SPECIFICATIONS – TECHNICAL PROVISIONS

PART B: POWER AND FIBER OPTIC CABLES

TP-1 GENERAL

This part of the Technical Specifications shall cover the local survey, design,
manufacture, factory testing, packing, delivery, transportation, laying and
installation, interfacing with the existing system, site testing, commissioning and
final acceptance of:

- Single-core high voltage XLPE cables and their accessories.

- All civil works related to installation of cables.

Including all works as described under "Scope of Supply" and shall be handed
over in good operational condition.

TP-2 DESIGN

The following shall form the basis for each Bidder to optimize his Bid with
regard to local facts, meteorological conditions manners and customs, and also to
the prevailing technical realities.

Climatic conditions are extraordinary; in coastal areas the atmosphere is

saliferous, humid and highly corrosive. Humidity is high and due to this
particular attention shall be paid to the severe corrosive conditions. Site
conditions and meteorological data is defined in Clause SP-03 of Volume-I,
however, on average, rainfall is light, although sudden, extremely heavy rainfall
(monsoon) does occur.

Some cable circuits shall run partly in ducts and shall partly be buried directly in
the ground. Some shall be laid in naturally ventilated concrete trenches designed
and constructed specially for this purpose. The relative soil temperature
conditions to be taken into consideration for Bid purposes only are:

- soil thermal resistivity (g) approximately 200 K-cm/W

- maximum ground temperature 35° C
- minimum ground temperature 5° C
- site level above sea level approximately 20 m
- maximum air temperature inside 55° C
concrete trenches

All these figures are to be assumed only for calculation purposes and for
filling-in the Specific Works Data.

Furthermore, the equipment offered must be suitable in all respects for operation
within the Employer's high voltage systems.

TP-91
The characteristics of these systems are:

- operation voltage/highest system voltage 132/145kV

- Low Voltage 380/220 V AC
- frequency 50 Hz
- system earthing 220 kV effective (solidly)

The Technical Specifications are intended to give the frame of the equipment
required. It is understood that the work includes everything requisite and/or
necessary to finish the entire work properly, and the equipment has to be
complete in every respect, notwithstanding the fact that every item may not be
specifically mentioned.

The routes for the cables, as well as the positions of the cable junction points,
have not yet all been exactly decided upon. Consequently, all particulars relating
to lengths shall be understood as preliminary only.

The binding delivery quantities shall, in the event of an award of a Contract, be

determined by the Employer and the Contractor. They shall be delivered
accordingly, and prices shall be adjusted accordingly.

The Employer will neither furnish manpower assistance for transportation,

laying or construction, nor equipment assistance or other material.

All incidental costs shall be included in the Bid Price. Should further
clarification of the local conditions be necessary for preparation of the Bid, then
this shall be the responsibility of the Bidder.

All cables and their accessories shall be designed in accordance with the latest
issue of IEC Publication as mentioned in Clause TP-3.1 & TP-3.2, or equivalent
standards. Complete sets of authorized English translations of all relevant
standards according to which the cable and accessories are manufactured shall be
attached to the Bid.

All cables and their accessories to be offered shall have insulation levels able to
withstand any voltage surge, due to switching operations, sudden load variations,
faults, etc., which is normally expected to occur in the power system in which
the cable is to be included.

The cables and their accessories shall be constructed to fulfil the requirements
when operating with full load or at any load factor. Special reference shall be
made to the climatic conditions as described in Clause SP-3. Contractors are
requested to submit:

- Calculation results of the continuous current rating (as indicated in the

Bid) of the proposed cables and their accessories.

- Calculation results of zero sequence impedance and positive sequence

impedance of the power cables.

TP-92
 - Report of on site measurements of the actual zero sequence impedance
and positive sequence impedance of the power cable.

- Report of on site measurements of the actual soil thermal resistivity and

prevailing ground temperature along the route before cable laying.

- Report of density, grain size distribution, cement/sand ratio and thermal

characteristics of proposed bedding material for power cables.

- Report of on site measurements of the actual soil thermal resistivity of

the backfilling material after cable laying.

- The correction factor of permissible transmission capacity applied for the

site conditions as a result of the chosen bedding and backfilling material
of the power cables and including all pipe crossings.

- Report on permissible overload current of the power cables, starting

from 50, 75 and 100% of the above mentioned continuous permissible
transmission capacity of 1, 2, 3, 4 and 5 hours.

- Curves showing the variation of the permissible transmission capacity

against:

a) The axial separation of the cables.

b) Soil thermal resistivity of surrounding material.
c) Depth of burial.

- Calculation of induced voltages in alarm cables installed in parallel with

the power cables.

- Report of on site measurements of induced voltages on alarm cable.

- Report of test procedures of impregnation and oil flow test.

- Calculation of earthing wire cross-sections and details of cross-bonded

systems.

- Calculation of charging current.

TP-3 STANDARDS

Each cable type and its accessory offered should, in general, comply with the
latest issue of the following publications:

TP-93
3.1 For Power Cables and their Accessories

IEC 60028 International standard of resistance for copper

IEC 60060 High voltage test techniques

IEC 60071 Insulation co-ordination

IEC 60093 Methods of test for volume resistivity and surface

resistivity of solid electrical insulating materials

IEC 60183 Guide to the selection of high voltage cables

IEC 60228 Conductors of insulated cables

IEC 60229 Tests on cable over-sheaths, which have a special

protective function and are applied by extrusion

IEC 60230 Impulse tests on cables and their accessories

IEC 60270 Partial discharge measurements

IEC 60287 Calculation of the continuous current rating of cables

(100% load factor)

IEC 60330 Methods of test for PVC insulation and sheath of electric
cables

IEC 60331 Tests for electric cables under fire conditions

IEC 60332-1 Tests on electric cables under fire conditions

IEC 60840 Test for power cables with extruded insulation for rated
voltages above 30 kV.

IEC 60853 Calculation of the cyclic and emergency current ratings of

cables

IEEE 48 Standard test procedures for HV-AC cable terminations

VDE 0207 Insulating and sheathing compounds for cables and flexible
cords

VDE 0271 PVC-insulated cables with nominal voltages up to and

including 6/10 kV

VDE 0278 Power cable accessories with nominal voltages U up to 30

kV (Um up to 36 kV); Requirements and test methods

VDE 0472 Testing of insulated cables, wires and flexible cords

TP-94
TP-95
 The Contractor may base his Bid on such standards and shall submit copies of
the standard in authorized English copies together with his Bid.

3.2 For Low Voltage Auxiliary/Control and their Accessories

IEC 60227 PVC insulated cables of rated voltages less than or

equal to 450/750 v

IEC 60502 Extruded solid dielectric insulated power cables for

rated voltages from 1 kV – 30kV

IEC 60794 Optical Fibre Cables

IEC 61300-2-36 Fibre Optic Interconnection Devices & Passive

Component-Basic
Test and Measurement Procedures – Part 2-36:
Tests-Flammability (Fire Hazards)
VDE 0816 External Cables for Telecommunication systems

VDE 0845 VDE Specification for protection of tele-

communication installations for over voltages

ITU-T,G 652 Characteristics of a single-mode optical fibre cable

TP-4 SINGLE CORE XLPE HIGH VOLTAGE CABLE CONSTRUCTION AND THEIR
ACCESSORIES

4.1 Cable Construction

The single core XLPE cables to be installed shall be in accordance with the
standards described in Clause TP-3. They shall comply with all the requirements
as described in Clause TP-2

The conductor shall be comprised of stranded, soft-annealed, electrolytic copper

wires.

Conductors shall have longitudinal water blocking to the requirement of IEC

60840.

Blocking by interlayer tape is preferred.

The conductor shall be covered with three layers (screen, insulation screen) of
low density polyethylene, chemically simultaneously cross-linked with added
organic peroxides. Triple extrusion of the screen and insulation shall be required
to ensure an intimate bond between insulation and screens. The manufacturing
technique shall be by continuous vulcanization. The Bidder shall submit details
of the proposed manufacturing technique. The conductor screen, insulation and
insulation screen shall be extruded simultaneously by dry curing process.

TP-96
 The manufacturer shall have fully enclosed materials filtration and compounding
facilities to ensure the best electrical properties of the insulation. The
cross-linking and cooling after the extruding process will be carried out in one
operation. The cable shall be proved against water penetration in longitudinal
and axial direction over the insulation screen. Water swell able tape shall be used
for this purpose.

The insulation shall be covered by annealed copper wires or copper tapes wound
helically for screening. The cable shall then be covered by a sheath of adequate
thickness, which shall be metallic and capable of carrying the full earth fault
current. This sheath shall be extruded continuously.

The over sheath shall be made from high-density polyethylene for buried parts
of the route.

The over sheath shall contain an anti-termite additive based on cypermethrin

which has been demonstrated to be effective and meets the environmental health
criteria of the World Health Organization.

For extruded Aluminium sheaths being offered; they shall have annular
corrugations in preference to helical corrugations to facilitate water blocking of
the core/sheath space

Finally, a thin layer of resin bonded graphite is to be applied to the outer

covering to permit electrical tests.

The cable structure is described to the full extent in "Specific Works Data".

A distinctive marking, including the following details, shall be identified at

regular intervals along the whole outer covering:

- Manufacturer's Name.
- Year of Manufacture.
- Nominal Voltage.
- Conductor Size.
- "XLPE Cable".
- Employer's Name.

4.2 Sealing Ends

The cable terminations should be suitable for application to single-core XLPE

underground cables as described in "Specific Works Data". The terminal of the
cable sealing end shall be suitable to accommodate single conductor 400 mm²
copper conductor from the overhead transmission line. They should be designed
to withstand the specified short circuit current.

The Contractor shall supply all necessary material (whether specifically

mentioned or not), including cable clamps, labels, cable markers, compounds,
tools, etc. for the proper termination of the cables.

TP-97
Bidder shall attach drawings to their Bids showing in detail the methods of
terminating the cable, earthing the sheaths, & detailed drawings showing
different methods of making of sealing ends.

The outdoor type cable sealing end bases shall be insulated from the structural
steel work and the cable glands of gas-immersed and oil-immersed type sealing
ends shall be insulated from the SF6 switchgear, and transformers. They shall
also be suitably protected by Metal reinforced glass fiber sheet towards the
lightning arresters side against the damage due to explosion of lightning arrestor
& consequent fire.

The arrangement to meet these requirements shall be subject to the approval of

the Employer.

For outdoor sealing ends, porcelain insulators shall be provided designed with a
creepage distance of 45 mm/kV line-to-line operating voltage.

For gas immersed terminations at the SF6 switchgear, blind-ended, epoxy resin
insulators are required.

The SF6 sealing ends shall comply with IEC recommendations.

Termination shall meet the dimensions specified in IEC 60859.

Supplier shall demonstrate that terminations meet the mechanical loading of IEC
60859. SF6 terminations shall be of a “dry type” construction, containing an
epoxy resin insulator and an elastomeric stress cone. The terminations shall not
contain any fluid.

All outdoor terminations shall be made using stress control cones. They shall
consist of either a single elastomeric stress cone, a prefabricated design
containing epoxy resin former and an elastomeric stress cone or a paper
capacitor cone type mounted on a resin impregnated former.

The arrangement of terminations should also be prevented by the heat effect of

direct sunlight by means of sheds. Moreover the terminations should be in clear
visibility and in case of any leakage from any part/component of the termination
provision of alarm signal to the operator in the control room is to be kept.

The stress control method must allow for the thermal expansion of the cable and
the Bidder must state how this is achieved. The sealing ends shall be filled with
high viscosity polyisobutylene, silicone oil, or equivalent and suitable expansion
devices are to be provided.

Supply and installation of the necessary hot-dip galvanized steel structures and
non-magnetic clamps, for supporting and fastening the cables at the gantries,
OHL Poles & switchgears shall be included in the Bid Price.

TP-98
 The arrangement of the terminations, the supporting structures including the
cable fastening shall be subject to the approval of the Employer. A complete and
detailed list of tools and equipment required for terminating the cables shall be
submitted with the Bid.

For proposal of alternative methods which shall be equivalent in performance to

the method specified, the Bidder shall submit information necessary to
demonstrate the performance and experience with the method.

4.2.1 Compatibility

It is essential that all the accessories have been fully type tested on the particular
manufacturer's cable which is offered, to ensure that the accessories and cable
are fully compatible.

4.3 Cable temperature monitoring

In order to monitor the continuous performance of each cable system in

operation, optical fiber distributed temperature sensing (DTS) device shall be
installed.

4.4 Joints

The joints should be suitable for application to single-core XLPE underground

cables as described in “Specific Works Data". They should be designed to
withstand the short circuit current as specified.

If cable insulating joints are required they shall be of the “taped” or

“prefabricated” type. The copper conductor shall be spliced by means of a
compression ferrule for copper conductors.

The intended method (e.g. compression) shall be identified in the Bid.

The Bidder shall explain in detail his proposed method of insulation at the joint
for the fully insulated cross bonded system.

The outer covering shall be prepared with a copper tube and protective glass
fiber box casing, filled with waterproof compound to the full satisfaction of the
Employer/Engineer.

For proposal of alternative methods, which shall be equivalent in performance to

the method specified, the Bidder shall submit information necessary to
demonstrate the performance and experience with this method.

TP-5 FIBER OPTIC CABLE

5.1 General

The fiber optic cable shall be designed to withstand all prevalent environmental
conditions including the effects of high electric and magnetic fields produced in

TP-99
 proximity of live power cables.

A service life of at least 25 years is required, and test evidence to support

supplier’s claim in this respect shall be submitted with the Tender.

5.2 Cable type

The fiber optic cable shall be of the single mode type equipped with at least 16
fibers complying with ITU-T recommendation G.652 and shall be suitable for
underground installation/direct burial alongside the power cables and for laying
in trenches/cable trays from the power cable outlets within the substations
premises.

5.3 Cable Construction

A loose tube, minimum strain configuration, which provides protection from

external forces, shall be supplied. The fibers shall be colour coded and lie
loosely inside plastic tubes filled with a gel to protect the fibers from the ingress
and propagation of moisture. The number of fibers inside any one tube shall not
exceed 8. Each tube and fiber shall be distinguishable from the other by means
of coloured ink. The cable shall be rodent protected and include a ruggedised
dual outer sheath of non-metallic construction, with a water barrier, and possess
high tensile strength/resistance to crushing.

Full constructional details of the cable offered shall be submitted with the
Tender.

5.4 Fiber optic characteristics

- number of fibers: ≥ 16
- transmission mode: single mode to ITU-T Rec.
G.652
Recs. G.652, G.653 and G.654,
- wavelength: 1310nm and 1550nm,
- maximum attenuation: 0.4dB/km at 1310nm,
0.25dB/km at 1550nm,
- maximum splicing loss: 0.2dB,
- maximum end-connector loss: 0.5dB,
- core diameter: 9-10µm ± 0.5µm,
- cladding diameter: 125µm ± 2µm,
- maximum concentricity error: 1µm,
- maximum cladding non-circularity: 2%,

- maximum chromatic dispersion: 4ps/nm.km at 1310nm,

20ps/nm.km at 1550nm,
- cut-off wavelength: ≤1270nm,
- mode field diameter: 9.2 ± 0.4µm,
- minimum bending radius: ≡12 x cable diameter

TP-100
5.5 Fiber optic cable technical characteristics

Water-tightness

The cable shall be filled and meet the longitudinal water-tightness test
requirements. A moisture barrier sheath shall be applied.

The water-tightness filler used in the rod shall be compliant with:

 the material making up the cable (rod, jackets, ribbons),

 the fiber and its coating,
 the colour coated fiber.

If an intermediate jacket is used, the water-tightness filler between jackets

shall be compatible with fiber and its coating. Further, the physical properties
of the products used shall be such as to satisfy the mechanical and thermal test
requirements.

The optic core shall be jacketed with high-density polyethylene, with a rated
thickness of not less than 1.5 mm.

Temperature withstanding

The operating temperature range shall be 0 to + 70°C.

Electrical withstanding

Considering there is a potential danger through fault or leakage currents, the

cable must be non-metallic.

Mechanical withstanding

The cable shall suitably withstand the mechanical radial stresses and shall be
protected against rodents and termites.

5.6 Ending rules

After factory acceptance, the inner end of the cable shall be fitted with a
suitable cap to ensure water-tightness; the outer end shall be fitted with a
watertight head compatible with cable pulling. Caps (material and
implementation) shall comply with applicable standards. They shall not be
removed until immediately prior to optical jointing.

5.7 Cable drums

Fiber optic cables shall be delivered on drums of wooden reels. The lengths
of the cable drums shall be such that no intermediate jointing is required on
any of the cable routes. The Fiber optic cable length to be laid has to be 100
meters more than the power cable route length.

TP-101
5.8 Labeling

All cables and cable ends should be labeled clearly in accordance with the
specification. The meter run should be marked on the outer sheath. This
speeds up localization of faults, which are detected during calibration of cable.

Drums shall be fitted with securely attached, unalterable identification plate

bearing the following information:

 Employer’s name
 Supplier’s name
 Contract number,
 Content (including drum no.),
 Manufacturing date,
 Length of cable on drum,
 Direction of rotation of the drum,
 Position of the cable nose,
 Weight of drum.

5.9 Storage and transport

The permissible mechanical stress values (tensile force, bending radius) shall
be adhered to during transport and storage. The barrel diameter of the
shipping drums shall be at least 30 times the outer diameter of the cable, but
not less than 400 mm.

The transportation and storage shall not be done in conditions exceeding the
permissible temperature limits.

5.10 Cable warning tape

A cable warning tape, bright yellow in colour and of plastic material 300 mm
side by 0.1 mm thick shall be supplied. The tape shall be continuously and
indelibly marked in English and Urdu with the words:

CAUTION CAUTION CAUTION

2
FIBER OPTIC CABLE 70 mm BELOW

The lettering shall be black on yellow.

5.11 Joint Box

Joint boxes shall be provided to protect splices and shall be suitable for
underground installation in harsh environment. The units shall be weather-
proof type of protection Class IP65 made of non corrosive Aluminum alloy or
similar material. All necessary hardware to terminate, protect and fix 32 nos.
spliced fibers shall be included. The cover shall be provided with a long life
neoprene gasket to provide a seal against moisture and dust. The cable inlets
shall be similarly sealed. Entry for four cables shall be available. A

TP-102
 nameplate giving important information shall be attached to the joint box.
This name shall have embossed characters and shall be made of weather proof
material. Operating temperature range shall be 0 to +70°C.

It is not anticipated that joint boxes would be required for initial installation as
the drum lengths are required to be covered by a single length of fiber cable.
However, the units shall be supplied for future splicing to meet the
contingency in case of a cable cut.

5.12 Fiber Optic Cable Installation

The fiber optic cable shall be directly buried alongside the underground power
cable in the same trench and shall be laid in 100 mm PVC ducts at road
crossings, rail crossings etc. The openings to the ducts shall be closed with
suitable compound after the cable has been laid. A 10 m loop shall be kept in
cable pits along the entire route every 1000 m.

At the grid station end, from the trench outlet to the control building,
PLC/telecom room, the fiber optic cable shall be laid in a 100 mm PVC duct
and in flexible duct on cable trays within the building premises. A 15 m loop
shall be kept in the PLC/telecom room for connection (b others) to the optical
equipment.

Drawings showing all the typical and specific installation details shall be
submitted to the Employer/Engineer for approval.

Any damage to the cable during installation, from whatever cause, shall be
made good by the contractor at his expense and to the satisfaction of the
Employer/Engineer.

Care shall be taken to ensure that no damage occurs to optical fiber cables
which are laid and exposed, but not protected. any such damage to optical
fiber cables shall be made good by the Contractor at his own expense.

TP-6 TESTS

Type tests, Sample tests, Routine tests and Site tests.

The cables and their accessories shall be subject to acceptance tests, to be

performed at the Contractor's premises (and at site, if applicable) in the presence
of the Employer, in order to verify conformity with the guaranteed values and
Contractor shall forward to the EMPLOYER triplicate sets of all principal test
records, test certificates and performance curves for all tests carried out in
accordance with the provisions of the Contract. These test records, certificates
and performance curves shall be supplied for all tests, whether witnessed by the
EMPLOYER or not.

The manufacturer shall be obliged to fabricate the cable in necessary lengths for
the test, over and above those within the Scope of Work, and to furnish them for
the test free of charge. Before energizing a cable circuit including all the

TP-103
 accessories, tests shall be performed on the complete installation as described.
The same tests, with the exception of the DC high voltage test for the power
cables including their accessories, shall be repeated for issue of the Final
Acceptance Certificate. Three copies of all official site test records signed by the
Contractor shall be supplied to the Employer.

The tests shall be performed as follows:

6.1 For HV/132kV XLPE Cables and their Accessories

The type test reports are to be provided by manufacturer(s) from the

internationally authorised/recognised testing laboratory (third party laboratory)
and may be waived if satisfactory type test certificates of the proposed cables
shall be submitted.

- Type tests for cable outer covering:

Construction and dimensions (IEC 60811)
Mechanical properties (IEC 60811)
Carbon black content
Water and saline absorption test (IEC 60229)
Shrinkage test
AC withstand voltage test (IEC 60229)
AC voltage test (10 kV/30 min and then increase in 10 kV steps of 10 min
duration each up to min 75 kV)
Impulse withstand voltage test (50 kV “10 Imp.) (IEC 60230)
Impulse voltage test to breakdown (40 kV/-3 Imp. step)

- Type test for cables and their accessories:

Generally, the standards of SS 4241417, IEC 60840 and IEEE 48 shall be
applied.

In addition the following shall be performed:

Water and saline absorption test of the insulation shrinkage test of the
insulation.

- Special cable tests according to:

SS 4241417, VDE 0263, IEC 60840 and IEC 60811.

In addition, the following shall be performed:

Impulse test 1.54 x BIL at + 20 EC, each 3 negative and positive impulses.

Dielectric test 3 x Uo for 4 hours.

Measurements of metal sheath thickness (IEC 60141, 13.2), weights of
copper, lead and steel per meter for adjustment of metal prices for final
Contract Price.

TP-104
 - Routine cable tests according to IEC 60840.

In addition, the following shall be performed:

Conductor resistance test (IEC 60228)
Capacitance test
Dielectric loss angle test
Test on corrosion - resistant covering (IEC 60229)

- Test after installation including all accessories:

According to IEC 60840.

In addition, the following shall be performed:

DC conductor resistance test (IEC 60228)
Capacitance test
DC sheath test (10 kV/1 minute) between metallic sheath/screen/ armouring
including cross bonding system, etc. and ground
Earthing measurements
Visual and function test of cross bonding system and cable sheath
temperature measurement system
Positive/negative and zero sequence impedance measurements

- Subsequent repeat tests (after guarantee period)

DC sheath test (5 kV/1 minute) between metallic sheath/screen/armouring

including cross bonding system, etc. and ground.

6.2 Fibre Optic Cable

The following tests shall be conducted on Fiber Optic Cable:

6.2.1 Type tests

The fibre optic cable shall be subjected to the following type test:

1. Geometric properties.
2. Longitudinal water-tightness.
3. Mechanical characteristics.
4. Thermal characteristics.

The test results shall be compliant with the relevant ITU-T recommendations.

6.2.2 Factory tests

The following test shall be performed for every fiber optic cable drum:
1. Optical attenuation, laboratory measurement.

TP-105
6.2.3 Tests during Installation

Optical attenuation, field measurements test shall be performed after delivery

on site of every optic cable drum, prior to laying.

Optical attenuation, field measurement shall be performed after laying of each

section and prior to splicing.

6.2.4 Site Tests

After splicing, final test shall be carried out on end-to-end basis.

All site testing as prescribed by this Specification shall be performed by

suitably trained and experienced staff who shall be familiar with the
equipment and methods to be utilised. A sufficient number of the testing
personnel shall be able to speak English, in order that safety requirements may
be adequately covered. The results of all tests carried out shall be presented in
English.

All test equipment required for testing during cable installation shall be
supplied and maintained in correct working order by the Contractor for the
entire during of the Contract. Mal-operation of any test equipment which
results in delays to the programme shall not be acceptable and shall be to
Contractor’s account.
All the procedures, protocols and equipment shall be subject to the approval
of the Employer/Engineer Engineer. No site testing shall commence until such
approval has been obtained.

TP-7 CABLE INSTALLATION

7.1 General

The cables and their accessories shall generally be installed, tested and
commissioned by the help of cable manufacturer’s own staff, with local skilled
and unskilled labourers employed only for excavation, cable bedding, cable
laying, and backfilling and for civil work, which shall also be adequately
supervised by the Contractor’s personnel.

The Contractor shall employ fully qualified and experienced personnel who have
been in his employment continuously for at least two years, and who have
previous experience with comparable installations. This shall cover, as a
minimum, the supervisory, civil, surveying, testing, and commissioning
Employers. No member of staff employed on the installation work shall be
changed without the prior written approval of the Employer.

Excavation cable bedding, cable laying, backfilling operations or civil work shall
not be sublet to another contractor without the written approval of the Employer.

All civil work shall be performed in accordance with clauses TP-11 to TP-14
and with the following articles.

TP-106
 The cable shall be laid along the routes and in the locations as finally approved.
The Employer shall have the right to alter the cable routes and locations where it
is considered necessary to avoid obstructions, or to suit finalized reserves
allocated by the Town Planning Authorities, for instance at the locations of
future substations, or others.

The Employer will, as far as possible, supply drawings showing the cable routes
provided and the locations of proposed circuits. In order to assist the Contractor,
he will also furnish records of existing cables and other services, the accuracy of
which, however, cannot be guaranteed.

Before starting work on site, the Contractor shall be responsible for obtaining the
exact approved routes and locations which have been selected by the Employer
and shall issue “Notices of Intent” to all concerned authorities at least four weeks
prior to commencement of the work, such as the Employer, Municipality,
Telecommunications Department, Traffic Police, etc. He shall furthermore obey
all relevant rules as applied by the Traffic Department with reference to traffic
signs, diversions, etc. during the performance of his work.

The Contractor shall be responsible for obtaining from the responsible

authorities all the most recent and correct information and details regarding the
final levels, road centre lines, reserves for cables and other services and any
other work in connection with his work.

The Contractor shall take all necessary precautions to prevent damage to the
existing services and electric cables. Damage to services and the costs of repair
and replacements and penalties shall be borne by the Contractor.

The Contractor shall be liable for any costs for making good damage caused in
the execution of the contractual work.

7.2 Erection liabilities of the Contractor

The Contractor shall lay and assemble all specified cables completely and shall,
pursuant to a final site test, hand them over in working order. Besides all other
necessary work and charges as covered by these Bid Specifications, the
provision of below mentioned erection work shall deemed to have been included
in his offer in particular:

- Survey of the cable routes to be approved by the Employer, selection of

delivery lengths and all necessary fittings.

- Sub soil investigations for exact design and construction of concrete cable
trenches as specified, if any.

- Supervision of excavation and, if necessary, the shuttering and dewatering

of the cable trenches as well as the preparation of the cable ducts and
supporting structures for installation of the cables.

TP-107
 - Coordination with other contractors where interfacing works are involved

- Cable laying, including bedding, or laying in ducts, sealing end and joint
supports.

- Supervision of procurement and laying of concrete slabs or protective

concrete layer, supervision of procurement, and laying of cable ducts at road
crossings.

- Supervision of procurement and filling-in of cable bedding and backfilling

material.

- Provision of auxiliary racks, erection structures such as free standing

structures, etc.

- Provision of the necessary fixing material for connection of the cables to the
switchgears, and transformers, as well as cable trays, clamps, grounding
material and all further accessories required for proper installation. To
ensure a successful finishing of the individual scope of work the Contractor,
the switchgear Contractor as well as the transformer Contractor will have to
cooperate.

- Assembly ready for use, including assembly for the connection of joints and
sealing ends. The electrical connection to the switchgears is also included in
the scope of supply.

- Provision of assembly material such as soldering and wiping material,

benzene, propane, acetylene, oxygen, liquid air, petrol, etc.

- Exact design based on sub soil investigations and construction of the

required concrete cable trenches for laying of certain underground cable
circuits as specified with adequate number of ducts for natural ventilation
with louvered tops and complete with lighting and fire detection system.

- Provision of necessary switchgear adaptors for testing purposes.

7.3 Excavation

Before submitting his Bid, the Bidder shall inform himself with regard to the
nature of the ground likely to be encountered during operations. The Bidder shall
include in his prices excavation of ground of any nature and all types of soil
likely to be met with and shall quote uniform flat rates. No claims for extra on
any account whatsoever shall be accepted. No increase in price shall be granted
for excavation in swamps areas or hard ground or rock, for pumping water,
well-point systems, for removal and recovery of pavement or footway such as
concrete tiles and curb stones, cutting and reinstatement of any asphalt surfaces,
or any other cause.

The exact location of each trench and concrete housing shall be subject to the
approval of the Employer.

TP-108
The Contractor shall arrange that no more than two adjacent sections of
excavated trench shall be open at any time.

The trenches shall be straight and shall be located exactly within the approved
reservation, the sides shall be straight and free from any sharp material/edges
likely to injure the cable or accessories, the bottom shall be firm and of smooth
contour and shall be free from any sharp material/pebbles, etc. likely to damage
the cables.

Where trenches pass from a footway to a roadway or at other positions where a

change of level is necessary, the bottom of the trench shall rise or fall gradually.
The Contractor shall take all precautions necessary to prevent damage to the
road or ground surface due to a slip or breaking-away from the side walls of the
trench.

If necessary, collapse of excavated trenches shall be prevented by proper

shuttering (e.g. in sandy areas, areas that have been previously excavated for
other services and are badly compacted). The Contractor shall deal with and
dispose of water in order to prevent any risk to the cables and other material,
which are to be laid in the trenches being detrimentally affected. He shall
provide all pumps; well points and appliances required and shall carry out all
necessary pumping and bailing. The Contract Price shall deemed to include for
such equipment and operations.

The Contractor shall be responsible for public safety and shall therefore provide
picket fences and ropes along the routes of open trenches, as well as danger
notices and barriers, and red/amber warning lights during the hours of darkness.
A watchman shall be provided for every open trench.

Unless otherwise agreed, provision shall be made during excavation for

reasonable access of persons and vehicles to property or places adjacent to the
route. This provision shall be maintained until interim restoration has been
completed.

Where, in the opinion of the Employer, other measures prove unsatisfactory, the
Contractor shall place plastic pipes, with an inner diameter of at least 3.0 times
the outer diameter of the cable, on the level of the cables which are to be laid,
and shall backfill this section of the cable trench completely with concrete slabs
and warning tape, etc. immediately thereafter in the presence of the Employer.
Supply and installation of the pipes as well as pulling through the cables is
deemed to be included in the contract price.

Excavation in paved sidewalks shall be carried out with special care and with the
granted permission of the concerned authority. When removing paving slabs, the
Contractor shall take the necessary precautions to avoid breakage. All slabs
removed during the performance of the work shall be re-established or replaced.

Whenever trenches run in parallel to existing services, cables, etc. the Contractor
shall maintain a distance of at least 0.5 m between the existing services, cables,

TP-109
 etc. and the edge of the new trench. The Contractor shall cross existing services
with the utmost care and shall ensure that the cables are adequately protected. At
least 0.5 m distance shall be maintained. He should obtain the written approval
of the Employer with regard to the method of crossing existing services in
advance.

Where the existing ground level is much higher than the future final ground
level, cables shall be laid to a depth measured from the final future ground level.
The amount of additional excavation is deemed to be included in the Contract
Price.

7.4 Cable Laying and Routing

In general, the arrangement of cables and the methods of laying shall be subject
to the approval of the Employer/Engineer. Cables shall be laid directly in the
ground, protected with protection covers or protective layer, drawn-in to pipes
and ducts, laid directly in troughs or in concrete trenches, as may be required by
the Employer/Engineer.

Rates for cable installation and laying shall be uniform flat rates irrespective of
the manner and method of installation, the route length/run of cable being
measured for payment purposes.

Generally, the three single-core 132 kV power cables of each circuit shall be laid
as indicated in drawing No. KESC/2480-07/TL105.

All 132 kV cables of each circuit shall be laid in flat formation with a minimum
space of three times the cable diameter between centres at any point, and a space
of minimum 1.7m between the edges of adjacent trenches/circuits.

7.5 Cables Laid Directly in the Ground

A minimum depth of:

- 120 cm for 132 kV

- 70 cm for control and alarm cables

From the road level or the level given by the Employer, whichever is the deepest
shall be maintained underneath the cables.

The levels and relative particulars will be ascertained by the Contractor from the
Town Planning Department/Municipal Authorities. The Bidder shall satisfy
himself with regard to the reference levels before submitting his Bid.

As stipulated above, a minimum trench depth of:

- 170 cm for 132 kV

- 90 cm for control and alarm. cables

TP-110
is required, but in some areas the existing levels may be more or less than the
required levels below the road levels or the levels given by the Employer. In
such cases, the Contractor shall backfill 130/55 cm soil upon the bottom of the
cable covers or protective layers as a minimum in any case, subject to the
Employer's approval.

After the trench has been excavated to the necessary depth, a minimum layer of
20 cm of approved sand bedding material shall be placed to form smooth
bedding for the cables. The bedding material shall have a maximum thermal
resistivity of 120K-cm/W under operation conditions and shall be chemically
neutral. In case a maximum thermal resistivity of 120 K-cm/W is not obtainable
under completely dried out conditions, the Contractor shall submit an alternative
proposal (e.g. weak mix concrete 1:20 for 20 cm below the power cables and 20
cm above the top of the uppermost cable) to cope with specified thermal
resistivity. The contractor’s proposal will be subject to the approval of the
Employer.

Pulling-in of cables shall not commence until the Employer has inspected and
approved the trench.

After the cables have been laid, and provided that their spacing has been
approved by the Employer, they shall be covered with an additional layer of the
approved bedding material and well compacted over and around the cables to a
level of 20 cm above the top of the power cable.

Cable covers of concrete shall then be carefully placed over the cables. The
concrete covers having concrete compressive strength of 3000 psi at 28 days
with sulphate resistant cement (Type-V) of aggregate conforming to ASTM C-
33 shall have a size (in centimetres) of 50x30x6 and attention shall be paid that
they are laid adjacent to each other without leaving spaces in between. The
concrete covers shall be supplied and installed by the Contractor.

If required and subject to the Employer’s approval, the protective layer shall be
alternatively made of a concrete layer of a thickness of minimum of 15 cm.
Cables shall be laid directly from the drums into the trenches and special rollers
placed at intervals of maximum 2 m shall be employed for supporting the cables
during pulling and laying. Rollers used during the laying of cables shall have no
sharp projecting parts likely to damage the cables. Before leaving the factory,
suitable pulling eyes shall be fitted to the power cables.

After the cables have been laid and until all the cables in the trench have been
covered with the concrete covers or protective concrete layer, no sharp tools
such as spades, pickaxes or fencing stakes shall be used in the trench or shall be
placed in such a position that they may fall into the trench.

The sand bedding over the cables and laying of the concrete covers shall follow
immediately after the cable pulling in order to avoid exposure and damage of the
cables.

Each single-core cable joint shall be so marked that the phase identity of each

TP-111
 joint may be easily ascertained.

7.6 Backfilling and Reinstatement

Filling-in of trenches shall not commence until the Employer has inspected and
approved the cables, protective covers or protective concrete layers at site. Such
inspection shall not be unreasonably delayed.

After placing of the cables' protective covers or the protective concrete layer, the
Contractor shall backfill the trench with selected and approved material in 20 cm
layers, each layer being well compacted, watered if necessary, and consolidated.
In case the excavated material does not meet the requirements for backfilling, the
Contractor shall use the same material for backfilling as applied for bedding of
the cables, without extra charge. He shall then carefully reinstate the paving
slabs, all to the satisfaction of the Employer.

At a level given by the Employer a 40 cm wide plastic warning tape shall be

installed. Warning tape to be marked "CAUTION! CAUTION! HIGH
VOLTAGE CABLE BELOW” in English and Urdu. Each refilled trench shall
be maintained in a thoroughly safe condition by the Contractor at his expense
until such time as he can carry out permanent reinstatement of the upper levels
and surface so as to restore these to their original condition or to the level of the
surrounding curb stones, respectively, whichever is higher. All excess excavation
material has to be removed without extra charge.

7.7 Cable in Concrete Trenches, Troughs, etc.

Cable for certain circuits is to be laid in ventilated trenches instead of direct

burial in ground unless specified otherwise.

Such Concrete trenches shall be made below ground level with dimension as 2.0
m x 2.0 m (width x height). These trenches shall have adequate openings with
louvered top covers for natural ventilation. Internal light and fire detection
system shall also be provided in these trenches. The Bidder shall satisfy himself
with regard to the type of construction based on nature of soil in that area, where
required, special measure may have to be taken against seepage of water inside
these trenches.

Design of the cable trenches is to be based on soil investigations to be conducted

by the Contractor and is to be approved by the Employer.

Cross-section of the trench may be revised if revealed from calculations that

ambient conditions inside the trench do not permit maximum current carrying
capacity.

Cable shall be laid inside these trenches in flat formation with a bonding system
to be designed and proved by the contractor for maximum current carrying
capacity.

TP-112
 All concrete trenches and covers shall be provided and shall be subject to the
approval of the Employer. All cables installed in concrete trenches shall be
supported by means of suitable spacers. For cable movements the laying of
snaked cables is requested. The cables should be laid in a regular snaked form in
the horizontal plane and they should be secured at regular intervals by clamps or
straps. The distance between the fixing points and the straps must take
electrodynamics stresses under short circuit conditions into account. They shall
run in a neat and orderly manner and the crossing of cables within the trench
shall be kept separate. On completion of the cable lying, all concrete trenches
supplied under this Contract shall be inspected, and the Contractor shall be
responsible for the replacement of any broken parts at no additional cost.

7.8 Road Crossing

The Contractor shall provide the plastic pipes for each phase separately
including one spare phase per circuit in the required positions. Except where the
Contractor considers that a larger size is necessary, plastic pipes shall consist of a
minimum internal diameter of 2.0 times the outer diameter of the pertaining
cable in a surrounding of 20 cm thick reinforced concrete. The ducts shall be laid
on level concrete foundations previously prepared by him, then carefully
connected and aligned, and consolidated with concrete. The ends of the ducts
shall protrude to a distance of 1.0 m beyond the curb stones. Contract prices for
cable laying and installation shall include all necessary road crossing ducts
including one spare, i.e. 4 pipes. The Contractor shall be responsible for all work
involved, including the breaking-up of the road surface and subsequent
reinstatement of the same in accordance with the requirements of the
Municipality Department.

The Contractor shall remove any loose material from the ducts and shall prove
them by drawing a mandrel of slightly lesser diameter than that of ducts
themselves through them immediately before pulling-in the cables.

After pulling-in the cables, the pipes shall be filled with a low thermal resistivity
mixture, if necessary, and sealed by an approved method. Cement may not be
used.

Any pipes or ducts not used shall be sealed by an approved method before
backfilling. All sealing material shall be supplied by the Contractor.

Existing spare pipes or ducts, if available, may be used only with the permission
of the Employer.

Excavation for road crossings shall be carried out on only half of the
carriageway at a time. Where asphalt surfaces have been broken, the Contractor
shall be responsible for topping and reinstatement of the surfaces.

The cable laying Contractor shall be bound to co-ordinate, if required, all his
work for road crossing with the relevant road constructor. The costs for complete
reinstatement work after crossing of roads are to be borne by the Contractor.

TP-113
 If the concerned Authority refuse the permission to carry out the cable
crossings as described above, which may be the case of major and busy roads
and of railway crossings, regardless whether in operation or not, the
Contractor shall consider other methods, e.g. drilling or pressing methods
while using steel pipes. The Bidder is advised to survey the proposed cable
routes to ascertain the extent of such cable crossings by means of thrust boring
with steel pipe. The Bid price is deemed to include any cable crossings
regardless the number, type and length.

7.9 Cable Markers

Cable markers and danger plates of an approved type shall be provided and
mounted on metallic; hot-dip galvanized and suitably painted posts of 0.1 m
diameter along each route of buried cables and shall be erected as reinstatement
is being carried out. The markers and danger plates shall be supplied and
installed by the Contractor and shall be made of permanent material. The
markers shall indicate the cable voltage, the KESC's name, the name of the
circuit, depth of the buried cable and the distance of trench and joints from the
markers, as well as the joint numbers. The general arrangement of cable and
cable markers is shown in drawing No. KESC/2480-07/TL106.

The types and details of the markers and danger plates proposed to be used shall
be submitted by the Contractor for the Employer's/Engineer approval before
cable installation work commences.

Markers shall be installed at all joint positions, all places where the route
changes direction, and on straight routes at distances not exceeding 50 m, and
shall be approved by the Employer/Engineer. Joint markers and marker plates
should always be installed together.

Each end of the cable run shall be provided with markers for identification
which shall be fitted in a suitable position under the cable terminal. Where
cables enter or leave ducts or pipes, suitable identification markers shall be
fitted.

The material of all markers, danger plates, labels and clamps shall be such as to
avoid corrosion due to the incompatibility of materials, and to ensure permanent
legibility.

Cable markers should be of anti theft design & should be painted with reflecting
paint or built in concrete reflectors. They should be erected at least 12// above the
ground.

Cable markers should also be installed at places where the depth of the cables is
not standard due to some unavoidable reasons.

7.10 Jointing and Sealing

The Contractor shall supply, if and where required, all material necessary for

TP-114
 jointing and termination of cables, including cast resin cones, stress control
cones, porcelain, as well as all tapes, papers, plumbing material, solder and other
consumable materials, and shall carry out all work necessary for the proper
jointing and sealing of all cables installed under this Contract. The Contractor
shall be held responsible for checking his jointing and sealing work and for
putting the completed cable installation into operation.

The Contractor shall be responsible for the correct phase connections of the
cables. Site tests shall be carried out by the Employer and-if faults are found-the
Contractor shall perform any correction free of charge.

Where insulated glands are provided, the Contractor shall ensure that the
insulation is maintained after the cables have been jointed and shall, if required,
demonstrate this to the satisfaction of the Employer.

7.11 Bonding and Earthing of High Voltage Cables

The bonding system of single-core HV cable sheath circuits as well as the design
of the relative individual accessories shall be subject to the approval of the
Employer.
Full load sheath voltages shall be limited to 65 Volts.

The bond connection shall be capable of carrying the normal sheath current as
well as the maximum fault current without undue heating. The completed
bonding system shall be subject to a test in the presence of the Employer.

The individual ground resistance at any Earthing point along the route shall not
exceed 3 Ohm. Where necessary, additional earth rods shall be provided to
obtain this value under all considerable circumstances.

The metal sheath of the cables shall be connected to the station earthing system
at the sealing ends. The cables of short runs may employ a suitable end point
bonding system.

Concerning single-core cable systems laid in flat formation, adequate measures

shall be taken in order to decrease sheath losses and to increase the load carrying
capacity of the cable system.

The induced voltages which exist at the free ends are required to be limited to 65
Volts.

Longer cable systems laid in flat formation shall employ a cross bonding system.

Provisions have to be made to reduce sheath over voltages due to short circuits
and to surges, travelling waves at the sheath sectionalizing/insulation points or
sealing ends to safe limits.

For these purposes, surge diverters/sheath voltage limiters have to be provided

these shall be of zinc oxide type and performance data should be supplied by the
Bidder. To make the diverters accessible they shall be mounted close to the joint

TP-115
 bay in link boxes housed in reinforced concrete housings with demountable links
in order to be able to disconnect them for maintenance purposes. A suitable
degree of protection shall be provided.

The link boxes in concrete housings shall be designed for heavy traffic load and
shall be easily accessible. Lids should be made of light-weight material with two
strong handles which shall move freely and shall not project after placing into
position.

A detailed description and calculation of the foreseen bonding design showing

the limit values of sheath losses and voltages under normal and fault conditions
shall be provided to the Employer for approval.

7.12 Fibre Optic Cable Installation

The fibre optic cable shall be directly buried alongside the underground power
cable in the same trench and shall be laid in 100 mm PVC ducts at road
crossings, rail crossings etc. The openings to the ducts shall be closed with
suitable compound after the cable has been laid. A 10 m loop shall be kept in
cable pits along the entire route every 1000 m.

At the grid station end, from the trench outlet to the control building,
PLC/telecom room, the fibre optic cable shall be laid in a 100 mm PVC duct
and in flexible duct on cable trays within the building premises. A 15 m loop
shall be kept in the PLC/telecom room for connection (b others) to the optical
equipment.

Drawings showing all the typical and specific installation details shall be
submitted to the Employer/Engineer for approval.

Any damage to the cable during installation, from whatever cause, shall be
made good by the contractor at his expense and to the satisfaction of the
Employer/Engineer.

Care shall be taken to ensure that no damage occurs to optical fibre optic
cables which are laid and exposed, but not protected. any such damage to
optical fibre cables shall be made good by the Contractor at his own expense.

7.13 Usable cut lengths and scrap cables

All cables supplied CIF and delivered to site against written authorization of the
Employer is the property of the Employer and the Contractor shall be
responsible for ensuring that all short cable lengths cut from the main lengths in
the process of erection and jointing are immediately collected and stored in a
safe place. Approved sealing caps of the correct size shall be supplied for all cut
length of cable exceeding 10 meters in length to enable them to be properly
stored for future maintenance purposes.

The Contractor shall be responsible for the immediate sealing of such cut lengths
and the cost thereof shall be deemed to be included in the Contract price. These

TP-116
 usable cut lengths and scrap lengths shall eventually be delivered by the
Contractor to the Employer's store and the cost for this is deemed to be included
in the Contract Price. The cutting allowance shall not exceed 2%.

TP-8 CABLE ROUTE RECORDS

The Contractor shall prepare all records concerning the cable route and shall
submit them, properly bound, for approval by the Employer. Record drawings
shall be to scale 1:1000, or as directed by the Employer.

The records shall be carefully taken on site during the installation of the work.
The final presentation of the records shall be approved by the Employer. The
schedules and records shall show the routes, the exact locations of each joint, the
date of jointing, the name of the jointers, the lengths between the joints, the
serial number of the cable drums, the direction of the lay of the cable, i.e. "A" or
"Z" ends, soil conditions and positions of ducts and sectional inserts of the cable
trench giving the relative positions of the cable, slabs, protective layer, depths,
spacing and any other services that cross the route of the cable, between joints
and between terminations. Records shall be kept of the "impregnation tests"
carried out after impregnation has been completed, and also of the date when the
cable was high-voltage tested. The records shall also include the route profiles
(to be determined at site) and, the position of terminations, joints, pressure
gauges, etc as appropriate.

TP-9 PACKING

The cables shall be delivered on strong metallic drums provided with wooden
battens to protect the cable from damage. The drums shall be marked to indicate
the direction of rolling and shall have the following details:

Employer's Name
Contract Number
Manufacturer's Name
Type of Cable
Nominal Voltage
Serial No. of Drum
Cable Length
Conductor Size
Direction of Cable
Cable End
Gross Wt
Net Wt

Details of temperature and pressure at time of despatch from manufacturer

should be clearly marked.

TP-10 DRAWINGS

The Bid shall be accompanied by detailed drawings showing the following:

TP-117
 - Cable cross-section each type and size (with dimensions).
- Cable sealing ends each type.
- Cable straight joints.
- Cable layout inside substation.
- Straight joint bay layout.
- Cable fastening method.
- Cable earthing method.
- Cable layout in ducts (road crossings).
- Combined gauge/alarm panel.
- Complete detailed drawings showing steps & dimensions involved during
making of joints & sealing ends.

TP-11 GENERAL CONSTRUCTION AND DESIGN FEATURES OF CABLE PITS

The principal features of construction and finishing of the civil work are
described as follows:

11.1 Scope

The scope of work shall comprise but shall not be limited to the complete
construction of joint housings, road crossings, gauge panel, foundations for
sealing ends, etc. including manufacture and installation of their steel supporting
structures. It shall, furthermore, comprise the construction and lying of cement
tiles and slabs, the construction and installation of cable markers and the
reinstallation of roads, pavements and fencing, required.

11.2 Preparation of Sites

All relevant site installations required by the Contractor for the performance of
the work due under this Contract shall be included in the offered price. The
Contractor shall make his own arrangements for the transport of material and
equipment to the sites. It has to be assumed that on the way to the required site,
probably soft ground may have to be crossed, and the Contractor shall have to
arrange his own precautions for the transport and execution of his work.

11.3 Fencing

The Contractor shall, in connection with the work, provide and maintain at his
own cost all light guards, temporary fencing and watching when and where
necessary or required by the Employer for the protection of the work and for the
safety and convenience of the public.

11.4 Setting Out

The Contractor shall be responsible for the true and proper setting-out of the
work and for the correctness of the positions, levels, dimensions and alignment
of all parts of the work and for the position of all necessary instruments,
appliances and services in connection therewith. If, at any time during the
progress of the work, any error should appear or arise in any part of the work,
the Contractor shall rectify all such errors at his own cost and to the satisfaction

TP-118
 of the Employer. The checking of any setting-out or of any level by the
Employer shall not in any way relieve the Contractor from his responsibility for
the correctness thereof. The Contractor shall carefully protect and preserve the
bench mark pegs, etc. used in setting out the work.

11.5 Excavation

All kinds of soil encountered at site shall be excavated according to relevant

drawings, and shall be loaded, transported and dumped at areas for which prior
permission has been obtained from the relevant authority. Backfill material may
be stockpiled nearby. For all excavation work, dewatering down to the bottom of
the pit must be considered and shall thus be included in the Contract Price.

If buried obstacles are encountered during excavation work, the Employer has to
be informed immediately and any demolishing and/or removal of such obstacle
shall commence only after receipt of instructions from the Employer.

11.5.1 Excavation of Top Soil

If the upper layer of soil is rich in organic matter, it shall be removed and
stockpiled in stacks of trapezoidal cross-section in specified height and width.
After the completion of all civil and pertaining work, the surfaces of the project
area shall be reinstated by placing the top soil in layers as directed by the
Employer. No additional payment shall be allowed for this work.

11.5.2 Finish of Excavation and Inspection

No excavation shall be refilled or any permanent work commenced until the

formation has been inspected by the Employer's representative and his
permission to proceed given. If required by the Employer's representative, the
bottom 15 cm of excavation shall not be removed until just before the
commencement of construction of permanent work.

11.5.3 Over-Excavation

If somewhere, and for any reason, excavations are executed beyond the
established lines, the Contractor shall backfill the volume corresponding to
over-excavation with rubble concrete at his own expense.

11.5.4 Manual Excavation

Manual excavation of soil by means of spade or graft, etc. shall be made on

special instruction and approval by the Employer and as the care of the work
requires. This shall be applicable for the observation of underground services in
the vicinity of any construction prior to commencement of the main excavation.

11.5.5 Obstacles

The Contractor shall take all necessary precautions to prevent damage in the
vicinity of existing cables and pipes.

TP-119
 The Contractor will be liable for any damage that might occur. He shall make
arrangements in good time for the Employer and Employer to be present, when
the cables and pipes are exposed and also during any shifting of these, should
this be necessary. The cost of cable and pipe shifting of a permanent nature will
be borne by the Employer after approval of the Employer has been obtained.

11.5.6 Excavation and Removal of Concrete Structures

The offered price shall be deemed to include all auxiliary work required for full
completion and of work in accordance with the drawings and conditions. Hence,
the auxiliary work comprises, but is not necessarily limited to, the following:

- Excavation and removal of concrete plates, beams, floors, boulders, rocks,

large stones or concrete foundations (if any).

- Removal of drainage and the like under embankment fills, difficulties

resulting from the specifications relating to fills, compaction tests,
elimination of unsuitable material from fills.

- Any transport and intermediate storage.

- Removal of loose earth at excavation bottoms and for fill concrete.

11.5.7 Groynes, Existing Pipe work, etc.

The removal of any groynes, buried pipes, wattle-work, fascines and the like
which might interfere with the excavation profiles, irrespective of whether or not
such structures are described in these Biding Documents, must be included in the
Contract Price.

11.5.8 Disposal of Excavated Material

Excavated material suitable for use as filling material shall be deposited as

directed by the Employer's representative. Surplus or material unsuitable for use
as filling shall be disposed of by the Contractor according to the regulations of
municipality of the city; no additional payment shall be allowed for this work.

11.6 Filling

Filling shall be approved selected material from excavation of other

predominantly granular material free from slurry, muddy, organic or other
unsuitable matter, and shall withstand compaction by ordinary means. Filling in
trenches and foundations shall be placed in 20 cm layers and compacted at
optimum moisture content by mechanical means where possible. Alternatively,
where allowed or approved by the Employer's representative, fill shall be placed
in layers and saturated with sufficient water, or otherwise compacted to produce
maximum compaction. Filling around pipes and cables shall be carefully placed
fine material to cover the pipe or cable completely before the normal filling is
placed. All filled areas shall be left neat, smooth and well compacted, the top

TP-120
 surface comprising normal site surface soil, unless otherwise directed. The
Contractor shall be responsible for the reinstatement of any surfaces or
structures, which may move or otherwise be affected by settlement of backfill.

11.7 Laboratory

The Contractor shall provide for the sole use of the Employer the following
equipment, all of which will revert to the Contractor at the end of the Contract:

- Standard metal cylinder moulds as required

- Speedy moisture apparatus
- Compacting factor apparatus
- Sand density cone apparatus
- One set sieves for aggregates (fine and coarse)
- One set of scales (100 N)
- Graduated measuring vessels
- Concrete compression test machine
- Concrete thermometer, maximum-minimum thermometer, water
thermometer.
- Slump cone equipment

The cost of such labour, materials and transport which the Employer may
require to assist him in carrying out tests and checks on material shall be
included in the billed rates for the permanent work.

TP-12 CONCRETE

12.1 Tests and Properties

Throughout the construction period, the quality of concrete mixed at site and/or
delivered to the site by the Contractor or by others has to be controlled. Tests
shall be carried out in the presence of the Employer or under the supervision of
an experienced representative of a licensed office for testing of such work.

The following minimum number of tests shall be carried out:

a) Cement

One (1) setting test according to vicat method per car-load One (1) boiling
test per car-load

b) Aggregates

One (1) sieve analysis per 100 m3 of compacted concrete Example for one
grading curve:

TP-121
 Test sieve Passing Residue
00.25 004 96
00.50 012 88
01.00 022 78
02.00 030 70
04.00 038 62
08.00 050 50
16.00 065 35
31.50 100 00

c) Water

One (1) Chemical water analysis every three months of construction. First
analysis before start of pouring of the first load bearing structural member.
If source of water is changed fresh tests shall be carried out to check
suitability of water.

d) Admixtures

One (1) of each kind of admixture and additive before use in concrete mix.

e) Concrete

One (1) set of test cylinders per 100 m3 compacted concrete. One (1) set
consists of 3 numbers of cylinders.

The compression strength test shall be carried out after seven days for the
first cylinder of each set, after twenty eight days for the second and third
cylinders of each set.

Two (2) slump tests daily or as per the Employer's direction, provided
concreting is proceeding.

12.2 Sulphate-Resistant Portland Cement

Cement with high sulphate-resistance (Portland Type V) shall be used

exclusively. The Contractor shall certify that the proposed cement is of required
quality regarding resistance to corrosion due to sulphate. Methods of testing this
quality shall be included in the Bid.

12.3 Execution

a) Concrete

Before starting the execution of load bearing structural members the Contractor
shall furnish the Employer with a detailed concreting programme, which shall be
subject to approval.

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 Next to the operator of the mixing plant the composition of one batch of
aggregates and cement and water and additives, if any, content in kg per m3 of
compacted concrete shall be displayed legibly.

Making and transporting as well as handling, placing and curing the concrete,
formwork, false work, stripping, propping and installing and embedment of
reinforcement shall conform to the ASTM or DIN 1045.

For concreting in hot weather various means should be employed to lower the
temperature of concrete, such as:

- Using cold water, even to the point of adding large quantities of ice.
- Avoiding the use of the hot cement.

- Insulating water supply lines and tanks and/or painting exposed portions
white.

- Cooling coarse aggregate with (having temperature < 35oc) water by

sprinkling or with cold air blasts.

- Shading mixer drums, facilities and material by use of permanent wet

burlap coverings.

- Working only during cooler daytime (evening until morning).

- Adequate watering of sub-grade, formwork and reinforcement by use of

cold water.

- Covering freshly poured concrete with wet burlaps.

- Intensive round-the-clock moist-curing of the concrete.

- Application of sealing compound at concrete surface against vaporization.

Attention to curing requirements is important at all times, especially in hot, dry

weather because of greater danger of cracking.

The use of ice for cooling water should be carefully controlled to ensure
complete melting before mixing is completed. The temperature of fresh concrete
must in no case exceed 35oc.

TP-13 DE-WATERING DURING CONSTRUCTION

This chapter applies to the methods and techniques for lowering of groundwater.
Before a choice of the method and technique is made, an adequate knowledge of
the ground and water conditions is necessary which can be obtained from the
results of soil investigation and/or other information which may be available
from the Employer.

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 The British Code of Practice (CP) 2004 shall apply for the method and technique
to be chosen by the Contractor.

The scope of supply includes the site installation and its removal after
completion specially required for the method and technique chosen by the
Contractor including operation and maintenance of the equipment.

Where necessary, cofferdams, sheet piles, pump sumps, channels, troughs, inlet
gutters, pipes and any other required works necessary to control and discharge
water found on the work site to keep the different work fronts free of water
during construction shall be part of the scope of supply. The de-watering system
shall be designed and installed in such a way that alterations and extensions can
be made any time throughout the operating time, if necessary. A reserve unit
shall be kept ready for service in case failure of any of the installed units occurs.

The Contractor has to consider the possibility of a temporary failure of the

electric power service and shall install emergency power units with sufficient
capacity to feed the necessary power to the installed unit at the moment of
failure.

The Contractor shall submit the detailed planning of the chosen de-watering
method and technique and the stand-by reserve units to the Employer. The
Contractor has to adjust the system if required by the Employer.

The Contractor must ensure that drainage works will be eliminated without
causing any interference to his own work or to that of other contractors operating
elsewhere on the construction site, or to structures already erected or still in
progress. Any damage occurring during the above mentioned period shall be
made good by the Contractor at his own expense.

TP-14 EARTH AND ROCKWORK

14.1 Auxiliary Work

All and any kind of work, material, services, safety measures, etc., as well as,
and if so requested by the Employer, all tests and samples required for the
completion of the work shall be included in the Bid. The auxiliary work
comprises, but is not necessarily limited to, the following:

a) Removal and storage of boundary stones, bench marks, etc.

b) Protection of survey points, designations by means of boards.
c) Survey and protection of all secondary survey points, profiles, etc.
d) Solution of difficulties where excavation may have to be carried out in
layers.
e) Keeping off or diversion of water, including any pumping required, difficult
work caused by water, etc.
f) Removal of any groynes, buried pipes, wattle work, fascines and the like

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 which might interfere with excavation profiles, irrespective of whether or
not such structures are specified in the Biding Documents.
g) Solution of difficulties resulting from the Biding Documents with regard to
fills, compaction tests, elimination of unsuitable material from fills and, if
necessary, mixing of different soil materials.
h) Transport of excavated material to fill or deposit, placing and spreading in
layers according to conditions and drawings, and careful compaction.
i) Solution of difficulties in transport due to existing ground conditions.
j) Grading of intermediate and top fill surfaces and slopes to final levels
required.
k) Sorting of excavated material which, if necessary, is to be used for special
purposes.
l) Any expenditure for provision, maintenance and later removal of
driveways; maintenance of existing ways and roads; provision, placing,
maintenance and later removal of conveying and dumping equipment which
might be required.

14.2 Tests and Properties

The control of working and test operations shall be carried out by the Contractor
in the presence of the Employer, or under the supervision of an experienced
representative of a licensed office for testing of such work.

The Contractor shall prepare sheets for statical analysis of the field and
laboratory tests, and shall submit such sheets to the Employer for approval.
Control will comprise field and laboratory tests such as compaction and density
tests, grain-size distribution, and shear tests.

If not otherwise specified under relevant items, the following tests have to be
carried out as a minimum:

a) Two (2) tests analysing ingredients of the existing ground-water. Samples

shall be taken from different spots or as directed by the Employer.

b) Two (2) tests analysing the ingredients of the water used for performance of
the work. The first test is required before any structural member is executed.
The second test is required at the beginning of the super structural work or
as requested by the Employer.

c) Three (3) tests for specific gravity of soil as per ASTM D 854, latest issue.

d) Three (3) tests for grain size analysis of soils, if "Replacement of Material"
is required as per ASTM D 422.

e) Three (3) tests for density of soil in place of Sancone method for each
second layer of "Backfilling and/or replacement of material and/or
roadwork" are required as per ASTM D 1556.

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All tests have to be recorded on forms acceptable to the Employer.

If not otherwise specified, the minimum required degree of the compaction of

the modified proctor density under pavements, parking areas and roads shall
be 95%.

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