SPECIFICATION FOR CIVIL WORKS

SUMMARY OF CONTENTS

ITEM DESCRIPTION PAGE NO.

SECTION 1 - GENERAL 1 – 23

SECTION 2 - SOIL INVESTIGATION - NOT ISSUED -

SECTION 3 - DESIGN OF SEWERAGE SYSTEM -

- NOT ISSUED

SECTION 4 - SITE CLEARANCE AND TRENCH WORK 4 – 20

SECTION 5 - SEWER MATERIALS AND FITTINGS 5–5

- NOT ISSUED

SECTION 6 - PIPELINE INSTALLATION AND MANHOLES 6 – 18

- NOT ISSUED

SECTION 7 - PIPE JACKING - NOT ISSUED 7–4

SECTION 8 - EARTHWORKS 8 – 12

SECTION 9 - CONCRETE WORKS 9 – 40

SECTION 10 - METAL WORKS 10 – 8

SECTION 11 - ROADWORKS 11 – 21

SECTION 12 - PAINTING AND PROTECTIVE COATINGS 12 – 8

SECTION 13 - ROCKS AND MASONRY WORKS – NOT 13 – 6

ISSUED

SECTION 14 - BRICK LAYING AND PLASTERING WORKS 14 – 3

SECTION 15 - PILING WORKS - NOT ISSUED 15 – 35

SECTION 16 - MECHANICAL AND ELECTRICAL WORKS - 16 - 15

NOT ISSUED
SECTION 17 - UTILITY AND CCTV SURVEY WORKS 17 – 17
– NOT ISSUED

SECTION 18 - MISCELLANOUES ITEMS 18-2

SECTION 19 - CURED IN PLACE SYSTEMS – NOT ISSUED 19-9

 SECTION 1

GENERAL

1.1 GENERAL REQUIREMENTS

The Conditions of Contract apply to all sections of the Technical

Specifications the same as if here written. Unless otherwise specified all
materials incorporated in the permanent work shall be new. Materials not
otherwise designated by detailed specifications shall be of the best
commercial quality and suitable for the purchase intended.

1.1.1 Workmanship

All workmanship shall be in conformance with the best trade practices.

Particular attention shall be given to the appearance of exposed work. Any
work or workmanship not conforming to the best practices shall be subject
to rejection.

1.2 SCOPE OF WORKS

1.2.1 The Scope of Works to be performed under this Contract shall comprise
the following tasks or activities summarised below:

1) General and Preliminaries :-

a) Contractual Requirements (Bond, Insurance and Statutory
Obligations)
b) Engineer / S.O / PD / ER Requirements (Method Statements, Work
Programme, Monthly Progress Report, As Built Drawing)
c) Project Requirements (Survey and Setting Out, Soil Investigation,
Utility Cost, Maintenance of Road, Clearance of Site Upon
Completion)
d) Occupational Safety and Health Requirements
e) Contractor’s Requirements (Site Agent, Dilapidation Survey, Mob
and Demob)
2) New Access Road :-
a) Earthworks
b) Premix works c/w testing
c) Road marking
3) Infraworks (Access Road)
a) New road side drain
b) New road kerb c/w opening inlet with large dimension and outlet
discharge to the road side drain.
c) Closed turfing
d) New culvert
e) New brick sump complete with grating cover
f) Automatic Boom Gate c/w access control system, to tap the
nearest DB for electric supply with proper cable management and
complete with T&C
g) New industrial sliding steel gate entrance

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 4) Building works, finishes and fittings (Guard House, Concrete Platform and
Walkway)
a) Excavation works and raft foundation
b) Polythene sheet damp proof membrane laid under ground floor
c) To construct Guard House size 3m x 3m 2.8m high reinforced
concrete structure including foundation, footing, lightweight roof truss
covered with metal deck roof, wall finishes, floor finishes, door,
window, m&e fittings (lighting and 3 nos power point).
d) To construct 2 nos concrete platform for cabin
e) To construct concrete walkway with suitable gradient and connect to
concrete platform and new road.

Completion period shall be 6 months from the Employer’s Representative’s

written order to Commence the works.

1.3 STANDARDS AND SUPPLEMENTARY SPECIFICATIONS

All workmanship, materials and components throughout shall where

applicable and unless otherwise stated in the Contract comply with the
following standards and codes.

1.3.1 American or British Standards and Codes of Practice

Compliance with relevant American or British Standard or Code of Practice

current on the date fixed for receipt of tenders.

1.3.2 Other Standards

Compliance with other Standards or Codes of Practice proposed by the

Contractor must be stated at the time of tendering provided that these other
Standards or Code of Practice are equivalent or superior to the relevant
American or British Standard or any Code of Practice.

Compliance with the Codes of Practice currently in use in Malaysia plus

known proposed Codes would be essential.

1.3.3 Standard Not Specified

If no standard is indicated, then the relevant American or British Standard,

if any, shall apply.

1.3.4 Latest Standards

Where reference is made within these documents to certain standard

specifications, the reference shall be construed to mean the standards, with
all-subsequent amendments, changes or additions as thereafter adopted
and published that are in effect at the date fixed for receipt of tenders.

1.3.5 Certificates

Where the relevant standard provides for the furnishing of a certificate to

the Employer or Engineer at their request, stating that the materials
supplied comply in all respects with the standard, the Contractor shall

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 obtain the certificate and forward it to the Engineer within 7 days prior to the
date when the material or product is to be used in the Contract.

1.3.6 Engineer's Approval

The acceptance of a tender based upon a Standard or Code of Practice

proposed by the Contractor shall only signify the Engineer's general
approval to the use of such Standard or Code of Practice, and shall not
make the Engineer liable to accept a standard of workmanship
subsequently found to be inferior to the corresponding American or British
Standard or Code of Practice.

1.4 ABBREVIATIONS

The abbreviations used in the plans and specifications are abbreviations

the meanings of which are established by general usage throughout the
industry, those shown on the Legend and Notes of the plans contained in
the Specification, and those defined hereinafter.

AASHTO American Association of State Highway and Transportation

Officials, USA.
AISC American Institute of Steel Construction, Inc., USA.
ASME American Society of Mechanical Engineers, USA.
ASTM American Society for Testing and Materials, USA.
API American Petroleum Industry
AWWA American Water Works Association, USA
BS British Standards, UK.
CIRIA Construction Industry Research and Information
Association, U.K.
CP Commercial Standard, US Department of Commerce, USA.
DIN German Standards, West Germany.
JIS Japanese Industrial Standards, Japan.

1.5 PRODUCTION OF DRAWINGS

1.5.1 Drawings

Drawings to clarify or identify additional work or requirements, if any, may

be issued to the Contractor by the Engineer as work progresses.

1.5.2 General Site Plan

The Contractor shall submit a general layout plan prior to commencement

of site works showing locations of site quarters, offices, store, spoil-tips,
access to site and places to stockpile materials. Sources of water supply
and electricity as well as routing on site shall also be indicated. Temporary
drainage systems and dewatering where required shall also be shown.

1.5.3 Temporary Works Drawing

The Contractor shall submit to the Engineer for his approval drawings and a
method statement for all temporary works for sewer trenching, shoring,

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 jacking together with relevant design calculations prior to commencement
of that section of the Works.

1.5.4 As-Built Plans

On completion of each section of the works, the Contractor shall provide 4

sets of A1 size paper print, 2 sets of intermediate tracings “As-Built Plans”
providing details of the bearing and distances of all sewer lines, pump
station and all process equipment and buildings, boundaries, levels,
locations, details, connection and positions to the satisfaction of the
Engineer. All as-built drawings shall also be supplied in digital form
(Autocad “DWG” format) in pen drive.

All surveys shall include property boundaries and frontages. All survey
details are to tie in with boundary stones and benchmarks that are
applicable for the area.

Should the Contractor fail to supply the As-Built Plans and manhole data as
required within a reasonable period of the works, not exceeding 2 months
in any case, the Engineer shall have the right to cause such survey to be
carried out and drawings prepared by a Third Party appointed by the
Employer or Engineer. All costs and expenses incurred in connection
thereof shall be deducted from monies due or to become due to the
Contractor.

1.5.5 Format of Drawings

The Engineer will specify the format scales and sizes of drawings. The
Contractor is required to conform to that format and to the numbering
system derived by the Engineer.

1.5.6 Presentation of Drawings

The Drawings are to be provided on Autocad Version 12 in disc format and

3 also as AO film copies unless otherwise agreed by the Engineer. The As-
Built Plans will also be in a similar format. The film copies will be presented
in numerical order and a list of drawings with the dates and details of any
amendments will be kept on Lotus 3.1 system to a format to be agreed.

1.5.7 Stamping of Drawings

Drawings will be stamped to record their status

(i) Tender Purposes

(ii) Contract
(iii) As-Built

1.6 MEASUREMENTS

The drawings and specifications have generally been developed utilizing

the metric system of units. Subject to the Engineer's approval, which will
not be unreasonably withheld, equipment and materials to equivalent

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 standard sizes and dimensions in the imperial system of units may also be
used.

1.7 OTHER CONTRACTORS

1.7.1 Consideration for Other Contractors

The Contractor must ascertain to his own satisfaction the scope of the
project and the nature of any other contracts that have been or may be
awarded by the Employer and the Contractor shall perform the Contract in
the light of such other contracts. Nothing herein contained shall be
interpreted as granting to the Contractor exclusive occupancy of the site of
the project. The Contractor shall not cause any unnecessary hindrance or
delay to any other contractor working on any project for the Employer.

1.7.2 Information on Subcontractors

The Contractor shall keep the Engineer and Employer informed of the
names of all subcontractors.

1.8 DISCREPANCIES

If the Contractor finds any discrepancy in Drawings or between standard

Drawings and standard Specifications, Schedules or other Documents in
this Contract, he shall immediately refer the matter to the Engineer, who
shall decide which is to be followed. His decision shall be final.

1.9 PROGRAMME OF WORK

The Contractor is required to submit a general outline of his construction

program at the time of submission of this tender.

Within 14 days after the receipt of the Letter of Acceptance of Tender, the
Contractor shall submit to the Engineer for his approval a detailed program
showing the order or procedure and method in which the Contractor wishes
to carry out the Works and shall whenever required by the Engineer or his
Representative, furnish for his information particulars in writing of the
Contractor’s arrangement for carrying out the Works and of the
construction plants and temporary works, if any, which the Contractor
intend to supply or use as the case may be.

The submission and approval by the Engineer or his Representative of

such program or the furnishing of such particulars shall not relieve the
Contractor of any of his duties or responsibilities under the Contract.

If at any time it should appear to the Engineer that the actual progress of
Works does not conform to the approved program referred to herein

before, the Contractor shall produce, at the request of the Engineer, a

revised program showing the modifications to the approved program
necessary to ensure the completion of the whole Works within the time of
completion as stated in the Contract.

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 If, in the opinion of the Engineer, the progress of the works is behind
schedule, the Engineer shall have the right to instruct the Contractor to
increase his plant and labour force and/or to continue work beyond normal
working hours, including night work in order to maintain the progress of the
work to his satisfaction. The Contractor is to allow here for any extra
expense (which shall include all additional expense connected with the
Employer’s and Consultants’ supervision of the Works) incurred from
complying with the Engineer’s Instruction to perform such work necessary
to adhere to the agreed Progress Schedule as no claim for extra payment
for additional labour or for working beyond normal working hours will be
entertained. In no case shall any night work be allowed without the written
permission of the Engineer.

1.9.1 Bar Chart and CPM

A bar chart and critical path network diagram showing the order in which he
proposes to construct the various parts of the Works the dates on which it
is proposed that the work activities will be started and completed,
relationships between activities and the proposed dates for starting and
completing the construction of the principal Temporary Works. For the
purpose of this Contract, Temporary Works shall be defined as all works of
a temporary nature required to execute and complete the Works.

1.9.2 Plans Schedule

The Contractor shall supply a plant schedule listing major items of plant
and showing their time on site related to the operations described on the
bar chart.

1.9.3 Graph

The Contractor shall supply a graph showing the build-up of labour force
and supervision related to the bar chart.

1.9.4 Revisions to Program

If during the course of the work a program revision becomes necessary,

details must be submitted to the Engineer for approval within one week of
the required revision and four copies of the revised program must be
supplied as soon as approval is given.

1.9.5 Rate of Work

Where progress has fallen behind the expected rate and the program, a
revised program must be accompanied by the Contractor's proposals for
increasing the rate of work to meet the new program. This will be required
within two weeks of the Engineer's request after acknowledgment by the
Engineer that the works are behind the expected rate and program.

1.10 SURVEY AND SETTING OUT THE WORKS

1.10.1 Data for Setting out the Works

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 The Contractor shall be deemed to have ascertained before the Tender
Date the extent and probable accuracy of the information and reference
points likely to be available to him and shall carry out all additional survey
work necessary for setting out the Works.

Elevations shown for the various parts of the work will refer to the LAND
SURVEY Datum. Where necessary, the Contractor shall establish the
necessary lines at the surface of the ground and at convenient locations for
the construction of the work. From the established base lines and Bench
Marks the Contractor shall extend the necessary lines and grades for
construction of the work and shall preserve all markers, and stakes set for
lines, Bench Marks, or measurements of the work in their proper places
until agreed by the Engineer. Any expense incurred in replacing said
stakes, which the Contractor may have failed to preserve, shall be borne by
the Contractor.

The survey of the works shall be presented in the format in the land office
standard revenue sheets. These shall from the basis on which all sewer
lines will be routed and determined on site.

1.10.2 Utility Lines Located (Not Included)

1.10.3 CCTV Survey (Not Included)

1.10.4 Sub-Surface Investigation Data

Details, if any, of additional auger holes and borings which may have been
carried out by the Contractor on the location of the proposed Works should
be shown on the drawings by the Contractor and made available to the
Engineer.

1.10.5 Access to Site

The Contractor shall arrange for, construct, maintain and afterwards

remove and reinstate any access required for in connection with the
execution of the Works. Reinstatement shall include restoring the area of
any access route to at least the degree of safety, stability and drainage that
was obtained before the Contractor entered the Site. Surface treatment and
paving will replace to the standard of existing on completion.

1.11 RIGHTS-OF-WAY

The Contractor shall obtain consent from the property owners and shall
make his own arrangements and pay all expenses for the area, access,
wayleaves, etc. required by him to perform the work outside of the land
provided by the Employer.

1.12 COMPLIANCE WITH LAWS AND REGULATIONS

The Contractor shall keep himself informed of all laws, ordinances and
regulations in any manner affecting those employed on the work, or the
materials used in the work, or in any way affecting the conduct of the work,
and of all orders and decrees of bodies or tribunals having any jurisdiction

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 or authority over the same. He shall at all time himself observe and comply
with, and shall require all his agents, employees and subcontractors to
observe and comply with all such applicable laws, ordinances, regulations,
orders and decrees in effect or which may become effective before
completion of this Contract, and shall protect and indemnify the Employer
against any claim of liability arising from or based upon the violation of any
such law, ordinance, regulation, order, or decree, whether by himself, his
employees, or his subcontractors.

1.12.1 Permits and Licenses

Unless otherwise explicitly provided in these specifications, all permits and

licenses necessary to the proper execution of the Works shall be secured
by the Contractor.

1.12.2 Movement of Plant and Heavy Equipment

The Contractor shall not transport plant and heavy equipment to and from
the work site until he has obtained the required permits and clearance from
the Public Works Department, the Local Authority and the Police.

1.12.3 Work in Streets

All work performed within streets, roads, lanes and highways shall be in
accordance with the requirements of all relevant Local Authorities, Police
and other agencies for highway works control. It shall be the responsibility
of the Contractor to determine all requirements of said agencies and to
comply with their requirements.

1.13 SUPERVISION AND INSPECTION

1.13.1 Inspection of Work

All materials and work shall be available for inspection by the Engineer or
his authorized representatives and any work done in the absence of the
said Engineer or authorized representative may be subject to rejection on
interim or final inspection. The Contractor shall notify the Employer and
Engineer two working days in advance of any work to be done, in order that
inspection services may be provided.

1.13.2 Recording of Activities

The Engineer may at any time film operations being undertaken by the
Contractor using a video camera for proof that work is or is not being
constructed in accordance with the Specifications. The usage of such
measures will be notified to the Contractor at the time of filming. The
Contractor may also use this method to demonstrate his working method
etc.

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1.14 MATERIALS IN GENERAL

The term "Materials" shall mean all materials, goods and articles of every
kind whether raw, processed or manufactured, and all equipment and plant
of every kind to be supplied by the Contractor for incorporation in the
Works.

1.14.1 New Materials

All materials shall be new and of the kinds and qualities described in the
Contract and shall be to the satisfaction of the Engineer, that the material
offered is equal or superior to the material specified for the use to which it
is to be put and has obtained from the Engineer approval in writing to its
use. Where materials to be used for any component have not been laid
down in the specification, the Contractor shall use only those materials in
such compositions as have been proved in actual service to be the most
suitable for the particular purpose. New materials and methods may be
used only if the Engineer has given express permission.

1.14.2 Brand Names

Brand names are used herein merely to describe the nature of the desired
equipment and not used to endorse or indicate a preference for a particular
product or manufacturer. Goods, which have similar characteristics and
provide performance and quality at least equal to those specified, are
acceptable unless otherwise scheduled.

1.14.3 Approval of Materials

As soon as practicable after receiving the order to commence the Works,

the Contractor shall inform the Engineer of the names of the suppliers from
whom he proposes to obtain any materials, but he shall not place any order
without the approval of the Engineer which may be withheld until samples
have been submitted and satisfactorily tested. The Engineer may in
instances of doubt submit such samples for testing by a third party. In the
event of failure, on expenses for such testing shall be borne by the
Contractor. The Contractor shall thereafter keep the Engineer informed of
orders for and delivery dates of all materials.

1.15 TESTING AND REJECTION

1.15.1 Operational and Field Testing

After all construction is complete and before acceptance, the Contractor

shall perform field tests as called for in the specification. The Contractor
shall demonstrate to the Engineer the operation of the facilities for proper
sequence of operation and satisfactory performance of the individual
components. Any improper operation of the system or any improper,
neglected or faulty construction shall be repaired or corrected to the
satisfaction of the Engineer. The Contractor shall make such changes,
adjustments or replacement of equipment as may be required to make
same comply with the specifications, or replace any defective parts or
material.

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1.15.2 Tests and Samples

The Contractor shall submit samples of such materials as may be required

by the Engineer and shall carry out the specified tests directed by the
Engineer at the Site, at the supplier's premises or at a laboratory approved
by the Engineer.

A. Samples shall be submitted and tests carried out sufficiently early to

enable further samples to be submitted and tested if required by the
Engineer. Samples for testing will generally be selected by the
Engineer from material to be utilized in the project and all tests will be
under the supervision of, as directed by, and at such points as may be
convenient to the Engineer.

B. Materials requiring testing shall be furnished in sufficient time before

intended use so as to allow for testing. No materials represented by
tests may be used prior to receipt of written approval of said materials.
Samples that are of value after testing shall remain the property of the
Contractor.

C. The Contractor shall give the Engineer at least 14 days notice in

writing of the date on which any of the materials will be ready for
testing or inspection at the supplier's premises or at a laboratory
approved by the Engineer and unless the Engineer shall attend at the
appointed place within the said 14 days the test may proceed in his
absence. Provided that the Contractor shall in any case submit to the
Engineer within seven days of every test such number of certified
copies (not exceeding six) of the test readings as the Engineer may
require.

D. Approval by the Engineer as to the placing of orders for materials or

as to samples or tests shall not prejudice any of the Engineer's
powers under the Contract.

E. The provisions of this clause shall also apply to materials supplied

under any nominated or other subcontract.

1.15.3 Defective Work or Materials

Defective work shall be made good, and unsuitable materials may be

rejected, notwithstanding that such work and materials have been
previously overlooked by the Engineer and accepted. If the work or any part
thereof, shall be found defective at any time before the final acceptance of
the whole work, the Contractor shall forthwith make good such defect, in a
manner satisfactory to the Engineer.

Should it be considered necessary or advisable for the Engineer at any time

before final acceptance of the work to make an examination of work already
completed by removing or exposing the work, the Contractor shall on
request promptly furnish all necessary facilities, labor and materials. If such
work is found to be defective in any respect due to the fault of the
Contractor or of his sub-contractors, he shall defray all the expenses of
such examinations and of satisfactory reconstruction. If however, such work
is found to meet the requirements of this Contract, the additional cost of

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 labor and material necessarily involved in the examination and replacement
shall be allowed to the Contractor.

1.16 SPOIL TIPS

1.16.1 Spoil Tips on Private Land and Additional Site Area

The Contractor shall make his own arrangements to dispose off excavated
material to spoil tips and for possession of any additional land area he may
require for a working or accommodation space. He shall be responsible for
obtaining the consent of the owner, tenant or occupier of private land for
such use or for other temporary purposes. Before entering upon private
land, the Contractor shall confirm in writing to the Engineer that he has
obtained such consent.

The Contractor shall pay all costs, expenses, rentals, fees, compensation
or other disbursements which may be incurred by him or in negotiations
with owner, tenant or occupier and during the subsequent use by him of
such private land for temporary purposes in connection with this Contract.

The Contractor shall note that his responsibility shall apply to the whole of
the land occupied or used by him for the purpose of the Works.

1.16.2 Responsibility for Damage

The Contractor will be held responsible for all damage which he may do to
land or property outside his necessary working space. Compensation for
damage to such land or property will be assessed by the Employer for
settlement by the Contractor through the Employer.

The Employer will be entitled to withhold from any payments due to the
Contractor sufficient sums as may appear to him to be necessary to cover
the Contractor's liabilities until evidence is produced by the Contractor to
the Engineer to show that the Contractor's liabilities in this respect have
been finally settled and discharged.

1.17 CLAIMS FOR DAMAGES

1.17.1 Claims for Damage to Persons or Property

Any claim received by the Employer or Engineer in respect of matters in

which the Contractor is required under the Contract to indemnify the
Employer will be passed to the Contractor who shall likewise inform the
Employer and the Engineer of any such claim which is submitted directly to
him by a claimant.

The Contractor shall do everything necessary including notifying the

insurers of claims received, to ensure that all claims are settled properly
and expeditiously and shall keep the Employer and the Engineer informed
as to the progress made towards settlement, failing which the Employer
shall be entitled to make direct payment to claimants of all outstanding
amounts due to them in the Employers opinion and without prejudice to any
other method of recovery to deduct the amounts so paid from any sums
due or which become due from the Employer to the Contractor.

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1.17.2 Indemnified Claims

If the Contractor receives a claim, which he considers to be in respect of

matters in which he is indemnified by the Employer under the Contract, he
shall immediately pass such claim to the Employer.

1.18 PROTECTION OF PROPERTY AND UTILITIES

1.18.1 Protection of Property

The Contractor shall conduct his operations in such a manner as to avoid

injury or damage to adjacent property, improvements, or facilities.
Buildings, trees, ground cover and shrubbery that are not designated for
removal, pole lines, fences, guide posts, culverts, property and other
markers, signs, structures, conduits, cables, pipelines and other facilities
within or adjacent to the street or right-of-way shall be protected from injury
or damage.

The Contractor shall provide and install suitable safeguards to protect such
objects from injury or damage, which objects if injured or damaged by
reason of the Contractor's operations, shall be replaced or restored to a
condition as good as when entered upon the work, or as required by the
specifications.

The Contractor shall not disturb any monuments, property corners or

survey markers without permission from the Engineer, and he shall bear
the expense of resetting any monuments, property corners or survey
markers which may be disturbed.

The Contractor shall be responsible for all damage to streets, utilities,

roads, highways, ditches, embankments, bridges, culverts or other public or
private property, which may be caused by transporting equipment,
materials, or men to or from the work. The Contractor shall make
satisfactory and acceptable arrangements with the property owner over the
damaged property concerning its repair or replacement.

1.18.2 Contact of Utility Owners

It shall be the responsibility of the Contractor, before commencing any

excavation, to contact all possible owners of utilities within the work area
and to ascertain from records or otherwise, including on-site detection by
suitable instruments the existence, position and ownership of all utilities,
utility structures and service connections. No error or omission regarding
the said utilities shall be construed to relieve the Contractor from his
responsibility in protecting all such facilities.

The owners of utilities the Contractor shall contact will include but not
limited to the following :

(i) Jabatan Kerja Raya (JKR)

(ii) Tenaga Nasional Berhad (TNB)
(iii) Jabatan Bekalan Air (JBA)
(iv) Telekom Malaysia Berhad (TMB)

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 (v) Jabatan Pengaliran dan Saliran (JPS)
(vi) Keretapi Tanah Melayu (KTM)
(vii) Petronas with reference to gas pipelines

1.18.3 Maintenance and Repair

Unless otherwise indicated on the Drawings or in these specifications, all

water lines, lighting, power, telephone, or radio cables and conduits; sewer
lines; house connection lines; and other subsurface structures of any
nature along the work shall be maintained by the Contractor and shall not
be disturbed, disconnected, or damaged by him during the progress of the
work.

1.18.4 Notification to Agencies and the Engineer

The Contractor shall notify utility owners affected and the Engineer
whenever utilities or services are encountered within the Contractor's work
area or proposed pipe route and shall not proceed with further work until
clearance has been obtained from the appropriate agency.

1.18.5 Private Sewers and Sanitary Facilities

The Contractor shall not disturb any existing private sanitary facilities.
Unless otherwise indicated on the plans, all private sanitary facilities shall
be maintained by the Contractor and shall not be disturbed or disconnected
by him. The Contractor shall install temporary pipes of adequate size to
carry off sewage from any private sewer facilities cut off by construction
work. Connections to temporary pipes shall be made immediately by the
Contractor upon cutting of the existing facility. No sewage shall be allowed
to flow from any severed facility upon the ground surface or in the trench
excavation. Pipe used in temporary sewers may be clay, metal, concrete or
composition. Upon completion of work the Contractor shall replace all
severed connections and restore to operating order the existing sanitary
facilities.

1.18.6 Storm Drainage and Drainage Culverts

The Contractor shall afford all reasonable protection to drains (of whatever
type) and culverts lying within the work site from damage during pipeline
installation. In the event of damage occuring to such drains and culverts
despite the Contractor's precautionary measures, the Contractor shall
repair or otherwise replace the same and to a standard of work approved
by the Engineer which shall not be lower than before the damage was
inflicted.

1.18.7 Water Service

No valve or other control of the water supply system shall be operated by

the Contractor without approval of the affected utility owner and all owners
and consumers affected by such operation shall be notified by the
Contractor at least four hour before the operation and advised of the
probable time when service will be restored.

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1.18.8 Fire Hydrant

The Contractor shall not draw any water from a fire hydrant for use on the
work, without first obtaining permission from the affected utility owner.
Access to all fire hydrants along the sewer alignments or within the areas of
work must be available throughout the entire period of work for the Fire
Department.

1.18.9 Rail Crossings

The Contractor shall make all arrangements and comply with all
requirements and regulations of the railway owner for crossing railway
lines. Any direct or consequential costs associated with such crossings
including permits, flagging and inconvenience charges, delays in obtaining
appropriate orders and procedures and/or uneconomic working
requirements (e.g. restricted work periods) shall be deemed to be included
in the Contract Price. A safe system of work shall be implemented and
which shall have the prior approval of the railway owner.

1.18.10 Bridge Crossings

The Contractor shall make all arrangements and comply with all
requirements and regulations of Authorities responsible for over bridges
and under bridges encountered during the work.

1.18.11 Right of Accessibility

The right is reserved to the Employer, to governmental agencies and to

owners of public utilities to enter upon any street, alley, rights-of-way, or
easement for the purpose of maintaining or of making necessary repairs or
changes in property made necessary by the work.

1.18.12 Lighting, Watchmen and Signposting

The Contractor shall supply all requisite plant for the proper execution of
the work including scaffolding, tackle, machinery, pumps, tools, barricades,
lights or other appliances and everything necessary for the use of his
workmen, together with the carriage thereof to the spot where required and
for their erection, operation and subsequent removal. The Contractor shall
be responsible for the adequate protection of the Works and shall provide,
all footways etc. necessary for the passage of pedestrian traffic to all
buildings bounding the sites of the works, particularly with regard to the
collection of night soil. The Contractor shall provide and maintain all
necessary traffic barriers, lights and all other requirements to the
satisfaction of the Engineer, Local Authorities, Public Works Department
and Polis Di Raja Malaysia (Traffic Division).

At each point where work is being carried out on a roadway or in any other
place open to the public, the Contractor shall provide appropriate temporary
signs in accordance with the requirements for Temporary Sign specified in
the Road Traffic Ordinance, 1958 : Traffic Signs (Size, Colour and Type)
Rules, 1959 and all amendments thereof including the Traffic Signs (Size,
Colour and Type)(Amendment) Rules 1984. These signs shall comply with

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 the Ordinance in every respect and shall be finished in the appropriate
colours of reflective sheeting such as `Scotchlite' (Engineering Grade) or
similar. The Contractor shall comply with all the requirements of the
Railway Administration while laying sewers across railway lines.

Any temporary signs of sizes and to legend as approved or as directed by

the Engineer shall be provided. Every sign placed on a site shall be further
illuminated at night by one or more lanterns as directed and the provision of
such lanterns shall be deemed to be part of the illumination as required
above. The Contractor should make his own arrangements for the
purchase or fabrication of any signs or notices required under this Clause.

The Contractor shall not commence work under any circumstances until the
Engineer is satisfied that an adequate number of barricades, lanterns, sign
and notices as described herein of this Specification have been provided
and are stored, ready for use, on the site.

If by neglect or omission the Contractor shall fail to provide adequate

barricading, lighting or signposting, or the services of watchmen, the
Employer reserves the right to enter upon the sites of the works and to
provide any or all of the services required under this Clause without prior
notice to the Contractor and the charges incurred shall be chargeable to the
Contractor and shall be deducted from monies due to him under this
Contract.

1.19 AMENITIES TO BE PRESERVED

The Contractor shall cause the least possible interference with existing
amenities, whether natural or man-made. No trees shall be felled except on
the instructions of the Engineer and clearance of the Site shall generally be
kept to the minimum necessary for the Works and Temporary Works.

The Contractor shall during the progress of construction, take proper

precautions to prevent damage to trees, plants, and shrubs. The piling of
excavated material, equipment, construction materials, or anything else on
top of branches or against tree trunks will not be permitted.

1.20 TEMPORARY WORKS

Within a reasonable time (and in any case not less than 21 days) before he
intends to commence construction of any of the Temporary Works, the
Contractor shall submit full particulars, including drawings, of the same for
the approval of the Engineer. The submission to and approval by the
Engineer of any such particulars shall not relieve the Contractor of his
responsibility for the sufficiency of the Temporary Works or of his other
duties and responsibilities under the Contract. The Contractor shall make
safe and reinstate all areas affected by Temporary Works.

1.21 WORKS TO BE KEPT CLEAR OF WATER

1.21.1 Temporary Facilities

The Contractor shall keep the Works well drained until the Engineer
certifies that the whole of the Works is substantially complete and shall

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 ensure that so far as is practicable all work is carried out in the dry.
Excavated areas shall be kept well drained and free from standing water.

The Contractor shall construct, operate and maintain all temporary dams,
water courses and other works of all kinds including pumping and well-point
dewatering that may be necessary to exclude water from the Works while
construction is in progress. Such temporary works shall not be removed
without the approval of the Engineer. The Contractor is to take all
necessary precautions to avoid flotation of any partially completed
structure.

1.21.2 Responsibility of the Contractor

Notwithstanding any approval by the Engineer of the Contractor's

arrangements for the exclusion of water, the Contractor shall be
responsible for the sufficiency thereof and for keeping the Works safe at all
times, particularly during any floods, and for making good at his own
expense any damage to the Works including any that may be attributable to
floods.

1.21.3 Discharge of Water into Existing Streams, Etc.

The Contractor shall make provision for the discharge or disposal from the
Works and Temporary Works of all water and waste products howsoever
arising, and the methods of disposal shall be to the satisfaction of the
Engineer and of any Authority or person having an interest in any pond or
water course over or in which water and waste products may be so
discharged.

1.22 USE OF EXPLOSIVES

The Contractor shall keep himself informed of all laws, ordinances, and
regulations governing the transportation, storage, and use of explosives.
The Contractor shall use the utmost care not to endanger life and property.
The Contractor shall be responsible for any and all damages resulting from
the use of explosives. No blasting shall be done which will damage
subsurface conduits or structures.

1.23 WORK SITE MAINTENANCE

1.23.1 Access to Property Abutting Work

Convenience of abutting owners along the street shall be provided for as

far as possible. Convenient access to driveways, houses and buildings
adjoining the work shall be maintained and temporary approaches to
intersecting streets and alleys shall be provided and kept in good condition.
When a section of surfacing, pavement or a structure has been completed,
it shall be opened for use to traffic at the request of the Engineer. In order
that unnecessary delay to the traveling public may be avoided, the
Contractor shall provide competent flagmen whose sole duty shall consist
of directing traffic either through or around the work.

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1.23.2 Access to Water Mains and Water Valves

The Contractor shall allow the free access to all water mains and water
valves by the Water Authority for purposes of operation and maintenance
of the same.

1.23.3 Accessibility Facility

The Contractor shall at all times provide proper facilities for access and
inspection of the work by the Engineer, his representative, assistants,
inspectors, agents and representatives of public agencies and utility owners
having such jurisdiction.

1.24 CONSTRUCTION FACILITIES

1.24.1 Water Supply

The Contractor shall provide suitable supplies of water for drinking,

washing, sanitation, and general cleaning down in addition to that required
for construction of the Works. All water used shall not be taken from private
houses or consumer's premises. The Contractor shall make his own
arrangements with the Water Department for supply of water.

1.24.2 Electrical Supplies

The Contractor shall make all arrangements for the supply, installation,
operation, maintenance, and subsequent removal of temporary supplies of
electricity for the air conditioning, lighting and ventilation of all offices,
stores, laboratories, and other temporary buildings used by him and by the
Engineer in addition to any supplies he may require in connection with the
construction of the permanent Works. He will be responsible for the
provision of power to the sites for commissioning the Works.

1.24.3 Sanitation

The Contractor shall maintain the Site and all working areas in a sanitary
condition and in all matters of health and sanitation shall comply with the
requirements of the local Medical Officer of Health or other competent
authority.

1.24.4 Telephone

Any telephone facilities which the Contractor may install in connection with
the work shall be made available for use of the Engineer or his
representatives without charge. A separate telephone shall be provided for
the Engineer's Office.

1.24.5 Transportation Facilities

The Contractor shall investigate the availability of transportation facilities

and shall make all arrangements necessary for the delivery of materials to
be used on the work. The Contractor shall make his own investigation on
the condition of available public roads, access rights-of-way, and of

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 restriction, bridge load limits and other limitations affecting transportation
and ingress and egress at the sites of work.

1.24.6 Temporary Fencing

The Contractor shall erect, maintain, and remove suitable and approved
temporary fencing to enclose such areas of the Works and all areas of land
occupied by the Contractor within the Site as may be necessary to the
satisfaction of the Engineer. Where any temporary fencing has to be
erected alongside a public road, footpath etc., it shall be of the type
required by and shall be erected to the satisfaction of the Authority
concerned.

1.24.7 Storage Facilities

The Contractor shall be responsible for the storage of all materials,

equipment and so on, which are used in the Work. All materials, equipment
and articles at the site shall be adequately housed by the Contractor or
otherwise protected by him against deterioration and damage. If any
materials stored at the site or any partially completed structures are not
adequately protected by the Contractor, the materials or the partially
completed structures may be kept protected by the Employer at the
expense of the Contractor.

1.24.8 Office Accommodation for Engineer (Not Included)

1.24.9 Office Equipment and Accessories for the Engineer (Not Included)

1.24.10 Contractor's Offices

The Contractor shall provide, erect, construct, maintain and subsequently

remove all temporary offices, sanitary conveniences, stores, workshops,
labourer’s quarters, compounds, parking areas and the like necessary for
the completion and maintenance of the Works and the siting and layout of
these shall be made with the general approval of the Engineer. The
Contractor shall pay all fees required by law to the relevant authorities.

1.24.11 Contractor's Site Services

The Contractor shall also provide, maintain and subsequently remove

temporary services for water supply, drainage, lighting and ventilating,
roads, paths, parking places and refuse disposal for his staff and other
employees and for the employees of his subcontractors. Details and layout
of buildings and services shall be made with the general approval of the
Engineer and the Contractor shall also obtain any necessary approval from
any local or other authorities concerned. The erection of Worker's quarters
on any public street is prohibited.

1.24.12 Signboard

The Contractor shall erect a signboard at each Site of the Project of size
2.74m x 4.08m at locations to be indicated by the Engineer. The signboard
shall be painted and the inscriptions on the boards shall be to the approval

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 of the Engineer. The signboard is to be erected immediately on
commencement of the Works unless otherwise approved by the Engineer.

1.24.13 Assistance for the Engineer's Staff

The Contractor shall provide every assistance to the Engineer and his staff
in carrying out their duties and shall provide a sufficient supply of pegs,
poles, paint lines, spirit levels and other materials and small tools for
checking the setting out and for measurement of work. The Contractor shall
also provide for the Engineer and his staff such waterproof clothing, safety
helmets, rubber boots, torches and the like as may reasonably be required
by them, but these articles shall remain the property of the Contractor.

1.24.14 Site Vehicle (Not Included)

1.25 COMPUTER EQUIPMENT AND ACCESSORIES (Not Included)

1.26 MOBILE PHONE (Not Included)

1.27 TEMPORARY OFFICES FOR THE S.O. AND HIS STAFF (Not Included)

1.28 SITE CONTROL AND SAFETY

1.28.1 Safety Measures and Public Convenience

The Contractor shall provide for the protection of all persons and property
at all times. The Contractor shall comply with the recommendations for safe
construction methods from the "Manual of Accident Prevention in
Construction", published by the Associated General Contractors of
America, Inc., to the extent that such provisions do not conflict with locally
applicable laws. Machinery and equipment shall be guarded in accordance
with the requirements set out in the Factories & Machinery Act 1967 or as
specified by the Factories & Machinery Department. The Contractor shall
take all necessary measures to protect the work and prevent accidents
during the construction. He shall provide and maintain sufficient night lights,
barricades, guards, temporary sidewalks, temporary bridges, danger
signals, watchmen and necessary appliances and to properly safeguard life
and property. He shall also protect all excavations, equipment and
materials with barricades and danger signals so that the public will not be
endangered.

1.28.2 Inconvenience

The Contractor shall so conduct his operations as to offer the least possible
obstruction and inconvenience to traffic, and he shall have under
construction no greater amount of work than he can handle properly with
due regard for the rights of the public. Where existing streets are not
available as detours, all traffic shall be permitted to pass through the work
with as little delay and inconvenience as possible, unless otherwise
authorised by the Engineer.

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1.28.3 Trespassing

The Contractor shall be responsible for all damage or injury which may be
caused on any property by trespass by the Contractor or his employees in
the course of their employment, whether the said trespassing was
committed with or without the consent or knowledge of the Contractor.

1.28.4 Dust Control

The Contractor shall conduct his operations and activities in such a manner
that no operation shall be conducted which will emit into the atmosphere
any flying dust or dirt which might constitute a nuisance. The Contractor
shall take all measures to keep the flying dust caused by any construction
work or activities to its minimum.

1.28.5 Clean Vehicles

The Contractor shall be responsible that all vehicles leaving the project site
must be sufficient cleaned/flushed prior to entering the public roads.

1.28.6 Pollution Control of Water Courses

The Contractor shall take precautions to avoid erosion of excavated areas

by storm water and surface run-off such as:
o restrict excavation only when construction work is ready to
commence;

o introduce adequate site drainage;

o undertaking dewatering of site and channeling water to necessary

water courses via adequate silt traps;

o topping and turfing of site previously worked on or after excavation

immediately after contouring.

1.28.7 Mosquito Control

No empty containers or other receptacles capable of collecting water and

forming breeding places for mosquitoes are to be left in the open and the
Contractor is responsible during the course of the work for all measures
necessary to prevent the breeding of mosquitoes on the sites of the work.

1.28.8 Fire Hazard (Naked Lights)

No naked light shall be used by the Contractor on or about the Site other
than in the open air without the permission in writing from the Engineer. If in
the Engineer's opinion the use of naked lights may constitute a fire hazard,
the Contractor shall take such additional precautions and provide such
additional fire fighting equipment (including breathing apparatus) as the
Engineer considers necessary.
The term "naked lights" shall be deemed to include electric arcs and oxy-
acetylene or other flames used in welding or cutting metals.

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1.27.9 Site to be Kept Tidy

Throughout the progress of his work, the Contractor shall keep the Site and
all working areas in a tidy and workmanlike condition and free from rubbish
and waste materials. Any Temporary Works, Constructional Plant,
materials or other things which for the time being are not required for use
by the Contractor may with the consent of the Engineer be removed from
the Site, but otherwise shall be dispersed about the Site in an orderly
fashion and shall be properly and securely stored thereon.

1.27.10 Representatives for Emergencies

The Contractor shall file with the Engineer, the names, addresses, and
telephone numbers of representatives who can be contacted locally, at any
time, in case of emergency. These representatives must be fully authorised
and equipped to correct unsafe or excessively inconvenient conditions on
short notice.

1.27.11 Safe Working in Sewers and at Sewage Works

The Contractor shall arrange for gas testing equipment to be available and
used before entry to any manhole over 1.6 meters depth or any confined
space where gas may be present. In addition emergency escape sets
comprising breathing apparatus sufficient for 10 minus in gas should also
be provided. The Employer will provide information and guidance on safe
procedures which are effectively used in the United Kingdom and
adherence to their procedures will be required under the Contract.

1.28 COMPLETION OF WORK

1.28.1 Clearance of Site on Completion

On completion of the Works, the Contractor shall clear away and remove
from the Site all Constructional Plant, surplus materials, rubbish and
Temporary Works of every kind and leave the whole of the Site and Works
clear and in a workmanlike condition to the satisfaction of the Engineer.

1.28.2 Final Conditions of Work

Before application is made for the Employer to accept the Works, all items
of work shall be complete, ready to operate and in a clean condition. All
trash, debris, unused building material and temporary structures shall have
been removed from the site of the work. Tools and construction machinery
not needed for repair and adjustment consequent to operational tests shall
not be on the Site. The walkways, parking areas, roadways, streets and
lanes shall be completely swept and broomed.

1.29 PROJECT MEETINGS

1.29.1 Attendance

Unless otherwise specified or required by the Employer, the meetings shall

be attended by the Employer, the Engineer, and the Contractor, his Agent
and Engineer. Subcontractors may attend when involved in the matters to

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 be discussed or resolved but only when requested by the Employer or
Engineer.

1.29.2 Meeting Records

The Engineer will record minutes of each meeting and will furnish copies to
the Contractor within 5 working days thereafter. If the Contractor does not
submit written objection to the contents of such minutes within 7 days after
presentation to him, it shall be understood and agreed that the Contractor
accepts the minutes as a true and complete record of the meeting.

1.29.3 Meeting Schedule

The dates, items and locations for the various meetings shall be agreed
upon and recorded at the preconstruction conference. Thereafter, changes
to the schedule shall be by agreement between the Engineer and
Contractor, with appropriate written notice to all parties involved.

1.29.4 Preconstruction Conference

Prior to commencement of the work, a preconstruction conference shall be

held at the location, date, and time designated by the Employer. In addition
to the attendees named herein, the meeting shall be attended by the
representatives of regulatory agencies having jurisdiction over the Works, if
required, and such other persons the Employer may designate.

Agenda in general and matters to be discussed or resolved and the

instructions and information to be furnished to or given by the Contractor at
the preconstruction conference include:

A. Project meeting schedule.

B. Progress schedule submitted by Contractor.

C. Communication procedures between the parties.

D. The names and titles of all persons authorised by the Contractor to

represent and execute documents for him, with samples of all
authorised signatures.

E. The names, addresses, and telephone number of all those authorised

by the Contractor to act for him in emergencies.

F. Construction permit requirements, procedures and posting.

G. Public notice of starting work.

H. Procedures concerning installation of Work on public or private

property not owned by the Employer.

I. Access and rights-of-way to be furnished by the Employer.

J. Quality Assurance.

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 K. Forms and procedures for Contractor's submittals.

L. Variation Order forms and procedures.

M. Payment application forms and procedures and the revised progress

schedule reports to accompany the applications.

N. Contractor's safety programme.

O. Contractor's provisions for barricades, traffic control, utilities, sanitary

facilities, and other temporary facilities and controls.

P. Project Signboard for Employer if required by the Specifications.

Q. Engineer's representative and his duties.

R. Construction surveyor and initiation of surveying services.

S. Testing laboratory or agency, and testing procedures.

T. Construction equipment and methods proposed by the Contractor.

U. Other administrative and general matters such as insurance

certificates as needed.

1.29.5 Progress Meetings

The meetings shall be held on a regular basis in accordance with the

agreed schedule. All matters bearing on the progress and performance of
the Work since the preceding progress meeting shall be discussed and
resolved, including without limitation any previously unresolved matters,
deficiencies in the work or the methods being employed for the Work, and
problems, difficulties, or delays which may be encountered.

1.29.6 Special Meetings

Upon appropriate notice to the other parties, special meetings may be

called by the Employer, Engineer, or Contractor. Special meetings will be
held where and when designated by the Employer.

1.29.7 Regulatory Agencies

When requested, the Contractor shall attend meetings held or required by

the Government regulatory agencies having jurisdiction over the Works.

1.29.8 Post Construction Conference

A post construction conference shall be held prior to final inspection of the

Work to discuss and resolve all unsettled matters. The Guarantees and
insurance to remaining force, and the other documents required to be
submitted by the Contractor will be reviewed and any deficiencies
determined. Schedules and procedures for the final inspection process and
for the rectification of defects, and deficiencies, shall be discussed and
agreed.

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 SECTION 4

SITE CLEARANCE AND TRENCHWORK

4.1 DEFINITIONS

The following terms shall have the meanings hereby assigned to them :-

"Topsoil" means any surface materials, including turf, suitable for use in soiling
areas to be grassed or cultivated.

"Rock" means material which in the opinion of the Engineer would normally have
to be loosened either by blasting or by the use of pneumatic tools (excluding clay
spades worked on an air compressor) or by other rock quarrying methods or, if
excavated by hand, by the use of wedge and sledge hammers. An isolated solid
boulder or detached piece of rock shall qualify as Rock only if it exceeds 0.15
cubic metre in volume.

"Bulk" means excavation in open cut (excluding Trench Excavation and

Incidental Excavation) down to levels specified on the Drawings or otherwise as
being the general levels after completion of excavation.

"Trench" means excavation of trenches into which pipes or excavation cables are
to be laid to levels and limits specified on the Drawings or otherwise directed by
the Engineer.

"Incidental" means excavation below or outside the limits of excavation bulk

excavation and trench excavation.

"Excess" means excavation outside the limits specified or excavation shown on

the drawings or directed by the Engineer for bulk, trench or incidental excavation.

All reference to "excavation" or "excavations" shall apply to bulk, trench,

incidental and excess excavation(s) except where clearly stated to the contrary.

4.2 LEVELS TO BE RECORDED

Before the surface of any part of the site is disturbed or the works thereon are
begun the Contractor shall take and record levels and cross sections along the
proposed line of excavation or any such part, in the manner specified or as
agreed with the Engineer in his presence and such levels when agreed with him
shall form the basis for measurement.

4.3 EXPLOSIVES AND BLASTING

The Engineer shall have power to regulate, restrict or prohibit blasting if in his
opinion it is necessary to do so for the safety of persons or property or to
safeguard the works. No blasting shall be carried out in any part of the works
without the permission in writing of the Engineer. Such permission shall not
absolve the Contractor from any of this obligations or liabilities under the
Contract and he shall take all necessary precautions including the use of blasting
nets to avoid damage, loss or injury to persons and to public or private property.

4-1
 The Contractor shall keep the Engineer fully informed at all times when blasting
is proposed to be carried out and of any details that may be required concerning
strength of charges and their positions.

Explosives shall not be used within 15 metres, or such greater or lesser

distances as the Engineer may direct, of concrete placed in the works, of any
existing structure, water main, electric cable, sewer or other services.

The Contractor shall obtain the necessary permits and licences for the use,
storage, transport and handling of explosives and shall provide a store or stores
suitable for explosives in accordance with local regulations.

4.4 EXCESS EXCAVATION TO BE MADE GOOD

The Contractor at his own expense shall remove from the site all material
resulting from excess excavation and shall make good the same with such kind
of fill material or in such class of concrete as may be reasonably required by the
Engineer having regard to the circumstances.

4.5 SITE CLEARANCE

All areas of the site marked on the Drawings or specified for clearance or from
which material is to be excavated or upon which filling is to be deposited shall be
cleared to the extent required by the Engineer of all buildings, walls, gates,
fences and other structures and obstructions and of all bushes, hedges, trees,
stumps, roots and other vegetation except for trees marked for preservation.
Material so cleared shall be disposed of off the site as directed by the Engineer.

4.6 TREES

Trees shall be uprooted or cut down as near to ground level as possible.

Branches and foliage shall be removed and burnt to ash or disposed of off the
site. Useful timber shall remain the property of the Government and shall be cut
into suitable length and stacked properly.

4.7 STUMPS

Stumps and roots whether existing or remaining after tree felling shall where
directed by the Engineer be grubbed up and disposed of off the site. The
resulting hole shall be filled with approved material deposited in 225 mm layers
and compacted to the same dry density as the adjoining soil.

4.8 MEASUREMENT OF SITE CLEARANCE

Items in the Bill of Quantities for site clearance shall include for clearing the site
all as specified including all fallen trees and their stumps. Site clearance shall be
measured as the area so cleared on plan to the Engineer's requirements and
instructions.

4.9 STRIPPING TOPSOIL

Where ordered by the Engineer topsoil shall be stripped, to such depths and over
such areas as he may direct, as a separate operation prior to any further
excavation which may be required.

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4.10 GENERAL EXCAVATION

General excavation means excavation, whether Bulk or Incidental, required for

structures and shall not include trench excavation.

The ground shall be excavation by such methods and to such dimensions and
depths as shall allow for the proper construction of the works.

Where nominal `payment' limits of excavation are not shown on the drawings or
otherwise specified they shall be deemed to be the minimum net limits which
would allow the outline of the completed structure to be lowered vertically from
ground level into its final position. The Contractor shall make his own allowance
for any working space required, and any excavation outside the aforesaid limits
which has not been ordered by the Engineer whether it be excavated to suit the
Contractor's method of working or unavoidable overbreak or due to his
carelessness or error, shall be held to be excess excavation.

4.11 TRENCH EXCAVATION

The line and level of trenches shall be as shown on the drawings or as directed
by the Engineer. Before commencing Trench Excavation, the route of the trench
shall be pegged out accurately and the existing ground levels shall be agreed
with the Engineer. Strong sight rails shall then be fixed and maintained at each
change of gradient, and at as many intermediate points as may be necessary.
On these rails shall be marked the centre line and the level to which the
excavation is to be carried out, such rails not more than 35 metres apart.

Trench Excavation shall be carried out by such methods and to such lines
dimensions and depths as shall allow for the proper construction of the works,
provided always that, unless the Engineer permits otherwise and subject to any
specific requirements of the Specification no Trench Excavation shall be less
than the widths stated below :-

Description Clear width of Clear width of trench

trench for backfill for backfill with sand
with excavated
material

Not exceeding 500 D + 450 mm D + 450 mm

mm
D + 600 mm D + 600 mm
Exceeding 500 mm
but not exceeding
1500 mm

Where D in mm is the external diameter of the pipe including any sheathing.

Notwithstanding the foregoing, any rock in trench excavation shall be so

excavated that the clearance between the pipe when laid and the rock sides and
bottom of the trench is kept to the minimum limits necessary to provide for the
specified thickness of bedding haunching and surround to the pipe. Any
excavations outside these limits whether for working space or due to overbreak

4-3
 shall be held to be Excess Excavation.

The sides of Trench Excavation shall be vertical unless the Engineer permits
otherwise.

Stones shall be removed from the trench invert and holes so formed shall be
filled with well compacted selected soft material. Where mechanical excavators
are used, the last 150 mm of the excavation shall be removed by hand to the
required depth, and the trench invert carefully trimmed true to level.

Any widening or deepening of Trench Excavations necessary to accommodate

curves, joints or bends in the pipe or to provide extra working space for the
construction thereof shall be held to be Excess Excavation.

Trench Excavation shall wherever practicable be carried out in such a way that
every part of the excavation is at least 600 mm clear of the existing edge of the
carriageway. In any event the Contractor shall take special precautions, which
shall include the continuous support of the sides of the excavation, from the time
when excavation is begun until the refilling of the trench is placed, to ensure that
there is no disturbance of the adjacent road or road foundation.

For the purpose of measuring certain work in connection with Trench Excavation
"nominal limits" of Trench Excavation are stated above or as stated in the
drawings and any excavation outside these limits which have not been ordered
by the Engineer shall be held to be Excess Excavation.

4.12 CONSTRUCTION ALIGNMENT AND GRADES

The line and level of trenches shall be in accordance with the design criteria or
as may be directed by the Engineer. Before commencing trench excavations, the
route of the trench shall be marked out accurately and the natural ground levels
shall be made available to the Engineer. Strong sight rails shall then be fixed and
maintained at each change of gradient, and at as many intermediate points as
may be necessary. On these rails shall be marked the centre line and the level to
which the excavation is to be carried out, such rails being not more than fifteen
metres apart. Alternatively, the use of laser beam directional instrumentation
may be employed for the alignment of pipes in the vertical and horizontal plane.
The siting of the instrument should be checked prior to pipelaying and
conventional checks made by surveying instruments as the work proceeds.

4.13 CHANGES IN LINE AND GRADE

In the event that obstructions not shown on the plans are encountered during the
progress of the work which will require alterations to the plans, the Contractor
shall have the authority to change the plans and effect the necessary deviation
from the line and/or grade with the agreement of the Engineer. The Contractor
shall not make any deviation from the specified line and/or grade without the prior
agreement of the Engineer.

4.14 TRENCH EXCAVATION IN ROADS, ROAD SHOULDERS AND FOOTPATHS

All Trench Excavation and other work carried out within the limits of any road
reserve shall be completed as rapidly as possible and not more than half of the
width of the carriageway shall be obstructed at one time. A minimum width of 4

4-4
 m wide or as required by the authority of traffic lanes shall have to be kept clear
for flow of traffic and where necessary the shoulder should be strengthened to
the satisfaction of the relevant Authorities at the Contractor's own cost. Road
drains and grids shall be kept free from obstruction.

Where trenches are excavated in public roads, road shoulders and footpaths of
congested areas necessitating carting spoil to distant tips, the Contractor shall
employ suitable plant to ensure that the passage of traffic past the works is not
impeded by the loading and unloading of spoil. Excavated materials shall not be
left standing on road pavement. All trenches on metalled roads shall not be left
open for more than one day and all trenches on road verges shall not be left
open for more than three days.

Tarmacadam and similar road surfaces shall be broken out neatly along the
trench line using a diamond disc road cutter to keep the edges straight and
vertical.

The Contractor shall take special precautions, including the continuous support
of the sides of the excavation from the time excavation is begun until refilling of
the trench is completed to ensure that there is no disturbance of the adjacent
road or road foundation. The Contractor shall also provide barricades to fence
off the works and approved road signboards placing at regular intervals to ensure
safety of the public and vehicles.

4.15 TRENCH EXCAVATION IN SURFACES OTHER THAN ROADS

Trench excavation in surfaces other than roads shall include all surfaces except
those asphalt surfaces which require road reinstatement. These surfaces include
but are not limited to fields, paddy fields, pasture land and the like, footpaths,
verges, non-asphalted roads, lanes, alleys, and all private lands. Trench
excavation located in fields shall if the Engineer so requires have temporary
fencing erected around that length. Temporary fencing shall not be removed
without the Engineer's permission, which will not normally be given until the
trench excavation has been refilled and reinstated. All additional land occupied
temporarily by the Contractor must be reinstated back to satisfactory condition
immediately upon completion of that particular stretch of pipeline. The Contractor
is hereby notified that generally all sewer and force main alignments not in
streets are covered with a vegetation growth which must be removed and
disposed off the site of work. The Contractor shall have particular regard to the
safety of livestock in fields or which may be introduced to the fields, and shall
ensure that all open excavations, access routes and steep or loose slopes arising
from the Contractor's operations in these fields are adequately fenced and
protected. After the erection of temporary fencing where required, the Contractor
shall remove topsoil to such depth and over such area as may be necessary to
provide sufficient material to ensure adequate surface reinstatement of the
working areas occupied by the Contractor for construction of the pipeline.
Separate storage areas must be provided for topsoil and subsoil.

4.16 TRENCH EXCAVATION IN TEMPORARY BUILDING SITES

Temporary building sites (squatters) may also occupy sewer rights-of-way or

construction sites. The Contractor shall notify the owners along sewer rights-of-
way one week in advance of work that the sewer construction may temporarily
disrupt their living accommodations. The Contractor shall negotiate and arrive at

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 an agreement with the occupants along sewer rights-of-way for temporary living
accommodations during the period of construction in the vicinity of the work,
removal and reinstatement of the temporary building or portion affected by
construction and other conditions which may affect the occupants.

In the event that the Contractor fails to reinstate the property to the satisfaction of
the occupants along sewer rights-of-way, the Employer will be entitled to withhold
from any payments due to the Contractor sufficient sums as may appear to the
Employer to be necessary to cover the Contractor's liabilities until evidence is
produced by the Contractor to the Engineer to show that the requirements in this
respect have been finally settled and discharged.

4.17 DEMOLITION ON TREATMENT PLANTS AND PUMPING STATIONS SITES

The Contractor shall totally demolish and remove redundant structures on the
treatment works and pump station sites. Items to be removed may include
temporary wooden structures, concrete and masonry structures, concrete slabs
and footings, drains, roadway pavement, utilities and other surface
improvements. Utility companies shall be notified 30 days in advance of
demolition to allow them time to remove meters, materials and equipment for
salvage to the extent chosen by the utility companies. Items not removed by
utility companies shall be removed by the Contractor. Piping and wiring shall be
capped and disconnected in accordance with utility company requirements.
Remove all abandoned electrical conductors. All material to be demolished and
removed shall be removed from the Site to a legal disposal area. Burning will
only be permitted upon the Engineer's written approval. Contractor may salvage
any materials not required by the various utility owners and all such salvage shall
be the Contractor's property. Public sale or auction of Contractor's salvage is not
permitted on Employer's property.

4.18 ROCK AND OTHER MATERIALS IN EXCAVATIONS

Any material in the excavations which the Contractor considers may be classified
as Rock as defined in Clause 4.1 shall be notified to the Engineer before
excavation of the material is begun. The quantities of Rock or material alleged to
be Rock excavated from within the nominal limits of excavation shall be recorded
by the Engineer and the Contractor each day or at such shorter intervals as the
Engineer may require. Only such proportion of material so notified, recorded and
signed shall qualify for additional payment as Rock. Overbreak (that is
excavation outside the nominal limits of excavation) shall be kept to a minimum
and shall be held to be Excess Excavation.

Materials like shale and weathered sandstone strata may not be classified as
`Rock' within the meaning of Clause 4.1. These materials are tough and may
exceed conventional methods of excavation. Bulk excavation of these materials
shall include the use of an efficient parallelogram type ripper having a single
shank in sound working condition for attachment to a track machine also in
sound working conditions with a minimum weight of 24 tonnes and a nett power
rating of not less than 240 hp. These materials shall only be classified as `Rock'
when, in the opinion of the Engineer they cannot be ripped efficiently as
described above.

Not withstanding anything to the contrary in this Contract, the Engineer’s decision
as to whether or not the material of the excavation is to be classified as rock,

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 shall be final and without appeal.

The quantities of rock excavation given the Bill of Quantities are PROVISIONAL
only and do not necessarily represent the quantities that may be encountered.
Nevertheless the Contractor’s price for rock excavation will apply to whatever
quantities which are finally measured and at whatever depth the rock is
encountered and excavated.

4.19 SUPPORTING EXCAVATION

The Contractor shall well and effectively support the sides and ends of all
excavations to prevent any fall or run from any portion of the ground outside the
excavation and to prevent settlement or damage to structure adjacent to the
excavation. Any extra excavation necessary to provide space for such support or
other working space shall be held to be Excess Excavation. If, for any reason,
any portion of the bottoms, sides or ends of any excavations shall give way the
contractor shall at his own expense take all necessary remedial measures
including the excavation and removal of all the ground thereby disturbed both
within and without the nominal limits of excavation and such extra excavation
shall be held to be Excess Excavation.

Where the Contractor elects and is permitted by the Engineer to perform

excavations with sloping faces (other than sloping excavations shown on the
drawings or required as permanent features of the works) and without shoring,
the excavated faces shall be to stable slopes and heights and the resulting extra
excavation shall be held to be Excess Excavation.

4.20 BATTERED TRENCH SIDES

Where the Contractor elects and is permitted by the Engineer to execute trench
excavations with battered sides instead of providing support as aforesaid they
shall be excavated to stable slopes and heights at a slope of not steeper than
one to one from a point 0.3 metre above the top of the sewer pipe, and to a less
steep side slope where necessitated by ground conditions.

4.21 TRIMMING EXCAVATIONS

When excavating to specified levels for the foundation of any structure or pipes
or to specified limits for the faces of any structure required to abut against
undisturbed ground the Contractor shall not excavate the last 150 mm until
immediately before commencing the constructional work, except where the
Engineer shall permit other wise.

Should the Contractor have excavated to within 150 mm above these specified
levels or to within 150 mm of these specified limits before he is ready or able to
commence the constructional work he shall, where required by the Engineer,
excavate further so as to remove not less than 150 mm of material immediately
before commencing the constructional work and such further excavation shall be
held to be Excess Excavation.

Before commencement of any constructional work all shattered and loose

material shall be removed from the excavations by hand so as to ensure that the
workrests on a solid and perfectly clean foundation or abuts against solid ground.

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4.22 TIMBERING

The term "Timbering" shall cover all normal methods of support including the use
timber, steel plate or such other materials as may be approved by the Engineer.

Unless otherwise provided in the Bills of Quantities, the Contractor shall allow in
his rates for excavation the supply and fixing of strong and sufficient timbering to
support the sides and/or bottom of the excavation when necessary to the
satisfaction of the Engineer and shall maintain the same until the Construction
work is sufficiently advanced in the opinion of the Engineer to permit the
timbering to be withdrawn, which shall be conducted only under personal
supervision of a competent foreman.

The Engineer may order the trench, excavation or work to be closely-timbered

whenever it may appear to him to be necessary and the Contractor shall carry
out such order and no extra charge shall be made for this by the Contractor.

The Contractor shall be responsible for any failure of his timbering during fixing,
when in position, and for any injury to the work and any advice, permission or
approval given by the Engineer in respect of the removal of the timbering shall
not relieve the Contractor from the responsibility herein defined.

4.23 TIMBER LEFT IN EXCAVATION

If, as the excavation are being filled in, it is necessary in the opinion of the
Engineer to leave in position any timber, the Contractor shall be paid for it at the
rates stated in the Bill provided that in the opinion of the Engineer the necessity
for leaving it in has not arisen from carelessness or neglect on the part of the
Contractor. Only the actual quantity of timber left-in will be paid for, payment will
not be paid for labour in cutting off at any level as directed by the Engineer nor
for the timber in ends thus cut off, nor for the disposal of additional surplus
excavated materials due to the leaving in of timber.

4.24 TRENCHES AND EXCAVATION TO BE KEPT CLEAR OF WATER

The Contractor shall keep the excavations clear of water by means of temporary
drains laid below the level of the permanent works and shall pump out all water
which may arise or flow into them.

Unless otherwise directed by the Engineer, all temporary drains or sub-drains

shall be finally blocked up with concrete till it is made watertight.

The Contractor shall provide, form, fix, maintain and work, where and as directed
by the Engineer, such engines, pumps, chutes, wells, dams and both things
necessary for keeping the subsoil or accumulated water out of the excavations or
at a level below the bottom of any permanent works for such a period as the
Engineer may direct. After raising the water herein referred to, the Contractor
shall at once convey it away in such a manner as not to cause any nuisance or
injury. No new or existing pipe or culvert shall be used for the purpose of
carrying water away from the excavation without permission in writing from
Engineer. When new or existing pipes or culverts have been used for this
purposes, the Contractor shall be responsible for clearing out and removing all
silt, etc. before handing them over for their normal function. Any damage
whatsoever resulting from such use or cleaning out of new or existing pipes or

4-8
 inverts shall be made good at the Contractor's expense.

All sumps and wells which may be required for the purpose for keeping the work
dry are to be sunk clear thereof, and care shall be taken to avoid undermining
any parts of the works by pumping. The Contractor shall afterwards refill and re-
install any such sumps or wells to the satisfaction of the Engineer and cost borne
by the Contractor.

4.25 REMOVAL OF FOUL & OFFENSIVE WATER AND VENTILATION

If any foul or offensive matter arises or flows into the excavation or trenches, the
Contractor shall immediately remove it from the works without extra cost.

The Contractor shall provide adequate ventilation and efficient apparatus to keep
all excavations, trenches, tunnels and headings free from all gases whether
generated in the strata or arising from the use of explosives for blasting or
otherwise and he shall take precautions to ascertain that they are in a safe
condition before allowing workmen to descend.

4.26 INSPECTION OF EXCAVATION

When the specified levels or limits of excavation are reached the Engineer will
inspect the ground exposed, and if he considers that any part of the ground is by
its nature unsuitable he may direct the Contractor to excavate further. Such
further excavation shall be refilled to the specified levels or limits with concrete,
selected excavated materials or selected imported material as directed by the
Engineer but shall not be held to be Excess Excavation.

Should the material forming the bottom of any excavation, while acceptable to
the Engineer at the time of his inspection, subsequently become unacceptable to
him due to exposure to weather conditions or due to flooding or have become
puddled, soft or loose during the progress of the works, the Contractor shall
remove such damaged, softened or loosened material and excavate further by
hand. Such further excavation shall be held to be Excess Excavation.

4.27 FILLING TO EMBANKMENTS AND BACKFILLING TO GENERAL

EXCAVATION

Excavated material including imported material used as filling or backfilling to

excavations or completed structures or as fillings to embankments or to raise the
ground level shall be free from clods and lumps and shall be approved by the
Engineer. The approved material shall be placed in layers not exceeding 225
mm depth before compaction and shall be compacted to a dry density not less
than 95% of the maximum dry density obtained in Test 12 of BS 1377. Where
necessary the Contractor shall adjust the moisture content of the fill or backfill
material either by drying out or adding of water. After such drying out or adding
of water, the fill shall be thoroughly mixed until the moisture content is suitable.

Should the material being placed as filling or backfilling, while acceptable at the
time of selection, become unacceptable to the Engineer due to exposure to
weather conditions or due to flooding or have become puddled, soft or
segregated during the progress of the works, the Contractor shall at his own
expense remove such damaged, softened or segregated material and replace it
with fresh approved material.

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 The Contractor shall when placing the filling or backfilling make due allowance
for any settlement that may occur before end of the Defects Liability Period.
Where necessary, the Contractor shall at the end of the Defects Liability Period
remove any excess material or make up any deficiency of backfilling or filling to
the specified levels.

4.28 TRENCHES NOT TO BE LEFT OPEN

No length of trench excavation shall be started until the pipes to be laid in that
length are available on site. Trench Excavation shall be carried out expeditiously
and, subject to any specific requirements of the Contract, the refilling and surface
reinstatement of Trench Excavation shall be commenced and completed as soon
as reasonably practicable after the pipes have been laid and jointed. Joint holes
may be left unrefilled until the joints have been air tested and moulded or
protected.

Pipelaying shall follow closely upon the progress of Trench Excavation, and the
Contractor shall not permit the carrying out of Trench Excavation in unreasonably
excessive lengths until pipelaying matches up with the progress of Trench
Excavation. The Contractor shall take precautions to prevent flotation of pipes in
locations where Trench Excavations may be flooded and these precautions may
include the partial refilling of the trench leaving pipe joints exposed while awaiting
tests of the joints.

If the Engineer considers that the Contractor is not complying with any of the
foregoing requirements he may prohibit further Trench Excavation until he is
satisfied with the progress of laying and refilling of Trench Excavation.

4.29 REFILLING TRENCH EXCAVATION

In backfilling trench excavation after permanent works therein have been

approved by the Engineer, the best and most suitable materials shall be used.
Where excavated materials are not considered suitable by the Engineer, selected
materials from approved sources shall be used for backfilling and bedding.

For trench excavations to be backfilled with excavated material, soft material free
from stones of all kinds shall be deposited in 150 mm layers and thoroughly
rammed under and around the pipe with suitably shaped rammers working
alternately on either side of the pipe (particular care being taken to avoid damage
to the pipe and any sheathing) until the trench has been refilled up to the swell of
the pipe, and thereafter until the soft filling has been carried up at least 300 mm
above the top of the pipe.

The remainder of the refilling may consist of coarse material free from boulders
and clods of earth larger than 150 mm in size provided that the compacted refill
is, in the opinion of the Engineer, sufficiently dense to prevent material from the
superimposed layers being washed into the voids in such refill. This coarse
material shall be spread in layers of depth not greater than 225 mm and be
thoroughly rammed by an approved mechanical rammer or pan vibrator.

The coarse filling is to be carried up to the level at which surface reinstatement is

to commence or to such level at which the surface reinstatement of the whole of
the topsoil, will leave the finished work sufficiently "proud" to allow for future
settlement to the original ground level. The reinstated surface shall be rolled with

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 a two-tonne roller when the material is dried. Any part of the reinstated surface
that settled beyond the adjacent original ground level the Contractor shall have to
make good of the settlement to avoid formation of drains or gulleys within the
refilled trenches.

For trench excavation to be backfilled with sand material the sand material shall
be deposited in 150 mm layers on both sides of the pipe simultaneously and
thoroughly compacted and around the pipe working alternately on either side of
the pipe until the trench have been filled up to 150 mm above the top of the pipe
except for pipes laid in roads where the sand backfill shall be brought up to the
base course formation level. The sand vibrator and/or by an approved system of
water jet. The topping of the refilling for trench excavation as described above
for backfill with excavated material.

Sand filling material shall be from a source approved by the Engineer. Quarry
dust shall not be considered for use as filling material.

Where necessary the Contractor shall adjust the moisture content of the refill
material either by drying out or by adding water to assist the compaction of the
material.

Should the material to be placed as refilling, while acceptable at the time when
approved, become unacceptable to the Engineer due to exposure to weather
conditions or due to flood or have become puddled, soft segregated during the
progress of the works, the Contractor shall not use such material for refilling
trenches and shall only use fresh approved material.

Trench Excavation shall be refilled with concrete to the heights and limits as
shown on the Drawings and where directed by the Engineer.

4.30 SOFT REFILL MATERIAL - SPECIAL MEASURES

Where in the opinion of the Engineer sufficient supply of the aforesaid soft
material for trench refilling cannot reasonably be obtained from Trench
Excavations within two hundred metres of the length of trench to be refilled
without resorting to sieving or other special means then the Engineer shall order
the Contractor :-

(a) to carry out such work as may be necessary to sieve out stones, or

(b) to transport suitable soft material from Trench Excavations at distances

greater than two hundred metres from the length to be refilled
("overhaul").

(c) to excavate soft material from suitable borrow areas and transport it to the
length of trench to be refilled.

4.31 TEMPORARY SPOIL TIPS ON THE SITE

Temporary spoil tips may be used to store excavated material as required and
shall be arranged by the Contractor subject to the Engineer's approval having
regard to any particular requirements of the Contracts.

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4.32 COMPACTION

Where necessary, the Contractor shall adjust the moisture content of the refill
material either by drying out or by adding water to assist the compaction of the
material. During compaction, the backfill shall have a uniform moisture content
equal to or a little above the optimum moisture content recorded in the
Compaction Test. Backfill shall be compacted to a dry density of not less than 95
per cent of the maximum dry density when tested in accordance with this
Specification.

Only material which is approved by the Engineer shall be placed in the temporary
spoil tips, topsoil being placed in separate spoil tips where so ordered. No tree
trunks, stumps, roots, branches or rubbish of any kind shall be placed in spoil
tips.

Temporary spoil tips shall be so shaped as to maintain stability and good

drainage at all times.

4.33 TREATMENT OF MATERIAL FROM EXCAVATION

Subject to any specific requirements of the Contract, the Contractor shall make
his own arrangements for the temporary storage of any excavated material which
is required for use in refilling Trench Excavation, and backfilling to general
excavation including any necessary double handling. In this connection the
Contractor shall have regard to the working areas available to him for the
construction of the works. Any temporary tips alongside the excavations shall be
to stable slopes and heights.

Where the nature of the excavated material is suitable the Contractor's

temporary storage as aforesaid shall include for the separate storage as the
Engineer may direct of any of the various grades of material hereinafter specified
for the refilling and surface reinstatement of excavations, namely, soft material,
coarse material, hard material and topsoil.

The Contractor shall ensure that no excavated material which is suitable and is
required for re-use in the works is disposed off outside site.

Any excavated material not required or not suitable for use in the works shall
become the liability of the Contractor and he shall be entirely responsible for its
removal from the site and for its ultimate disposal. The Contractor shall comply
with all the regulations for the disposal of surplus excavated materials off the site
including the payment of royalties, fees, etc. which may be imposed by the
relevant Authorities.

4.34 DISPOSAL OF SURPLUS SOIL

The Contractor shall allow in his excavation prire for the removal and disposal of
all surplus excavated materials, earth, rubbish and waste matters. Suitable
material and topsoil surplus to the total requirements of the works and all
unsuitable material shall, unless the Engineer permits otherwise, be run to spoil
in tips provided by the Contractor. However, the Engineer may direct that
surplus materials be disposed of at particular locations in or around the Site and
his decision on this matter must be obtained before any surplus material is
removed from site.

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 The Contractor shall make all arrangements for the loading, transport, dumping,
spreading and compaction or removal of this material as above specified.

The general filling of spoil formed as above shall be cover-cropped immediately

to avoid erosion and consequent sedimentation of drains and other water
courses.

When removing surplus spoil, the Contractor shall dispatch, clear up all
carriageways, footways and verges affected by his work, and leave the site of the
works clean an tidy. If surplus spoil is tipped into or removed from private
property the operations shall be executed with the approval of and the least
possible inconvenience to, the owner and occupier of the same.

4.35 SURFACE REINSTATEMENT IN ROAD VERGES, FIELDS, ETC.

Where Trench Excavation is in road verges, fields and grassed areas the turf
previously removed will suffice for surface reinstatement providing that the grass
has not been killed during stacking and that the surface is free from all loose
stones.

After refilling Trench Excavation as specified, the Contractor shall replace all
topsoil previously removed and it shall be evenly distributed and levelled over the
full extent of the stripped area. The working space occupied by the Contractor
which was originally covered with grass if destroyed during the course of
construction shall be covered with 75 mm of topsoil, close turfed and maintained
until the new grass is properly established at the Contractor's expense. Other
areas not originally covered with grass shall be restored to their former state.

Road verges shall be restored to their original width and to a minimum fall of 1 in
24 away from the road and towards the ditch (if any). Restoration of the dip shall
be carried out unless the fact that no dip existed prior to pipelaying has been
recorded in writing and agreed to by the Engineer.

The Contractor shall restore all surfaces in a condition not inferior to that which
existed prior to commencement of works.

Any damage to the metalled road due to pipelaying work alongside road verges
or shoulders shall be reinstated to the satisfaction of the authority concerned at
no extra cost to the Government.

4.36 WORKS IN ROADS AND ROAD RESERVES

Where work is carried out within road reserve, the Contractor shall comply fully
with all regulations and requirements in force in that place by all relevant local
and public authorities (hereinafter referred to as Authorities).

The times of working allowed by the Authorities may or may not fall within day
light hours or within the normal working hours of the Authorities.

The Authorities may impose charges for works carried out on road verges and
metalled roads and the Contractor shall pay the Authorities and recover the cost
under the appropriate items in the Bill of Quantities.

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4.37 SURFACE REINSTATEMENT IN ROADS AND FOOTPATHS

Surface reinstatement of roads and footpaths shall be restored to the approval of

the Engineer and to the requirements of the Authorities concerned or the owner
or tenant. Any settlement or defects prior to final surface reinstatement shall be
made good by the Contractor to the satisfaction of the Engineer.

The consolidated surface shall be brought up to the same level or the adjoining
road. Any subsidence shall be filled in by the Contractor using the same
materials. The road shall be kept continuously at its proper level to the
satisfaction of the Engineer and the Authorities from the date of filling in the
trench until the surface is finally restored. All materials for this reinstatement and
subsequent maintenance shall be supplied by the Contractor.

When any section has been reinstated as specified the Contractor shall notify the
Engineer who in the presence of the Contractor shall inspect the length of
reinstated trench. The Engineer shall at this inspection indicate any further
reinstatement required and the Contractor shall complete this work to the
satisfaction of the Engineer and the authority concerned within fourteen days of
the inspection. Acceptance of reinstatement by the Engineer or the Authorities at
this inspection shall not relieve the Contractor of his responsibility for the
maintenance of surfaces as specified above.

4.38 PAYMENT FOR ROAD RESTORATION

Items in the Bill of Quantities for Restoration of Metalled Roads except where
expressly stated otherwise shall apply to road reinstatement. The charges if any
imposed by the Authorities for work carried out on metalled road shall be deemed
to be included in the relevant items in the Bill of Quantities under Restoration of
Metalled Roads.

Where the restoration is to be carried out by the Contractor, measurements shall

be in accordance to the Bill of Quantities provided.

Where the restoration is to be carried out by the Authorities, the Contractor shall
comply fully with all regulations and requirements as stipulated by the Authorities
and such restoration shall be deemed to have been restored by the Contractor.
The Contractor shall be paid in accordance to the appropriate rates in the Bill of
Quantities. Temporary reinstatement prior to final restoration shall be measured
separately in addition to permanent restoration.

If after due notice to the Contractor calling his attention to the necessity for
further reinstatement of any trenches across roads and footpaths, he has failed
to make good the reinstatement, the Government or the appropriate Authorities
may proceed with such repairs and the cost of such reinstatement shall be
deducted by the Government from any payments due to the Contractor.

Towards the end of the Defects Liability Period the Engineer will inspect the
pipeline route in the presence of the Contractor.

In the event that final road reinstatement is to be carried out by the Authorities
concerned, the Contractor shall carry out temporary reinstatement for the
vehicles to pass over it. The temporary reinstatement includes the trench to be
refilled with sand, topped with required thickness of crusher run material and

4-14
 followed by a layer of tack coat and the required thickness of dense bituminous
mix wearing course. All filled materials shall be compacted by approved means.

The Contractor shall carry out final reinstatement of public roads and footpaths
only if he is instructed by the Engineer. Otherwise final reinstatement of these
roads will be carried out by the Authorities as and when agreed between the
Authorities, the Engineer and the Contractor. The Contractor shall pay the
Authorities and shall recover the cost under the appropriate items in the Bill of
Quantities. No quantities of final reinstatement beyond the limits of Trench
Excavation specified or reinstatement due to Excess Excavation, settlements
adjacent to Trench Excavations or damage to road surfaces in the course of
pipelaying shall be measured for payment.

4.39 LAND DRAINS

Where land drains, mole drains or field drains are severed by Trench
Excavation they shall be kept in effective temporary operation during
construction of the pipeline. The Contractor shall submit to the Engineer for
approval a temporary drainage arrangement to ensure the water course is not
hindered during the construction.

The drain on either side of the Trench Excavation shall be cut-back for at least
300 mm and temporary pipes of suitable length and diameter shall be jointed to
the existing drain and laid resting with the ends on solid ground with suitable
stopping to prevent the subsequent run of land drainage water into the pipe
trench. During trench re-filling, the refill material shall be carefully placed and
thoroughly compacted under the temporary pipes to give them adequate
support.

Should any existing sub-soil or field drains be uncovered during general

excavation, the Contractor shall either carefully replace them when backfilling,
or if this is impracticable shall divert them to new drains or ditches, or otherwise
relay them as the Engineer may direct.

At the appropriate stage of refilling the Trench Excavation the drains shall be
permanently restored to the satisfaction of the Engineer.

4.40 CARE OF EXISTING SERVICES

Information relating to the positions of all existing mains, cables, culverts, pipes,
drains or services of any kind shall be ascertained by the Contractor.
Notwithstanding any information which may be furnished by the Engineer, the
Contractor shall be responsible for ascertaining from his own inspection of the
site and from the respective supply authorities and other public authorities the
positions of all mains, pipes and cables whether underground or overhead,
within or near the site. Where services are shown on the drawings or where
there is evidence of services in the ground, the Contractor shall also determine
their exact positions. In addition the Contractor shall watch for and determine
the position of any service which may not have been marked.

Where Trench Excavation is carried out close to or across the line of sewers,
pipes, cables and other services the Contractor shall provide temporary
adequate supports to secure the services and where such sewer, pipe, cable or
other service is temporarily displaced or disturbed it shall be restored to its

4-15
 original state. If restoration or any service to its original state cannot be
achieved then it shall be replaced and made good. The cost of excavating
around any service which crosses the trench, and of temporally supporting it
while pipelaying is undertaken, shall be deemed to be included in the rates for
excavation.

All damage to drains, kerbs, services etc shall be made good to the satisfaction
of the Engineer and the authorities concerned. The cost of making good any
damage shall be deemed to be included in the rates for excavation. In the event
that any damaged services shall only be repaired by the authority concerned, all
costs whatsoever relating to the repairing of the damaged service undertaken by
the authority shall be at the Contractor's expense. Where damage to a service
had already existed prior to excavation or other work, repair of the damaged
service shall be undertaken by the Contractor, if so ordered by the Engineer and
the Contractor shall be paid on Daywork for repairing such service.

Where in the opinion of the Engineer, construction of the pipeline cannot

reasonably be carried out unless the sewer, pipe, cable or other service is
permanently severed or permanently diverted or permanently supported the
Contractor shall undertake such work is so ordered by the Engineer. Any such
work if carried out shall be to the satisfaction of the Engineer and of the
authority concerned and shall be paid for at Daywork where necessary and at
the appropriate Contract Rates.

Where pipes are laid under culverts they shall, subject to other provisions in the
Contract and to the Engineer's instructions, be given a concrete surround
extending for 600 mm clear on each side of the culvert, and a concrete half
haunch to the culvert shall be provided over the width of the trench cast directly
on top of the concrete surround. The cost of all work in removing any piles and
concrete bend under culverts and of temporarily supporting the culvert during
pipelaying shall be deemed to be covered by the rates for the items in the Bill of
Quantities for pipe crossing under culverts.

4.41 HEDGES, FENCES AND WALLS

Where the Trench Excavation passes under barriers such as hedges, fences
and walls the Contractor shall, as a temporary measure during construction of
the pipeline, provide temporary fencing for any parts of such barriers as have
had to be removed.

After trenches have been refilled and surfaces reinstated, the Contractor shall
carry out work as the Engineer may order for permanent restoration of such
barriers. In the case of a hedge the section removed shall be replaced by new
plants of the appropriate variety and where ordered by the Engineer, the plants
shall be protected from livestock on both sides by an adequate post and barbed
wire fence. During the Defects Liability Period all hedges replanted in the above
manner shall be inspected and any dead plant replaced by the Contractor.

4.42 CROSSING WATER COURSES, ETC.

Where the pipeline crosses underneath rivers culverts and other watercourses
the Contractor shall be deemed to have allowed for all the additional measures
necessary for the proper construction of the pipeline including maintaining the
full flow of water.

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4.43 MEASUREMENT OF GENERAL EXCAVATION

Items in the Bill of Quantities for "excavation" except where expressly indicated
otherwise shall apply to excavation where Bulk, Incidental or Trench in any
material and shall not only include for all work in connection with excavation but
shall also include for all loading and transportation, temporary fencing, double
handling, filling, backfilling and for disposal of surplus materials, the means of
disposal being the Contractor's responsibility.

Items for "Excavation in Rock" shall include for any allowance the Contractor
considers necessary to cover overbreak and the making good thereof.

All work in connection with excavating and subsequent disposal of excavated

material as specified shall be valued by measurement of such items as are set
forth in the Bill of Quantities for "excavation" and where appropriate of the
Excavation Rock. All such measurements unless otherwise specified shall be the
net volume of the voids to be formed by the removal of material excavated to the
specified levels and limits described herein or shown on the Drawings, no
allowance being made for bulking. No separate payment shall be made in
respect of Excess Excavation or the backfilling thereof.

Incidental Excavation for removal of unsuitable material shall (unless it is held to

be Excess Excavation) be measured as the volume ordered by the Engineer to
be excavated beyond the nominal dimensions of general excavation and shall
include for the disposal of the excavated material off the site and for refilling the
excavation with approved material emanating from excavation elsewhere or
refilling with the grades of concrete ordered by the Engineer.

4.44 MEASUREMENT OF TRENCH EXCAVATION

Items for Trench Excavation shall apply to excavation in any material and shall
include not only for all work in connection with excavation but also for refilling of
trenches spreading and compacting excavated material over pipeline reserve as
directed and for disposal of surplus material, for temporary fencing and, in fields,
for the stripping and subsequent reinstatement of the top surface all as specified.

Trench Excavation shall be measured by length along the centre line of the
pipeline at the various depths stated in the Bill of Quantities and the Contractor
shall be deemed to have made his own assessment (subject to any specific
requirements of the Contractor) of the widths of Trench Excavations necessary
for the proper construction of the works including all allowances to provide
support for the excavations, to accommodate joints and bends in the pipeline and
to provide working space. The length of Trench Excavation shall be measured
through and including any space occupied by manholes, chambers, thrust blocks
and the like. No extra payment shall be made for trenches which are curved in
plan or elevation.

The depth of Trench Excavation for pipes shall be measured normal to the profile
of the ground along the centre line of the trench from the original ground level of
where appropriate from the ground level remaining after the completion of any
general excavation down to the specified invert level of the pipe. The
Contractors shall allow for additional excavation required for the thickness of
bedding for sewer pipe as specified and shown on the drawing.

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 The sides of Trench Excavation shall be deemed to be vertical in all materials
and the nominal widths defined in Clause 4.11 shall apply to any depth of trench
and whether or not bedding or surround to the pipe is specified.

Trench Excavation and all work in connection therewith as specified shall be

valued by the measurement only of such items as are set forth in the Bill of
Quantities, except where expressly provided for otherwise by the inclusion in the
Bill of Quantities of any of the following further items:-

Incidental Excavation for Structures situated in the pipeline shall be measured

only to the extent that the net excavation required to accommodate the structures
falls outside the nominal dimensions of the Trench Excavation.

Incidental Excavation for removal of unsuitable material shall (unless it is

held to be excess Excavation) be measured as the volume ordered by the
Engineer to be excavated beyond the nominal dimensions of Trench Excavation
and shall include for the disposal of the excavated material off the site and for
backfilling the excavation with approved material emanating from Trench
Excavation elsewhere or for backfilling the excavation with the grades of
concrete ordered by the Engineer.

Rock, shall be measured as the volume of Rock within the nominal limits of
Trench Excavation in Rock.

Excess Excavation and the backfilling thereof shall not be measured for
payment.
Trench Excavations in roads and in footpaths as specified shall be measured
(E.O. Trench Excavation) as the area calculated by multiplying the length of
trench so excavated by its nominal width. The stripping of the top surface and
the surface reinstatement of Trench Excavation in road verges, fields, etc. shall
be included in Trench Excavation and shall not be separately measured.

Crossing hedges, fences and walls shall include for all temporary measures
for dealing with such barriers as specified and shall be measured as the length of
such barriers so dealt with within the nominal width of Trench Excavation. Any
permanent measures required by the Engineer shall be ordered by him as
additional work.

Crossing rivers culverts and other watercourses shall include for all additional
measures necessary to make the crossings as specified. Only such crossings as
may be itemised in the Bill of Quantities will be measured (E.O. Trench
Excavation) for additional payment. The length of measured for payment for
crossing natural watercourses shall be defined as the width of the waterway
along the pipeline at the time of construction of the crossing (except flash floods
and floods).

4.45 MEASUREMENT OF FILLING FOR EMBANKMENT

Items in the Bill of Quantities for "forming embankment" for roadwork, for raising
the ground level of the site or for filling under structures shall include for the
supply, spreading, compacting and shaping all as specified.

Filling for embankment shall be measured as the volume after compaction of the
fill material placed to the limits and depth shown on the Drawings or ordered by

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 the Engineer. The Contractor shall be deemed to have made his own allowance
for compaction and for any "loss" of material into the ground below the
embankment.

4.46 PAYMENT FOR TRENCH EXCAVATION AND RESTORATION

Payment for trench excavation shall be made in two stages, as follows :-

(a) 75% of the total amount due will be paid on completion of pipelaying.

(b) The remaining 25% for any length, will be due on completion of
restoration of the final surface, including reinstatement of all surface
damage, completion of chambers, thrust blocks, etc.

Payment for the second stage shall be due only after restoration of any length
has been inspected and approved by the Engineer and by any relevant authority.
Payment for the separate items in roads, footpaths, etc. will be made at the
same time as the second stage payment for excavation.

4.47 TOP SOILING

Topsoil shall be evenly spread and trimmed over embankments and other areas
to the slopes and levels shown on the Drawings or ordered by the Engineer. The
depth after spreading and trimming shall be 75 mm unless otherwise directed,
measured normal to the surface. All clods and lumps shall be broken up and any
rubbish, stones, roots and weeds shall be removed.

4.48 TURFING

The contractor shall establish grass by continuous or spot turfing as directed.

Each turf shall be approximately 200 mm by 50 mm thick. Turf shall be laid

immediately after delivery to site.

Where turf is laid on slopes steeper than 1 on 3.0, each turf shall be securely
pegged down with two cleft wooden pegs 150 mm long.

All turfed areas shall be lightly rolled with an approved roller or punned
immediately after laying, and shall be watered regularly until the grass has been
established.

Grass areas affected by trench excavation shall be restored as specified above.

4.49 MEASUREMENT OF TOP SOILING AND TURFING

Items where included in the Bill of Quantities for spreading topsoil shall include
for obtaining topsoil from spoil tips on the site, hauling and spreading all as
specified.

Items where included for turfing shall include for all work in connection with
turfing as specified, and for cutting and trimming and weeding at least once a
month until the end of the Defects Liability Defects.

Topsoiling shall be measured as the areas so treated, and except where

4-19
 expressly indicated otherwise items shall apply to sloping as well as to horizontal
surfaces.

Topsoiling and turfing of re-filled trenches shall be included in items for Trench
Excavation and shall not be separately measured for payment.

4.50 PAYMENT FOR TURFING

Payment for continuous turfing shall be the area covered by the turves provided.
Where spot turfing is required the distance between the centre lines of divots in
the form of a triangular pattern shall not exceed 500 mm and the percentage of
the area covered shall be agreed and payment made on the total area spot
turfed multiplied by the percentage.

Turfing will be paid for in two parts :-

(a) at fifty percent of the Contract Rate when the turfing has been carried out;

(b) at fifty percent of the Contract Rate when the Engineer is satisfied that
the grass has established itself.

Where grass fails to establish itself, the Contractor shall turf the relevant area
again at no extra cost to the Government.

4.51 PAYMENT OF FEES TO AUTHORITIES

The Contractor shall pay to all Authorities all deposits, fees and charges required
to be paid in relation to the execution of the works or to any temporary works.

If after due notice to the Contractor calling his attention to the necessity for the
payment of fees and/or charges to the Authorities the Contractor has failed to
make payment, the Employer shall be entitles to pay such fees and/or charges
direct to the Authorities concerned out of any moneys at any time due to the
Contractor under the contract and such payment shall be deemed to be payment
made to the Contractor under and by virtue of the Contract.

The cost of all fees and charges payable by the Contractor shall be deemed to
be included in the Contract Rates unless otherwise expressly provided for in the
Bill of Quantities.

4-20
 SECTION 8
EARTHWORKS

8.1 LEVELS TO BE CHECKED

Before the surface of any part of the Site is disturbed or the works thereon are begun,
the Contractor shall conduct all necessary checks to satisfy himself that the levels of
any such part do not differ significantly from drawings or measured directly by any of
his agents or sub-contractors. Any discrepencies which may necessitate design
changes or which may affect the full functionality of the permanent works shall be
brought to the attention of the Engineer. The levels so measured prior to
commencement of works shall be recorded and confirmed in the presence of the
Engineer.

8.2 GENERAL EXCAVATION

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 lining and walls where required. Slopes and
drainage features shall present a neat uniform appearance upon completion of the
work and shall be approved by the Engineer. Excavated materials meeting the
requirement of fill materials may be conserved for subsequent use of placed as earth
fill immediately after excavation upon approval of the Engineer. Large rocks
unacceptable as earth fill material may be stockpiled for use as subject to all
requirements specified for being met in the specifications. The suitability of re-use of
excavated material for specific purposes shall be determined by the Engineer, and the
Contractor shall not waste or otherwise dispose of suitable excavated material. All
excavation shall be performed under the limitations and requirements set out in the
sections of this specification pertaining to control of water.

8.3 EARTHWORK

Earthwork shall include all site preparation, excavation of all materials of whatever
nature encountered, handling, hauling and compaction of required fill materials,
disposal of all excess excavated material, shoring and protection work, preparation of
subgrade, dewatering as necessary, protection of adjacent property, backfill, surface
reinstatement, and embankment to the lines and grades indicated in the drawings.

8.4 BRACING AND SHORING

All excavation works exceeding 1.2m in depth shall be adequately supported at the
sides in a manner agreed to by the Engineer to safeguard the work and workmen, to
prevent sliding or settling of the adjacent ground, and to avoid damaging existing
improvements. The width of the excavation shall be increased if necessary to provide
space for sheeting, bracing, shoring, and

8-1
 other supporting installations. The Contractor shall furnish, place and subsequently
remove such supporting installations as necessary.

8.5 BORROW EXCAVATION

When the quantities of suitable materials obtained from specified excavations are
insufficient to construct the specified fills, additional materials shall be obtained from
approved borrow areas. Borrow pits shall be excavated and finally dressed in a
manner to eliminate steep or unstable side slopes or other hazardous or unsightly
conditions. The extent and depth of borrow pits within the limits of the designated
borrow areas shall be approved by the Engineer.

8.6 CONTROL OF WATER

The Contractor shall furnish, install and operate all necessary machinery, appliances,
and equipment to keep excavations free from water during construction and shall
dispose of water so as not to cause injury to private property, or to cause a nuisance
or menace to the public. 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.

8.7 HEADINGS, TUNNELS AND SHAFTS

When excavating headings, tunnels and shafts, the Contractor shall provide sufficient
spoil storage capacity to avoid the need to remove excavated material from shaft
sinking, heading or tunnel driving compounds between 19.00 hours on any day and
07.00 hours on the following day. It shall be the responsibility of the Contractor to
decide the need for, and to undertake, any ground investigation ahead of the face of
any tunnel, heading or shaft.

Excavations for headings and tunnels shall be adequately supported at all times. The
faces of all headings and tunnels, other than in solid rock, shall be fully boxed
whenever excavation has been, or will be, stopped for a period exceeding 12 hours.
All working shafts shall, unless otherwise permitted, be supplied with speaking tubes
or telephones in communication with the Works below ground. Such tubes or
telephones shall be provided with coloured light signalling systems.

Tolerances for driving headings or tunnels shall be horizontal ±75mm and vertical
±75mm in 30 metres.

8.8 ROCK BLASTING - GENERAL

8.8.1 License

The Contractor shall obtain all necessary licenses and permits for the storage,
transport, handling and use of explosives and shall provide a store or stores suitable
for explosives in accordance with local regulations.

8.8.2 Responsibility

The Contractor shall be solely responsible for injury to persons or property that may
result from his use of explosives, and the exercise of, or failure to exercise control on
the part of the Engineer shall in no way relieve him of responsibility for injury or

8-2
 damage resulting from their use. He shall take all necessary safety precautions
including the use of blasting nets, shields or other safety devices to avoid damage or
loss of property, or injury to persons, during blasting operations.

8.8.3 Supervision

All blasting shall be done under the supervision of a competent blasting expert, and
subject to Malaysian regulations for blasting.

8.8.4 Storage

Only small amounts of explosives shall be kept underground, well ventilated and
under lock, the key to be only in the hands of a trustworthy person. Caps and
exploders shall not be kept in the same place as explosives. Blasts shall be properly
matted and securely covered.

8.8.5 Blasting Approvals and Permits

The Engineer shall have power to regulate, restrict or prohibit blasting if in his opinion
it is necessary to do so for the safety of persons or property or to safeguard the
Works. No blasting shall be carried out in any part of the Works without the
permission in writing of the Engineer. Such permission shall not absolve the
Contractor from any of his obligations or liabilities under the Contract.

8.8.6 Electrical Detonators

Electrical detonators should be able to operate safely in the area where blasting is
carried out without causing interference to radio services. Special precautions should
be taken to warn operators of radio equipment to stop transmitting in any area in
which blasting operations are in progress. Blasting operations should be discontinued
when there is the likelihood of lightning strikes.

8.8.7 Vibrational Amplitude

Where blasting is proposed adjacent to a building or other structure, the Contractor

shall ensure that the safe value of vibrational amplitude and peak particle velocity as
specified in BS 5607 will not be exceeded.

8.9 CONTROLLED BLASTING

[This Section of the Specifications has been deleted]

8.9.1 Definition

Presplit and Postsplit are controlled blasting techniques. In the former, fracture
surfaces are developed along a design slope by drilling holes in the plane of the slope
and simultaneously detonating light charges in these holes prior to bulk blasting in the
main area to be excavated.

8-3
8.9.2 Objective

The objective of the presplit or controlled blasting is to minimise disturbance of

rock in the design slope caused by nearby bulk blasting. Stability of the design
slope is thus optimised.

8.9.3 Workmanship

All materials and workmanship shall be in accordance with the appropriate current
British Standards or Codes of Practice except where the requirements of the
British Standards/Codes of practice are in conflict with this Specification in which
case the content of this Specification shall take precedence.

8.9.4 Approval of Proposal

Before any blasting is carried out, the Contractor shall submit to the Engineer for
approval the description of the method he proposes to adopt to carry out the
controlled blasting and excavations in the bedrock giving full particulars of the
plant, equipment and material required for the drilling, charging, blasting and
excavation of rock.

Notwithstanding the approval of the Contractor's proposal by the Engineer, the

Contractor shall be and remain solely responsible for the successful controlled
blasting and excavations.

The Contractor's attention is drawn to the existence of structures and homes close
to the boundary of the site. The Contractor shall take all necessary precautions to
ensure that his proposed method of blasting and excavation does not pose any
danger to the people and property adjoining the boundary of the project site. The
Contractor shall undertake full responsibility for any damage caused to the people
and property as a result of his blasting and excavation works and shall take these
aspects into account giving them utmost importance in his proposals to be
submitted to the Engineer.

8.9.5 Presplit Blasting

(a) Site Preparation and Setting Out

Overburden

All overburden including weathered and loose rock, shall be removed prior to
drilling and a fresh working surface formed.

Where, due to great thickness of overburden, this is not practicable, and on

approval of the Engineer, some method of hole support such as plastic
casing must be used to support the length of hole drilled through overburden.
The hole shall remain supported during the blast.

8-4
 Panel Size

A panel shall usually consist of 12 consecutive boreholes, and shall consist of

not less than 6 or more than 12 boreholes, unless otherwise approved by the
Engineer.

Burden

The burden shall usually be greater than 9 metres in front of the presplit
plane. The burden may be reduced on approval of the Engineer to a
minimum of 7 metres.
Position

All holes shall be drilled to lie on the design slope. The position of each hole
in a panel shall be accurately surveyed in and clearly marked on the exposed
rock surface or the soil surface before drilling commences.

Spacing

Unless otherwise approved by the Engineer, holes shall have a spacing of 10

times the hole diameter. Spacings are to be measured along the strike of the
design slope as the distance between adjacent holes centres.

(b) Drilling

Diameter

All drill holes shall be drilled using drill bits of a single approved diameter.

Attitude

All holes shall trend at right angles to the strike of the design slope and dip at
an angle equal to that of the design slope.

Tolerance

No part of any drill hole shall deviate from its theoretical position by more
than one-fifth of the specified hole spacing measured in a direction at right
angles to the plane of the design slope nor by more than one-third of the
specified hole spacing measured in a direction parallel to the plane of the
design slope.

Length

Holes shall be drilled to a length consistent with the design and at least 1
metre below the level of any subsequent blast holes.

8-5
 Lifts

The total height of the face shall be excavated in a series of lifts. The height
of each lift shall be dependent on the design layout and shall not exceed 11.5
metres. The contractor shall demonstrate his ability to drill within the
tolerances required over such lengths during the presplit trials. Failure to
satisfy the Engineer in this respect may exclude the contractor from
consideration to conduct the main contract.

Lift Offsets

Lift offsets shall be according to the design which shall generally be 1.5
metres unless otherwise instructed by the Engineer.

(c) Charging and Detonation

Freedom from obstruction

All holes shall have been drilled to their entire depth and shall be free of
obstructions to this depth before charging commences.

Explosives

Only standard explosives prepared and packaged by explosive

manufacturers for presplit blasting shall be used. Spacers shall be employed
to ensure the charge lies centrally in the presplit hole.

Bottom Charges

Additional charging towards the base of a drill hole in an attempt to cause

'kick-out' of the toe is not permitted.

Stemming

Stemming, if used, shall be limited to the top 0.5 to 1.0 metres of each hole.
Where overburden remains above the solid rock, as in Clause 3.2.2,
stemming shall be to within 0.5 to 1.0 metres of the soil/rock interface.
Stemming material shall be granular, dry, free-running, pass a 10mm sieve,
and fill the specified length of the hole to the collar, or to the soil/rock
interface.

Matting

Matting, held in place by chain, strong netting or other approved means of

constraint, may be laid on the ground surface over the presplit holes to
contain air blast and reduce fly rock.
Detonation

Detonation shall be strictly in accordance with the manufacturers

recommended procedure unless otherwise approved or directed by the
Engineer. Detonation of holes within each panel shall be simultaneous.

8-6
8.9.6 POSTSPLIT BLASTING

(a) Site Preparation and Setting Out

Overburden

All overburden including weathered and loose rock, shall be removed prior to
drilling and a fresh working surface formed.

Where, due to great thickness of overburden, this is not practicable, and on

approval of the Engineer, some method of hole support such as plastic
casing must be used to support the length of hole drilled through overburden.
The hole shall remain supported during the blast.

Panel Size

A panel shall usually consist of 12 consecutive boreholes, and shall consist of

not less than 6 or more than 12 boreholes, unless otherwise approved by the
Engineer.

Position

All holes shall be drilled to lie on the design slope. The position of each hole in a
panel shall be accurately surveyed in and clearly marked on the exposed rock
surface or the soil surface before drilling commences.

Spacing

Unless otherwise approved by the Engineer, holes shall have a spacing of 10

times the hole diameter. Spacings are to be measured along the strike of the
design slope as the distance between adjacent holes centres.

(b) Drilling

Diameter

All drill holes shall be drilled using drill bits of a single approved diameter.

Attitude

All holes shall trend at right angles to the strike of the design slope and dip at
an angle equal to that of the design slope.

Tolerance

No part of any drill hole shall deviate from its theoretical position by more
than one-fifth of the specified hole spacing measured in a direction at right
angles to the plane of the design slope nor by more than one-third of the
specified hole spacing measured in a direction parallel to the plane of the
design slope.

8-7
 Length

Holes shall be drilled to a length consistent with the design and at least 1
metre below the level of any subsequent blast holes.

Lifts

The total height of the face shall be excavated in a series of lifts. The height
of each lift shall be dependent on the design layout and shall not exceed 11.5
metres. The contractor shall demonstrate his ability to drill within the
tolerances required over such lengths during the presplit trials. Failure to
satisfy the Engineer in this respect may exclude the contractor from
consideration to this conduct the main contract.

Lift Offsets

Lift offsets shall be according to the design which shall generally be 1.5
metres unless otherwise instructed by the Engineer.

(c) Charging and Detonation

Charging

Charging of every other borehole.

Freedom from obstruction

All holes shall have been drilled to their entire depth and shall be free of
obstructions to this depth before charging commences.

Explosives

Only standard explosives prepared and packaged by explosive

manufacturers for presplit blasting shall be used. Spacers shall be employed
to ensure the charge lies centrally in the presplit hole.

Bottom Charges

Additional charging towards the base of a drill hole in an attempt to cause

'kick-out' of the toe is not permitted.

Stemming

Stemming, if used, shall be limited to the top 0.5 to 1.0 metres of each hole.
Where overburden remains above the solid rock, as in Clause 3.2.2,
stemming shall be to within 0.5 to 1.0 metres of the soil/rock interface.
Stemming material shall be granular, dry, free-running, pass a 10mm sieve,
and fill the specified length of the hole to the collar, or to the soil/rock
interface.

8-8
 Matting

Matting, held in place by chain, strong netting or other approved means of

constraint, may be laid on the ground surface over the presplit holes to
contain air blast and reduce fly rock.

Detonation

Detonation shall be strictly in accordance with the manufacturers

recommended procedure unless otherwise approved or directed by the
Engineer. Detonation of holes within each panel shall be simultaneous.

8.9.7 Bulk Blasting

(a) Drill Holes

Position

Bulk blast holes shall be positioned such that rock behind the presplit plane is
not adversely affected. In any event they shall not at any point come within 2
metres of the presplit plane or with 2 metre of the bench.

Pop Blasting

Any toes of hard rock remaining at the base of the design face can be
removed by 'pop' blasting providing that the small diameter holes and light
charges used do not cross the presplit plane.

Attitude

The bulk blast holes nearest the presplit plane shall be drilled parallel to the
design slope.

Length

The bulk blast holes shall terminate at least 1 metre above the level of the
bottom of the nearest presplit hole.

(b) Charging and Detonation

Charging

Reduced charging and decreased spacing shall be considered for bulk blast
holes nearest to the presplit plane.

A time interval of at least 50 milliseconds shall exist between detonation of

the last presplit charge and detonation of the first bulk blast charge. Bulk
blast charges shall be delayed progressively towards the presplit plane to
minimise disturbance and vibration.

8-9
8.9.8 Damage to Design Face

Any blasting technique which results in damage or disturbance to the design face
shall be discontinued immediately and the situation reappraised by the Engineer.

8.9.9 Monitoring of Vibrations

Vibration levels due to blasting shall be monitored at all times during the blasting
works. Should the vibration levels exceed the permissible vibration levels
permitted by the local governing authorities, the Engineer shall be informed of it
and all blasting works to be suspended immediately. Blasting works shall only
resume after the blast design factors are revised and approved by the Engineer
and upon an appraisal of the extent of damage caused by the incident.

8.10 TRIAL HOLES EXCAVATION AND REFILLING

Trial holes shall be excavated well ahead of the trench excavation to such depths as
necessary to determine and confirm the alignment for the trench and suitability of the
design. Trial holes will also be required to be performed by the Contractor to
determine the position of underground services, sub-soil drains or for any other
reason.

The Contractor shall arrange for the refilling and reinstatement of trial holes to be
carried out immediately after the required information is obtained. The reinstatement
of the surfaces of trial holes shall be carried out to the approval of the Engineer and to
the same standards as those specified for sewer trench reinstatement.

8.11 CLEANING UP

Upon completion of work of each section, all rubbish, debris and excess or waste
material shall be removed and the entire area involved shall be left in a neat, clean
and acceptable condition. The Contractor shall take extra precautions to ensure that
existing trees, buildings, etc. adjacent to the works are not damaged during this or
subsequent operations. The Contractor shall repair, replace all damage caused to the
trees or buildings by virtue of his negligence in this respect.

8.12 GENERAL TO FILLING WORK

Only suitable material from approved sources shall be used for filling up to the
required platform levels in accordance with the Drawings and compacted in 225mm
thick layers. Before commencement of filling the original ground must be cleared and
any trees or organic material removed to the satisfaction of the Engineer.

8.13 SUITABLE FILL MATERIAL

Suitable material shall comprise all that which is acceptable for use in the Works
which is capable of being compacted in the manner specified in Clauses for
Compaction to form a stable fill having slopes as indicated on the design Drawings.

8.14 COMPACTION TO FILL MATERIAL

Except otherwise directed by the Engineer, earthfill shall be compacted in layers not
exceeding 225mm thick and shall achieve a degree of compaction specified in

8-10
 Section 8.15 of this Specification. All materials used in embankments and as filling
elsewhere shall be compacted as soon as practicable after deposition.

8.15 DEGREE OF COMPACTION

All compacted fill material shall have a dry density corresponding to the following at
the moisture content of the sample in question:

A. for the topmost 600mm below final ground level, 95 per cent of the maximum
dry density obtained from B.S. Standard Compaction tests;

B. for the remainder below final ground level 90 per cent of the maximum dry
density obtained from B.S. Standard Compaction tests.

8.16 UNSUITABLE FILL MATERIAL

Materials unsuitable as fill shall comprise:

A. Materials from swamps, marshes or bogs, running silt peat, log, stumps,
perishable material, slurry or mud.

B. Any material:

- Consisting of highly organic clay or silt;

- Which is clay having a liquid limit exceeding 80 and/or a plasticity index

exceeding 55, unless otherwise approved by the Engineer;

- Which is susceptible to spontaneous combustion;

- Consisting of such clinkers, clinker ashes, fly ashes and domestic ashes
which by virtue of their physical or chemical composition or of their
moisture content will not compact to form a suitable fill.

8.17 TURFING

8.17.1 Quality of Turf

All turfs shall be cut 300mm wide and at least 300mm long and 75mm thick. They
shall consist of healthy dense indigenous carpet grass firmly rooted into at least
50mm of top-soil. The turf shall be free from mimosa, lalang and any other
objectionable plants, and should be preferably laid on the day it is cut. Turf which
cannot be laid within three days of cutting may, at the discretion of the Engineer, be
used as top-soil.

8.17.2 Planting of Turf

Where turf is to be laid, a 100mm thick layer of approved top-soil shall be spread and
compacted on the surface to be turfed. Turf shall be firmly bedded in freshly prepared
top-soil dressing and where necessary shall be pegged down with wooden pegs. The
Contractor shall be deemed to have allowed in his rates for regular watering of newly
laid turf during dry weather until such time as it is firmly established. Any turf which

8-11
 dries through lack of water before the end of the period of maintenance shall be
replaced. All turfing shall be finished to give a smooth compact surface.

8.17.3 Spot Turfing

Where spot turfing is employed, the turf shall not stand out above the level of the
surrounding top-soil. Turfing shall keep pace with spreading of top-soil. Spot turfing
shall be of 600mm centre to centre.

8.17.4 Close Turfing

Close turfing shall consist of turfs laid so that they cover the whole area without any
space between them.

8-12
 SECTION 9

CONCRETE WORKS

9.1 GENERAL

(1) The standard of materials and workmanship shall not be inferior to the
recommendations of the current :-

(i) British Standard Code of Practice CP 1 1 0 : The Structural Use of

Concrete.

(ii) British Standard Code Of Practice BS 5337 1976 : The Structural

use of Concrete for retaining aqueous liquids.

(iii) British Standard Code of Practice BS 8007 1987 : Design of

Concrete Structures for retaining aqueous liquids.

(iv) An appropriate Malaysian Standard approved by the S.O.

(2) The requirements outlined in the above documents must be read with
those of this Section of the Specification and where any conflict exists
between the recommendations of the above and of this Specification, the
requirements of this Specification shall prevail.

(3) As and when required by the S.O. the Contractor shall prepare and
submit, before commencing the work, a time- chart (additional to the
general programme) detailing the various operations for concrete work.

(4) No material shall be used in the Works until prior approval for its use has
been given by the S.O., neither shall any change in the nature, quality,
kind, type, source of supply or manufacture be made without the S.O.'s
permission.

(5) Names of manufacturers and test certificates shall be supplied as soon as

possible to the S.O.

(6) The cost of providing samples and the cost of carrying out tests required
by 9.6.1 together with the cost of supplying equipment for sampling and
site testing indicated in Columns 3 and 4 (part) of Table 1.6A of this
Section of the Specification shall be borne by the Contractor (see also
Clause 9.6.1).

(7) During the progress of the Works, consignment notes shall be supplied to
the S.O. giving details of each consignment.

(8) The use of the word "approved' in this Specification refers to the approval
of the S.O. Cross reference between certain Clauses of this Specification
have been shown in brackets following the particular item.

9-1
9.2 CONCRETE

9.2.1 Requirements

(i) The mix proportions shall be selected to ensure that the workability of the
fresh concrete is suitable for the conditions of handling and placing,
having regard to the structural element being constructed, the disposition
of reinforcement, the climatic conditions prevailing and the limitations set
by Table 1.2A of this Clause for the particular grade of concrete specified.

(ii) Notwithstanding the strength requirements of this Specification, in order

to ensure adequate durability of the finished concrete, while at the same
time limiting its shrinkage characteristics, the following limits shall not be
exceeded:

TABLE 1.2 A - WATER AND CEMENT

RELATIONSHIPS

Grade Of W/C (by Total water Cement Content per

Concrete wt) per 50 Kg. cu.m
Of cement of finished concrete
(kg)
(litres) (litres) (max) (min)

45 0.45 20.0 500 430

35 0.45 24.0 420 400

30 0.50 25.0 400 325

25 0.525 25.3 360 300

20 0.55 27.5 325 270

(iii) In all cases of mix proportioning, the added water shall be included with
due allowance for the moisture contained in the aggregate and shall be
the minimum consistent with the workability requirements. Where
difficulty is experienced in maintaining the correct workability for the
water-cement ratio outlined in Table 1.2A the use of a water reducing
additive may be permitted subject to Clause 9.2.9 where aggregates do
not conform to the moisture requirement of Clause 21.2 of BS 5337 but
are permitted for use, in the case of water- retaining structures the water
content indicated in Table 1.2A shall be reduced by 2.5 litres per 50 kg of
cement.

(iv) Where the concrete is to be used in structures protected from the

elements and are not water retaining the water indicated in Table 1.2A
may be increased by 2.5 litres per 50 kg of cement.

9-2
9.2.2 Strength

(i) The basis for assessing the strength of concrete shall be related to the
characteristic strength, defined as the strength of the concrete at 28 days,
as determined by the standard method of testing (Clause 9. 6. 1) below
which not more than 5% of the test result shall fail.

(ii) The relationship between the grade of the concrete and the characteristic
strength shall accord with Table 1.2B.

TABLE 1.2 B - Concrete Strength Requirement

Grade of concrete Characteristic Strength N/sq mm

28 - day 7 - day

45 45.0 2/3 times the

35 35.0
30 30.0 corresponding 28 days
25 25.0 characteristic
strength
20 20.0 (Clause 9.2.4)

9.2.3 Mixes

(i) Structural concrete porportions may be determined by an approved Mix

Design Method or/and by using the standard mixes set out in Table 1.2 D
having regard for the limitations indicated for fine aggregate gradings
refered to under Clause 9.2.7. For small sections of work the S.O. may
give permission for Nominal Mix proportioning to be used. Non-structural
concrete shall conform to the requirements set out in Table 1.2 C.

(ii) If in the opinion of the S.O. the Design Mix/Standard Mix or Nominal mix
methods of proportioning will not produce concrete to satisfy the
requirements of this Specification the mix shall be specially designed.

(a) Design Mixes

Proportions shall be determined in accordance with Road Note 4,

or other approved methods, for the requirements set out in
Clauses 9.2.1 and 9.2.2

For purpose of determining the design mean strength of the

concrete a margin shall be added to the characteristic strength
(indicated in Table 1.2 B) for the particular grade of concrete.
This design margin shall be assessed on the degree of control
reasonably to be expected in the manufacture of the concrete and
shall not be less than 7.5 N/sq mm nor less than 1.64 times the
standard deviation. Until such time as the standard deviation has
been assessed the margin shall be not less 1 5 N/sq mm.

9-3
 The mix proportions shall be based on the results of a programme
of trial mixes to be carried out by the Contractor and presented not
less than 1 5 days in advance of placing the first batch of
concrete. The S.O. reserves the right to order modifications to the
grading of the aggregates and the water content in order to meet
the requirements of resistance to weathering, watertightness and
workability of the concrete.

(b) Prescribed / Standard Mixes

Proportions for the several grades of concrete shall conform to the

requirements of Table 1.2D.

(c) Nominal Mixes

Nominal mix proportioning is applicable only to non-structural

concrete Class "D" and in exceptional cases when permitted by
the S.O. for concrete grade 15 and 20. Proportions shall conform
to the requirements of Table 1.2 C.

TABLE 1.2 C - Nominal Mixes

Approx. volume Approx. Remarks

Grade of aggr. (cu.m) per cement per
Concrete cu.m concrete cu.m finished
concrete, in
bags
(each 50 kg)
Fine Coarse
Non- Aggregate max.
structur 1.350 3 size not exceeding
al 40mm. All-in
Class D aggregate
permitted.

15 0.450 0.900 5 Aggregate max.

size to be 20mm
Fine aggregate to
Zone 2 of BS 882

20 0.452 0.850 6

9-4
 TABLE 1.2 D - Prescribed/Standard Mixes

Weight of cement and total dry aggregates in kg to produce approximately 1 cu. M of fully
compacted concrete and percentages by weight of fine aggregate in total dry aggregates.

Workability Slump Max. Size of Aggregate (mm)

40 20 10
Med. High Med. High Med.
High
50-100 100-150 50-100 100-150 50-100
100-150
Conc. Class Material
Cement 250 270 280 310 -
-
15 Total
Aggregate 1850 1800 1800 1750 - -
Fines
Content % 30-45 30-45 35-50 35-50 -
-
Cement 300 320 320 350 360
410
Total
Aggregate 1850 1750 1800 1750 1750
1650
20 Sand
Content %
Zone 1 35 40 40 45 50
55
Zone 2 35 35 35 40 45
50
Zone 3 30 30 30 35 40
45
Conc. Class Material
Cement 370 390 400 430 460
510
Total
Aggregate 1750 1700 1700 1650 1650
1550
30 Sand
Content %
Zone 1 35 40 40 45 50
55
Zone 2 35 35 35 40 45
50
Zone 3 30 30 30 35 40
45

9-5
9.2.4 Quality Control

(i) The principle basis of control shall be by comparison of the results of

compression tests on 150 mm sample at 28 days, except for small
quantities of concrete strength can be otherwise derived and which is
permitted for use by the S.O.

(ii) For each main grade of concrete 6 samples for each concreting day shall
be taken for 5 days and from each sample two cubes shall be made.
Thereafter samples of concrete shall be taken according to the following
approximate frequencies and not less than once a day for each class of
concrete being used. From each sample two cubes shall be made.

No. of cu. M concrete No. of samples per

of day
each grade per day

1- 5 1
5 - 10 2
Greater than 10 3

(iii) One cube from each sample shall be tested at 7 days and one at 28 days.
The relationship between the cube crushing strength at 7 and 28 days for
each grade of concrete used shall be established at an early stage and
adjustments made to the mix proportions on the basis of the 7-days
results in advance of the basis of control as outlined above.

(iv) The 28-days cube test for results for each main class of concrete shall be
examined individually in 10 consecutive sets of four and the standard
deviation and mean strength of each set calculated. The concrete mix
proportions will be acceptable if all of the following requirements are
complied with :-

(a) Not more than two results in 40 are less than the characteristic
crushing strength.

(b) No value of the average for any set of four results is less than the
characteristic strength plus one half of the design margin (Clause
9.2.2)

(c) When 40 results have been obtained and the mean strength and
standard deviation are calculated, the mean strength minus 1.64
times the standard deviation or the mean strength minus 7.5 N/sq
mm (whichever is the lesser) shall exceed the characteristic
strength (Clause 9.2.2).

(v) Where the results do not conform to the above requirements the following
action shall be taken

9-6
 (a) Adjustments to the mix shall be made to obtain the
strength required.

(b) In the case where any result is less than 80% of the characteristic
strength the structural implications shall be considered and action
taken as ordered by the S.O. (as provided in Clause No. 9.5.4
(xiv)).

(vi) For those standard mixes required to be tested requirements (i) and (ii)
only will be applicable.

9.2.5 Production

(i) Aggregate and cement shall be proportioned by weight-batching, and

water shall be proportioned by volume. Subject to the prior approval of
the S.O. Volume batching of aggregate may be used for small section of
work, but volume-batching of cement will in no case be accepted. The
Contractor may, however, so proportion the mix that each batch shall use
a whole bag or bags of cement, the weight of which is known precisely.
Where permission has been given for volume batching of aggregates, all
gauge boxes shall be accurate and strongly constructed and due
allowance shall be made for bulking of the aggregate in assessing the
correct volume to be used (Clause 602 of CP 1 14).

(ii) The aggregate and the cement shall be thoroughly mixed in a clean
mechanical mixer for a period of time agreed with the S.O. and the water
added on the basis of the approved design.

(iii) The amount of water added shall conform to the requirement of Clause
9.2.1.

(iv) Batch mixing machines shall comply with the requirements of BS 1305.
They shall be provided in such numbers and of such capacity as to
ensure a continuous supply of freshly mixed concrete at all times during
construction.

(v) Continuous mixing machines shall be used only with the written
permission of the S.O.

9.2.6 Cement

(i) Ordinary and Rapid-hardening Portland cement shall comply with BS 12.

(ii) Sulphate resisting cement shall comply with BS 4027.

(iii) High Alumina, supersulphated, pozzolanic, low heat, blast-furnace or

other cements shall only be used as directed by the S.O. They shall not
be considered within the scope of this Specification but shall be subject to
the requirements of a supplementary Specification when required to be
used.

9-7
 (iv) No extra payment will be made to the Contractor if on his own initiative he
used Rapid-hardening Portland cement.

(v) Cement shall be fresh when delivered to Site and the consignments shall
be used in the order of their delivery. The Contractor shall mark the date
of delivery on each consignment and each consignment shall be stored
separately and in such manner as to be easily accessible and identifiable.

(vi) No cement in bags or other containers shall be used unless these and the
manufacturer's seals are intact at the time of mixing.

(vii) If the cement is delivered in bags it shall be stored in a water-proof shed

or building at a temperature of not less than 8 degree C and the bags
shall be placed on dry boards above the floor to prevent deterioration or
contamination from any cause.

(viii) Bulk cement may be used provided it is stored in an approved container.

(ix) The Contractor shall not use cement which has hardened into lumps, but
subject to removal of the lumps by screening, the S.O. may allow such
cement to be used in non-structural concrete mixes.

(x) Cement of different types shall be kept separate in storage and shall not
be mixed together in the production of concrete.

(xi) Different consignments of cement shall be stored in such an order that

the first consignment is used first and the rest in order of arrival. Covered
lorries shall be used for transporting cement.

9.2.7 Aggregate

(i) Fine and coarse aggregate shall be as defined by and be of the quality
and nature required by BS 882 and BS1201 whichever is applicable. In
addition they shall be chemically inert to alkali reaction.

(ii) They shall conform to the moisture absorption requirements of Clause

21.2 of BS 5337; otherwise the Contractor shall prove the durability of the
finished concrete by approved tests (Clause 9.6.1) when used for making
concrete required for liquid-retaining structures.

(iii) Aggregates of round shape capable of producing a concrete of good

workability with the minimum addition of water shall be preferred.

(iv) The Contractor shall ensure that the gradings of aggregates remain
reasonably consistent, and shall, if necessary, stockpile and include
different gradings to ensure that the overall grading remains constant for
each section of the work.

(v) Dust or flour resulting from crushing the aggregate shall not be allowed to
contaminate the stockpiles. When in the opinion of the S.O. such
contamination has taken place it shall be removed by an approved means
or otherwise the aggregates shall be rejected.

9-8
 (vi) For mass concrete, in order to improve the consistency of the mix, dust or
flour resulting from crushing the aggregate, may subject to test, be
included in controlled quantities to supplement the fine aggregate.

(vii) The aggregate of various sizes shall be kept separate and away from all
possible contamination and shall be stored on a hard-standing area or in
bins, provided with proper drainage at the base of the stockpiles.

(viii) Except where aggregates have been otherwise specified on the Drawings
the grading of aggregates shall be as follows

Coarse Aggregate

(a) 10 mm max. size, graded, for all "Fine" concrete

(b) 20 mm max. size, graded, for all reinforced concrete in beams and
for walls and slabs with the minimum concrete cover of 40 mm or
less.

(c) 40 mm max. size, graded, for all reinforced concrete walls and
slabs with the minimum concrete cover of 60 mm or more.

Fine Aggregate :

(a) Where aggregates conforming to Zones 2 or 3 of BS 882 are

available they shall be used.

(b) For Nominal Mixes, where permitted to be used, Zone 2

aggregate only shall be used, except for non structural concrete -
grade 15 where all - in aggregates may be used.
9.2.8 Water

(i) The Contractor shall supply all water, make all arrangements and pay all
charges in respect of such supply. Where water can be obtained from a
public potable water supply it shall be used.

(ii) Where water cannot be obtained from a public supply it shall be tested in
accordance with the BS 3148 and if necessary shall be treated to assure
compliance therewith.

(iii) Water for washing and curing shall be such that it will not impair either the
strength of the finished concrete or its appearance.

9.2.9 Concrete Admixtures

(i) Admixtures may be used in the works with the approval of S.O. (Table
1.6)

(ii) Where concrete additives have been approved by the S.O for use in the
works, the contractor shall ensure that careful control is exercised in
maintaining correct proportions in the mix.

9-9
 (iii) Where incorrect proportioning has been carried out which in the opinion
of the S.O. will adversely influence the concrete, the concrete shall be
treated in accordance with Clause 9.5.4.

9.2.10 Displacers

Displacers shall be approved clean, hard, durable rock with no softening or

weathering and shall be of reasonably regular shape. Displacers shall measure
not less than 200 mm or greater than 400 mm in any direction.

9.3 REINFORCEMENT

9.3.1 Steel

(i) Reinforcement shall be : -

(a) Plain round mild steel or high yield steel bars to conforming to BS
4449

(b) Cold worked steel bars conforming to BS 4461 or

(c) Fabric reinforcement conforming to BS 4483.

(d) The Contractor shall obtain from his suppliers certificates of the
mechanical and physical properties of the reinforcement and shall
submit them to the S.O. for approval.

(e) Where galvanized reinforcement is specified, galvanizing shall

comply with requirements of BS 729, Part 1.
9.3.2 Storage

Reinforcement shall be stored on Site under cover and supported clear of the
ground and in such manner as to make identification easy. Support shall be
such that distorting of the steel is avoided and contamination and corrosion
prevented.

9.3.3 Bending and Fixing

(i) The Contractor shall provide on Site facilities for cutting and bending
reinforcement whether he is ordering his reinforcement bent or not and
shall ensure that a token amount of straight bar is available on Site for
bending as and when directed by the S.O.

(ii) Reinforcement shall be wire brushed and cleaned at the Contractor's

expense, before and/or after it is placed in position, if required by the S.O.

(iii) All steel reinforcement bars shall be bent accurately to the form and
dimensions shown in the drawings. Bars shall be bent cold in an
approved machine or by other approved means producing a gradual and
even motion. Bars incorrectly bent shall not be straightened or rebent but
shall be rejected.

9-10
 (iv) The reinforcement shall be fixed in strict accordance with the Drawings as
regards cover, spacing and position and suitable precautions shall be
taken by the Contractor to prevent the displacement of reinforcement
during the placing and compaction of concrete.

(v) When required to support and retain the reinforcement in its correct
position the Contractor shall provide templates stools or other supports at
his own cost.

(vi) Precast concrete support blocks for reinforcement shall be manufactured

from grade 20 concrete to ensure the correct cover thickness. They shall
be well cured before use and carefully stored on Site to avoid
contamination. Plastic and metal supports, chairs, etc. may be used
subject to the S.O.'s prior approval.

(vii) In the case of mild steel, a lap of not less than 40 diameters of the smaller
bar shall be provided at the junction of two bars for which the lap is not
specifically detailed on the drawings and, in the case of High Yield steel, a
lap of not less than 50 diameters.

(viii) All intersection of bars in walls and slabs and all connections between or
links and main bars in columns or beams shall be tied with soft iron wire
ties or with fixing clips which shall not be allowed to make contact with the
shuttering or to project materially into the specified cover.

(ix) Unless permitted by the S.O., welding of bar reinforcement at

intersections or for the joining of bars is prohibited. Where permission is
granted, welding shall be carried out in accordance with the
recommendations of the Institute of Welding for the welding of reinforcing
bars for reinforced concrete construction.

(x) When fixed reinforcement is to be left exposed for a delayed period of

time, it shall be thoroughly cleaned and painted with neat cement grout.

(xi) Where galvanished reinforcement is used any damage suffered by the

galvanising shall be made good by the application of an approved
galvanised formulation, before concrete placing is commenced.

9.4 SHUTTERING

9.4.1 Requirements

(i) The term "shuttering" shall be taken to include centering, formwork,

strutting, bracing and the like.

(ii) Shuttering shall be of such accuracy, strength and rigidity as to carry the
weight and pressure from the concrete to be placed on or against it,
together with all construction, wind or other loads likely to be imparted to
it, without producing deformation of the finished concrete in excess of the
tolerances outlined in Clause 9.4.5 and Table 1.4A and their design and
construction shall in all respects be subject to the approval of the S.O.

9-11
(iii) All shuttering shall be sufficiently tight, without plugging, to prevent loss of
grout during the vibration of the concrete.

(iv) Faces of shuttering shall be clean, free from projecting nails, adhering
grout and other imperfections or defects which would prevent the
specified surface finish from being attained. They shall be treated with
approved mould oil before positioning. Great care shall be exercised to
prevent reinforcement or steelwork from being contaminated by the oil
during erection of the shuttering.

(v) Shuttering which as a result of prolonged use or general deterioration

does not, in the opinion of the S.O. conform to the particular requirements
set out in this clause, shall not be used.

(vi) Through-bolts or ties will not be permitted in liquid- retaining structures.

The Contractor shall use only such bolts or ties as are capable of being
removed in whole or in part so that no part remaining embedded in the
concrete shall be nearer the surface of the concrete than the specified
thickness of cover to the reinforcement.

(vii) Beam soffits shall be erected with an upward camber of 5 mm for each 3
metres of span.

(viii) Top shuttering shall be counterweighted or otherwise anchored

against flotation.

(ix) Boxes for forming shall be constructed so as to be easily removable

without damaging the concrete during removal.

(x) Openings for inspection of the inside of beam, wall, column and similar
shuttering and for cleaning-out purposes shall be formed so that they can
conveniently be closed before the placing of concrete.

(xi) All props shall be supported on adequate sole plates and shall not bear
directly on or against concrete. They shall be capable of being released
gently and without shock from the supported shuttering. No appliance for
supporting the shuttering shall be built into the permanent structure
without the S.O.'s prior approval. Props for upper levels, shall be placed
directly over those at lower levels, and the lower most props shall bear
upon work sufficiently mature to carry the load.

(xii) Shuttering shall be such as to allow for its removal without damaging the
concrete, and in the case of suspended floors, for the removal of the
beam sides and slab soffits without disturbing the beam-bottom boards
and their props.

(xiii) Before concreting, the areas which are intended to receive the concrete
shall be cleaned by jetting with compressed air, and all water and
extraneous material removed.

(xiv) Where timber is used for shuttering it shall be properly cured, free froril
wrap, straight, clean and free from loose knots.

9-12
 (xv) Where metal forms are used for shuttering they shall be of the type
strengthened by intermediate ribs or cross bracing.

9.4.2 Sawn Shuttering

Sawn shuttering shall produce an ordinary standard of finish consistent with

normal good practice as approved by S.O. for use where the face of finished
concrete will not be exposed. The face in contact with the concrete shall consist
of sawn timber boards, sheet metal or other approved material.

9.4.3 Wrought Shuttering

Wrought shuttering for use where the face of the finished concrete is to be
exposed shall produce a high standard of finish consistent with the best practice
as approved by the S.O. The face in contact with the concrete shall consist of
wrought and thicknessed boards tongued and grooved of not less than 30 mm
finished thickness, framed plywood or metal panels or other approved material.
Joints between boards and/or panels shall be arranged in a uniform pattern.

9.4.4 Special Wrought shuttering (for fair faced finish)

Special wrought shuttering shall provide the highest standard of finish where the
face of the finished concrete is to form a particular feature. The face in contact
with the concrete shall consist of large smooth sheets, unless otherwise
specified, arranged in an approved uniform pattern, with joints coinciding with
possible architectural features, sills, window heads, or change in direction or
surface. Accurate alignment of all joints shall be maintained. Wrought boarding
and standard steel panels shall not be used unless specially faced.

9.4.5 Tolerances

Unless otherwise indicated in the Drawings, the tolerances of the finished

concrete with respect to the dimensions shown on the Drawings shall not exceed
the limits set out in Table 1.4A except that in the case of Sawn Shuttering the
dimensions of the finished concrete shall not be less than those shown on the
drawings.

TABLE 1.4A
Item Tolerance (mm)

Overall dimensions and +5

levels
Column Sizes +5
Beam Sizes
Wall Sizes 0
Vertical lines out of plumb 5 mm + 5 mm in every 15 m

9-13
9.4.6 Striking and Removal of Shuttering

(I) The S.O. shall be informed in advance when the contractor intends to
strike any formwork.

(ii) Attention is drawn to the provisions that the concrete shall at no time be
subjected to loading, including its own weight which will induce a
compressive stress in it exceeding 0.33 of its strength at the time of
loading or of the specified 28 days strength. The assessment of the
strength of the concrete and the stresses produced by the loads shall be
subject to the agreement of the S.O.

(iii) The time at which the formwork is struck shall be the

Contractor's responsibility, but the minimum periods between
concreting and the removal of forms are given in the following
table:-

TABLE 1.4B - Period Between Concreting and

Formwork Removal
Vertical faces of beams, walls columns, piles 3 days
foundation plinth and precast items
Undersides of slabs and beams 10 days
Propose to slabs and beams 14 days

(iv) The periods stated above are based on a constant temperature of the
concrete of 27 degree C and the use of ordinary Portland Cement. They
may be changed if other types of cement are used, subject to the S.O.'s
agreement.

(v) Formwork shall be constructed so that the side-form members can be

removed without disturbing the soffit forms and, if props are to be
removed, these props shall not be disturbed during the striking.

(vi) For prestressed units the side forms shall be eased as early as possible
and the soffit forms shall permit deformation of the member when the
prestress is applied.

(vii) All formwork shall be removed without damage to the concrete and not to
leave wood slivers adhering to the concrete.

(viii) When it is intended that formwork is to be reused it shall be cleaned and

made good to the satisfaction of the S.O.

9.5 CONCRETING

9.5.1 Requirements

The finished concrete shall be dense, durable, impervious to the ingrees of

water, free from cracks and honeycombing, resistant to wear and mild chemical
attack.

9-14
9.5.2 Transporting of Concrete

(i) Concrete shall be transported to the place of final deposit by

approved means.

(ii) Barrows, spades and other equipment used in the process of

transporting concrete shall be thoroughly cleaned before each
day's work or after a long interruption and they shall be free from
hardened concrete.

(iii) Concrete shall be transported as soon as possible after mixing, by

methods which will prevent the segregation, loss or contamination
of the ingredients.

(iv) Proper bridging arrangements for traffic over reinforcement shall

be provided so that the reinforcement is not distorted, damaged or
displaced.

(v) Where approval is obtained for concrete to be conveyed by

chutes, these shall have a slope (not exceeding 1 vertical to 2
horizontal) such as to ensure a continuous flow of concrete.
Additional water shall not be introduced to assist the flow. If
deposition is to be intermittent the chutes shall be arranged to
discharge into a storage hopper. In no case will a clear fall of
more than 1 m be permitted at the discharge end of the chute.

(vi) Where approval is obtained for pumping the concrete, the pump
manufacturer's recommendation shall be followed. The pumps
used shall be of adequate capacity and power to ensure delivery
of a continuous supply. The Contractor shall provide adequate
alternative arrangements for transporting the concrete in case of a
breakdown of the pumping equipment.

(vii) Where transport of concrete is interrupted for any length of time

(period of over 1 hour shall be treated as such) the chutes,
pumps, pipes and any other means of distribution shall be
thoroughly flushed out and cleaned. These shall also be flushed
out immediately prior to resumption of concreting and shall be
kept free from hardened concrete. All washwater used shall be
discharged outside the shuttering and clear of any freshly placed
concrete.

9.5.3 Placing and Compaction

(i) No concrete shall be placed until the has obtained approval to do

so from the S.O.'s Representative. When the Contractor intends
to place concrete he shall inform the S.O.'s Representative in
sufficient time to enable him to inspect the reinforcement,
shuttering surface on which the concrete is to be placed and the
Contractor shall provide all facilities for such inspection.

9-15
(ii) Concrete shall be placed within 30 minutes of mixing to uniform
level, in layers not exceeding 50 cm deep in such manner as to
avoid segregation, and each layer shall be compacted by means
of approved vibrators to form a dense material free from
honeycombing and other blemishes. Compaction by hand may be
used only with the prior approval of the S.O.

(iii) Vibration time, the effective radius and other vibration

characteristics shall be in accordance with the vibrator
manufacturer's recommendations a copy of which shall be sent to
the S.O in advance of the operation.

(iv) If internal vibrators are used, they shall be withdrawn immediately

after a thin film of mortar begins to appear on the surface of the
concrete. Withdrawal shall be carried out slowly to avoid
cavitation.

(v) Where two distinct batches of concrete, placed at different periods

of time and forming part of the same concreting operation are
required to be formed monolithically with each other, the more
mature concrete shall be penetrated by the vibrator to a sufficient
depth to effect plastic movement between the two batches.
Where the concrete does not respond to the action of the vibrator,
it shall be deemed to have set, and no further disturbance will be
permitted. Unless otherwise instructed by the S.O. the condition
shall be treated as for a "stoppage of work" and the marrying up of
the two concrete shall be effected only when both concretes have
properly set.

(vi) If shuttering vibrators are used, the shuttering shall be strong

enough to withstand the forces of vibrations.

(vii) Temporary or permanent stoppages of work shall be made only

against stop ends .

(viii) Unless otherwise specified, before placing new concrete against

concrete which has already hardened, the face of the older
concrete shall be prepared by the removal of any laitance and
loose aggregate, and shall be cleaned by jet of compressed air.

(ix) When displacers are permitted to be used they shall be so placed

that no displaces is within 30 cm of any finished face, permanent
masonry shuttering or any other displacer. On completion of any
lift, displacers shall be so arranged that they project for half their
height above the surface. Before placing any displacers the
Contractor shall carry out full scale tests.

9-16
9.5.4 Concreting in Deep Lifts

(i) Limitation

(a) Any height exceeding 2.5 m from which concrete is poured

into shuttering to form sections of wall be considered within
the terms of this Clause.

(b) Deep lift construction will not be permitted where the reinforcing
bars are to be placed closer than 10 cm to one another in any
direction or, where the clear width at the point of admitting the
concrete between one layer of reinforcement and another (or
in the case of singly reinforced walls between reinforcement
and shutter) is less than 200 mm.

(c) The method shall only be used where trial sections reveal that,
in the S.O.'s opinion, it can be satisfactorily employed, in which
case the requirements of this Specification shall apply except
where they are in conflict with the requirements of this
particular clause, when the latter shall prevail.

(ii) Concrete

(a) In order to prevent segregation of aggregates, concrete mixes

shall be designed for increased cohesion or where suitable on
a gap-graded basis. The use of approved admixtures may be
made to achieve this end (Clause 9.2.9).

(b) At the same time, the mix shall be such as to limit the amount
of bleeding in the concrete, and where in the opinion of the
S.O. the quantity of free water rising to the surface is
excessive, the mix shall be corrected before further concreting
is undertaken.

(c) In order to offset any increase in the water-cement ratio at the

upper levels, the S.O. may require the concrete mix to be
modified for the upper depositions.

(d) A slump of 80 mm shall not be exceeded.

(iii) Reinforcement

(a) In order that reinforcement is not distorted or displaced during

construction as a result of it being used for gaining access in
or out of the shuttering, all intersections of vertical and
horizontal steel shall be properly fastened.

9-17
 (b) All obstructions caused by spacer blocks or chairs shall be
eliminated so as to permit an unobstructed passage for the
concrete to the bottom of the shuttering. The Contractor may
use sliding timber spacer instead of fixed concrete or plastic
spacer blocks to position the reinforcement.

(iv) Shuttering

(a) In view of the high pressures to be expected from this form of

construction extra attention shall be paid to the strength and
stability of the shuttering, to the prevention of loss of grout,
and to the prevention of displacement of adjacent panels.

(b) The use of approved through-bolts and other accessories

which might interfere with the free passage of concrete
between and around the reinforcement shall be reduced to a
minimum by the use of properly designed shuttering.

(v) Concreting

(a) Particular attention shall be paid to the concreting of the initial

sections at the bottom of the shuttering to prevent segregation
caused by rebound from the hard surface of the kicker, base
and or lower sections. The initial depositions shall therefore
be made by using trunking methods, or by placing the
concrete through openings formed in the sides of the
shuttering. Such openings shall not be higher than the hard
surface by 2.5m.

(b) In order to reduce differential settlement, and consequently,

cracking between two sections of concrete placed at different
intervals of time, concreting between one section and another
shall be carried out on a gap-construction basis (Clause
9.5.4(xi)).The gap shall subsequently be concreted in distinct
lifts each not exceeding 2.5 m height. For the same reason,
for concreting heights (e.g. where boxing out is included), the
difference in height shall not exceed 15% of the height of the
deeper section.

(c) Concreting from the upper level of the shuttering shall be

carried out in such manner as to ensure that concrete is
admitted centrally between the faces of the shuttering. For
this purpose the Contractor shall make use of trunking or shall
use funnel-shaped hoppers extending for a distance of not
less than 1.5 m into the shuttering. A sufficient number of
such hoppers shall be provided, and or they shall be capable
of movement along the length of the shuttering, to enable the
concrete to be placed in continuous heaps at the base of the
pour. Such heaps shall not exceed 46 cm in height.

9-18
 (d) Where excessive bleeding is in evidence, the excess water
shall be removed before placing further concrete (see sub-
clause "Concrete" of this clause).

(vi) Compaction

(a) Compaction shall be carried out where possible by manual

operation of poker vibrators within the shuttering. Where this
is not possible poker vibrators shall be suspended in sufficient
numbers to ensure uniform compaction along the length of
wall receiving the concrete, without the need for their
withdrawal and re-insertion. The means of suspension shall
be such that the vibrators may be progressively and
systematically lifted as the concreting proceeds to ensure that
every section of placed concrete is married into adjacent and
underlying sections.

(b) The use of vibrators to reposition deposited concrete is

prohibited.

(c) Surface vibrators attached to the shuttering may be used only

to supplement the main means of compaction.

(vii) Hot Weather Concreting (for temperatures above 20 degree C)

(a) Concreting shall not be permitted if its temperature at placing

is in excess of 38 degrees C. In order to maintain the
temperature of the concrete below this value the following
precautions shall be taken wholly or in part as instructed by the
S.O.:-

1. All aggregate stockpiles, water lines and tanks as well as

the mixer shall be protected from the direct rays of the
sun;

2. Coarse aggregate shall be cooled by constant watering

where possible.

3. Mixing water shall be cooled by the addition of ice to the

storage tanks where necessary;

4. Rapid-hardening cement shall not be used;

5. Where the above precautions are inadequate concreting

shall be carried out during the cooler parts of the day or
during the night as may be directed by the S.O.

9-19
 (b) When the air temperature is above 20 degree C loss of mixing
water by evaporation shall be considered in arriving at the
amount of water to be added to the mix (Clause 9.2.1). In
order to maintain the water/cement ratio within permissible
limits an approved water-reducing agent shall be 3 included in
the mix (Clause 9.2.9). The maximum water/cement ratios
indicated in Clause 9.2.1) may be increased with the S.O.'s
permission by 0.05 (or 2 1/2 liters/50 kg of cement) during
mixing, but on no account shall water be added to concrete
directly or indirectly once it has left the mixer.

(c) In order to reduce premature drying of the concrete during

transporting and placing, all chutes, shuttering and
reinforcement shall be cooled by watering when possible, or
shall otherwise be protected from the direct rays of the sun.
Any water so used shall be removed by jetting with
compressed air before placing the concrete in close contact.

(d) As soon as possible after concreting, the shuttering shall be

stripped (Clause 9.4.6) and the surface of the concrete shall
be kept moist for a period of 4 days by mist spraying or, when
permitted by the S.O. by covering with wetted hessian or sand
or by treatment with an approved curing membrane.

(e) When drying winds are encountered, wind shields shall be

positioned as directed by the S.O. to protect exposed surfaces
of the curing concrete.

(viii) Wet Weather Concreting

(a) Concreting during periods of constant rain shall not be

permitted unless aggregate stockpiles, mixers and transporting
equipment, and the areas to be concreted are adequately
covered.

(b) During showery weather, the Contractor shall ensure the work
can be concluded at short notice by the provision of stop ends.
On no account shall work be terminated before each section,
between one stop end and another, is complete. Adequate
covering shall be provided to protect newly placed concrete
from the rain.

(ix) Holes, Cavities and Fixing

(a) The Contractor shall be responsible for the coordination of all

requirements of his sub-contractors as regards provision of
holes, chase, cavities and fixings and shall, if required by the
S.O. prepare drawings giving details of his and his sub-
contractor's requirements and shall send copies of each
drawings to the S.O. prior to construction.

9-20
 (b) Holes, etc. shall be accurately marked and boxed-out before
concreting operations commence, and without the S.O.'s prior
approval, no such holes, etc. shall be formed after the
concrete has set.

(c) Where bars, if placed to specified spacing, would foul holes of

size less than 25 cm x 25 cm the bars shall be cut on site and
lapped with additional equivalent bars, or as otherwise
indicated on the Drawings.

(d) Wherever possible, the Contractor shall built in all pipework,

ironwork, etc. which passes through walls and floors, and the
pipework, ironwork, etc. shall first be thoroughly cleaned and
freed from any deleterious matter, and every care shall be
taken to ensure that it is thoroughly encased in concrete.

(e) Bolts, hooks and other fixings shall be embedded in concrete,

or holes shall be drilled and fitted with threaded expanding
anchors to receive the bolts. The Contractor shall ensure that
bolts, hooks, etc. are accurately positioned. Holding down
bolts for machinery shall be set to template.

(f) Where brick or stonework is to form a facing to the concrete or

where the end of a brick or stone wall butts against a concrete
face ,galvanised metal ties of approved manufacture to BS 1
243 shall be incorporated. The distance between ties shall be
gauged with due regard for the bonding of the walls, and at
intervals required by the S.O.

(x) Protection and Curing

(a) Newly placed concrete shall be protected by approved means

from rain, drying winds, sun and concrete with substances
which can adversely affect it.

(b) No traffic or constructional loads shall be permitted on newly

placed concrete until it has hardened sufficiently to take such
traffic or load, and only then with the approval of the S.O.

(c) Exposed faces of concrete shall be kept moist after placing for
not less than 3 days if Ordinary Portland and 2 days if Rapid-
Hardening cement is used unless otherwise stated in the
plans. Membrane curing by approved materials may be used
when permitted by the S.O.

(d) Any concrete surfaces, arises and treads of stairways which

might be damaged during the construction of the Works shall
be adequately protected.

(xi) Joints

(a) Construction Joints

9-21
1. The position of construction joints, when not shown on
the Drawings or otherwise required by this Specification,
shall be decided on site having regard to the plant and
labour made available by the Contractor for the
manufacture, placing and compaction prevailing at the
time of concreting, the climatic conditions prevailing at
the time of concreting, the nature and size of the
shuttering, and the conditions of operation of the work.
The Contractor shall submit his proposals to the S.O. for
his approval before commencing the work.

2. Construction joint surfaces shall be treated by the "wash-

off" method explained below, except where it cannot be
practically effected, in which case it shall be treated in
accordance with the placing of new concrete to hardened
concrete.

3. When expanded metal lathing is used for the formation

of construction joints a rebate will not be required to be
formed. The expanded metal lathing shall be left in the
work and shall not extend closer to the finished surface
of the concrete than 25 mm. It shall be securely fixed to
the reinforcement.

4. Slabs supported on the ground

In order to ensure control in the placing of concrete the

Contractor shall provide control boards to form panels
not larger than 15 sq m in area. These shall be lifted as
the concreting proceeds except where they are of
expanded metal in which case they may be left in
position as part of the permanent works, provided that
they shall not extend closer to the finished surface of the
concrete than 25 mm. In the event of a breakdown in the
supply of concrete the Contractor shall ensure that an
alternative supply of concrete is made available (to finish
the work against the control boards acting as stop ends).
The joint so formed shall then be treated as a
construction joint. Where ready mixed concrete is
permitted the control boards shall be positioned so as to
enclose a volume of concrete equal to that delivered by
each truck. Construction joints and control shall be
formed normal to the surface of the retained concrete.

5. Suspended Beams and Slabs

The reference to control boards in the foregoing

paragraph (4) shall apply, but generally, unless otherwise
shown on the Drawings or permitted by the S.O.,
construction joints shall be arranged in positions for
which approval is to be obtained from the S.O. T-beams
shall be formed to their full depth integrally with the

9-22
 adjacent slab and without horizontal joints.

6. Walls

Horizontal construction joints in walls shall be formed

along straight lines coinciding with the full height of the
shuttering. The height of the shuttering thus controlling
the height of the pour shall be determined with reference
to the availability of concrete, the size and type of
shuttering used, the thickness of the wall, the size and
amount of reinforcement and the means of compaction
available.

Unless otherwise indicated on the Drawings or otherwise

permitted by the S.O. for the construction of circular
tanks, concreting shall be carried out continuously for the
full circumference without vertical joints. Where
permission is granted for the use of vertical joints the
S.O. may order, at no extra cost to the Employer, the
inclusion of an approved type of water-stop.

In the case of rectangular tanks, vertical joints shall not

be positioned closer to any corner than 1 metre. They
shall be formed with properly rebated stop ends or,
where conditions permit, by the use of expanded metal
lathing.

Unreinforced manholes shall be constructed without

vertical joints.

7. The "Wash-off Method" of preparing Construction joints

As soon as possible after concreting, and while the

surface is still green, the surface of the concrete forming
the joint shall be freed of loose aggregate and sprayed
with a fine spray of water to prevent the formation of
laitance. Subsequently all excess water shall be
removed by a jet of compressed air and the surface left
clean to receive further concrete.

Where expanded metal lathing is used for construction

joints, this method of surface preparation shall be used in
every case.

8. Construction Joints in Liquid Retaining Structures

In liquid retaining structures not including spillways,

P.V.C. or rubber water stops not less than 125 mm wide
shall be built into all construction joints in floor, all vertical
construction joints in walls and all horizontal construction
joints in walls which are exposed. Construction joints
shall be formed in the positions shown on the Drawings
at additional or alternative positions agreed by the S.O.
9-23
 (b) Movement Joints

1. These shall include contraction and expansion joints and

shall be as indicated on the Drawings.

2. Contraction joints will be either full contraction joints or

partial contraction joints. Where partial contraction joints
are specified a period of at least five days shall elapse
between the concreting of the section on each side of the
joint.

3. Where the Drawings indicate a contraction gap be

formed in any panel (this gap will not exceed 1 metre),
concreting in either side of the gap shall be carried out so
as to form partial contraction joints as each side of the
gap. Prior to the concreting of the gap section, the joint
surface shall be cleaned but otherwise left untreated.
The concreting of the gap section shall not be carried out
until a period of at least five days has elapsed after
completion of the adjacent sections.

4. Alternate panel construction (other than contraction gap

construction outlined above) will be permitted only with
the approval of the S.O., or in those cases where either
the reinforcement is not continuous through the joint or
where the panels are separated by expansion or
contraction joints.

(xii) Waterstop and Jointing Materials

(a) Waterstop and jointing materials shall be obtained from an

approved manufacturer.

(b) All waterstop and jointing materials which are not required for
immediate use shall be stored at all times in a cool place.

(c) Waterstop shall be manufactured of rubber or P.V.C.

(polyvinyl-chloride) as stated in the Bill of Quantities and shall
be of the type and size shown on the Drawings. Site joints
shall be made strictly in accordance with the manufacturer's
instructions and all intersection and junctions shall be obtained
prefabricated from the approved manufacturer.

(d) Joint filler shall be manufactured of resin bonded cork or other

approved material. Joint shall be cut and trimmed accurately
in position by means of an approved adhesive.

(e) Joint sealing compounds shall be approved rubber/ bituminous

compounds suitable for sealing joints in horizontal and vertical
sloping concrete surfaces as appropriate. Sealing compounds
shall be applied strictly in accordance with the manufacturer's
instructions and shall completely fill the joint recess.

9-24
 (f) Water stop shall be located and maintained accurately in
position and details of the proposed method of fixing shall be
submitted to the S.O. for approval. On no account shall
waterstop be secured 'by nails or any other means involving
puncture of or damage to the waterstop material.

(xiii) Finishes

(a) All exposed faces of concrete unless otherwise specified shall

be hard, smooth and free from honeycombing, air and water
holes and other blemishes.

(b) All projecting imperfections shall be rubbed down with

carborundum stone or by other approved means and the grit
and dust therefrom shall be thoroughly washed off with clean
water.

(c) The normal finish to slabs unless otherwise billed, shall be

formed by smooth floating the accurately levelled and
screeded surface. Care shall be taken to ensure that the
concrete is worked no more than is necessary to produce a
uniform surface free from screed marks.

(xiv) Other Surface Finishes

(a) Granolithic Pavings

1. Granolithic concrete shall be mixed in the proportions by

volume of two parts of 9 mm approved granite chippings,
one part of clean sharp sand and one part of ordinary
cement.

2. The granolithic paving shall be 25 mm thick laid on green

structural concrete. This layer shall be in addition to the
depth of structural slab specified. Unless otherwise
specified, granolithic surface shall be worked to a hard,
even finish with a high resistance to abrasion and to
correct levels and falls as shown on Drawings or as
directed.

3. As soon as pavings are completed, they shall be

protected against rapid drying by erection of barriers
against direct sunlight and wind. The floor shall be cured
continuously for a period of seven days by means of an
approved water-proof sheeting which shall be kept in
close contact with the surface of the paving.

(b) Smooth-trowelled

Finishes shall be formed while the concrete is still wet by

means of a steel trowel applied to an accurately levelled and
screeded surface.

9-25
 (c) Screed finishes shall be formed by levelling and screeding the
concrete to produce a uniform, plain or ridged surface as
specified.

(d) Bush-hammered or Pattern-Worked finishes

1. When exposed aggregate is to be the surface texture,

the contractor shall ensure that a uniform distribution of
the coarse aggregate takes place at the face. The
shuttering shall be removed as soon as possible from the
face to be treated; the surface shall be thoroughly wetted
and wire- brushed, and bush-hammered or pattern-
worked as and when instructed. Surface retarders shall
be used only when permitted by the S.O.

2. Bush-hammering or pattern-working shall not be relied

upon to obscure any defects in the concrete face which
arise from shuttering imperfections.

(xv) Making Good

(a) Honeycombed or damaged surfaces of concrete, which in the

opinion of the S.O., are not such as to warrant the cutting out
and replacement of the concrete, shall be made good as soon
as possible after removal of the shuttering as follow:-

1:1.5 Portland cement and sand mixture shall be worked into

the pores over the whole surface with fine carborundum float
in such a manner that no more materials is left on the concrete
face than is necessary to completely fill the pores so that a
uniformly smooth and dense surface colour is finally
presented.

(b) In water retaining structures the cement mortar used in filling

recesses in the concrete formed by tbobbins in connection with
shuttering shall contain an approved expanding admixture.

(xvi) Unsatisfactory Concrete

The Contractor shall on the S.O.'s instruction to do so cut out and

replace any concrete in any part of the structure if in the S.O.'s
opinion:-

(a) the concrete does not conform to the Specification, or

(b) deleterious material or materials which are likely to produce

harmful effects have been included in the concrete, or

(c) the honeycombed or damaged surface are too extensive, or

(d) the finished concrete sizes are not in accordance with the
Drawings within permissible tolerances, or

9-26
 (e) the setting-out is incorrect, or

(f) the steel cover has not been maintained, or

(g) the protection, including curing, of the concrete during the

construction was inadequate, resulting in damage, or

(h) the work of making good or other remedial measures the S.O.
may indicate are not carried out to his satisfaction, or

(i) undue deformation of or damage to the works has taken place

due to inadequate shuttering, or to premature traffic, or to
excessive loading, or any combination of the above points has
taken place resulting in unsatisfactory work.

9.6 TESTING

9.6.1 (a) Sampling and Testing

(i) The Contractor shall provide equipment, staff and labour for
carrying out the sampling and testing outlined in Columns 3 and 4 of
Table 1.6A, and he shall carry out any or all these tests at such
times and with such frequency as may be requested by the S.O.

(ii) Standard laboratory tests in respect of concrete, aggregates etc. are

summarised in Column 5 of Table 1.6 A. The Contractor shall
provide laboratory facilities for the necessary test to be carried out
as instructed by the S.O. and make available all records for
inspection. Tests which are carried out at the site or at approved
laboratories, the cost shall be borne by the Contractor.

(iii) All equipment at the site shall be calibrated and checked from time
to time as the S.O. may require.

(vi) The Contractor shall provide all samples required by the S.O. Those
samples to be tested in a laboratory as required by Column 5 of
Table 1.6 A shall be carefully forwarded by the Contractor to an
approved laboratory. Results of laboratory and site tests shall be
kept on site and copies of all test reports shall be forwarded in
duplicate to the S.O.'s Representative.

(v) Frequency of tests and the number of samples required will be

governed by the results of previous tests, the quality of the materials
revealed during the tests, and the u niformity of that quality. Should
it become evident that the quality of the concrete is deteriorating the
S.O. may require additional samples to be taken and test cubes to
be made and tested to determine the cause.

9.6.2 (b) Loading Tests

(i) The S.O. may direct that a loading test be made on the Works or
any part thereof if he deemed such a test to be necessary for one or

9-27
 more of the following reasons

(a) failure of "Site Cubes" to attain the strength requirements of

Clause 9.2.2;

(b) premature removal of shuttering;

(c) overloading of structure during construction;

(d) improper compaction and/or curing of concrete;

(e) any other circumstances attributable to alleged negligence on

the part of the Contractor, which, in the opinion of the S.O may
result in a structure being of less than the required strength.

(ii) Loading tests shall be carried out in accordance with Clause 605 of
CP 1 14, or as required by the S.O.

(iii) If the results of the test are not satisfactory, the S.O. will direct that
the part of the work concerned be taken down or removed and
reconstructed to comply with the Specification, or that such other
remedial measures as he may think fit be taken to make the work
acceptable.

(iv) The S.O. may also instruct the Contractor before a loading test
takes place to take out cylindrical core specimens from the
structures concerned and have them tested. The cutting equipment
and the method of doing the work shall be to the S.O's approval.
The specimens shall be dealt with in accordance with BS 1881.
Prior to testing, the specimens shall be made available for
examination by the S.O.

9-28
 TABLE 1.6 A - Sampling, Testing and - Acceptance Standard

Site Testing Accepted

Material Testing Sampling Standards Remarks
On In
Site Laboratory
1 2 3 4 5 6 7
CEMEN Ordinary Portland BS 4550 BS 12 Manufacturer
T Rapid Hardening BS 12 Test
Sulphate Resisting BS 4027 Certificates

Description and BS 812 BS 812 - BS 882 Whichever is

Classification Part 1 Part 1 applicable

Particle Size “ Visual BS 812 BS 882

Part 1

Particle Shape “ Visual BS 812 ) Mix design

Part 1 )

Sp. Gravity “ - BS 812 ) Requirement

Part 2 )

Density “ - BS 812 )
Part 2 )

Voids “ BS 812 )
Part 2 )

Absorption “ BS 812 BS 5337

Part 1 Cl.21.2

Organic Impurities “ - -

Bulking of Fine “ CP 114 BS 812 Nominal Mix

Aggregate Cl. 602 Part 2 Proportioning

Moisture Content “ BS 812 For

Part 2 adjustment
of added
water for
concrete
making

Mechanical BS 812 BS 182 BS 882 or Ten per cent

Properties Part 1 Part 3 1201 pine value

9-29
 Site Testing Accepted
Material Testing Sampling Standards Remarks
On In
Site Laboratory
1 2 3 4 5 6 7
Suitability BS 3148 - BS 3148 BS 3148 Not required
for potable
water

Compacting ) BS 1881 BS BS 1881 This Spec. Workability

Factors Slump ) Part 1 1881 Part 2 Table 1.2
) Part 2 Table 1.2 Tests

Crushing ) - BS 1881 This Spec. Cube Test

) Part 4 Table 1.2B

Flexture ) - Ditto CP 114 As Required

) Cl. 208 c
Water ) BS 1881 BS 340
absorption ) Part 5 para 19 (b)

Electrolytic ) As required
Efflorescence ) for salt
containing
aggregates
or saline
water

Cores BS 1881 BS 1881 BS 1881 See Cl 9.6.2

Part 4 Part 4 Part 4
Para 3.3
with ref. 2/3
x concrete
strength of
this Spec.
When
corrected to
28 days
strength

Compability with As Test to be

cement required carried out
by by Indepen-
laboratory dent
Laboratory
as required

9-30
9.7 SPECIFICATION FOR GRADE 35A CONCRETE (TO BE USED FOR WATER
RETAINING STRUCTURE)

9.7.1 Concrete and cement mortar shall be in accordance with:-

1. Concrete structures shall be designed in accordance with MS 1195,

except that concrete structures for retaining sewage and other aqueous
liquids shall be designed in accordance with BS 8007

2. Concrete shall generally comply with the relevant requirements in MS 523

3. Concrete for structures retaining sewage shall have a strength grade not
less than grade C35A. Strength grades higher than C35A shall be
specified as required by the DGSS.

4. Concrete for purposes other than structures retaining sewage shall have
a strength grade not less than grade C20 where unreinforced and not less
than grade C30 where reinforced. Strength grades higher than the
minimum shall be specified as required by the DGSS.

5. Concrete structures retaining sewage but not unit process structures shall
be lined with high alumina cement mortar of 20 mm minimum thickness

6. Concrete and cement mortar exposed to soils or groundwater shall be

made using a cement suitably resistant to sulphate attack as specified
herein. Where part of a concrete structure is exposed to soils or
groundwater, a cement suitably resistant to sulphate attack shall be used
in the entire structure.

7. Concrete and cement mortar not exposed to soils or groundwater shall be

made using ordinary portland cement

8. Cement to be used to resist sulphate attack shall be sulphate-resisting

portland cement complying with MS 1037. Where not available one of the
following cements shall be used to resist sulphate attack:

 portland pulverised fuel ash cement complying with MS 1227

 ground granulated blast furnace slag complying with MS 1387

Where the above cement are not available, the following cements shall be
used to resist sulphate attack:

 high silica content portland cement

 sulpersulphated cement complying with BS 4248

9. Aggregates shall comply with MS 29 and shall be coarse aggregate of 20

mm nominal maximum size

10. Sand for use with cement mortar shall comply with MS 701

9-31
11. Lime for use with mortar shall comply with BS 890

12. Mortar shall consist 1 part cement to 3 parts sand and may include 1/4
part lime

13. Approval for admixtures shall be obtained prior to inclusion in the

concrete mix. All admixtures shall comply with MS 822.

All reinforced concrete shall be a designed mix grade C35A designed to

resist Class 2 Sulphate Conditions as defined in BS 8110 Table 6.1 and
BRE digest 363. The mix will be designed to BS 8110 - with a target
mean strength greater than the required grade strength by at least the
current margin. The current margin for each particular type of concrete
mix should be determined: it may be taken as having the smaller of the
values given by (i) and (ii).

(i) 1.64 times the standard deviation of cube tests on at least 100
separate batches of concrete of nominally similar proportions of
similar materials and produced over a period not exceeding 12
months by the same plant under similar supervision, but not less
than 1/3 of the grade strength for concrete of grade 7, 10 or 15: or
7.5 N/mm2 for concrete of grade 20 or above.

(ii) 1.64 times the standard deviation of cube tests on at least 40

separate batches of concrete of nominally similar proportions of
similar materials and produced over a period exceeding 5 days but
not exceeding 6 months by the same plant under similar
supervision, but not less than 1/3 of the grade strength for concrete
of grade 7, 10 or 15; or 7.5 N/mm2 - for concrete of grade 20 or
above.

Where there is insufficient data to satisfy (i) or (ii) above, the margin
for the initial mix design should be taken as two-thirds of the grade
strength of the concrete of grade 7, 10 or 15; or 15 N/mm for
concrete or grade 20 or above. This margin should be used as the
current margin only until sufficient data is available to satisfy (i) and
(ii) above. However, when the required grade strength approaches
the maximum possible strength of concrete made with a particular
aggregate, a smaller margin not less than 7.5 N/mm may have to
be permitted for the initial mix design.

(iii) Evidence should be submitted to the Engineer not less than 7 days
before the start of concrete production for each grade of concrete
showing that at the intended workability, the proposed mix
proportions and manufacturing method will produce concrete of the
required quality.

Documentation must include the following:

1) Certificate of mix design.

2) Portland Cement test reports.
3) ggbs/pfa blended cement test reports.
4) Aggregate physical and mechanical properties.
9-32
 5) Petrographic description of aggregate.
6) Details of proposed admixtures.

If adequate data for 'target mean strength' are not available, trial
mixes should be prepared in accordance with Clause 9.2.3 or, for
ordinary structural concrete up to grade 30, the Prescribed mixes
given in BS 5328 may be used for initial production.

9.7.2 The minimum cement content for Grade C35A concrete to resist a Class 2
Sulphate Condition shall be and maximum free water/cement ratio shall be in
accordance with Table 2.1.

9.7.3 All reinforced concrete that is required to be air entrained, shall include only air-
entraining admixtures complying with BS5075, Part 2. Admixtures containing
calcium chloride shall not be used.

9-33
 Table 2.1 Concrete exposed to sulphate attack

Dense, fully compacted concrete

made with 20mm nominal
Class Concentration of sulphates maximum size aggregates (1)
expressed as SO3 complying with BS 882 of BS
Cement complying with 1047
In soil(2) Inground
water
Total SO3 in Cement Free water/
SO3 2:1 content not cement ratio
water:soil less than not more than
extract
% g/l g/l Table 1 kg/m3
MS 522, BS 146, MS 1227

1 Less Less Less MS 522 combined with less than 25%

than than 1.0 than 0.3 pfa
0.2 MS 522 combined with less than 70%
ggbs

2 0.2 to 1.0 to 1.9 0.3 to 1.2 MS 522, BS 146, MS 1227

0.5 330 0.50
MS 522 combined with less than 25%
pfa
MS 522 combined with less than 70%
ggbs

MS 522 combined with 25% to 40% 310 0.55

pfa
MS 522 combined with 70% to 90%
ggbs
BS 4246 with at least 70% ggbs
MS 1227 with at least 25% pfa
BS 6610 with not more than 40% pfa

MS 1037 (SRPC) 280 0.55

BS 4248 (SSC)

3 0.5 to 1.9 to 3.1 1.2 to 2.5 MS 522 combined with 25% to 40%
1.0 pfa
MS 522 combined with 70% to 90% 380 0.45
ggbs
BS 4246 with at least 70% ggbs
MS 1227 with at least 25% pfa
BS 6610 with not more than 40% pfa

MS 1037 (SRPC) 330 0.50

BS 4248 (SSC)

4 1.0 to 3.1 to 5.6 2.5 to 5.0 MS 1037 (SRPC) 370 0.45

2.0 BS 4248 (SSC)

5 Over Over 5.6 Over 5.0 MS 1037 and 370 0.45

2 BS 4248 (SSC) both adequate
protective coating (see MS 1195)

9-34
1) Adjustments to minimum cement content should be made for aggregates of nominal maximum size other than
20mm in accordande with 8

2) If much of the sulphate is present as low solubility calcium sulphate, analysis on the basis of 2:1 water extract
may permit a lower site classification than that obtained from the extraction of total SO 3.
Reference should be made to BRE Current Paper 2/79 for methods of analysis and to BRE Digests 250 and 276
for interpretation in relation to natural solids and fills, respectively.

NOTE 1 - Within the limits specified in this table, the sulphate resistance of combinations of ggbs and pfa with SRPC
will be at least equivalent to combinations with cement complying with MS 522.

NOTE 2 - It is recommended that the alumina content of ggbs does not exceed 15%.

(i) The total quantity of air in air-entrained concrete as a percentage of

the volume of the mix shall be as follows, within the tolerances given
in BS5328.

Nominal Aggregate Size Air Content %

ram
20 5
40 4

(ii) The air content shall be determined at the point of delivery to the
paving plant by a pressure type air meter in accordance with BS1881,
at the rate of at least one determination for each 20m length of slab of
less constructed at any one time or at least 3 times per day. If the air
content is outside the specified limits a further test shall be made
immediately on the next available load of concrete before discharging.
If the air content is still outside the limit the contractor shall
immediately adjust the air content of the concrete or improve its
uniformity before any further concrete is used in the works.

(iii) The air-entraining agent shall be added at the mixer by an apparatus

capable of dispensing the correct dose within the limits given in
BS5328, and so as to ensure uniform distribution of the agent
throughout the batch during the mixing.

9.8 TRANSPORTING PLACING AND COMPACTING

The Contractor shall give the Engineer 24 hours notice of his intention to pour
concrete in order that the formwork, reinforcement and other relevant details may
be inspected during normal working hours.

The Contractor shall not pour any concrete in any location until the Engineer has
inspected and approved the formwork and reinforcement and given his consent
for the pour to proceed. In the event of the Contractor failing to comply with this
requirement the Engineer may exercise his right to have the work in question
removed and replaced at no additional cost.

9-35
 The period of 24 hours for inspection shall commence after the work is clean and
ready for concreting. In the event that the work shall not be approved, the
Contractor shall give similar notice again after the necessary correction or
modification has been carried out.

If concreting is not started within 24 hours of consent being given, consent shall
again be obtained. Concreting shall then proceed continuously over the area
between construction joints. Fresh concrete shall not be placed against the insitu
concrete which has been in position for more than 30 minutes unless a
construction joint is formed. When insitu concrete has been in place for 4 hours
no further concrete shall be placed against it for a further 20 hours.

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, 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.

No pour shall commence which, in the opinion of the Engineer, cannot be

completed before 1500 hours GMT.

Concrete shall be deposited in horizontal layers to a compacted depth not

exceeding 450 millimetres where internal vibrators are used or 300 millimetres in
all other cases, unless otherwise agreed in writing by the Engineer.

Vibrators shall enter a previously layer in a continuous pour.

9.9 CONCRETE TEMPERATURE

Concrete when deposited shall have a temperature of not more than 250C (200C
for sections greater than 500mm thick).

The Contractor shall provide a thermometer suitable for measuring the

temperature of aggregates and concrete and a maximum and minimum
thermometer which shall be hung in a position indicated by the Engineer.

9.10 CURING THE CONCRETE

Immediately after compaction and for 4 days minimum thereafter concrete shall
be protected against harmful effects of weather, including solar heat gain, rain,
wind, rapid temperature changes, frost, and from drying out. When elevated
temperature curing is used, the rate of rise in the temperature of the concrete
must not exceed 150C per hour for the first three hours and thereafter the rate of
rise and fall of temperature of the concrete must not exceed 350C per hour. The
temperature of the concrete during heat of hydration must not exceed 700C. The
method of curing employed must prevent loss of moisture from the concrete
protection and curing shall be approved in writing by the Engineer. The
proposals must cover concreting during the whole of the contract period and
have regard to the prevailing weather conditions at the time of casting.

9-36
 The Contractor, where requested by the Engineer, shall provide in situ
temperature measurements to show compliance with the above requirements.

The contractor shall submit details of his proposals to cure the concrete,
including details of insulation where appropriate, seven days prior to placing and
concrete.

Table has been included as a guide to controlling early age thermal cracking-
'Particular attention should be given to the necessary different ways in the
dealing with thick and thin sections.

TABLE 2.2

Minimum Periods Of Curing and Protection

Type of Ambient conditions Minimum periods of curing and protection

Cement after casting Average surface temperature of concrete

5°C to 10°C Above ‘t’ (any temperature

10°C between 5°C and 25°C)
Average Days Days Days
PC, SRPC 4 3 60/(‘t’ + 10)
Poor 6 4 80/(‘t’ + 10)
All except PC Average
& all SRPC &
all with ggbs or
pfa
Poor 10 7 140/(‘t’ + 10)
All Good No Special Requirements

Note 1 Abbreviations for the type of cement used are as follows:

PC - Portland cement, Class 42.5 to BS 12 (1991)
SRPC - Sulphate-resisting Portland cement, Class 42.5 to BS 4027 (1991)

Note 2 Ambient conditions after casting are as follows:

Good - damp and protected(relative humidity greater than 80% protected from sun
and wind);
Average - intermediate between good and poor;
Poor - dry or unprotected (relative humidity less than 50% not protected from sun
and wind)

The temperature differential between the core of the concrete and its external
surface shall not exceed the following:-

 Using limestone coarse and fine aggregates 300C

 Using granite coarse and fine aggregates 200C
 Using quartzite coarse and fine aggregates 200C

9-37
 When other types of cement or admixtures are used, longer or shorter period
may be required by the engineer.

TABLE 2.3

Summary of the Factors which help prevent or control early-age thermal cracking
Factor Worst Choice Best Choice Comments
Aggregate Shape Rounded Angular -
Aggregate Type High Low Co-eff. expansion
Cementitions Materials PC SRPC SRPC/fa SRPC/GGBFS This is subject to many
RHPC PC/fa PC/GGBFS conditions and the present level
of knowledge (Particularly on
tensile strain capacity). Check
durability requirements.

Admixtures None Water reduces As cementitious material

Superplasticiser reducers. Check durability
requirements.

Placing Temperature High Low Is cooling the concrete before

placing feasible and economic?

Ambient Temperature High Low Little or no control over this

Cooling of Placed concrete Effective but expensive

a) Cooling pipes Should only be used in sections
b) Surface cooling under about 500mm thick.

Formwork Material
(a) Section thickness Insulated plywood GRP steel The aim is to minimise the
under about 500mm thermal gradients across the
(b) Large isolated section Steel GRP plywood insulated section.

Formwork Striking Times

(a) Construction sequence
Long period Short period
(b) Large isolated sections Also keep the upper surface
insulated
Long period Short period

Reducing Restraint Alternative bay Sequential Sequence of casting is not

(a) Construction sequence Long period between construction or short significant if the joints are full
forming successive infill bays movement joints
lifts
Short slip period
b) Movement joints None. Partial between lifts
movement joints Full movement joints

(c) Prestressing the base Plain bars, large dia Type 2 high yield Not normally economic
Control of crack widths bars at wide small dia bars at
with reinforcement spacings close spacings

9-38
9.11 STRUCTURAL PRECAST CONCRETE

Structural units of precast concrete shall be manufactured in the grade of concrete

and to the sizes and details shown on the Drawings. The concrete shall comply in
every aspect with the provisions of the Contract whether such units are
manufactured on the site or obtained from other manufacturers.

All cement, aggregate and other materials for precast concrete units with faces
which are exposed either internally or externally shall be from the same sources
throughout. Exposed surfaces of the units shall be uniform in colour and in texture.

Formwork and unformed surfaces for precast concrete units shall comply with the
requirements for F3 formed surfaces and U3 unformed surfaces except that the
dimensional variations shall not exceed the values listed below, unless otherwise
detailed on the Drawings.

Length - +/-6 mm

Cross-section - +/6 mm each direction

Straightness - 6 mm (deviation from intended line)

Flatness - 3 mm (deviation from a 1.5 m straight edge placed in any

position on a nominally plane surface)

Squareness when considering the squareness of a corner, the

longer of the two adjacent sides being checked shall be taken
as the baseline, and the shorter side shall not vary in its
distance from the normal so that the differences between the
greatest and the shortest dimension exceeds 6 mm. When the
nominal angle is other than 90 degrees, the included angle
between the check line shall be varied accordingly.

Twist any corner on any nominally plane surface shall not be

more than 6 mm from the plane containing the other three
corners.

The positions of individual connecting bolts, bolt holes, projecting steel and other
devices in any associated group (eg. the joint of two precast units) shall be within 3
mm of their true position in the group in which they are cast. The location of any
such group shall be within 6 mm of its true position in the unit in which it is cast,
provided that such deviation does not adversely affect the proper assembly of the
whole structure.

The Contractor shall submit to the S.O. for approval, full details of his proposed
method of carrying out all operations connected with the manufacture and
assembly of precast concrete structural members, including :

- a description of the types of casting bed, mould and formwork for the
various types of members;

9-39
 - the procedure for concrete casting and the method of curing the concrete;

- the procedure for transporting, handling, hoisting and placing of each type
of precast structural member;

- full details of temporary supports necessary to ensure adequate stability

during erection, due account be taken of construction loads, including wind.

9.12 INSTALLATION OF PRECAST CONCRETE UNIT

At all stages and until completion of the work, precast members shall be
adequately protected to preserve all permanently exposed surfaces, arises and
architectural features. The protection shall not mark or otherwise disfigure the
concrete.

All units shall be laid, bedded, jointed and fixed in accordance with the lines, levels
and other details shown on the Drawings.

Dry-pack mortar jointing for packing shall consist of one part of volume ordinary
Portland cement and two and half parts by volume of fine aggregate passing a 1
mm sieve. The mortar shall be mixed with only sufficient water to make the
materials stick together when being moulded in the hands. The mortar is
thoroughly compacted.

Any precast concrete structural member which is found to be cracked, damaged or

otherwise inferior in quality either before or after erection, shall be rejected and
replaced by the Contractor.

9.13 PRESTRESSED CONCRETE

Prestressed concrete work whether precast or cast in-situ shall be as detailed on

the Drawings and the Contractor shall provide full details of his proposed method of
carrying out all operations connected with prestressing including :-

(a) design of concrete mix

(b) description of concrete casting and curing operations

(c) procedure for prestressing and method of checking and recording the
prestress, wire extension and anchorage slip.

d) procedure for handling, hoisting and placing of any precast units.

(e) grouting of ducts

All tendons, duct forming devices, anchorages and other components shall be kept
free of mud, oil (except water soluble oil applied for protection), paint, retarders,
loose rust, or other foreign matter. They shall be placed with a tolerance of +/-3
mm in concrete dimensions of 300 mm of less or +/- 6 mm in concrete dimensions
over 300 mm.

9-40
 SECTION 10
METALWORK

10.1 GENERAL FOR METALWORK

The work of this section consists of the furnishing of all labour, materials, apparatus, and
appurtenance work in connection with metalwork in accordance with these specifications.

Work of this section shall be fully coordinated with work of other trades. Particular attention is
required for items to be embedded in concrete and masonry.

10.1.1 Scope of Work for Metalwork

The work includes, but is not limited to the following:

A. Galvanised sheet metal

B. Cast Iron Castings
C. Anchors, Pipehangers and other appurtenances.
D. Any other work shown on the drawings herein specified.

Related Work not Included in this Section:

A. Reinforcing steel
B. Piping, conduits, fittings and hangers

10.1.2 Submittal for Metalwork

Shop drawings shall be submitted to the Engineer for approval prior to fabrication of any work.
Shop drawings shall be based on plans, specifications, and field measurements, and shall
present complete information as to fabrication, installation and proper fitting with other
construction. Shop drawings should show all welds, fabrication and finish details, and shop
painting.

10.1.3 Quality Assurance for Metalwork

Unless otherwise specified, all work specified herein and shown on the drawings shall conform
to the applicable requirements of the following specifications and codes:

A. Fabrication and erection of structural and miscellaneous steel shall be in accordance with
the latest edition of the AISC "Speification for the Design, Fabrication and Erection of
Structural Steel for Builidngs, and Bridges."

B. Welding of steel shall be in accordance with BS 5135 or BS 4570 as appropriate.

10.2 MATERIALS FOR METALWORK

A. Steel shall conform to BS 449.

B. Threaded Bolts and Nuts shall conform to the relevant British Standard.

C. Steel Pipes shall conform to BS 534 for water and sewage works, and BS 1387 for
galvanised iron pipes in general.

D. Welding Electrodes shall conform to BS 807 or BS 2493

E. Iron Castings shall conform to BS 3468 or BS 3100 as appropriate.

F. Galvanizing work shall conform to BS 729 : 1971.

10-1
 G. Grout shall be of approved factory-package non-shrink grout, non-metallic type.

H. Galvanised Iron or Sheet Steel shall conform to BS 2989 or BS 3083 as appropriate.

I. Solder work shall conform to BS 219.

J. Flux shall be of approved brand of non-corrosive or raw muriatic acid killed with zinc.
Excess flux shall be removed and surfaces neutralised after soldering.

K. Nails, Bolts, Screws and Rivets for Sheet Metalwork shall be of best type suited for the
intended purpose and shall be galvanized.

10.3 FABRICATION AND ERECTION

10.3.1 Welding for Metalwork

Before fabrication, all steel shall be thoroughly wire brushed, clean of all scale and rust, and
thoroughly straightened by approved methods that will not injure the materials being worked on.
Welding shall be continuous along the entire line of contact except where tack or intermittent
welding is permitted. Where exposed, welds shall be cleaned of flux and ground smooth.
Welding shall be performed by experienced tradesmen, and made with specific electrodes or
submerged are of suitable grade.

10.3.2 Anchor Bolts

Galvanised and fabricated as shown, or as specified by the equipment manufacturer. Suitable

expansion bolts may be used in lieu of anchor bolts at certain locations. It shall be the
responsibility of the Contractor to request the substitution and obtain the Engineer's approval
regarding type and location of expansion bolts proposed to be used prior to pouring concrete.

10.3.3 Galvanizing of Metal

All galvanizing shall be carried out in accordance with BS 729 using the hot-dip process with
spelter, not less than 98% of which shall be pure zinc. Bolts, nuts and washers shall be
completely galvanized including threads, but galvanized coatings removed in the course of nut
fixing may be replaced with an approved zinc rich paint.

10.3.4 Shop Painting

Before leaving the shop all steel not shown or specified to be galvanized shall be given one
coat of primer as specified in the Painting Section of these specifications. Final painting shall be
as specified under the Painting Section of these specifications. That portion of steel to be
embedded in concrete or masonry shall not be painted.

10.3.5 Iron Castings

Iron castings shall be made from properly prepared patterns and moulds. All castings for dead
end and manhole frames and covers shall be tough grey iron, free from warps, cracks, holes,
swells, and cold shuts, and have a workmanlike finish. Before leaving the foundry all castings
must be thoroughly cleaned and subjected to a hammer inspections after which they shall be
dipped twice in a preparation of asphalt or coal tar applied at a temperature of 149 oC in such a
manner as to form a firm tenacious coating.

All manhole covers and frames when fitted shall be watertight and air-tight. Defective manhole
covers and frames shall be rejected and replaced.

10-2
10.4 STRUCTURAL STEELWORK

This Section of the Specification is intended to cover the supply of all materials, fabrication and
erection of steel bridge trusses. Workmanship and general fabrication procedure shall be in
accordance with the relevant clause in B.S. 5950.

10.4.1 Materials for Steelwork

All main structural steel members, unless otherwise specified, shall comply with the
requirements of Grade 43A of B.S. 4360. All steel materials shall be clean, free from loose rust
and loose mill scale. All members shall be straight, free from twists, cracks, flaws, laminations,
rough jagged and imperfect edges and other defects.

Mild steel electrodes for metal arc welding shall comply with the requirements of B.S. 639.

All mild steel bolts and nuts shall have an ultimate tensile strength of not less than 430 N/mm 2
and a mininum elongation of 17%. Dimensions shall comply with the requirements of B.S. 4190
or B.S. 1580 or B.S. 3643.

All plain, tapered or other specially shaped washers for bolts shall be made of steel or
malleable cast iron complying with B.S. 3410 and B.S. 4320.

10.4.2 Tests and Inspections for Steelwork

A. The Contractor shall afford all facilities for the inspection of the work at all stages by the
Engineer at the Contractor's works and those of his sub-contractors. All work shall be
subjected to inspection before shipment to the Site.

B. The Contractor shall give such reasonable notice to the Engineer of the progress of the
work as will enable him to arrange for the inspection, examination and testing as
required.

C. Samples of materials and workmanship to be employed in the Works may be called for at
any time by the Engineer.

D. The Contractor shall arrange for all materials to be tested at the manufacturer's works
and when required in the presence of the Engineer. When material is obtained from a
supplier's stock the Contractor shall:

1. by means of identification marks stamped on the material together with the

manufacturer's test certificate, show that such material complies with the
requirements specified herein;

2. arrange for samples to be taken and tested to prove the requisite quality. Two
copies of all test certificates shall be forwarded to the Engineer.

E. Notwithstanding compliance with the above tests, nothing shall affect the right of the
Engineer to reject materials found not suitable after delivery to the site.

F. The Engineer reserves the right to require independent analyses and tests on the
materials by an analyst or Testing Laboratory selected by him, in order to check the
works analyses and tests. For this purpose, the Engineer will take drillings for analyses
and have pieces cut out side by side with pieces subjected to test in the workshops, in
order that a comparison of the results of the two tests can be made. Should the result of
any independent analysis or test be unsatisfactory, the material represented will be
rejected.

10-3
10.4.3 Fabrication of Steel

Cuttings may be effected by shearing, cropping or sawing. Gas cutting may only be used when
specifically authorised in writing by the Engineer. The edges of all plates shall be perfectly
straight and fair throughout. Sheared members shall be free from distortion. Edges of all
members shall be machined or ground smooth before welding is effected.

Holes for bolts shall be drilled or punched. It shall not be formed by a gas cutting process,
except with specific approval from the Engineer.

10.4.4 Welding and Flame-Cutting Procedure Trials

A. When directed by the Engineer and before fabrication is commenced, welding and flame
cutting procedure trials shall be carried out using representative samples of materials to
be used in the work. The samples of materials shall be selected and marked by the
Engineer when the materials for the work are inspected at the Contractor's workshop.

B. Trials on material 20mm thick shall be taken to include all materials up to, but not
exceeding 20mm thick.

C. The welding and flame cutting trials shall demonstrate to the satisfaction of the Engineer
the procedure to be adopted in the fabrication of the work which shall include:

1. Welding procedure in accordance with B.S. 5135.

2. The heat control techniques required to ensure that the flame cut surfaces of steel
are free from cracks, local hardness and any other defects which would be
detrimental to the finished work.

D. The trials shall include specimen weld details representative of the actual construction
which shall be welded in a manner simulating the most unfavourable conditions liable to
occur in the particular fabrication. Where primers are to be applied to the work prior to
fabrication, they shall be applied to the sample material before the procedure trials are
made. After welding, the specimens shall be held at ambient temperature for a period not
less than 72 hours, and shall then be sectioned and examined for cracks and other
defects, and shall be subject to the tests specified hereunder.

E. The following tests for fillet welds shall be carried out to B.S. 709 in accordance with
Clause 10.6:

1. Fillet weld fracture test

2. Macro examination test

10.5 WELDING IN STEELWORK

10.5.1 Qualification and Testing of Welders

The Contractor shall provide to the Engineer satisfactory evidence that the welders employed
have passed the tests specified in B.S. 4872 appropriate to the work being performed.

Only skilled welding operators who satisfy the appropriate welding tests specified therein shall
be employed. Notwithstanding compliance with the above requirements, the Engineer reserves
the right to have any welding operator re-tested at any time and may require that this testing be
carried out in his presence.

10.5.2 Welding Plant

The welding plant shall be capable of maintaining at the weld the voltage and current specified
by the manufacturer of the electrodes, and shall comply with the requirements of B.S. 638.

10-4
10.5.3 Welding Process

Manual metal arc welding complying with B.S. 5135 shall be used for all weldings, except for
tack welds and temporary attachments. Approval in writing shall be obtained from the Engineer
if other welding methods are employed.

10.5.4 Acceptance of Welded Structures

The acceptance of the welded work shall depend upon correct dimensions and alignment,
absence of distortion in the structure, satisfactory results from examination and testing of the
joints and the test specimens, soundness of the welds, and upon general good workmanship.

10.5.5 Welding at Site

Welding other than in properly equipped fabrication shops will normally be limited to non-
structural members, except where specifically permitted by the Engineer.

10.5.6 Repair of Defective Welds

Should any weld fail to comply with the above requirements, further radiographs shall be taken
to determine the extent of such defective welds. Defects shall be repaired by chipping or
melting out such defects from one or from both sides of the joint as required, and re-welding.
The method of effecting such repairs of defective welds shall be to the approval of the
Engineer. All repair welds shall be checked by repeating the original test procedures.

10.6 TESTING OF WELDS (X'RAY METHODS INCLUDED)

The tests detailed in the earlier sections shall be carried out in accordance with B.S. 709. The
test results of welded joints shall not be inferior, in any respect, to the British Standard test
requirements for the parent metal.

10.7 BOLTING IN STEELWORK

10.7.1 Bolts

All black bolts shall be of mild steel with well formed heads forged from one solid piece and
shall be dipped in hot boiled linseed oil, or other approved oil, as soon as they are made. The
nuts shall be a good fit on the bolts so that they can only just be turned by hand and one clear
thread shall show through the nut when it has been finally tightened up. Every bolt, unless
otherwise specified, shall be provided with a washer under the nut.

10.7.2 Washers

Mild steel flat washers shall be circular, of a diameter 2.5 times that of the bolt and 5mm
minimum thickness. Where bolt heads or nuts bear upon bevelled surfaces, they shall be
provided with square taper washers of suitable thickness to afford a seating square with the
axis of the bolt.

10.7.3 Bolt Holes

All holes must be correctly aligned to permit the bolts to be freely placed in position. The driving
of bolts is not permitted.

10.8 ERECTION WORK IN STEEL STRUCTURE

10.8.1 Accuracy of Setting

The Contractor shall be responsible for the correct lining and levelling of all steelwork on Site.

10-5
10.8.2 Stability of Structure

The Contractor shall be responsible for the stability of the structure at all stages of its erection
on Site.

10.8.3 Erection Work

No member of the structure shall be finally bolted, riveted or welded until the whole or a major
section is approved by the Engineer for line, levels and verticality. Connections shall be
completed as soon as possible after receipt of the Engineer's approval.

10.8.4 Tolerances for Erected Steelwork

A. Permissible deviation from specified length of width

1. up to and including 15m + 5mm

2. over 15m up to and including 30m + 10mm
3. over 30m + 15mm

B. Permissible deviation between the specified

level and that of the erected member + 5mm

10.9 STRUCTURAL STEELWORK, NUTS AND BOLTS

Structural steelwork shall conform to the requirements of B.S. 449, steel shall comply with B.S.
4360 and steel tubes for structural purposes shall comply with B.S. 1775 and shall be obtained
from a manufacturer to the prior approval of the Engineer.

Steelwork shall, when perfectly dry and free from millscale, be primed with two coats of red lead
primer before leaving the manufacturer's works and any damage to this coating shall be made
good before erection.

Welding of structural steelwork shall be carried out in accordance with B.S 5135. Only welders
who have satisfied the conditions of BS 449, Part 6 shall be employed on the fabrication and
erection of permanent Works. Structural steelwork shall be fabricated, stored, handled and
erected in accordance with Part 5 of B.S 449.

Bolts, ragbolts, nuts and washers shall conform to B.S. 4360 as regards materials for steel
bolts and B.S. 916 as regards dimensions. Each bolt shall be provided with two washers and
bolts shall be long enough to show a full thread through the nut after fixing.

10.10 MEASUREMENT OF AND RATES FOR STRUCTURAL STEELWORK

Structural steelwork will be measured by net weight or length, no allowance being made for
rolling margin, bolt holes, cleats, bolts, nuts washers and weld metal (except connecting
plates).

The Contract Rates for structural steelwork shall include for the full cost of supplying, erecting,
painting the steelwork, bracings, cleats, bolts, nuts, washers and welding electrodes as may be
necessary.

10.11 GALVANISED METALS

All metals to be galvanised shall be of the full dimension shown or specified and all punching,
cutting, drilling, screw tapping, welding and the removal of burrs shall be completed before the
galvanising process commences.

All galvanising shall be done by the hot dip process with spelter, not less than 98% of which shall
be pure zinc. No component which is likely to come into contact with oil shall be galvanised.

10-6
 Bolts, nuts and washers shall be completely galvanised including the threads but galvanising
removed in the course of nut fixing may be replaced with an approved zinc rich paint.

The galvanising shall be uniform, clean, smooth and as free from spangle as possible. It shall
weigh not less than 6.0 grams per square metre of area covered.

All galvanised metal parts shall be protected from damage due to electrolytic action, white rust
and abrasion during delivery, storage and erection. Minor damage shall be touched up with an
approved metallic compound but if, in the opinion of the Engineer the damage to the galvanising
is too severe or extensive, the part shall be removed and re-galvanised.

10.12 DISSIMILAR METALS

The Contractor shall not use fixtures and fittings for metalwork (including pipework) in which
dissimilar metals likely each other.

Wherever aluminium alloy angles, tees and bolts are required to be bedded, the Contractor shall
ensure that they are liberally coated with bituminous paint and allowed to dry prior to fixing.

10.13 CHEQUER PLATING

Chequer plating shall be mild steel with a non slip pattern on its upper face.

Chequer plates shall be securely bolted with counter sunk screw studs to frames set in the edges
of and spanning the ducts or opening. The sizes of plates shall be such that no discernible
deflection occurs under the weight of a man standing upon it. Where it is not practicable to
provide individual frames to each plate, the plates shall be stiffened by welding galvanised steel
angles on their underside to eliminate discernible deflection.

The edges of all chequer plates shall be finished straight or to the outline of obstructions and shall
be free of burn marks of irregularities. Plates cut with a torch shall afterwards be ground to
present a straight edge.

Chequer plating shall before delivery be thoroughly wire brushed and shall be painted on each
surface and side with two coats of chromate primer and two coats of bituminous paint.

10.14 HANDRAILING

Handrailing shall be of heavy duty hot-dipped galvanised mild steel, G.I pipe or aluminimum as
shown in the drawing.

Sockets and base plates shall be welded onto the stanchions. Base plates shall have holes
drilled for fixing to concrete with three 13mm diameter rawl bolts.

Before manufacturing the handrailing, the Contractor shall submit detailed drawings to the
Engineer for his approval. The drawing shall show the position of standard joints, expansion
joints and all fixing details. Fabrication shall not start until these drawings have been approved by
the Engineer. Expansion joint shall be provided where the handrailing is more than 18 metre
long.

Handrailing will be measured in length on plan. No separate measurement will be made for
stanchions and intermediate railing. The Contract Rates for handrailing shall include for the full
cost of supplying, transport to and temporarily storing on the Site, hauling and handling, erecting,
base plates, rawl bolts, grouting and painting as necessary.

10-7
10.15 LADDERS

Ladders shall unless otherwise specified be of aluminium and obtained from an approved
manufacturer. Unless detailed on the Drawings, the Contractor shall submit to the Engineer
detailed drawings of a ladder for approval before placing any orders.

Ladders shall be of welded construction and shall not have an unsupported length of more than 3
metres. Intermediate support between the ends of the ladder shall be by means of stays
securely fixed to the nearest part of the structure. Where shown on the Drawings safety rings
shall be provided.

The Contract Rates for ladders shall include for supply, fixing, painting and for all nuts, bolts,
stays, base plates, etc. necessary for securing ladders in place.

10.16 STEP IRONS

Step irons shall be either bent from 25mm square aluminium alley. Aluminium alloy step-irons
shall be similar to the type manufactured by Norton Engineering Alloys Co. Ltd., Noton, Malton,
Yorkshire Y017 9HQ, England.

The Contract rates shall include for supply and all necessary fixing work.

10-8
 SECTION 11

ROADWORKS

11.1 PREPARATION OF FORMATION TO RECEIVE ROAD PAVEMENT

The preparation of formation shall be carried out only after completion of all sub-
grade drainage, piped drains, services and ducts or any other drainage work that
might affect the works, unless otherwise agreed by the S.O.'s representative and
such preparation shall be carried out immediately prior to the laying of the sub-base
or the road base where no sub-base is required.

The surface of the formation shall be substantially uniform in density throughout its
entire width and shall conform to the density requirements for compaction. It shall be
trimmed to conform to the lines, camber, grades and typical cross sections shown on
the drawings or as directed by the S.O.'s representative. Where ruts or other
objectionable irregularities occur as a result of construction traffic or other causes, the
contractor shall reshape and re-compact the formation to the required density before
the subbase or road base is placed.

11.2 EARTH FORMATION

Where soft spots and unsuitable material occurs, they shall be removed and
backfilled with approved stable material and compacted by not less than 4 passes of
a smooth-wheeled roller weighing not less than 1 0 ton or an equivalent vibrating
roller. The formation shall then be checked and the final trimmed surface shall be
rolled by one pass of a smoothed-wheeled roller of not less than 5 tons or an
equivalent vibratory roller prior to the laying of the sub-base or base.

The formation shall be so constructed to drain surface water to the side ditches or
other drainage system. If the contractor allows the moisture content of the completed
formation to reach a value above the permitted maximum for the compacted material,
the contractor shall allow the material to revert to an acceptable moisture content and,
if directed by the S.O.'s representative, make good the surface by recompaction
before laying the sub-base.

11.3 FORMATION OF ROCK FILL

The formation shall be trimmed to conform to the lines, camber grades and typical
cross-sections shown in the drawings or as directed by the S.O.'s representative, and
shall lie within any specified tolerances. The surface shall be blinded with approved
fine graded material to seal the surface.

11-1
]
 The trimmed formation shall be rolled by one pass of a smooth wheeled roller of not
less than 5 tons weight or an equivalent vibratory roller.

A roughly compensating maximum deviation of 25 mm plus or minus will be permitted

on the surface of the final completed formation.

11.4 PAVEMENT THICKNESS AND C.B.R. TESTS

The thickness of the various layers of the pavement shall be as shown on the
drawing. However before the construction of the pavement the S.O.'s representative
shall carry out California Bearing Ratio (C.B.R.) Soaked tests as described in B.S.
1377 on the prepared subgrade to check the required thickness of pavement. The
Contractor shall provide all equipment and assistance in carrying, out such tests.

The S.O.'s representative may vary the thickness of the various layers of the
pavement as shown in the typical cross-section drawings as a result of the above
tests.

11.5 SUB BASE MATERIAL

The sub-base material shall be hard, durable and clean. It shall be granular material
such as sand or crushed rock and shall be free from organic material, clay balls, and
any other deleterious substances.

The crushed rock or gravel shall conform to one of the following grading:

B.S Sieve Size Percentage By Weight Passing

(A) (B)
40 mm ( 1 ½) 100 -
25 mm (1) 75 - 100 100
20 mm (3/4 ) 60 -100 70-100
10 mm (3/8 ) 60 - 90 58 - 75
5 mm (3/16 ) 45 - 75 35- 65
2.4 mm (No.7 ) 30- 60 25 - 60
420 microns (No. 36) 20-50 15-30
75 microns (No.200) 0-2 0-2

The sand shall conform to the following grading:

B. S. Sieve Size Percentage By Weight Passing

10 mm (3/8 ) 100
5 mm (3/16) 95 - 100
12 mm (No.14) 45- 80
300 microns (No. 52) 10 - 30
150 microns (No.100) 2 - 10

Alternative suitable material may be used subject to the prior approval of the S.O.'s
representative. The proposed sub-base material shall have a CBR value not less
than 20% when compacted to 95% of maximum dry density as determined by the
Modified Compaction Test. The material shall be free from vegetable matter, soft
particle or clay lumps and shall conform to one of the following grading

11-2
]
 B.S. Sieve Size Percentage By Weight Passing
(A) (B)
40 mm ( 1 ½ ) 100 -
20 mm (3/4 ) 80-100 100
10 mm (3/8 ) 55-90 80-100
5 mm (3/16 ) 40-70 55-90
2.4 mm (No.7) 30-55 40-70
420 microns (No. 36) 12-30 20-40
75 microns (No.200) 5-20 8-25

The portion passing the 420 microns (No. 36) sieve shall, if it is plastic, have a liquid
limit not greater than 35 and a plasticity index greater than 11.

11.6 COMPACTION OF SUB-BASE

The sub-base shall be laid in one layer to the thickness required on the prepared
formation. It shall be thoroughly compacted with suitable and adequate compaction
equipment, approved by the S.O.'s representative.

Rolling operations shall begin from the outer edge toward the centre, gadually in a
longitudinal direction; except on super elevated curves where rolling shall begin at the
low side and progress towards the high side.

The finished sub-base shall not vary more than 3/4" plus or minus, from the grade or
level shown in the drawing.

11.7 ROADBASE MATERIAL

The crusher run road base to be placed on top of the sub-base shall be wet-mix
macadam consisting of crushed aggregate laid in layers each of thickness not
exceeding 150 mm (6") and to give the specified total compacted thickness and
width, correct line and levels shown in the drawings.

The material shall be crushed rock of hard durable particles or fragments of rock
crushed to the correct size, well graded and lie within the following grading limits
shown on the next page:

B. S. Sieve Size Percentage By Weight Passing

50mm (2”) 100
40mm (1½”) 95-100
20mm (3/4”) 60-80
10mm (3/8”) 40-60
5mm (3/16”) 25-10
2.4mm (No.7) 15-30
600 microns (No.36) 8-22
75 microns (No.200) 5-12

Note:
1. The particle size shall be determined in accordance with the requirements of
B.S.1377.

2. The material passing the 240 micron (No.36) B.S. sieve when tested in
accordance with B.S. 1377 shall be non-pastic.

11.8 LAYING AND COMPACTION OF CRUSHER RUN ROAD BASE

All work on the portion of the subgrade or sub-base on which the road base is to be
laid shall be properly shaped and compacted in accordance with the requirements of
this specification before the placing of the road base material. The preparation of the

11-3
]
 subgrade or sub-base shall be completed at least 182.88mm ahead of the placing of
road base materials. The road base shall be constructed to the full compacted
thickness as shown in the drawing.

All material shall be placed and spread evenly to the full width of the road base. The
maximum compacted thickness of any one layer shall not exceed 150mm (6”). When
the specified compacted thickness of base course exceeds 150mm (6”) the base
shall be constructed in two or more layers of approximately equal thickness. Each
layer shall be compacted to not less than 95% of the maximum dry density of the
material tested in accordance with the requirement of Tests No.14, 15 (B) of B.S.
1377 : 1975 before the next layer is placed. At least one density test is to be carried
out for each 1200 sq. yards of each layer of the road base laid and compacted. Care
shall be taken to prevcent segregation of the material into the coarse and fine
fractions. Segregated surface of a base construction or base material contaminated
to such an extent that it no longer complies with the required specifications shall be
removed and replaced with well graded and satisfactory material.

The material shall be spread by a motor grader or any other approved mechanical
plant. When a road base is spread adjacent to concrete kerbs or gutter sections,
extreme care shall be exercised so as not to damage the kerbs or gutters. Any
damaged kerbs or gutters shall be removed and replaced, all at the Contractor’s
expense.

Compaction shall be completed as soon as possible after each layer has been spread
and shaped satisfactorily. Each year shall be thoroughly compacted with suitable
compaction equipment to the requirement specified in Table 3.1 ‘Compaction
Requirements for Granular Basecourse Materials’.

Rolling operations shall begin along the edges and progress towards to the centre
gradually in a longitudinal direction. On superelevated curves, the rolling shall begin at
the low side and progress towards the high side. The rolling operation for each layer
shall continue until all rolling marks, ridges or cracks are eliminated. Any irregularities,
segregation or loose material which may develop in the surface during or after
construction shall be corrected or removed and the defective areas made good to the
full thickness of layer and recompacted.

Before the laying of each layer of crusher run a partial width of the shoulder, not less
than 1 foot wide, shall be constructed to the top of each uncompacted layer of the
base to act as a haunch to support the edges of the crusher run base during rolling.

Road base material shall be maintained at the correct moisture content necessary for
the proper compaction. It shall be watered by sprinkling with an approved sprayer
which gives a uniform distribution of water over the whole area or if the material is too
wet, it shall be loosen and dried by any means approved by the S.O. which will
achieve the required optimum moisture content.

The surface of the aggregate roadbase shall be well drained at all times.

11.9 FINISHED ROADBASE SURFACE

The furnished road base surface shall be even, free from hungry patches,
irregularities, loose material or fines and true to cross-section, lines and level. Any
irregularities on the finished base course surface of more than 12mm when measured
with a straight edge 10 feet long laid either parallel to the centre of the road or laid
transversely, shall be corrected by loosening, adding or removing material, reshaping
and recompacting.

11-4
]
 Table 1.1 : Compaction Requirements for Granular Materials
Number of Pases Of
Type of Compaction Not greater Not greater Not greater
Plant Category than 115 mm than 150mm than 225mm
(4½”) layer (6”) layer (9”) layer
Smooth, Wheeled Load per 25mm width
Roller 69-136 kg (151-300 16 Unsuitable Unsuitable
lbs) 136 Kg (300 lbs) 8 16 Unsuitable
Pneumatic Typed Wheel Load
Roller Tons - - -
4-6 12 12 Unsuitable
6-8 12 12 Unsuitable
8-12 10 10 Unsuitable
more than 12 8 8 Unsuitable
Vibratory Roller Static load per mm
width of vibratory
roller kg (lb)
19-32 (41-70) 16 Unsuitable Unsuitable
32-45 (71-100) 6 16 Unsuitable
46-59 (101-130) 4 6 10
60-73 (131-160) 3 5 9
73-91 (161-200) 3 5 8
91-109 (201-240) 2 4 7
109-127 (241-280) 2 4 6
Vibrating Plate Static pressure under - - -
Compactor base plate N/mm²
(lb/in²)
0.013-0.017 (2-2½) 8 Unsuitable Unsuitable
0.017 - 0.021 (2½-3) 5 8 Unsuitable
more than 0.021 (3) 3 6 10
Virbo-Tamper Weight Kg. (cwt) - - -
50.0-63.5 (1-1¼) 4 8 Unsuitable
63.5-76.0 (1¼-½) 3 6 10
more than 76.0 (½) 2 4 8
Power Rammer or Weight Kg. (cwt)
Dropping Weight 100-510 (2-10) 5 8 Unsuitable
Compactor more than 510 (1) 5 8 12

11.10 PRIME COAT AND TACK COAT

A bituminous prime coat shall be applied to the top of the completed crusher run base
course before laying the asphaltic concrete binder course. The Contractor shall apply
the prime coat on the completed portion of the granular base course as soon as
practical. However, he shall not apply the prime coat if the moisture content in the top
50 mm (2") of the aggregate base course exceeds the higher of either:

(a) the average of the optimum moisture content as determined by the standard
compaction test, and the absorption of the plus 5 mm (3/16") sieve fraction, or

(b) two-thirds of the optimum moisture content as determined by the standard

compaction test.

The surface shall be cleaned immediately prior to the application of the prime coat.
The bituminous material shall be applied by means of a distributor at suitable rates
but not to be less than 0.435 litres per sq. metre (0.08 gallon per sq. yd.) and at the
temperature within the range shown in table 1.2 for the particular material being used.

The surface of the dense asphaltic concrete binder course shall be cleaned
immediately prior to the application of the tack coat. The bituminous material shall be
applied by means of distributor at suitable rates but not to be less than 0.34 litres per
sq. meter (0.06 gallon per sq. yd.) and at the temperature within the range shown in
table 1.2 for the particular material used.

11-5
]
 The bituminous material for the tack coat shall be either a rapid curing cut back given
in B.S. 3690:1970 or a rapid breaking emulsion. Bitumen emulsion shall be of the
anionic type unless the cationic type is explicitly required.

Anionic emulsified bitumen shall conform to the requirements for the appropriate
grade given in B.S. 434:1960.

Cationic emulsified bitumen shall conform to the requirement for the appropriate
grade given in B.S. 434 in respect of general properties. The grade and use of either
type of emulsion shall be in accordance with B.S. 2542:1960.

The S.O. may require the Contractor to provide a certificate stating that a particular
emulsion distributor has been tested within the previous six (6) months and that the
rest indicates conformity of the distributor with the requirements of B.S. 3136 for
emulsion distributors.

Table 1.2 : Spraying Temperature For Bitumen

Grade Temperature
Cut Back New Grade
Old Grade (Approx.) °F °C
R.C. or M.C. 0 30 100-135 38-37
1 70 135-150 57-71
2 250 170-200 77-94
3 190-220 88-104
4 800 210-235 99-113
5 3000 245-270 118-132

Emulsion Ambient temperature or hotter as necessary for uniform spraying

and satisfactory penetration.

11.11 ASPHALTIC CONCRETE

11.11.1 Description

This work shall consist of furnishing, placing, shaping and compacting asphaltic
concrete binder course and/or wearing course on a prepare and accepted
bituminous or bitumeo primed pavement course, and shall include the careful and
thorough cleaning of surfaces which are to be covered without receiving a
bituminous tack coat. The work shall be carried out all in accordance with these
Specifications and the lines, levels, grades, dimensions and cross-sections shown
on the Drawings and/or as required by the S.O.'s representative.

11.11.2 Materials

(a) Aggregates

Aggregate for asphaltic concrete shall be a mixture of coarse and fine

aggregates, and if necessary mineral filler. The individual aggregates shall
be of sizes suitable for blending to produce the required gradation of the
combined aggregate, all to the satisfaction of the S.O.'s representative.
Coarse aggregates shall be screened crushed hard rock, angular in shape,
and free from dust, clay, vegetative and other organic matter, and other
deleterious substances. They shall conform to the following physical and
mechanical quality requirements

(i) The aggregate crushing value when tested in accordance with M.S. 30
shall be not more than 30

11-6
]
 (ii) The weighted average loss of weight in the sodium sulphate soundness
test (5 cycles) when tested in accordance with AASHTO Test Method T
104 shall be not more than 12%

(iii) The flakiness index when tested in accordance with M.S. 30 shall be
not more than 30

(iv) The water absorption when tested in accordance with M.S. 30 shall be
not more than 2%

(v) The polished stone value when tested in accordance with M.S. 30 shall
be not less than 40 (only applicable to aggregates for wearing course).

Fine aggregates shall be clean natural sands, screened quarry fines, or

mining sand. Mining sand shall be thoroughly washed before use. Other
types of fine aggregate may be used subject to the approval of the S.O.'s
representative. Fine aggregate shall be non-plastic and free from clay, loam,
aggregations of material, vegetative and other organic matter, and other
deleterious substances. They shall conform to the following physical and
mechanical quality requirements:

(i) The weighted average loss of weight in the sodium sulphate soundness
test (5 cycles) when tested in accordance with AASHTO Test Method T
104 shall be not more than 12%.

(ii) The water absorption when tested in accordance with M.S. 30 shall be
not more than 2%.

The gradation of the combined coarse and fine aggregates, together with
ordinary Portland cement added as an adhesion and anti-stripping agent and,
if necessary, any other mineral filler, shall conform to the appropriate
envelope in Table 1.3.

Table 1.3 : Gradation Limits for Asphaltic Concrete

Wearing Course Binder Course Binder Course

B.S Sieve Size ACW20 ACB20 ACB40
Percentage Passing by Weight
37.5 mm - - 100
28 mm - - 85-100
20 mm 100 100 72-93
14 mm 80-95 70-95 58-82
10 mm 68-90 56-81 50-75
5 mm 52-72 40-65 36-58
3.35 mm 45-62 32-58 30-52
1.18 mm 30-45 20-42 18-38
425 um 17-30 12-28 11-25
150 um 7-16 6-16 5-14
75 um 4-10 4-8 3-8

The gradation envelopes in the above table are purposedly wider than the
tolerances for good works control of asphaltic concrete mixes. For each type
of mix required in the works, the Contractor shall established a job mix
formula gradation which shall consist of a single definite percentage passing
for each sieve size in the above table and shall produce a smooth curve
within and essentially parallel to the appropriate gradation envelope. This job
mix formula gradation, with the allowable tolerances for a single test as
specified in Section 1.11.3 ( c ) then becomes the job control envelope, and

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 this job control envelope must be totally within the limits of the appropriate
gradation envelope in the above table.
(b) Mineral Filler

Mineral filier shall be finely divided mineral matter such as rock dust,
limestone dust, hydrated lime, hydraulic cement, or such other suitable
material as the S.O.'s representative shall approve. At the time of use it shall
be sufficiently dry to flow freely and shall be essentially free from
agglomerations. Not less than 70% by weight shall pass the B.S. 75um
sieve.

(c) Bituminous Material

Bituminous binder for asphaltic concrete shall be penetration graded bitumen

of 80-100 grade conforming to M.S. 124.

(d) Anti-Stripping Agent

Ordinary Portland cement shall be added to the combined aggregate for

asphaltic concrete to serve as an adhesion and anti-stripping agent. The
amount of cement added for this purpose shall be 2% by weight of the
combined aggregate. (Additional cement may also be added, if necessary, to
serve as filler).

Ordinary Portland cement for this purpose shall conform to the requirements
of M.S. 522, and shall be dry, free flowing and free from agglomerations at
the time of use.

Notwithstanding the use of ordinary Portland cement as an anti- stripping

agent as specified above, the Contractor shall be responsible for ensuring
that the bitumen binder adheres satisfactorily to the aggregate and does not
strip from it during the service life of the asphaltic concrete.

Accordingly the Contractor shall carry out bitumen stripping tests with the
proposed aggregates to demonstrate to the complete satisfaction of the
S.O.'s representative that the aggregates will perform satisfactorily in service
with the specified bitumen binder. Such tests shall be carried out in
accordance with AASHTO Test Method T 182, or such other test methods as
the S.O.'s representative shall direct or approve. When AASHTO Test
Method T182 is used, the coated area at the end of the mixture's period of
immersion in water shall be not less than 95%.

The Contractor may propose to use an adhesion and anti- stripping agent
other than ordinary Portland cement in addition to, or wholly or partially
instead of, the ordinary Portland cement specified above. Such agent shall
be of a type approved by the S.O.'s representative, and shall be thoroughly
mixed with the bituminous binder all in accordance with the manufacturer's
instructions. In such case the agent shall be added to the bitumen binder
used in the bitumen stripping tests in the appropriate amount and manner.

Aggregate which does not perform satisfactorily in the bitumn stripping tests,
using the approved adhesion and anti-stripping agent when appropriate, shall
not be used in asphaltic concrete.

11.11.3 Asphaltic Concrete Mix Design

(a) Job Mix Formulae

After obtaining supplies or production (as applicable) of all aggregates

consistent as to gradation and other qualities, the Contractor shall propose a

11-8
]
job mix formula for each class of mix required in the works. In order to attain
optimum quality of the mixtures, the job mix formula for each class shall be
prepared on the basis of Table 1.3 at an appropriate range of bitumen
contents. As a guide to the testing range of bitumen contents, the design
bitumen content will usually be in the appropriate range in table 1.4.

TABLE 1.4
Design Bitumen Contents

Class of Mix Normal Range of Design Bitumen

Contents by Weight of Mix
ACW 20 - Wearing Course 5.0 - 7.0 %
ACB 20- Binder Course 4.5 - 6.5 %
ACB 40 - Binder Course 4.0 - 6.0 %

A sample of each trial mix (i.e. each combination of trial gradation and
bitumen content) shall be subject to a comprehensive Marshall method test
and analysis as follows :

(i) Preparation of specimens for the standard stability and flow test in
accordance with AASHTO Test Method T 245 using the 50 blows
per face compaction standard.

(ii) Determination of the bulk specific gravity of the specimens in

accordance with AASHTO Test Method T 166.

(iii) Determination of the stability and flow values in accordance with

ASSHTO Test Method T 245.

(iv) Analysis of the density and voids parameters to determine the

percentage of voids in the compacted aggregate, the percentage of
voids in the compacted aggregate filled with bitumen, and hence the
percentage of air voids in the compacted mix.

For each trial mix conforming to a proposed job mix formula, the parameters
of the above test and analysis shall conform to the requirements of the
appropriate type of mix in Table 1.5.

Air voids shall be defined as the small pockets of air between the coated
aggregate articles in a compacted asphaltic concrete mix. The portion of the
bitumen absorbed into the aggregate particles must therefore be allowed for
when calculating the air voids. For combined aggregate with a water
absorption of not more than 2.0%, the absorbed bitumen may be estimated
on the basis that the absorption of bitumen will be approximately 20% of the
water absorption.

TABLE 1.5
Test and Analysis Parameters for Asphaltic Concrete

Parameter Wearing Course Binder Course

Stability S, kg >500 >450

Flow F, mm 2.0 - 4.0 2.0 - 4.0

Stiffness S/F, mm >250 >225

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 Air voids in mix % 3.0 - 5.0 3.0 - 7.0

Voids in aggregate % 75 - 85 65 - 80
filled with bitumen

Voids in the aggregate of a mix shall be calculated on the basis of the

weighted average bulk specific on an over dried basis of the coarse and fine
aggregate fractions (separated by the ASTM # 10 sieve) as determined in
accordance with AASHTO Test Method T 84 and T 85 as applicable.

The Marshall density of an asphaltic concrete mix is defined as the average

density of a set of three test specimens moulded for the standard stability and
flow test in accordance with AASHTO Test Method T245 using the 50 blows
per face compaction standard.

The Contractor shall submit to the S.O.’s representative full details of this
proposed job mix formula for each class of mix required in the work including

(i) The gradation analysis of each aggregate to be used in the mix.

(ii) The proportions for cold batching the aggregates.

(iii) The mixing plant screen sizes, the smallest of which shall not be
more than 3.2mm.

(iv) The gradation analysis of the aggregate in each of the mixing plant’s
hot bins and of the mineral filler (including ordinary Portland cement
added as anti-stripping agent).

(v) The job mix formula gradation of the combined aggregate and filler.

(vi) The proportions for combining the hot bin aggregates and filler.

(vii) The bitumen content (by weight of total mix).

(viii) The dry and wet mixing times if a batch plant is to be used, or the
mixing time if a continuous mix plant is to be used.

(x) The full results of the comprehensive Marshall method tests and
analyses as described above for each trial mix used in determining
the job mix formula.

The S.O.’s representative may require changes of any of the factors

in each proposed job mix formula and further tests and analyses in
order to attain optimum quality of the asphaltic concrete mixes.

(b) Plant Trials

After having received the S.O.’s representative preliminary approval of his

proposed job mix formulae, the Contractor shall arrange to mix, lay and
compact asphaltic concrete conforming to the proposed formula for each
class of mix required in the works. Approximately 100 tons of each mix shall
be placed in trial areas to demonstrate to the satisfaction of the S.O.’s
representative that the mixing, laying and compacting equipment conforms to
the requirements of these Specifications, and that the proposed mixes are
satisfactory. The trial areas shall not be part of the Contract works but shall
be provided by the Contractor at his own expense; they shall be approved by
the S.O.’s representative.

11-10
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 As directed by the S.O.’s representative, comprehensive sampling and
testing of each class of mix shall be carried out to check for satisfactory
compliance with its job mix formula, and for a satisfactory degree of
compaction.

As a result of the plant trials, the S.O.’s representative may require

amendments to the job mix formulae, further tests and analyses, and possibly
additional plant trials before finally approving the mixes for full scale
production and use in the Works.

(c) Compliance with the Job Mix Formulae

The S.O.’s representative final approval of the job mix formulae shall bind the
Contractor to furnish asphaltic concrete mixes meeting the precise gradations
and bitumen Contents specified in these formulae within the tolerances set
forth in Table 1.6.

Modifications to a job mix formula may only be made with the approval of the
S.O.’s representative. Should the S.O.’s representative at any time have
reason to believe that the materials and methods of mixing and laying are
different from those approved, he shall so advise the Contractor, and may
order that asphaltic concrete works be discontinued pending further trials and
testing.

TABLE 1.6 : Tolerances For Asphaltic Concrete Mixes

Parameter Permissible Variation %

by Weight of Total Mix
Bitumen content + 0.2 %

Fractions of combined aggregate passing + 5.0 %

5.0mm and larger

Fractions of combined passing 3.35mm and + 4.0 %

1.18mm

Fractions of combined aggregate passing + 3.0 %

425um and 150um

Fractions of combined aggregate passing + 2.0 %

75um sieve

11.11.4 Equipment

The Contractor shall provide all the plant and equipment necessary for executing
the work in accordance with these Specifications, and shall furnish the S.O.’s
representative with such details of particular items of equipment, e.g. manufacturer
model type, capacity, weight, operating features, etc., as the S.O.’s representative
shall require.

(a) Road Cleaning Equipment

Road cleaning equipment will be required where asphaltic concrete is to be

laid on a surface which is not to receive a tack coat. The equipment shall be
the same as that required for preparing a surface for a tack coat, and shall
include a power broom and compressed air blower as specified below

11-11
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 (i) Power Broom

The power broom shall be a rotary type specifically designed for

sweeping road surfaces, and shall be approved by the S.O.’s
representative.

(ii) Compressed Air Blower

The compressed air blower shall comprise a portable air compressor

3 m3/min. capacity at 0.7 N/mm 2 delivery pressure with a suitable
hose and nozzle for blowing clean a road surface after power
brooming, and shall be approved by the S.O.’s representative.

(b) Asphalt Paver

The asphalt paver shall be recognized manufacture and shall be approved by

the S.O.’s representative. It shall conform to the requirements described
hereunder.

The paver shall be self-propelled and capable of reverse as well as forward

travel. It shall be equipped with a hopper at the front designed to receive the
paving mixture from tip-trucks, and shall have a mechanical distribution
system for spreading the mixture evenly and without segregation over the
surface to be paved in front of a screeding and compacting unit, which shall
be equipped with a suitable heating device.

The screeding and compacting mechanism shall be capable of confining the

edges of the material being laid without the use of stationery side forms, shall
be adjustable to strike off the mixture to the thickness and cross-section
shape required, and shall be controlled by an automatic levelling device to
produce an even carpet of bituminous mixture with a uniform surface texture
free from indentations, ridges, tear marks or other irregularities. The paver
shall be capable of laying the bituminous mixture in paving widths in the
range 2.5 to 3.75m and of finishing the pavement layer true to the required
lines, grades, levels, dimensions and cross-sections, subject to compaction
by rolling, all to the satisfaction of the S.O.’s representative.

(c) Rollers

A pneumatic typed roller and two steel wheeled tandem rollers shall be
provided; however a three wheeled steel roller may be substituted for one of
the tandem rollers if the S.O.’s representative shall so approve. All rollers
shall be of recognized manufacture and shall be approved by the S.O.’s
representative.

(d) Pneumatic Tyred Roller

The pneumatic tyred roller shall be of recognized manufacture and shall be

approved by the S.O.’s representative. It shall conform to the requirements
described hereunder.

The pneumatic tyred roller shall be self-propelled and capable of being

reversed without backlash; it shall be equipped with power steering and dual
controls allowing operation from either the left or right side.
The roller shall have nine wheels equipped with smooth threaded tyres all of
the same size and construction, and capable of operating at inflation
pressures of up to 0.9 N/mm 2. Five wheels shall be on the driven axle and
four on the steering axle, all equally spaced on both axles and arranged so
that the tyres on the steering axle track midway between those on the driven
axle with a small overlap. The roller shall be equipped with water tanks,

11-12
]
 sprinkler systems and pads of coconut matting to keep all tyres evenly wetted
during operation.

The roller shall be equipped with means of adjusting its total weight of
ballasting so that the load oar wheel can be varied in the range 1.0 to 2.0
tons. In operation, the ballasted weight and the tyre inflation pressure shall be
adjusted to meet the requirements of each particular operation. Each tyre
shall be kept inflated at the specified pressure such that pressure difference
between any two tyres shall not exceed 0.04 N/m2. Means shall be provided
for checking and adjusting tyre pressures at all times at the place of the
works.

The Contractor shall provide the S.O.’s representative with a calibration chart
for the roller showing the relationship between the quantity or depth of ballast
and total weight, and also a chart showing the relationship between wheel
load, tyre inflation pressure and contract pressure.

Steel wheeled rollers shall conform to the requirements described hereunder.

Steel wheeled rollers shall be self-propelled and capable of being reversed
without backlash; they shall be equipped with power steering and dual
controls allowing operation form either the left or right side. They shall be
equipped with water tanks, sprinkler systems and scraper blades to keep all
wheels evenly wetted and clean during operation.

Each steel wheeled roller shall be ballasted so that its total operating weight
is in the range 8 to 10 tons and its driven roll (or rolls) shall exert a rolling
force of not less than 3.5 tons/metre of roll width. The Contractor shall
provide the S.O.’s representative with a calibration chart for each roller
showing the relationships between the quantity or depth of ballast and total
weight and rolling force.

11.11.5 Construction Methods

(a) General Conditions

Asphaltic concrete paving work shall only be carried out in dry weather when
the surface to be covered is dry, or if so specified, has received a bituminous
tack coat which shall have achieved a satisfactory degree of tackiness, all to
the satisfaction of the S.O.'s representative. All laying, rolling and finishing
work shall be carried out during daylight hours, unless the Contractor shall
have provided suitable flood-lighting for the job site, to the satisfaction of the
S.O.'s representative.

The S.O.'s representative may order the discontinuation of work on account

of adverse weather, unsatisfactory condition of materials, equipment or
surface to be paved, or such other conditions as he shall consider detrimental
to the work.

(b) Surface Preparation and Cleaning

Prior to constructing an asphaltic concrete pavement layer, the surface to be

covered shall have been prepared in accordance with the appropriate
sections of these Specifications. Notwithstanding any earlier approval of this
surface, any damage to or deterioration of it shall be made good before
asphaltic concrete paving work is commenced.

If the surface to be covered is not to be provided with a bituminous tack coat,

then immediately prior to commencing asphaltic concrete paving, it shall be
swept using a power broom followed by a compressed air blower, and if
necessary scraped using hand tools, to remove all loose particles, dirt, dust

11-13
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 and other objectionable material, all to the satisfaction of the S.O.'s
representative.

If the surface to be covered is to be provided with a bituminous tack coat,

then this shall be applied all in accordance with the provisions of Section 1.10

(c) Aggregate Handling and Heating

Each aggregate to be used in the asphaltic concrete mixes shall be stored in

a separate stockpile near the mixing plant. Stockpiles of sand and other fine
aggregates shall be kept dry using waterproof covers and other means as
necessary. In placing the aggregates in the stockpiles and loading them into
the mixing plant's aggregate feed bins, care shall be taken to prevent
segregation or uncontrolled combination of materials of different gradation.
Segregated or containminated materials shall be rescreened or rejected for
use in the works and removed from the mixing plant site.

The aggregates shall be fed into the dryer at a uniform rate proportioned in
accordance with the appropriate job mix formula. The rate of feed for each
aggregate shall be maintained within 10% of the rate prescribed, and the total
rate of feed shall be such that the plant's screens shall never be overloaded.

The aggregates shall be dried and heated so that when delivered to the mixer
they shall be at a temperature in the range 1500C to 1700C when the binder
is bitumen of penetration grade 80-100. If the binder is other than bitumen of
penetration grade 80-100, the S.O.'s representative shall specify an
appropriate range for the mixing temperature.

Immediately after heating, the aggregate shall be screened into four (or
more) fractions which shall be separately stored in the hot aggregate storage
bins in readiness for mixing.

Ordinary Portland cement and/or other mineral filler to be used in the mix
shall be stored separately and kept completely dry. Its rate of feed into the
plant shall be accurately controlled by weight or volumetric measurement, all
to the satisfaction of the S.O.'s representative.

(d) Heating of Bitumen

The binder shall be heated so that when delivered to the mixer it shall be at a
temperature in the range 1400C to 1600C when the binder is bitumen of
penetration grade 80-100. If the binder is other than bitumen of penetration
grade 80-100, the S.O.'s representative shall specify an appropriate range for
the mixing temperature.

(e) Mixing Asphaltic Concrete

The mixing plant shall be so co-ordinated and operated as to consistently

produce asphaltic concrete mixes within the tolerances prescribed in these
Specifications, all to the satisfaction of the S.O.'s representative.

(i) Mixing in Batch Plants

For each batch the screened hot aggregates shall be weighed out
into the aggregate weigh hopper in accordance with the proportions
prescribed in the appropriate job mix formula; the sequence of
weighing out progress down to the fines, unless the S.O.'s
representative shall otherwise approve. Mineral filler shall be
weighed out into the filler weigh hopper, where this is provided, or
added last to the aggregate weigh hopper, in accordance with the job
mix formula proportions.

11-14
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 The hot binder shall be weighed out into the binder weight bucket in
accordance with the proportions prescribed in the job mix formula.

The hot aggregates and filler shall be discharged into the pugmill and
mixed dry for the dry mixing time prescribed in the job mix formula,
which shall usually be in the range 5 to 10 seconds. The hot binder
shall then be added and wet mixing performed for the wet mixing
time prescribed in the job mix formula, this shall be sufficient so that
all particles of aggregate are uniformly coated with bitumen, and shall
usually be 45 seconds or more for dense graded mixtures.

The volume of each batch shall be such that the tips of the pugmill
paddle blades just break out of the mixture at height of their action.

After the completion of wet mixing, each batch of asphaltic concrete

shall be discharged from the pugmill either into a storage hopper or
directly into a truck for hauling to the paving site. Care shall be taken
that no segregation of the mix occurs.

(ii) Mixing in Continuous mix plant

The screened hot aggregates and filler shall be fed continuously from
their storage bins in accordance with the proportions prescribed in
the appropriate job mix formula, combined in the plant, and fed
continuously into the mixer. The hot binder shall be sprayed on to
the combined aggregate as it enters the pugmill at the rate required
to achieve the bitumen content prescribed in the job mix formula.
The materials shall then be carried throught the pugmill and in the
process be thoroughly mixed by the action of the paddles, and
discharged over the dam into the storage hopper. The mixing time
shall prescribed in the job mix formula; this shall be sufficient so that
all particles of aggregate are uniformly coated with bitumen, and shall
usually be 45 seconds or more for dense graded mixtures.

The plant shall be so adjusted as to maintain the level of mixture in

the pugmill such that the tips of the paddle blades just break out of
the mixture at the height of their action.

(f) Transportation of Asphaltic Concrete

Asphaltic concrete shall be transported from the mixing plant to the site of
the paving works in loads of not less than 5 tons using tip-trucks. Except
where asphaltic concrete is to be hand laid, it shall be discharged directly into
the paver hopper, as required, from the tip-trucks. Care shall be taken in the
truck loading, hauling and unloading operations to prevent segregation of the
mix. During transportation, the asphaltic concrete shall be protected from
contamination by water, dust, dirt and other deleterious materials.

The temperature of the asphaltic concrete immediately before unloading from

the truck either into the paver hopper or on to the road for hand spreading
shall be not less than 1250C when the binder is bitumen of penetration grade
80-100, the S.O.'s representative shall specify an appropriate minimum
unloading temperature. Any load which has cooled below the specified
temperature in the truck shall be rejected for use in the works and removed
from the site of the works.

(g) Laying Asphaltic Concrete

The sequence of laying operations shall be planned in advance by the

Contractor and approved by the S.O.'s representative. Generally each paving

11-15
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 layer shall have a compacted thickness of not less than twice the nominal
maximum aggregate size of the mixture, and not more than 100 mm. Where
applicable, e.g. on superelevated sections and on carriageways with cross
slope in one direction only, laying shall commence along the lower side of the
carriageway and progress to the higher side. Laying shall not be carried out
in a downhill direction along any section of road.

As far as is practicable, laying shall be carried out using a paver approved by

the S.O.'s representative. Hand-casting of bituminous mix on to the machine
finished surface shall be kept to the practicable minimum necessary for
correcting blemishes and irregularities. In any areas inaccessible to the
paver, laying shall be carried out by hand methods using rakes, lutes and
other hand tools, all to the satisfaction of the S.O.'s representative. All laying
of bituminous mix shall be such that after compaction by rolling the specified
course or layer thickness and surface profile shall be achieved. Care shall be
taken to achieve a uniform surface texture free from indentations, ridges, tear
marks or other irregularities, and to prevent segregation of the mix.

During laying operations the temperature of asphaltic concrete shall be not

less than 1100C when the binder is bitumen of penetration grade 80-100. If
the binder is other than bitumen of penetration grade 80-100 the S.O.'s
representative shall specify an appropriate minimum laying temperature.

Material which has cooled below the specified temperature before laying shall
not be used and shall be removed from the site of the works. The Contractor
shall provide accurate thermometers at the paving site at all times, and shall
check the temperature of asphaltic concrete in the paver hopper at regular
intervals and before laying restarts after each interruption of the paving
operation.

As far as is practicable, the paver shall be operated continuously and the

supply of bituminous mix shall be regulated so as to enable continuous
paving. Transverse joints in a paving lane shall be kept to a practicable
minimum, and intermittent stopping and restarting of the paver shall be
avoided as far as practicable.

Care shall be taken that no bituminous mix is placed on expansion joints at

bridges, inspection covers for utilities ducts, drainage and sewerage
manholes and the like, and that catchpits, drainage openings through kerbs,
etc., remain properly open and serviceable. During laying operations, such
areas and openings shall be protected by suitably shaped and secured
boards or other materials approved by the S.O.'s representative, and
compaction of mix in the immediately surrounding or adjacent areas shall be
completed by hand methods, all to the satisfaction of the S.O.'s
representative. Alternatively, bituminous mix shall be laid and compacted by
hand methods as necessary around surfacing discontinuities of these types,
all to the satisfaction of the S.O.'s representative.

(h) Construction Joints

Existing bituminous surfacing which new bituminous mix is to adjoin shall be

cut back to present a straight, vertical edge not less than 25 mm deep and a
smooth transition section not less than 0.5 metre long against which to lay the
new material. The specified thickness of the new surfacing shall be built up
gradually from the vertical joint to avoid any bumps or ridges across the
carriageway.

When longitudinal or transverse joints are required in a layer of bituminous

mix under construction, the material first laid and compacted shall be cut
back to a vertical face for the full thickness of the layer, on a line satisfactory
to the S.O. before the adjacent area is paved.

11-16
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 At all construction joints a thin uniform coating of bitumen emulsion of grade
RS-1 shall be brushed on to the vertically cut joint faces some 10 to 15
minutes before laying the next section of bituminous mix commences to
ensure good bonding. Also all contact surface of kerbs, gutters, manholes,
datchpits, etc., shall be similarly treated with a coating of bitumen emulsion
before bituminous mix is placed against them.

Construction joints in a layer of bituminous mix shall be offset from those in

any immediately underlying bituminous layer by at least 100 mm for
longitudinal joints and at least 0.5 metre, where possible, for transverse
joints.

(i) Compaction of Asphaltic Concrete

For each layer of asphaltic concrete, compaction by rolling shall commence

as soon after laying as the material will support the rollers without undue
displacement; nevertheless the temperature of asphaltic concrete at the
commencement of rolling shall be not less than 1100C when the binder is
bitumen of penetration grade 80-100. If the binder is other than bitumen of
penetration grade 80-100, the S.O.'s representative shall specify an
appropriate minimum rolling temperature.

In any areas inaccessible to the rollers, proper compaction shall be carried

out using vibrating plat compactors, hand tampers or other suitable means,
all to the satisfaction of the S.O.'s representative.

Initial (or breakdown) rolling shall be carried out with an approved steel
wheeled tandem roller or three wheeled steel roller. The principal heavy
rolling shall be carried out with an approved pneumatic typed roller
immediately following the initial operating weight of not less than 15 tons and
its tyre inflation pressure shall be not less than 0.7 N/mm2 . The final rolling
shall be carried out with an approved steel wheeled tandem roller and shall
serve to eliminate minor surface irregularities left by the pneumatic typed
roller.

All rollers shall operate in a longitudinal direction along the carriageway with
their driven wheels towards the paver. Rolling shall generally commence at
the lower edge of the paved width and progress uniformly to the higher edge,
except that where there is a longitudinal construction joint at the higher edge,
this shall be rolled first ahead of the normal pattern of rolling. Generally
successive roller passes shall overlap by half the width of the roller, and the
points at which the roller is reversed shall be staggered. However, when
operating on gradients in excess of 4%, the breakdown roller shall not pass
over any previously unrolled mix when operating in the downhill direction.

In all cases compaction shall be carried out in such a manner that each
section receives equal comparative effort, all to the satisfaction of the S.O.'s
representative.

The steel wheeled rollers shall operate at speeds of not more than 5 kph and
the pneumatic typed roller shall operate at speed of not more than 8kph. No
roller or heavy vehicle shall be allowed to stand on newly laid bituminous mix
before compaction has been completed and the material has thoroughly
coiled and set. Rolling shall continue as long as is necessary to achieve the
appropriate requirement in the following table

TYPE OF PAVEMENT LAYER REQUIRED COMPACTED DENSITY

Wearing Course 98-100% Marshall Density

11-17
]
 Binding Course 95-100% Marshall Density

all be taken to prevent over-compaction of asphaltic concrete.

24 hours of laying and compacting the bituminous mix, the Contractor shall
cut core samples of not less than 100 mm nominal diameter at locations
selected by the S.O.'s representative. The rate of sampling shall be 1 sample
per 500m2 Of mix laid, but not less than 2 samples for the work completed in
each paving session. These core samples shall be used by the S.O.'s
representative to determine the thickness of the compacted density of the
material in accordance with either ASTM Test Method D 1188 or ASTM Test
Method D 2726, whichever is applicable.

(j) Finished Asphaltic Concrete

Asphaltic concrete binder and wearing coruses shall be finished in a neat and
workmanlike manner; their widths shall be everywhere at least those
specified or shown on the Drawings on both sides of the centre-line. For a
binder course or wearing course the average thickness over any 100 metre
length shall be not less than the required thickness, and the minimum
thickness at any point shall be not less than the required thickness minus 5
mm.

The top surface of a wearing or binder course shall have the required shape,
super elevation, levels and grades, and shall be everywhere within the
tolerances specified in Section 1.11.6.

(k) Opening to Traffic

Asphaltic concrete shall not be opened to traffic until compaction has been
completed and the material has thoroughly cooled and set in the opinion of
the S.O.'s representative. This will usually be not less than 4 hours after the
commencement of rolling. Where it is necessary to allow earlier use of the
finished surface to facilitate the movement of traffic, vehicles may be allowed
to run on the work after rolling has been completed, provided that speeds are
restricted to 30 kph or less and sharp turning movements are prohibited.

11.11.6 Horizontal Alignment. Surface Levels and Surface Regularity of Pavement

Courses

11.11.6.1 Horizontal Alignment

Horizontal alignment shall be determined from the centre-line of the pavement

surface shown on the Drawings. The edges of the pavement as constructed and all
other parallel construction lines shall be correct within a tolerance of +50 mm and -0
mm from the centre-line, except for kerbs, channel blocks and edge lines which
shall be laid with a smooth alignment within a tolerance of +25 mm and -0 mm from
the centre-line.

11.11.6.2 Surface Levels of Pavement Courses

The design levels of pavement courses shall be calculated from the vertical profile,
crossfall and pavement course thickness shown on the Drawings. The level of any
point on the constructed surface of a pavement course shall be design level subject
to the appropriate tolerances in Table 1.7.

The combination of permitted tolerances in the levels of different pavement courses

shall not result in a pavement thickness less than that shown on the Drawings.
Each pavement course shall have an average thickness not less than that shown

11-18
]
 on the Drawings

11.11.6.3 Surface Regularity

The regularity of surfaces shall be within the relevant limits in Table 1.8.

A longitudinal irregularity is a variation in profile of the road surface as measured by

the rolling straight-edge or wedge and straightedge device. The permissible number
of such longitudinal irregularities is indicated in Table 1.8.

TABLE 1.7
Tolerances in Surface Levels of Pavement Courses

Pavement Tolerance

Wearing Course + 5mm

Binder Course + 5 mm

Roadbase + 0 mm
- 20 mm

Subbase and Lower + 0 mm

Subbase -20 mm

The traverse length of 300 mm and its associated maximum permissible number of
irregularities shall apply wherever the continuous length of the completed
carriageway is 300 mm or more, whether or not is constructed in shorter lengths.

Where the total length of pavement is less than 300 m the measurements shall be
taken on 75m lengths.

The transverse regularity of a newly laid surface shall be measured with a 3 m

straight-edge and shall have no greater depression under the straight-edge than
that shown in the Table

11-19
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 TABLE 1.8
Tolerances in Surface Levels of Pavement Courses

Class of Longitudinal Section Transverse

Surface Direction
Irregularity
Maximum
Max. Permissible Number Of Surface Irregularities Permission Depth
Of Transverse
Irregularities
Depth Exceeding 4 mm Depth Exceeding 7 mm
Over Over Over Over
Transverse Transverse Transverse Transverse
Length Of Length Of Length Of Length Of
300mm 75mm 300m 75mm

Class SR 1 20 9 2 1 4 mm

Class SR 2 40 18 4 2 8 mm

Class SR 3 60 27 6 3 12 mm

No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR 1 Surface Regularity

and no longitudinal irregularity exceeding 15 mm shall be permitted for Class SR 2 and Class SDR 3
Surface Regularities

The class of Surface Regularity for each portion of the Works shall be as stated on the Drawings or
in the Bills of Quantities.

11.11.7 Road Shoulders

11.11.7.1 Road shoulders shall be constructed to lines grades, levels, dimensions and cross-
sections shown on the drawings and as directed by the S.O.

11.11.7.2 The subgrade of tire shoulder shall be stripped of all vegetation, grass, etc., before
material for the shoulder is placed.

The shoulders shall be constructed on a previously prepared subgrade finished as

required in the Specification. The work shall be carried out in conformity with the
requirements for simultaneous construction of sub-base where required and as
approved by the S.O.'s representative.

(a) Sub Grade Material Conforming

(i) Liquid limit not more than 30%

(ii) Plasticity index not less than 6 and not more than 15.

(iii) Passing B.S. sieve 75 micron not greater than 25%.

(iv) Passing B.S. sieve 3/16" 30% - 80%.

11-20
]
 (b) Lateriate, gravel, mining ballast or other suitable material conform to the
grading limits given in Table 1.9 for laterite pavement.

11.11.7.3 Shoulders shall be placed and compacted in layers not exceed 200mm thickness
before compaction. The layers shall be compacted to 95% of' maximum dry
density as determined by B.S. Heavy Compaction Test.

11.11.7.4 Payment of all cost of material and royalties at the rate determined by the State
Government shall be paid by the Contractor.

TABLE 1.9
Grading Limits For Granular Pavement Material

Percentage By Weight Passing

B.S. Sieve Size
(A) (B)

40 mm 100 -

20 mm 80 - 100 100

10 mm 55 - 90 80 - 100

5 mm 40 - 70 55 - 90

2.4 mm 30 - 55 40 - 70

420 microns 12 - 30 20 - 40

75 microns 5 - 20 8 - 25

11-21
]
 SECTION 12
PAINTING AND PROTECTIVE COATINGS

12.1 GENERAL ON PAINTING AND PROTECTIVE COATINGS

The work included in this section consists of the furnishing of all labour, materials,
apparatus, scaffolding, and all appurtenant work in connection with the painting, in
accordance with these specifications.

12.1.1 Surface to be Painted

In general, the following surfaces are to be painted:

A. All exposed piping and other metal surfaces, interior and exterior.

B. All submerged metal surfaces.

C. All structural and miscellaneous steel, including tanks.

D. The interior of tanks.

E. Exterior above ground concrete and brick masonry as specified and shown on
the design plans.

F. The interior of structures as specified in the painting schedule and shown on the
design plans.

G. Equipment furnished with and without factory finished surfaces, except as

specified below.

H. Doors, woodwork, and architectural trim work as specified and shown on the
plans.

12.1.2 Surfaces Not To Be Painted

The following surfaces in general shall not be painted:

A. Concrete surfaces subject to pedestrian traffic.

B. Plastic surfaces.

C. Nonferrous metal unless otherwise noted or indicated. (Galvanised metal shall

not be considered a nonferrous metal).

D. Mechanical equipment with approved factory finish as specified in the design.

12-1
 E. Electrical equipment with approved factory finish as specified in the design.

F. Piping which is specified as galvanised.

G. Chain Link fencing.

In no case shall any concrete, wood, metal, or any other surface requiring protection
be left unpainted even though not specifically defined herein.

12.1.3 Submittals On Painting Works

Material specifications, surface preparation, application instructions, colour cards and

samples cards shall be submitted to the Engineer for approval before commencement
of any painting work.

12.2 MATERIALS FOR PAINTING WORKS

All paint materials shall be of first quality products manufactured for the exposures
involved, as approved by the Engineer. All paints should conform to the relevant
British Standard Specifications.

12.2.1 System A Materials

Primer - Zine-rich epoxy primer.

Intermediate - Universal type primer.
Finish - Vinyl acrylic finish.

12.2.2 System B Materials

Primer -Epoxy primer.

Intermediate -Polyester epoxy enamel.
Finish - Same as intermediate.

12.2.3 System C Materials

Primer - Zinc-rich epoxy primer.

Intermediate - Coal-tar epoxy polymide coating.
Finish - Same as intermediate.

12.2.4 System D Materials

Primer - Vinyl-based cementitious block filler.

Intermediate - Vinyl acrylic emulsion.
Finish - Same as intermediate.

12.2.5 System E Materials

Intermediate and finish coats as specified for System C.

Primer is not required.

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12.2.6 System F Materials

Primer - Latex base

Intermediate - Latex flat
Finish - Same as intermediate.

12.2.7 System G Materials

Primer- Pigmented oil primer

Intermediate - Enamel under coat
Finish - Semigloss enamel

12.2.8 System H Materials

Primer - Exterior wood primer

Intermediate - Exterior gloss wound
Finish - Same as intermediate

12.2.9 System I Materials

Primer - For ferrous metal, red lead primer

For galvanised, zinc-dust zinc-oxide primer
Intermediate - Exterior gloss enamel
Finish - Same as intermediate

12.3 WORKMANSHIP FOR PAINTING WORKS

12.3.1 Protection Of The Works

The Contractor shall take the necessary steps to protect the work of other during the
time his work is in progress. Paint shall be applied only during periods of favourable
weather.

12.3.2 Preparation Of Paint

All materials specified or selected for use under these specifications shall be delivered
unopened at the job site in their original containers. Paint containers shall be opened
only when required for use. Paint shall be thoroughly stirred or agitated to uniformly
smooth consistency suitable for proper application.

In all cases, paint shall be prepared and handled in a manner to prevent deterioration
and inclusion of foreign matter. No paint shall be reduced or applied in any way
except as herein specifically called for or, if not specifically call for, then it shall be
applied in accordance with the manufacturer's recommendations.

12.3.3 Preparation Of Surfaces

The Contractor shall examine carefully all faces to be finished and before beginning
any of his work shall see that the work of the other trades has been left or installed in
a workmanlike condition to receive paint. Metals shall be clean, dry, and free from mill
scale, rust, grease, and oil.

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12.3.4 Workmanship for Painting Works

Each coat of paint shall be applied at the proper consistency and brushed evenly, free
of brush marks, sags, runs, with no evidence of poor workmanship. Care shall be
exercised to avoid lapping paint on glass or hardward. Paint shall sharply cut to lines.
Finished paint surfaces shall be free from defects or blemishes.

12.3.5 Protective Coverings

Protective Covering or drop cloths shall be used to protect floor, fixtures, and
equipment.Care shall be exercised to prevent paint from being spattered onto
surfaces which are not to be painted. Surfaces from which such paint cannot be
removed satisfactorily shall be painted or repainted, as required to produce a
satisfactory finish.

12.3.6 Tints

Whenever two(2) coats of paint are specified, the first coat shall contain sufficient
powdered aluminium or carbon black to act as an indicator of proper coverage, or the
two(2) coatings must be of contrasting colour.

12.3.7 Brushing

All paint shall be applied by brush unless otherwise specifically approved by the
Engineer.

12.3.8 Instructions

All coatings shall be performed by personnel experienced in the application of said

coating systems and in accordance with the Manufacturer's printed instructions. The
final appearance shall exhibit a uniformly textured and coloured coating free of
excessive gloss or dull spots, blemishes, sags, runs, pinholes, and other defects.

12.3.9 Ventilation

The Contractor shall not permit painting to begin in enclosed places, until a forced
draft ventilation system of sufficient air volume has been placed in operation.

12.3.10 Right of Rejection

No exterior painting or interior finishing shall be done under conditions which may
jeopardize the appearance or quality of the painting or finishing in any way. The
Engineer shall have the right to reject all material or work that is unsatisfactory, and
require the replacement of either or both.

12.4 APPLICATION OF PAINTING SYSTEMS

12.4.1 System A Application

Metal subject to corrosive moisture or atmosphere and condensation.

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 A. Surface Preparation to all metal surfaces shall be field sand-blasted. Weld
surface, edges, and sharp corners shall be ground to a curve and all weld
splatter removed.

B. Prime coat shall have a minimum thickness of 50 micron. An intermediate coat

shall have a minimum thickness of 50 micron, and finish coat shall have a
minimum thickness of 100 micron. The total system shall have a minimum dry
film thickness of 200 micron.

C. A minimum of 12 hours time is required before additional coats may be applied

to the prime coat, two hours for the intermediate coat, and two hours for the
finish coat.

12.4.2 System B Application

Metals not subject to chemical attack, normal indoor exposure, except as specified for
buildings.

A. All surfaces shall be freed of dirt, dust, grease, or other foreign matter before
coating. Weld surfaces and rough edges shall be ground and weld splatter
removed.

B. 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.

C. The coating system shall have a minimum of total dry film thickness of 100
micron resulting from a prime coat and at least two finish coats.

12.4.3 System C Application

Metals submerged or intermittently submerged in water or corrosive liquid.

A. All metal surfaces shall be field sand-blasted in accordance with Structures

Painting Council Specification SSPC-SP-10 (Near-White Blast Cleaning). Weld
surface, edges, and sharp corners shall be ground to a curve and all weld
splatter removed, and welds neutralized with thinner.

B. Application shall be 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.

C. The prime coat shall have a minimum thickness of 75 micron and two or more
finish coats shall have a minimum total thickness of 400 micron. The total
system shall have a minimum dry film thickness of 475 micron.

12.4.4 System D Application

Exterior or interior brick, concrete, and concrete block work exposed to view not
subject to immersion in sewage and not subject to pedestrian traffic except as
otherwise specified. Interior surfaces not specifically indicated shall not be painted. All

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 concrete block surfaces to be painted shall be filled with a latex type block filler
supplied by the paint manufacturer whose products are used prior to first or prime
paint coat.

A. All surfaces shall be freed of dirt, dust, grease, and other foreign matter before
coating. Cracks and voids shall be repaired or filled with a suitable caulking
material compatible with the specified paint.

B. The first coat shall be applied to cover and provide a smooth base. The finish
coat shall be applied to a dry film with minimum thickness of 37.5 micron.

C. The filler coat may be recoated in 12 hours, the finish coat is dry for a recoat in
two hours.

12.4.5 System E Application

Concrete subject to intermittent submergence including wet wells, surge chambers,

flume, distribution and by pass chamber and manholes.

A. All internal walls and slabs shall be applied with High Alumina Cement plaster
(20mm min cement:sand ratio 1:3) prior to coating.

B. All surfaces shall be cleaned of all dirt, dust, form oil, curing compounds, and
other deleterious compounds. In general, the concrete shall be reasonable
smooth, and free of pockets and cavities.

C. Prime coat shall be two parts coal tar epoxy with one part manufacturer's thinner
mixed according to the manufacturer's recommendations. The finish coats shall
be two or more coats of coal tar epoxy (undiluted) to a dry film thickness of 500
micron.

D. All coats shall be applied within 24 hours of the previous coat.

12.4.6 System F Application

Interior concrete, masonry, and plaster surfaces of building scheduled or directed to

have a flat finish. Concrete block masonry surfaces shall be given a coat of block filler
according to System D prior to painting.

A. Surface preparation, coating system and time between coats are as specified for
System D.

12.4.7 System G Application

Interior concrete, masonry, and plaster of building scheduled to have an enamel

finish. Concrete block masonry surfaces shall be given a coat of block filler according
to System D prior to painting.

A. All surfaces shall be freed of dirt, dust, grease, and other foreign matter before
coating. Cracks and voids shall be repaired or filled with a suitable caulking
material compatible with the specified paint. Efflorescence shall be neutralized
with zinc sulfate solution and allowed to dry.

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 B. The prime coat shall be applied to cover and provide a smooth base. The
undercoat and finish coat shall be applied to a total dry film with minimum
thickness of 75 micron.

C. Each coat shall be shall be completely dry before the next coat is applied.

12.4.8 System H Application

Interior and exterior wood.

A. Unless already properly handsanded, sandpaper smooth by hand and dust

clean. Neatly fill nail holes, cracks and depressions herein with approved filler,
coloured to match required finish; when dry, sandpaper flush and smooth.

B. Prime coat shall be applied to cover and provide a smooth base. Each finish
coat shall be applied to a minimum dry film thickness of 50 micron.

C. Time between coats is as specified for System G.

12.4.9 System I Application

For interior and exterior metal not painted under Systems A, B and C.

A. For ferrous metal, specified for System B. Wash galvanized surfaces with
solvent thinner.

B. Apply each coat to a minimum dry film thickness of 50 micron.

C. Time between coats is as specified for System G.

12.5 PAINT SCHEDULE

12.5.1 General for Paint Schedule

The following schedule shall indicate the coating system to be used. All surfaces shall
be painted except those specified deleted herein. The Engineer shall select the
colours.

12.5.2 Process Piping Colour Code

All exposed pipe, including tubing, galvanized pipe, and polyvinyl chloride pipe, shall
be identified by colour code to show its function. Painted surfaces shall be colour
coded in accordance with the coding schedule and adhesively applied colour bands of
an approved tape type shall be used on plastic and any other pipe not readily
suspectible to painted finish. Piping which is not painted shall be provided with 30 cm
wide colour bands every 3m and each change of direction. Labels and arrows
showing direction of flow shall be installed on all piping every 3m and at each change
of direction. Colours and labels shall conform to the following schedule or as selected
by the Engineer where not shown or otherwise required by applicable codes and
regulations.

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 PROCESS PIPING COLOUR CODE SCHEDULE

Item Colour Label

Vacuum System Orange VS

Process Air Green AA
Foul Air Green with Red Bands FA
Sewage Grey Sewage
Potable Water Light Blue PW
Drains Dark Blue Drain

12.5.3 General Coating Systems

The following list shall indicate the coating system. For this coating system "Piping"
shall be defined as all pipe, valves, fittings, supports, operating stems and guides.
Mechanical equipment shall include all drives, motor control panels, and all other
electrical equipment shall be selected by the Engineer. Architectural coating systems
are specified on the plans.

COATING SYSTEM SCHEDULE

Item System Colour

A. Manholes

All interior concrete surfaces E Black

G. Miscellaneous

All miscellaneous interior exposed

metal surfaces B *

All miscellaneous exterior exposed

metal surfaces A *

All submerged metal surfaces C Black

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* Colour per pipe colour code schedule or as selected by the Engineer

12-8
 SECTION 14
BRICK LAYING AND PLASTERING WORKS

14.1 BRICKS

All bricks shall be clay bricks obtained from an approved kiln and shall be of standard
size, hard, sound, well burnt and free from active lime giving a clear ring when struck
to and to BS 3921. No soft, broken, twisted or otherwise defective bricks shall be
allowed to be used.

No brick shall absorb more than 15% of its own weight when soaked in water for 24
hours. Testing of bricks shall be in accordance with BS 3921. Bricks shall be
unloaded by hand and stacked on a clean hard surface.

14.2 CEMENT MORTAR

Cement, sand and water shall as specified under the Section 9. Mortar for brickwork
in general shall be composed of 1:3 cement and sand unless otherwise specified on
the drawings or directed by the Engineer.

14.3 BRICKWORK

A. Build all walls, piers, etc. in English bond when the thickness is 215mm or more
and in stretcher bond where the thickness of wall is 102.5mm. Sufficient bricks
for one day's work shall be well soaked in water before being laid and the
Contractor shall provide sufficient containers and water for this purpose. Bricks
shall be protected from direct sunlight by damp gunny sacks for at least 2 days
after being laid.

B. Mortar Joints shall not exceed 9.5mm in thickness. Vertical Joints of alternative
courses shall be directly above one another. Bricks shall be properly bedded in
mortar and surplus mortar struck off flush. Exposed joints on walls for rendering
shall be raked out to a depth of 12.5mm as the work proceeds, to form a key.

C. Brickwork shall be accurately set out and built true to line and face with vertical
surfaces truely plumb and horizontal joints truely level. Intersections, angles,
plasters and piers shall be properly bonded. Broken bricks may be used only to
obtain bond.

D. No brickwork shall be carried up more than 900mm above adjacent work. No

overhead work will be permitted and scaffolding shall be carried up as the work
proceeds. The use of scaffolding with putlog ends built into the brickwork will not
be permitted.

E. Build all half brickwalls in stretcher bond, reinforced at every fourth course with
approved brick reinforcement similar to "Exmet", commencing at two courses
above base of the wall.

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14.4 CRAMPS

Provide and fix wrought iron cramps 38mm x 12.5mm x 300mm long at the rate of 2
cramps per window jamb and 3 cramps per door jamb. The projecting end shall be
bent down to fit over the end of the brick and the other end bent up and screwed to
jamb. Cramps shall be coated with bitumen and built in as the work proceeds.

14.5 CUTTING, ETC.

Perform cuttings, straight or circular, rough and fair, firm all sinkings, setbacks and
projections, cut or leave chases for edges, flashings, etc., cut and leave holes through
walls and slabs for passage of pipes, wiring etc., built in fittings and fixtures and do
everything else necessary for the proper completion of the brickwork.

14.6 DAMP PROOF COURSE

A. Provide and lay under all brickwalls at ground level or within 150mm above
ground level damp proof course (to the full width of the wall or more as directed
to form "Bell-Cast") composed of "Pulvex" or other equal and approved hessian-
based bituminous D.P.C. complying with BS743 and weighing not less than 3.8
kg. per square metre. It shall be lapped 150mm at joints and laid on a 19mm
thick cement/sand mortar (1:3) bed coated with bitumen or as specified.

B. In all cases of doubt the Contractor must enquire the exact location of the damp
proof courses and if he neglects to do so he will be held responsible for
amending, if required, their positions.

14.7 ROOF AND FLOOR SCREEDS

Roofing screeds and screeds for floors and channels shall be formed with 1:3
cement-sand mortar finished neatly to the fall and dimensions shown on the
Drawings.

The mixing shall be as specified for concrete with the water content just sufficient to
produce a dense mortar or adequate workability.

Before commencing to roof screed, the roof surface shall be thoroughly roughened by
picking or wire brushed to expose a fresh surface and cleaned. The concrete shall
then be soaked with water over-night, after which the excess water shall be removed.
A thin layer of cement grout shall, just before the screed is laid, be well brushed into
the roughened surface. The screeding shall be kept damp for a period of seven days
after laying.

14.8 CEMENT RENDERING

A. Render all concrete floors, steps, aprons and drains in cement sand mortar of
1:3 mix or as specified, to a thickness of 19mm laid to falls as shown or directed.
Rendering shall be applied while base concrete is green. The base concrete
shall be thoroughly brushed clean and wetted before mortar is applied.

B. Set out rendering in panels not exceeding 10 sq.m. separated with 13mm
limewashed timber fillets which shall be withdrawn on completion and the space
filled with 1:3 cement mortar. Dusting with neat cement will not be permitted.

14-2
 C. Form 19mm thick skirting 150mm high with 38mm radius core at bottom against
all rendered surfaces. Skirting shall finish flush with wall rendering and shall
meet it in a neat "V" joint.

D. All wall surfaces to be rendered shall be cleaned and well damped before
rendering is applied and where necessary raked to form a key. Carry all
rendering into reveals, setbacks, etc. and form all finished edges, arises and
internal angles neatly and accurately.

E. Render all walls in cement sand mix of 1:3 or as specified, applied in two coats
to a final thickness of 19mm. Steel trowelled to a smooth even surface.

14.9 PLASTERING

Mortar for plastering to soffits, beams, etc. shall be composed of one part of cement
to six parts of sand or as specified with the addition of an approved mortar plasticiser
and used strictly in two coats to a total thickness of 19mm.

14-3