construction Impacts
on Structures,” shall identify all structures and services within the zone of
influence of the pipeline construction. Each structure identified shall be

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

categorized according to Table 16.1.

d) The Contractor shall show that structures outside of the zone of influence of
the pipeline construction are not affected by short term or long term ground
deformations arising from the Works.

Table 16.1 Slope, Settlement, and Risk Categories for Structures

Maximum
Maximum Slope Description of Probable
Settlement
(mm/mm) Damage
(mm)
Negligible: Superficial damage
< 1/500 <10
unlikely
Possible superficial damage
1/500 to 1/200 10 to 50 which is unlikely to have structural
significance
Expected superficial damage to
structures; Possible damage to
1/200 to 1/50 50 to 75
structures; Possible damage to
rigid utilities
Expected structural damage to
>1/50 > 75 structures; Expected damage to
utilities

e) For each tunnel drive, the Contractor shall measure the actual settlement
occurring and compare this with the predicted values. The operation of the
TBM shall be adjusted to limit the rate of spoil removal to bring the settlement
back into line with the allowable values.

16.2.4 Detailed Assessment and Final Assessment Report

a) The installation, operation and removal of geotechnical instrumentation and

monitoring equipment shall be in accordance with the requirements of
Section 15 “Geotechnical Instrumentation and Monitoring”.

b) The contractor shall carryout:

1. A detailed assessment of the anticipated displacements induced by the

Works and the damage potential caused by those displacements shall
be carried out for all structures influenced by the works and for those
structures and services in Risk Category II or higher as determined from
the preliminary assessment.

2. The potential for groundwater drawdown and vibration effects shall be

further investigated for all structures and services influenced by the
works and for those structures and services in Risk Category II or higher
as determined from the preliminary assessment.

3. For structures in the proximity of excavations where the use of large

plant creates ground vibrations, the peak particle velocity shall be
measured at the face of the building or any other location where it is

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

necessary to limit vibration.

4. The measurements of peak particle velocity (PPV) shall be obtained

from instruments capable of measuring along three orthogonal axes, one
of which shall be aligned parallel to the centre line of the excavation, and
another shall be vertical.

5. The Contractor is to provide supports for the measuring instrument if so

required by the manufacturer’s instructions.

6. The measurement of particle velocities shall be the responsibility of the

Contractor. Copies of the readings in an agreed form shall be supplied to
the Engineer.

7. Equipment for the measurement of vibration shall be in accordance with

BS ISO 4866:2010. Following the commencement of works, the
Contractor shall demonstrate that the peak particle velocities given in BS
7385 Part 2:1990 are not being exceeded.

8. Ground displacements shall be estimated by numerical methods

acceptable to the Engineer.

9. The report entitled, “ Draft Final Report: Assessment of Construction

Impacts on Structures,” shall identify all buildings, structures and
services influenced by the works and those buildings, structures and
services in Risk Category II or higher as determined from the preliminary
assessment. As a minimum, include for each identified structure and
service, the following:

i. Subsurface conditions
ii. Estimated peak particle velocity (PPV) and corresponding
frequencies
iii. Potential for damage due to construction vibrations
iv. The potential for damage due to construction impacts, e.g.
surface settlement, heave, etc.
v. Summary and the results of detailed numerical analyses
vi. Proposed preventative and remedial measures for protection
vii. Instrumentation and monitoring requirements

10. The report entitled, “Draft Final Report: Assessment of Construction

Impacts on Structures,” shall contain, at a minimum, the following:

i. Summary of findings from the preliminary assessment report

ii. Proposed construction equipment, methods, and sequencing
iii. The results of the assessments for additional structures,
should the pipeline or shaft locations change positions since
the preliminary assessment was performed
iv. Description of all analyses performed

11. The above report shall be submitted to the Engineer 30 days prior to the
Commencement of any excavation and shall be approved by the

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Engineer before issuance as the final report.

12. Following the approval by the Engineer, a final report entitled, “Final
Report: Assessment of Construction Impacts on Structures,” duly
endorsed by a Registered Professional Engineer or Chartered Engineer
or Engineer with equivalent qualifications shall be submitted to the
Engineer and shall be unchanged from the approved draft report, except
for minor editorial changes.

DM/DNID Section 16 Protection of Existing Structures & Services Rev 00 June 2016 Page 5 of 5
 ROADS & TRANSPORT
AUTHORITY

‫ ﺗطوﯾر وﺻﻠﺔ اﻷﺻﺎﯾل‬- ‫ ﺗﺣﺳﯾﻧﺎت ﻣﺣور اﻟﺷﯾﺦ راﺷد‬- 1060/2‫ط‬

PROJECT: R1060/2
– IMPROVEMENT OF SHEIKH RASHED
DEVELOPMENT OF AL ASAYEL LINK

TENDER DOCUMENT

VOLUME 2 – PART II – BOOK 2

DUBAI MUNICIPALITY SPECIFICATIONS, PART 2

EMPLOYER: CONSULTANT:

Roads & Transport Authority AECOM Middle East Ltd.

Roads Department P.O. Box 51028
P.O. Box 118899 Dubai – U.A.E.
Dubai – U.A.E.

RTA MAY 2024

 R1060/2 - Improvement of Sheikh Rashed – Development of Al Asayel link
Tenderer & Contract Conditions

PROJECT R1060/2:
IMPROVEMENT OF SHEIKH RASHED –
DEVELOPMENT OF AL ASAYEL LINK

GENERAL INDEX

VOLUME 1 - TENDERER & CONTRACT CONDITIONS

VOLUME 2 - SPECIFICATIONS

 PART I - RTA SPECIFICATIONS

o BOOK 1 – ROAD WORKS

o BOOK 2 – SERVICE WORKS & APPENDICES

 PART II - DM SPECIFICATIONS

o BOOK 1 - DM GENERAL SPECIFICATIONS, PART-1

o BOOK 2 - DM GENERAL SPECIFICATIONS, PART-2

& APPENDICES

Volume 3 - BILL OF QUANTITIES

Volume 4 - DRAWINGS

Volume 5 - GEOTECHNICAL INVESTIGATION REPORT

May 2024 Tender Document 1

 General Specifications
Dubai Municipality
Drainage and Irrigation Department

DUBAI MUNCIPALITY

DRAINAGE AND IRRIGATION DEPARTMENT

General Specifications
PART 2

Table of Contents
Section 17 General Electrical and Mechanical Specification

Section 18 Electrical & Instrumentation Works

Section 19 Mechanical Works

Section 20 Fire Fighting Works

Section 21 Geotechnical Investigation Works

Appendices

Appendix 1 Standard Details for Road Construction, Road Diversions,

Road Signs and backfilling to GRP pipes

Appendix 2 Testing and Workmanship of Insitu Lining Material

Appendix 3 Manhole entry (Including Elevated Manholes and Access to

Elevated Sewers)

Appendix 4 Additional Specifications relating to Road Works

Appendix 5 Laboratory Testing

Appendix 6 Standard Details for Sewerage, Drainage and Irrigation

 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 17

GENERAL MECHANICAL & ELECTRICAL WORKS

DM/DNID Section 17 General Mechanical & Electrical Works Rev 00 June

2016
 General Specifications for Mechanical & Electrical Works
Dubai Municipality
Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 17 General Mechanical & Electrical Works Rev 00 June Page i of iii

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 General Specifications for Mechanical & Electrical Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 17
GENERAL MECHANICAL AND ELECTRICAL WORKS

CONTENTS
17 GENERAL MECHANICAL AND ELECTRICAL WORKS .............................................. 1
17.1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED ........................................... 1
17.2 TROPICALISATION .............................................................................................................. 1
17.2.1 General ...................................................................................................................... 1
17.3 PLANT AND EQUIPMENT .................................................................................................... 3
17.3.1 Resistance to Corrosion ............................................................................................. 3
17.3.2 Robustness ................................................................................................................ 4
17.3.3 Adaptation of Equipment ............................................................................................ 4
17.3.4 Co-ordination.............................................................................................................. 5
17.3.5 Special Tools.............................................................................................................. 5
17.3.6 Spares........................................................................................................................ 5
17.3.7 Lubrication of Plant .................................................................................................... 6
17.3.8 Noise and Vibration .................................................................................................... 6
17.4 ELECTRICAL EQUIPMENT .................................................................................................. 7
17.4.1 Compliance ................................................................................................................ 7
17.4.2 Operating Voltages .................................................................................................... 8
17.4.3 Protection and Co-ordination ...................................................................................... 8
17.4.4 Power Factor Correction ............................................................................................ 8
17.4.5 Harmonics .................................................................................................................. 9
17.4.6 Electromagnetic Compatibility .................................................................................... 9
17.4.7 Motor Starting............................................................................................................. 9
17.4.8 Electrical Control Panels .......................................................................................... 10
17.4.9 Standard Designs/Circuit Requirements................................................................... 11
17.4.10 Segregation of Services ........................................................................................... 11
17.5 ELECTRICAL APPARATUS FOR HAZARDOUS AREAS ................................................. 12
17.5.1 Scope ....................................................................................................................... 12
17.5.2 Standards ................................................................................................................. 12
17.5.3 Apparatus Group and Temperature Class ................................................................ 12
17.5.4 Certification .............................................................................................................. 13
17.5.5 Index of Protection ................................................................................................... 13
17.6 SAFETY .............................................................................................................................. 13
17.6.1 General .................................................................................................................... 13
17.6.2 Authorized Persons .................................................................................................. 14
17.6.3 Permit to Work Arrangements .................................................................................. 14
17.7 PLANT SUPPLIERS FOR THIS CONTRACT ..................................................................... 14
17.8 WORK IN DANGEROUS AREAS ....................................................................................... 14
17.9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE ............................................. 15
17.10 HEALTH AND SAFETY AT WORK, ETC. ACT 1974 ..................................................... 15
17.11 DRAWINGS & INFORMATION FOR ELECTROMECHANICAL PLANT ........................ 16
17.11.1 At the Start of the Contract ....................................................................................... 16
17.11.2 Drawing Maintenance............................................................................................... 16
17.11.3 Prior to Delivery of the Plant ..................................................................................... 17
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Drainage and Irrigation Department

17.11.4 Prior to the Issue of the Taking-Over Certificate ....................................................... 17

17.12 FACTORY ACCEPTANCE TESTS ................................................................................. 18
17.12.1 General .................................................................................................................... 18
17.12.2 Pumps ...................................................................................................................... 20
17.12.3 Motors ...................................................................................................................... 20
17.13 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL PLANT21
17.13.1 General requirements............................................................................................... 21
17.13.2 Testing and Commissioning Procedures and Documents ........................................ 24
17.13.3 Primary Tests and Checks ....................................................................................... 25
17.13.4 Unit Testing .............................................................................................................. 25
17.13.5 System validation tests............................................................................................. 25
17.13.6 COMMISSIONING AND SETTING TO WORK......................................................... 26
17.14 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF......................................... 26
17.15 OPERATING AND MAINTENANCE MANUALS ............................................................. 27
17.15.1 General .................................................................................................................... 27
17.15.2 Requirements and Contents ..................................................................................... 27
17.16 GUARANTEE .................................................................................................................. 30
17.17 IDENTIFICATION ............................................................................................................ 31
17.17.1 General .................................................................................................................... 31
17.17.2 Nameplates .............................................................................................................. 31
17.17.3 Tags ......................................................................................................................... 32
17.17.4 Stencils .................................................................................................................... 32
17.17.5 Pipe Markers ............................................................................................................ 32
17.17.6 Instruction Notices .................................................................................................... 32
17.17.7 Safety Warning Signs and Notices ........................................................................... 33
17.17.8 Identification Colours ................................................................................................ 33
17.17.9 Colour Schedule for Plant and Equipment................................................................ 33
17.17.10 Identification Colours for Plant and Equipment ......................................................... 33
17.17.11 Identification Colours for Pipelines ........................................................................... 33
17.17.12 Preparation .............................................................................................................. 33
17.17.13 Installation ................................................................................................................ 33
17.17.14 Schedules ................................................................................................................ 34
17.18 STANDARDS AND REGULATIONS ............................................................................... 34
17.18.1 General Requirements ............................................................................................. 34
17.18.2 Purpose of Standards............................................................................................... 35
17.18.3 International Standards ............................................................................................ 36
17.18.4 Local Regulations ..................................................................................................... 36

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Drainage and Irrigation Department

17 GENERAL MECHANICAL AND ELECTRICAL WORKS

17.1 Electrical and Mechanical Plant to be supplied

a) Electrical and Mechanical plant shall be supplied and installed as detailed and in
accordance with sections 17 through 19 of the specification.

b) Particular care shall be taken to ensure that all components are suitable for the
corrosive climatic and environmental conditions specified elsewhere in this
document.

c) This document sets out the general standards and information requirements for
Mechanical, Electrical, Instrumentation and Control (ICA) Works, and mention of
any specific material or plant does not necessarily imply that such is included in the
Works.

d) All component parts of the Works, including procedures, practices and services
shall, unless otherwise stated in the contract, should comply with the provisions of
this section. All work undertaken and equipment supplied should comply with all
standards, codes of practice, local regulations and specifications referred to
throughout the contract documents.

e) Where equipment is to be installed into existing Works, the Contractor shall ensure
at the pre-tender visit that the provisional location is adequate for the installation of
the proposed plant and equipment, or indicate otherwise in their tender return.

17.2 Tropicalisation

17.2.1 General

a) All plant and equipment shall be designed for the Dubai, UAE climate having salt
laden dusty atmosphere.

b) Only tropical grade materials shall be used throughout the installation, with the
exception of hermetically sealed equipment.

c) Small iron and steel parts, other than stainless steel of all instruments and electrical
equipment, the cores of electromagnets and the metal parts of relays and
mechanisms are to be treated in an approved manner to prevent corrosion. Cores
etc., which are built up of laminations or cannot for any other reasons be anti-rust
treated, shall have all exposed parts thoroughly cleaned and heavily enamelled,
lacquered or compounded.

d) Unless suitably protected from the elements, the use of iron and steel shall be
avoided in instruments and electrical relays. Screws shall be either of stainless steel
or cadmium or chromium plated.

e) Instrument screws (except those forming part of a magnetic circuit) shall be of brass
or bronze. Springs shall be of stainless steel, brass, bronze or other non-rusting
material. Pivots and other parts for which non-ferrous material is unsuitable are to
be of an approved stainless steel.

f) Fabrics, cork, paper and similar materials that are not subsequently to be treated by
impregnation are to be adequately treated with an approved fungicide. Fabrics
treated with linseed oil or linseed oil varnishes, are not to be used.

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Dubai Municipality
Drainage and Irrigation Department

g) The use of wood in equipment is to be avoided as far as possible. When used,

woodwork is to be thoroughly seasoned teak or other approved wood that is
resistant to fungal decay and is to be free from shakes and warp, sap and wane,
knots, faults, and other blemishes. All woodwork is to be suitably treated to protect it
against the ingress of moisture and from the growth of fungus and termite attack. All
joints in woodwork are to be dovetailed or tongued and pinned as far as possible.
Metal fittings, where used, are to be of a non-ferrous material or stainless steel.

h) The use of hygroscopic insulating materials shall not be permitted except where
immersed in oil or suitably sealed to prevent ingress of moisture.

i) All electronic and ICA equipments shall be suitable for installation in G3

environment where harsh level of corrosion severity and high probability of corrosive
condition prevails.

j) Sun shading shall be provided for all outdoor installations to ensure that plant and
equipment operates satisfactorily in the specified ambient conditions.

k) The minimum de-rating for all electrical equipment including cables shall be in
accordance with the relevant Electrical Standards appertaining to the specified
climatic conditions.

l) Switchboards, motor control centres, and electrical equipment shall be suitable for
continuous operation in an ambient temperature of 55°C. The fact that switch gear,
control rooms, pump rooms may be air conditioned shall not be taken into account.

m) When it is necessary to use dissimilar metals in contact these shall be selected

such that the electro-chemical potential difference is not greater than 250 mV.

n) The below climatic and ground condition should be taken into account. The plant,
equipment and materials shall be suitable for continuous operation under these
conditions.
Table 17–1: Climatic and Ground Conditions

Element Value

Maximum ambient air temperature 55ºC

Minimum ambient air temperature 1ºC

Design Ambient Temperature 55ºC

Maximum Surface Temperature recorded under

85ºC
direct sunlight)

Minimum Barometric Pressure 998 mb

Average Barometric Pressure 1015 mb

Maximum Ambient Humidity 100%

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Dubai Municipality
Drainage and Irrigation Department

Element Value

Minimum Ambient Humidity 20%

Design Ambient Humidity 100%

Design Wind Speed 160 km/hr

Average Yearly Rainfall 80 mm - 150 mm

Thermal Resistivity of soil in summer 2°C m/W

Temperature of soil in Summer at 0.7m depth 30ºC

Class G3 of ISA-
Maximum pollution level
S71.04-1985

o) The climate in Dubai is relatively mild from November to April, and hot from May to
October with high relative humidity.

p) Under certain combinations of the above climatic conditions, considerable

condensation may take place.

q) Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with the
extremely high ambient humidity can produce severe corrosion.

r) Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance. However, sudden heavy rainfall can occur in a very short period of
time.

s) The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr and sand storms occur in
the summer months.

17.3 PLANT AND EQUIPMENT

17.3.1 Resistance to Corrosion

a) All materials utilised in the plant shall be the most suitable for the duty concerned,
shall be new and of first class commercial quality and be selected to eradicate or
reduce corrosion to a minimum.

b) Particular attention shall be paid to material selection to minimise corrosion due to

atmospheric conditions, electrolytic action of dissimilar metals, presence of high
concentration of H2S gas or any other causes that may reasonably be associated
with the overall performance of the Works.

c) The use of organic materials shall be avoided whenever possible but where they
have to be used; they shall be treated to make them fire-resistant and non-flame
propagating.

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Dubai Municipality
Drainage and Irrigation Department

d) Use of wood is to be avoided wherever possible but where this has to be used, all
woodwork shall be treated to protect it against damage by fire, moisture, fungus,
bacteria or chemical effect.

e) Where, in the opinion of Dubai Municipality/Engineer, during the maintenance

period any moving parts show signs of undue wear, chemical attack or unsuitability
for the purpose for which they are installed, they shall be replaced, at no cost to
Dubai Municipality, notwithstanding that they may otherwise be working in a
satisfactory manner.

17.3.2 Robustness

a) All equipment furnished shall be new, of best commercial quality and guaranteed
free from defects in materials, design and workmanship. It shall be the
manufacturers’ responsibility to ascertain the conditions and service under which
the equipment will operate and to warrant such operation trouble-free in service and
meeting the specification.

b) All equipment shall be designed, fabricated, and assembled in accordance with the
best modern engineering and shop practice. Individual parts shall be manufactured
to standard sizes and gauges so that repair parts, furnished at any time, can be
installed in the field. Like parts of duplicate units shall be interchangeable.

c) Unless otherwise specified, stainless steel that will be submerged all or in part
during normal operation shall have a minimum nominal thickness of 6mm and be of
at least Grade 316L stainless steel.

17.3.3 Adaptation of Equipment

a) No responsibility for alteration of a planned structure to accommodate substitute

equipment shall be taken by the Engineer. Equipment which requires alteration of
the structures will be considered only if the Contractor assumes all responsibility for
making and co-ordinating all necessary alterations, at no additional cost to the
Dubai Municipality. All modifications to structures, mechanical, electrical, or other
work made necessary by such substitution shall require the approval of the
Engineer. The cost of this work shall be made at the Contractor's expense.

b) After approval of the mechanical and electrical drawings the Contractor shall
prepare and submit to the Engineer revised drawings showing any necessary
revisions to the proposed building and civil structures. The location, size and details
of box-outs and fixings for mechanical and electrical and other equipment shall be
shown on the revised drawings and the Contractor shall be responsible for providing
in the civil structures the correct location and size of the box-outs and fixings shown
on the approved mechanical and electrical drawings. The Contractor shall prepare
at his own cost the necessary revised civil drawings and detailed structural and
other design calculations and submit them to the Engineer for approval. The
Contractor shall not be entitled to an extension of time for completion for any delays
from the preparation of such revised drawings. The Contract price shall not be
increased as a result of any changes in the civil structure from that designated
unless such changes are the result of variation properly ordered by the Engineer.

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Dubai Municipality
Drainage and Irrigation Department

17.3.4 Co-ordination

a) The Contract Drawings show in a general arrangement form the layout desired for
the principal equipment, piping, and similar appurtenances, and shall be followed as
closely as possible. Proper judgment shall be exercised in carrying out the work to
secure the best possible headroom and space conditions throughout, to secure neat
arrangement of all equipment and accessories, to overcome local difficulties and
interference with structural conditions wherever encountered.

b) The Contractor shall take all measurements for his work at the installation site,
verify all dimensions and conditions at the place of installation verify the sub-
Contractor's drawings and be responsible for the proposed installation, of the
equipment within the available space specified and shown on the Drawings.
Proposed deviations from the Drawings and Specification shall be submitted to the
Engineer in writing giving full details and reasons for the requests. The Engineer’s
approval must be obtained for any modification of the original works.

c) The Contractor shall employ an experienced electro-mechanical Engineer to

cooperate with the manufacturers/supplies of electrical and mechanical equipment.
This Electro-mechanical Engineer shall have at least 15 year experience and shall
be approved by the Consultant for this project and Dubai Municipality.

17.3.5 Special Tools

a) The Contractor shall provide one set of new and unused special tools (i.e. Torque
wrench, breakers test kit (tool used for assessing the whole mechanism and control
electronics of relays), High Voltage Tester complete with Digital reading instruments
for voltage measurements, earth lead and battery charger (if applicable), PLC,
controller, instrument & relay programming / configuration tools complete with
licensed software and various machine related special tools) for maintenance and
testing/operation of each supplied equipment / plant. These special tools shall be
supplied as part of the plant and deemed included in the contract.

b) Any special tools (i.e. breakers draw out trolleys, operation lever, handles and
ramps, machine dismantling tools, and grease gun etc.) needed for the operation
and maintenance of the electrical and mechanical works shall be supplied and
handed over to Dubai Municipality as part of the plant. Prior to handover, Dubai
Municipality and Contractor shall examine the tools that have been used during
plant erection to ensure that they are not damaged and are in good condition.

c) The Contractor shall provide a lockable metal tool box to contain two sets of special
tools as required by (A & B) above together with two sets of steel combination
spanners to fit every nut/bolt size on the plant including the holding down bolts and
unions, plus other tools of a special nature necessary for general maintenance.

d) Recommended tools required for maintenance of the electrical and mechanical

works shall be set out in the appropriate technical schedule and be clearly
referenced in the O&M Manual.

17.3.6 Spares

a) The Contractor shall produce a schedule for all spares recommended by the
manufacturers to cover a minimum period of 2 years operation of the Plant. The

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Drainage and Irrigation Department

cost of these spares shall be deemed included within the respective equipment
price in the BOQ.

b) Spares shall be packed and protected for storage to the appropriate standard.
Electrical equipment shall be sealed in polythene or similar bags with a liberal
supply of desiccant. Other items shall be protected so as to avoid corrosion and
spoilage for a minimum of twelve months after handover to the Client. Machined
surfaces of all mechanical components shall be further protected by the application
of a protective coating which may be easily removed at the time of installation. Each
package shall have attached to it a un-tarnish able metal plate giving information for
identification. This shall include the maker’s name and reference description as
shown on the marked-up drawings supplied.

c) The packages of items of spares shall be collected together by the Contractor into
consignments of reasonable size and then packed in secure cases each of which
shall contain a contents list. Where electrical items are involved the cases shall be
of tongue and groove boarding. Each case shall be durably marked with the
contract number and site address, and shall be sent to site after detailed
instructions have been received. Each package shall be clearly identified as to its
contents in both English and Arabic.

d) The Contractor shall provide the detailed agreed schedule in duplicate of the spares
supplied one copy to be retained by the Engineer after checking the goods.

17.3.7 Lubrication of Plant

a) Adequate and, as far as is practicable, automatic means of lubrication shall be

provided for all moving parts.

b) The positions of all greasing and oiling points shall be arranged so as to be readily
accessible for routine servicing. Where necessary, to achieve this, suitable
extension pipes shall be fitted.

c) Lubrication grease points shall comprise hexagon headed nipples except where the
lubrication required is of a special nature. In such event they shall be fitted with
metal labels to indicate the special lubricant required.

d) Where continual grease or oil feeding is required the capacity of the reservoir shall
be sufficient for not less than seven days continuous services.

e) The Contractor shall supply the initial charges of oil, grease electrolyte and similar
materials necessary for the correct setting to work and operation of the Plant.

f) A supply of the recommended lubricants sufficient for a period of two year's running
shall be supplied for the plant. This does not relieve the Contractor of the
responsibility of ensuring that all grease lubricants have been filled and the grease-
gun applied to all nipples before starting up the plant.

g) Lubricants or their equivalents shall be those obtainable in the Dubai markets.

17.3.8 Noise and Vibration

a) The sound levels generated from plant, equipment and the whole of the installation
with the envisaged maximum number of items of plant running 'on load', shall be

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Drainage and Irrigation Department

measured outside an envelope of one metre radius from any items of plant, and
shall not exceed the following limit of noise levels at one metre.

i) Internal Noise levels (with all plant running) shall not exceed:
Process and Plant Areas 85 dB (A)
MCC Rooms 55 dB (A)
ii) External noise levels to comply with planning requirements for noise level
at site boundary.
b) The Contractor shall include for suitable sound attenuation, if needed, to better this
level. This will apply in the audible frequency range 20 Hz to 20 kHz. Above 20 kHz,
the Contractor must state whether any fundamental frequencies are generated in
the ultrasonic region.

c) Before leaving the manufacturer's works, all major items of rotating machinery shall
be subjected to noise tests and test certificates shall be provided to Dubai
Municipality/Engineer for approval.

d) Machinery vibration shall not exceed the limits defined in BS 7854-1.

17.4 ELECTRICAL EQUIPMENT

17.4.1 Compliance

a) Electrical equipment shall comply with Dubai Electricity and Water Authority
(DEWA) Regulations; relevant IEC standard and all other applicable statutory
requirement prevails in Dubai.

b) The Contractor shall be responsible for establishing the exact characteristics of all
installed electrical equipment, including fault levels and then ensuring this complies
with the specific regulatory requirements. The prevailing supply characteristics are
as follows:

i) High Voltage (HV): 11,000 V, 3-phase, 3-wire, 50Hz.

ii) Low Voltage (LV): 400V, 3-phase, 4-wire, 50Hz.
iii) Voltage: ±10% at LV (from DEWA)
iv) Frequency: ±3% Transient Disturbed Conditions (from DEWA).
c) Typical system characteristics are as follows:
Table 17–2: Typical System Characteristics

Description 33kV 11kV 400V

Rated Service Voltage 33 11 400/230
Highest System Voltage 36 12.5 1000
Impulse Test Voltage 170 95 ----
Number of Phase 3 3 3
31.5kA for 3 25kA for 3 65/50kA for
Design Fault level
seconds seconds 1 second
Solidly Solidly Solidly
Neutral
Earthed Earthed Earthed

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17.4.2 Operating Voltages

a) The following nominal operating voltages shall be used for the applications listed
below:

i) 400Vac TP and N for all main three phase and three phase and neutral
circuits, including motors and drives.
ii) 230Vac for building services equipment, for single-phase
distribution/power circuits, for power supplies to instrumentation
transmitters and supplies to ICA panels.
iii) 230Vac for all control circuits internal to motor starter equipment through
isolating transformer.
iv) 24Vac control supply for control circuits.
v) 24Vdc regulated power supplies for signalling circuits and for loop
powered instrumentation.
vi) 60Vdc Main circuit breaker supervision trip supplies.
17.4.3 Protection and Co-ordination

a) The protection for the electrical distribution system shall be designed to ensure
correct co-ordination of protective devices, in particular in relation to the co-
ordination of the main LV distribution switchboards and the MV protection devices
and co-ordination with the DEWA distribution system protective devices supplying
the site.

b) A protection design shall be submitted for the stations, which shall be incorporated
into the manuals and shall provide details of the distribution system and its
protection. This documentation shall include a schedule of all devices and settings
and a set of system curves showing the co-ordination of devices as set up.

17.4.4 Power Factor Correction

a) The complete installation shall achieve a minimum power factor of 0.95 lagging and
a maximum of unity under all conditions of plant loads. The power factor of the
stations shall never become leading under any circumstances.

b) Power factor correction shall be achieved by the provision of stand-alone power

factor correction facilities installed at each Low Voltage Distribution Board.

c) This capacitor shall be self-healing type with a pressure monitoring device which
should open the contactor in case of an internal failure or over pressure may occur
and avoid the capacitor from bursting.

d) The power factor correction panel shall be provided with forced air cooling. The air
must be able to flow from bottom to top through cubicle.

e) The reactor / capacitor combination shall be designed to have a tuning frequency

below the lowest critical order of harmonic (usually the 5th) where the non-linear
load exceeds 15% of total connected load as to allow the capacitors to operate in a
harmonic environment.

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f) The capacitor must have a minimum dielectric voltage rating of 565V. In accordance
to IEC 600831, the capacitor temperature classifications should be “D”.

g) The reactor shall be supplied with a temperature sensor which should open the
contactor on its stage if that stage should overheat.

h) Detune capacitor bank is in addition to active harmonic filter, which is obligatory to

be supplied by the contractor while VFDs, soft starters, battery chargers, AC to DC
power supplies and UPS etc. are installed in the station/plant.

17.4.5 Harmonics

a) Total Harmonic Distortion (THD) at the point of common coupling shall comply with
the requirements of IEC 61000 / IEEE519, or otherwise agreed with DEWA. All
equipment generating harmonic currents shall be designed such that the specified
limits of THD are met at all times and under all operating conditions.

b) The Contractor shall submit calculations of the harmonic currents expected before
any equipment manufacture commences and obtain approval from DEWA/Engineer
for the connection of this equipment.

c) When all equipment has been installed and commissioned, the Contractor shall
carry out tests to measure the harmonics generated on the Station. The tests shall
be carried out with all main equipment, including the main water pumps, running at
full load. The harmonic currents shall be established at each frequency to determine
that individual and total values are within the limits stipulated in IEC 61000 / IEEE
519.

d) Additional approved equipment/devices shall be installed by the Contractor without

any additional costs to the Dubai Municipality if the installation is not approved by
DEWA for connection onto the supply.

17.4.6 Electromagnetic Compatibility

All electrical and ICA equipment and systems shall comply with the European
electromagnetic compatibility directive 89/336/EEC and all relevant associated British
Standards. As such all electrical and ICA equipment supplied under this Contract shall
conform to European directives and shall carry the required CE marking.

17.4.7 Motor Starting

a) The Contractor shall provide a motor starting study for all large electric motors and
drives over 110KW in size to determine voltage dip or power inrush limitations at
selected locations due to starting of motors.

b) The Contractor shall obtain from the motor supplier the necessary information to
perform the study. Certified curves for “Safe Time vs. Current at 100% Voltage” and
“Accelerating Time vs. Current at 100% Voltage” and shall become part of the final
report.

c) Motor starters should be provided with full type 2 coordination in accordance with
IEC 60947.

d) For motors greater than 5 KW where assisted starting is required, Soft starter with
bypass contactors shall be the preferred starting method unless the process
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requirements necessitate the use of a variable speed drive. Soft Starters shall have
soft start / soft stop facility.

17.4.8 Electrical Control Panels

a) All electrical control panels shall be designed for standalone operation conforming
to the requirements contract documents and local authority’s regulations.

b) The LV switchboards and MCC’s shall be constructed to IEC 61439 Form 4 Type 6
constructions and shall be fully type tested. The enclosure system shall be
extendable for future additions, modular in all 3 axes.

c) MCCs shall be fully factory equipped, tested and tagged ready to interface with
communication devices such as telemetry, remote terminal units, instrumentation
and other microprocessor-based controllers etc.

d) All circuit breakers rated 800A and above shall be of the withdrawable type.

e) Rated short time current and times shall be determined by assessment of the
protective short circuit currents of the distribution system. The main LV switchboard
however shall have a minimum short time rating in accordance with the following
guide;
Table 17–3: Guide to Short Time Rating

Transformer
Impedance and Fault Level Switchboard specification
Rating
3200kVA 9% 52kVA 65kA for 1 second
2500kVA 8% 44kA 65kA for 1 second
2000kVA 7% 40kA 50kA for 1 second
1500kVA 7% 32kA 50kA for 1 second
1000kVA 5% 30kA 50kA for 1 second
800kVA 4% 26.8kA 50kA for 1 second
500kVA 4% 18kA 50kA for 1 second

f) All electrical panels shall be finished to the same standard and colour.

g) The Contractor shall carryout functional safety study in accordance with IEC 61508
of the plant and related area and should implement a complete system of interlocks
and safety devices shall be provided, as necessary, for the safe and continuous
operation of all installed plant and equipment in order to provide for the following:

i) Safety of personnel engaged in operation and maintenance of the plant.

ii) Correct sequence of operation of the plant during start up and shut down.
iii) Safety of the plant when operating under normal or emergency conditions.
iv) Interlocks and interlocking schemes that is preventative and not corrective
in operation. The design of the interlocks is subject to Dubai Municipality
/Engineer approval.

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v) Locks for interlocking purposes that are of the figure lock type (Castell or
equivalent approved). No spare or master key shall be provided.
h) Rubber matting shall be supplied and fitted along the front and rear lengths of all
switchboards and MCCs. The insulating matting shall be manufactured and marked
in accordance with BS 921 or IEC 61111. The contractor shall allow for longitudinal
cutting and fitting of matting to obtain suitable fitting around obstructions.

17.4.9 Standard Designs/Circuit Requirements

a) A standard approach to MCC internal circuit design shall be developed and

enforced on the MCC and control panel suppliers, to ensure that all similar circuit
types are used across the Project. This shall include panels provided by package
plant suppliers. In particular, the standard requirements for panel construction,
wiring and components shall be noted.

b) This approach shall also be applied to external circuit design, e.g. for instrument
loops etc.

c) All safety interlocks of the plant shall be hardwired.

d) All drives and starters shall be provided with the facility for automatic control from
the MCC control section or ICA panel, whether used for automatic control or not.

e) Conventional drives and starters shall be provided with a separate interlock relay for
the operation of protective circuits operated from the equipment. Drives and starters
utilising intelligent relay/protection unit shall provide interlocks via intelligent
relay/protection unit inputs and outputs.

f) For conventional drives and starter auto-control and interlock circuits shall be
provided by interposing relays. These shall operate in a failsafe manner at 24Vdc
sourced from the control section. The interposing relays shall be installed in the
starter/drive compartments. Drives and starters utilising intelligent overload
relay/protection unit shall provide control interlocks, in a fail safe manner, via the
intelligent relay/protection unit inputs and outputs.

g) Wherever a machine is provided with a protective device such as pump protection

unit, thermistor, bimetal, anti-condensation heater, RTD, enclosure fan, vibration
monitoring system etc. the Contractor should cable/wire it in to provide that
protective function.

h) The MCC compartments shall be spacious for easy maintenance.

17.4.10 Segregation of Services

a) Electrical services shall be segregated as specified throughout the installation to

obviate the following:

i) Electrical interference from one circuit to another.

ii) A fault on one circuit affecting another.
iii) Unnecessary fire damage.
iv) Difficulties in circuit identification.
v) Voltage limits for general safety.

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b) All raceways shall be kept clear of other services except where intentionally earthed
or bonded. Generally, raceways shall be kept 150 mm away from and above hot
water and 75 mm away from other services.

c) Fire alarm cables shall be segregated from other services throughout.

d) Unless specifically indicated otherwise, normal, emergency, low voltage cables and
wiring shall be segregated throughout the installation.

17.5 Electrical apparatus for Hazardous areas

17.5.1 Scope

a) The Contractor shall carryout Hazardous Area Zoning Study to determine the
hazardous area of the plant and should select/provide fitting equipment in line with
the following applicable standards.

17.5.2 Standards

a) Electrical apparatus and systems for use in hazardous areas shall be manufactured
and tested in accordance with IEC 60079 Electrical apparatus for explosive gas
atmosphere – ALL PARTS

17.5.3 Apparatus Group and Temperature Class

a) For areas which have been classified as Zone 1 or Zone 2 hazardous areas as
defined in IEC 60079-10 and where the potentially explosive atmospheres contain
hydrogen sulphide, methane and air, the types of protection used shall not be less
than the following:

i) For flameproof apparatus, EExdIIBT3.

ii) For intrinsically safe apparatus and systems, EExiaIIBT4.
iii) For apparatus with special protection, ExsIIBT4.
iv) For increased safety apparatus, EExeIIBT3.
b) Where types of protection, other than those described in above, are used, they shall
be with the project manager.

c) For areas which have been classified as Zone 0 hazardous areas as defined in IEC
60079-10 and where the potentially explosive atmospheres contain hydrogen
sulphide, methane and air, the types of protection shall not be less than the
following:

i) For intrinsically safe apparatus and systems, EExiaIIBT4

ii) For apparatus with special protection (specifically certified for use in
Zone 0), ExsIIBT4
d) For hazardous areas in which the potentially explosive atmospheres are other than
described in (a) above, the apparatus group and temperature class shall be as
specified or otherwise determined by assessment by the Contractor.

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17.5.4 Certification

a) All electrical apparatus and systems for use in hazardous areas shall be certified for
use in these areas. Each component shall be marked with the certifying agencies
reference for the component and certificates of conformity, certificates of assurance
and certificates of component approval shall be provided.

b) Copies of all such certificates shall be submitted to the Engineer.

c) Certificates shall be by BASEEFA or other recognised national certifying authority.

d) Where certificates are in a foreign language, for example German for PTB
Certification, copies shall be submitted in the original language version plus copies
of a legally authenticated translation in English.

e) Apparatus shall not be despatched to site until such certificates have been
submitted to and accepted by the Engineer.

17.5.5 Index of Protection

a) Equipment shall have enclosure index of protection not less than IP66.

b) Where equipment may be submerged, for example submersible pumps, the

enclosure index of protection shall be not less than IP68 to the specified depth of
submersion for the equipment/plant installed.

17.6 SAFETY

17.6.1 General

a) The Contractor shall operate a safe system of working in relation to electrical and
ICA works. This shall encompass control of all sites working, in particular in the
energising of electrical equipment at MV and LV supply voltages and at ELV
voltages when associated with the automatic control of plant.

b) The contractor shall implement the requirements of EU’s machinery directive

98/37/EC that no person should be put at risk if a relay sticks or if a transistor or two
electrical conductors short-circuit.

c) A fault in the control circuit logic or failure of or damage to the control circuit must
not lead to dangerous situation. This requirement shall be achieved by introducing
safety relay. The safety relay should comply with standards 98/37/EC or EN 60204-
1 and IEC 60204-11.

d) Unit control panel of machines were supplied shall be provided with 400/230-volt
industrial control circuit transformer, being able to handle the inrush current of
control circuit in accordance with IEC 60204-1 (Safety of machinery – Electrical
equipment of machines – Part 1: General requirements). The control transformer
shall comply with IEC 61558-2-2. Provide fuses on both the primary and secondary
sides of the control transformer. Secondary side of the control transformer shall be
centre-tapped and earthed, via a removable bolted earth link.

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e) The requirements and recommendations of IEC 60204 relating to the electrical

equipment of machines shall be implemented to achieve the followings.

i) Safety of persons and property

ii) Consistency of control response
iii) Ease of maintenance
f) Each type of machine has unique requirements to be accommodated to provide by
the contractor for adequate safety related to guarding, interlocking, or control and
the documentation that are needed or required in order to protect persons from
hazards other than electrical hazards.

g) The contractor shall implement a system of permits to work to access energised

plant to ensure that personal injury is avoided. This permit system shall be
presented to the Engineer for approval prior to commencement of any (including
temporary) electrical works on site.

h) The Contractor shall appoint an authorized person or persons at site who shall take
responsibility for ensuring safe working of the Contactor and his subcontractor’s
personnel during construction and commissioning.

17.6.2 Authorized Persons

a) The Contractor should provide a Senior Authorised Person on site, to plan and carry
out necessary switching operations during construction and commissioning,
particularly where MV plant is installed.

b) All Senior Authorised Persons and Authorised Persons carry a current recognized
training certificate for carrying out such operations.

17.6.3 Permit to Work Arrangements

a) The permit to work system shall involve the issue of a permit by an authorized
person to the person carrying out the work.

b) The permit shall have a sign-on and sign-off arrangement and a copy shall always
be held by the authorized person to ensure that no more than one permit is ever
issued against the same item of equipment at the same time.

17.7 Plant Suppliers for this Contract

a) In order to limit the number of manufacturers of electrical and mechanical

equipment used by Dubai Municipality and to simplify related maintenance, the
vendor list is selected and provided in Section 18 &19 for this Contract specification.

b) The Contractor shall be responsible for liaising with the suppliers, obtaining,
checking for accuracy and issuing all drawings and other documents and for co-
ordination of supply and installation.

17.8 Work in Dangerous Areas

a) The Contractor shall comply with any safety precautions called for by the Engineer
such as a "Permit to Work" system for access to designated high risk areas

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including wet wells, sumps, valve chambers sewers and buildings in addition to
Electrical Danger Areas.

b) A minimum of 21 days notice in writing shall be given when requesting Permits to

Work. No unauthorised interruptions to the plant operations will be tolerated. The
applications for permits to work/plant shutdowns shall be accompanied by approved
method statements addressing all working practices, operational implications, safety
procedures, hazards and risks.

c) The "Permit to work" system will be administered by the Engineer.

17.9 Protection and Packing for Shipment/Storage

a) All Plant shall be adequately protected and packed in accordance with the approved
standard. In addition the Plant shall be so protected as to be safe from spoilage
and corrosion until installation or in the case of spare parts for a period not less than
24 months from its date of handover to the Client.

b) Items of plant which are finished painted at the manufacturer’s works such as
switchboards shall be suitably encased in wood (such as hardboard secured by
screws to a wood framework) for their protection before dispatch.

c) Particular care shall be taken in the packing of electrical apparatus. It shall be

packed separately in sealed polythene or similar approved bags (including a liberal
supply of desiccant) taking all precautions to exclude moisture.

d) Packing cases shall be strongly constructed using tongued and grooved boards with
internal and external battens. Each packing case shall be durably marked with the
Contract number and site address and such other marking as may be directed.

e) The Contractor shall make good to the satisfaction of the Engineer any deterioration
of the protective coatings, paintwork, etc., which may occur during transportation.
The Contractor shall be responsible for making all the arrangements necessary for
the transportation of equipment and plant to site including investigation of the route
for bridge clearances, loading etc and for the provision of a police escort, if required.
All transportation details shall be submitted to Dubai Municipality / Engineer for
approval.

f) Unless otherwise specified, temperatures up to 75ºC and Relative Humidity up to

95% shall apply during transport, storage and installation. Equipment subjected to
these extreme service conditions without being operated shall not suffer irreversible
damage when operated under normal specified conditions.

17.10 Health and Safety at Work, Etc. Act 1974

a) The entire installation and apparatus shall comply with the Health and Safety at
Work, etc. Act 1974 (incorporating provisions of the UK Factories Act) which lays
down standards of safety and shall also be in accordance with the current Institution
of Electrical Engineers (UK) Regulations for the Electrical Equipment of Buildings.

b) Copies may be obtained from the Government Bookshop, P.O. Box 569, London
SE1 9NH, UK and local authority requirement such as DEWA/DM.

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17.11 Drawings & INFORMATION for ELECTROMECHANICAL PLANT

As well as complying with the specified procedures for approval the following
documentation shall be supplied and procedures followed for all items of electrical and
mechanical plant in the Contract.

17.11.1 At the Start of the Contract

a) Within 30 days of the Engineer’s order to Commence the Works the Contractor shall
submit the specified request for approval which shall include :-

i) Detailed drawings (6 No.) of the general arrangements and specifications

of all electrical and mechanical plant showing all apertures, holes, chases,
trenches and ducts required in associated structures.
ii) Drawings (6 No.) of electrical and electronic equipment and specifications
giving details, dimensions, circuitry, component details and schematic
diagrams with a legend of symbols used and a written description of the
operation of the circuits marked thereon.
iii) Any additional drawings of particular items, called for by the Engineer.
b) The manufacture of items of Plant shall not be commenced until written approval of
all relevant drawings and specifications have been obtained.

c) If the drawings are not approved one copy will be returned to the Contractor marked
to indicate the alterations required.

d) Upon final approval one copy will be marked ‘Approved’ and returned.

e) After approval of drawings a further six copies shall be provided to the Engineer.

17.11.2 Drawing Maintenance

a) During the course of the Works the Contractor shall maintain a detailed record of
the progress of the works including changes to ensure that these drawings are in all
respects a true record of the installation.

b) The drawings shall be maintained by the Contractor and shall show the complete
works including the sizes and routes of all ducts, pipework and cables. The scales
used shall be such that all details are legible when reduced for inclusion in the
Operation and Maintenance manuals. All drawings shall show scale bars as
appropriate.

c) The drawings shall clearly show the names of the plant manufacturers, giving
model, type numbers and all details of plant and machinery duty ratings, sizes,
current settings, fuse ratings, etc. of all items of plant including electrical distribution
cabling and wiring installations.

d) The Contractor shall provide three prints of all drawings and schedules correctly
modified as final drawings. These shall be submitted to the Engineer for approval
before the issue of a Taking over Certificate and shall be a complete record of the
Mechanical and Electrical installation.

e) If the drawings are not approved, one copy shall be returned to the Contractor with
marked indications of the alterations required.

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f) Upon final approval, one copy of the drawings or document shall be stamped
“Approved” and returned to the Contractor.

g) One set of the approved drawings on paper shall be included in each of the
Operation and Maintenance manuals. These may be full size drawings folded and
inserted into clear plastic sleeves bound directly into the document. Reduced size
drawings shall be legible in all respects, and the actual reduced scale clearly
marked on the drawings.

h) The Engineer will not issue a Taking over Certificate for the Works until approved all
record drawings.

17.11.3 Prior to Delivery of the Plant

a) Before plant is delivered the Contractor shall provide for the use of the Dubai
Municipality and the Engineer:

i) Copies of all Test Certificates demonstrating compliance with the

specifications.
ii) Two copies of Draft Instructions for the Operation of the Plant which shall
describe the installation as a whole and shall give step by step procedures
for every operation in the running of the Plant. All necessary drawings and
sketches shall be included.
iii) Two copies of Draft Instructions for the Maintenance of the Plant. These
instructions shall include charts showing lubrication, checking, testing and
replacement procedures to ensure trouble free operation.
b) A separate section of these Instructions shall be devoted to a complete parts list
based on sectional arrangement drawings of the Plant. The maker’s name, address
and catalogue/serial numbers shall be given for each component of the Plant
supplied.

c) Recommendations for consumable supplies, e.g. lubricants, packing, etc. shall be

included.

d) The Contractor shall obtain the Draft Instructions from the suppliers, check them for
accuracy and shall bind each Instruction Book in Uniform bindings, the cover of
which shall be finished with a black and greaseproof material and the title printed on
the front and the spine including the word ‘Draft’. Draft manuals shall be forwarded
within 2 months of issue of Taking over Certificate. Binding shall be A4 sized, loose
leaf four ring binders with rigid covers. Covers for instructions related to sewerage
works shall be red in colour, those for drainage works in blue and those for irrigation
works in green or as directed by the Engineer.

e) The Instructions shall be specific to this Contract; a collection of manufacturer’s

descriptive leaflets will not be acceptable.

f) The Plant shall not be considered to be completed for purposes of delivery until the
above information has been provided.

17.11.4 Prior to the Issue of the Taking-Over Certificate

a) Within 3 months of the issue of the Taking-Over Certificate, the Contractor shall
provide for the use of the Dubai Municipality and the Engineer:

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i) Three copies of Approved Instructions for the Operation of the Plant which
shall describe installation as a whole and shall give step by step
procedures for every operation in the running of the Plant. Copies of the
as-built record drawings and sketches shall be bound in the document.
ii) Three copies of Approved Instructions for the Maintenance of the Plant.
These instructions shall include charts showing lubrication, checking,
testing and replacement procedures to ensure trouble free operation.
iii) 1 No. copy on CD or memory disk with digital drawings in latest version of
Microstation as appropriate and two hard copies of the following as-built
record drawings:
iv) Drawings showing the internal construction of the major items, with parts
list and reference numbers for ordering spares.
v) Complete assembly drawings of machinery and ancillary plant showing all
pipe connections and fittings.
vi) General arrangement drawings showing all equipment, cabling, and tray
work, etc.
vii) Detailed arrangement of any conduit work buried in floors, walls or
ceilings, in any structure.
viii) Detailed wiring diagrams of the main circuits.
ix) Diagrams of connections between all items of equipment (e.g. main and
auxiliary switchboards, generators, control boards, motors, starters,
batteries, meters, instruments, relays, and allied equipment, etc. with
component values
x) Three copies of detailed revised Specifications and Schedules of the Plant
as actually installed.
b) Upon the approval of the above drawing/document by the Engineer, the Contractor
shall provide two prints of each drawing or detail on thick paper for the use of the
Purchases, and one 35 mm photographic negative of each drawing or detail
mounted in a card frame 187 mm x 83 mm for the use of the Engineer.

c) A separate section of these Instructions shall be devoted to a complete parts list

based on sectional arrangement drawing of the Plant. The maker’s name, address
and catalogue/serial numbers shall be given for each component of the Plant
supplied.

d) Recommendations for consumable supplies, e.g. lubricants, packing, etc. shall be

included.

17.12 Factory acceptance tests

17.12.1 General

a) All MEICA equipment shall be tested both on the manufacturer’s premises (at
factory acceptance tests) and on site (at site acceptance tests) and Test Certificates
shall be submitted to Engineer for approval.

b) Unless otherwise stated, Dubai Municipality / Engineer shall witness the inspection
and testing of fabricated equipment and/or Factory Built Assemblies at the factory.

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c) All products shall be subjected to inspection, examination and witness testing by the
Dubai Municipality / Engineer or its representative.

d) The Contractor shall notify Dubai Municipality / Engineer 4 weeks prior to such
tests, so that preparation for travelling to the factory inspection and testing can be
arranged.

e) The Contractor shall provide prepaid air travel, hotel accommodation, surface travel
and other advanced arrangements for designated personnel from Dubai Municipality
/ Engineer to witness the manufacture or testing of plant and associated systems.
Airline transportation shall be, as a minimum, full fare economy class. Hotels shall
be single rooms, minimum of 4 stars following a recognised grading criterion.
Surface transportation shall be by rental car or similar private means. The
Contractor shall also provide a per diem amount for subsistence equal to Euro 200
per person per day. The full cost of the programme shall be borne by the Contractor
and shall be included in the unit price of the equipment, or system indicated in the
Contract schedule of prices.

f) Prior to the witness test, the Contractor shall assure Dubai Municipality / Engineer
that the equipment requested for inspection and testing has already been
thoroughly tested by the manufacturer. Provisional Test Reports of such tests,
showing that the plant has past such tests shall be submitted to Dubai Municipality /
Engineer prior to the works witness test.

g) Where tests and inspections have been completed to the satisfaction of Dubai
Municipality / Engineer and when test certificates, tabulated and graphical results,
etc. have been checked, Dubai Municipality / Engineer shall confirm acceptance.
The plant shall not be incorporated in the Works and made ready for delivery until
this acceptance has been received.

h) Successful works witness testing shall allow the manufacturer to deliver the
equipment to the site, but it does not constitute final acceptance or approval of the
equipment. Such approval will only be granted on successful completion of final
testing during commissioning tests of the installed equipment.

i) No inspection or passing by the Dubai Municipality / Engineer, of plant or materials

covered by this Contract, whether carried out or supplied by the Contractor, shall
release him from any of his obligations under the Contract.

j) If works tests are beyond the resources of the manufacturer, the Contractor shall
state another location for these tests to be conducted in the appropriate tender
technical schedules.

k) During the course of the contract, additional testing, or retesting may be requested
by Dubai Municipality / Engineer to prove that the plant, equipment, product,
material or workmanship meets the specification. Such tests will be at no extra cost
to Dubai Municipality.

l) Test results shall be submitted to Dubai Municipality / Engineer for approval in

accordance with the submittals section of this specification.

m) The Contractor shall carry out tests as stated in the current appropriate ISO, British
Standard, IEC and/or Harmonised European standards or other approved
equivalent standard.

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n) All test certificates, curves, supporting engineering calculations, drawings and

documentation, etc. shall be submitted to Dubai Municipality / Engineer within two
working weeks from the date of completion of any witnessed tests.

o) Equipment that fails witness testing shall be subjected to retest. All costs involve
rearranging the test, including the Dubai Municipality / Engineer costs, shall be
borne by the Contractor. An extension of time for the preparation and retesting will
not be allowed unless approved by Dubai Municipality / Engineer.

p) Testing equipment and instruments used during witness testing shall have been
recently calibrated and comply with the appropriate testing standard and safety
regulations and/or requirements for the safety of the Plant and the men working
thereon. The test equipment furnished by each Contractor shall have a calibration
tag of an acceptable calibration service.

17.12.2 Pumps

a) Pump sets shall be subjected to a works test to ensure that they function correctly,
perform to the guaranteed duty, and are manufactured and supplied to the
specification.

b) For all pump sets regardless of size, type test certificates shall be submitted as
indicative of the pump set performance. Where such certified evidence is not
available, a letter of intent from the testing authority shall be submitted.

c) Each pump shall be statically and hydraulically tested at the works to a pressure at
least 50% greater than the maximum working pressure it will incur on site. During
the test, the pump shall show no signs of leakage or failure of any components.

d) Each pump shall be tested with its own motor supplied from its soft starter or
variable speed controller at the manufacturer's premises to show the plant is
capable of achieving the guaranteed duty point values as detailed in the Contract.
Site conditions shall be simulated as near as possible, particularly the suction
conditions.

e) Pump characteristic curves shall be produced for the following:

i. Head/Quantity.
ii. Power Absorbed/Quantity.
iii. Overall Efficiency/Quantity.
iv. NPSH Required/Quantity.
f) Contrary to ISO 9906: 2000, the overall efficiency of each combined motor-pump
derived in accordance with the tests shall not be less than that guaranteed.

g) Cavitation tests, as detailed in ISO 9906: 2000, shall form part of the tests.

17.12.3 Motors

a) Witness testing may be waived on standard types of small motors from recognised
manufacturers and on small components used in the manufacture of units of plant.

b) Motors of 15 kW and above shall be witness tested for performance to the approved
standard.

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c) Type test certificates shall be provided and shall include the following information for
all motors:

i) Approved standard of manufacture

ii) Class of insulation
iii) Size and type of cable fittings
iv) Type of bearings, sizes and lubricant
v) Type and rating of heaters
vi) Brush sizes and maker (if fitted)
vii) Line current all phases
viii) Phase current balance
ix) Efficiency and P.F. at 100%, 75% and 50% of Full load
x) Temperature rise test
d) After initial witness testing each motor shall be combined with its driven units and
witness tested to demonstrate satisfactory performance, correctness of assembly
and ease of re-assembly at site. The assembled units shall be adequately marked
and dowelled.

17.13 Site Testing and Commissioning of Electrical and Mechanical Plant

17.13.1 General requirements

a) Works tests shall be carried out in order to determine whether the components
and/or pump station items comply with the Specification and to provide the
necessary functional data. Where appropriate, all tests shall be arranged to
represent the working conditions as closely as possible.

b) Unless an alternative place of testing is agreed or specified the tests shall be carried
out at the Manufacturer's Works.

c) Not less than three weeks notice of all tests shall be given to the Employer, in order
that he may be present if he so desires. This duration shall be extendable if the
Employer/Engineer is unable to obtain the necessary approvals for travel. As many
tests as possible shall be arranged together, in accordance with a programme to be
agreed with the Employer. Six copies of the Contractor's records of all tests shall be
submitted to the Employer for approval immediately after the conclusion of each
test. These records shall be clearly marked so that the Contract equipment items or
components to which they refer can be readily identified.

d) Type tests will not be required in those cases where the Contractor can produce
certified evidence to the satisfaction of the Employer that the required type tests
have been performed successfully on identical equipment or equipment which is for
practical test purposes similar and produced in the factory where the equipment
offered is to be manufactured. Evidence to this effect shall be submitted at the time
of tendering, or as soon as practicable thereafter.

e) After the Contract has been awarded, a Manufacturers Inspection and Testing
Programme shall be established by the Contractor, in the form of detailed Quality
Control Plans for each item of plant and equipment. The Contractors Quality Control

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Plans will be subject to the Employer's approval. The Employer reserves the right to
call for additional tests as may be necessary to prove compliance with the
Specification. The Contractor shall pay the cost of all such tests.

f) Cables laid underground shall be tested in accordance with the appropriate

standard specification and to Dubai Electricity & Water Authority (DEWA).

g) The connections of all electrical circuits shall be proved to be correct and the whole
installation shall be tested for insulation resistance and earth loop resistance in the
presence of the Engineer or DEWA - Electricity Division Representative with
instruments provided by the Contractor. Any faults or defects shall be remedied at
the Contractor’s expense.

h) On completion of erection, all pipelines shall be tested to ensure tightness of joints

and connections.

i) Penstock shall be tested to maximum working pressure for on-seating and off-
seating permissible leakage.

j) Lubrication and fuel lines, sumps, tanks, etc., shall be adequately flushed to remove
any foreign matter before being put to use.

k) On completion of erection of each item of Plant the Contractor shall test and check it
and as far as is possible proving it under working conditions.

l) The Contractor will check that the installation is in safe working order and fulfils the
function for which it is intended.

m) Operational demonstrations and system validation tests are required for all
mechanical and electrical equipment, instrument, control and automation system.

n) Cost of consumable i.e. diesel, lubricant, coolant, materials, water, chemicals and
electrical power required to carry out testing, commissioning and validation of
equipment / systems shall be borne by the Contractor.

o) Temporary facilities, storage, and similar facilities necessary for these testing,
commissioning and validation of equipment / systems shall also be supplied by the
Contractor.

p) Testing and commissioning shall be performed under continuous presence of

Engineer’s representative.

q) All defects and malfunctions found during testing and commissioning shall be
corrected immediately, using approved method and new materials for repairs as
required. Interruption time necessary for corrective work may, at the Engineer's
discretion, be added to the specified testing and commissioning period.

r) Satisfactory completion and approval of required commissioning and testing is one

of the conditions for precedent to the Engineer's acceptance of the work, but does
not constitute final acceptance.

s) The contractor to provide all necessary measuring instruments, indicators,

temporary pipe work, temporary pumping plant and all other apparatus necessary to
carry out tests. The Contractor shall provide all necessary skilled personnel required
for the testing and commissioning.

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t) The Contractor should liaise with his sub-Contractors associated with the
completion of any part of the Works to ensure that all parties concerned are present
during any tests to carry out their responsibilities within the defined limits of their
individual sub-contracts.

u) Testing and commissioning shall be in accordance with the project specification,

relevant International Standards, DEWA regulation and requirements, Dubai
Municipality requirements, industrial norms and to the Engineer's approval.

v) A record of bearing, coupling clearances, protective device settings and alignments

shall be tabulated to show the "as-built" condition of each pump set.

w) A record of all limit switches, relays and protective settings etc. shall be tabulated to
show the "as-built" condition of each applicable part of FBA’s and other electrical
switchgear.

x) All cables shall have an insulation test to confirm the integrity of the insulation. A
tabulated record of results shall be made.

y) All earthing systems shall be tested to demonstrate the resistance of the electrodes
to earth and the earth conductor continuity is in accordance with the Specification.
The tests shall be made on completion of the installation.

z) Earth loop impedance shall be tested for each circuit.

aa) The control centre, control panel and instrumentation shall be tested together to
confirm the correct sequence and functional operation.

bb) Each pump shall be operated individually over the entire operating range with a
temporary arrangement using fresh water recirculation.

cc) All equipment subject to water pressure shall be hydraulically tested at 1.5 times the
maximum working pressure or 1.5 times the surge pressure whichever is greater.

dd) The hydraulic tests shall also be applied to the above ground pipework. The
Contractor shall provide the necessary equipment including any temporary blank
flanges which may be required to isolate equipment.

ee) All cranes shall be tested at works with a load 25% in excess of the rated load and
shall be tested and certified by relevant local authority.

ff) Any instruction of the Employer's personnel may be performed simultaneously but
requires written agreement of the Engineer if this constitutes a variance to the
contract specification.

gg) Testing shall be carried out in stages as follows:

i) Primary tests and checks

ii) Unit testing
iii) System validation tests
iv) Commissioning and setting to work
hh) The Contractor shall not proceed from one stage to the next without the Engineer's
approval.

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17.13.2 Testing and Commissioning Procedures and Documents

a) At least 45 days before testing and commissioning is to be performed, a detailed

and comprehensive method statement shall be submitted for the performance of
each separate test.

b) Method statement shall describe and itemise the involved system including
associated electrical equipment, instrumentation and control system.

c) Evidence of an organised step-by-step procedure, properly co-ordinating the efforts

of the various trades and manufacturers representative involved, and of the
operations of the facilities should be provided.

d) Method Statements shall include an estimated duration and commencement date

for each procedure and a schedule of personnel and equipment required.

e) Method statement shall include the following information, as applicable:

i) Description of temporary facilities, including drawings and sketches as

necessary to fully illustrate the requirements
ii) List of material and estimated quantities
iii) List of instruments either these are part of the final system or furnished
separately for temporary use.
iv) Calibration certificates of testing equipment.
v) Names of supervisor and participating personnel
vi) Recording intervals
f) Instruments, gauges, and other sensors and display devices forming a part of the
various systems shall be employed for data acquisition where applicable.

g) The Contractor shall furnish all required instrument, gauge, recorder and testing
devices etc. conforming to approved method statement.

h) All applicable data such as, but not limited to, level, flow, pressure, head
differentials, duration of run, various instrument reading, voltage setting, drive
speeds, motor running current, torque, voltage etc. in accordance with approved
testing procedure shall be recorded at the start and finish of each operational
demonstration and at 30 minute intervals during system validation tests, unless
other intervals are specified.

i) Contractor shall take prior approval of forms required to record various tests.

j) Test records shall be maintained by the Contractor. Forms shall be designed to

record the following aspect and parameters:

i) Result anticipated
ii) Result obtained
iii) If incorrect, corrective action taken
iv) Re-test/check result

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k) Test and commissioning reports including results, final settings and adjustments
made shall be provided in a separately bound volume of the Operations and
Maintenance Instruction Manuals.

17.13.3 Primary Tests and Checks

a) All component unit and complete systems shall conform to the Specification,
Drawing and the approved working drawings, samples, construction manuals,
materials lists, and other approved submittals.

b) All specified components and complete systems shall have been installed
satisfactorily and are operable.

c) All installation shall be safe to use. Temporary access, covers etc., will only be
permitted if approved by the Engineer.

d) All cleaning work shall be completed.

e) Equipment shall be free from physical damage due to mechanical force, exposure to
the elements, incorrect connection etc.

17.13.4 Unit Testing

a) Unit testing is defined as tests on individual equipment items such as pumps,

compressors, deodorisers, blowers, fans, conveyors and all similar equipment
items. Tests may be performed simultaneously on groups of identical equipment,
items, and groups of items supplied by one manufacturer, if practicable.

b) Clean water shall be used to fill tanks, wells piping and systems that contain water,
sewage or sludge in normal operation. Where necessary specified chemical shall
be used for chemical systems but shall not exceed in-service concentrations.

c) Tests shall show that all component units operate with the quantities, efficiency,
repeatability, and accuracy specified.

d) Tests shall be carried out continuously for a minimum period of 24 hours.

17.13.5 System validation tests

a) System validation tests shall not commence until primary test & check and unit
testing have been satisfactorily completed and accepted.

b) This is defined as testing of complete systems that perform a discrete process

function such as auto operation of pumping systems, odour control system,
emergency power system, control system, SCADA and similar systems. Each
system shall include associated structures, tanks, piping, utilities, instrumentation
and controls, and like related items.

c) Clean water shall be used for system validation tests if it is possible to carry them
out satisfactorily with this medium. If the tests require use of the medium used in
service, then this shall be used.

d) System validation tests shall be carried out for minimum of 24 hours, unless longer
is needed to prove the performance of the system.

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17.13.6 COMMISSIONING AND SETTING TO WORK

a) The commissioning shall be carried out as follows under the control of the
Contractor's staff and the supervision of the Engineer. The purpose of these trials
shall be as follows:

i) To confirm the performance guarantee

ii) To provide a comprehensive record of machinery performance
b) Commissioning is defined as the testing of all the equipment and system together
under actual operating conditions using all the mediums used in actual operating
conditions. Once the equipment and systems are operating satisfactorily they are
left to work.

c) Each system shall be tested including standby equipment by continuous operation

under the "in-service" condition for not less than 14 consecutive days, with no
interruptions except for normal maintenance or corrective work. Where the in-
service condition is an automatically controlled cycle with on/off intervals it shall be
so operated.

d) Systems shall be operated continuously under constant inspection of trained

operators. System operation shall be cycled from lean load to peak load, as
practicable. Variable speed equipment shall cycle through the applicable speed
range at a steady rate of change. Simulated alarm and failure operating conditions
shall be induced as and when directed by Engineer during commissioning and
testing period. Controls and protective devices shall be tested for correct operation
in adjusting system functions or causing system shutdown.

e) Subject to Contractor's request and Engineer's approval in each case, the

Contractor may simulate certain operating conditions relating to flow rates, water
levels and malfunctions. Permission for simulations will be granted only where it is
unwise or impossible to obtain the conditions covered by the capability of ranges or
equipment. The simulation method shall reflect reasonable anticipated operating
conditions.

17.14 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF

a) The Contractor shall provide qualified personal to instruct and train the Employer
nominated staff for plant operation and maintenance.

b) After the equipment has been installed, tested, adjusted and placed in the
satisfactory operation the Contractor shall provide the service of the manufacturer’s
representative at site for the training of nominated operation and maintenance staff.

c) An instruction and training programme shall be conducted for up to 6 operators or

as nominated by the Employer.

d) The Contractor shall give the Employer at least two month written notice of the
proposed instruction and training programme. Instruction and training shall cover
the basic system operation theory, routine maintenance, repair, and "hands on”
operation of equipment.

e) The duration of the instruction and training period shall be based on the complexity
of equipment involved and the equipment manufacturer’s recommendations. The

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Engineer/ Employer acceptance of the satisfactoriness of training received must be

obtained before terminating the programme.

17.15 Operating and Maintenance Manuals

17.15.1 General

a) The Operating instructions shall be prepared in English in such a way as to provide

a step by step description of the preparation and setting to work of the plant and its
shutting down.

b) A copy of the appropriate schedules and instructions shall be mounted on neatly

finished plywood boards suitably protected by clear varnish or other approved
material and fixed on the wall adjacent to the item of plant to which they refer.

c) The Maintenance Instructions shall be in English and include the following:-

i) Schedules of routine maintenance for each item of the plant.

ii) Schedule of equipment supplied giving manufacturer's name and
appropriate Make/Model No. /Cat. No.
iii) Schedule of spares supplied.
iv) Schedule of tools supplied.
v) Sectional arrangement drawings of major items of plant i.e. pumps, valves
etc. with dismantling instructions.
vi) Plant layout drawings showing the "as erected" installation.
vii) General arrangement and schematic diagrams of the "as installed" control
panel.
viii) "As wired" diagrams of all electrical connections between the control panel
and installed loads.
ix) Full and comprehensive instructions for the maintenance of all items of
equipment installed.
x) Test certificates for motors, pumps, compressors, pressure vessels, lifting
equipment, transformers, electrical installation and other items where
appropriate.
xi) Pump performance curves as tested.
xii) System curves.
xiii) Schedule of recommended lubricants and their equivalents.
17.15.2 Requirements and Contents

a) Two copies of the draft manuals shall be submitted to the Engineer for review and
approval before delivery of the equipment.

b) The final copies of the manuals shall be provided in CD and also 6 sets in hard copy
to the Engineer within 60 days of the commencement of the maintenance period.
They shall include all revisions and comments made by the Engineer and any
revisions or corrections necessitated by changes made during installation and
testing.

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c) Manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment.

d) Where several sub-Contractors and manufacturers have supplied equipment the

Contractor shall provide a complete integrated manual which clearly demonstrates
the inter-relation of the equipment.

e) Manuals shall be provided in durable hard backed A4 sized loose-leaf four ring
binders according to DIND standard O&M manual format. Lever arch binders are
not acceptable.

f) The manuals shall enable the client to safely operate, maintain, dismantle,
reassemble and adjust all part of the works.

g) Original copies of leaflets and instructions provided by the specialist manufacturers

shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text.

h) All instructions and manuals shall be written in accordance with appropriate National
Standards and other recognised guidelines on technical manual writing.

i) These shall comprise a number of volumes, dependent on the amount and technical
content of the equipment installed. The operating instructions shall always form a
separate volume. Manuals shall include sections containing information as
described in the following paragraphs.

j) Introduction:

i) The name, address, telephone and fax numbers of the Site, the Engineer,
the Consultant, the Contractor, Sub-Contractors, Manufacturers and their
Agents.
ii) The date the Contract commenced, and the date of the Taking Over
certificate.
iii) A brief description of the plant provided and the contractual scope of the
work, with descriptions of any work subcontracted.
k) General description of equipment:

i) General description of the mechanical equipment. This shall provide a

brief description of all mechanical plant provided.
ii) General description of the electrical equipment and control system. This
shall provide a brief description of the equipment provided, listing
individual control panel compartments and the remote controls.
l) Detailed description of the mechanical equipment.

i) This shall provide details of all the mechanical equipment including

manufacturer type, rating, duties, characteristic performance curves
ii) Schedules for all components stating serial numbers.
m) Detailed description of the electrical and control system.

i) This shall provide details of all electrical equipment and cables including
information on the control panel(s), listing the display and controls

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available for each compartment and stating the rating, manufacturer and
supplier of main components,
ii) Component schedules with serial numbers, calibration procedures
iii) Schedule of input and output signals, signal type, polarity, digital open or
closed state and analogue range.
n) Operating instructions.

i) These shall provide details of how each piece of plant is controlled and
operated in both automatic and hand modes, including the control
philosophy and its interrelationship with other interdependent plant.
ii) Details of plant operation under non-routine conditions
iii) Details of start-up and shut-down procedures with any associated safety
checks shall be provided.
o) Inspection and maintenance instructions.

i) These shall provide schedules recording the time interval for routine
inspection, maintenance and lubrication tasks, with reference to individual
manufacturer's instruction manuals for full details. They shall describe
briefly the more complex tasks that must be under taken at irregular
intervals. In addition to the routine operating and maintenance task this
section should identify the following:
ii) More complex tasks, involved with plant shut-downs, fault rectification to
components level, fault diagnostics, overhauls, etc.
iii) Specific hazards associated with operating and maintaining the plant, e.g.
auto starting, high voltage, noise levels.
iv) Highlight any particular complex or critical tasks over the above normal
requirements.
v) Measurements and guidance on limits of acceptable wear for all items
subject to wear.
p) Fault finding and correction. This shall provide a guide to first line checks that can
be undertaken in the event of plant failure without the need for reference to the
detailed instructions.

q) Inventory of installed plant. A schedule of this shall be provided.

r) Drawings list. A list of the ‘As-Built’ drawings shall be provided.

s) ‘As Built drawings’. Approved copies of all "As-Built" drawings shall be included for
the following:

i) Process and instrumentation diagram

ii) Site layout showing main works operational features
iii) Equipment and machinery layout
iv) Mechanical and electrical details
v) Electrical power circuit diagrams
vi) Control schematic diagrams

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vii) HV and LV distribution single line diagrams

viii) HV and LV cable routes
ix) Hard / soft copy of PLC and RTU programmes or computer programmes
x) One master copy of the proprietary software package shall be provided to
the Engineer within one week of Contract completion. All software licenses
and/or registration requirement must be forwarded promptly to the
Engineer for subsequent registration with the manufacturer. Sole rights to
all software developed and written on all schemes financed by the
Engineer shall be retained by the Engineer.
xi) Assembly drawings shall clearly show the construction details and be in
sufficient detail to facilitate re-assembly.
xii) Cable schedules shall include cable reference numbers and core
reference numbers relating to power circuit diagrams.
xiii) The above are to be supplied to the satisfaction of the Engineer. The
Contractor shall provide the Engineer black and white prints of each on
thick paper and one ISO size A2 (594 x 420) negative of each. All
drawings shall be prepared on a MICROSOFT system and printed on DM
standard sized paper (650 x 1250) unless specifically requested
otherwise. Each drawing shall be marked with the Engineers Consultant's,
Contractor's and manufacturers names and references, drawing number,
title, scales, date of completion and a full description and date of all
amendments, and shall be certified 'As-built'. The project title shall be
included in a box at the bottom right had corner of each drawing.
17.16 Guarantee

a) The Contractor shall provide a guarantee for the maintenance period for all
equipment in accordance with the General Conditions of Contract. In addition to the
general guarantee requirements, equipment warranty shall cover:

i) Faulty or inadequate design

ii) Improper assembly or erection
iii) Defective workmanship or materials
b) During the guarantee period, a warranty check of each system required to be
validation tested shall be performed twice by qualified technical representatives of
the various system manufacturers, including manufacturers of equipment
components within systems. Checks shall be detailed and complete, requiring not
less than 8 hours at the site, and shall be performed under the observation and to
the satisfaction of Dubai Municipality / Engineer. All costs for in-service checks
shall be included in the Contract Price.

c) The Contractor shall notify Dubai Municipality / Engineer in writing at least ten days
prior to the start of each warranty check and obtain his approval of the proposed
dates.

d) At the time of each warranty check, each qualified technical representative shall
review the O&M Manual and the pertinent operational and maintenance problems
encountered, and furnish technical advice and recommendations to Dubai
Municipality / Engineer.

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e) The initial warranty check shall be performed approximately six months after final
acceptance of the plant. The second warranty check shall be performed within thirty
days of the end of the contractual guarantee period.

f) The Contractor shall submit a written report of each warranty check, signed by the
appropriate manufacturer or his representative, to Dubai Municipality / Engineer
within ten days following the check. The report shall describe the checking
procedure in detail, and shall restate all advice and recommendations given to
Dubai Municipality / Engineer.

17.17 IDENTIFICATION

17.17.1 General

a) Pipes, valves, pumps, compressors etc shall be colour coded. The coding shall
indicate the contents of the pipelines, purposes of the valves etc. and show whether
or not the fluids being handled are dangerous.

b) Tape banding of pipes of the appropriate colour shall be spaced at 3m intervals and
at every valve or junction. Direction of flow arrows shall be provided together with
process stream contents.

c) Lagged pipe work shall be colour coded prior to lagging. Lagging surface shall be
continuously colour coded.

d) Stainless steel shall not have any paint system applied to its surface but
imperfections and heat-affected zones shall receive a suitable treatment to give a
high quality, uniform surface appearance.

e) CE/UL labels shall be fixed on all electrical equipment, components and

accessories.

f) The Contractor shall provide and fix necessary diagrams and/or instructions, notices
for all systems. They shall be located adjacent to the appropriate items of Plant.
Such notices shall be protected from the environment by glass or clear plastic
covers as approved by Dubai Municipality / Engineer.

17.17.2 Nameplates

a) The Contractor shall supply and fix name and rating plate(s) to each item of plant.

b) The plates shall be engraved or stamped with, but not limited to:

i) Manufacturer's name.
ii) Type and serial number of the Plant.
iii) Details of the loading and duty at which the item has been designed to
operate.
iv) Sufficient detail to allow the assembly to be readily identified in
correspondence and when ordering spare parts.
c) Additional information shall be engraved on the plate as specified in specific
sections of this specification.

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d) A schedule of plant nameplates shall be provided at the detailed design stage to

enable these numbers to be allocated.

e) The plates shall be robust, weatherproof and resistant to cracking and fracture.

f) Colourfast numbering and lettering, in block capitals and/or symbols, shall not be
less than 5mm high, engraved in both Arabic and English.

g) The plates shall include a maintenance reference number obtainable from Dubai
Municipality / Engineer, for the item of plant to which they are fixed.

h) All plates shall, where practicable, be mechanically fixed to plant. The use of other
fixings shall be subject to specific written approval of Dubai Municipality / Engineer.

17.17.3 Tags

Metal Tags shall be of Stainless Steel with stamped letters; tag size shall be minimum
40mm square with smooth edges.

17.17.4 Stencils

a) Stencils shall be produced with clean cut symbols and letters of the following sizes:

i) 20-30mm Outside Diameter of Insulation or Pipe: 200mm long colour field,

15mm high letters.
ii) 40-50mm Outside Diameter of Insulation or Pipe: 200mm long colour field,
20mm high letters.
iii) 65-150mm Outside Diameter of Insulation or Pipe: 300mm long colour
field, 30mm high letters.
iv) 200-250mm Outside Diameter of Insulation or Pipe: 600mm long colour
field, 65mm high letters.
v) Over 250mm Outside Diameter of Insulation or Pipe: 800mm long colour
field, 90mm high letters.
vi) Ductwork and Equipment: 65mm high letters.
b) Stencil Paint shall be semi-gloss enamel, colours conforming to BS4800.

17.17.5 Pipe Markers

a) Pipe marking colours shall conform to BS4800.

b) Plastic pipe markers shall be factory-fabricated, flexible, semi-rigid plastic,

preformed to fit around pipe or pipe covering; minimum information indicating flow
direction arrow and identification of fluid being conveyed.

c) Plastic tape pipe markers shall be flexible, vinyl film tape with pressure sensitive
adhesive backing and printed markings.

d) Underground plastic pipe parkers shall be bright coloured continuously printed

plastic ribbon tape, minimum 150mm wide by 4mm thick, manufactured for direct
burial service.

17.17.6 Instruction Notices

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a) The Contractor shall supply all necessary diagrams and instructions and notices for
special systems.

b) All diagrams, instructions and notices shall be located and fixed adjacent to the
appropriate items of plant.

17.17.7 Safety Warning Signs and Notices

a) Signs and Notices specifically required for Safety and Warning purposes shall
comply with the requirements of Dubai Municipality / Engineer.

b) Any items of equipment that start automatically shall have permanent warning signs
affixed to them with the legend in English and Arabic stating “Warning Equipment
Automatic Starting, Isolate Elsewhere”.

17.17.8 Identification Colours

BS 4800 shall be used for mechanical and electrical equipment.

17.17.9 Colour Schedule for Plant and Equipment

The contractor shall prepare colour coding schedule based on BS/RAL and submit it
for Dubai Municipality / Engineer approval.

17.17.10 Identification Colours for Plant and Equipment

The contractor shall prepare colour coding schedule based on BS/RAL and submit it
for Dubai Municipality / Engineer approval.

17.17.11 Identification Colours for Pipelines

The contractor shall prepare colour coding schedule based on BS standard and
submit it for Dubai Municipality / Engineer approval.

17.17.12 Preparation

a) Surfaces shall be degreased and cleaned to receive adhesive for identification

materials.

b) Surface preparation shall be in accordance with Section 09900 for stencil painting.

17.17.13 Installation

a) Nameplates shall be installed with corrosive-resistant mechanical fasteners, or

adhesive. Sufficient adhesive shall be applied to ensure permanent adhesion and
shall be sealed with a clear lacquer.

b) Tags shall be installed with corrosion resistant chain.

c) Plastic pipe markers shall be installed in accordance with manufacturer's

instructions.

d) Plastic tape pipe markers shall be installed completely around the pipe in
accordance with the manufacturer's instructions.

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e) Underground plastic pipe markers, shall be installed 150 to 200mm below finished
grade, directly above buried pipe.

f) Air handling units, pumps, heat transfer equipment, tanks, and water treatment
devices shall be identified with plastic nameplates or stencil painting. Small
devices, such as in-line pumps, may be identified with tags.

g) Control panels and major control components outside panels shall be identified with
plastic nameplates.

h) Thermostats relating to terminal boxes or valves shall be identified with nameplates.

i) Valves in main and branch piping shall be identified with tags.

j) Air terminal units and radiator valves shall be identified with numbered tags.

k) Automatic controls, instruments, and relays shall be tagged and referenced to

control schematics.

l) Concealed or exposed piping shall be identified with plastic pipe markers, plastic
tape pipe markers or stencilled painting. Tags shall be used on piping of 20mm
diameter and smaller. Service, flow direction and pressure shall be identified in clear
view and aligned with axis of piping. Identification points shall not exceed 6m
intervals on straight runs including risers and drops. They shall be adjacent to each
valve and tee and be at each side of penetrations of structures or enclosures, and at
each obstruction.

m) Ductwork shall be identified with plastic nameplates or stencilled painting. Air

handling units shall have an identification number and area served. Identification
shall be provided at air handling units, at each side of penetrations of structures or
enclosures, and at each obstruction.

n) Ceiling tags shall be provided to locate hidden valves or dampers above T-bar type
panel ceilings. They shall be located in the corner of a panel closest to the
equipment.

17.17.14 Schedules

a) When identifying specific equipment, the Contractor will provide an appropriate

schedule.

b) The following may assist in developing such a schedule:

i) Equipment type.
ii) Identification size/colour.
iii) Background size/colour.
iv) Lettering.
17.18 STANDARDS AND REGULATIONS

17.18.1 General Requirements

a) All products and services shall comply with any International ISO, IEC, BS EN, BS
and ASME covering such items, as a minimum, unless otherwise specified. Unless

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otherwise stated, ISO shall take precedent over IEC, which shall take precedence
over BS EN, which will take precedence over BS, which will take precedence over
all remaining standards.

b) Supportive technical literature shall be provided at the material submittal stage from
Contractor to show that products comply with the specification. Where requested by
Dubai Municipality / Engineer, or specified, the Contractor shall submit supporting
test data to substantiate compliance in conformity with specified standards,
complete with a statement from the manufacturer that original non-conformities
have been observed, and subsequently addressed to meet this specification.

c) The laws and regulations of UAE include regulations for electrical Installations and
associated regulations managed by the DEWA-ED. The Contractor shall make
himself aware of all the relevant requirements and shall implement the Works in
strict compliance with them.

d) All component parts shall be manufactured to a strict system of ‘Limits and Fits’ and
complete inter-changeability of similar parts are required, where international
standardisation of such parts is in place.

e) All references to codes, regulations, specifications and standards referred to in the

contract documents shall, unless otherwise stated, mean the latest edition,
amendment or revision of such reference standard in effect as of the date of
submission of these bid documents by the bidders.

f) Quoted reference standards referred to in the contract documents shall deem

mandatory under this contract. Products or workmanship specified by association,
trade, or other consensus standards, are also deemed mandatory, except when
more rigid requirements are specified or are required by applicable codes.

g) Should specified reference standards conflict with contract documents, then

clarification shall be sought from Dubai Municipality / Engineer before proceeding
with the supply or manufacture of plant and equipment.

h) References to published standards shall be construed as reference to a recognised

equivalent standard.

i) Obtain an original copy of the latest edition of all codes, regulations, standards and
technical literature referred to in the Contract documents and the same shall be kept
on the project site, properly indexed and maintained in good order and readily
available to Dubai Municipality / Engineer at all times. Upon completion of the works
the said codes, standards, etc., shall be handed over to Dubai Municipality.

j) Manufacturer’s manufacturing premises, sub-Contractors and suppliers shall

operate on an internationally recognised and approved quality system, or an
equivalent in-house quality system approved by the Engineer. The Contractor shall,
if required supply full details of the quality system to the Engineer for his review and
approval.

17.18.2 Purpose of Standards

a) Standards shall be treated as a documented agreement with respect to the

technical specifications and shall be followed throughout as rules and guidelines to
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ensure that the equipment, plant, materials, installation and systems, etc. are in
accordance with the requirements of the specification.

b) To ensure that the proposed equipment, plant, materials, installation and systems,
etc. have been carefully examined by the Contractor that ensure product full
compliance with the those requirements specified in the basic standards, product
manufacturing standard, functional standards and quality standards.

17.18.3 International Standards

a) The following International Standards shall be used:

i) ISO International Organization for Standardization

ii) IEC International Electrotechnical Commission
iii) BS EN British Standards European Norm
iv) BS British Standards
v) PD Published Documents
vi) CEN European Committee for Standardization
vii) UL Underwriters Laboratories
viii) NFPA National Fire Protection Association
ix) ATEX Explosive Atmospheres Directive

17.18.4 Local Regulations

a) The following Local Regulations shall be followed:

i) DEWA Dubai Electricity & Water Authority

ii) FEA Federal Environmental Agency
iii) ETISALAT Emirats Telecommunication Corporation Ltd.
iv) DU Telecommunications Service provider
v) DCD General Directorate of Civil Defence
vi) JAFZA Jebel Ali Free Zone
vii) RTA Road Transport Authority
viii) DM Dubai Municipality
ix) DUSUP Dubai Supply Authority
x) MOD United Arab Emirates - Ministry of Defence

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 General Specifications for Mechanical & Electrical Works
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Drainage and Irrigation Department

Table 17–4: STANDARDS

Sr. STANDARDS DESCRIPTION

Measurement of fluid flow by means of pressure
differential devices inserted in circular cross-
1 BS EN ISO 5167-1
section conduits running full. General principles
and requirements
Measurement of fluid flow by means of pressure
2 BS EN ISO 5167-2 differential devices inserted in circular cross-
section conduits running full. Orifice plates
Rotodynamic pumps. Hydraulic performance
3 BS EN ISO 9906
acceptance tests. Grades 1 and 2
Reciprocating internal combustion engines.
4 BS ISO 3046-1 Performance. Declarations of power, fuel and
lubricating oil consumptions, and test methods.
Reciprocating internal combustion engines.
5 BS ISO 3046-3
Performance. Test measurements
Reciprocating internal combustion engines.
6 BS ISO 3046-4
Performance. Speed governing
Reciprocating internal combustion engines.
7 BS ISO 3046-5
Performance. Torsional vibrations
8 BS EN 3 Specification for Portable Fire Extinguishers
Specification for Control and Indicating Equipment
9 BS EN 54-2 and -4
(Supersedes BS 5839 : Part 4)
Fire Detection and Fire alarm System. Heat
10 BS EN 54-5
Detectors. Point Detectors
Smoke Detectors. Point Detectors using Scattered
11 BS EN 54-7
Light, Transmitted Light or Ionisation.
12 BS EN 54-11 Specification for Manual Call Points
Fire detection and fire alarm systems. Smoke
13 BS EN 54-12 detectors. Line detectors using an optical light
beam
Ductile iron pipes, fittings, accessories and their
14 BS EN 545 joints for water pipelines. Requirements and test
methods
Industrial valves. Face-to-face and centre-to-face
15 BS EN 558 dimensions of metal valves for use in flanged pipe
systems. PN and Class designated valves
16 BS EN 593 Industrial valves. Metallic butterfly valves
Specification for Hose Reels with Semi Rigid Hose
17 BS EN 671-1
Overall dimensions of rotodynamic pumps.
18 BS EN 735 Tolerances

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Drainage and Irrigation Department

Sr. STANDARDS DESCRIPTION

Valves for water supply. Fitness for purpose
requirements and appropriate verification tests.
19 BS EN 1074-1 General requirements

Valves for water supply. Fitness for purpose

20 BS EN 1074-2 requirements and appropriate verification tests.
Isolating valves
Valves for water supply. Fitness for purpose
21 BS EN 1074-4 requirements and appropriate verification tests. Air
valves
Valves for water supply. Fitness for purpose
22 BS EN 1074-5 requirements and appropriate verification tests.
Control valves
Flanges and their joints. Circular flanges for pipes,
23 BS EN 1092-2 valves, fittings and accessories, PN designated.
Cast iron flanges
Valves. Materials for bodies, bonnets and covers.
24 BS EN 1503-1
Steels specified in European Standards
25 BS EN 1563 Founding. Spheroidal graphite cast iron
26 BS EN 1711 Industrial valves. Cast iron gate valves
27 BS EN 1982 Copper and copper alloys. Ingots and castings
Continuously hot-dip coated steel sheet and strip.
28 BS EN 10143
Tolerances on dimensions and shape
Seamless steel tubes for pressure purposes.
29 BS EN 10216-1
Technical delivery conditions
Welded steel tubes for pressure purposes.
30 BS EN 10217-1 Technical delivery conditions. Non-alloy steel tubes
with specified room temperature properties
Non-alloy steel tubes suitable for welding and
31 BS EN 10255
threading. Technical delivery conditions
Industrial valves. Testing of valves. Pressure tests,
32 BS EN 12266 test procedures and acceptance criteria.
Mandatory requirements
33 BS EN 12334 Industrial valves. Cast iron check valves
34 BS EN 13157 Cranes. Safety. Hand powered lifting equipment
35 BS EN 13789 Industrial valves. Cast iron globe valves
Measurement of fluid flow in closed conduits.
36 BS EN 24006
Vocabulary and symbols
Electromagnetic compatibility. Requirements for
37 BS EN 55014-1: household appliances, electric tools and similar
apparatus. Emission. Product family standard

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Sr. STANDARDS DESCRIPTION

Specification for pipe threads for tubes and fittings
38 BS 21 where pressure-tight joints are made on the
threads (metric dimensions)
Threaded pipe fittings in malleable cast iron and
39 BS 143
cast copper alloy
Specification for power driven overhead travelling
40 BS 466 cranes, semi-goliath and goliath cranes for general
use
Fire tests on building materials and structures.
41 BS 476-20 Method for determination of the fire resistance of
elements of construction (general principles)
42 BS 5158 Specification for cast iron plug valves
Valves for waterworks purposes. Predominantly
43 BS 5163 key-operated cast iron gate valves. Code of
practice
Rules for the design of cranes. Specification for
44 BS 2573-1 classification, stress calculations and design
criteria for structures
Rules for the design of cranes. Specification for
45 BS 2573-2 classification, stress calculations and design of
mechanisms
Standards. Specification for high tensile steel
46 BS 2903 hooks for chains, slings, blocks and general
engineering purposes
Specification for class II arc welding of carbon steel
47 BS 2971
pipework for carrying fluids
Fire hydrant systems equipment. Specification for
48 BS 5041-1
landing valves for wet risers
Code of practice for fire extinguishing installations
49 BS 5306-1 and equipment on premises. Hose reels and foam
inlets
Fire extinguishing installations and equipment on
50 BS 5306-2
premises. Specification for sprinkler systems
Fire extinguishing installations and equipment on
51 BS 5306-3 premises. Commissioning and maintenance of
portable fire extinguishers. Code of practice
52 BS 5306-4 Specification for Carbon Dioxide Systems
Fire Detection and Alarm Systems for Buildings;
53 BS 5839-1 Code of Practice for System Design, Installation,
Commissioning & Maintenance
Fire detection and alarm systems for buildings.
54 BS 5839-3 Specification for automatic release mechanisms for
certain fire protection equipment
55 BS 5839-6 Fire detection and fire alarm systems for buildings

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Sr. STANDARDS DESCRIPTION

Code of practice for fire protection for electronic
56 BS 6266
equipment installations
57 BS 7121) Code of practice for safe use of cranes
Specification for steel and copper alloy wafer check
58 BS 7438
valves, single-disk, spring-loaded type
Recommendations for colour coding to indicate the
59 BS 7863 extinguishing media contained in portable fire
extinguishers
Non-magnetic coatings on magnetic substrates –
60 ISO 2178 Measurement of coating thickness – Magnetic
method
Specification for Metallic flanges and bolts for Cast
61 ISO 7005-2
Iron, Part 2.
Quality Management and Quality System Elements
62 ISO 9004
Guidelines
63 ISO 10474 Steel and steel products -- Inspection documents
Mechanical vibration -- Evaluation of machine
64 ISO 10816-3 vibration by measurements on non-rotating parts --
Part 3: Industrial machines
Welding -- General tolerances for welded
65 ISO 13920 constructions -- Dimensions for lengths and angles
-- Shape and position
66 DIN 8563 Welding classes standards
67 DIN 15018 Crane classification
68 DIN 15020/FEM Hoist classification
69 DIN 15401 Manufacturing of single hooks
70 DIN 15402 Manufacturing of double hooks
71 DIN 15404 Certification of hooks
72 DIN 18800 Construction for quality of welding
73 DIN 30677 Epoxy coating standard
74 NFPA-10 Standard for Portable Fire Extinguishers
Standard on Carbon Dioxide Extinguishing
75 NFPA-12
Systems
76 NFPA-13 Standard for Installation of Sprinkler System
77 NFPA-20 Standard for Installation of Centrifugal Fire Pumps
Standard for the Installation of Private Fire Service
78 NFPA-24
Mains and their Appurtenances
79 NFPA-70 National Electrical Code
80 NFPA-72 Standard for Protective Signalling Systems
81 NFPA-72E Standard for Automatic Fire Detectors
Standard for the Installation of Air Conditioning and
82 NFPA 90A
Ventilating Systems
83 NFPA 220 Standard on Types of Building Construction

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Drainage and Irrigation Department

Sr. STANDARDS DESCRIPTION

Method of Test of Surface Burning Characteristic of
84 NFPA 255
Building Material
Recommended Practice for Fire Flow Testing and
85 NFPA-291
Marking of Hydrants
86 IEC 60423
87 ARI 210 Unitary Air Conditioning Equipment
Standard for Sound Rating of Outdoor Unitary
88 ARI 270
Equipment
Commercial and Industrial Unitary Air-Conditioning
89 ARI 340/360
Equipment
Forced Circulation Air-Cooling and Air-Heating
90 ARI 410
Coils
91 ARI 430 Central Station Air-Handling Unit
92 ASHRAE 15 Safety Code for Mechanical Refrigeration
Methods of Testing for Rating Remote Mechanical
93 ASHRAE 20
Draft Air Cooled Refrigeration Condensing Units
Methods of Testing for Rating Positive
94 ASHRAE 23
Displacement Condensing Units
Method of Testing Air Cleaning Devices Used in
95 ASHRAE 52 General Ventilation for Removing Particulate
Matter
96 ASHRAE Hand Books
97
Power Piping Code 11. ISO 10474 Steel and Steel
98 ASME B31.1
Products
Standard Specification for Pipe, Steel, Black and
99 ASTM A 53/A 53M
Hot Dipped coated Welded and Seamless.
Standard Specification for Composition Bronze or
100 ASTM B 62
Ounce Metal Castings
Standard Test Method for Weight of Coating on
101 ASTM A 90/A 90M
Zinc-Coated (Galvanized) Iron or Steel Articles
Standard Specification for Seamless Copper Tube
102 ASTM B 280
for Air Conditioning and Refrigeration Field Service
Specification for Sintered Nickel Steel Structural
103 ASTM B 484
Parts
Standard Specification for Cellular Glass Thermal
104 ASTM C 552
Insulation
Standard Specification for Steel Sheet, Zinc-
ASTM A 653/ A
105 Coated by the Hot-Dip Process, Lock-Forming
653M
Quality
106 PD 5304 Safe use of machinery
Specification for Drives Using Classical Multiple V-
107 RMA IP-20
Belts, And Sheaves – Cross Section A, B, C and D.
108 UL 181 Factory-Made Air Ducts and Connectors

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Drainage and Irrigation Department

Sr. STANDARDS DESCRIPTION

Refrigerant – Containing Components and
109 UL 207
Accessories, Nonelectrical
110 UL 900 Standard for Safety Air Filter Units
UL Standard for Safety Heating and Cooling
111 UL 1995
Equipment.
VDE 0113, VDE Electrical equipment of crane and applicable CEE
112
0100 standards
113 WIS 4-52-01 Specification for Polymeric Anti-corrosion Coatings
114 IEC-60034 Rotating electrical machines
115 IEC 60034-1 Rating and performance
Methods for determining losses and efficiency of
116 IEC 60034-2
rotating electrical machinery from tests
Degrees of protection by enclosure for rotating
117 IEC 60034-5
machinery
118 IEC 60034-6 Methods of cooling rotating machinery
Classifications of types of construction and
119 IEC 60034-7 mounting arrangements of rotating electrical
machinery
Terminal marking and direction of rotation of
120 IEC 60034-8
rotating electrical machines
121 IEC 60034-9 Noise limits
122 IEC 60034-11 Built-in thermal protection
Mechanical vibration of certain machines with shaft
123 IEC 60034-14 heights 56 mm and higher measurement,
evaluation and limits of the vibration severity
Impulse voltage withstand levels of rotating a.c.
124 IEC 60034-15
machines with form-wound stator coils
Efficiency classes of single speed, 3 phase, cage
125 IEC 60034-30
induction motors
Selection of energy efficient motors including
126 IEC 60034-31
variable speed applications- application guide
127 IEC 60038 Standard voltages
128 IEC 60044 Instrument transformers
129 IEC 60050 International Electrotechnical Vocabulary
Direct acting indicating analogue electrical
130 IEC 60051
measuring instruments and their accessories
131 IEC 60059 Standard current ratings
132 IEC 60060 High-voltage test techniques - ALL PARTS
133
Dimensions and output series for electrical
134 IEC 60072
machines
135 IEC-60076 Power transformers
136 IEC 60076-6 Power transformers - Part 6: Reactors

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137 IEC 60076-7 Loading guide for oil-immersed power transformers
Determination of transformers and reactors sound
138 IEC 60076-10
levels
139 IEC 60076-11 Dry type power transformers
140 IEC 60079 Electrical apparatus for explosive gas atmosphere
Explosive atmospheres - Part 0: Equipment -
141 IEC 60079-0
General requirements
Explosive atmospheres - Part 1: Equipment
142 IEC 60079-1
protection by flameproof enclosures ‘d’
Explosive atmospheres - Part 2: Equipment
143 IEC 60079-2
protection by pressurized enclosures ‘p’
Explosive atmospheres - Part 5: Equipment
144 IEC 60079-5
protection by powder filling ‘q’
Explosive atmospheres - Part 6: Equipment
145 IEC 60079-6
protection by oil immersion 'o'
Explosive atmospheres - Part 7: Equipment
146 IEC 60079-7
protection by increased safety 'e'
Electrical apparatus for explosive gas atmospheres
147 IEC 60079-10
- Part 10: Classification of hazardous areas
Explosive atmospheres - Part 11: Equipment
148 IEC 60079-11
protection by intrinsic safety 'i'
Electrical apparatus for explosive gas atmospheres
149 IEC 60079-14 - Part 14: Electrical installations in hazardous areas
(other than mines)
Electrical apparatus for explosive gas atmospheres
150 IEC 60079-15 - Part 15: Equipment protection by type of
protection 'n' electrical apparatus
Electrical apparatus for explosive gas atmospheres
151 IEC 60079-18 - Part 18: Equipment protection by type of
protection encapsulation 'm' electrical apparatus
Electrical apparatus for explosive gas atmospheres
152 IEC 60079-25
- Part 25: Intrinsically safe systems
Explosive atmospheres - Part 26: Equipment with
153 IEC 60079-26
equipment protection level (EPL) Ga
Electrical Insulation - Thermal evaluation and
154 IEC 60085
designation
Surge arresters - Part 1: Non-linear resistor type
155 IEC 60099-1
gapped surge arresters for a.c. systems
156 IEC 60127 Miniature fuses
Insulated bushings for alternating voltages above
157 IEC 60137
1,000V

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Drainage and Irrigation Department

Sr. STANDARDS DESCRIPTION

Semiconductor converters - General requirements
158 IEC 60146-1-1 and line commutated converters - Part 1-1:
Specification of basic requirements
Semiconductor converters - General requirements
159 IEC 60146-1-2 and line commutated converters - Part 1-2:
Application guide
Semiconductor convertors - General requirements
160 IEC 60146-1-3 and line commutated convertors - Part 1-3:
Transformers and reactors
Semiconductor converters - Part 2: Self-
161 IEC 60146-2 commutated semiconductor converters including
direct d.c. converters
Semiconductor convertors - Part 6: Application
162 IEC 60146-6 guide for the protection of semiconductor
convertors against over current by fuses
Insulating liquids - determination of the break down
163 IEC 60156
voltage at power frequency
Safety of machinery - Electrical equipment of
164 IEC 60204
machines -ALL PARTS
Polyvinyl chloride insulated cables of rated
165 IEC 60227
voltages up to and including 450/750 V
166 IEC 60228 Conductors of insulated cables
167 IEC 60230 Impulse tests on cables and their accessories
Rubber insulated cables - Rated voltages up to and
168 IEC 60245
including 450/750 V
169 IEC 60255 Electrical relays
IEC 60265 / IEC High-voltage switches - Part 1: Switches for rated
170
62271-103 voltages above 1 kV and less than 52 kV
171 IEC 60269 LV fuses (Part 1 to 4)
172 IEC 60282 High-voltage fuses
173 IEC 60287 Electric cables - Calculation of the current rating
Fluids for electrotechnical applications - Unused
174 IEC 60296 mineral insulating oils for transformers and
switchgear
Standard colours for insulation for low-frequency
175 IEC 60304
cables and wires
Plugs, socket-outlets and couplers for industrial
176 IEC 60309
purposes - ALL PARTS
177 IEC 60331 Fire resisting characteristics of electric cables
Tests on electric cables under fire conditions- Part
178 IEC 60332-1-1
1: Test on a single vertical insulated wire or cable
Safety of household and similar electrical
179 IEC 60335-2-29
appliances; battery charges
180 IEC 60364 Low-voltage electrical installations
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Conduit systems for cable management - Outside
181 IEC 60423 diameters of conduits for electrical installations and
threads for conduits and fittings
Basic and safety principles for man-machine
interface, marking and identification – Identification
182 IEC 60445/60446
of equipment terminals, conductor terminations and
conductors
High-voltage alternating current contactors and
183 IEC 60470
contactor-based motor-starters
Stabilized power supplies, d.c. output. Part 4: Tests
184 IEC 60478
other than radio-frequency interference
Higher performance protocol for the standard
185 IEC 60488
digital interface for programmable instrumentation
Power cables with extruded insulation and their
186 IEC 60502 accessories for rated voltages from 1 kV (Um = 1,2
kV) up to 30 kV (Um = 36 kV) - ALL PARTS
Artificial pollution tests on high-voltage insulators to
187 IEC 60507
be used on a.c. systems
Classification of degrees of protection provided by
188 IEC 60529
enclosures (IP code)
189 IEC 60534 Industrial-process control valves
190 IEC 60584 Thermocouples
191 IEC 60598 Luminaries
Identification of apparatus terminals and general
192 IEC 60616 rules for a uniform system of terminal marking,
using an alpha-numeric notation
193 IEC 60617 Graphical symbols for diagrams (Part 1 to 13)
Secondary cells and batteries containing alkaline
194 IEC 60622 or other non-acid electrolytes - Sealed nickel-
cadmium prismatic rechargeable single cells
Secondary cells and batteries containing alkaline
195 IEC 60623 or other non-acid electrolytes - Vented nickel-
cadmium prismatic rechargeable single cells
Industrial-process measurement and control
196 IEC 60654-1 equipment - Operating conditions - Part 1: Climatic
conditions
Operating conditions for industrial-process
197 IEC 60654-2 measurement and control equipment. Part 2:
Power
Operating conditions for industrial-process
198 IEC 60654-3 measurement and control equipment. Part 3:
Mechanical influences

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Operating conditions for industrial-process
199 IEC 60654-4 measurement and control equipment. Part 4:
Corrosive and erosive influences
Insulation coordination for equipment within low-
200 IEC 60664
voltage systems
Switches for household and similar fixed-electrical
201 IEC 60669
installations
Mineral insulated cables and their terminations with
202 IEC 60702-1 a rated voltage not exceeding 750 V - Part 1:
Cables
Mineral insulated cables and their terminations with
203 IEC 60702-2 a rated voltage not exceeding 750 V - Part 2:
Terminations
Short-circuit temperature limits of electric cables
204 IEC 60724 with rated voltages of 1 kV (Um = 1,2 kV) and 3 kV
(Um = 3,6 kV)
Common test methods for insulating and sheathing
205 IEC 60811
materials of electric cables and optical cables
206 IEC 60851-1 Methods of test for winding wires
Electrical accessories - Circuit-breakers for over
207 IEC 60898 current protection for household and similar
installations - ALL PARTS
Low voltage switchgear and control gear (Part 1 to
208 IEC 60947
7)
209 IEC 60981 Extra heavy-duty electrical rigid steel conduits
Short-circuit temperature limits of electric cables
210 IEC 60986 with rated voltages from 6 kV (Um = 7,2 kV) up to
30 kV (Um = 36 kV)
Separating transformers, autotransformers,
211 IEC 60989
variable transformers and reactors
212 IEC 61000 Electromagnetic compatibility (EMC)
Residual current operated circuit-breakers without
213 IEC 61008 integral over current protection for household and
similar uses (RCCBs) - ALL PARTS
Electromechanical switches for electronic
214 IEC 61020
equipment
Preparation of documents used in
215 IEC 61082
electrotechnology
Cable trunking and ducting systems for electrical
216 IEC 61084
installations
217 IEC 61111 Live Working – Electrical Insulating Matting
218 IEC 61131 Programmable controllers ALL PARTS
Terminal markings for valve device stacks and
219 IEC 61148
assemblies and for power convertor equipment

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Drainage and Irrigation Department

Sr. STANDARDS DESCRIPTION

Low voltage switchgear and controlgear
220 IEC 61439.
assemblies (Part 1 to 2)
Adjustable speed electrical power drive systems
221 IEC 61800 Part 3: EMC requirements and specific test
methods- ALL PARTS
Communication networks and systems in
222 IEC 61850-SER
substations - ALL PARTS
223 IEC 62040 Uninterruptible power systems (UPS) - ALL PARTS
Class 0.5, 1 and 2 alternating-current watt-hour
224 IEC 62053-11
meters
High-voltage switchgear and controlgear - ALL
225 IEC 62271
PARTS
226 IEC 62305 Protection against lightning - ALL PARTS
Power electronics systems and equipment -
227 IEC 62578 Operation conditions and characteristics of active
in feed converter applications
228 BS 4444 Electrical Earth Monitoring
229 BS 5308, Part 1 Control and instrumentation cables

Reciprocating internal combustion engines BS

230 BS 5514
5514 or VDE.
231
Specification for Polyethylene Insulation and
BS 6234
Sheath of Electric Cables
232 BS 6651 Code of practice for protection of structures against
lightning
BS6739 Code of practice for instrumentation in process
233 control systems: installation design and practice
234 BS 7430:1998 Code of practice for earthing
BS 7671 Requirements for electrical installations. IEE Wiring
235 Regulations. Seventeenth edition
IEEE Std. General requirements for liquid immersed
236
C57.12.00: distribution, power, and regulating transformers
237 ISA SP71.04 G3 Corrosion Resistance specification
Process Instrumentation terminology
238 ISA 5.1/5.3
Roller bearings - Method of evaluating dynamic
239 ISO 281
load ratings
Roller bearings - Method of evaluating dynamic
240 ISO 281
load ratings
Reciprocating Internal Combustion Engines - Fire
241 ISO 6826
Protection
Reciprocating Internal Combustion Engine Driven
242 ISO 8528
Alternating Current Generating Sets – all relevant

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243 ISO 9001 Quality Control
244 ISO 9002 Quality Control
Process Measurement Control Functions and
245 ISO 3511/1
Instrumentation Symbolic Representation
Measurement of fluid flow by means of pressure
246 ISO 5167
differential devices
Measurement of fluid flow – Evaluation of
247 ISO 5168
uncertainties
Process measurement control functions and
248 ISO 3511/1
instrumentation symbolic representation
249 ISO 44 Degree of protection of enclosures
Measurement of water flow in closed conduits
250 ISO 4064/1
meters for cold potable water
251 ISO 9003 Quality Control
252 ISO 7005/2 Instrumentation Flanges
International Telecommunication Union –
253 ITU-T G.652 Characteristics of a Single-Mode Optical Fibre
Cable
254 VDE 0871 Radio Interference Suppression
VDI/VDE
255 Rules for Control System Design
3501/2/3/7

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 DUBAI MUNICIPALITY
DRIANAGE AND IRRIGATION DEPARTMENT

GENERAL SPECIFICATIONS

SECTION 18

ELECTRICAL & INSTRUMENTATION WORKS

DM/DNID Section 18 Electrical & Instrumentation Rev 00 June

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Drainage and Irrigation Department

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description

DM/DNID Section 18 Electrical & Instrumentation Rev 00 June Page 1 of 4

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 General Specifications for Electrical & Instrumentation Works
Dubai Municipality
Drainage and Irrigation Department

SECTION 18
ELECTRICAL AND INSTRUMENTATION WORKS

CONTENTS
18 ELECTRICAL AND INSTRUMENTATION WORKS 1
18.1 SCOPE OF ELECTRICAL WORKS SUPPLY AND SERVICES 1
18.2 MAINS POWER SUPPLY 3
18.3 EMERGENCY POWER SUPPLY 3
18.4 MV SWITCHBOARD AND MCC COMPONENTS 4
18.4.1 General Requirements 4
18.4.2 Design Considerations 6
18.4.3 Construction Requirements 7
18.4.4 MV Switching Devices 10
18.4.5 Isolating Facilities 13
18.4.6 Earthing 13
18.4.7 Terminals 14
18.4.8 Protective Devices 15
18.4.9 Instrument and Control Power Transformers 16
18.4.10 Auxiliary Circuits 19
18.5 LV SWITCHBOARD AND MCC COMPONENTS 20
18.5.1 General Requirements 20
18.5.2 Design Considerations 21
18.5.3 Construction Requirements 22
18.5.4 SWITCHGEAR AND MCC COMPONENTS 34
18.6 DISTRIBUTION TRANSFORMERS 43
18.6.1 General Requirements 43
18.6.2 Design Considerations 44
18.6.3 Construction Requirements 44
18.7 MEDIUM VOLTAGE MOTORS 52
18.7.1 General Requirements 52
18.7.2 Design Considerations 52
18.7.3 Construction Requirements 54
18.8 LV SQUIRREL CAGE INDUCTION MOTOR 60
18.8.1 General Requirements 60
18.8.2 Design Considerations 61
18.8.3 Construction Requirements 62
18.9 ELECTRIC ACTUATOR – INTEGRAL MOTOR CONTROL 66
18.9.1 General Requirements 66
18.9.2 Construction Requirements 67
18.10 DIESEL GENERATOR 73
18.10.1 General Requirements 73
18.10.2 Codes and Standards 74
18.10.3 Design Considerations 75
18.11 DIRECT CURRENT SUPPLY SYSTEM 88

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18.11.1 General Requirements 88

18.11.2 Design Considerations 88
18.11.3 Construction and Electrical Requirements 89
18.11.4 Performance Requirements 93
18.11.5 Auxiliary Equipment 95
18.12 UPS SYSTEM 97
18.12.1 General Requirements 97
18.12.2 Design Considerations 98
18.12.3 Construction and Electrical Requirements 100
18.12.4 Materials 103
18.12.5 AC Distribution Sections 104
18.12.6 Performance Requirements 105
18.12.7 Auxiliary Equipment 106
18.13 FIELD MOUNTED COMPONENTS 108
18.13.1 General Requirements 108
18.13.2 Emergency Stop Pushbuttons 109
18.13.3 Isolators 109
18.13.4 Local Control Stations 109
18.13.5 Marshalling Panels and Junction Boxes 110
18.13.6 GRP Kiosk 111
18.13.7 Labeling and Name Plates 112
18.14 EARTHING 112
18.14.1 General Requirements 112
18.14.2 Design Considerations 113
18.14.3 Equipment Earthing 116
18.14.4 Surge and Transient Protection 116
18.15 CABLES 117
18.15.1 General 117
18.15.2 XLPE PVC SWA PVC Cables 119
18.15.3 PVC Insulated Cables 119
18.15.4 PVC Insulated MICC Cables 119
18.15.5 Instrumentation and Pilot Cables 119
18.15.6 Telephone Cables 119
18.15.7 Optical Fiber Cables 120
18.16 DISTRIBUTION BOARDS 125
18.17 LIGHTING AND SMALL POWER 126
18.17.1 General 126
18.17.2 General Purpose Luminaries 129
18.17.3 Bulkhead Type Luminaries 129
18.17.4 Floodlighting Luminaries 130
18.17.5 Emergency Lighting 130
18.17.6 Luminaries for Hazardous Areas 130
18.17.7 Handlamps 130
18.17.8 Lamps 130
18.17.9 Wiring Devices 131
18.17.10 External Lighting on Buildings 135
18.17.11 Conduit 135
18.17.12 Wiring and Cabling 136
18.18 ROADWAY LIGHTING 137
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18.18.1 General 137

18.18.2 Columns 137
18.18.3 Lanterns 138
18.18.4 Roadway Lighting Controls 138
18.19 LIGHTNING PROTECTION 138
18.19.1 Building Lightning Protection 138
18.20 TELEPHONE SYSTEM 141
18.21 CABLE INSTALLATION 141
18.21.1 Cable Installation Requirements 141
18.21.2 Cable Installation in Buildings or External Structures 143
18.21.3 Cables Buried Direct in the Ground 143
18.21.4 Marking of Buried Cables and Joints 144
18.21.5 Installation in Cable Ducts 145
18.21.6 Cables in Concrete Trenches 145
18.21.7 Cable Entry Seals through Ducts and Rectangular Cut-Outs - Cable Transit
Systems 146
18.21.8 Steel Conduit Systems 147
18.21.9 Plastic Conduit Systems 147
18.21.10 Trunking Systems 148
18.21.11 Cable Trays and Ladder Racks 149
18.21.12 Cable and Core Identification 149
18.21.13 Cable Glands 149
18.22 DUCT BANKS AND DRAW PITS 150
18.22.1 General 150
18.22.2 Draw Pits 150
18.23 SCOPE OF INSTRUMENTATION CONTROL AND AUTOMATION (ICA) 151
18.23.1 Electrical Requirements for ICA 151
18.23.2 Supply Isolation 152
18.23.3 Environmental Requirements 152
18.23.4 Mode of Operation 154
18.23.5 Signalling and control 155
18.23.6 Instrumentation and Control panels 156
18.23.7 Field Mounted instrumentation 159
18.23.8 PLC's and Microprocessor Equipment 175
18.23.9 Control system Application Software 180
18.23.10 Local Operator Panels 182
18.23.11 Remote Telemetry Units (RTU's) 183
18.24 VENDOR LIST 187
18.24.1 List of Approved Manufacturer / Supplier 187

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18 ELECTRICAL AND INSTRUMENTATION WORKS

18.1 SCOPE OF ELECTRICAL WORKS SUPPLY AND SERVICES

a) The scope of electrical works shall include the preparation of shop drawing, related
detail engineering, supply, and installation, testing, commissioning and setting to work
a complete electrical and control system of the plant/station/installation etc.

b) Each piece of equipment belonging to the Electrical Works specified and required shall
be complete with necessary supports, sunshade, holding-down bolts, main
connections, secondary connections, auxiliary switches, process interlocks, safety
interlocks, terminal boards, fuses, links, small wiring, screens, guards, tags, labels,
indicators and sundries to complete the installation whether specified in detail or not.

c) All electrical equipment and systems shall be designed and installed in accordance
with the relevant International, British and European Standards and manufacturers’
recommendations, installation guidelines and instructions.

d) The Electrical Sub-Contractor shall be registered by DEWA and approved by the Dubai
Municipality to carry out electrical installation work of similar size and nature.

e) Testing and commissioning of equipment and services of specialized nature shall be

supervised by the manufacturer's technical representative(s).

f) The Contractor shall provide the complete works even if the Equipment or Services to
be provided are not mentioned, specifically including the following scope of incidental
supplies and services:

i. 400/230Vac Building and Site Services Switchgear and distribution Boards

ii. 230/230Vac and 24Vdc Sub-Distribution Panel boards for power supplies to
Control and Monitoring Systems
iii. UPS system for PLC/HMI
iv. UPS system for local SCADA system (if local SCADA system is specified in the
contract)
v. 48V DC battery and battery charger system for medium voltage switchgear (if
medium voltage switchgear is specified in the contract)
vi. Complete detail labelling of all installations
vii. Set of special tools and equipment for maintenance, inspection and repair
viii. MCC room door limit switches, high level klaxon and flasher etc.
ix. Training, inspection and supervision services by the Manufacturer
x. Spare parts for supplied equipment and panels – manufacturer’s
recommendation for 2 year operation
xi. Complete documentation as specified, etc.
g) Contractor to comply with local authorities requirements for fire protection, safety and
electrical work.

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h) Contractor should liaise with the authorities to acquire required inspections and work
completion certificates.

i) The scope of electrical and control works for the plant/station/installation shall include
but not be limited to:

i. Undertake all liaison work and obtain all necessary approvals by Dubai
Electricity and Water Authority (DEWA) for permanent electricity and water
supply connection.
ii. Undertake all liaison work and obtain all necessary approvals by Etisalat / Du for
the Telephone (PSTN / GSM) connection required for SCADA connectivity to
central control system at Dubai Municipality facility.
iii. Arranging and obtaining all necessary approvals with the Directorate of Civil
Defence, Ministry of Interior - UAE for the fire alarm, protection and fighting
system.
iv. Construction of substations (civil work) as required in accordance with the
details furnished by DEWA.
v. Connection to the new mains power supply provided by DEWA for this contract.
vi. The contractor shall conduct and submit an engineering analysis and
coordination study for the entire electrical system. The analysis shall include a
short-circuit analysis with protective device evaluation and a protective device
coordination study. In addition, the studies shall include motor starting study,
load flow/voltage drop study and harmonics analysis. The studies shall be
performed with the aid of a digital computer program and in compliance with the
latest applicable IEC 60909 standards.
vii. The studies shall oblige the contractor to optimize circuit usage, ensure proper
voltage profiles, correctly size, set protection and operating parameters.
viii. The harmonic analysis shall be performed by a computer aided circuit
simulation of the electrical system of pumping station. Total Harmonic Distortion
(THD) at the point of common coupling shall comply with the requirements of
IEC 61000 / IEEE519.
ix. Permanent standby generator system shall include all associated switchgear,
auxiliary panel, synchronization panel, fuel storage and transfer system and air
inlet (motorized louver +filter + silencer + fans) and outlet (motorized louver +
silencer) arrangement.
x. Low Voltage Panels complete with Active Harmonic Filter, Detuned Capacitor
Banks, Instrument Control and Automation panel / common control section
including PLC and RTU complete.
xi. Main Distribution Boards & Sub Distribution Boards.
xii. All field mounted electrical equipment including local isolators, emergency
pushbutton stations, local control panels, junction boxes.
xiii. All power, control, instrumentation and communications cabling systems,
including cables, containment, cable transits, fire seals, fixings, termination and
connection.

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xiv. All control system software development and programming and configuration of
existing SCADA central station for controlling and monitoring of
plant/station/installation constructed / modified under this contract.
xv. All control system hardware.
xvi. Fire alarm and suppression system.
xvii. Hazardous gas detection and alarm system – if specified.
xviii. Area lighting.
xix. Building services lighting and small power.
xx. Earthing system
xxi. Lightning protection systems for buildings / structures.
xxii. Any work which can be reasonably inferred as necessary for the safe,
satisfactory operation of each system, whether such work is specified or not.
xxiii. Supply and installation of cables, cable support systems, boxes and termination
points, for the motors, starters, controls for equipment supplied under this
contract.

18.2 MAINS POWER SUPPLY

a) The mains power will be provided by the Dubai Electricity and Water Authority (DEWA).

b) The civil infrastructure shall be designed and constructed to house DEWA supplied
equipment, in accordance with the requirements of DEWA.

c) The Contractor shall enter into negotiations with DEWA and procure the provision of
the mains supplies to the plant / station. In order to do this the Contractor shall compile
a complete assessment of the required maximum and average loads and all other
documents / information as required by DEWA.

d) The DEWA supply works will be undertaken under a separate contract let by the
Employer with direct payments expended from a Provisional Sum within this Contract.
The DEWA works entail installation of new intake substations with new switchgear.

e) The Contractor shall liaise with DEWA in the timing, installation and commissioning of
the new LV or MV supply and intake substation switchgear or RMU etc. Neither the
Employer nor the Engineer shall be responsible for any delays to the works due to the
Contractors late submission of information required to enable DEWA to carry out their
works.

f) The interface between the DEWA and the works undertaken as part of this Contract
shall be the Contractors connection terminals for receiving the DEWA supply cable(s).

18.3 EMERGENCY POWER SUPPLY

a) Emergency power shall be provided by a permanent or mobile diesel generator sets as

indicated on contract Single Line Diagram.

b) When the plant/station is specified with permanent diesel generator sets, the bulk fuel
tank shall be sufficient capacity to operate the generator at maximum rated capacity for
a minimum period of 3 days without replenishment of the bulk fuel storage tanks.
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c) The maximum allowable period of uninterrupted running shall be at least 7 days.

d) The generator shall be arranged for automatic start up and changeover of supply on
loss of mains supply to the plant / station. The system shall automatically return the
plant / station to mains supply on restoration of mains power.

e) The control shall be provided with the appropriate time delays to prevent spurious
operation due to surges on the mains and to allow for the appropriate operating regime
of the diesel engine.

f) The system shall start within 10 seconds of mains failure and connect to the load within
1 minute.

g) The diesel generator sets shall be installed indoors in the building designated for that
purpose. The Contractor shall provide adequate room heating, cooling and ventilation
to allow the set to start and operate under all external climatic and environmental
conditions prevailing in the project area.

h) Re-order alarms shall be provided on the fuel storage system.

i) The diesel generator sets shall be designed to prevent inadvertent parallel connection
to DEWA distribution network in all circumstances.

18.4 MV SWITCHBOARD AND MCC COMPONENTS

18.4.1 General Requirements

a) This specification covers the general requirements for the design, manufacture, testing
and supply of MV switchboards and Motor control centres. That is assemblies for the
control of voltages above 1KV up to and including 52KV.

b) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements. All
components utilised in the construction of this switchboard shall be of the latest design,
new and in current production. Materials and equipment shall be approved by the
appropriate authority where applicable.

c) Further to the international standards MV boards shall also conform to the local
standards and/or regulations (DEWA), when these are higher, more stringent or of
special nature.

d) The design of the electrical system and equipment shall ensure that all operating and
maintenance activities can be performed safely and conveniently. Even under extreme
conditions of major short circuit or malfunction there shall be no danger to persons in
the vicinity of the assembly.

e) The Contractor shall ensure complete selectivity of the entire fault current protective
system.

f) On re-assembly at site, all bus bar connections shall be re-torqued to the

manufacturers recommended settings and marked. A check sheet of torque settings
shall be logged for each connection. The check sheet shall be submitted to the
Engineer on completion of the assembly before testing and energize.

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g) The following protections and monitoring shall be provided for the electrical equipment.

Protection:

ANSI
Protections Feeder Busbar Transformer Motor Generator
Codes
Phase Over
50/51     
Current
Earth Fault 50N/51N     
Negative
Sequence / 46  
Unbalance
Phase Over 67N
Current / Earth 67/67N   
Fault
87T/87M
Differential 87T 87M 87M
/87B
Restricted Earth
64REF  
Fault
Overload 49/49T/38    
Motor Phase 37/48/

Over Current 51LR / 66
58/27,
Voltage    
59N
81H/81L/
Frequency    81R
81R
25, 27D 50N/51 32P &
(neutral 32Q, 32P &
Specific * - point), 27D / 32Q / 25,
50/51 (tank 47 50V/51V
earth), 27R

i. 25 - Synchro Check
ii. 27D - Positive Sequence Under Current
iii. 27R - Remnant Under Voltage
iv. 32P - Directional Active Over Power
v. 32Q - Directional Reactive Over Power
vi. 50V/51V - Voltage – Restrained Over Current
vii. 47 - Negative Sequence Over Voltage
viii. 81R - Rate of Change of Frequency

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Monitoring:

Measurements Application Feeder Busbar Transformer Motor Generator

Current I1, I2, I3     
Peak Demand IM1, IM2,
    
Current IM3
TRIP I1, I2,
Tripping Current     
I3
U21, U32,
Line Voltage     
U13
Phase Voltage V1, V2, V3     
Residual
V0     
Voltage
Positive
Sequence Vd     
Voltage
Frequencies f     
P/Q, PM/Q,
Powers     
Cos Φ
Energies Ea/Er     
Temperatures   

18.4.2 Design Considerations

18.4.2.1 Ratings

a) The assembled switchgear and all its power circuit components shall be capable of
withstanding the thermal and dynamic stresses resulting from RMS and symmetrical
peak short circuit currents and earth fault currents expected and determined by the
electrical system design. Thermal capability shall be sufficient to allow these currents to
flow for a minimum of one second, without causing any deterioration or damage to the
assembly.

b) For standard voltages, frequencies and currents reference is made to IEC 60038,
60196 and 60059 respectively.

c) Medium voltage, current-carrying components shall furthermore be capable of carrying

their rated current continuously at rated voltage and under specified service conditions
without exceeding the permissible temperature limits when mounted in the completely
assembled switchboards.
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d) Selected standard rating for switchboards shall be those listed in IEC publication
62271-100.

18.4.2.2 System Variation

All equipment and components of the MV boards shall be capable of continuous

operation at their full current and voltage ratings and without detriment or malfunction
at system continuous deviation of up to and including the following percentages of the
normal values.

Voltage: ± 10% according IEC 60038

Frequency: ± 5% according IEC 60196

Absolute total voltage and frequency variations: 10%

18.4.2.3 Performance Requirements

All components shall be capable of withstanding the dynamic, thermal and dielectric
stresses resulting from the test duties specified in IEC publication 62271-100.

18.4.2.4 Temperature Rise

The temperature rise of the MV distribution and motor control centre shall not exceed
temperatures indicated in IEC 62271-100.

18.4.3 Construction Requirements

18.4.3.1 Housing / Enclosure

a) All MV switchboards and motor control centres shall be manufactured and tested to the
requirements of IEC 62271-200.

b) All MV switchboards and Motor Control Centres shall be of a floor mounting, multi-
compartment withdrawable type metal enclosure. The MV switchboards and Motor
Control Centres shall be extendable in its design. They shall be suitably strengthened
for lifting during installation and shall be provided with suitable lifting facilities. Lifting
eyebolts shall be of the screw in type and shall be removed on completion of
installation, and replaced with suitable plugs.

c) The materials of construction shall be properly prepared and treated against rust or
corrosion. The switchgear and controlgear shall be self-supporting and suitable for front
entry and operation.

d) The front of the MV boards shall be provided with a plastic or equivalent line mimic
diagram illustrating the main circuit and its components.

e) The painting shall be suitable for the specified service conditions. Unless specified
otherwise painting shall be of manufacturer's standard. Manufacturer to provide
particulars procedures of paint and finish colour.

f) MV switchboards and Motor Control Centres shall be provided with adequate bottom
plates to prevent access by vermin.

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g) The degree of protection shall be in accordance with IEC publication 60529 and shall
be of minimum ingress protection as follows:

i. For the enclosure: IP4X

ii. For the partitions : IP2X
h) All components requiring periodical maintenance shall be easily accessible.

18.4.3.2 Internal Arrangement

a) The switchboard shall comprise a busbar system and consist of one or more sections,
each having one incoming feeder panel placed as indicated on one line drawings of the
electrical load. Each section shall be equipped with a busbar connected voltage
transformer for metering supply, preferably to be mounted in the incoming feeder panel
or in a separate measuring panel. In case the total load for metering and control
exceeds the standard rating, a second busbar connected voltage transformer shall be
provided for supply control only.

b) The current rating of the incoming feeders and the busbars shall in general be of equal
value for each part of a combined panel or as indicated on the drawing.

c) All incoming switches and bus couplers shall be equipped with facilities for padlocking
both in the "in" and in the "out" position.

d) The lay-out of the operational front and the location of the components of the assembly
shall be arranged in a logical and systematic sequence and standardized throughout.

e) Alphanumeric notation, generally in accordance with IEC 60445, shall be used for
identification and marking of phases, conductors and terminals.

f) The system of construction for the MV distribution and motor control boards shall be a
factory-built assembly of a standard well tested design of the draw-out type.

g) All incomers, bus couplers and outgoing feeders shall be operated through three
positions i.e. In-Out-Test. In all three positions, limit switches and indications shall be
available for each position.

18.4.3.3 Interchange-ability

a) Electrically identical components shall be of one type and make.

b) Withdrawable sub-assemblies containing one or more components with identical

functions and capacities shall be mechanically interchangeable.

c) Withdrawable sub-assemblies with identical functions but of different capacities might

be mechanically interchangeable provided the sub-assembly can be adapted easily for
its new capacity.

18.4.3.4 Anti-Condensation Precautions

a) Effective precautions shall be taken to prevent the formation of harmful condensation

inside the enclosure, under both operating and non-operating conditions and service
conditions.

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b) 230 V - 1 phase space heaters shall be provided. The space heaters shall be controlled
by a thermostatic switch and shall be wired to outgoing terminals.

c) The heating device shall be of sufficient capacity to raise the internal temperature by
5oC above the ambient temperature. The heater shall be covered safely to avoid
accidental contacts and heater terminals shall be adequately shrouded.

18.4.3.5 Arcing Faults

a) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements and shall be fitted with gas exhaust chamber,
flap and top chimneys.

b) The design and construction of the MV distribution and motor control boards shall be
such as to provide the highest possible degree of personnel protection against
radiation, overpressure and hot gases.

18.4.3.6 Insulation

a) A Solid-Air-Solid insulation system where failure of one solid layer does not lead to
voltage breakdown is preferred.

b) MV components of switchboards shall be suitable for an exposed electrical system with

unearthed neutral, in accordance with IEC publication 62271-100.

18.4.3.7 Busbar Systems

a) Bus-bars shall be of high conductivity electrolytic copper with joints by means of non-
corrosive high tensile steel bolts, nuts and washers, and secured against loosening.
Insulated bus-bars are preferred. Bus-bars and assembly shall be suitable for
extension to the left or to the right as required.

b) Bus-bars shall be accessible for maintenance purposes, etc.

18.4.3.8 Compartments and Partitions

a) Adequate compartments and partitions shall be provided to allow easy maintenance

operation e.g. fuse replacement.

b) Main circuit compartments shall always have individual overpressure relief.

18.4.3.9 Rating Plates and Nameplates

a) Switchgear shall have a rating plate permanently fixed in the front of the equipment
giving at least the following information:

i. Rated voltage and frequency.

ii. Rated SC capacity and current capacity of busbars.
iii. Standard to which equipment conforms.
iv. Year of manufacture.
v. Manufacturer's name, type and serial number.
vi. Weight.

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b) Rating plates shall be made of corrosion-resistant metallic material and have indelible
inscriptions in English language.

c) Enamelled plates are not acceptable.

d) Each panel shall be provided with nameplates, mounted on the front of a non-
removable part.

e) Circuit identification nameplates shall be placed on the front and back of each
switchgear frame

f) All components (switching devices, contactors protection relays, instruments etc.) shall
be fitted with a rating plate in accordance with the relevant IEC requirements. All
functional units shall be clearly labelled to identify the service. All relays, meters,
switches etc. shall be labelled in accordance with the wiring diagrams.

g) The details of label shall be as specified in LV switchgear section of this document.

18.4.4 MV Switching Devices

18.4.4.1 Type

a) MV switching devices shall be of draw-out type which is tested and certified by an

official authority to meet the requirements of the national/local regulations.

b) Switching devices shall be vacuum type circuit breaker.

c) The circuit breakers shall be electrically operated, 3-pole, draw-out type, with electric
motor and manual charging of a spring type stored energy operating mechanism. The
power circuit breaker shall be provided with self-aligning line-side and load-side
disconnecting devices.

d) Mechanical interlocks shall be provided on all boards to prevent connecting or

disconnecting the circuit breaker while closed and to prevent the closing of the circuit
breaker unless the separable contact are in full contact or separated by a safe
distance.

e) For motor feeder panels vacuum type circuit breakers are preferred.

f) The type of switching device and its operating mechanism shall be selected in
accordance with its duty and the number of load operations.

g) The following switching devices shall be provided as a minimum:

i. ON-OFF indicators
ii. Motorised spring charging
iii. Anti-pumping
iv. Emergency 'OFF' pushbutton
v. Closing/trip coil suitable for control voltage
vi. Blocking for manual switch 'ON' facility
vii. Breaker carriage earthing

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viii. Earth switch interlock

ix. Padlock arrangement
18.4.4.2 Control Mechanism

a) Rated voltages for closing, tripping, control and auxiliary circuits shall be selected from
IEC 62271-100.

b) Control mechanism of switching devices may be of the following types:

i. Electromagnetically operated with DC control supply;

ii. Spring-operated hand charged in case of local control only;
iii. Spring-operated power charged.
c) All switching devices shall open automatically, be trip-free and have their energy for the
opening operation stored prior to the completion of the closing operation. Furthermore
they shall be provided with a local manual-operated tripping feature protected against
inadvertent tripping.

d) The power charged spring-operated mechanism shall not require more than 25
seconds for spring charging.

e) Power charged spring-operated mechanism of remote controlled switching devices

shall be charged when the switching device is in its normal service position.

f) Switching devices for motor panels shall be protected against "pumping".

g) All electrical charging and electromagnetic mechanisms as well as the closing control
components shall be capable of operating when the auxiliary or control supply is
between 85% and 105% of its rated value.

h) Control voltage and trip voltage shall be as follows:

i. The breaker motor charging range shall be (48VDC).

ii. The trip voltage shall be (48VDC).
iii. The close voltage shall be (48VDC).
iv. Close and trip circuits for each breaker shall be separately fused. Fuse blocks
shall be dead front, pull-out type, which provides the control power
disconnecting means.
i) Each switching device shall be provided with visual mechanical indicators, one marking
the closed position with "I" and/or a red flag and the open position with "O" and/or a
green flag, and in case of a stored energy closing mechanism one marking whether the
operating mechanism is charged or discharged. These indicating devices shall be
directly driven by the switching mechanism.

j) The switchboard manufacturer shall ensure that all required information is available to
him before preparation of his detailed logic/control scheme drawings.

18.4.4.3 Disconnectors

Disconnectors (isolators) are not permitted, even with safety interlocks, except when
used for the separation of fixed and moving parts.

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18.4.4.4 Earthing Devices

a) Three-phase earthing facilities at the cable sides and for the bus-bar system of each
section shall be provided.

b) Integrally mounted three-phase earthing switching devices shall be provided for each
type of MV switching device.

c) These devices shall be capable of making and carrying the prospective short-circuits
current at the point of earthing. The earthing devices shall be suitable for local, manual
operation only.

d) Padlock facilities for locking in the open and closed position shall be provided.

e) When earthing devices are to be applied in a compartment it shall not be possible in

the following conditions:

i. To insert a portable earthing device in the closed position.

ii. To insert a withdrawable switching device into the service position of the
compartment concerned.
iii. To close a fixed-type switching device in the compartment concerned.
f) Generally, circuits shall not be earthed automatically, i.e. when withdrawing the
switching device the earthing device has to be inserted deliberately.

g) Outgoing circuits for motor starting may be earthed automatically when the switching
device is being withdrawn.

h) Clear instructions, preferably pictorial, shall be submitted showing the proper methods
of how and where to fit the earthing devices.

18.4.4.5 Current Chopping

a) Switching devices shall not cause switching surge voltages which exceed the insulation
level of the connected equipment. Motors switching needs special care and switching
devices shall be appropriately designed.

b) Vacuum switching devices shall be equipped with ZnO over-voltage protection devices.

18.4.4.6 Auxiliary Contacts

a) Each switching device shall be provided with at least 4 make and 4 break auxiliary
contacts directly driven by the switching mechanism.

b) These contacts shall be completely wired up to terminal blocks in the secondary

terminal compartment.

c) The rated making and thermal-breaking capacities of these contacts shall be:

Making capacities Thermal-breaking capacities

16A at 500 V AC and power factor 0.3 1A at 500 V AC and power factor 0.3
1.7A at 110 V DC inductive 1A at 110 V DC inductive
4A at < 60 V DC inductive 2A at < 60 V DC inductive
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18.4.5 Isolating Facilities

18.4.5.1 Isolation of Main Circuits

a) Switch panels shall be provided with safe means of isolating the circuit side from the
busbar side.

b) Panels containing combinations of fuses and contactor shall be equipped with isolating
facilities permitting safe changing of fuses by hand.

18.4.5.2 Interlocks

a) Interlocks in accordance with IEC 62271 shall be provided to prevent unsafe operation
of the switchboard.

b) They shall permit operating the switching device only when:

i. The isolating device in fully operating position; the switching device is in a

specifically provided test position with the isolating device in the closed position
and the control and auxiliary circuits operative but with panel control facilities
only.
ii. They shall mechanically interlock the isolating device in its closed position when
the switching device is closed. Alternatively, they shall cause tripping of the
switching device upon attempted operation of the isolating device.
18.4.5.3 Safety Shutter Devices

a) The panel shall be fitted with a set of shutters to cover each 3-phase group of
stationary isolating contacts, i.e. both on the busbar and on the circuit side.

b) The shutters shall open or close automatically by a mechanical drive from the switching
device when the latter is being racked in or out.

c) Each set of shutters shall be equipped with padlocking facilities in its closed position.
When padlocked, the shutters shall prevent access to the stationary isolating contacts.

d) Shutters on the busbar side shall be painted red and shall be clearly labelled
"BUSBARS" in large white letters.

e) Shutters on the circuit side shall be painted yellow and shall be labelled. “Isolating
Contacts for Secondary Circuits”.

f) The connection in the secondary circuits between the fixed and the moving parts of
panels shall be by means of self-aligning contact.

g) These connections shall be maintained when the moving portion of the equipment is in
the test position.

18.4.6 Earthing

a) Earthing shall be in accordance with IEC 62271; colour coding of protective conductors
shall be in accordance with IEC 60446.

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b) A main earth bar shall be fitted along the whole length of the switchboard. This shall be
made from hard-drawn, high-conductivity copper and be capable of carrying the short-
circuit rating of the board but have a cross section of at least 125 mm².

c) The earth bar shall be bolted to switchboard frame and equipped with convenient
facilities for connecting of all parts of the switchboard which require earthing.

d) Joints in the main earth bar shall be bare copper and bolted with galvanized steel bolts,
nuts and washers, secured against loosening.

e) For direct connection to the station earthing grid, earthing bolts (M12) with nuts and
spring washers shall be provided at both ends of the main earth bar.

f) In addition to ensure adequate electrical continuity between all metal parts of the
switchboard and its cables and the main earth bar particular care shall be taken to
ensure the followings:

i. Housings of withdrawable switching devices shall be positively earthed in the

service position by appropriate earthing connections;
ii. Band joints of compound-filled busbar chambers shall be suitably earthed to the
frame of the switchboard;
iii. The earth connections of voltage transformers and current transformers shall be
made directly from the terminal board to the earth bar.
g) Means shall be provided of ensuring that the earthing connection of each withdrawable
switching device and voltage transformer to the main earth bar is made prior to its
primary connections.

18.4.7 Terminals

18.4.7.1 General

a) Each panel shall be provided with appropriate facilities for the independent terminals to
connect the MV main cable and the LV auxiliary cables.

b) The terminal compartments for MV and LV connections shall be effectively segregated,

see IEC 62271.

c) The terminals shall be so arranged that all connections can be made safely, even when
the assembly is energized.

d) Suitable terminating facilities of adequate dimensions and thermal rating shall be

provided for each conductor.

e) Inside the compartments separate terminals or bolts, one for each cable, are required
for earthing purposes.

f) Efficient means to prevent strain on the actual conductors and cable connection shall
be provided.

18.4.7.2 Terminals for MV Cables

a) Cable termination shall be suitable for the specified cable.

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b) For PVC or XLPE type cables, dry type cable termination is preferred. When two or
more cables are required, a suitable marshalling box may be required to obtain
uncluttered straight terminal connections.

c) Single-core cables: The terminal box and its cable entries on a relevant panel shall be
suitable for the specified cable.

d) Single conductor entries shall be mounted in non-magnetic plates. The end sleeves or
glands shall also be of non-magnetic material.

18.4.7.3 Terminations for Auxiliary LV Cables

a) Terminal blocks fitted with tubular type contacts with non-loosening screws shall be
provided for termination of auxiliary LV cables including that required for wiring
between cubicles or panel sections. Crimped conductor ferrules are required at
terminal blocks to ensure sound contact. Non-screw type terminal blocks are not
permitted. Within the panel compartments suitable clamping devices shall be provided
for securing of the cables.

b) Terminals in current measuring circuits shall be special purpose with suitable bridging
links and measuring facilities.

c) Specified auxiliary contacts for remote circuits shall be wired and connected to an
accessible terminal block in the vicinity of the cable entries.

d) Termination compartments for auxiliary and control cables shall have adequate
dimensions, with ample accommodation for the required number of terminals and
cables.

e) Two or more conductor terminations on one terminal are not acceptable unless the
terminals are designed for more than one conductor.

f) Metal cable glands suitable for the cables specified shall be included in the supply of
the assembly.

18.4.8 Protective Devices

a) Selection of relays shall be in accordance with the relevant circuit requirements.

b) All protection relays shall be of static type of approved make. Means shall be provided
for secondary injection testing of relays without disconnecting wiring.

c) All protective relays, auxiliary relays, indicating instruments, recording instruments,

indicating lights, transducers, etc. shall be housed in the Low Voltage Compartment.
The Low Voltage Compartment shall isolate the above mentioned equipment such that
in the event of a fault, the equipment will be protected from the forces created by the
fault. A multi-function, 3-phase microprocessor based relay and control package will be
used. Door-mounted protective relays will be draw-out type whenever practical.

d) Protective relays and test devices shall be semi-flush mounted. The relays shall be so
arranged that they can be tested in position on the panel and readily withdrawn from
the panel for inspection or replacement.

e) The relays will be provided with targets that can be externally reset

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f) Switchgear device function numbers shall be in accordance with ANSI Standard

C37.20.

g) An ABB DPU200R distribution protection relay or equivalent shall be provided with the
following functions:

i. 3-phase over current protection (time and instantaneous)

ii. Ground over current (time and instantaneous)
iii. Multi-shot reclosing
iv. High set instantaneous
v. Ammeter, demand and peak demand ammeters
vi. Event recording
vii. Accumulation of breaker interrupting duty
viii. Continuous self-checking
ix. RS-232 and RS-485 communications ports for remote terminal connection.
h) The protective relay shall be dustproof flush-mounted / removable type, provided with
calibrating and testing facilities. Current transformer terminals of the relays shall be
automatically short-circuited at withdrawal of the relays.

i) MV motor protection shall be through comprehensive motor protection relay with

provision for protection against negative phase sequence, earth fault, over load,
stalling, RTD protection for alarms and trip to be incorporated.

18.4.9 Instrument and Control Power Transformers

18.4.9.1 General

a) The contractor/supplier/manufacturer (whatever) shall use an experienced protection

engineer to design the protection circuits including CTs, VTs, protection relays and
tripping circuits.

b) All voltage and current transformers shall be cast resin type.

18.4.9.2 Current Transformers

a) CT nameplates shall be located on the CT housing and information provided shall be

including rating, accuracy class and part number and manufacturer detail. The CT
winding shall terminate on a screw type terminal on the CT housing and shall be wired
to shorting terminal blocks.

b) Each current transformer shall have a primary rating as required for the circuit fault
rating.

c) Rated output capacity of the transformers shall be matched to cover the burden
required by the equipment connected and be selected from the range of standard
values.

d) Rated primary current shall preferably be selected from the range of standard values.

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e) Rated secondary current shall be either 5 or 1A; for remote metering 1A only is
acceptable.

f) Ratings and accuracies shall be in accordance with BS EN 60044-1 and IEC 60044-1
for the metering and relay applications.

g) Generally, measuring current transformers shall be Class 3, except those for

measuring the supply of third parties, which shall be Class 1.

h) The over-current limit factor shall be < 5 in order to prevent damage of instruments at
maximum fault current.

i) Protective current transformers are to be Class 5 P.

j) Each current transformer shall have a short-circuiting device (shorting type terminal
blocks). The first termination of each current transformer shall be at the short-circuiting
device terminal blocks where the ground connection is also made.

k) Low voltage ring core type CT’s will be bushing-mounted, located behind the shutters
and accessible from the front. Bushing design shall accommodate up to four standard
accuracy CT’s per phase for all ratings.

l) Secondary terminals of current transformers shall be wired up to a terminal block with

short-circuiting links, located at an accessible place. One side of the secondary winding
of each current transformer shall be connected at this terminal block to the earth bar.

18.4.9.3 Voltage Transformers

a) Voltage transformers will be mounted on a draw-out unit in an auxiliary enclosure,

which disconnects them from the primary circuit safely.

b) Voltage transformers shall be mounted in a separate draw-out compartment (truck

assembly) and so arranged that the unit can be withdrawn from the operating position
via a raking device with the door closed. In the withdrawn position, the fuses shall be
completely disconnected from service and all exposed parts shall be visibly grounded.

c) The voltage transformers compartment shall incorporate extension rails to allow

changing MV fuses and general maintenance without the need to take the truck
assembly completely out of its compartment.

d) Voltage transformers shall be connected to the line or load via solid copper rod, bus or
shielded cable.

e) An impact resistant viewing window shall be on the front of the voltage transformer
door.

f) Each transformer shall be protected with current-limiting MV primary fuses, and shall
be designed to withstand the basic impulse level of the switchgear.

g) The secondary voltage of measuring and protection transformers shall be 110/√3 V.

h) Rated output capacity of the transformers shall be matched to cover the burden
required by the equipment connected, and preferably be selected from the range of
standard values.

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i) Generally, measuring voltage transformers are Class 0.5, except those for measuring
the supply of third parties which shall be Class 0.2.

j) Protective voltage transformers shall be of Class 3 P.

k) The winding connection is depending on the metering and protection system

connection.

l) At HV side, high-rupturing capacity, short-circuit current-limiting fuses shall be provided

in accordance with IEC 60282-1;

m) Fuses shall be readily accessible and suitable precautions shall be taken to enable
safe removal and replacement of fuses.

n) At LV side, Industrial ZED-type cartridge fuses shall be used.

o) The connection between transformer and fuse base shall be as short as possible.

p) All protective fuses shall be capable of handling the inrush currents for all service
conditions, without abnormal ageing or deterioration.

q) Voltage transformers for automatic voltage regulators shall have no fuses at all, but
shall be connected within the protective zone of the differential protection of the
generator.

18.4.9.4 Control Power Transformers

Control power transformers shall be dry type with disconnecting type current limiting
primary fuses and fused 120 volt secondary. Transformers up to 15kVA single phase
(or fuses above 15kVA) shall be mounted on a truck assembly, which is moved
between the connected and disconnected position via closed door racking and utilising
the same raking device as the circuit breaker.

18.4.9.5 Ammeters

a) Ammeters shall be flush-mounted, square type (96 x 96 mm). They shall have an
element rated at 1 or 5 ampere.

b) Ammeters in the motor circuit shall have an overload scale of 5 x In.

18.4.9.6 Voltmeters

a) Voltmeters shall be flush-mounted, square type (96 x 96 mm).

b) They shall have the following full-scale readings:

i. For 3 or 3.3 kV: 0 -4,000 volts

ii. For 6 or 6.6 kV: 0 -8,000 volts
iii. For 10 or 12 kV: 0 - 15,000 volts
iv. For 15 or 17.5 kV: 0 - 20,000 volts
18.4.9.7 Watt-hour Meters

Watt-hour meters shall have cyclometric registers. Watt-hour meters for motors may be
of the single-element, balanced-load type.
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18.4.9.8 Counters

Each switching device shall be provided with an operation counter.

18.4.9.9 Accuracy

Ammeters and voltmeters shall be of Class 1.5 and watt-hour meters shall be of Class
2.5 as specified in IEC publication 51 and 521. Power factor meters shall be class 1.5.

18.4.10 Auxiliary Circuits

a) Control devices, control buses, local control, instrument cables and wiring on the
equipment shall be installed at the factory. Cables shall be enclosed in earth metal
cable ways when routed through a high voltage compartment. The wires shall be neatly
bundled and tie wrapped where applicable, protected from rubbing against door flanges
or other parts of the enclosure.

b) Control relays, auxiliary contacts and small mechanisms shall be enclosed and
protected but shall be accessible for maintenance.

c) Auxiliary circuits shall be clearly grouped and be protected adequate. All current wires
shall be at least 2.5 mm² others 1.5 mm² of the PVC type and be able to withstand
2500 V impulse test. All wires shall be connected to terminals individually and clearly
identified at both ends by ferrules of isolating material or plastic code markers in
accordance with the wiring diagram(s).

d) Colour coding of secondary wiring shall be in accordance with IEC 60446. Wiring
between two terminals shall be continuous; joints or interconnections are not allowed.

e) To accommodate and support the secondary wiring, covered plastic channels,

insulated tubes or plastic strips shall be used.

f) Secondary wiring shall never be mounted direct to metal. The filling factor for channels
shall not exceed 70%. Where supporting of a wire is not feasible the wire or part of it
shall be as short as possible.

g) Terminal blocks shall be conveniently located for external connection without accessing
the high voltage compartments. Terminal blocks will be clearly marked for wiring. A
wire label at both ends will identify each internal interconnecting wire. Terminal blocks
to be Klippon or equivalent. Terminal blocks for current circuits to be shorting type or
equivalent.

h) All circuits shall be protected by miniature circuit-breakers of the airbreak-type or

cartridge-type fuses.

i) Contacts for remote alarm shall be normally closed.

j) Protective devices shall have protective action indication.

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18.5 LV SWITCHBOARD AND MCC COMPONENTS

18.5.1 General Requirements

a) This specification covers the general requirements for design, manufacture, testing and
supply of Low-voltage switchgear and controlgear assemblies. Unless specified
otherwise Low-voltage switchgear and controlgear assemblies shall conform in design,
material, construction and performance to the latest editions of the IEC standards

b) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements. All
components utilised in the construction of this switchboard shall be of the latest design,
new and in current production. Materials and equipment shall be approved by the
appropriate authority where applicable.

c) Further to the international standards the Low-voltage switchgear and controlgear

assemblies shall also conform to the local standards and/or regulations (DEWA), when
these are higher, more stringent or of special nature.

d) The design of the electrical system and equipments shall ensure that all operating and
maintenance activities can be performed safely and conveniently. Even under extreme
conditions of major short circuit or malfunction there shall be no danger to persons in
the vicinity of the assembly.

e) The Contractor shall ensure complete selectivity of the entire fault current protective
system.

f) On re-assembly at site, all bus bar connections shall be re-torqued to the

manufacturers recommended settings and marked. A check sheet of torque settings
shall be logged for each connection. The check sheet shall be submitted to the
Engineer on completion of the assembly before testing and energization.

g) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements. The design and construction of the Low-voltage
switchgear and controlgear assemblies shall be such as to provide the highest possible
degree of personnel protection against radiation, overpressure and hot gases.

h) The MCC panel middle sections shall be equipped with terminal strips serving as
connection compartment for the control signal connections to and from the control
system. On one side of the terminal strips the control wiring from the motor
compartments will be connected on the other side the control signal cables to the ICA
panel / common control section will be connected.

i) All circuit breakers rated 800A and above shall be ACB of the withdrawable type.

j) MCCs shall have an end section for control and instrumentation with RTU / PLC
controller and HMI operator screen for access to instrumentation information and local
alarms of the equipment concerned. This shall provide local operator functions
(including alteration of set points) and is intended for the main running of the Plant /
station where the plant / station is not specified with local SCADA.

k) The Plant / stations shall be monitored and controlled (start, stop of individual pumps
and inhibiting the station as whole while in auto mode) from Dubai Municipality central
SCADA station. The requirement of RTU and configuration of plant / station to Dubai
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Municipality existing SCADA central control station shall be similar to the existing plant
/ stations of the network in terms of its functionality and connectivity.

l) The main LV Distribution switchboards shall provide the following functions:

i. Control of mains/generator supply auto-changeover, including mains and

generator automatically operated ACBs, supply monitoring and changeover
control system.
ii. Power distribution to services including building services DBs,
iii. DEWA metering
iv. Digital power monitor
m) As a minimum, the following protection shall be provided (for comprehensive
requirement refer to MV Switchboard section of this document):

i. Mains incomer: Combined over current and unrestricted earth fault IDMTL,
restricted earth fault and auxiliary trip from medium voltage protection
equipment (as required).
ii. Generator incomer: Combined over current and unrestricted earth fault relay.
iii. Main MCC feeders: Combined over current and unrestricted earth fault relay.
iv. Services distribution and spare feeders: Combined over current and unrestricted
earth fault relay

18.5.2 Design Considerations

18.5.2.1 Ratings

a) Low-voltage switchgear and controlgear assemblies shall be rated on the basis of

voltage, current, frequency and the symmetrical breaking capacity of incorporated LV
automatic switching devices as defined in appropriate IEC publication.

b) For standard voltages, frequencies and currents reference is made to IEC 60038 and
60059.

c) Low voltage, current-carrying components shall furthermore be capable of carrying

their rated current continuously at rated voltage and under specified service conditions
without exceeding the permissible temperature limits when mounted in the completely
assembled boards.

d) Unless otherwise specified the switch board shall be natural air cooled.

18.5.2.2 System Variation

a) All equipment and components of the Low-voltage switchgear and controlgear

assemblies shall be capable of continuous operation at their full current and voltage
ratings and without detriment or malfunction at system continuous deviation of up to
and including the following percentages of the normal values.

i. Voltage ± 10%
ii. Frequency ± 5%

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18.5.2.3 Performance Requirements

All components shall be capable of withstanding the dynamic, thermal and dielectric
stresses resulting from prospective short-circuit currents without damage or injury of
personnel.

18.5.2.4 Temperature Rise

The temperature rise of the Low-voltage switchgear and controlgear assemblies shall
not exceed temperatures indicated in IEC 60947 part 1 and part 2.

18.5.3 Construction Requirements

18.5.3.1 Housing / Enclosure

a) All LV switchgear (less than 1000vac) and control gear shall be constructed in
accordance with the following standards:

i. IEC 61439 LV switchgear and controlgear assemblies.

ii. IEC 60947 LV switchgear and controlgear.
iii. BS 1432:1987 Copper for electrical purposes.

b) The enclosure / panel shall be with internal form of separations according to IEC 61439
Form 4, type 6.

c) Busbar compartment shall be fitted with a removable cover, the removal of which
necessitates the use of a tool. A warning label shall be provided on each such cover.

d) Compartment containing a functional unit shall be fitted with a door which can be
opened only after all live parts above 50 V rms ac or 50 V dc have been disconnected
from the supply. The switch disconnector should also be provided with auxiliary
contacts to disconnect any control voltages sourced external to the starter remaining
energized (e.g. from duty standby changeover circuits). This is with the exception of
24Vdc control supplies to the auto control interposing relays.

e) It shall be possible to padlock the switch-disconnector in the open position to prevent

operation during maintenance of external apparatus.

f) The degree of protection for low voltage assemblies for location in purpose designed
switch room with controlled environment shall have a minimum degree of protection of
IP54 to IEC 60529. For outdoor location the degree of protection shall not be less than
IPW55.

g) All internal components shall be mounted on removable steel mounting boards which
shall be finished in the same manner as the rest of the switchboard. The components
shall be laid out neatly on the mounting board and labelled, allowing sufficient space for
the interconnection cabling terminations and cable containment. Cable boxes, gland
plates and terminations shall be arranged to facilitate easy access for installation and
connection of cables and cable circuit testing.

h) Cable gland plates shall be manufactured from sheet steel for multicore cables and
non-ferrous metal for single core cables. Gland plates shall be mounted to provide a
minimum of 300mm straight cable length below the gland to facilitate installation.
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i) All switchboards and MCCs shall be arranged for bottom cable entry only, unless
otherwise specified.

j) Adequate space shall be provided for the termination of oversize cable conductors and
multiple terminals shall be provided where circuits require parallel connected cables.

k) The enclosure shall be manufactured from steel sheet of minimum thickness 2 mm,
folded and welded to form a robust and rigid structure. Over-lapping surfaces of the
sheet shall be completely sealed by welding and all welds that are visible when covers
are in place shall be ground flush to give a neat appearance.

l) Alternatively overlapping surfaces after coating may be joined by non-corrodible rivets,

which shall not be visible, when covers are in place.

m) The finish should also be to a standard colour finish agreed with the Engineer or
otherwise specified, and shall be applied to all LV switchgear, control panels, PLC /
RTU panels and motor control centres throughout the installation.

n) Each transport unit shall be provided with roof eyebolts for lifting. Lifting eyes shall be
removable and replaced with bolts after installation.

o) Unless otherwise approved, floor-mounting enclosures shall not exceed 2500mm in

height including plinth and Busbar enclosure.

p) Where two or more enclosures are fitted together, they shall form a flush fronted
continuous suite of uniform height.

q) Switch and motor starter enclosures shall be logically grouped to reflect, as far as
possible, the process with which they are associated.

r) Unless otherwise approved, instruments and meters, relays, control devices and
indicator lights shall be mounted not less than 300mm and not greater than 2100mm
above finished floor level.

s) Front of panel mounted components shall be arranged in a neat, functional and logical
manner and shall be mounted flush with the front of the enclosure.

t) Indicating instruments controls and relays mounted on different enclosures but having
similar functions shall, where practical, be located in a physically similar position.

18.5.3.2 Access

a) The arrangement of equipment within enclosures shall permit easy access for
installation and maintenance. All switchboards and motor control centres shall be
designed and installed so as to provide full front, side and rear access.

b) Access from the front of an enclosure shall be through a hinged door or, for
withdrawable apparatus, by removal of the withdrawable unit. Enclosure doors and
withdrawable units shall be lockable in the service position.

c) All equipment required for the safe removal and return of the withdrawable equipment
shall be provided. This shall include trolley units for transporting a withdrawable unit
and lifting facilities where the unit weight exceeds the manual lifting regulations.

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d) Where rear access is required for maintenance of operational equipment and

components, lockable lift-off hinged doors shall be provided. The hinges of lift-off
doors shall be designed so that one shank engages before the other for ease of fitting.

e) Access to other switchgear compartments containing busbars and similar primary

power conductors shall be by bolted cover plates.

f) Front access doors shall open at least 120o and shall be fitted with a numbered locking
handle or handles with three keys. Locking combinations requiring different keys shall
be approved before manufacture. Doors shall be secured to ensure firm pressure on
the seal around the whole periphery to maintain the units required IP rating.

18.5.3.3 Safety

a) Electrical equipment shall be designed and constructed to provide a safe working

arrangement for operational and maintenance personnel.

b) Where access to low voltage enclosures is necessary with equipment energized from
an external source, all such equipment and terminals shall be shrouded to prevent
accidental contact and warning labels shall be fitted. Shrouds shall have a minimum
degree of protection IP30.

c) Covers fitted to enclosures in which live conductors are installed shall be fitted with a
warning label.

d) Measures shall be taken to prevent the occurrence of internal arcing faults in

accordance with the IEC requirements.

e) Integral Switchboard shall permit safe access to fuse carriers and miniature circuit
breakers without the need for isolation. All live connections when fuse carriers and
plug-in type miniature circuit breakers are removed shall be fully shrouded.

18.5.3.4 Earthing

a) Low voltage assemblies shall be provided with a continuous earth busbar that shall
extend over the full length of the assembly. Each cubicle shall be bonded to the earth
busbar.

b) The earth busbar shall be installed in a manner to provide unrestricted access. The
earth busbar shall be provided with two terminal assemblies for connection to the
electrical system main earth terminal.

c) All steelwork parts shall be equi-potentially bonded. A positive earth connection shall
be provided to all enclosure doors, removable gland plates and removable covers via a
welded stud not less than 8mm. Earthing via the door hinge shall not be provided as an
earth connection.

d) A removable connection shall be provided between the main neutral busbar and the
earthing busbar (TN-S distribution system). This connection shall be located in the
incoming panel

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18.5.3.5 Busbars and Busbar Connections

a) Busbars and busbar connections shall be of hard drawn high conductivity tinplated
electrolytic copper correctly rated for the specified voltage, short-time current and
frequency and insulation level.

b) Insulated coloured busbars are preferred. Busbars shall be suitable for extension to the
left or to the right as required.

c) Busbars shall be accessible for maintenance purposes, etc.

d) Busbars and busbar connections shall form part of a fully type-tested assembly and
shall comply with the performance criteria given in IEC 61439-1.

e) Busbars & primary conductors shall be tinned copper hard drawn, high conductivity
99.9% purity. Moulded PVC shrouds shall be provided over joints. Expose edges of the
busbars due to cutting shall tin re-coated. Busbars shall be continuously rated for an
ambient temperature of 50oC. The busbars shall be rated at 50 or 65 kA for 1 second
depending upon the rating of upstream transformer. Throughout the length of the board
the busbars shall be of uniform cross sectional. The busbar joints are to be made by
means of bolts and nuts with spring washers’ type DIN 6796

f) Busbars and primary conductors shall be contained in segregated compartments

accessed only by bolted removable cover plates.

g) Busbars shall be colour coded at each switchboard section access point using shrink
wrap sleeve.

h) Busbar supports shall be resin monoblock mouldings or similar approved.

i) Busbars and busbar connection arrangements shall have been type tested by an
independent testing authority to verify thermal, dielectric and short-circuit withstand
performance.

j) Busbar and busbar connection systems whose performance cannot be verified will not
be accepted.

k) Low voltage assemblies rated at 160A or below may be manufactured without a type
tested busbar assembly where the assembly has a maximum of eight outgoing circuits.
In this case, the internal distribution shall be provided by a suitably fault rated
distribution block and internally cabled feeder cables. In this arrangement, feeder
cables shall be segregated from outgoing circuits.

18.5.3.6 Internal Wiring

a) Power wiring (400V, 230V) shall be a minimum of 2.5mm² cross section, single or multi
core, stranded or flexible conductors and insulation grade 1000V, in accordance with
BS 6231. Power wiring shall be sized according to the maximum anticipated current
demand for the relevant power circuit.

b) Control wiring (230V, 24V) shall be a minimum of 1.0mm² tinned electrolytic annealed
copper stranded conductor, insulation grade 600V, in accordance with BS 6231).
Control wiring shall be sized according to the maximum anticipated current demand for
the relevant control circuit.

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c) Signal wiring (4-20mA, RS232/485) shall be a minimum of 1.0mm² tinned electrolytic

annealed copper stranded conductors and overall screen, suitable for the signalling
application as recommended by the manufactures of the signalling equipment.

d) Wire selection shall be determined so as not to exceed the recommended insulation

operating temperatures under the prevailing ambient temperature and load current
conditions.

e) Internal wiring shall be colour identified as follows:

i. Power wiring (400V, 230V)

red, yellow, blue or all black with red,

Phases of AC power circuits
yellow, blue sleeves at wire ends

Neutral of AC power circuits black

Protective earth conductor green/yellow

ii. Control wiring (230V, 48, 24V)

AC control circuits Grey

DC control circuit White

Alarm and volt free indication circuits White

Circuits interconnecting components between

Orange
different panel compartments

Telemetry Connections Violet

iii. Signal wiring (4-20mA, RS232/485)

Outer sheath screened twisted pair tinned

electrolytic annealed copper stranded grey
conductor
Inner cores of twisted pair or other signal
(As signalling standard)
cable

Inner cores of twisted pair for 4-20ma circuits Red (positive) / black (negative)

f) All wiring shall be installed in a neat systematic manner in plastic cable. Trunking shall
be routed to ensure component access is not impeded.
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g) Each cable or wire shall be fitted with a full ring interlocking type identification ferrule at
each end. The numbering shall read left to right on vertical terminal banks and bottom
to top on horizontal terminal banks. All terminals should be fitted with numbered labels
for identification. The wiring identification shall correspond with the wiring diagram.

h) Where wiring passes through metalwork the access hole shall be fitted with a suitable
grommet.

i) At enclosure break points, interposing terminal blocks shall not be provided each side
of the break.

j) Wiring on to hinged doors or plates that are subject to movement shall be run in helical
binding and shall be supported securely at both ends of the moving section.

k) Wiring associated with instrumentation and electronic equipment that could be affected
by power frequency interference shall be screened and/or physically segregated.

l) Crimped-on type terminal connectors shall be fitted to all cable and wire ends. These
shall be fitted using suitably sized ratchet operated (or hydraulic for large power cables)
crimping tools. Hand compression crimping pliers or other hand tools shall not be
used.

m) Cable trunking, tray and other supports for accommodating and supporting switchboard
and control board wiring, shall be fixed by means of screw fasteners to the board
structure; fixing by adhesive will not be permitted.

18.5.3.7 Labelling

a) Labels shall be colourless transparent plastic materials not less than 3 mm thick with
bevelled edges to half the thickness. Each shall be reverse engraved in Arabic and
English the engraving being filled white and the reverse side painted blue unless
otherwise detailed. Main labels shall be provided as detailed and subsidiary labels are
provided for each item on the face of the board, stating what it indicates or controls.
Any item, which is not isolated at the board, shall, in addition, be provided with a
warning label "Danger Live Terminals Isolate Before Maintenance" with flash and
voltage in red letters on white background in Arabic and English.

b) A drawing giving label sizes and a list of inscriptions shall be submitted to the
Employer’s Personnel for approval before manufacture. All labels shall be fixed before
the panel can be energized.

c) All external labels shall be affixed with chrome-plated nuts and bolts with slotted holes
to allow for expansion of the label. All internal labels shall be engraved multi-layered
plastic to an approved design affixed with chrome-plated nuts and bolts or a permanent
adhesive.

d) The switchboard shall have, at regular intervals along its length, external warning
labels in accordance with BS 5378 Part E1. The inscription shall be formed in black
characters on a yellow background.

e) A data rating plate of a durable and easy to read nature shall be fixed in a prominent
position on each switchboard giving the following information:

i. Manufacturer’s name, and country of origin

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ii. Equipment type (e.g. FORM 4 DISTRIBUTION SWITCHBOARD AND MOTOR

CONTROL CENTRE)
iii. Details of system voltage, phases, wires and frequency (e.g. 400 VOLT 3
PHASE 4 WIRE 50 HERTZ), Rated fault current (e.g. 65 kA 1 SEC), Busbar
rating (e.g. 1600 AMP), Year of manufacture (e.g. 2012), Manufacturer’s serial
number (e.g. ABC123).
f) Each compartment door shall carry an engraved label, with a minimum letter height of
4mm giving the equipment tag reference and duty (e.g. PMP–003, STORM PUMP
No.3) and shall state the full load current of the motor.

g) Each control switch, pushbutton and indicator shall be identified local to the device by
its duty (e.g. HAND/OFF/AUTO, START and RUNNING).

h) All internal components shall each be identified with permanent plastic (black and
white) labels, with a minimum letter height of 4mm, attached to a non-removable part of
the panel. The identification on these labels shall directly relate to a relevant reference
on the appropriate schematic diagram.

i) Where Switchboard are provided, each board shall include a rectangular circuit chart
either laminated or enclosed in a transparent protective cover attached to the inside of
the relevant door, showing the following information:

i. Designated number of each way.

ii. Circuit reference.
iii. Rating of the protective device.
iv. Circuit description.
j) All circuit information provided on circuit charts shall be typed or of a permanent
typeface. Handwritten circuit cards shall not be provided at any project stage.

k) All equipment not isolated by the main incoming switch, or relevant compartment
incoming switch, shall be shrouded and identified by a warning label with black
characters on a yellow background and entitled “DANGER 400V-ISOLATE
ELSEWHERE” (referring to relevant voltage) and the location of the isolating device.

l) All keys supplied for the equipment shall include engraved identification discs of a
durable material. The discs shall be engraved with the associated equipment
identification number or title.

18.5.3.8 LV Motor Starters

a) LV Motor starters shall be of intelligent type and shall be of the combination as defined
in IEC 60947: Part 4. Theses shall generally comprise:

i. Motor duty type Moulded Case Circuit Breakers / Air Circuit Breakers with
magnetic trip unit with adjustable threshold
ii. AC contactor
iii. Digital Motor protection Relay
b) The rated operational current of the starter (Ie) shall be not less than the full-load
current of the motor. The starter shall be rated for un-interruptible duty.

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c) Short-circuit co-ordination of the combination shall be Type 2 fully coordinated as

defined in Clause 7.2.5 of IEC 60947-4-1 for a prospective short-circuit current not less
than the value determined by the Contractor’s electrical system design.

d) The features of intelligent starters shall be fully utilized by employing bus system to
convey all parameters to PLC/SCADA controller for motor control and monitoring.

e) Flexible and modular motor management system for low-voltage motors shall be
provided. The system shall be connected with higher level automation systems via
PROFIBUS DP or other approved protocol by engineer. The motor management
system should provide the protection, monitoring and control functions for every motor
feeder. The motor management system shall provide a high degree of detail on the
status and performance of each motor component. The information of actual motor
current, motor direction, phase status and overload status shall be displayed on a
simple-to-read graphic display on an ICA panel HMI.

f) In the event communication to the PLC/SCADA controller is disrupted, the motor

should run locally. The motor management system shall execute its own logic
internally, making local control of the motors possible as a back-up solution for failsafe
requirement of the operation. Sufficient number of on board I/O shall be provided to
allow direct connection and monitoring of local field devices.

g) Thermal overload relays shall be Type 3c as defined in Clause 4.7.2 of IEC 60947-4-1.
Time current characteristics shall be supplied by the Manufacturer on 28 mm x 56 mm
logarithmic decades. These curves shall have a tolerance not exceeding + 10%.

h) Starters shall be suitable for both automatic and non-automatic methods of control.
When opening by overload relay involves energising an auxiliary relay from the control
supply, the pick-up voltage of this auxiliary relay shall be below the drop-out voltage of
the contactor.

i) Motor starter control circuits shall be 230Vac, derived from an individual integral starter
control transformer (isolating).

j) Where assisted start motor starters are required in order to reduce motor starting
currents, these shall be as follows:-

i. Electronic soft starters (motors including and more than 5kW).

ii. Variable speed drive (determined by process requirements).
k) Assisted soft start operation shall be automatic with integral contactor bypass.
Assisted soft start shall be selected in order to provide 120% of the required duty of the
equipment to be controlled, under conditions of continuous running.

l) All electronic boards of soft starters shall be conformal coating. Conformal coatings
shall be 1-2 mm. thick polymeric films that cover or encapsulate printed circuit
assemblies and connectors, which shall protect the assemblies from airborne
contaminants and corrosion by sealing out the contaminants and humidity. The
conformal coating shall meets or exceeds the following standards:

i. ANSI/ISA-S71.04-1985, Class G3 environments

ii. IEC 60654-4 Class 1 and 2 environments
iii. UL746E
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m) Contactors shall be provided with auxiliary contacts to provide all required control
signalling functions and shall be provided with two additional spare normally open and
two spare normally closed contacts.

n) The operating mechanism of the fuse combination unit shall be mounted on the front of
the cubicle, operated by a pistol grip type handle. The mechanism shall be interlocked
with the door to prevent opening when in the on position. The mechanism shall be pad
lockable in the off position.

o) Each intelligent starter shall be provided with the following controls and indications as a
minimum:-

i. Door interlocked breaker.

ii. Intelligent Overload Keypad
iii. Running/stopped Lamp
iv. Interlock healthy Lamp
v. 2 no. Fault Lamps
vi. Local /Manual Selection/lamp
vii. Emergency Stop Healthy Lamp
viii. Trips rest pushbutton
ix. Lamp test pushbutton.
x. Auto control via the control system.
xi. Ammeter with selector switch
xii. Hour run meter
xiii. Emergency stop push button
p) All control signals to the PLC/SCADA controller shall be via the control bus link.

q) Each starter shall be provided with a test facility which shall energise the control circuit
when operated. The test switch shall be arranged to automatically release when the
starter door is closed. The test facility shall enable the control circuits to be operated
for testing purposes with the main motor circuit isolated.

r) Each starter shall be provided with the facility to disconnect the main feeder breaker of
the starter via a remote emergency stop pushbutton. Where such push button is not
installed connection facility shall still be provided, but linked out. All emergency stop
operations shall require resetting of the breaker.

s) Each starter shall be provided with the facility to disconnect the controls via a remote
early break contact on an isolator located adjacent to the motor.

t) Where a motor is supplied with auxiliary protective devices (e.g. thermistor protection
or moisture protection), the protective relays and associated controls shall be
incorporated into the design of the starter.

u) Submersible motor starters shall have control unit supplied by the manufacturer to
provide protection against moisture, high winding temperature, etc.

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v) Where a motor is supplied with an anti-condensation heater, an on/off switch shall be

provided on the front of the starter to isolate the heater. The heater shall be switched
via an auxiliary contact on the main contactor operating so that the heater is energised
whenever the motor is off.

18.5.3.9 Variable Speed Inverter Drives

a) The VSD shall be designed to have a site rating at least 20% above the installed motor
nameplate rating at 40oC. It is to be noted that the motor which are to be supplied
under this contract shall be de-rated for 50oC ambient.

b) VSD system efficiency shall be a minimum of 96% at 100% speed & 100% load.
System efficiency shall include VSD, input transformer or line reactor, harmonic filter
output filter and DC choke. Control power supplies, control circuits, cooling fans or
pumps, shall be included in all loss calculations.

c) The VSD shall be of a well tested and proven design which ensures maximum safety to
personnel, maximum service reliability and economic operation for an operational
lifetime of at least 20 years.

d) The VSD shall be capable of maintaining a minimum true power factor (Displacement
P.F. X Distortion P.F.) of .98 from 30-100% load.

e) All electronic boards of Variable speed inverter drives shall be conformal coating.
Conformal coatings shall be 1-2 mm. thick polymeric films that cover or encapsulate
printed circuit assemblies and connectors, which shall protect the assemblies from
airborne contaminants and corrosion by sealing out the contaminants and humidity.
The conformal coating shall meets or exceeds the following standards:

i. ANSI/ISA-S71.04-1985, Class G3 environments

ii. IEC 60654-4 Class 1 and 2 environments
iii. UL746E
f) The backup protection shall comprise an ultra-rapid semiconductor fuse and electronic
type overload relay.

g) The system should be provided with LOCAL/REMOTE-PC MODE, ON/OFF control by

key switch for local and remote/AUTO operation. All data shall be kept in non-volatile
memory to save them upon power failure conditions. Battery backed up memory is not
preferable. All drive parameters read out values shall be selectable on the
alphanumeric keyboard. Parameter setting should also be made possible on the panel
with password protection facility.

h) The VSD shall utilize sensor less direct vector control or full vector control, with pulse
tachometer feedback, for optimum performance of dry installed pump set.

i) The VSD system shall be designed for a Mean Time Between Failures (MTBF) of
100,000 hours.

j) The converter panel(s) shall form an integral part of the complete L.V. Board as far as
possible especially for smaller size converters.

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k) The converter sound pressure shall not exceed 80 dB (A), at any location 1 m distant
from the converter under any load and/or frequency condition within the operational
speed range of the VSD.

l) The system may include critical speeds which could include the following amongst
others

i. Minimum motor speed for flow to occur

ii. Minimum speed as specified by the motor supplier
iii. Maximum speed as specified by the motor supplier
m) The VSD shall be designed to run through the minimum critical speeds of the whole
system in the shortest time possible.

n) The drive control system shall be designed to ensure that the drive operates in a stable
manner under all operating conditions, including hydraulic conditions such as surges or
pump run-out.

o) The estimated total running up time shall be stated by the manufacturer at rated
voltage at the line terminals of the frequency converters. The pump & motor inertia
shall be estimated or be based on data given in IEC 60034-12, Table III.

p) The operation speed range of the VSD shall be 20-100% of the rated maximum speed.

q) The VSD shall have at least:

i. 120% Max. Rated torque for 10 sec. for starting and re-starting.
ii. 110% Max. Rated torque for 60 sec. for starting, re-starting and acceleration.
iii. During continuous operation, the VSD shall be capable of developing sufficient
torque under load conditions to respond to 20% alteration in set point within a
time of not more than 30 sec.
iv. The minimum time interval between set point changes will be not less than 30
sec.
r) Each drive shall be supplied with an operator keypad to provide access to the drive for
programming and manual control of the drive. The operator keypad shall be flush
mounted in the door of the inverter compartment so that it can be accessed without
opening the door or isolating the drive.

s) Other door mounted controls shall be provided as follows:-

i. Door interlocked MCCB / ACB.

ii. Running lamp.
iii. Stopped lamp.
iv. Available lamp.
v. Fault/tripped lamps as required.
vi. Hand/off/auto selector switch.
vii. Hours run meter.
viii. Stop and start manual pushbuttons.

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ix. Emergency stop pushbutton.

t) Manual speed control of each drive shall be selected via the operator keypad, not via a
separate panel mounted potentiometer.

u) The drives shall be installed in accordance with the manufacturer’s installation guides
and shall be provided with adequate cooling and ventilation to prevent the drive from
overheating during normal operation. The cooling fans shall be low noise type. They
should delay off upon stopping of the motor.

v) Cables from variable speed inverter drives to motors shall be earthed and screened as
necessary in accordance with the manufacturer’s recommendations for the specific
application.

w) The type/model of drive shall be selected in order to minimise the overall effects of
Harmonics in order that the site complies with the IEC 61000 / IEEE519 and /or the
requirements of DEWA. Where final installed Harmonics exceeds the standard either in
total Harmonic distortion or at any particular harmonic frequency, then the Contractor
shall install appropriate equipment to correct the deficit in order to comply with the
directive. Harmonic distortion shall be kept to a level such that both equipment and
cables suffer no harmful effects, overheating or incorrect operation.

x) All drives shall incorporate Radio Frequency filters. The rectifier device shall be IGBT
type. VSD shall comply with the latest edition of IEC 61800-3:2004 Harmonic
Guidelines. The VSD shall be PWM rectifier (Active Front End) with Selective Harmonic
Elimination and AC line reactor and harmonic filter.

y) LV drives shall be installed within an MCC enclosure and shall be supplied with the
following controls:

i. Motor duty type Moulded Case Circuit Breakers / Air Circuit Breakers with
magnetic trip unit with adjustable threshold
ii. Main AC contactor feeding the drive, to be energised when the drive is selected
for operational duty, either hand control or duty or standby auto modes and in
test mode
iii. Control circuits separately protected and isolated via MCBs.
iv. Ventilation for compartment shall be separately protected via an MCB.
v. Interposing control relays for remote operation as specified for LV motor
starters.
vi. Anti-condensation heater with controlling thermostat and separate MCB.
vii. Circuits for motor anti - condensation heater and motor protective devices.
viii. Test circuit for operation of the inverter under no load conditions, e.g. with the
motor disconnected.
z) The drives shall be programmed to incorporate the minimum and maximum speed
settings operable in auto and manual modes. These shall be set in accordance with
the appropriate hydraulic conditions and duty of the drive. In auto this shall be via field
bus communications.

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aa) Automatic control of the speed of the drive shall be via a 4-20mA signal from the
equipment control system. This shall operate over the selected speed range of the
drive.

bb) Protection shall be provided as follows:-

i. Short circuit and overcurrent protection equivalent to meet the requirements of

IEC 60947-4-2 Type 2 coordination.
ii. Phase failure and phase reversal protection.
iii. Over and under voltage.
iv. Earth fault protection as per DEWA requirement.
v. Output fault (e.g. Loss of phase, phase imbalance).
vi. Motor over temperature protection.
cc) All necessary signals shall be provided to connect to the equipment control system. As
a minimum the following shall be provided via field bus communications:-

i. Running/stopped.
i. Available for auto control.
ii. Fault.
iii. Run/stop interposing relay(s) 24Vdc.
iv. Protection interposing relay(s) 24Vdc.
v. Remote speed indication 4-20mA opto-isolated in the drive or compartment.
vi. Remote speed control 4-20mA from equipment control system.
18.5.3.10 Mimic Diagram

The front of the LV Switchboard shall be provided with a plastic or equivalent line mimic
diagram illustrating the main circuit and its components.

18.5.4 SWITCHGEAR AND MCC COMPONENTS

18.5.4.1 Low Voltage AC Contactors

a) Contactors shall be indoor air-break electro-magnetic mechanical switching devices

complying with the recommendations of the following standards:

i. IEC 60947-4-1 LV switchgear and Controlgear.

ii. BS 5424: Part 3 Contactors.

b) The number of poles shall be as required by the Contractor’s design or as specified in

the Particular Requirements. All contactors shall be rated for uninterrupted duty and
intermittent duty Class 12 with on-load factor of 60% and utilisation category AC-3.

c) The rated operational voltage (Ue) shall be not less than 400V ac and the rated
insulation voltage (Ui) shall be not less than 660V ac.

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d) The rated operational current (Ie) shall not be less than the rated operational current
(Ie) of the starter.

e) All contactors shall be of the block type designed for easy replacement of coils and
contacts. In the position of rest the contactor shall be in the open position and shall
give its rated performance in any mounting position. All terminals shall be accessible
from the front.

f) Contactors should be provided with auxiliary contacts to provide all control circuit
switching requirements.

g) Test certificates shall be supplied for the following type tests to IEC 60947-4-1.

i. Temperature-rise Limits (Sub-clause 8.3.3.3).

ii. Dielectric properties (Sub-clause 8.3.3.4).
iii. Operation and operating limits (Sub-clauses 8.3.3.1 and 8.3.3.2).
iv. Rated making and breaking capacities (Sub-clause 8.3.3.5).
v. Performance under short-circuit conditions (Sub-clause 8.3.4).
vi. Conventional operational performance (Sub-clause 8.3.3.6).
vii. Ability of contactors to withstand overload current (Sub-clause 8.3.5).
viii. Short-circuit tests shall be certified by ASTA, KEMA or PEHLA.
h) The following routine tests shall be carried out on all contactors to IEC-60947-4-1 and
test certificates shall be supplied:

i. Operation test (Sub-clause 8.3.6.2).

ii. Dielectric tests (Sub-clause 8.3.6.3).
18.5.4.2 Fuse-Combination Units for Motor Circuits

a) Fuse-combination units, comprising a combination of a switch-disconnector and a fuse-

switch, on ac motor circuits shall be indoor air-break mechanical switching devices
complying with IEC 60947-3.

b) The number of poles shall be as required by the Contractor’s design or as otherwise

specified.

c) The rated insulation voltage (Ui) shall be not less than 660 V ac and the rated
operational voltage (Ue) shall be not less than 400 V ac.

d) The rated operational power at 380 V for uninterrupted duty and utilisation category
AC-23B shall be not less than the motor rating. The rated thermal current (Ith) and the
corresponding (Ithe) with the equipment mounted in the control gear shall be entered in
the Technical Schedule.

e) The rated fused short-circuit current with the maximum rating of motor circuit fuse-link
listed in Clause E1.20 shall be adequate for the short-circuit conditions specified.

f) Independent manual operation shall be used for both closing and opening operations.

g) All fixed contacts shall be shrouded to prevent accidental contact by maintenance

personnel.
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h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.6, (IEC 60947-3). Test
8.3.6 shall be performed with the maximum rating of motor circuit fuse-link listed in
Clause E1.20 and shall be certified by ASTA, KEMA, PEHLA or other authority
approved by the Project Manager.

i) Routine tests listed in Clause 8.4 (BS EN 60947-3) shall be carried out on all
equipment and test certificates shall be supplied for all routine tests.

18.5.4.3 Fuse-Combination Units for Distribution Circuits

a) Fuse-combination units comprising a combination of a switch-disconnector and a fuse-

switch, on ac distribution circuits shall be indoor air-break mechanical switching
devices complying with IEC 60947-3.

b) The number of poles shall be as required by the Contractor’s design or as otherwise

specified.

c) The rated insulation voltage (Ui) shall be not less than 660 V ac and the rated
operational voltage (Ue) shall be not less than 400V ac.

d) The rated operational current (Ie) for uninterrupted duty and utilisation category AC-
23B shall be required by the Contractors design or as otherwise specified. The rated
thermal current (Ith) and the corresponding (Ithe) with the equipment mounted in the
control gear shall be entered in the Technical Schedule.

e) The rated fused short-circuit current shall be adequate for the short-circuit conditions
specified.

f) Independent manual operation shall be used for both closing and opening operations.

g) All fixed contacts shall be shrouded to prevent accidental contact by maintenance

personnel.

h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.6, (BS EN 60947-3).
Type test 8.3.6 shall be certified by ASTA, KEMA, PEHLA or other authority approved
by the Project Manager.

i) Routine tests listed in Clause 8.4 (IEC 60947-3) shall be carried out on all equipment
and test certificates shall be supplied for all routine tests.

18.5.4.4 Switch Disconnector

a) Switch-disconnector shall be indoor air-break mechanical switching devices complying

with IEC 60947-3.

b) The number of poles shall be as required by the Contractor’s design or as otherwise

specified.

c) The rated insulation voltage (Ui) shall be not less than 660 V ac and the rated
operational voltage (Ue) shall be not less than 400 V ac.

d) The rated operational power at 380 V for uninterrupted duty and utilisation category
AC-22B shall be as required by the Contractors design or as otherwise specified. The
rated thermal current (Ith) and the corresponding (Ithe) with the equipment mounted in
the switchgear shall be entered in the Technical Schedule.

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e) The rated short-time withstand current and the rated short-circuit making capacity shall
be adequate for the short-circuit conditions specified.

f) Independent manual operation shall be used for both closing and opening operations.

g) All fixed contacts shall be shrouded to prevent accidental contact by maintenance

personnel.

h) Test certificates shall be supplied for type tests 8.3.3, 8.3.4, 8.3.5, (BS EN 60947-3).
Test 8.3.5 shall be certified by ASTA, KEMA, PEHLA or other authority approved by
the Project Manager.

i) Routine tests listed in Clause 8.4 (IEC 60947-3) shall be carried out on all equipment
and test certificates shall be supplied for all routine tests.

18.5.4.5 LV Fuses for AC Power and Control Circuits

a) All LV fuses for use on ac power circuits and directly connected control circuits shall be
of the general purpose type rated not less than 400 V and shall comply with IEC
60269:1999 for Low voltage fuses.

b) Motor circuit fuse links may have two current ratings: a continuous current rating and a
rating on which their time/current and cut-off characteristics are based (e.g. 100M160).

c) Fuse holders and bases used on motor circuits shall have a breaking capacity to match
the highest rating of motor circuit fuse link which can be accommodated.

d) Test certificates, for type tests in accordance with Clause 8 of BS EN 60269: Part 1
shall be supplied. Short-circuit tests shall be certified by ASTA, KEMA or PEHLA.

e) The preferred ratings for fuse links are as follows:

General Purpose
Fuse Link Motor Circuit Fuse Link
Fuse Link Rating Fuse Holder or
Dimensions Rating (gM)
(gG) Base Rating
Reference Amps
Amps
A2 2 up to 32 32M35 up to 32M63 32
A3 35 up to 63 63M80 up to 63M100 63
A4 80 up to 100 100M125 up to 100M200 100
B2 125 up to 200 200M250 up to 200M315 200
B3 250 up to 315 315M355 up to 315M400 315
C1 355 up to 400 400M500 450
C2 450 up to 630 630M670 630

18.5.4.6 Low Voltage AC Circuit Breakers (Fault Level above 10 kA)

a) Circuit-breakers used on low voltage ac systems having a fault level in excess of 10 kA

shall be steel cassette mounted indoor trip-free air-break mechanical switching devices
complying with IEC 60947-2.

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b) Circuit breakers shall be 3 pole or 4 pole as required by the application or as otherwise

specified.

c) The rated insulation voltage (Ui) shall be not less than 660 V ac and the rated
operational voltage (Ue) shall be not less than 400 V ac.

d) Circuit breakers shall be of utilisation category B.

e) The rated current (In) and the rated service short-circuit breaking capacity (Ics) shall be
as required by the design or as otherwise specified.

f) The rated short time withstand current (Icw) in kA and the rated short time in seconds
shall be as required by the design or as otherwise specified.

g) The closing operation during switching shall be performed by one of the following
methods.

i. Independent manual closing

ii. Dependent power closing (solenoid energised from main circuit and a
removable lever solely for dependent manual mechanical operation).
iii. Stored energy closing (spring charged by electric motor and manual means with
both electric and manual release).

h) Circuit-breakers shall be fitted with manual opening release, either inverse time-delay
over current release and instantaneous short-circuit current release (direct or indirect)
or shunt opening release. Time current characteristics on 28 x 56 mm logarithmic
decades shall be supplied by the manufacturer and approved by the Project Manager.
The voltage for the shunt opening release shall be independent of the main circuit
voltage and, unless specified otherwise in the Particular Requirements, shall be 30V
dc.

i) Two auxiliary contacts of each kind (N/O and N/C) shall be provided for future use.

j) Circuit-breakers shall be designed to be maintained in accordance with BS 6423.

Operational performance capability of circuit breakers shall be in accordance with
Clause 7.2.4.2 of BS EN 60947-2.

k) Test certificates shall be supplied for type tests described in Clause 8.1.2 and Clause
8.1.3 of IEC 60947-2. Type tests to Clauses 8.3.4, 8.3.5 and 8.3.6 shall be certified by
ASTA, KEMA, PEHLA or other authority approved by the Project Manager.

l) Routine tests described in Clause 8.1 and Clause 8.4 of IEC 60947-2 shall be carried
out on all circuit breakers and test certificates shall be supplied.

m) Factory testing of circuit breakers in switch and control gear shall include primary
injection testing of the protective relay/circuit breaker combination.

18.5.4.7 Indicating Instruments and Meters

a) Indicating instruments shall be of the industrial class. They shall be continuously rated,
heavy duty, flush mounted type, with black bezels and anti-reflex dial glass and shall
be to BS 89.

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b) Ranges shall be selected to show normal equipment operation between 50% and 75%
of full scale deflection.

c) Instrument sizes shall be not less than 96x96 mm for incoming supply requirements
and not less than 72x72 mm for other instruments.

d) Compressed upper scale indicators shall be provided for motor starter current
indicators for motor starting purposes.

18.5.4.8 Indicating Lamps

a) Indicating lamps shall be 22.5mm diameter standard incorporating high intensity multi-
cluster light emitting diodes. Where necessary the assembly shall incorporate a
transformer. LED assemblies shall have a maximum operating voltage of 24V ac/dc in
control panel and 230Vac in motor starters and drives.

b) Filament type lamps of circular or rectangular pattern shall only be used where
specified for special purposes. Lamp voltage shall not exceed 24V ac/dc and the lamp
shall be replaceable from the front without the use of a tool.

c) Indicating lamps shall comply with IEC 60947, Part 5.

d) Indicating lamps shall be coloured in accordance with BS EN 60073. The lens

colouring shall be within the lens material and not in an applied coating and shall be
provided in accordance with the following table:

Indicator
Meaning Application
Colour
Danger electrical circuit Isolator or circuit breaker closed
Red energised, (unsafe to work on protective system energised
or enter equipment) (e.g. CO2 fire system)
Motor or pump running.
Green Equipment in normal operation
Valve open

Caution (change of state from Equipment tripped. (Do not

Amber
normal operation) work on until made safe.)
Equipment available for control.
Motor or pump stopped,
White Information valve closed.
Isolator or circuit breaker open

e) A test facility enabling all lamps and LEDs to be tested whilst the equipment is in
service and without affecting operation shall be provided. Lamp test shall be achieved
by incorporating ‘push to test’ action on each indicator or by providing a separate lamp
test pushbutton where the number of lamps on an enclosure door exceeds two. The
lamp test pushbutton shall be mounted on the same enclosure door as the lamps.

18.5.4.9 Pushbuttons

a) Pushbuttons shall comply with IEC 60947: Part 5. Unless otherwise specified, colours
of the buttons shall comply with IEC 60073.

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b) Pushbuttons shall be flush mounted and have normally closed and normally open
contacts as required and shall be coloured as follows:-

Pushbutton Colour Application

Black Lamp test or circuit test
Blue Reset
Green Close or start
Red Open or Stop or emergency stop
Yellow Alarm accept
Blue others as required (inc. process control)

c) Emergency stop pushbuttons shall be of the latched type with quarter turn release and
shall be of the mushroom head type. Emergency stop pushbuttons shall be connected
in control circuits so they are effective under all equipment operating conditions.
Resetting of the pushbutton shall not automatically re-energise the isolated equipment.

18.5.4.10 Terminal Blocks

a) Terminal blocks shall be of the shrouded DIN rail mounted type. Terminal mouldings
shall be in polyamide 6.6 or equivalent approved non-brittle material.

b) Terminals shall be of the pillar indirect pressure type compliant with IEC 60947, Part 7.
Screw less terminals will not be accepted.

c) DIN mounting rails shall be of zinc coated and yellow passivated steel channels. The
same style of DIN rail shall be used across the site.

d) At least 20% spare terminals shall be provided at all blocks.

e) No more than one conductor may be connected to one side of a terminal. Where
duplication of terminal connection is required, multiple solid bridge linked terminals
shall be provided.

18.5.4.11 Control and Selector Switches

a) Manually operated control and selector switches for equipment control and circuit
selection purposes shall conform to IEC 60947, Part 5.

b) Control and selector switches shall have a rotary action. All switch positions and
functions shall be clearly labelled.

c) Contacts of all switches shall be shrouded.

18.5.4.12 Anti Condensation Heaters

a) Unless otherwise specified, each switchboard and control gear panel and circuit
compartment shall be provided with an anti-condensation heater. Alternatively, low
voltage multi-compartmented switchgear may be provided with a common heater
located at the base of each panel if appropriate to the manufacturer’s standard design,
and providing there is adequate means of internal conduction.

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b) Heaters shall be mounted as low as possible in enclosures and panels. Heaters shall
be located to ensure free air flow over the heating element and to have no detrimental
effect on temperature sensitive devices or adjacent cabling.

c) Heaters shall be fitted with a safety guard the surface temperature of which shall not
exceed 60°C.

d) Heaters shall be rated to ensure condensation does not occur under the ambient air
temperature and relative humidity conditions prevailing at the location where
enclosures and panels are installed.

e) Individual panel heaters shall be complete with protective device, ON/OFF switch and
thermostat.

f) Heater circuits not isolated by the enclosure switch-disconnector shall have all live
terminals fully shrouded and a warning label fitted.

18.5.4.13 Current Transformers

a) Current transformers shall comply with IEC 60044 and shall be of the wound primary or
ring type as dictated by output, accuracy, short-time current and space considerations.

b) Unless otherwise specified, the rated insulation level shall be as the associated
switchgear, the accuracy class shall be 1.0 for metering, 3.0 for indicating instruments
and 5P for protection.

c) The rated secondary current, rated output, accuracy limit factor for protection
application, and frequency shall be as required for the application. The accuracy class
and excitation characteristics of protection circuit current transformers for differential
and zoned earth fault protection shall be that required to provide protection system
performance and operational stability for power system through fault and switching load
conditions.

d) The secondary winding(s) of each current transformer or of each set of star-connected

three phase current transformers shall be earthed at one point only, via a bolted link.
The link shall be located in the instrument wiring chamber.

e) Separate current transformers shall be used for metering and protection. Indicating
instruments may be supplied from current transformers associated with non-unit
protection.

f) Multi-ratio current transformer tappings shall be connected to link-boards located in the

instrument wiring chamber. Connection options shall be clearly labelled.

g) Ring type current transformers shall be fixed to prevent movement under normal
service and through-fault conditions, and shall be easily removed.

18.5.4.14 Protection Relays

a) Protection relays shall be mounted on the front of the switchgear or relay panel in such
a position that operation and maintenance can be conveniently carried out. Auxiliary
relays may be mounted internally and shall be located to be readily accessible.

b) Protection relays shall be contained in a dust proof case with a clear front cover
providing a minimum protection classification IP52 to IEC 60529.
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c) Relays shall have provision for testing the operation and calibration without
disconnecting the permanent wiring by integral or separately mounted plug-in test
terminal assemblies.

d) Relays shall be flush, solid state type. Each relay shall have an indicator device to
show the relay has operated and its specific operating function. Each indicator shall be
hand resettable. Resetting devices shall not require the removal or opening of the
relay. It shall not be possible to operate or adjust the relay settings without opening the
case.

e) Protection relays shall be of the solid state module pattern.

f) Multiple function modular relays shall incorporate plug board or similar approved
function and characteristic changing devices.

g) All relay protection elements shall have controls for protection set point and time setting
adjustment. Relay characteristics, functions and settings shall be clearly indicated on
the relay element front plate.

h) Protection relays shall comply with IEC 60255-21.

18.5.4.15 Control Relays

a) Relays for switchgear applications shall be selected from a range of standard industrial
control devices dependent on size, current capacity and duty. They shall conform to
IEC 60255.

b) Relays for general applications, shall be of the 8, 11, or 14 pin plug in type. They shall
have break before make contacts, and clear indication of the operational status.
Appropriate DIN rail mounted bases shall be provided for connection, complete with
proprietary retaining clips.

c) The operating mechanism shall give consistent results under fluctuating voltage
conditions with “pull in” and “dropout” parameters as follows:-

i. Pull in - by 85% of nominal voltage.

ii. Drop out - less than 60% nominal voltage.
d) Relay coils shall be continuously rated, and capable of sustaining a voltage 10% in
excess of nominal voltage without reduction in life.

18.5.4.16 Residual Current Circuit Breakers

a) Residual Current Circuit Breakers shall comply with IEC 61008-1 and IEC 61008-2.

b) Residual Current Circuit Breakers shall be double pole for single phase and four pole
for three phase and neutral circuits.

c) RCCBs shall include provision for testing the residual current tripping function with a
test pushbutton and manual reset.

18.5.4.17 Power Monitoring Device

a) Microprocessor based power monitoring device should be provided and the same shall
be connected onto an open communications bus back to the PLC/SCADA controller.

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b) The Power monitor should provide numerous display measurements and programming
characteristics.

i. Current (Per Phase, Neutral, Average, Positive, Negative Sequence & Percent
Current Unbalance)
ii. Voltage (Per Phase, Neutral, Average, Positive, Negative Sequence & Percent
Voltage Unbalance
iii. Phase Rotation
iv. Frequency in Hz
v. Power ( kW, KVAR, KVA & kWh)
vi. Power Factor (True ,Displacement, Distortion PF)
c) It shall be possible to configure and monitor the power monitor through an in-built
keypad as well as through the communication Network. It should be possible to provide
password interlock to protect from the unauthorized users.

18.6 DISTRIBUTION TRANSFORMERS

18.6.1 General Requirements

a) The transformer shall be of a standard, well tested and proven design which ensures
maximum safety to personnel, maximum service reliability and economic operation for
their operational lifetime. Design and construction shall be simple and shall provide
good accessibility to components and parts.

b) Further to the international standards, transformers shall in any case conform to the
local standards (DEWA), if these are higher, more stringent or of special nature and
shall be previously approved by DEWA.

c) The requirements of this specification shall not relieve the manufacturer of the
responsibility of complying with the industry codes and standard requirements.

d) All components utilised in the construction of distribution transformer shall be of the

latest design, new and in current production. Materials and equipment shall be
approved by the appropriate authority where applicable.

e) In case Transformer terminal box is provided with Current Transformers then relevant
IEC standard for Current Transformer is also applicable.

f) The transformers supplying Variable Speed Drives shall be of convertor duty

transformer. These transformers shall be design, manufactured and tested in
accordance with the following standard.

i. IEC 61378-1: 1997, Converter transformers, Part 1, Convertor transformers -

Part 1: Transformers for industrial applications
ii. IEEE Std, C57.18.10-1998, Practices for Semiconductor Power Rectifier
Transformers
g) In case standard distribution transformers are used for special convertor applications,
all applicable de-rating should be applied.

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h) Transformers feeding frequency converters shall be provided with static screening to

suppress the radio frequency interference (RFI).

i) Unless otherwise specified the transformer shall be suitable for indoor installation.
Ventilation requirement for indoor installation of oil immersed sealed / dry type
transformers shall be specified by the manufacturer.

18.6.2 Design Considerations

a) Transformers kVA and voltage rating shall comply with the preferred values of the
standards specified. Unless otherwise specifically stated to the contrary the rated kVA
shall be based on natural air cooling. Voltage insulation of windings shall be for
unearthed system.

b) The nominal primary voltage shall be 30kV or 11kV, 50Hz and the highest voltage for
equipment shall be 36KV or 12kV.

c) The nominal secondary voltage shall be 6.6KV or 3.3KV or 400/230V, 50Hz. The
neutral point shall be earthed.

d) The normal voltage ratio of the transformers at principal tapping shall be 11000/400
Volts / 11000/3300 Volts / 11000/6600 Volts or 30000/400 Volts / 30000/3300 Volts /
30000/6600 Volts.

e) For oil immersed sealed and dry type transformers, manufacturer shall indicate the
base rating of the transformer for operation in an ambient of 40ºC and furnish the
de-rating factors for equipment rating at 50ºC ambient temperatures.

f) The short circuit impedance shall be strictly in compliance with the DEWA standard
specification and requirements. The tolerance shall be ±10.0% of the declared value at
principal tapping and ±15.0% of the declared value at other tappings.

g) Temperature rise of the oil immersed sealed type transformers shall not exceed the
values specified by DEWA, when operating continuously at the maximum kVA ratings,
at the rated voltage, frequency and climatic/installation specified conditions.

h) The primary winding connection shall be ∆ connection (3-phase 3-wire) and the
secondary winding connection shall be Y (3-phase 4-wire) connection. Unless
otherwise specified or required by the electrical system design the Vector group shall
be Dyn11.

i) All transformers with their accessories shall be designed and manufactured to reduce
noise pressure and vibration to acceptable level. The average surface noise pressure
level of transformers shall not exceed the values specified in DEWA standard
specification or IEC. The transformer shall be subjected to sound level measurement
as per IEC 60076-10.

18.6.3 Construction Requirements

18.6.3.1 Internal Arrangement

a) Transformer core shall be of robust design adequately braced to prevent displacement

due to electromagnetic stresses of short circuits, and the mechanical shocks of normal
moving and handling of the transformer without any need for special shipping braces.
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b) The core shall be constructed of the best quality low loss; cold-rolled grain oriented
steel laminations conforming to the latest edition of IEC 60404. The core shall be
assembled in a manner which reduces vibration and minimize inherent noise. Both
sides of individual stampings shall be coated with an insulating material which shall be
resistant against oil and temperature. The complete core shall be effectively earthed.

c) The core laminations shall be evenly secured to prevent settling of the core and
minimize noise and vibration when transformer is in operation.

d) The flux density in any part of the core shall not exceed 1.72 Tesla at nominal voltage
and frequency. Thickness of a lamination shall not exceed 0.3mm (M5).

e) The core plates shall be insulated from one another to minimize the core loss and the
core shall be held together by bolts and clamping plates all of which shall be
adequately insulated. The completed core and winding assembly shall be provided with
lifting eyes to facilitate its removal from the transformer tank and shall be adequately
braced and supported to prevent movement during transit or service.

f) The core construction shall be such that removal and replacement of the coils would
require the removal of minimum possible number of core laminations.

18.6.3.2 Tank or Enclosure

a) For oil immersed sealed type transformers the tank, cover, radiators and any
other attached compartments, shall be rigid steel construction.

b) Radiator tubes or fins shall be so arranged that external cleaning and repainting can be
carried out at site without dismantling.

c) For sealed type transformers the tank cover shall be welded with continuous joint.
Bolted connection with tack-welded bolts is not acceptable. After filling the tank with oil
the filling orifice shall be permanently sealed in a tamperproof manner.

d) The tank cover, radiators etc. shall have adequate strength to withstand without
deformation due to the internal pressure of the oil, air and gas under operation
conditions.

e) Pressure relief valves, when specified, shall be fitted and set to operate at static
pressure of less than the hydraulic test pressure of the tank.

f) There shall be an oil level mark inside the tank that indicates proper oil level at 30°C of
ambient temperature.

g) The transformer undercarriage shall be provided with bi-directional rollers to allow

longitudinal and transverse movement on flat surfaces.

18.6.3.3 Tank finish

a) The painting process of steel parts shall ensure that no corrosion takes place under.
The painting process of steel parts shall ensure that no corrosion takes place under
severe climatic conditions prevailing in Dubai. Prior to the painting of the tank and the
cover shall be sand-blasted or shot-blasted for removal of mill and welding scale. The
painting shall be made with a single coat of one-pack epoxy paint. The finishing paint
shall be made with two or three coats.

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b) The primer coat shall contain rust inhibitor, both oil and heat resistant. Secondary coats
shall contain resistant components of salt spray, chemicals and humidity.

c) Minimum thickness of coats shall not less than average 60μm and shall not less than
80% at any point. The outside colour of the tank shall be painted in grey.

18.6.3.4 Gaskets

All the gaskets used for sealing the tanks and connected external parts shall be made
of NBR (Nitrile (Acrylonitrile) Butadiene Rubber) or better that totally prevents the
leakage of oil and ingress of humidity and air to the oil and windings under all operating
conditions. The minimum thickness shall be 6mm. The gaskets shall not have any joint
and shall withstand insulation oil. It shall not have variation of characteristics caused by
temperature variation.

18.6.3.5 Windings

a) The windings shall be made of best soft drawn copper having high conductivity and
complying with the requirements of the latest edition of IEC 60228. The windings shall
be designed to meet the three fundamental requirements: mechanical, thermal and
electrical.

b) The windings shall be capable of sustaining short circuit forces.

c) All windings shall be fully insulated according to IEC 60076 for standard insulation level
and for a system highest voltage of 36KV or 12kV. And windings shall be wound with
adequate bracing and securing tapes in order to achieve a strong, self supporting
structure. Adequate cooling ducts shall be provided to ensure that temperature rise is
within the permissible limits at normal operating conditions.

d) The HV and LV windings shall be separated without difficulty for replacing each
winding.

e) The neutral point of star connected windings shall be brought out separately to a
terminal on the respective winding side.

f) The winding coils shall be adequately braced to prevent distortion of the windings or
movement of the coils on the core limbs under short circuit condition or normal moving
and handling of the transformer.

g) All windings shall be fully insulated and the insulation shall be free from any
composites likely to soften, shunt or collapse during service. The insulating material
shall be of a type that does not shrink, disintegrate, carbonize or become brittle in hot
oil for oil immersed transformer.

h) Insulation varnish treatment shall be accomplished by vacuum impregnation.

18.6.3.6 Oil and Fillings

a) Mineral oil for immersed sealed type transformers shall be Shell DIALA B, D or AX
alternative oils complying IEC 60296.

b) Oil shall be dried prior to filling of the transformer which shall be performed under
vacuum.

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c) PCB synthetic liquids (Poly Chlorinated Biphenyls) or other chlorinated hydro carbons
with trade names Askarel, Pyranol, Clapnen, Pyralene, etc. are not acceptable and
shall not be used.

d) Instructions for cleaning and filtering of the liquid used shall be furnished with
each transformer.

e) The dielectric strength of oil or synthetic liquid shall be more than 125kV/cm.

f) Oil immersed sealed type transformers shall be filled with the oil at the manufacturer’s
works. The brand and type of oil shall be stated on the rating plate.

18.6.3.7 Terminals

a) To provide a 4-wire system, the low voltage star point connections shall be brought out
on a separate terminal.

b) Terminals shall be marked in accordance with the connection diagram marked on the
rating plate.

c) The stems and bushing of the terminals shall be sealed in leak proof manner into the
tank wall or cover, rotations of terminal stems shall be prevented by effective locking.

d) External terminals for the connection of cables shall be provided with bolted type
conductor connections of adequate dimensions and ratings and if two or more
conductors per terminal are required, provision shall be made to accommodate the
same.

e) All bushings shall be self-contained and shall be sealed into the enclosure air/gas and
liquid tight with non-deteriorating gaskets suitable for the liquid used.

f) All transformers shall be provided with external earthing terminal. This shall be either a
threaded bolt or bolted clamp. The minimum diameter shall be 8 mm.

18.6.3.8 Cable Boxes

a) Cable entries into the boxes shall be located such that conductors can be clamped
straight into the terminal connectors with minimum of bending inside box.

b) Extension pieces bolted to the actual terminal with additional bolted conductor clamps
in line with the cable entry may be required.

c) Single core type cables shall be glanded to non-magnetic plates.

d) The transformer shall have HV and LV cable boxes. The HV and LV cable boxes shall
be mounted on opposite sides of the tank and arranged for cables entering vertically
from bottom.

e) All cable boxes shall be completely sealed and provided with sealing glands to suit
cables. HV cable box shall be suitable for terminating a three (3) core XLPE up to
300mm2 cable via 1 gland.

18.6.3.9 Terminations and glands

a) Cable terminations for lower voltages shall be with double compression type glands.
Single core cable entries shall be mounted on non-magnetic plates.
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b) For star point earthing an extra gland, suitable for PVC insulated cable shall be
provided.

c) The glands shall be electrically separated from cable box, and the dielectric
characteristics of the insulation between gland and cable box shall meet the
requirements listed below.

i. Power frequency withstand voltage: 2 kV at least

ii. Impulse withstand voltage: 6 kV at least
d) Cable clamp supports shall be provided by the manufacturer.

18.6.3.10 Off-Load Tap Changers

e) Tap changing on the MV winding shall be done by externally hand operated off-load
tap changing switch.

f) The HV winding of the transformers shall have 5 tapping positions they are principal
tapping and ± 2.5%x2 tapping positions operated by an off-circuit tapping switch clearly
marked position indicator. Tapping position shall be visible at the safe distance. Tap
changer shall have locking device.

g) Switching position of No. 1 shall correspond to maximum plus tapping. The contacts of
the tap changer shall be of robust and shall have sufficient surface area. Insulating
sleeves for the transformer tapping shall be in crepe paper or better.

h) The switch shall preferably satisfy the following requirements:

i. The switch shall be operable by its handle without the need of additional tool
and without risk to personnel safety.
ii. The contact changing shall be positive snap action arranged so that it is
impossible for the contacts to be left in a position where the circuit remains
interrupted.
iii. The stops shall be robust type to prevent overrunning.
iv. Padlocking of the switch shall be provided.
v. Tap positions shall be clearly marked.
vi. The driving rod through the tank cover or wall shall be sealed to prevent leakage
of air, gas or liquid under all service conditions.
18.6.3.11 Earthing

a) MV cable boxes shall have an earthing terminal of adequate dimensions for the cable
earthing wires. LV cables boxes shall have earthing terminals of adequate dimensions
for each cable earthing sheath wire.

b) For connection to the external earthing network, the enclosure shall have earthing pads
with threaded holes for connection to a 70 sq mm stranded copper earthing cable.

18.6.3.12 Fittings and Accessories

a) The following shall be provided for all transformers as a minimum:

i. Pressure relief device - alarm / trip signal

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ii. Winding temperature indicator with contacts.

iii. Oil temperature indicator with contacts (for oil immersed sealed transformers).
iv. Oil level switch with contacts (for oil immersed sealed transformers).
v. Lifting lugs for lifting the entire transformer.
vi. Skid under base with bi-directional rollers.
vii. Rating plate.

b) Cabling / wiring on the transformer shall be run through cable trays fitted on
transformer.

c) Lifting lugs for lifting tank cover with or without core and coil assembly. If without,
further lifting lugs for core a coil assembly shall be provided.

d) A pressure relief device of sufficient size, capable of functioning without electrical

power shall be provided for the rapid release of any pressure that may be generated
within the tank and which might result in damage to the equipment. It shall also be
capable of maintaining the oil tightness of the transformer under all conditions of
normal service. The device shall operate at a static pressure of less than the hydraulic
test pressure for transformer tanks and shall be designed to prevent further oil flow
from the transformer following its operation.

e) Valves shall be of the fully sealing full-way type suitable for minimum and maximum
temperatures specified without any deterioration. Valves to open when turned counter
clockwise. All valves opening to atmospheres shall be fitted with blanking plates.

f) Explosion vents with single diaphragm to be provided.

g) Cooling system of the transformers shall be natural circulation of oil and air (ONAN).

h) Detachable radiators with valves to be provided and shall be through connected to the
main tank. Radiator thickness to be 1.20mm (minimum) and shall be fitted with lifting
lugs machined, flanged inlet and outlet pipes.

i) Plugs shall be fitted at the top and bottom of each radiator for filling and draining. The
oil circuit of all coolers shall be provided with the following as appropriate to tank
mounted on separate bank coolers:-

i. Valve at every point of connection to the transformer.

ii. Valve at the bottom of every cooler of main oil connection.
iii. Loose blanking plates to permit the blanking off of the main oil connection to the
top of each cooler.
iv. A 50 mm oil filtering valve at the top and bottom of each cooler, the bottom
valve shall also function as a drain valve.
j) A thermometer pocket fitted with a captive screwed cap on the inlet and outlet oil
branches of each cooler.

k) Where M.V. cables shall be terminated in a cable box, an air insulated disconnecting
chamber with removable links shall be provided. The disconnection chamber shall have
a removable cover and the design of the chamber shall be such that ample clearances
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are provided to approach the terminations of the disconnecting links, and also
facilitates either the transformer or each cable to be subjected separately to high
voltage tests.

l) Cable termination box shall be provided with suitable arrangement to provide

supporting structure from floor.

m) Cables boxes for 6.6 kV and below need not be attached with disconnecting link
chambers.

n) Terminal boxes to be provided with bushings with Air clearance and creepage suitable
for outdoor mounting type transformer.

o) An earthing terminal shall be provided in each disconnecting or sealing end chamber to

which the connections from the transformer or reactor winding can be earthed during
cable testing.

p) Terminals shall be marked in a clear and permanent manner.

q) Oil temperature indicating (OTI) devices shall be fitted with one set of contacts
adjustable over the range 60oC to 110oC for initiating a DC operated alarm.

r) Winding temperature indicating (W.T.I.) devices shall indicate the temperature of the
hottest spot of the winding and shall have a load-temperature characteristic
approximating to that of the main winding. Two sets of contacts shall be provided for
initiating of alarm and trip relays.

s) Separate Current Transformer shall be used for W.T.I.

t) Temperature indicating devices shall incorporate a dial and a pointer indicator and a
separate pointer to register the maximum temperature reached.

u) The capillary connected sensing bulbs of temperature indicators shall be positioned in

separate oil-tight pockets arranged in the top oil.

v) The temperature indicating devices shall be so designed that it shall be possible to

move the pointers by hand for the purpose of checking the operation of the contacts
and associated equipment. The working parts of the instruments shall be made visible
by the provision of dials and glass fronted covers.

w) The characteristics of the winding temperature indicating devices shall be forwarded to

the DM/Engineer for approval prior to the delivery of the transformers and shall also be
included in the operating and maintenance instructions.

x) All temperature indicators shall be housed in the marshalling kiosk or box and shall be
mounted so that they will not be affected by vibration.

y) HV bushings shall be plug-in type which are connected with elbow connector or tee
connector. They shall be mounted on the tank and sealed by cable box. The minimum
phase to phase clearance and phase to earth clearance shall not be less than those
stated in Table 5 of IEC 60076-3. HV bushings shall be connected with three core
XLPE insulated 300mm2 copper cable.

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z) The plug-in type HV bushings shall be installed in a manner to prevent ingress of

moisture and to facilitate easy connection with heat shrinkable or pre-moulded
connectors.

aa) Current rating of plug-in type HV bushings shall be 200A and number of bushings shall
be 3 Nos. Dimensions of HV bushings shall comply with IEC specification.

bb) LV bushings including neutral bushing shall be outdoor porcelain type conforming to
IEC 60137. They shall be mounted on tank and sealed cable box. Bushing palms shall
be made of brass be suitable for the bolting of conductor compression lugs of
termination for indoor use. The minimum phase to phase clearance shall not be less
than those stated in Table 5 of IEC 60076-3.

cc) The porcelain shall not engage directly with the hard metal and gaskets shall be
interposed between them and the surface in contact with the gasket shall be unglazed.
They shall be installed in a manner to prevent ingress of moisture and to facilitate easy
removal.

dd) In case of overhead line connected transformers, bushing shall suitable with creepage
for outdoor and to be provided with arcing horns. Bushings to be provided for earthing
the neutral.

ee) A separate box shall be provided to accommodate neutral C.T. for restricted fault relay.

ff) All bushings shall be marked with symbols as per rating plate and connecting diagram.

gg) The rating plate(s) shall be of non-corrosive material. Enamelled plates are not
acceptable.

hh) The rating plate(s) shall give the following information:

i. The international specification to which the transformer conforms to.

ii. Vector group and winding connection.
iii. Percentage tapping positions of rated voltage.
iv. Rated MV voltage at zero tapping.
v. Rated LV voltages at no load and full load at above condition.
vi. Rated ambient temperature.
vii. Rated kVA at self air cooling at above conditions.
viii. Rated full load current and short circuit current withstand for 3 seconds.
ix. Impedance Voltage at principal tap.
x. Rated reactance.
xi. Make, type, volume, and weight of insulation liquid.
xii. Enclosure class of transformer.
xiii. Lifting weight of the core and winding assembly.
xiv. Lifting weight of the entire transformer with liquid.
xv. Transformer type, make, serial number, year of manufacture and purchase
order number.

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18.7 MEDIUM VOLTAGE MOTORS

18.7.1 General Requirements

a) This specification covers the general requirements for Medium Voltage, 3-phase
squirrel case, induction type motors.

b) All motors shall be from a reputed and approved manufacturer and shall comply with
the requirements of the relevant Contract. They shall be complete with terminal boxes,
cable glands and with heaters and monitoring instruments. Motors of the same type
must be fully interchangeable and shall comply with IEC motor standard dimensions.
Unless otherwise specified and/or approved, AC motors shall be of the squirrel cage
type, provided with either deep slots or double squirrel cages.

c) The general construction shall be stiff and rigid, no light metal alloy casings will be
accepted. All precautions shall be taken to avoid any type of corrosion and electrical
ionisation effects taking place between different kinds of metals.

d) All motors for fire pump applications shall conform to the requirements specified under
NFPA 20.

e) The motor efficiency classification should be IE2 in accordance with IEC 60034-30.

f) Surface treatment of motor shall correspond to corrosion category C4M specified by

ISO/EN 12944:2, suitable for industrial area with high humidity and aggressive
atmosphere.

g) The power factor for MV motors shall be not less than 0.84 under full load.

h) The installed motor output shall be 1.15 times the required power at the shaft of the
driven pump at its duty point unless specified otherwise.

i) The motor shall be de-rated to the ambient temperature of 50 Deg C.

j) All MV pump set shall be provided with condition monitoring system as specified
elsewhere in contract document.

k) The condition monitoring system offered shall be as per recommendations of the pump
manufacturer and necessary co-ordination with the instrument manufacturer to ensure
compatibility of the system offered and same shall be the responsibility of the
equipment supplier / manufacturer.

l) The make and model no. selected for the vibration monitoring system shall be subject
to approval by DM/Engineer.

18.7.2 Design Considerations

18.7.2.1 Insulation Level

a) MV motors shall be suitable for continuous operation on systems with the neutral at
near earth potential.

b) They shall also be suitable for operation on unearthed systems with one line at earth
potential for infrequent periods of short duration, e.g. as required for normal fault
clearance.
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18.7.2.2 Sound Pressure Level

a) The sound pressure produced by motor operating at rated voltage and frequency at
either no load or full load shall not exceed 82 dB(A) under free field conditions at 1.0 m
from the motor.

b) The sound pressure produced by the combined pump and motor at full load shall not
exceed 85 dB (A) at 1.0 M from the equipment.

18.7.2.3 Bearing Vibration Velocity

a) The effective velocity of vibration measured on the bearing on a horizontal plane

through the shaft centre line of horizontal motors shall be in accordance with IEC
60034-14 but in any case shall not exceed the following:

i. when free suspended, the vibration shall not exceed 1.8 mm/s RMS
ii. when rigid mounted, the vibration shall not exceed 2.8 mm/s RMS
b) The vibrations limits above shall apply to all operating temperatures between ambient
and maximum and all operating load conditions between no-load and full load.

c) For two pole motors, the contribution of the twice the supply frequency i.e. 100 Hz to
the overall vibration shall not exceed 1.4 mm/s RMS.

18.7.2.4 Bearing Vibration Amplitude

a) The unfiltered double amplitude (peak-to-peak) of the shaft vibration including shaft
run-out relative to each bearing shall not exceed the following:

i. 15 um at 50 Hz
ii. 7 um at 100 Hz
b) The vibration limits above shall apply to all operating temperature conditions from
ambient to maximum temperature and all operating load conditions from no-load to full-
load.

18.7.2.5 Duty Type and Starting Duty

a) Unless otherwise specified, motors shall be designed for continuous running duty type
S1, with 3 years continuous operation without stopping the motor for maintenance
purposes.

b) The starting duty of the motors shall be suitable for more than 5000 starts for lifetime
and should not be less than 300 starts per year.

18.7.2.6 Operation with Variable Frequency Drives

a) Motors to be used with frequency converters shall be specially designed to meet all the
stringent requirements of the frequency converters.

b) Motors for use with variable frequency inverter type speed controllers shall be rated for
continuous running over the specified speed range. The motor shall take into account
the increase in heat, vibration and noise from the inverter output, reduced cooling at
lower speeds and effect on bearings lubrication and critical motor speeds.

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18.7.2.7 Starting Conditions

a) Motors shall be suitable for three (3) direct on-line (DOL) starts per hour equally
spaced. Furthermore, they should be suitable for two successive starts per hour with
the motor already at running temperature under the following conditions:

i. Motor terminal voltage : 85% of rated voltage

ii. Load torque : varying with the square of the speed from
zero to rated motor torque
iii. Inertia : 125% of own inertia
iv. Pull out torque : >160% of the rated torque
b) To ensure successful re-acceleration, the motor torque shall be minimum 110% of the
torque required by the driven equipment under load conditions, over the entire rpm-
range and with the motor terminal voltage at 85% of the rated voltage. The
manufacturer shall state the total running-up time from standstill (RT) based on the
above-mentioned conditions.

c) The motor starting current in DOL starting shall not exceed 600% of the full load
current at rated voltage and frequency. The manufacturer shall also give the allowable
running-up time (ART) of the motors offered. ART may be calculated based on the
same conditions as mentioned for the starting requirements above.

d) All motors shall be suitable for restarting against full residual voltage.

18.7.2.8 Running Conditions

a) MV Motors shall be capable of operating continuously under rated output conditions at

any frequency between 48 and 52 Hz and/or with any voltage variation between 90%
and 110% of the nominal voltage. Motors shall be capable of delivering the maximum
torque as required by the driven machine when running at 70% nominal voltage for a
period of 10 seconds without injurious overheating and maintain stable operation limits.

b) The pull-out torque for intermittently loaded motors shall be 200% of the rated torque.

c) After a loss of voltage up to 3 seconds, motors must be capable of reaccelerating their

driven equipment in less than 10 seconds under a voltage of 70%.

18.7.2.9 Critical Speed

Motors with a rigid, sub critical rotor bearing system shall have the first critical speed
not lower than 125% of the rated speed. Motors with a flexible, overcritical rotor
bearing system shall have the first critical speed below 80% of the rated speed and the
second critical speed shall not be lower than 125% of the rated speed.

18.7.3 Construction Requirements

18.7.3.1 General

a) Adequate provisions shall be made to avoid difficulties caused by condensation under

site conditions specified.

b) All motors shall be provided with anti-condensation heaters.

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c) Each motor shall be provided with eye bolts, lugs or extension pieces for hoisting.

d) All motors shall be provided with an earthing bolt of at least 8 mm diameter, tapped into
the frame or an earth stud inside the cable box.

e) When air inlets are protected by a screen, such a screen shall be of corrosion-resistant
material. Galvanised steel mesh wire is not acceptable.

18.7.3.2 Construction and Mounting

a) For general information reference is made to IEC 60034-7.

b) Dimensions of foot-mounted motors and mounting flanges shall be in accordance with

IEC 60072.

18.7.3.3 Enclosures

a) For general information reference is made to IEC 60034-5.

b) The minimum acceptable degree of protection is IP-54 for the motor and auxiliaries, IP-
55 for the terminal boxes.

c) Vertical motors with downwards shaft shall be provided with a canopy covering the air-
inlet of the fan cooling. For vertical motors with upwards shaft the sealing of bearing
housings shall be such that no water can penetrate the motor via the shaft.

d) To determine the type of enclosure appropriate to a possible dangerous atmosphere,

the area in which the motor will be used will be classified to the degree of probability of
the presence of a dangerous atmosphere according to IEC 60079-10.

18.7.3.4 Stator

a) All motors shall have their windings delta-connected unless otherwise stated
elsewhere.

b) Both ends of each phase winding shall be brought out to a terminal of adequate
current-carrying capacity. The connection shall be made in the terminal box by
removable links.

c) Classification of materials for the insulation of motor windings in relation to their thermal
stability in service shall conform to IEC 60085.

d) Temperature rise by resistance at rated load shall not exceed the value as specified in
the IEC publications.

e) The use of magnetic slot wedges is not allowed. When the use of magnetic type slot
wedges is unavoidable they shall be of the iron powder type, fully guaranteed by the
manufacturer and subject to DM/Engineer approval. Laminated or wire type wedges
are not acceptable.

f) The insulation of motors shall be class H, with class B temperature rise for starting and
steady state operation at full load. The insulation shall not contain shellac or asphaltic
components. Insulation shall have high mechanical and electrical strength, Low Loss
factor, impervious to moisture, vermin and chemical substances.

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g) The stator winding shall be suitably braced to withstand the forces due to direct-on-line
starting at 110% nominal voltage and where applicable, occasional transfer from the
nominal supply to an auxiliary supply with 100% residual voltage at the motor
terminals.

h) Inter-phase connections inside the machine shall be made at the non-driving end and
the winding connection and tails shall be non-hygroscopic. Non-hygroscopic materials
shall be used to the maximum extent. Both ends of each phase winding shall be
brought out to terminals of adequate current carrying capacity.

i) The stator winding shall be of sufficient cross-sectional area to withstand the maximum
prospective fault current for the period of time determined by the protective devices.

18.7.3.5 Rotor and Fans

a) The external fan shall be of non-corroding materials or be treated with a corrosion-

resistant coating. Rotor and fans shall be dynamically balanced with the half key in
position at the free shaft end.

b) The rotor winding shall be designed to give trouble free continuous service including
repeated direct-on-line starting. The rotor shall be subjected to a 120% over speed test
in workshop for 2 minutes to show that there is no winding dislocation.

c) When the motor manufacturer has to supply the coupling or when a coupling half is
made available, the balancing has also to be done with this coupling half mounted on
the shaft. If for balancing additional weight is required, this material shall not be of lead
or similar soft material. The fans shall be located by driving keys, or by studs, which are
off pitched so that it is impossible to assemble them incorrectly.

d) The flow of cooling air shall be in the direction of the driving end of the motor to prevent
contaminated warm air from the driven unit being drawn into the cooling system of the
motor.

e) If directional fans are fitted, the direction of rotation for which the motor is designed
shall be permanently indicated by means of an arrow. A painted arrow is not
acceptable.

f) The shafts ends shall be provided with a suitably threaded hole or holes to facilitate the
assembly or removal of coupling and bearing faces.

g) Shaft extension, keys and key ways shall be in accordance with IEC 60072.

18.7.3.6 Motor Ventilation

a) Unless otherwise specified all motors shall be of the totally enclosed fan cooled type,
protection class IP 54 according to IEC recommendation 60034-6 and 60529.

b) Where motors are installed outdoors a weather-proof design shall be chosen. Unless
otherwise specified all motors shall be of the natural air cooled self ventilating type.
Generally the cooling air shall be drawn from the end of the motor that is not connected
to the load.

c) In design calculation for the motor cooling system the site ambient condition shall be
taken as reference and the motor nameplate ratings shall be based on these figures.

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d) Where cooling tubes are used for air-to-air heat exchangers, such tubes shall be made
of stainless steel 316Ti.

e) At least one drilled hole shall be provided at the lowest point of the casing for draining
condensed moisture. Motors shall be equipped with automatically controlled heating
resistors for protection against internal condensation of moisture during standstill
periods. Such AC heater shall suitably be fixed inside the winding covers; the leads
shall be led to a separate LV terminal box. Each MV motor shall be provided with 3
Nos. of double element (one active + one spare) space heaters rated for single phase
230V, 50 Hz AC power supply.

18.7.3.7 Bearing

a) Self lubricating ball and roller bearing with solid races shall be provided for MV motors.

b) The B-10 lifetime for ball and roller bearings of straight coupled motors shall be in
excess of 40,000 hours and shall be calculated in accordance with ISO R281. The
calculation shall take full account of internally generated forces (e.g. magnetic forces)
with the worst aggregate of dimensional tolerances as obtained during manufacture.
When external forces are imposed on the motor shaft and the B-10 lifetime calculation
shall then take this into account. A reduction to 32,000 hours is allowed in this case.

c) The motor shall be suitable for continuous operation for at least 25,000 hours without
stoppage for maintenance.

d) All motors shall be equipped with a type of lubrication which permits greasing while the
motor is running and which prevents over lubrication. Additionally, the bearings shall be
fitted with grease nipples permitting the use of a universal grease gun.

e) Where sleeve bearings are used, they shall be of the self or forced lubricating type. If
forced lubrication is required it shall be arranged common to both the motor and the
driven machine and provisions shall be made to ensure lubrication during start-up and
shut-down operations without the necessity to start an auxiliary lube oil pump. Self-
lubricated bearings shall be equipped with an easily accessible lubrication pot with
overflow pipe and oil collecting vessel.

f) Self lubricated bearing shall be equipped with an easily accessible lubrication pot with
overflow pipe and oil collecting vessel.

g) The sleeves bearing shall be designed such as to permit the immediate formation of an
oil film during the first shaft rotations. These shall likewise be possible after sustained
stand still periods of at least six months.

h) Sleeve bearing shall be designed for easy removal and check without dismantling the
whole bearing. All bearings shall be carefully protected against soil or duct penetration
and oil leakages.

i) Motors shall be fitted with excess grease collecting sumps, which shall be easily
removable and replaceable.

j) In case of independent bearings, motor and bearing pedestals shall be fitted on

common base plate.

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k) For motors equipped with ball or roller bearings, adequate means are to be provided
during stand still periods to prevent the brinelling effect. During transport and shipping
such motors shall receive a special bearing insert.

l) Unless otherwise specified, vertical motors shall be either ball or roller thrust bearings
designed to withstand all thrust forces to support the motor and the driven equipment.
Thrust bearings shall each have sealed lubrication system capable of re-lubrication in
service where ball or roller bearings cannot be used, specially designed bearings (such
as Kingsbury thrust bearing) must be employed.

m) Necessary provision shall be made to prevent damage to bearings by shaft currents, by

insulating the drive and non-drive end bearings and their associated connections, the
insulation at the drive end bearing being bridged by a removal copper strap.

18.7.3.8 Shafts and Couplings

a) Unless otherwise specified the motors shall be provided with a free shaft extension of
cylindrical shape with key and keyway according to IEC recommendation 60072-1.

b) The motor-half-coupling shall be pressed on the motor shaft and shall be balanced
together with it. A coupling guard shall be provided.

18.7.3.9 Terminal Boxes and Earthing

a) The terminal boxes shall be of ample sizes to enable connection to be made in a

satisfactory manner. Cable supports shall be provided with terminal boxes.

b) The terminal boxes with the cables installed shall be suitable for connection to supply
systems having the short-circuit capacity and fault clearance time determined by the
upstream motor protective devices.

c) Terminal boxes shall be sized so that feeder cables can be connected to motor leads
without damage to the cable or the leads.

d) The terminals leads, terminals, terminal boxes and associated equipment shall be
designed to withstand future short-circuit level of 500MVA.

e) Unless otherwise specified or approved, the terminal box shall be positioned on the
right hand side of the motor when viewed from the driving end and shall permit turning
by 90 and 180 degrees.

f) A permanently attached connection diagram shall be mounted inside the terminal box
cover giving the desired direction of rotation. If motors are suitable for only one
direction of rotation this shall be clearly indicated.

g) Terminal boxes shall be robust design and totally enclosed (IP 55) to prevent the
ingress of moisture and dust. All joints shall be flanged with gaskets of neoprene or
similar material. Terminal boxes or parts thereof shall consist either of grey cast iron,
light metal alloy or galvanised steel.

h) Terminal boxes of MV motors shall be of the phase segregated type. Opening of the
terminal box cover shall not expose the internal part of the motor.

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i) Terminal boxes shall be fitted with an approved cable sealing and dividing box and a
pressure relief diaphragm located to direct flames and/or hot gases away from
personnel.

j) The cable sealing box shall be amply sized to fit with the number and kind of cables
used as advised by the contractor. The neutral point ends of MV motor windings shall
be brought out to a second terminal box and shorting with shoring link may be used for
connection of the feeder cable.

k) All winding ends shall be brought out to terminal blocks or stud type insulators.

l) All six terminal of the winding shall be brought out.

m) Space heaters shall be completely wired with leads brought to a terminal box separate
from power and RTD terminal boxes.

n) For earthing purposes each motor shall have two (2) adequately sized bolts with
washers at the lower part of the frame. In addition each terminal box shall likewise
contain one earthing bolt.

o) The resistance of the wire from motor to common earth shall not exceed 0.1 Ohm.

18.7.3.10 Lifting and Installation Dispositions

a) All motors shall be provided with one or more lifting eye-bolts, rings or lugs capable of
supporting the total weight of the motor. If lugs are concealed by enclosure, name-
plates shall be attached to both sides of the motor warning against improper lifting.

b) The equipment to be supplied shall include all accessories necessary to the installation
of the motors (e.g. dowel holes, anchor bolts, etc.).

18.7.3.11 Wiring

All secondary wiring shall be of the heat resistant type silicone rubber insulation
reinforced and protected with metal braid. All wiring for measuring and monitoring is to
be brought to one common terminal box.

18.7.3.12 Rating Plates and Marking

a) Manufacturer’s serial number of the motor shall be die-stamped on a non-removable

part of the frame. This number shall also be shown on the rating plate. The direction of
rotation of motors shall be clearly indicated by means of arrow located on the non-
driving end shield of the motor.

b) The rating plate or plate shall be stainless steel, fixed to a non-removable part of the
frame, and shall be marked with the appropriate items in accordance with IEC 60034-1,
whereby the values given shall be those actually measured.

c) In addition to these items the following information shall be indicated:

i. Type of enclosure in accordance with IEC 60034-5 (IP classification)

ii. Locked rotor torque in % of rated torque
iii. Locked rotor current in % of rated current
iv. Allowable running-up time in seconds (ART)
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v. Bearing type, size, fit, re-greasing period and type of grease

vi. Net weight
vii. Purchase order number

18.8 LV SQUIRREL CAGE INDUCTION MOTOR

18.8.1 General Requirements

d) This specification covers the general requirements for Low Voltage, 3-phase squirrel
cage, induction type motors.

e) All motors shall be from a reputed and approved manufacturer and shall comply with
the requirements of the relevant Contract. They shall be complete with terminal boxes,
cable glands and with heaters and monitoring instruments. Motors of the same type
must be fully interchangeable and shall comply with IEC motor standard dimensions.
Unless otherwise specified and/or approved, AC motors shall be of the squirrel cage
type, provided with either deep slots or double squirrel cages.

f) The general construction shall be stiff and rigid, no light metal alloy casings will be
accepted. All precautions shall be taken to avoid any type of corrosion and electrical
ionisation effects taking place between different kinds of metals.

g) All motors for fire pump applications shall conform to the requirements specified under
NFPA 20.

h) The motor efficiency classification should be IE3 (Premium efficiency) in accordance

with IEC 60034-30.

i) The installed motor output shall have minimum of 1.15 times the required power at the
shaft of the driven pump at its duty point unless specified otherwise.

j) The motor shall be de-rated to the ambient temperature of 55o C.

k) All LV pump set above 200KW shall be provided with condition monitoring system.

l) The condition monitoring system offered shall be as per recommendations of the pump
manufacturer and necessary co-ordination with the instrument manufacturer to ensure
compatibility of the system offered and same shall be the responsibility of the
equipment supplier / manufacturer.

m) The make and model no. selected for the vibration monitoring system shall be subject
to approval by DM/Engineer.

n) Surface treatment of motor shall correspond to corrosion category C4M specified by

ISO/EN 12944:2, suitable for industrial area with high humidity and aggressive
atmosphere.

o) The motor shall have a minimum thermal capability of 10 starts per hour, under normal
start-up condition with a supply voltage during starting of 80% of rated voltage.

p) All motor above frame size 160 shall be supplied with slide rails.

q) All motors above frame size 280 shall be supplied with silencer.

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18.8.2 Design Considerations

18.8.2.1 Noise Level

The noise level produced by motors operating at rated voltage and frequency at either
no load or full load shall be below the established industrial limits and shall meet IEC
publication no. 60034-9.

18.8.2.2 Vibration

The effective velocity of vibration measured on the bearing on a horizontal plane

through the shaft centre line of horizontal motors shall not exceed the values as given
in IEC 60034-14 for the completely assembled motor, running on no-load at rated
voltage and speed.

18.8.2.3 Cooling

a) For general information reference is made to IEC 60034-6.

b) Air-to-air cooling is preferred (TEFC).

c) Where cooling tubes are used for air-to-air heat exchangers, such tubes shall be made
of corrosion-resistant material or treated to render the material corrosion-resistant.

18.8.2.4 Operation with Variable Frequency Drives

a) Motors to be used with frequency converters shall be specially designed to meet all the
stringent requirements of the frequency converters.

b) Motor bearing shall be of insulated type with insulated inner and outer races. Where
directed by engineer for special applications motors shall be provided with hybrid
bearing – bearing with non-conductive ceramic rolling elements.

c) Motors for use with variable frequency inverter type speed controllers shall be rated for
continuous running over the specified speed range. The motor shall take into account
the increase in heat, ventilation, winding insulation, shaft seals, vibration and noise
from the inverter output, reduced cooling at lower speeds and effect on bearings
lubrication and critical motor speeds.

18.8.2.5 Rating and Duty Type

a) Rotating electrical machines rating and performance shall be as per IEC 60034 – part1.

b) Motor shall be selected for continuous running duty (Duty type S1) as stipulated in IEC
60034.

18.8.2.6 Starting Performance

a) Locked rotor, pull-up and breakdown torque shall be in accordance to IEC 60034-12.

b) Locked rotor current shall not exceed the values specified in IEC 60034-12.

18.8.2.7 Starting Conditions

a) Except where a motor is used with a Variable Frequency Drive, motors shall be
suitable for star/delta (or soft starter) or direct on-line starting as specified elsewhere.
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b) The maximum torque of the motor must be at least 30% higher than the load torque
over the whole duty range.

c) The manufacturer shall state on the motor data sheet the total running-up time from
standstill (RT) based on the above-mentioned conditions.

d) The manufacturer shall also give the allowable running-up time (ART) of the motor.
This ART may be calculated based on the same conditions as mentioned for the
starting requirements above.

e) All motors shall be suitable for restarting against full residual voltage.

18.8.3 Construction Requirements

18.8.3.1 General

a) The motor shall be manufactured for horizontal installation.

b) For general information reference is made to IEC 60034-7.

c) Motors for Fire Protection Systems shall be constructed in accordance with relevant
Fire Protection System Standards (NFPA, BS, UL, FM etc.).

18.8.3.2 Enclosures

a) For general information reference is made to IEC 60034-5.

b) The minimum acceptable degree of protection is IP-54 for the motor and auxiliaries, IP-
55 for the terminal boxes.

c) The motor installed in outdoor location shall be of IPW-55, and shall be additionally
provided with effective sunshade.

d) When air inlets are protected by a screen, such a screen shall be of corrosion-resistant
material. Galvanized steel mesh wire is not acceptable.

18.8.3.3 Stator

a) Both ends of each phase winding shall be brought out to a terminal of adequate
current-carrying capacity. The connection shall be made in the terminal box by
removable links.

b) Classification of materials for the insulation of motor windings in relation to their thermal
stability in service shall conform to IEC 60085.Non-hygroscopic materials shall be used
to the maximum extent. Winding insulation shall be thermal class H or better to BS EN
60085 and the maximum temperature shall not exceed that permitted for thermal class
B. The winding shall be provided with over temperature sensors such as thermistor,
bimetal, PT100.

c) Temperature rise by resistance at rated load shall not exceed the value as specified in
the IEC publications.

d) The use of magnetic slot wedges is not allowed. When the use of magnetic type slot
wedges is unavoidable they shall be of the iron powder type, fully guaranteed by the
manufacturer. Laminated or wire type wedges are not acceptable.

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18.8.3.4 Rotor and Fans

a) The external fan shall be of non-corroding materials or be treated with a corrosion-

resistant coating.

b) Rotor and fans shall be dynamically balanced with the half key in position at the free
shaft end.

c) When the motor manufacturer has to supply the coupling or when a coupling half is
made available, the balancing has also to be done with this coupling half mounted on
the shaft.

d) If for balancing additional weight is required, this material shall not be of lead or similar
soft material.

e) The flow of cooling air shall be in the direction of the driving end of the motor to prevent
contaminated warm air from the driven unit being drawn into the cooling system of the
motor.

f) If directional fans are fitted, the direction of rotation for which the motor is designed
shall be permanently indicated by means of an arrow. A painted arrow is not
acceptable.

g) The shafts ends shall be provided with a suitably threaded hole or holes to facilitate the
assembly or removal of coupling and bearing faces.

h) Shaft extension, keys and key ways shall be in accordance with IEC 60072.

18.8.3.5 Anti Condensation Heaters

a) Anti-condensation heaters shall be fitted to all motors with frame number 112 and
above except motors with Type Ex ‘e’ and Type Ex ‘N’ protection for use in hazardous
areas.

b) All motors without heaters shall be fitted with drain holes with removable plugs.

18.8.3.6 Lifting Facilities

Each motor above 25 kg in weight shall be provided with eye bolts, lugs or extension
pieces for hoisting.

18.8.3.7 Terminals

a) Terminal connections shall be constructed in such a way that direct contact between
screws, bolts or nuts and the conductor is avoided.

b) The terminals shall be alphabetically or numerically marked (e.g. U, V, W or 1, 2, 3) in

such a way that if the supply cyclic phase sequence in time corresponds to the
alphabetical or numerical sequence of the terminal markings, then direction of rotation
of the motor shall be clock wise when facing the driving end.

18.8.3.8 Terminal Box

a) A terminal box of sturdy metal construction shall be provided with ample space for
connecting the cable. The enclosure shall be IP 55. In view of the maximum acceptable
voltage drop, large numbers of cables in the same trench and short-circuit rating of the
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system; the prescribed cable size can be larger than considered normal by the
manufacturer.

b) Consequently a larger cable connecting box than manufacturer's standard may be

required.

c) The design shall be such that small items cannot be dropped into the motor frame. The
method of fixing the box and its component parts to the motor frame shall be in
accordance with the type of motor enclosure.

d) Inside the terminal box an earthing bolt of adequate dimensions shall be fitted for
connection of the cable earthing. This bolt is additional to the external equipment
earthing bolt.

e) The terminal box must be adequately weatherproofed with a gasket of suitable non-
sticking re-usable non-hygroscopic material. The use of paint, grease or plastic
compounds for this purpose is not acceptable.

f) Motor’s heaters, thermistors or other temperature detectors or such devices

connections must be brought out to terminal boxes separated from each other and from
the main cable terminal box.

g) The terminal boxes shall be provided with cable sealing end boxes or cable glands
suitable for the cables.

18.8.3.9 Cable Entries

a) All types of cable connections shall allow for removal of the motor without breaking or
stressing the supply cable sealing.

b) It is preferred that the end sleeve or gland assembly, complete with the cable, can be
withdrawn from the box in such a way that the cable termination can be prepared
outside the box.

c) Where a cable entry with sealing chamber is used, the latter shall be of the detachable
type.

18.8.3.10 Bearings

a) In general, motors shall be equipped with two ball bearings, wherever possible grease-
packed and preferably sealed for life. In connection with high radial forces, however,
the application of a combination of ball and roller bearings may be necessary.

b) Ball and roller bearings shall be grease-lubricated.

c) The B-10 lifetime for ball and roller bearings of straight coupled motors shall be in
excess of 40,000 hours and shall be calculated in accordance with ISO R281. The
calculation shall take full account of internally generated forces (e.g. magnetic forces)
with the worst aggregate of dimensional tolerances as obtained during manufacture.

d) The motor shall be suitable for continuous operation for at least 25,000 hours and the
construction of the bearing housing shall be such that re-lubrication, if required, can be
carried out without stopping the motor.

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e) The bearing shall then be designed in such a way that it is impossible to over-grease
the bearing and a suitable "grease relief valve" must be fitted, which makes it possible
to re-lubricate the motor bearings as many times as necessary to arrive at an operating
time of 25,000 hours. The grease relief device or valve must be approved by the
bearing manufacturer.

f) When bearings are used which have to be re-lubricated, a minimum re-lubrication

interval is required of 4,000 hours for horizontal motors, and 2,000 hours for vertical
motors, independent of the actual number of running hours.

g) Motors for use with variable frequency inverter type speed controllers shall be provided
with insulated bearing on the motor side.

18.8.3.11 Protective Systems

a) Submersible motor starters shall have control unit supplied by the manufacturer to
provide protection against moisture, high winding temperature, etc.

b) Motors shall be protection by means of temperature-sensitive thermistors embedded in

the windings.

c) Thermistors shall be of the positive temperature coefficient (PTC) type and be supplied
complete with auxiliary equipment by the motor manufacturer under his full guarantee.

18.8.3.12 Rating Plate

a) Manufacturer's serial number of the motor shall be die-stamped on a non-removable

part of the frame. This number shall also be shown on the rating plate.

b) The rating plate or plates shall be made of a corrosion-resistant metallic material, fixed
to a non-removable part of the frame, and shall be marked with the appropriate items in
accordance with IEC 60034-30, whereby the values given shall be those actually
measured.

c) In addition to these items the following information shall be indicated:

i. The standard specifications to which the motor conforms.

ii. Locked rotor current in percent of rated current.
iii. Locked rotor torque in percent of rated torque.
iv. Allowable running-up time in seconds (ART).
v. Enclosure protection class.
vi. Enclosure protection class (IP).
vii. Frame size (according to IEC 60072).
viii. Bearing type, size, fit, re-greasing period and type of grease.
ix. Net weight.
d) When special features are involved, a separate plate showing the appropriate
instructions shall be fixed to the motor frame, e.g. limited end float.

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18.9 ELECTRIC ACTUATOR – INTEGRAL MOTOR CONTROL

18.9.1 General Requirements

a) The electric actuators for valves, gates and penstocks etc. shall be of a standard, well
tested and proven design which ensures maximum safety to personnel, maximum
service reliability and economic operation. Design and construction shall be simple and
well laid-out and shall provide good accessibility to components and parts.

b) The actuators shall be suitable for use on a nominal 400 V, 3 phase and 50 Hz power
supply and are to incorporate motor integral reversing starter, local control facilities and
terminals for remote control and indication connections housed within a self-contained,
sealed enclosure.

c) The electrical actuator shall be designed as per VDE 0530 / IEC 60034 / EN ISO 5210 /
EN ISO 5211.

d) All electronic boards of electrical actuator shall be conformal coating. Conformal

coatings shall be 1-2 mm. thick polymeric films that cover or encapsulate printed circuit
assemblies and connectors, which shall protect the assemblies from airborne
contaminants and corrosion by sealing out the contaminants and humidity. The
conformal coating shall meets or exceeds the following standards:

i. ANSI/ISA-S71.04-1985, Class G3 environments

ii. IEC 60654-4 Class 1 and 2 environments
iii. UL746E
e) The electrical actuator control/wiring/termination compartment shall be remotely
mounted on an independent support (physically isolated from the valve/motor
assembly) as directed by engineer due to high vibration on the pipeline or machine.

f) In order to maintain the integrity of the enclosure, setting of the torque levels, position
limits and configuration of the indication contacts etc. shall be carried out without the
removal of any actuator covers over an Infra-red interface. Sufficient commissioning
tools shall be provided with the actuators and must meet the enclosure protection and
certification levels of the actuators. Commissioning tools shall not form an integral part
of the actuator and must be removable for secure storage/authorised release. In
addition, provision shall be made for the protection of configured actuator settings by a
means independent of access to the commissioning tool.

g) The actuator shall include a device to ensure that motor runs with the correct rotation
for the required direction of valve travel with either phase sequence of the three phase
power supply connected to the actuator or signal the wrong phase sequence.

h) Except in the case of the supply of an actuator to be retrofitted to an existing valve, all
electric actuators shall be supplied as an integral part of the valve or penstock to be
controlled, complete and fully tested before shipment.

i) The actuator shall be sized to guarantee valve closure at the specified differential
pressure. The safety margin of motor power available for seating and unseating the
valve shall be sufficient to ensure torque switch trip at maximum valve torque with the
supply voltage 10% below nominal. The operating speed shall be such to give valve
closing and opening at approximately 10 - 12 inches per minute unless otherwise
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stated. Actuator opening and closing rates shall be set so as not to impose
unacceptable surge pressures on pipe-work.

j) The electric actuator shall be capable of functioning in the specified climatic conditions.

k) Actuators for hazardous area applications shall meet the area classification, gas group
and surface temperature requirements specified elsewhere.

l) Actuator designed for potentially explosive atmospheres shall be qualified by a test

authority ATEX 94/9/EC or NEC (approval by FM) or the CEC (approval by CSA).

m) Actuator installed outdoor shall be provided with an effective stainless steel sunshade.

n) Actuator shall be provided with adjacent local isolator switch (which can be padlocked
in off position) to make sure that the actuator circuit can be completely de-energised for
service or maintenance purposes.

o) Painting and coating shall be suitable for corrosive/humid environment to

Manufacturer's standard finish.

p) Each actuator must be performance tested and individual test certificates shall be
supplied free of charge.

18.9.2 Construction Requirements

18.9.2.1 Motor

a) The motor shall be totally enclosed non-ventilated type, 3 phase squirrel cage, Class H
insulated with a class B temperature.

b) For short-time duty type, the motor shall be of S2-30 at 50°C or thrice the valve
stroking time, whichever is longer, at an average load of at least 33% of maximum
torque required by the valve.

c) For intermittent duty type, the motor shall be of S4 and the running time for modulating
actuators should be at least 25 %. The mechanics and motor have to be designed as to
be able to withstand the high number of starts without any deterioration in control
accuracy.

d) Electrical and mechanical disconnection of the motor should be possible without

draining the lubricant from the actuator gear case.

e) Following protection shall be provided for the motor.

i. Motor shall be de-energized in the event of a stall when attempting to unseat a

jammed valve;
ii. Motor temperature shall be sensed by a thermostat to protect against
overheating;
iii. Single phasing and incorrect phase sequence protection.
iv. Phase rotation correction

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18.9.2.2 Gearing

a) The actuator gearing shall be totally enclosed in an oil or grease-filled gear case
suitable for operation at any angle. All gearing must be of metal construction. The drive
shall incorporate a lost-motion hammer-blow feature. The output shaft shall be hollow
to accept a rising stem, and incorporate thrust bearing of the ball or roller type at the
base of the actuator. The design shall be such as to permit the gear case to be opened
for inspection or disassembled without releasing the stem thrust or taking the valve out
of service. Partial turn actuator’s drive gear shall be self-locking to prevent the valve
back-driving the actuator.

b) The gear case shall be provided with provision for installing polycarbonate cover for
rising stem and its supporting system. The polycarbonate cover shall be calibrated for
penstocks fully closed/open positions. The length of the stem shall be sufficient to
adequately protrude through gear assembly even in fully closed position.

18.9.2.3 Hand Wheel

a) A hand wheel shall be provided for emergency operation, engaged when the motor is
declutched by a lever or similar means, the drive being restored to power automatically
by starting the motor. The hand wheel or selection lever shall not move on restoration
of motor drive. Provision shall be made for the hand/auto selection lever to be locked in
both hand and auto positions. It should be possible to select hand operation while the
actuator is running or start the actuator motor while the hand/auto selection lever is
locked in hand without damage to the drive train.

b) Clockwise operation of the hand wheel shall give closing movement of the valve unless
otherwise stated in the data sheet. For linear valve types the actuator hand wheel drive
must be mechanically independent of the motor drive and should be such as to permit
valve operation in a reasonable time with a manual force not exceeding 400N through
stroke and 800N for seating/unseating of the valve.

18.9.2.4 Drive Bushing

a) The actuator shall be furnished with a drive bushing easily detachable for machining to
suit the valve stem or gear box input shaft.

b) The drive bush shall be positioned in the detachable base of the actuator to facilitate
the use of standard length valve system. Thrust bearing, when housed in separate
thrust base, should have sealed for life type.

18.9.2.5 Torque and Turns Limitation

c) Torque switches shall be provided for the mechanical disengagement of the valve at its
extremes of operation in the event of excess torque. The torque settings shall be set at
commissioning to suit the operating criteria of the valve and actuator.

d) Torque and turns limitation to be adjustable as follows:

i. Position setting range – multi-turn: 2.5 to 100,000 turns, with resolution to 15

deg. of actuator output.
ii. Position setting range – direct drive part turn actuators: 90 +/-10, with
resolution to 0.1 deg. of actuator output.

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iii. Torque setting: 40% to 100% rated torque.

e) Measurement of torque shall be from direct measurement of force at the output of the
actuator.

f) A means for automatic “torque switch bypass” to inhibit torque off during valve
unseating and “latching” to prevent torque switch hammer under maintained or
repeated control signals shall be provided.

18.9.2.6 Remote Position Indication

a) Four contacts shall be provided which can be selected to indicate any position of the
valve, with each contact selectable as normally-open or normally-closed. The contacts
shall be rated at 5A, 230V AC, 30 V DC.

b) As an alternative to providing valve position any of the four above contacts shall be
selectable to signal one of the following:

i. Fully open;
ii. Fully close;
iii. Travelling in motion;
iv. Actuator fault;
v. Remote control available
c) Contact-fewer transmitters shall be provided to give 4-20mA analogue signal
corresponding to valve travel and position for remote indication.

18.9.2.7 Local Indication

a) The actuator shall include a position indicator with a display from fully open to fully
close. Red, green and yellow lights corresponding to OPEN, CLOSED and
INTERMEDIATE/ FAULT positions shall be included on the actuator.

b) Red, green, and yellow lights corresponding to open, closed, and intermediate valve
positions shall be included on the actuator display when power is switched on. The
digital display shall be maintained and updated during hand wheel operation when all
power to the actuator is isolated.

c) The digital display shall be capable of indicating real time torque and valve position
simultaneously, both being displayed in 1% increments of valve position and actuator
rated torque. In addition torque shall also be displayed in horizontal bar graph form.

18.9.2.8 Integral Starter and Transformer

a) The reversing contactor starter, control transformer and local control shall be built into
the valve actuator and suitably housed to prevent breathing and condensation build-up.
The starter shall be suitable for 60 starts per hour, and must comprise mechanically
and electrically interlocking reversing contactors rated according to the motor size, with
coils fed from a control transformer with a suitable rating.

b) The common connection of the contactor coils shall be grounded at the transformer so
that the contactors may drop out in the event of a leakage to ground. The primary
winding shall be separated from the secondary winding by a grounded screen.

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c) The control transformer shall have taping as

i. 230 AC contactor coils.

ii. 24V DC output for remote controls
iii. Supply for all the internal electrical circuits.
d) Primary and secondary windings shall be protected by easily replaceable cartridge type
fuses.

18.9.2.9 Integral Pushbuttons and Selector

a) Integral to the actuator shall be local control for OPEN, CLOSE and STOP, and a
Local/Remote selector switch pad lockable in any one of the following three positions:

b) Local control only, off (no electrical operation) remote control plus local stop only. It
shall be possible to select maintained or non-maintained local control.

c) The local control shall be arranged so that the direction of valve travel can be reversed
without the necessity of stopping the actuator.

18.9.2.10 Control Facilities

a) The necessary wiring and terminals shall be provided in the actuator for the following
control functions:

b) Removable links for substitution by internal interlocks to inhibit valve opening/closing.

c) Connections for external remote controls fed from an internal 24V DC supply to be
suitable for any one or more of the following methods of control:

i. Open, Close and Stop.

ii. Open and Close.
iii. Two-wire control, energize to close (or open), de-energize to open (or close).
d) Selection of maintained or push-to-run control for modes (i) and (ii) above shall be
provided and it shall be possible to reverse valve travel without the necessity of
stopping the actuator. The starter contactors shall be protected from excessive current
surges during travel reversal.

e) The internal circuits associated with the remote control and monitoring functions are to
be designed to withstand simulated lightning impulses of up to 2kV.

f) Provision shall be made for operation by distributed control system utilising the
following network systems.

i. Modbus
ii. Profibus
iii. Foundation Fieldbus
iv. DeviceNet
18.9.2.11 Monitoring facilities

a) Facilities shall be provided for monitoring actuator operation and availability.

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b) Monitor (availability) relay, having one change-over contact, the relay being energized
from the control transformer will de-energise under any one or more the following
conditions:

i. Loss of main or customer 24V DC power supply

ii. Actuator control selected to local or stop
iii. Motor thermostat tripped
iv. Actuator internal fault
c) Actuator text display indication of the following status/alarms:

i. Closed Limit, open limit, moving open, moving closed, stopped

ii. Torque trip closing, torque trip opening, stalled
iii. ESD active, interlock active
iv. Thermostat trip, phase lost, 24V supply lost, Local control failure
v. Configuration error, Position sensor failure, Torque sensor failure
vi. Battery low, power loss inhibit
d) Integral data-logger to record and store the following operational data:

i. Opening last /average torque against position

ii. Closing last /average torque against position
iii. Opening motor starts against position
iv. Closing motor starts against position
v. Total open/closed operations
vi. Maximum recorded opening and closing torque values
vii. Event recorder logging operational conditions (valve, control and actuator)

e) The data-logger shall record relevant time and date information for stored data.

f) Data-logger data is to be accessed via non-intrusive IrDA communication. Sufficient

standard intrinsically safe tools shall be provided for downloading data-logger and
actuator configuration files from the actuators and subsequent uploading to a PC. The
actuator manufacturer shall supply PC software to enable data-logger files to be
viewed and analysed.

18.9.2.12 Wiring and Terminals

a) Internal wiring shall be of tropical grade PVC insulated stranded cable of appropriate
size for the control and 3-phase power. Each wire shall be clearly identified at each
end.

b) The terminals shall be embedded in a terminal block of high tracking-resistance

compound, or the use of multi pin plug and socket.

c) The terminal compartment shall be separated from the inner electrical components of
the actuator by means of a watertight seal.
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d) The terminal compartment of the actuator shall be provided with a minimum of 3

threaded cable entries which shall be delivered fitted with blanking plugs for protection.

e) All wiring supplied as part of the actuator to be contained within the main enclosure for
physical and environmental protection. External conduit connections between
components are not acceptable.

f) A durable terminal identification card showing plan of terminals shall be provided

attached to the inside of the terminal box cover indicating:

i. Serial number
ii. External voltage values
iii. Wiring diagram number
iv. Terminal layout
18.9.2.13 Enclosure

a) Enclosure of the actuator shall be O-ring sealed, watertight to IP 68 fully protecting the
motor and all the other internal electrical elements of the actuator from ingress of water
and dust.

b) The Actuator assembly enclosure and local control station shall be rated to IP68
designed to be fully submerged up to 7 meters for at least 72 hours if the installation is
done below ground level or in underground chamber.

c) The actuators assemble installed in Electrical apparatus for potentially explosive

atmospheres (hazardous areas) shall be and tested in accordance with the Standard
IEC 60079 and certificates of conformity, certificates of assurance and certificates of
component approval shall be provided.

d) An effective stainless steel sun shade shall be provided for the actuator installed
outdoors.

e) Enclosure of the actuator must allow for temporary site storage without the need for
electrical supply connection.

f) All external fasteners shall be stainless steel.

18.9.2.14 Nameplate

a) The nameplate shall be of corrosion resistant material fixed to a non-removable part of

the motor actuator. Nameplate shall give the following information:

i. Manufacturers name
ii. Serial number and year of manufacture
iii. Rated ambient temperature
iv. Rated power
v. Rated voltage, phase, frequency
vi. Rated full load current
vii. Insulation class

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viii. Rated starting current

ix. Enclosure class and protection

18.9.2.15 Start-Up Kit

Each actuator shall be supplied with a start-up kit comprising installation instructions,
electrical diagram and sufficient spare cover screws and seals to allow for any site
losses during the commissioning period.

18.10 DIESEL GENERATOR

18.10.1 General Requirements

a) This specifications covers the general requirements for the design, manufacture,
delivery and testing of prime rated diesel engine driven generators for automatic mains
standby applications.

b) While it is not intended to give the full details of design and construction of generators,
this specification sets the minimum acceptable requirements.

c) If there are conflicts between this specification, data sheet and project specification and
international standards specified in this document, then the more stringent
requirements shall prevail.

d) It is required that the equipment manufacturer shall have an authorized dealer in Dubai,
UAE equipped fully with service and spare parts facilities, and competent manpower for
testing, commissioning and maintenance.

e) The generator prime rating shall be provided that will be the kVA rating for continuous
running at variable load for unlimited periods with 10% overload available for 1 hour in
any 12 hour period.

f) The specified prime power rating shall be available after de-rating for maximum
ambient temperature of 55oC.

g) The Diesel Generator system shall be composed but not limited to the following
components:

i. Diesel Generator engine driven generator

ii. Day and Bulk fuel (double skinned) storage system in line with NFPA 37
iii. Fire suppression system for bulk fuel system
iv. Jettison tank system for day tanks
v. Diesel Engine Starting system
vi. Local circuit breaker panel
vii. Neutral Grounding Resistor (NGR) panel
viii. Acoustic treatment of building
ix. Air intake and Exhaust (generator building) system
x. System Control Panel

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xi. Fire suppression system as per civil defence / NFPA 30 and NFPA 37
requirements etc.

18.10.2 Codes and Standards

18.10.2.1 IEC Standards

a) Unless specified otherwise, the Diesel generator set shall conform in design,
construction, material and performance to the latest following editions of the IEC codes
and standards.

IEC 60204 Electrical equipment of industrial machines

IEC 60034 Rotating electrical machines
IEC 60034-1 Part 1: Rating and performance
IEC 60034-2 Part 2: Methods for determining losses and efficiency of
rotating electrical machinery from tests
IEC 60034-5 Part 5: Degree of protection by enclosure for rotating
machinery
IEC 60034-6 Part 6: Methods of cooling rotating machinery
IEC 60034-7 Part 7: Symbols for types of construction and mounting
arrangements of rotating electrical machinery
IEC 60034-8 Part 8: Terminal marking and direction of rotation of rotating
machines
IEC 60034-9 Part 9: Noise limits
IEC 60034-11 Part 11: Built-in thermal protection
IEC 60034-22 Part 22: AC generators for reciprocating internal combustion
engine driven generating sets
IEC 60050 International Electrotechnical Vocabulary chapter 411
IEC 60072-1 Dimensions and output ratings for rotating electrical machines
– Frame numbers 56 to 400 and flange numbers FF 55 to FF
1080 and FT 55 to FT 1080
IEC 60072-2 Dimensions and output ratings for foot mounted electrical
machines with frame numbers 355 to 1000
IEC 60038 IEC Standard Voltages.
IEC 60044 Instrument Transformers.
IEC 60060 High Voltage Test Techniques
IEC 60071 Insulation co-ordination.
IEC 60076 Power Transformers
IEC 60099 Surge Arrestors.
IEC 60255 Electrical relays
IEC 60439 Low voltage switchgear and control gear assemblies

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IEC 60529 Classification of degrees of protection provided by enclosures

IEC 60715 Dimensions of low voltage switchgear and control gear
IEC 60934 Circuit breakers for equipment
IEC 60934 Low voltage switchgear and control gear
IEC 60085 Thermal evaluation and classification of electrical insulation

18.10.2.2 Other standards

a) Reciprocating internal combustion engines BS 5514 or VDE.

b) Reciprocating Internal Combustion Engines - Fire Protection ISO 6826

c) Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets

– all relevant ISO 8528

18.10.2.3 Local standards

Further to international standards, the complete equipment shall also conform to the
Civil Defence standards and/or regulations of the DEWA, if these are higher, more
stringent or of special nature.

18.10.3 Design Considerations

18.10.3.1 General

a) The engine, radiator, alternator and auxiliary components shall be mounted on a

common base frame. The starting battery shall be supplied loose for positioning
adjacent to the starter motor.

b) The complete unit shall be designed for free standing operation on a flat level surface
(isolated foundation) and shall be supplied with anti-vibration mountings.

c) The isolated foundation shall be provided for generator set to reduce both active and
passive vibrations. Further, vibration isolation mountings are required to reduce the
transmission of vibration and shocks

d) The base frame shall be of fully welded construction of rolled steel section or folded
steel plate designed to provide a sturdy support to complete assembly and fitted with
lifting points to aid handling.

e) All exposed moving parts such as fans, couplings, drive belts, etc. shall be guarded in
accordance with relevant standards.

f) Oil drip trays, with drainage facility, shall be provided below the engine to prevent floor
contamination.

g) Engine should be accessible otherwise a permanent maintenance and access platform

shall be provided.

18.10.3.2 Diesel Engine

Type:
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a) The engine shall be air or water-cooled, single block design, four stroke cycle
compression ignition diesel. Two stroke engines are not acceptable. Diesel engines
requiring premium fuels will not be accepted. The engines shall be suitable for the
locally available distillate fuels. The engine type shall have been in commercial
operation for a period of not less than 1 year.

b) The engine shall be of the 4 stroke, water cooled direct injection compression ignition
type with an in-line or vee cylinder configuration. The engine may be naturally aspirated
or turbo-charged. The nominal speed shall not exceed 1500rpm.

c) The engine shall be rated in accordance with IEC 60034-1 (prime rated) and shall be
capable of continuous operation at rated output plus a 10% overload for 1 hour in any
12 consecutive hours running. All chain and gear drives shall be located in oil-tight
cases and shall be pressure lubricated.

d) The diesel engine and alternator rating shall be sized for the load characteristics. The
sizing of the generator shall take account of all of the following types of loads:

i. Continuous running of all motors; starting of the largest motor with all other
motors running on full load;
ii. Non-linear loads (VSD, UPS, rectifiers, discharge & fluorescent lighting, switch-
mode power supplies etc.)
iii. Large linear loads (heating, boilers)
iv. Loads requiring stability voltage, frequency and waveform within specified
tolerances to ensure correct operation
e) Torsional vibrations of the complete rotating system shall be within the limits specified
in Lloyds Register of Shipping Rules and Regulations over a range minus 5 percent to
plus 10 percent of the rated speed.

f) The engine shall accept full rated load within a maximum of 20 seconds from initiation
of the starting sequence when starting from cold at the minimum specified ambient air
temperature. The initial step load shall be not less than 40 percent of the full load
value.

g) Instruments as follows shall be provided:

i. Lubricating oil pressure gauge.

ii. Lubricating oil temperature gauge.
iii. Cooling water temperature gauge.
iv. Tachometer.
v. Battery charge ammeters for electric start engines.
vi. Engine stop pushbutton.
vii. Day tank and bulk tank volumetric measuring system
viii. Other instruments as considered necessary by the engine manufacturer.

h) Devices shall be fitted and arranged to stop the engine under the following conditions: -

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i. Oil pressure low.

ii. Oil temperature high.
iii. Coolant temperature high.
iv. Over speed.
v. Fuel low.
Governing

a) Engine governing shall be of the electronic type having a droop characteristic

adjustable over the range 0 to 5%. The governor shall be Type 1 to BS 5514 and shall
be Accuracy Class A1 or better. The maximum transient speed change shall not
exceed 5 percent with the maximum step load application. Provision shall be made for
remote adjustment.

Cooling System

a) An engine-mounted, heavy duty, closed circuit, tropicalized folded core radiator with
blower type fan shall be sized to maintain safe operation at 55oC maximum ambient
temperature.

b) Radiator shall be sized for 110% of the engine full load rating and continuous loading at
maximum ambient temperature.

c) The radiators shall be mounted on the generating set base frame the fan shall be
driven by vee belts from the engine crankshaft. Where specified for larger capacity
generator remote radiator shall be provided.

d) All exposed hot or moving parts and in particular, fans, belt drives, couplings and
flywheels, shall be guarded in accordance with BS 5304 and to ensure safe operation.

e) To permit the adjustment and inspection of drives, apertures with secured cover plates
shall be provided in the guards at appropriate points.

f) Engine mounted radiators shall be provide with a flange for the fitting of flexible
ducting.

g) Engine driven pump(s) shall circulate the jacket water and lubricating oil if appropriate
through the radiator sections. The coolant shall be circulated by an engine driven pump
having a pressure gauge on the outlet pipework.

h) A thermostatically controlled diverter or by-pass valve shall be fitted in the engine

cooling water discharge pipe work, with a return to the circulating pump suction, to
maintain the circulating water at the optimum temperature irrespective of load. A dial
type indicator showing the coolant temperature at the hottest point of the cooling
system shall be provided.

i) The cooling system shall be provided with plugged valves as necessary to enable all
parts to be drained.

j) The flexible connecting section between radiator and fixed, (silencer) exhaust louvers
and intake louvers (actuated, intake fans, silencer, sand filter and sand trap) shall be
sized and located to provide sufficient intake air for engine combustion and to provide
required air flow through the radiator.
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k) The generator room ventilation system shall be provided to dissipate the radiated heat
from generator building. The ventilation system for generator room shall be complete
with a sound attenuation system, electrically operated fans and motorised louvers with
manual override facility, which will open automatically 5 seconds prior to engine start-
up and close automatically 30 seconds after the engine shut down to protect the unit
from dust. The inlet and outlet opening shall be provided with multi-plate flap air shutter
which shall be driven by servo motors and shall be provided with weather protective
coating. It shall be not possible to start the engine if the inlet louvers are not opened
and the engine in operation shall shut-down in the event of closing the inlet louver
manually or due to any fault. Gravity type louvers not acceptable.

l) Generator room ventilation opening shall be provided with silencers comprising non-
inflammable, water repellent and abrasion resistant baffles, damping to a free-field
overall sound pressure level of maximum 85 dB(A) at 1 m distance from generator
room. Air filter system shall be provided for particles ≥ 10 μm. The air filter media class
shall be of G3 to standard EN 779, with approximately 85% average synthetic dust
weight arrestance for the air inlet opening of the generator room. Safety switch for high
back pressure supervision shall be provided.

Engine air intake system

a) Engines shall be suitable for uninterrupted running on specified prime power rating (in
accordance with ISO8528, ISO3046) over a prolonged period, the following features:

i. Extra heavy duty “Desert” centrifugal type air filter with pre-cleaner alarm.
ii. Dry air cleaner with changeable filter element.
iii. Service indicator to optimize changing of filter.
Engine exhaust System

a) Engines shall be provided with a complete exhaust system comprising rigid and flexible
pipe-work, stainless steel bellows, silencer(s) and all necessary brackets, hangers, wall
sleeves and plates and sundries for a complete installation. Pipe wall thickness shall
not be less than 3mm.

b) Silencers shall be of the residential type.

c) The first section of exhaust from the engine manifold shall include a flexible bellows
unit. The next section of pipe shall be supported to allow movement without imposing
forces on the manifold.

d) Exhaust support brackets shall be designed to allow for pipe expansion and contraction
movement.

e) Bends in the exhaust pipe-work shall be kept to a minimum and shall be of the long
radius type.

f) Where the exhaust pipe passes through a wall, a wall sleeve and plates shall be fitted.
The annular space between the pipe and sleeve shall not be less than 25mm. The
space between the pipe and sleeve shall be filled with heat resistant material.

g) Exhaust terminations shall not be located in close proximity to air inlet grills or opening
windows were exhaust gas can re-circulate into the building. The exhaust outlet shall
be arranged to prevent the ingress of water.
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h) For long exhaust runs, a water drain point or condensation trap shall be fitted near to
the engine.

i) Exhaust pipe inside rooms/enclosures shall be lagged with heat resistant material and
shall be provided with aluminium cladding so as to have a surface temperature not
exceeding 60°C.

j) The lagging shall be clad with aluminium sheet secured by stainless steel band clips.

k) Exhaust pipe shall be sized so that it is sufficient to ensure that exhaust back pressure
does not exceed the maximum limit as specified by the generator set VENDOR.

Fuel System

a) Microprocessor based fuel injector should be provided. The electronic fuel injector shall
provide high pressure fuel injection at all engine speeds, electronically controlled
injection timing and variable injection intensity during one injection.

b) Inlet and outlet fuel connections to engine should be through suitable flexible lines. An
engine mounted Dual in-line fuel filters, fuel pressure gauge and engine fuel priming
pump shall be provided.

Lubrication system

a) The lubrication shall be forced feed type equipped with a gear driven lube oil pump with
a coarse strainer on the suction side. A full flow filter of nominal micron rating not
greater than 10 and having a pressure operated by-pass valve shall be provided on the
delivery side. Manual lubrication of any part of the engine shall not be accepted. The
lubrication system shall not require priming prior to starting the engine.

b) The engine lubricating oil dipstick shall be easily accessible and minimum and
maximum levels shall be clearly marked.

c) The engine sump shall have an easily accessible drain point or drainpipe, fitted with a
BSP plug.

d) The filters should be easily replaceable. Heat exchangers for oil cooling should be
engine mounted. Lubricating oil filters shall be Dual in-line type.

Starting system

a) The starting battery shall be of the nickel-cadmium or lead acid type installed on a non-
corrodible tray or stands and shall have a terminal cover of insulating material. The
battery shall have sufficient capacity for three consecutive start attempts each of 10
seconds duration. In addition, the battery shall have sufficient capacity after the three
start attempts to supply the maximum demand of the control panel for a minimum
period of 24 hours.

b) The battery charger shall employ transistor controlled magnetic amplifier circuits to
provide continuous taper charging and shall maintain rated output voltage within +/- 1%
from no-load to full load with boost/float control. It should be rated at minimum 8 Amps
and be short-circuit proof to withstand the starting inrush current.

c) In the "Float" charge mode the charger shall automatically maintain the battery in a fully
charged condition whilst supplying standing loads. In the "Boost" charge mode, the
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charger shall be capable of fully charging the battery from a fully discharged condition
in a period not exceeding 6 hours.

d) The charging characteristics for the nickel-cadmium vented type battery shall minimize
electrolyte gassing.

e) The charger shall be complete with:

i. Incoming supply On/Off switch.

ii. Supply On indication.
iii. Output voltmeter.
iv. Output ammeter.
v. Float/Boost Charge selector switch.
vi. Charger Failed relay with voltage free changeover set of contacts wired to
terminals.
vii. Charger Failed indication.

f) The minimum requirement for the "Charger Failed" alarm shall be the detection of a.c.
supply and d.c. output failure. The relay shall not operate under a transient a.c. supply
failure condition.

g) An engine shut down solenoid shall be fitted, this shall be of the "energised to run type"
for operation from the engine control system battery. An emergency stop push button
shall be provided. Emergency air shut off flaps shall be incorporated at air intake to the
engine (at inlet of the charge air cooler). The shut–off flap shall be actuated manually
on pushing the emergency button or automatically in the event of governor failure. The
flap on closing interrupts the air feed to the cylinders and shuts down the engine. After
emergency shutdown, the flaps can only be re-opened manually for resuming the
operation. The shut-off flap shall have necessary limit switches to energise suitable
optical or acoustic alarms.

h) Stopping shall be attained by interrupting the shutdown solenoid circuit and this shall
also cancel any outstanding repeat start attempts.

18.10.3.3 Alternating Current Generators (Alternators)

General

a) Generators shall be brushless, single bearing salient pole, revolving field self-regulating
alternators of fabricated steel construction throughout, and shall comply fully with IEC
60034.

b) They shall have a dynamically balanced rotating field, salient pole construction with
heavy damper windings. The machine shall have an exciter and liberally rated silicon
diodes assembly with a self-contained excitation system with automatic voltage
regulator (AVR). It shall be screen protected and drip proof with a large terminal box
suitable for the outgoing cabling.

c) Automatic voltage regulators shall be of the solid state three-phase sensing type with
in-built protection against sustained over excitation. The voltage regulation shall be not
less than Grade VR2.21 to BS 4999: Part 140.
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d) With the application of the maximum step applicable in the electrical system design at
any power factor between 0.2 and 0.8 lagging, the initial voltage shall not drop below
85 percent of the nominal value recovering to 94 percent within 1.5 seconds.

e) The generators shall be star connected.

f) The generators shall be capable of maintaining their continuous maximum rated output
when operating within ±5% rated voltage and at rated power factor.

g) The output waveform shall be sinusoidal, with THD less than 5%, and shall be entirely
suitable for operation of electronic equipment with a high percentage third harmonic
current of up to 80% of total current.

h) All windings shall be tropicalized and suitably impregnated to withstand the site
ambient conditions.

Stator

a) The stator core shall consist of high permeability, low loss steel stamping, tightly
clamped and securely located within the machine casing.

b) The windings shall consist of electrolytic copper conductors insulated throughout with
class 'H' materials.

c) The windings shall be effectively braced to withstand the maximum forces arising from
any short circuit that may occur at the stator windings terminals. Any material that is
liable to shrink in service shall not be used for bracing, packing or wedging. The
ventilating circuit shall be designed to avoid hot-spots and to permit adequate cleaning
by a portable centrifugal blower.

d) Both ends of each stator windings shall be brought out to terminal positions on the
stator casing, the phase and terminal box being arranged for 3-phase and neutral
connection.

Rotor

a) The rotor shaft and hub shall be of forged steel preferably in one piece. The rotor poles
shall be constructed of steel laminations, keyed and securely fixed to the rotor hub and
fitted with interconnected damper windings to absorb the cyclic irregularity of engine.

b) The field winding shall consist of electrolytic copper conductors insulated throughout
with class 'H' materials. Rotor should be precision wet layer wound to ensure complete
encapsulation of rotor winding resulting in excellent environmental protection and
protection against centrifugal forces. Rotor should withstand 124% over speed.

Excitation system

a) The main exciter output shall be fed to their main rotor windings through a 3 phase, full
wave bridge rectifier. The diode bridge shall be protected against surge and voltage
transients caused, for example, by short-circuit or out of phase paralleling by a surge
arrestor. The automatic voltage regulator shall have following minimum features:

i. Three phase sensing for optimum voltage control with unbalanced three phase
loads.

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ii. Volts-per-hertz regulation for optimum block load voltage and frequency
recovery.
iii. Steady state voltage accuracy better than 0.5 % for precise control and quick
recovery.
iv. Voltage regulation, 1% from no load to full load (maximum).
v. External gain adjustment for constant voltage output across the operating range.
vi. No moving parts should be there. All solid-state design for better reliability.
vii. Voltage adjustment range - 20% to 10%.
viii. Built in under voltage and under frequency protection for voltage regulator and
generator.
ix. Paralleling capability.
x. Telephone Interference Factor (TIF) less than 50.
xi. EMI/RFI suppressions to commercial standards.

Waveform Distortion

a) The total harmonic distortion (THD) of the open circuit voltage wave-form shall be in
the order of 1%. Under three phase balanced linear conditions the (THD) shall be of
the order of 3%.

b) The output winding shall be 5/6-pitch design to optimize 3rd, 5th and 7th harmonics on
the voltage wave-form.

18.10.3.4 Remote Mounted Control Panel

a) Control panel shall be of a highly reliable design with protection against short circuit,
reverse battery polarity and overvoltage transient surges.

b) The generator shall have an electronic modular free standing control panel with solid-
state microprocessor based modules for engine control, AC metering and adequate
environment protection.

c) The panel should be equipped with self-diagnostic capability to help trouble shooting
for ease of maintenance.

d) Panel should have one engine control module to display engine operating information,
system checking diagnostics, and fault shutdown using 18 inch HMI display. The HMI
display shall have sequential display of operating hours, engine rpm, battery volts, oil
pressure and jacket water temperature. Any of these values shall be displayed by
means of a selector switch the controls shall be designed to provide the following
facilities:

i. Automatic starting and stopping of the engine.

ii. Manual starting and stopping of the engine.
iii. Simulated mains failure for testing the automatic starting and stopping of the
engine.

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e) Subject to the approval of the DM/Engineer, the facilities specified below may be
modified to suit the manufacturer's standard control unit conditional on compliance with
the overall operating concept.

f) Control equipment shall be installed in a composite generator control panel which shall
be floor mounted in control room.

g) Indicating instruments shall be provided as follows:

i. Phase ammeters or ammeter with phase selector switch.

ii. Voltmeter with phase selector switch.
iii. Wattmeter.
iv. Frequency meter.
h) Control switches shall be provided as follows:

i. Hand/Auto/Off.
ii. Auto Return On/Off.
iii. Key operated Simulate Mains Failure/Off.
iv. Engine heater(s) supply On/Off.
v. Generator anti-condensation heater supply On/Off.
vi. Push-buttons shall be provided as follows:-
vii. Engine Start/Stop.
viii. Engine Emergency Stop.
i) Hand regulating controls shall be provided as follows:

i. Engine speed.
ii. Generator voltage.
iii. Indicator lights shall be provided as follows:-
iv. Main supply available.
v. Standby supply available.
vi. Alarm annunciation shall be provided as follows:-
vii. Engine failed to start.
viii. Engine high cooling water temperature.
ix. Engine low lubricating oil pressure.
x. Engine over speed.
xi. Engine under speed.
xii. Generator voltage high.
xiii. Generator voltage low.
xiv. Generator circuit-breaker auto trip.
xv. Fire detection system operated.

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xvi. Emergency stop operated.

xvii. Battery charger failed.
xviii. Bulk fuel tank overflow/leakage
xix. Daily service tank overflow/leakage.
xx. Daily service tank overflow/leakage.
xxi. Fuel transfer pump fault.

j) The control system shall initiate the automatic generating set start-up and shut-down
sequences as described below. The controls shall be designed to operate on an
"energise to run" and de-energise to stop" basis.

k) With the engine control selection switch in the AUTO position, the control system shall
operate as follows:

i. On loss of main supply and after a preset adjustable time delay of 0-10
seconds, engine starting shall be initiated via a mains failure relay located in the
incomer unit of the associate switchboard. Concurrent with the starting of the
engine the inlet and outlet electrically operated air louvers shall be opened and
air intake fans shall be operated.
l) The engine cranking sequence shall comprise a maximum of three 10 second periods.
The control system shall provide facilities for adjusting both the number and duration of
the cranking sequence.

m) When the generating set reaches full speed and voltage, and after a preset adjustable
time delay of 0-5 seconds, a voltage-free relay contact shall close to initiate the closing
of the associated standby supply incomer breaker.

n) Should the main supply be restored before the closing of the standby supply incomer
breaker, the closing of the main supply incomer breaker shall be initiated and after
receiving a “normal mains supply incomer closed” signal and after a preset adjustable
time delay of 0-5 minutes the engine shall be shut-down.

o) On restoration of the main supply with the AUTO RETURN control switch in the ON
position and after a preset adjustable time delay of 0-5 minutes, opening of the standby
supply incomer breaker, closing of the main supply incomer breaker and engine
shutdown shall be automatically initiated. The shutdown procedure shall be in
accordance with the engine manufacturer's standard practice.

p) On restoration of the main supply with the AUTO RETURN control switch in the OFF
position the generating set shall continue to supply the load. The automatic shut-down
sequence shall be initiated by returning the switch to the ON position.

q) The facility shall permit the testing of the generating set automatic start-up sequence
under a simulated main supply failure condition. With the test facility switch in the
SIMULATE MAINS FAILURE position the automatic start-up sequence shall be
initiated. The engine shall be stopped by returning the switch to the OFF position.

r) The engine shall automatically stop and lock-out under the following conditions:-

i. Engine failed to start.

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ii. Engine high cooling water temperature.

iii. Engine low lubricating oil pressure.
iv. Engine over speed.
v. Engine under speed.
vi. Generator voltage high.
vii. Generator voltage low.
viii. Generator circuit breaker auto trip.
ix. Fire detection system operated.
x. Emergency stop operated.
xi. Daily service tank low level.

s) Alarm and lock-out systems shall be inhibited during normal starting and stopping
operations.

t) Restarting of the engine shall be prevented until the alarm has been reset.

u) The emergency stop shall operate in all control modes.

v) Voltage-free changeover contacts shall be provided for remote indications as follows:

i. Common group alarm for Generating Set Failed comprising each of the single
alarms causing engine lock-out.
ii. Generating set running.
iii. Generating set available for automatic mains failure operation.
w) The contacts shall be wired to a marshalling box.

x) Provision shall be made for the connection of an external emergency stop push-button
or switch. The associated terminals shall be fitted with a link.

y) A fire detection system shall be installed above the generating set. The system shall
comprise fusible links and tensioned operating wires and a Fire Push located adjacent
to each door entry to the Generator Room.

z) Link fusing or Fire Push operation shall initiate the operation of the engine fuel supply
fire valve, daily service tank jettison fire valve and switches for initiating engine lock-
out, remote alarm and fuel transfer pump stop.

18.10.3.5 Fuel Systems

a) The fuel system shall comprise an engine driven feed pumps with duplex filters, daily
service tank with supporting structure and bund, bulk fuel tanks and bund, fuel transfer
pumps and all interconnecting pipework including flexible engine connection pipe.

b) Daily service tanks shall be fitted with the following:

i. High, intermediate and low levels float switches for the control of a fuel oil
transfer pump and/or alarm initiation.

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ii. A jettison connection fitted with fire valve. The connection shall be sized to
drain the contents of the tank in a period not exceeding 5 minutes.
iii. The bulk fuel tanks shall be provided with foam fire suppression system as a
minimum requirement.
c) The Local Authority and Fire Service shall be consulted, regarding the sitting of tanks
holding large quantities of fuel.

d) The capacity of daily service tanks shall be sufficient for eight hours full load operation
of the generating set. The Day Tank shall sit within a bund.

e) Galvanised steel shall not be used for any part of the fuel system.

f) Bulk Fuel Tank(s) shall have a capacity sufficient for 3 days continuous running on full
load.

g) Bulk tank(s) shall be located at a lower level than the Day tank in order to permit
overflows from the Day tank to gravitate back to the Bulk Tank.

h) The Contractor shall provide adequate permanent access for fuel delivery vehicles.

i) Bulk tank(s) located under-ground. The under-ground containment for the bulk fuel tank
shall be suitably skirted to prevent ingress of rainwater. A level switch shall be installed
in the containment and be wired to a spillage alarm in the Engine Control Panel to
indicate leakage in the tank. Additional contacts shall be wired to terminals in the
Engine Control Panel for output to telemetry.

j) Bulk tanks shall be constructed in line with all relevant BS standards.

k) Tanks shall be suitably treated and coated. The interior shall be coated with oil at the
manufacturer’s works, to prevent corrosion occurring before being placed in service.

l) The Bulk fuel tank shall be fitted with a man way cover and shall have the following
facilities:

i. Filler connection.
ii. Fuel draw off connection, (piped to base of tank with foot valve for buried tanks).
iii. Tank Breather connection.
iv. Day tank overflow connection.
v. Fuel contents gauge, with output for remote indication.
vi. Pump up gauge.
vii. Overfill Alarm.
viii. Digital fuel capacity gauge, calibrated in litre

m) All fuel transfer pumps, for both day-tank and bulk-tank, shall have proper dry run
protection and pump control shall be with necessary float regulators suitable for fixing
inside fuel tanks and compliant to international safety regulations for identical
application.

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n) A lockable outdoor Filling Cabinet, of stainless steel construction with a drip tray of not
less than 5 litre capacity, shall be provided. The fill pipe, overfill alarm, and a pump up
gauge, shall be housed within the enclosure.

o) Fuel transfer pumps shall be self-priming rotary-vane design and shall be provided as
duty/standby configuration. The pump shall be suitable for the duty taking into
consideration the location of the bulk tank(s). The pumps shall be located so as to
permit repair or replacement without removing other equipment. Diesel pump induction
motor shall be certified as ATEX/Ex Cat. EEx d IIB T3 and shall be suitable to be
installed within an ATEX Zone 1 area. If the system is not a flooded suction type (i.e.
where the Bulk Tank is below ground) then facilities shall be provided to prime the
pumps.

p) All fuel pipe-work shall be manufactured from mild steel and shall be a pipe within a
pipe. The inner pipe carrying the fuel. The outer pipe being provided to carry the fuel
back to the Bulk Tank bund in the event of the inner pipe fracturing. A detector shall be
provided in the outer pipe of the return pipe-work, nearest the Bulk Tank, to initiate an
alarm in the event of the inner pipe leaking.

q) The pipe-work shall have a continual fall from the Day tank back to the Bulk tank. All
joints, in both the inner and outer pipe-work shall be welded. All pipe-work shall be
treated, externally to resist corrosion.

r) Pipe-work above ground and external to buildings shall be trace heated, and lagged, to
prevent waxing. Pipe-work laid in the ground shall be half lap covered in a non-woven
synthetic fibre fabric impregnated and coated with a neutral compound based on
saturated petroleum hydrocarbons and inert siliceous fillers.

s) The following pipe-work shall be provided:

i. Filler pipe-work from the Outdoor Filler Cabinet to the Bulk Tank.
ii. Suction pipe-work from the Bulk tank to the pump.
iii. Delivery pipe-work from the pump to the Day Tank.
iv. Overflow pipe-work from the Day Tank to the Bulk Tank.
v. Overflow pipe-work from the Day Tank Bund to the Bulk Tank.
vi. Engine feed and return pipes.
vii. Bulk tank and Day tank breather pipes.
viii. Day tanks shall be of welded steel construction.
t) The Day Tank shall be fitted with:

i. Semi rotary manual pump complete with filler pipe-work and isolating valve to
prevent run back or overflowing of fuel oil.
ii. Drain / draw off with pipe-work and valve.
iii. Breather.
iv. Inspection Plate.
v. Digital fuel capacity gauge, calibrated in litre, with Stop/start contacts for pump
control, High/High and Low/Low alarm contacts wired to the Engine Control
Panel for output to Telemetry.
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vi. Fire Shut Off valve with contacts wired to the Engine Control Panel for output to
telemetry.
vii. Overflow to the bulk tank.
viii. Tee off connection with valve and hose connection on tank inlet to permit the
pumping through of dirty fuel prior to the first filling of the Day Tank.
ix. The bund shall be provided with:
x. Overflow to the Bulk Tank Bund
xi. Level switch wired to a spillage alarm in the Engine Control Panel.

18.11 DIRECT CURRENT SUPPLY SYSTEM

18.11.1 General Requirements

a) This specification covers the design, manufacture, testing at works and supply of a
Direct Current Supply System complete with Distribution Section and Battery Discharge
Test Set.

b) The purpose of the unit is to supply a DC-Voltage to the specified essential services 24
hours a day, 365 days a year.

c) All rectifiers shall be subject to a load-duration test performed at rated voltage for a
period of not less than 48 hours prior to the execution of functional tests.

d) A battery discharge test shall be performed at the rated current of the DC supply unit
and the final battery voltage, after the specified time, shall be recorded.

18.11.2 Design Considerations

18.11.2.1 General

a) The design of the Direct Current Supply System shall be based on achieving the
following minimum lifetimes.

i. 20 years for the rectifier and auxiliaries;

ii. 15 years for nickel cadmium battery cells.
b) Electrolyte type capacitors shall maintain their capacity within the tolerances for at least
10 years.

18.11.2.2 Safety and Reliability

a) The equipment shall be of a standard, well set and proven design which ensures
maximum safety to Personnel, maximum service reliability.

b) Design and construction shall be simple and provide good accessibility to components
and parts.

c) All equipment and parts shall be of modern design and of the highest industrial grade,
free from all defects.

d) Capacitors of the electrolyte type shall be non-toxic.

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18.11.2.3 System Variations

The input voltage of the Direct Current Supply System, with transformer/rectifiers
disconnected, will be sinusoidal according to IEC 60146. The input voltage shall be
400V AC, 3 phase, 50 Hz, from a mains supply with system variations not exceeding
the following values:

Static ± 10 %
Dynamic + 16 % ; -20 %
Spikes 2 kV
Frequency ±5%
18.11.2.4 Arrangements

a) The DC Supply System shall be of the parallel redundant type and comprise of the
following items:

i. Two constant voltage, current-limiting rectifier

ii. Two battery banks (nickel cadmium)
iii. Auxiliary equipment
iv. Distribution section as integral part of the charger cubicle.
v. Battery Discharge Test Set.

b) The system shall have 2 x 100% charger 2 x 50% capacity battery.

c) The output of the rectifier shall either rapid (boost) charge the battery along with the
load or float charge the battery and simultaneously supply the power requirements of
the load. In the event of failure of the AC mains supply to the rectifier, the battery shall,
without interruption, immediately take over and supply the power requirements of the
load.

d) Each battery charger unit shall be suitable for operation in parallel with unsynchronized
supplies.

e) Interlocks between battery/battery chargers combination and the DC distribution board

shall be provided to prevent boost charging voltages from appearing on the dc
distribution system. The interlocks shall ensure the followings:

i. Only one battery charger can be selected to boost charge at any one time.
ii. Bus bars shall be interconnected prior to boost charging commencing
iii. Boost voltage shall not be applied to the dc distribution bus bar and system

18.11.3 Construction and Electrical Requirements

18.11.3.1 Accessibility and Enclosure

a) The unit shall have a complete metal enclosure of thickness at least 2 mm and shall be
self-supporting, suitable for floor mounting. The protection class of the unit shall be at
least IP42.

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b) The enclosure shall be free standing sheet steel cabinets suitable for indoor operation.
The enclosure shall be arranged for front operation and maintenance.

c) Removable side (end) panels shall be provided. Rear access shall not be required.
Adequate ventilation shall be provided. The redundant equipment shall be in separate
cubicles to allow maintenance without interruption of supply.

d) Access hinged doors shall be lockable from a common key.

e) The design shall include measures to avoid condensation.

f) Battery enclosure shall be provided with vent fan and ducting system up to outside of
battery room.

g) Adequate means shall be provided to ensure the safe removal of fuses. Fuses can only
be removed under no-load conditions. The fuses must be visible and easily removable
when the compartment doors are open.

18.11.3.2 Secondary Cables and Wiring

a) Auxiliary circuits shall be clearly grouped and be protected. All wires shall be at least
1.5 mm² of the PVC type and be able to withstand 2500 V impulse test. All wires shall
be connected to terminals individually and clearly identified at both ends by ferrules of
isolating material or plastic code markers in accordance with the wiring diagram(s).

b) Colour coding of secondary wiring shall be in accordance with IEC 60446. Wiring
between two terminals shall be continuous; joints or interconnections are not allowed.

c) To accommodate and support the secondary wiring, covered plastic channels,

insulated tubes or plastic strips shall be used.

d) Secondary wiring shall never be mounted direct to metal. The filling factor for channels
shall not exceed 70%. Where supporting of a wire is not feasible the wire or part of it
shall be as short as possible.

e) Terminal blocks shall be conveniently located for external connection. Terminal blocks
will be clearly marked for wiring. A wire label at both ends will identify each internal
interconnecting wire. Terminal blocks to be Klippon or equivalent.

f) For all wires and conductors individual terminals shall be provided unless terminals are
specially made for more than one conductor.

g) All circuits shall be protected by miniature circuit-breakers of the air-break type or

cartridge-type fuses.

h) Individual wires or cables, which may reasonably be expected to require disconnection

for the purpose of component testing or replacement, shall be identified at both ends by
means of ferrules of insulating material (slip-on-clips), marked in accordance with the
related wiring diagram.

i) Terminals shall be of non-loosening construction and of the wedge type, constructed in

such a way that direct contact between screw, bolt or nut and conductor is avoided.

j) Stranded conductors shall be provided with cable lugs for terminal connection.

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k) Terminals carrying different voltages shall be logically grouped and separated. Barrier
plates shall be provided.

l) Furthermore sufficient spare terminals shall be provided for future purposes with a
minimum of 20 % of the installed terminals.

18.11.3.3 Anti-condensation heaters

a) Enclosures shall be equipped with anti-condensation heaters of sufficient capacity to

prevent the formation of condensation within the enclosure under the service conditions
and suitable for operation at 230 VAC.

b) Thermostat controlled anti-condensation heaters shall be installed at the bottom of

each cubicle and shall be individually protected by miniature circuit breakers.

c) The main anti-condensation bus feeder breaker shall be provided with alarm contacts.

18.11.3.4 Marking

a) Unit shall be provided with name/rating plate of corrosion resistant material fixed to a
non-removable part. At least the following information shall be indelible marked in
English and Arabic language:

i. Year of manufacture;
ii. Name of manufacturer;
iii. Type and serial number of the unit;
iv. Nominal input voltage and current;
v. Nominal output current and voltage;
vi. IP class
vii. Type of battery/electrolyte
viii. Number of cells
ix. Ah capacity
x. Phase or pole marking of AC and DC supply terminals
b) Labels shall be colourless transparent plastic materials not less than 3 mm thick with
bevelled edges to half the thickness. Each shall be reverse engraved in Arabic and
English the engraving being filled white and the reverse side painted blue unless
otherwise detailed.

18.11.3.5 Battery Cells and Containers

a) The battery shall be of the nickel cadmium sealed type.

b) Battery cells shall be assembled in flame retardant, heat resistant, shock-absorbing

plastic containers with covers attached to form a permanent leak-proof seal. Covers
shall be sealed against creepage of electrolyte and shall be fitted with spray-proof vent
plugs.

c) Containers shall be marked on front side of each container.

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d) Batteries shall be mounting in forced ventilated sheet steel enclosure. The enclosure
shall be made of electrolyte resistant material, designed to provide easy access to
each battery cell for maintenance or testing purpose.

e) Two polarities shall be insulated from earth.

f) Supplementary cells shall not be used as means of dc voltage control.

g) The battery shall be furnished complete with insulated inter-cell, inter-row and inter-tier
connections and hardware.

h) The battery connection to the DC distribution section shall be through an isolating

switch located in the section.

i) To disconnect the battery at the source, a circuit breaker with shunt trip, rated for full
battery capacity, shall be installed at the battery cabinet.

j) The terminals shall be capable of carrying the battery current as well as withstanding
the effects of a short circuit that might occur at the battery.

k) The top tier of cells shall not be more than 1.5 meter above floor.

l) Vendor shall consider ageing factor and temperature correction factor based on
specified site condition while sizing the batteries.

18.11.3.6 Switching Devices

Switching (mechanical) shall be of the independent manually operated air-break type

for continuous duty. They shall as a minimum comply with utilisation category AC 23 for
use on the AC side and DC 23 for the use on the DC side in accordance with IEC
60947-3.

18.11.3.7 Earthing

a) A copper main earth bar shall be fitted along the whole width of the cubicle. This bar
shall be bonded to the enclosure of the unit. Within the cubicle an earthing bolt shall be
mounted M10.

b) A high resistance shall be connected between Positive and Negative poles of the
system and the center point of the resistance shall be earthed through an earth fault
relay, designed to indicate whether the earth fault exists on the Positive or Negative
pole of the system. The Value of resistance connected across the Poles shall be such
that in the event of a fault on either Pole the earth fault current does not exceed 10mA.

18.11.3.8 Finish

a) All structural work shall be adequately protected against corrosion. Painted structural
work shall be at least comprised:

i. One coat of primer;

ii. Two coats of oil-resistant finishing paint.
iii. Colour of finishing paint (subject to DM/Engineer approval)

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18.11.3.9 Materials

a) The fuses shall be of the D-type and/or Hadkin knife-in type in accordance with IEC
60269-2. Fuse holders for quick acting fuses shall be marked "special thyristor fuse.

b) All Printed circuit cards shall be of plug-in-type, interlocked to prevent insertion in a

wrong slot. Each card shall have LED indication to indicate healthiness of the card.

c) All PCBs shall have test points which shall be easily identifiable and accessible for
testing. All printed circuit board shall be fully coated against corrosion confirming to
ANSI/ISA-S71.04 for class G3 Environment.

d) All power wiring shall be carried out with stranded insulated copper conductors
adequately sized for the required duty. Gland plate shall be of nonmagnetic material.

18.11.3.10 DC Distribution Section

a) A separate section shall be provided for DC distribution system. Facilities shall be

provided for automatic disconnection of distribution before end of battery discharge.
Manual reclose facilities shall also be provided.

b) The distribution shall be unearthed and an earth fault detector relay shall be installed to
provide local and remote alarms. Protection shall be based upon detection of a low
frequency AC current circulation between DC network and earth. A front panel
mounted indicator shall permanently indicate the value of network insulation
impedance

c) The DC distribution section shall be rated on the basis of voltage and current ratings of
the charger.

d) Current-carrying components shall furthermore be capable of carrying their rated

current continuously at rated voltage and under specified service conditions without
exceeding the permissible temperature limits.

e) The MCBs shall be of two pole construction and shall be provided for the outgoing
feeders. Operating mechanism shall be quick make, quick break and trip free type. The
MCB's shall be provided with the following features:

i. Instantaneous tripping on short circuit.

ii. Common trip bar for simultaneous tripping of both poles.
iii. Mechanical position indicator.
iv. Auxiliary NO/NC contacts for remote indication of tripping.

18.11.4 Performance Requirements

18.11.4.1 General

a) The rated output of the rectifier shall be based on standard duty class 1 of IEC 60146.
The unit shall be suitable for continuous duty, operating under service conditions.

b) Battery chargers shall be fully automatic, silicon controlled rectifier type. Under normal
operating conditions both battery chargers will operate in parallel. In case of the failure

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of one charger, the second will individually ensure the system duty. During switching
from one charger to another, the DC supply shall be uninterrupted.

c) In case of failure of incoming voltage or failure of both chargers, the battery will
continue to supply the load for 5 hour duration.

18.11.4.2 Battery Float-Charge Operation

a) The rated output current of the rectifier shall be the current corresponding to the
maximum load in KVA divided by the nominal DC system voltage, plus the current
required for the charging of battery from end cell voltage in 8 hours.

b) The rectifier steady-state DC output voltage variations shall be controlled to within plus
1% and minus 1% of the set value. This corresponds to the battery float-charge voltage
during load variations between zero and the rated output current of the DC supply unit
and during steady-state input voltage and frequency variations referred to in.

c) During transient input voltage depressions up to 20% of nominal voltage, the rectifier
DC output voltage variations shall be controlled to a value that will at least prevent the
initiation of battery discharge.

d) Facilities for on-line adjustment of the set value of float-charge voltage shall be
provided. A suitable potentiometer shall be provided on panel front for this purpose.

e) The DC output current of the rectifier, when operating under constant current limiting
conditions, shall be controlled within plus 2% and minus 2% of the set value.

f) The rms value of the voltage ripple, with the battery connected, shall not exceed 3% of
the nominal DC system voltage.

18.11.4.3 Battery Rapid-Charge Operation

a) The "rapid"-charge cycle shall be according to a constant current/constant voltage

characteristic.

b) The duration of the "rapid"-charge operation shall be automatic and after the elapsed
time, will re-instate the rectifier output voltage to that corresponding to continuous float-
charge operation.

c) When operating under constant current-limiting conditions, the DC output current of the
rectifier shall be controlled to within plus 2% and minus 2% of the set value.

d) When operating under constant output voltage conditions, the voltage shall be
controlled to within plus 1% and minus 1% of the set value.

e) The applied set value of the rapid-charge voltage and the duration for which it is
applied to the battery shall restore the battery to 100% of its nominal ampere hour
capacity within 8-hour period.

f) Facilities shall be provided for on-line adjustment of the set of final voltage applied to
the battery, by a potentiometer provided at the front of the panel.

18.11.4.4 Battery Discharge Test

A switch shall be provided to isolate each battery bank whilst the charger and other
battery bank continue to supply the load to carryout battery bank discharge test. An
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auxiliary contact shall be provided for local and remote indication of “battery isolated”
condition.

18.11.4.5 DC Supply Unit Output Voltage

The voltage at the output terminals of the DC supply unit shall be limited to within plus
10% and minus 10% of the nominal DC system.

18.11.4.6 Audible Noise Limitation

a) If not otherwise specified, the sound pressure level (ref 20 microPa) measured at one
meter distance from the equipment at any position, shall not exceed 70 dB(A) at any
load between zero and rated output of the unit. If tonal components are present, the
noise limit shall be taken 5 dB (A) more stringent.

b) If the above values are unobtainable without the use of absorptive materials,
precautions shall be taken to limit their effect on cooling, dust deposits and fire
hazards, with minimal use of materials.

18.11.4.7 Radio Frequency Noise Limitation

The protection of radio frequency interference voltage shall not exceed the value of
suspension grade "N" as stated in VDE 0875.

18.11.5 Auxiliary Equipment

18.11.5.1 Indications and Alarms

a) The following indication equipment shall be provided on the cabinet door

i. AC "mains supply failure"

ii. Rectifier "charge failure"
iii. Rectifier "high DC float voltage".
iv. Alarm contact to main alarm system.
v. Rectifier "Low DC float voltage"
vi. Charger on boost
vii. Charger on Float
viii. Earth Fault
ix. Over temperature (shut down)
x. Overload
xi. Reverse polarity (tripping)
b) Indications shall be provided with in-built test facilities. Alarm indications shall have
manual reset facilities. They shall have a built-in memory to retain indication upon total
supply failure.

18.11.5.2 Measurements

a) The following measuring instruments shall be provided on the front of the panel of the
unit.
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i. DC voltmeter measuring rectifier output voltage (with selection switch to

measure position to Negative, Positive to earth and Negative to earth Voltage).
ii. DC ammeter, with zero at mid-scale, measuring battery current
iii. DC ammeter measuring rectifier output current.
iv. AC Voltmeter measuring input voltage.
v. AC Ammeter measuring input current.
vi. Voltmeter for battery voltage.
vii. Percentage load indicator
b) The accuracy of the instruments shall be not less than that corresponding to class 1.5
of IEC 60051.

18.11.5.3 Protection and Control

a) The following protective and control equipment shall be provided as a minimum

requirement:

i. Rectifier AC mains contactor with on/off control circuit switch and fuses
ii. Rectifier AC mains supply monitoring assembly
iii. Manually operated float-charge/rapid-charge selector switch mechanically
interlocked with the DC supply unit
iv. Output isolation switch
v. Manually operated DC supply unit output isolation switch
vi. Adjustable rapid-charge time control relay
vii. Rectifier DC output circuit fuses
viii. Battery circuit fuses.
ix. Auto/manual selector switch
x. Float/boost
xi. Input side filter to reduce harmonics on the mains side
xii. Potentiometer to set float and boost voltages in 'Auto' mode( * )
xiii. Potentiometer to vary float and boost voltage in 'Manual' mode( * )
* Range to be determined by VENDOR based on Battery requirements.
b) The AC mains supply monitor shall operate to open the rectifier AC mains supply
contactor in the event of AC supply voltage dips or supply unbalance that would if
impair the performance of the DC supply unit, and shall automatically re-close the
contactor on restoration of AC supply voltage.

c) Rectifier output and battery circuit fuses shall be in accordance with IEC publication
60269-2. The rating of rectifier output and battery circuit fuses shall be coordinated
such that the battery supply to the load is maintained in the event of rectifier bridge
short circuits.

d) The rectifier shall have the necessary equipment to ensure soft/slow starting upon
connection of the mains supply, to limit the in-rush current from the mains supply.
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e) The DC supply unit shall incorporate necessary protection to protect the unit and its
components from excess current under all operating conditions.

18.11.5.4 Battery Discharge Test Set

a) An automatic, unattended battery discharge test set shall be provided for performing
discharge test on standby batteries. The unit shall be microprocessor controlled solid-
state electronic load bank based together with a non-volatile data-logging voltmeter.
The discharge current shall be continually monitored and the load bank automatically
adjusted so as to maintain the discharge current constant.

b) The charging state of the battery shall be checked by means of measuring method of
the voltage during discharge. The unit shall be design with MOSFET technology at 20
KHz and shall be Pulse Width Modulated type. High frequency electronic control shall
be incorporated to smooth the DC current drawn from the battery without ripple.
Discharging time shall be adjustable for partial discharging. LCD display shall be
provided for operator interface.

c) The unit shall be supplied with parallel interface for PC / printer port and shall have RS
232 interface for communication with plant control system. All required software and a
rugged, field deployable notebook PC shall be provided with the unit for operation and
diagnostic purpose.

d) Battery load unit shall be added as an integral part of the system with selection facility
to discharge the battery bank at a constant current rate (C5 rating) and shall be
mounted in a separate compartment with sufficient ventilation arrangement, indication
for battery on float, on load and discharge mode to be provided.

18.12 UPS SYSTEM

18.12.1 General Requirements

a) This specification gives the minimum technical requirements for an AC Uninterrupted

Power Supply unit (AC-UPS). The purpose of the unit is to supply uninterrupted
400V/230V, 3phase with a constant frequency of 50 Hz to a specified load 24 hours a
day for 365 days a year. Battery backup shall be for 4 hours.

b) The basic AC-UPS system shall be composed but not limited to the following
components:

i. Rectifier/charger (dual)
ii. Battery banks;
iii. Inverter (dual, Parallel redundant)
iv. Static bypass switch.
v. Manual bypass switch
vi. Distribution section
c) Internal cooling of the unit shall be by natural or forced air ventilation. The unit shall be
capable of continuously delivering its rated output with any ventilation fan out of order
while the maximum temperature of the components shall not be exceeded.

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d) The unit shall not incorporate cooling air filters that require periodic cleaning and/or
replacement.

e) When air inlets and outlets are protected by a screen, such a screen shall be of
corrosion resistant material.

f) The converters shall be loaded to its rated output, at 0.8 power factor lagging,
throughout a 48 hours test period. If an appropriated load is not available, the test shall
be carried out with a resistive load such the DC input current of the inverter is of the
rated value.

g) All functional tests shall be performed on the converters. The manufacturer test
protocol will be acceptable. The correct functioning of all measuring instruments,
alarms and indications, protections and (manual) controls shall be verified.

18.12.2 Design Considerations

18.12.2.1 General

a) The design of the AC-UPS System shall be based on achieving the following minimum
lifetimes.

i. 20 years for the rectifier and auxiliaries;

ii. 15 years for nickel cadmium battery cells.
b) Electrolyte type capacitors shall maintain their capacity within the tolerances for at least
10 years.

18.12.2.2 Safety and Reliability

a) The equipment shall be of a standard, well set and proven design which ensures
maximum safety to Personnel, maximum service reliability and economic operation for
an operational lifetime of at least 20 years.

b) Design and construction shall be simple and provide good accessibility to components
and parts.

c) All equipment and parts shall be brand new and unused, of current manufacturers, of
modern design and of the highest industrial grade, free from all defects that might
affect the performance of the unit.

d) Electrolyte type capacitors shall be of non-toxic and free from any PCB's.

18.12.2.3 System Variations

The input voltage of the AC-UPS, with rectifier disconnected, will be sinusoidal
according to IEC 60146. The input voltage is 400 Volt, 3phase, 50 Hz, which will not
exceed the following values:

Static ± 10 %
Dynamic + 16 % ; -20 %
Spikes 2 kV
Frequency ±5%
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18.12.2.4 Arrangements

a) The equipment shall comprise but not limited to the following items:

i. 1 feeder selector switch

ii. 2 constant voltage, current limiting rectifiers
iii. 2 battery banks
iv. 2 inverters
v. 1 static bypass switch
vi. 1 manual bypass switch
vii. 2 transformers.
viii. Distribution section as part of the charger cubicle.
ix. Auxiliary equipment
x. Microprocessor for overall operation and control

b) The AC UPS System shall have 2 x 150% charger, 2 x 150% capacity battery and 2 x
150% inverter.

18.12.2.5 Rectifier

a) The output of the rectifier shall supply the power requirement of the load via the
inverter and at the same time maintaining the battery in the float-mode.

b) If there is an AC-supply failure the battery will take over the power requirement of the
load via the inverter for not less than the specified time.

c) If the AC-supply is restored, the rectifier will then recharge the battery and at the same
time supply the power requirement of the load. The rate of recharging the battery shall
be sufficient to restore it to a capacity that is capable to fulfil the power requirement of
the load in case again an AC-supply failure may occur. The recharging has to take
place within 6 hours.

d) The inverter converts the input DC voltage into an AC output voltage. The output
voltage to the requirements is 400 V, 3phase, 50 Hz.

e) The dynamic output voltage variations shall not exceed ± 10 % of the rated output
voltage in case of an instantaneous load variation of 100 %. The steady state output
voltage variation shall not exceed ± 5 % of the rated output voltage in case of a load
variation of 100 %, the steady state output voltage shall be restored within 0.1 sec.

f) The waveform of the output voltage shall be sinusoidal according to IEC 60146 with a
relative harmonic content not exceeding 5% under linear load conditions and 10%
under non-linear load conditions.

g) The angular displacement of the 3