PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

CONSTRUCTION OF BUILDINGS, HOUSING AND SEWERAGE SYSTEMS

PTS 20.105 DECEMBER 1988

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use PTS rests with three categories of users : 1) 2) 3) PETRONAS and its affiliates. Other parties who are authorised to use PTS subject to appropriate contractual arrangements. Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.

CONTENTS 1. 2. 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 SCOPE CODES OF PRACTICE AND STANDARDS CONSTRUCTION REQUIREMENTS AND SPECIFICATIONS Excavation Piling Concrete Work Structural Steelwork Brickwork Roofing Carpentry, Joinery and Ironmongery Metalwork Ceiling Plastering and Tiling Paving Glazing Plumbing and Sanitary Fittings Painting and Decorations Sewerage Gas Installation Electrical

REVISION REGISTER Revision No. 1 2 Date 11/83 12/88 Details of Revision First issue. Second revision

1.

SCOPE This specification gives the minimum general requirements for the construction of all onshore buildings in reinforced concrete, steel, brick and timber. This specification does not cover the construction using prestressed concrete, fibre-reinforced concrete and reinforced earth.

2.

CODES OF PRACTICES AND STANDARDS The following Codes and Standard are referred to in this specification. The latest editions of which shall be used. A. PETRONAS Technical Specifications 1. PTS 34.28.00.31. 2. PTS 34.19.20.31. 3. PTS 40.48.00.30. Steel Structures Reinforced Concrete Foundations and Structures Paints and Paint Materials Nov., 1981

4. Technical Specs B-1-1 New Buildings B. BRITISH STANDARD 1. B.S.449 2. B.S.1881 3. B.S.12 4. B.S.812 5. B.S.882, 1983 6. B.S.4449, 1978 7. B.S.4483, 1985 8. B.S.4360, 1986 9. B.S.5950 10. B.S.5135 11. BS 4190 12. BS 1769 13. BS 3139 BS 3294 BS 4395 BS 4604 14. BS 8110 15. BS 8301, 1985 16. BSCP 331 17. BS 8004 18. BS 8005 19. BSCP 112 20. BS 1377 The use of Structural Steel in Building Methods of Testing Concrete Portland Cement, 1978 Testing Aggregates Specification for aggregates from natural sources. Hot rolled steel bars for the reinforcement of concrete. Steel fabric for the reinforcement of concrete Weldable Structural Steel Structural use of Steelwork in Building Specifications for Arc Manganese Steels. Welding of Carbon and Carbon

Black bolts, screws and nuts. Black bolts, screws and nuts (heavy series). High strength friction grip bolts for use in structural steel. High strength friction grip bolts for use in structural steel. High strength friction grip bolts for use in structural steel. High strength friction grip bolts for use in structural steel. The Structural use of Concrete. Code of Practice for Building Drainage. Installation of pipes and meters for town gas. Code of Practice for Foundations. Sewerage The Structural Use of timber. Methods of Test for Soils for Civil Engineering Purposes.

C.

Malaysian Standards and Bylaws 1. M.S. 544 The Structural Use of timber 1978.

2. Uniform Building Bylaws, 1984. 3. Drainage, Sanitation and Sanitary Plumbing Bylaws, 1974. The use of asbestos construction materials has been discontinued. Any reference made in the above codes of Practices and Standards pertaining to any construction materials made, in whole or in part, of asbestos and its recommended uses shall be deemed to be deleted.

3. 3.1 3.1.1

CONSTRUCTION REQUIREMENTS AND SPECIFICATIONS Excavation Nature of Excavation The Contractor shall be allowed access to any soil reports available but any information given in such reports shall be given without prejudice. The Contractor must satisfy himself as to the nature of the ground to be excavated. Prices for excavations shall include for excavating in whatever type of soil as encountered except rock unless specifically stated otherwise. Before commencing the works, the Contractor shall ascertain the location and nature of all existing underground services and having obtained the C.S.R.s permission to proceed shall then take every possible precaution against any damage occurring to them, and/or interference therewith, during the execution of the works.

3.1.2

Excavation The whole of the excavation shall be carried out to the widths, lengths and depths as described or directed. Should the Contractor excavate to a greater depth or width than shown on the drawings or instructed by the C.S.R. he shall, at his own expense, fill in such greater depth or width of excavation with concrete as described for foundations. No more ground shall be removed than is absolutely necessary and if loose, soft or bad ground is encountered, the matter shall be reported at once to the C.S.R., and his instructions sought. If in the Opinion of the C.S.R additional excavation is necessary a written instruction will be issued and the Contractor shall carry out such additional work and will be paid an extra in accordance with the Schedule of Rates.

3.1.3

De-watering Excavation All excavations shall at all times be kept free from water and mud by pumping and bailing as required. De-watering of excavations for foundations may be carried out by well-pointing at the Contractors cost.

3.1.4

Precautionary and Remedial Measures The Contractor shall take all necessary precautions so as not to damage or endanger any property, structures, roads, installations or services in the vicinity of his operations. The Contractor shall immediately report to the C.S.R. should their operations cause damage or endanger any such property structures, roads, installation or services and shall take such remedial measures to the satisfaction of the C.S.R.

The Contractor shall provide and place all shoring, sheeting, planking, sheet piling and shuttering and any other materials necessary to secure and maintain the sides of the excavation, adjacent buildings or services until ready for backfill or deposition of concrete and shall remove the same on completion. Where any slips or falls of trench and pit sides should occur, the Contractor shall remove all loosened and disturbed material and replace the same at his own expense with properly compacted fill material or with concrete as the C.S.R. may require. The Contractor shall provide all necessary boards or coverings and lay same to protect the trenches or excavations from the effect of inclement weather if so required by the C.S.R. The Contractor shall make all necessary and adequate measures to prevent water from the sites of his operations from causing a nuisance on or in any adjacent contract sites and neighbouring property either by causing flooding or by depositing sediment on the ground surface or in drains or natural watercourses. The Contractor shall construct wherever necessary temporary drainage channels, contour drains, silt traps or other siltation prevention structures. The Contractor shall remove all sediment which may accumulate on any land or in any drains or natural water courses as a result of his operations. The Contractor shall take all necessary precautions to minimise the loss of materials by erosion and to prevent displacement of the ground in slopes adjacent to his operations. The Contractor shall limit all working faces to such heights and slopes as are stable and provide any necessary timbering as required. The Contractor shall construct the drainage works as indicated on drawings or as instructed by the C.S.R. and temporary drainage works at the earliest practical date and preferably before the execution of and displacement of ground nonetheless occur, the Contractor shall make good the same and the effects thereof with such materials and in such manner as the C.S.R. may direct at his own cost.

3.1.5

Disposal of Excavated Material All excavated materials except the materials the C.S.R. considers suitable for use as fill materials shall be removed off the site to a tip to be provided by the Contractor at his own expense. The Contractor shall take all measures to ensure that excavated material is not allowed to fall or be tipped over any hill slopes. The Contractor shall be responsible for any slope failures due to his own negligence in this respect and pay for the cost at his own expense for any remedial measures required. The excavated material considered by the C.S.R. to be suitable for use as fill material shall be loaded, transported, spread and compacted in areas where filling is required. The Contractor shall load, transport, unload, spread, level and compact all surplus excavated material at Contractors own tips.

3.1.6

Top Soil All top soil shall be excavated separately to such depth as directed by the C.S.R. not exceeding 225 mm deep and shall be left in separate spoil heaps where directed for reuse in turfing. The Contractor shall take all precautions necessary to prevent the top soil being removed from the site and shall ensure that the top soil is adequately protected in the spoil heaps against erosion and deterioration from the weather. The C.S.R. reserves the right to object to the use of this topsoil if found unsuitable. The Contractor shall make his own arrangements to import any shortfall of topsoil required for turfing work.

3.1.7

Excavation to receive Foundations The Contractor shall report to the C.S.R. when excavations are ready to receive concrete foundations and shall not proceed with concreting until they have been checked and approved. Any concrete or other work put in before this has been done shall be removed if so required by the C.S.R. Excavation which is to be followed immediately by placing of blinding layer may be taken down to the formation levels shown on the drawings. Any excavation which will not be completed and immediately followed by the placing of blinding layer shall be taken down not lower than 150mm above the formation levels. Where excavation is for reinforced concrete work the formation shall first receive a 50mm thick blinding layer of 1:3:6 concrete before the reinforced concrete work is placed.

3.1.8

Removal of Soft Areas or Unsuitable Material In cutting, where directed and authorised in writing by the C.S.R. soft, wet or unstable areas of depths, exceeding 150 mm below the base formation of concrete structures which exist or develop during construction, shall be excavated and replaced with approved stable material in layers not exceeding 150 mm loose thickness, compacted as hereinafter specified.

3.1.9

Backfilling The Contractor shall not fill in over any work until it has been approved by the C.S.R. The fill shall then be brought back from the place where it was temporarily deposited and the trenches or excavations which require backfilling shall be filled up to the required level in layers of not more than 150mm in loose thickness. Each layer shall be carefully and thoroughly rammed and compacted by approved power driven mechanical tamper or power roller and shall be further consolidated by the addition of water. All refilling to raise level of site shall be done in similar layers with approved fill materials rammed and consolidated in like manner. Filling over and around pipes, culverts and other structures shall be placed in such a manner that will avoid unbalanced loading and that will not cause movement or place undue strain on any structure. Formation in cut section when completed to the line, level and cross-fall of the planned formation, shall be scarified up to a depth of 150mm and compacted to 95% of the maximum dry density as determined by B.S. Heavy Compaction Tests. (BS 1377) Construction equipment and traffic shall not be allowed on the fill while it is in a wet condition. Material which has become excessively wet shall be dried or removed from the site and replaced by material of suitable moisture content for compaction at the Contractors expense. At locations where it would be impractical to use mobile power compacting equipment, filling shall be compacted to the specified requirements by any approved method that will obtain the specified compaction.

3.1.10 Compaction Tests Compaction Tests shall be carried out by the C.S.R. or officials from the Public Works Department. The Contractor shall provide all assistance and labour required to assist the officials carrying out the test at his own cost.

3.1.11 Hard Core Hard core where specified to be used shall consists of cement concrete, stone rubble or such other hard material broken to a 75 mm gauge subject to C.S.R.s approval. Where hard core is specified under slabs or other concrete it shall be broken to pass a 150 mm diameter ring, spread over the prepared ground or filling, well consolidated, and levelled off. Under no circumstances shall lime concrete be allowed as hard core. Blind surfaces of hardcore beds which are to receive concrete with sand, or other approved fine materials. 3.1.12 Damp Proof Membrane A damp proof membrane shall be laid under all ground floor concrete slabs, unless specifically stated otherwise. It shall be a 0.25 mm thick approved polythene sheet and shall be laid with 150 mm laps and turned up 150mm at abutments with walls etc. Great care is to be exercised to avoid tearing or puncturing the membrane and it shall be fixed firmly in position before the concrete is laid.

3.2 3.2.1

Piling General Piling shall conform in all respects with the principles contained in British Standard Code of Practice No. 8004 Foundations issued by the Institution of Civil Engineers, London and PTS 34.18.02.31 - Piling by PETRONAS. In addition to submitting the records required under Clause 3.2.2.8 the Contractor shall report immediately to the C.S.R. any circumstance which indicates that the ground conditions differ from those expected by the Contractor from his interpretation of the Soil Survey so as to affect materially the bearing capacity of the pile. The type of pile to be used at any particular structure shall be as indicated on the Drawings. The lengths of piles indicated on the Drawings are based on information obtained from the precontract Soil Survey. The Contractors attention is however drawn to the fact, that suitable founding strata may be encountered at depths which require the actual installation of different lengths of pile which give rise to considerable variation within any particular site or pile groups. No extra costs will be admitted on the grounds of any such difference or variation in lengths. At each structure site where piling is to be installed, the C.S.R. may select for testing one or more working piles which the Contractor shall construct or drive in advance of the remaining piles at the Site. Piles selected for this purpose shall be constructed or driven with the same equipment as proposed for the main piling work, to the depths required by the C.S.R. The remaining piling at the site shall not proceed until the testing of the advance piles has been completed to the satisfaction of the C.S.R., and meets the requirements of acceptance quoted in Clause 3.2.2.7. The C.S.R. may also instruct the testing of further piles during the course of the works. All pile testing shall be carried out in accordance with Clause 3.2.2.7 of this specification. In the case of driven piles the C.S.R. will direct the lengths of piles to be manufactured and pitched after the testing of test piles. He will also direct the lengths of any necessary extension of piles. Each pile shall be placed within 76 mm of its correct position and shall be within 1 in 80 of its correct rake as shown on the Drawings. Piles which have not been positioned within these limits shall not be corrected by forcible means and any remedial measures taken shall be subject to the approval of the C.S.R. The cost of such remedial measures and of the repair or replacement of any pile which may have been condemned by the C.S.R. owing to damage, inferior quality or excessive deflections, shall be borne by the Contractor, including the cost of any addition to the pile cap necessitated by the replacement unless the Contractor can prove that the damage or deflection of the condemned pile was caused by circumstances beyond his control.

Piling work shall be carried out under the direction of a competent supervisor experienced in the particular system of piling to be used. He shall be employed full time for the duration of the piling operations and his appointment shall be subject to the approval, in writing, of the C.S.R. before the commencement of piling work.

3.2.2

Precast Concrete Piles

3.2.2.1 General The manufacture, storage and handling of reinforced concrete piles shall comply in all respects with Section 3.3, Concrete Work of this Specification, with the following amplifications:(i) (ii) (iii) Piles shall be supported, handled and pitched so as to avoid damage. Where piles have to be stored they shall be placed on sufficient supports on firm ground to avoid damage by excessive bending. Each pile shall be marked indelibly to show its identification number, length and date of casting.

3.2.2.2 Pile Shoes Shoe bases where required shall be cast iron of clean grey tough metal free from sand, honeycombing or porous places, air holes or other defects. Straps shall be of mild steel or wrought iron cast into the base and shall run continuously through it. All shoes shall be fitted to the reinforcement as shown on the Drawings. 3.2.2.3 Driving Piles shall not be driven until at least 21 days after casting unless agreed by the C.S.R. The C.S.R. shall be notified 24 hours before the commencement of driving. Piles shall be driven with an approved hammer and in a sequence of driving approved by the C.S.R to a set as shown on the Drawing or to the depths instructed by the C.S.R. The C.S.R. shall be informed at least 1 hour before the set is taken. Piles shall not be left partially driven. Followers will not be permitted where piles are driven beyond the bottom lead, without the written approval of the C.S.R. Raking pile shall be driven with leads capable of adjustment to the required angle of rake. 3.2.2.4 Risen Piles Piles which have risen as a result of driving adjacent piles shall be re-driven to the requirements of the C.S.R. 3.2.2.5 Extension of Piles Basic and extension piles shall be cased with angles and plates as shown on the drawings and where piles are required to be extended the extension pile shall be jointed to the basic pile by welding the external angles as shown on the drawings. The quality of materials and workmanship in extension piles shall be as specified in relevant clauses. Any welding shall be carried out in the presence of the C.S.R. and the workmanship shall conform to the requirements of BS 5135: 1984. Driving shall not be resumed after lengthening until:(i) and (ii) the approval of the C.S.R. has been obtained. the cube strength of the concrete in the extension pile is at least equal to the specified 28 days cube strength of the concrete in the pile,

3.2.2.6 Stripping of Pile Heads After the piles have been driven to the required set or depth, the piles shall be cut off when instructed by the C.S.R., at a level 760 mm above the underside of the pile cap and the surplus length removed from Site. The length within the pile cap shall be carefully stripped of concrete to expose the reinforcement for incorporation in the cap. 3.2.2.7 Pile Tests Piles selected by the C.S.R. shall be tested by the Contractor as follows :(i) The test load shall be applied by a jack by a method approved by the C.S.R. and shall be measured within an accuracy of 2 percent. Settlement and recovery shall be measured within an accuracy of 0.25 mm. from a datum that will not itself be affected by any movement of the ground due to the test loading or other causes. The C.S.R. may require independent checks on the level of the datum by an accurate levelling instrument. The jack shall be properly calibrated by an approved testing station and the appropriate certificate produced before any tests commence. The measuring equipment and supports employed shall be adequately protected from the sun and weather elements and the readings of the air temperature shall be made and recorded at the same time as those on the gauges of the several measuring instruments used. Application of Test Load The test shall be carried out by the equal load increment method up to a test load equal to twice the working load, each increment of load being 12% of the test load. Settlement readings shall be taken immediately before and after each increment of load, and thereafter at intervals of two, four, eight, fifteen and thirty minutes and subsequently at hourly intervals. No additional load shall be applied until average dial gauge readings do not vary by more than 0.127 mm in an hour. When the load has reached the specified value of test load as stated in the drawings, it shall be maintained for a period of twenty-four (24) hours or such longer period as the C.S.R. may decide. Taking of settlement readings at hourly intervals shall be continued within the period. The test load shall be released in stages to seventy five, fifty, twenty five and ten percent of its value and then removed. Settlement reading shall be taken as when the loads are applied. Each reduction of load shall be carried out an intervals not less than one (1) hour and until recovery is less than 0.127 mm/hour. The final recovery twenty-four (24) hours after complete release of the load shall be measured. (iv) Supervision The Contractor shall provide an experienced supervisor to be present full time for the duration of the pile tests to ensure that the loading sequences and method of taking settlement readings are strictly followed and that true load is maintained at all times. Pile tests shall be carried out only in the presence of the C.S.R. (v) Abandonment of Pile Tests Should any tent have to be discontinued due to:(1) (2) (3) (4) (5) Faulty jack or gauge, Instability of kentledge, Improper setting of datum, Unstable bench marks or scales, and re-jacking or pre-loading before commencement of the test,

(ii)

(iii)

the Contractor shall entirely at his own expense carry out further tests to the C.S.R.s instructions. The cost of the abandoned test shall be borne by the Contractor.

(vi)

Failure of Piles A pile shall be deemed to have failed if any of the following occurs: (1) The maximum settlement under the full test load exceeds 6mm, (2) The permanent settlement exceeds 2.5mm after removal of the test load, and (3) Inability to complete a test load due to failure of the pile cap through whatever cause. Any piles which fail under test loading shall be replaced as directed by the C.S.R. at the Contractors expense. The Contractor shall bear the cost of the test that failed and in addition, shall entirely at his own expense carry out two further tests to the C.S.R.s instructions.

(vii)

Submission of Pile Test Record The Contractor shall, within 24 hours of the completion of the tests, submit to the C.S.R. for each pile tested a detailed record of testing and, in addition, graphs prepared to suitable scale, showing :(a) Load and settlement plotted above and below a common base line of time; (b) Settlement and recovery plotted vertically against a base line of load.

3.2.2.8 Pile Records 1) A record of all piles driven or installed shall be kept by the Contractor and a copy of the record of the work done each day shall be given to the C.S.R. within 24 hours. 2) The record shall consist of all relevant information as required by the C.S.R. 3) When instructed by the C.S.R. the Contractor shall record the number of the blows for each foot of penetration of the advance piles and submit this information on graphs. 4) On completion of the piling, the Contractor shall deliver to the C.S.R. a drawing recording the final depths of all piles relative to datum level.

3.2.3

Timber Piles a) General All piles shall be straight and sound, free from splits and shakes, knots of sufficient size to weaken the pile and insect or fungus attack. The piles shall be supplied in the minimum lengths and to the sizes stated. Timber piles shall either be Bakau piles where the water table is above cut off level or treated hardwood piles - Hicksons Tanapile, GL Piles or equivalent. b) Bakau Piling Bakau piles shall be Bakau Timber freshly cut and free from loose bark. They shall have a minimum girth of 89 mm and shall be supplied in 6 m lengths. Bakau piles shall be capable of carrying safe working loads of 1.27 tonnes and shall be driven using hammers and to sets which are to be approved by the C.S.R. Where it becomes necessary to splice or lengthen a pile, the ends of the pile and the extension shall be trimmed to form a well fitting butt joint and shall be joined to each other by means of a galvanised iron sleeve approved by the C.S.R.

3.2.4

Treated Hardwood Piles Treated hardwood piles shall be hardwood timber of grade equivalent to Standard Structural Grade specified under Section J. Stress Grading, Special Marketing Specification of the Malaysian Grading Rules for Sawn Hardwood Timber (1968 Edition) or equivalent. All piles shall be pressure treated with copper - chrome - arsenate wood preservative in accordance with B.S. 4072:1966 to the following requirements :(i) (ii)
2 all piles shall be pressure impregnated at a pressure of not less than 1.4N/mm with 3 copper - chrome - arsenate to an average dry salt retention of 24.1 kg/m .

the minimum penetration shall be 25 mm on the heartwood face.

Anti-splitting plates of a minimum of 18 gauge shall be fixed at both ends of the pile. Piles shall be supplied in lengths of 6 m and shall be driven to set approved by the C.S.R. in accordance with the specified safe working load. Piles shall be extended using Standard Pile Sleeve Details as recommended by the suppliers. Piles shall be cut off at levels as shown on the Drawings or as directed by the C.S.R. The cut off pile head should be given two flood coats of Hicksons Special Tanapile Ensele or equivalent, allowing each application to soak into the end grain completely. Approximately one hour should be allowed between each application. After the Ensele application has dried, the pile head should be heavily coated with Shell Flintcoat or equivalent for the whole depth that the pile will be encased in the pile cap.

3.3 3.3.1

Conrete Work General This specification covers the concrete for all reinforced concrete construction except prestressed concrete. All concrete mix shall contain Ordinary Portland Cement, fine and coarse aggregates from natural sources and water to comply with requirements of 3.3.2. This specification is based mainly on the approach taken in CP110. All concrete work shall be carried out in strict accordance with this specification, the detailed drawings and the C.S.R.s instructions.

3.3.2

Constituent Materials of Concrete

3.3.2.1 Cement All cement used shall be Ordinary Portland cement of approved manufacture to comply with B.S. 12. Cement shall be delivered on the site in sound, strong, bituminous lined paper bags, or other containers which shall be plainly marked with brand and name of the manufacturers and shall be accompanied by the manufacturers test certificates which shall be handed to the C.S.R. The cement on arrival on the site shall be stored in a suitable building approved by, the C.S.R. This building shall have a wooden floor or platform raised 300 mm from the ground on wooden runners on which the cement bags may rest clear of the ground. Each consignment of cement shall be inspected immediately on arrival on site, or as soon as practicable afterwards, specifically to determine any damage which may have occurred due to excess moisture penetrating the containers. Any cement containing lumps or other evidence of such damage shall be rejected immediately and if the C.S.R. considers that the proportion of

containers found to be damaged is dangerously high, he shall be entitled to reject the entire consignment. Each consignment of cement on the site shall be kept separate and plainly marked with An approved identification mark, and shall be used in the works in the order in which it was delivered to the site. The failure of any cement of a consignment shall entitle the C.S.R. to reject the entire consignment and to prohibit the use on the work of any further consignment of the same brand. Rejected cement shall immediately be removed from the site at the Contractors cost. Any delay caused by the rejection of cement shall be the Contractors sole responsibility. 3.3.2.2 Fine Aggregate Fine aggregate or sand to be used in concrete, plaster, screed and tiling shall comply with the requirements of B.S. 882 when tested according to B.S. 812. It shall be clean, sharp, tough and uniformly graded down from coarse particles not exceeding 5 mm in diameter, and shall be free from salt, mica, dirt, loam and (organic matter and shall contain not more than 3% by weight of clay, silt and fine dust when tested by the decantation method given in B.S. 812. The use of natural sand from local beaches will not be permitted. If the C.S.R. so directs, the sand shall be washed with clean water and/or screened before use to comply with the foregoing standards and requirements. Broken stone screenings graded to B.S. 882 Grading Zone 2 may be accepted by the C.S.R. as sand, provided that, in his opinion they otherwise comply with the aforegoing clause describing the sand to be used in concrete. 3.3.2.3 Coarse Aggregate Aggregate shall be crushed stone or gravel complying with B.S. 882 obtained from approved quarries crushed so that all of it shall pass, in the case of stone for plain concrete through a 38 mm diameter ring, in the case of stone for reinforced concrete, through a 19 mm diameter ring and in the case of precast concrete through a l0 mm diameter ring and so that none shall pass through a sieve having holes of 5 mm diameter. Within these limits the particles shall be evenly graded in accordance with B.S. 882. The coarse aggregate shall be clean, not flaky, hard, durable, angular and free from clay film, mica, shale and other organic impurities and shall, if the C.S.R. so directs, be washed before use. On no account shall any aggregate contain any iron pyrites and soluble sulphate salts. 3.3.2.4 Water The water used for mixing and curing shall be clean and free from harmful matter, particularly organic or chemical substances. The water used shall comply with B.S. 3148. 3.3.2.5 Admixture No admixture shall be used in concrete mixes unless it was specified otherwise or approved by the C.S.R. By no means the admixture shall contain chloride. 3.3.2.6 Samples At least two weeks before the delivery of materials to the site, the Contractor shall submit for the approval of the C.S.R. samples of the fine and coarse aggregates that the Contractor proposes to use on the work and shall state the source of each. No material shall be delivered until the C.S.R. has approved the samples, and the materials as delivered shall be equal in all respects to the approved samples.

3.3.2.7 Storage of Aggregate The fine and coarse aggregates shall be stored on clean, hard surfaces at the site separately so as to prevent any contamination and admixture with foreign materials. Any materials which have been damaged, contaminated or have deteriorated or do not comply with all the requirements of this Specification shall be rejected and shall be removed immediately from the site at the Contractors own cost.

3.3.3

Requirements of Fresh Concrete The workability of the fresh concrete should be such that the concrete is suitable for the conditions of handling and placing so that after compaction it surrounds all reinforcement, tendons and ducts and completely fills the formwork. Workability should be assessed by means of the slump test, compacting factor test or VB consistometer test as appropriate in accordance with B.S. 1881. The Contractor shall provide all necessary apparatus, tools and skilled labour for at least one of the above tests at his own cost at any time as requested by C.S.R., preferably the slump test. Concrete which has been allowed to attain its initial set before placing or tamping shall be removed from the work and shall on no account be used in the work.

3.3.4

Requirements of Hardened Concrete The minimum requirements of the hardened concrete are the characteristic strength, the density and durability of the concrete. Concrete to be used whatsoever specified, shown on the drawings or directed by the C.S.R. shall have the characteristic strengths shown in Table 1. It shall be recognised that in all cases the proportions shown in Table 2 are purely nominal and the criteria shall be density, workability and exhibiting the required crushing/characteristic strengths, and the C.S.R. shall be empowered to vary the nominal proportions as necessary. The Contractor shall be responsible for ensuring that the resulting structure is durable and watertight. If during the period of maintenance, the structure shall prove to be faulty, it is the responsibility of the Contractor to adopt whatever steps are deemed necessary by the C.S.R. to make it right and acceptable. The characteristic strength of concrete is that determined from 150 mm test cubes at 28 days.

3.3.5

Grades of Concrete Table 1 Grades of Concrete

Grade 20 25 30

Characteristic Strength, N/mm 20.0 25.0 30.0

The grades of concrete is defined by a number which represents the characteristics strength of concrete (in N/mm) based on cube tests at 28 days.

3.3.6

Prescribed Mixes for Ordinary Structural Concrete Concrete Mixes are specified to have proportions of the constituents by weights. The mix proportions for the various grades of concrete are given in Table 2. Table 2 : Prescribed Mixes Based on a bag of cement (nominal 50 kg)

Max. Size of Aggregate Grade Workability Medium Slump (mm) 10 20 Total Aggregate Fine content Total Aggregate Sand Zone 1 Zone 2 Zone 3 Total Aggregate Sand Zone 1 Zone 2 Zone 3 Total Aggregate Sand Zone 1 Zone 2 Zone 3 (kg) (%) (kg) (%) 25 75 385 35 50 280 40 35 30 (kg) (%) 245 40 35 30 (kg) (%) 210 40 35 30 20 mm High 75 125 345 35 50 245 45 40 35 215 45 40 35 190 45 40 35

25

30

3.3.7

Trial Mixes Trial mixes shall be prepared by the Contractor for each grade of concrete used in the work at his own cost before any concreting work commence. Where trial mixes are required, three separate batches of each grade of concrete should be made using materials likely to be typical of the proposed supply and preferably under full scale production conditions and under the supervision of the C.S.R. If circumstances make this inconvenient, the batches may be mixed in a laboratory unless this is specifically precluded by the C.S.R. All sampling and testing shall be in accordance with B.S. 1881.

3.3.8

Testing of Concrete The concrete cubes when set shall be marked with the date and at identification number. A record shall be kept of the consignment of cement from which the cubes are made and of the particulars of the aggregate, the water/cement ratio and the slump of the concrete. Six preliminary test cubes of each batch of trial mixes shall be made for each grade of concrete used in the Works. Three of the cubes shall be tested to destruction at 7 days and three at 28 days, or such other periods as the C.S.R. shall direct. No concreting shall be permitted until the average strength of the nine cubes tested at 28 days is at least equal to the figure shown in the column headed Preliminary Test of Table 3.

Table 3 : Crushing Strength of Concrete Cubes

Grade of Concrete Age : 10 20 25

Crushing Strength of Cube, in N/mm Preliminary Test 7 days 11.2 21.0 24.3 28 days 16.7 31.5 36.5 7 days 10.0 13.5 16.5 Work Test 28 days 16.7 20.0 25.0

In addition to the preliminary crushing tests the C.S.R. may direct that further tests be made during the progress of the works on cubes made from the concrete about to be place in the Works. In addition to the record required above a record shall be kept of the section of the Works represented by each cube. All sampling of materials, making concrete cubes and testing of hardened concrete cubes shall only be done at the presence of C.S.R. by the Contractors authorised Supervisor(s) in strict accordance with B.S. 1881.

3.3.9

Production of Concrete

3.3.9.1 General The Contractor shall employ supervision such as to ensure the required standard of control over materials and workmanship. The C.S.R. shall be afforded all reasonable opportunity and access to inspect the materials and the production of concrete and to take any samples or to make any tests. 3.3.9.2 Batching and Mixing The quantity of cement, the quantity of fine aggregate and the quantities of the various sizes of coarse aggregate should be measured by weight except that aggregates may be measured by volume in concrete of Grade 10. Batch weighing machines shall be installed of such a design as will ensure that the precise weights of cement, fine and coarse aggregates appropriate to the mix is discharged into the mixer. However, the cement may alternatively be measured by using a whole number of bags in each batch. The batch weights of aggregate should be adjusted to allow for a moisture content typical of the aggregates being used. The mixing time should be not less than that used by the manufacturer in assessing the mixer performance, and in no case shall the time of mixing be less than 2 minutes. 3.3.9.3 Water - Cement Ratio The amount of water to be added to each batch of concrete shall be the minimum necessary to give sufficient workability for full compaction of the concrete and be subjected to the approval of the C.S.R. In no case shall the water-cement ratio exceed 0.55 unless specifically authorised or specified otherwise. The C.S.R. is empowered to reject any batch of concrete if the mix does not comply with this clause. 3.3.9.4 Transporting Concrete Concrete shall be conveyed from the mixer to its place in the works as rapidly as possible by methods which will prevent segregation and contamination with water or any other materials.

Concrete shall be placed before initial set has occurred and in no case later than 30 minutes after the addition of water to the mix. 3.3.9.5 Batching by Volumetric Measurement No measurement of cement, sand and coarse aggregate by volume shall be allowed unless specifically authorised and approved by the C.S.R. Only for relatively small and structurally unimportant parts of the works where only small quantities of concrete (less than 10 cubic metres of wet concrete mix) are required, the fine and coarse aggregate may be measured by volume in proportion to full bag of cement (50 kg), which is subject to C.S.R.s approval. The aggregates shall not be packed more closely than by throwing in the usual way into the measuring boxes. Due allowance shall be made for bulking if the aggregates are wet. No other device shall be used for volumetric measurement other than properly constructed measuring box. 3.3.9.6 Mixing of Concrete by Hand Hand mixing of concrete shall not be permitted.

3.3.10 Placing Concrete Concrete shall be placed only in the presence of the C.S.R. and then only after the reinforcement and the cleanliness and adequacy of the formwork has been checked and approved by him. No concreting will be allowed during storms, floods, or heavy rains, and where there is water inside the formwork for underground concrete work. Before concreting all shavings and other debris shall be carefully removed and the formwork well watered. Formwork may be treated with an approved non-staining releasing agent before concreting to prevent the concrete adhering but care must be taken to prevent the releasing agent coming in contact with reinforcement. Concrete shall be placed gently and not tipped or dropped from a height. It shall then be thoroughly rammed and/or vibrated so as to fill the forms and surround the reinforcement without displacing it and without the formation of voids or cavities, but shall not be over-vibrated such that the concrete segregates. No reinforcement which is to be left protruding from concrete shall be subjected to shaking after concreting. During one week after placing, concrete shall be protected from damage by sun and rain and from mechanical injury. All surfaces shall be kept continually wet and shall be protected from the direct rays of the sun by wet sacks, a layer of wet sand or other approved method for at least seven days. The work shall be so planned by the Contractor as to ensure the practical minimum of construction joints (Refer Clause 3.3.15 of this Specification). Concrete shall be placed continuously until completion of the portion of the work between construction joints. Shuttering to form construction joints shall be firmly fixed and scribed around the reinforcement and shall include recesses of approved size and type in order to form a key with the subsequent concrete. A minimum of 2 no. pneumatic or electrically driven vibrators having a frequency of not less than 3000 impulses per minute shall be used for consolidating newly placed concrete, either attached to the shuttering or screeding boards or immersed in the concrete, whichever is applicable to the class of working being performed.

3.3.11 Compliance with specified requirements 3.3.11.1 General Provided that the C.S.R. is satisfied that the materials used are in accordance with Clause 3.3.2 of this Specification and that correct methods of manufacture (Clause 3.3.9) and practices of handling raw materials and manufactured concrete have been used, the compliance of a prescribed mix should be judged by the 28 days crushing strength of the hardened concrete, in comparison with the specified characteristic strength in Table 1. 3.3.11.2 Strength The characteristic Strength of concrete is that 28-day cube strength below which not more than 5% of the test results may be expected to fall. Compliance with the specified characteristic strength should be judged by tests made on cubes at an age of 28 days unless there is evidence, satisfactory to the C.S.R., that a particular testing regime is capable of predicting the strength at 28 days of concrete tested at an earlier age, when compliance may be based on the results of such tests alone. The rate of sampling at any time may be expected to fluctuate according to the random selection of batches to be sampled and may be increased in appropriate circumstances. In any case at least one sample should be taken on each day that concrete of that grade in used. 3.3.11.3 Testing Plan Each cube shall be made from a single sample taken from a randomly selected batch of concrete. The samples should, where practicable, be taken at the point of discharge from the mixer. Compliance with the specified characteristic strength may be assumed if (i) (ii) the average strength determined from any group of four consecutive test cubes exceeds the specified characteristic strength by not less than 7.5 N/mm, and each individual test result is greater than 85% of the specified characteristic strength.

If only one cube result fails to meet the second requirement then that result may be considered to represent only the particular batch of concrete from which that cube was taken provided the average strength of the group satisfies the first requirement. If more than one cube in a group fails to meet the second requirement or if the average strength of any group of four consecutive test cubes fails to meat the first requirement then all the batches represented by all such cubes shall be deemed not to comply with the strength requirements. For the purposes of this subclause the batches of concrete represented by a group of four consecutive test cubes shall include the batches from which samples were taken to make the first and the last cubes in the group of four, together with all the intervening batches. 3.3.11.4 Action to be taken in the event of non-compliance with the testing plan When the average strength of four consecutive test cubes fails to meet the first requirement of Clause 3.3.11.3, the mix proportions of subsequent batches of concrete should be modified to increase the strength. The action to be taken in respect of the concrete which is represented by the test cubes (Clause 3.3.11.3) which fail to meet either of the requirements of Clause 3.3.11.3 must be determined by the C.S.R. and the C.S.R. shall have the right to require the Contractor to demolish and re-build that portion of the Works at the Contractors expense. The Contractor shall be held responsible for all delay and cost incurred by the Company. The C.S.R. may wish to carry out tests on the hardened concrete in the structure at the Contractors cost. These may include non destructive methods or the taking of cored samples. The results of any such tests should not nullify the establishment of non-compliance with the testing plan provided that this was based on valid cube test result.

3.3.12 Reinforcement 3.3.12.1 Material All mild steel and high tensile deformed steel reinforcing bars used in the concrete work shall comply in all respects with BS 4449: 1978 Hot rolled steel bars for the reinforcement of concrete. All mixed steel wire mesh reinforcement shall comply with BS 4483: 1969 Steel fabric for the reinforcement of concrete. All mild steel bars shall have characteristic tensile strength of 250 N/mm and all high tensile deformed bars shall have characteristic tensile strength of 410 N/mm. 3.3.12.2 Supply Where bars are supplied ex-merchants stock, they shall be delivered in the batch loads as supplied from the manufacturer and the Contractor shall supply to the C.S.R. the manufacturers Test Certificates for each particular batch. No steel shall be bent or brought onto the site without the C.S.R.s prior approval regarding the country or origin and compliance with this specification. 3.3.12.3 Stacking Reinforcing steel shall be stacked immediately on delivery at the site in approved racks so that it is clear of the ground. Protection and Cleaning The steel reinforcement shall be protected at all times from injury. At the time of concreting it shall be free from dirt, loose mill scale, rust and also from paint, oil, grease or other coatings including dried concrete from previous placements which would destroy or reduce the bond of the steel with the surrounding concrete. The Contractor shall therefore operate on all steel as may be necessary to produce this condition by satisfactory methods to the approval of the C.S.R. at his own cost. Even though steel has been cleaned any approval of the methods used or standard of cleaning attained shall be subject to the stipulation that the reinforcement shall be in a satisfactory condition at the time of concreting and should undue delay occur between cleaning and concreting so that further loose rust or other coatings become present on the steel then this shall be removed by the Contractor before concreting. 3.3.12.4 Fabrication The reinforcement shall be carefully bent to the shapes and dimensions shown on the drawings and all bends shall be made cold in approved bending machines. The reinforcement shall not be bent or straightened in a manner that will injure the material. Rods with kinks or bends not shown on the plans shall not be used. All reinforcement must be straight between the bends shown and the rods shall be straightened before being bent if considered necessary by the C.S.R. The minimum diameter of former for use when bending round mild steel bars shall be four times the diameter of the bar. No bar showing any sign of cracking or fracture during bending shall be used in the work and shall be removed from the site at the Contractors cost. All steel reinforcement for the Contract must be stacked and bent on the site.

3.3.12.5 Laps and Hooks All reinforcement shall be furnished in full lengths as indicated in the drawings. Except where shown on the drawings, no lapping of rods will be permitted without the approval of the C.S.R. For all rods, laps shall have a length of not less than twenty five times the nominal diameter of the rods +150mm and except where shown otherwise shall be made with hooks at each end. 3.3.12.6 Welding Welding of rods other than as specified or indicated on drawings will not be permitted. Welder rods shall be fabricated and placed so that the welds are located as shown on the drawings. 3.3.12.7 Placing and Fastening All reinforcing steel shall be accurately placed in position as shown on the plans and during the pouring and compacting of the concrete shall be firmly hold against displacement. The steel shall be so placed and supported that in no case shall any bar in a column come closer to the finished surface of the concrete than 38 mm, in beams 25 mm and in slabs 12 mm or the thickness of the bar whichever is greater or at such distance as shall be designated on the working drawings. Soft iron wire not thinner than No. 18 SWG nor thicker than No. 14 SWG shall be used for tying the reinforcing rods at intersections. Ties shall be located at sufficiently close intervals to maintain the rods in their correct positions. Distances from the forms shall be maintained by means of stays, blocks, ties, hangers or other approved supports. Blocks for holding reinforcement from contact with the forms shall be clean precast mortar blocks of approved mixture, shape and dimensions. Reinforcement in any member shall be placed and then inspected and approved by the C.S.R. before the placing of concrete begins. Concrete placed in violation of this provision shall be liable to rejection and removal at the Contractors cost. Provision shall be made for workman to reach any part of the work without standing on the reinforcement. 3.3.12.8 Conduits and Pipes Conduits and other pipes whose embedment is allowed shall not with their fittings displace the concrete of a column on which stress is calculated or which is required for fire protection to a greater extent than four percent (4%) of the area of the cross section. Sleeves or other pipes passing through floors, walls or beams shall not be of such a size or in such locations as to impair unduly the strength of the construction. Such sleeves or pipes may be considered as replacing structurally the displaced concrete, provided they are not exposed to rusting or other deterioration, are of uncoated iron or steel not thinner than standard steel pipe, having a nominal inside diameter of not over 50 mm and are spaced at not less than three diameters centre to centre. Except where plans of conduits and pipes are provided by the Engineer or Architect, embedded pipes and conduits, other than those merely passing through, shall not be larger in outside diameter than one-third the thickness of the slab, wall, or beam in which they are embedded nor shall they be spaced closer than three diameters centre to centre, nor so located as to impair unduly the strength of the construction. Circular uncoated or galvanised screwed electric conduit or iron or steel may be considered as replacing the displaced concrete. Conduits for electrical wiring, embedded in concrete shall comply also with the requirements of relevant PETRONAS specifications. All holes, openings, pockets, ducts, chases, recesses and other cavities shall be formed before the concrete is placed. No holes shall be cut in any concrete without the prior approval of the C.S.R.

3.3.12.9 Bonding Ties Where ends of brickwalls abut against reinforced concrete columns, or walls they shall be secured to the concrete with 6 mm mild steel rods 450 mm long hooked around column or wall reinforcement and cast with concrete and/or spot welded to surface of structural steel stanchions and projected and built into joints or brickwork at 450 mm centres.

3.3.13 Formwork 3.3.13.1 General The design, construction and removal of formwork and falsework shall be the sole responsibility of the Contractor. No concrete shall be placed until forms have been checked and approved by the C.S.R. Any forms not conforming to the requirements of the specification shall not be used and shall be removed without delay. The general requirements of formwork shall be as follows : (i) (ii) (iii) (iv) (v) (vi) The formwork shall be sufficiently rigid to prevent undue deflection during the placing and compaction of the concrete. It should be of sufficient strength to carry the working loads and the weight or pressure of the wet concrete and to withstand incidental loading and vibration of the concrete . It should be set to line and level within the specified tolerance and include any camber which may be required. The joints should be sufficiently tight to prevent loss of mortar from the concrete. The size of panels or units should permit easy handling. The design should permit an orderly and simple method of erection and striking. The arrangement of panels should be such that they are not trapped during striking, and it should be possible to strike side forms from beams without disturbing the soffit formwork. Where brickwork or other in-filling is to be built flush with the surfaces of concrete members, the corners of those members shall be finished square. Elsewhere the corners of all exposed concrete members shall be chamfered 25 mm.

(vii)

3.3.13.2 Timber Formwork The timber for formwork shall be free from all defects and to the approval of C.S.R. All vertical supports shall be supported by folding wedges upon ample sole plates so that shuttering may be struck without causing shock or jerk to the structure. 3.3.13.3 Surface treatment of formwork Where the appearance of the concrete is of importance it is vital that care be taken with the surface of the form. All marks on the form, such as vibrating poker burns, as well as varying properties in the form-face material, such as uneven water absorbency in timber, will shown on the finished concrete. Forms shall have all loose wire and other debris cleaned out of them prior to concreting with a compressed air hose. It is particularly important that all steel particles be removed as they will rust and spoil the final appearance of the concrete.

To prevent damage to the concrete, the surface of the form must be coated with approved release agent prior to concreting. Release agents should be applied to give a very thin film. A common fault is the use of too much oil. If the oil is thin, application by an airless spray is recommended. Thicker oils may be applied by brush or cloth and spread as far as possible, all excess being removed with a cloth. Waxes may be applied with a squeegee. If paint is not used, three coats of mould oil should be applied before the form is used for the first time. To avoid contamination of the reinforcement, the release agent should be applied before the forms are erected, but to do this is may be necessary to protect the forms from the weather. 3.3.13.4 Striking of formwork The period which should elapse before the formwork is struck will vary from job to job and will depend on the concrete used, the weather and exposure of the site, any subsequent treatment to be given to the concrete, the method of curing and other factors. Formwork must not be removed until the concrete is strong enough to be self-supporting and able to carry imposed loads. Thus the time of striking should be related to the strength of the concrete and obviously, soffit forms to beams and slabs must be left in place longer than is necessary for the side forms. The length of time between concreting and the removal of formwork is the sole responsibility of the Contractor. It shall, however be competent to the C.S.R. to require the following minimum lengths of time: Sides of column Sides of beam Sides of walls Soffits of slabs and beams 3 days after concreting 7 days after concreting 3 days after concreting 21 days after concreting

The Contractor shall ensure that in striking the shuttering the structure is not distorted, damaged or overloaded in any way, and upon slabs and beams as may be required by the C.S.R. such struts and shores shall be erected and wedged with great care and shall only be removed with the approval of the C.S.R. No concentrated loads of any kind shall be placed upon any beam, slab or column after concreting without the permission of the C.S.R. 3.3.13.5 Tolerances On all setting out dimensions 3 m and above, a tolerance of plus or minus 6 mm will be allowed. On all setting out dimensions under 3 metres a tolerance of plus or minus 3 mm will be allowed. A tolerance of plus or minus 3 mm will be permitted on the cross-section dimensions of structural members unless otherwise required by the drawings. The top surface of concrete floor slabs and beams shall be within 6 mm of the nominal level and line shown on the drawings. Columns and walls shall not be more than 6 mm out of plumb in their storey height and not more than 19 mm out of plumb in their full height. The Contractor will be responsible for the cost of all corrective measures required by the C.S.R. to rectify work which is not constructed within the tolerance sat out above. 3.3.13.6 Concrete Finish and Making Good After removal of shuttering, unless instructed to the contrary the face of exposed concrete shall be rubbed down immediately to remove fins or other irregularities. In the event of parts of, the concrete being honeycombed such portions shall be cut to a depth and shape required by the C.S.R. and made up with fine concrete of equal grade in such a manner as shall be directed by him. The face of concrete for which shuttering is not provided, other than slabs, shall be smoothed with a wooden float to give a finish equal to that of the rubbed-down face where shuttering is provided. The top face of a slab which it is not intended to be covered with other materials, shall be levelled and floated, while unset, to a smooth finish to the levels or falls shown on the drawings or elsewhere. The floating shall be done in a manner which will not bring an excess of mortar to the surface of the concrete. The top face of a slab intended to be surface with mortar, granolithic or similar materials shall be left with a tamped finish and not trowelled smooth.

Concealed concrete faces shall be left as from the shuttering except that honeycombed surfaces shall be made good. Where rub-down, smooth or fair-face finish is described, the concrete shall be brought to a perfectly true, smooth and even surface by rubbing with carborundum stone dipped in cement grout. Alternatively, the Contractor is permitted, at no extra cost, to provide smooth linings to the forms which will achieve required finish without rubbing down. Rub down surfaces shall be true to form and free from all board marks, joint marks, honeycombing, pitting, etc. Painted surfaces are to be treated as rub-down or smooth finish surfaces. The paint used shall be in accordance with Clause 3.14 of this specification and shall comply with the recommendations of BS 6150: 1982 - Code of Practice for Painting of Buildings.

3.3.14 Precast Concrete Precast concrete shall comply generally with the preceding section relating to concrete and also with the following requirements. All precast units shall be cast on a suitable bed or platform on firm ground. The Contractor shall be responsible for the accuracy of the level or slope of the bed or platform. All edges shall be sharp or accurately formed to the required chamfers or radii and shall form the correct angles as shown on the drawings. Exposed faces shall be smooth and free from board marks, honeycombing, crazing, discolouration and other surface defects. The method and time after casting the units of striking the side shutters shall be the responsibility of the Contractor. In the event of any damage resulting from unsuitable or premature removal of the shutters, the unit or units concerned will be liable to rejection and to replacement by the Contractor at his own expense. The lifting and handling of precast units shall be undertaken without causing shock, vibration or undue bending stresses to or in the units. Precast units shall not be lifted, transported or built into the work before they are sufficiently matured. In the event of any cracks, spalled edges or other defects arising, the unit or units will be liable to rejection, in which case the Contractor shall at once break up the unit or units and replace it or them at his own cost. All precast units shall be cured, by methods to be approved by the C.S.R., for at least 10 days after casting. All precast units shall be open stacked to permit ventilation and protected from rain and rising damp.

3.3.15 Construction Joints Construction joints shall be vertical or horizontal tongue and groove joints as required, except that in an inclined or curved member the joints shall be at right angle to the axis of the member. The joints shall be found only in places indicated in the drawings or approved by the C.S.R. Construction joints where indicated in the drawings or where directed by the C.S.R. shall be keyed by use of battens placed in the concrete and subsequently removed. Before placing new concrete against concrete that has already set or hardened, the face of the old concrete shall be cleaned and roughened and scum and loose aggregate removed therefrom leaving a surface of clean exposed aggregate. Immediately before placing the new concrete the face shall be thoroughly wetted and a coating of neat cement grout applied thereto. The new concrete shall be well rammed against the prepared face before the grout sets.

3.3.16 Provision of Testing Apparatus The Contractor shall make available at his own cost the following apparatus for use of making tests on concrete at times and places as requested by the C.S.R. who is empowered to stop concreting work if these are not available:i) ii) 3.4 3.4.1 One sat of slump test equipment viz.: a truncated steel conical mould 100 mm in diameter at the top, 200 mm at the bottom and 300 mm high, a steel tamping rod 16 mm diameter and 600 mm long, round at one end. 36 nos. 150 mm steel cube moulds for cube test, as specified in B.S. 1881. part 3.

Structural Steel Work Material All steel shall be new and well and clearly rolled to the dimensions, sections and weights specified. They shall be sound and free from cracks, surface flaws, laminations and other defects and shall be finished in a workmanlike manner. All paint for structural steelwork shall be gloss epoxy paint or any approved equivalent industrial coatings of proved corrosion resistant quality. All structural steel shall be Grade 43 steel complying with BS 4360 Weldable Structural Steels and BS 449 The Use of Structural Steel in Buildings. All bolts shall be black bolts complying with BS 916 Black Bolts, Screws and Nuts.

3.4.2

Shop Drawings The Contractor shall prepare all shop detail drawings from the drawings supplied by the Company. All such details shall be approved in writing by the Company before work is put in hand. Every drawing shall show the number and sizes of all bolts, complete details of welds, type of electrodes, welding procedure and any other relevant information. The Contractor shall be wholly responsible for the correctness of his shop details and for shop fittings and site connections. Before any fabrication commences, the Contractor shall verify all dimensions shown on the drawings and inform the C.S.R. of any discrepancies, errors or omissions immediately. It is the responsibility of the Contractor to work according to the latest revision of all drawings supplied by the Company.

3.4.3

Workmanship during Fabrication

3.4.3.1 General All steelwork before and after fabrication shall be straight and free from twist. All component parts shall be assembled in such a manner that they are neither twisted nor damaged, and forcible connection to fit the members together shall not be used. All steelwork shall be cut and fabricated to a tolerance of 1 mm in its length. End plate shall be truly at right angles to the longitudinal axis of the section. No work shall be painted, packed or dispatched from the manufacturers works until it has been tested and complies with or has been certified to comply with all the tests and requirements of the standard applicable to the material specified and until it has been inspected and passed by the C.S.R.

3.4.3.2 Holing & Bolting Holes through connection plates and end plates of adjoining units shall be drilled after the members are assembled and tightly clamped or bolted together. The plates which have been so drilled shall be separated after drilling and the burrs removed. The matching holes shall register with each other so that a gauge 1.5 mm in diameter less than the diameter of the holes shall pass freely through them. Finished holes shall be not more than 1.5 mm in diameter larger than the diameter of the bolt passing through them. No variation of the number, type or position of the joints or connections shown on the drawings shall be made without the written approval of the C.S.R. The threaded position of each bolt shall project through the nut at least one thread after tightening up. All bolts shall be provided with circular washers which shall be planed or tapered as applicable. 3.4.3.3 Welding All welding shall be carried out at the shop except where indicated otherwise in the drawings. For welding of any particular type of joint, welders shall give evidence acceptable to the C.S.R. of having satisfactorily completed appropriate tests as described in Clause 77 of BS 449, or shall be Company qualified welders. Welding electrodes for manual operation shall comply with BS 639 and shall be as recommended by the manufacturers for the location and the type of weld required. Welding shall be in accordance with BS 5135 : 1984. Surfaces to be welded shall be free from loose scale, rusts, grease, paint, slag and other foreign materials. Welds shall be uniform and of the specified sizes and shall be free from incomplete penetration, lack of fusion, slag inclusion, undercutting, burn-throughs, voids, cracks, porosity and other defects. Where required by the C.S.R. welds shall be subjected to X-ray tests or other tests carried out by the Companys Inspection Engineer. The weld will be rejected if found defective. The Contractor shall carry out all remedial measures arising out of the defective weld ordered by the C.S.R. All cost and delay caused by such rejection shall be the responsibility of the Contractor. 3.4.3.4 Shop Priming The structural steel surfaces shall be sandblasted, cleaned of all loose scale and rust, unless stated otherwise. The surfaces shall then be given one coat of red oxide primer done only when they are perfectly dry and clean. 3.4.3.5 Testing and Inspection Manufacturers Mill Test certificates for all structural steel shall be supplied to the C.S.R. No steelwork shall be despatched from the manufacturers works until it has been tested and complied with, or has been certified to comply with all the test and requirements of this Specification and BS 4360. 3.4.4 Erection Prior to erection the Contractor shall submit to the C.S.R. for approval, drawings showing the proposed erection scheme together with all calculations for erection stresses, etc. During erection, members must be lifted in a manner so as not to cause damage or twisting to the structure. The positioning and levelling of all steelwork, the plumbing of stanchions and the placing of every part of the structure with accuracy shall be in accordance with the drawings and to the satisfaction of the C.S.R.

During erection the work shall be securely, bolted or otherwise fastened and if necessary temporarily braced so as to make adequate provision for all erection stresses and conditions including those due to the erection equipment and its operation. No permanent bolting or field welding shall be done until the proper alignment has been obtained. Any damage to materials on the site due to inadequate precautions being taken during the erection of the steelwork shall be made good to the satisfaction of the C.S.R. at the Contractors expense, 3.4.5 Touching Up and Painting All painting work shall be done according to Clause 3.14 of this Specification, Painting and Decoration. After erection of the steelwork, all bolt heads shall be cleaned and shall be given one coat of approved red oxide primer. All surfaces must be thoroughly cleaned before painting commences.

3.5 3.5.1

Brickwork Materials

3.5.1.1 Bricks Bricks shall be first class quality common bricks from an approved kiln, machine pressed, well burnt, hard, rectangular, of uniform shape, colour and size with sharp clean arises and free from all defects. Sample bricks shall be submitted to the C.A.R. for approval before placing order for bricks. When tested in accordance with BS 3921, the average compressive strength shall not be less than 7.0 N/mm. Soft underburnt bricks and bricks containing salt will be rejected. 3.5.1.2 Mortar Brickwork generally shall be built and bonded in 1:1:6 cement, lime, sand mortar but brickwork in manholes shall employ 1:3 cement sand mortar. Mortar shall never be retempered and if not used within 30 minutes after adding water it shall be discarded. All materials shall be accurately gauged and mechanically mixed wherever practicable. Mixing done by hand must be carried out on a clean platform. Cement sand and water used shall be as specified in concrete work. Lime shall be approved hydrated lime or quick lime to BS 890 and is to be delivered to site in sealed bags bearing the manufacturers name or brand. The lime shall be properly slaked, run to putty and allowed to stand for at least 16 hours before use. 3.5.1.3 Reinforcement Reinforcement shall be 64 mm wide Exmet by the Expanded Metal Co. Ltd. U.K., or other approved continuous strand galvanised reinforcement in each 112 mm wall thickness of brickwork at every fourth course. 225 mm. thick brickwork shall be reinforced with 100 mm wide Exmet reinforcement at every sixth course. 3.5.1.4 Damp Proof Course Damp-proof coursing in all walls at ground level shall consist of two layers of 2-ply self-finished, approved bituminous felt (to BS 743), weighing 3.8 kg. per square m., placed over the full thickness of the walls. The damp-proof course shall be stepped where shown in the drawing or as directed. Joints in damp-proof course shall be lapped not less than 150 mm. Cold bitumen rubber compound shall be spread brushed and punched into joint and interstices in three coats on to clean dust-free surfaces. All surfaces on which damp-proof material is to be bedded shall be carefully flushed up with 1:3 cement sand mortar to form an even bed.

3.5.1.5 Mastic for Pointing Shall be Secomastic manufactured by Expandite Ltd., or other equal and approved to match colour of finishes. All mastics shall be gun applied.

3.5.2

Storage of Materials Bricks shall be properly stacked on level and hard standing and be adequately protected from inclement weather. Cement and lime shall be stored off the ground, under cover and away from damp and in such a manner to enable them to be used in rotation in order of delivery. Sands shall be stored separately according to type, on clean hard, dry standings and protected from contamination. Sands for pointing shall be stored separately, away from all other sands and shall be obtained in sufficient quantity at one time to enable material of the approved colour to be used for whole of the work.

3.5.3

Workmanship All half brick walls, brick on edge walls and cavity walls shall be laid in Stretcher Bond. Except where otherwise shown on the drawings 229 mm walls shall be built in English bond, that is alternate courses of stretcher bricks and header bricks with a closer brick on each alternate header course to keep the bond. All bricks shall be thoroughly wetted before laying and every course shall be thoroughly flushed up with mortar before the next course is laid. All surfaces on which brickwork is to be built shall be clean. All brickwork shall be built uniform, true and level, with all perpends vertical and in line, and is not to rise more than twelve inches every four courses. No work shall rise more than 1.52 m above adjoining work and all such risings are to be properly raked back. All bricks shall be laid frog uppermost on even full beds of mortar. Vertical faces of all bricks shall be well buttered before being laid and the whole well grouted at each course. Faces of walls which are to be rendered or plastered shall have their joints raked out to form a key. All other wall faces and partitions shall be flush jointed. All jointing shall be completed with pointing as the work proceeds. Brickwork and blockwork against concrete soffits and timber joint shall include for cutting to give normal 10 mm joint and complete filling thereof with mortar. All ducts, recesses for services lines and the like shall be formed to the correct dimensions.

3.5.4

Protection of Brickwork Architectural features, finished surfaces and quoins shall be protected against damage during the progress of the work. Newly laid brickwork shall be protected from the harmful effects of hot sunshine, rain, running surface water and shocks, until the mortar has set. Any work that is damaged shall be taken down or the joints raked out and replastered as the C.S.R. shall direct and the costs of any such remedial work shall be borne by the Contractor.

3.5.5

Cleaning Down Replace all defective bricks and tiles, build up putlog holes and point up faulty joints and make good other imperfections. On completion of brickwork the whole of the surface of the exposed work shall be cleaned down with clean water.

3.5.6

Completion On completion make good all damaged joints on exposed faces of brickwork and make good after all other trades. All fair face work shall be protected with a layer of protecting polythene sheet or other equal and approved material on completion of the work. Remove and make good surfaces where necessary after completion of all other trades.

3.6. 3.6.1

Roofing General All roofing work shall be carried out by tradesmen and on completion shall be thoroughly watertight. If any defective workmanship shall be found on finishing, it shall be stripped out to the extent ordered by the C.S.R. and re-laid by the Contractor at his expense. Generally perform all necessary cutting, fitting and dressings and leave all roofs and wall claddings in a sound and watertight condition to the satisfaction of the C.S.R.

3.6.2

Steel Roofing and Cladding Where indicated zinc coated steel sheet coverings to pitched roof and wall claddings shall be Lysaght Spandek Colorbond sheeting or other equal and approved. Sheets to be fixed and lapped in accordance with the manufacturers instructions with the recommended fixings. The sheets shall be obtained in sufficient lengths to cover each roof slope without end laps. Turn ups and turn downs, in accordance with the manufacturers instructions, must be made at ridges parapets and eaves etc. Ridges, flashings and other fittings and accessories shall be those manufactured to suit the sheeting. The general care and handling of the sheets must be in strict compliance with the manufacturers recommendation or C.S.Rs instructions.

3.6.3

Water-proofing Treatment for R.C. Roof Where specified, the metallic waterproofing for reinforced concrete roof shall be Embecon metallic waterproofing or other equal and approved. The whole of the Embecon metallic waterproofing shall be carried out by approved trademen. The r.c. roof shall be given 4 coats of Embecon metallic waterproofing brushed on top of the surface and cured strictly in accordance with the manufacturers specification and/or recommendation. In gutters and at abutments with parapet walls or fascia and other projects above the roof, the Embecon metallic waterproofing is to be dressed over the angle fillet and up the face of the, projection to a height of at least 152 mm (where possible), under the flashing. The coats of waterproofing shall be properly dressed and bonded to roof outlets, pipes etc.

3.6.4

Flashing All flashing is to be of 18 gauge galvanised iron sheet metal. Joint to be lapped not less than 150 mm.

3.6.5

Rainwater Outlets Where indicated, rainwater outlets shall be Fulbora, or other equal and approved cast in the roof slab.

3.6.6

Insulation All roofs except r.c. roof shall receive a layer of heavy duty, double-sided, fire retardant and reinforced aluminium foil as Simefoil 850 or approved equivalent laid over a layer of 50 mm chicken wire mesh which is fixed to the purlins or battens. The foil shall be laid with minimum laps of 150 mm so that it will serve as vapour barrier. For metal roof, an additional layer of Microlite fibreglass of 0.75 lb/sq. ft. or 3.67 kg/m shall be laid between the metal sheets and the aluminium foil.

3.7 3.7.1

Carpentry, Joinery & Ironmongery Timber Generally Timber shall be sound, well conditioned, properly seasoned to suit the particular use, free from defects or combination of defects rendering it unsuitable for the purpose intended, cut square, free from excess of wane, large loose or dead knots and incipient decay. Sapwood will not be permitted. Samples of all timber to be used in the Work shall be submitted for approval. Moisture content shall be less than 15%. Hardwoods shall be First and Second grade hardwoods. Kapor Bukit, Keruing, Semayur shall be used. Softwoods shall be teak wood and Meranti or other approved softwood. Plywood shall be to B.S. 1455 with Water-boil proof bonding with selected hardwood veneers of local timbers or meranti. Plastic sheet shall be Formica high density melamine faced plastic laminated with approved pattern; fixed with an adhesive as recommended by the manufacturer together with a compensating balancing veneer.

3.7.2

Preservation of Timber: 1. Timber where described as pressure treated shall be impregnated under vacuum/pressure with an approved proprietary wood preservative to protect it against fungus and insect attack, so as to give the nett dry salt content stated below: min. net dry salt content a) Structural Timber and all concealed fixing blocks, plates, rough grounds, noggings, studs and the like. b) Exterior window frames sashes, casements and cills. External door frames and cills. Fascias barge boards and weather boards. 5.61 kg. per cu. m 8.02 kg. per cu. m

Timber shall not be treated which has a moisture content of more than 25% by weight. Where possible all labours such as planning, cross cutting, rebating boring shall be carried out before the timber is treated. Where it is necessary for labours to be carried out after the timber is treated, all exposed surfaces shall be treated with preservative as specified in sub-clause 3 hereof. 2. The method of treatment shall be the full cell vacuum/pressure impregnating process. The timber shall be subjected to hydraulic pressures of not less that 1.03 N/mm for period of not less than 45 minutes duration. The pressure and period of duration shall, however, be such as will give the gross volumetric absorption that will ensure the stipulated final retention of dry salt. The treated timber shall be air dried for three weeks before use. The Contractor shall produce a certificate from the firm which has treated the timber stating the quantities and sizes of timber treated and the nett retention of dry salt obtained. 3. Timber where described as surface treated shall be heavily coated with two coats of an approved wood preservative before fixing. All sawn ends, notches rebates shall be similarly coated before the timbers are built in. No timber is to be treated whilst damp.

3.7.3

Joinery Generally Joinery shall be prepared immediately after the placing of the contract, framed up (but not glued) and stored until required for installation, when it is to be glued and wedged up. Any portion that warps or develops shakes or other defects shall be replaced before being wedged up. Note: All dimensions given on drawings are finished sizes. The contractor shall make allowance for wrought faces.

3.7.4

Termite Treatment The whole of the timber for carpenters and joiners work shall be made thoroughly termite proof to the entire satisfaction of the C.S.R. by means of Atlas A or other similar and approved preventative which shall be used strictly in accordance with the manufacturers instructions. The Contractor shall provide all necessary baths and tanks for the complete immersion of all timbers and they shall be immersed in the cold solution before framing up. The strength of solution and period of immersion shall be in accordance with the manufacturers recommendations. After thorough immersion the timber shall be withdrawn and stacked to dry before being used. Atlas A shall be handled and stored with care. Drums, when opened, shall be kept in lock-ups and when empty, the drums shall be washed out thoroughly several times and allowed to drain. Atlas A is poisonous and the Contractor shall take every care and precaution in its storage and use. Any cross cutting, boring, notching etc. after impregnation shall be treated with the above solution brushed on in concentrated form.

3.7.5

Adhesive Glues shall be cold setting synthetic resin (Phenolic and amino plastic) to B.S. 1204.

3.7.6

Workmanship The workmanship shall be of best quality. Scantlings and boardings shall be accurately sawn and shall be of uniform width and thickness throughout. All carpenters work shall be left with a sawn surface except where otherwise described. It shall be accurately set out in strict accordance with the drawings and shall be framed together and securely fixed in the best possible manner and with properly made joints. All brads, nails, screw, plugs, pins, etc. shall be provided as necessary and as directed and approved by the C.S.R. All wood posts etc. shall be in one length between supports of fixings. The preparation of timber is to commence simultaneously with the beginning of the work generally and should proceed continuously until all the woodwork is prepared and stacked on or near the site. All timber of large scantlings shall be sawn immediately when the building is commenced to allow for any shrinkage that may take place. Sawn timbers shall hold to the full dimensions specified. All Joiners work is to be accurately set out, framed and executed in accordance with the detail drawings and finished off in a proper and workmanlike manner to the approval of the C.S.R. The hollow cored flush doors shall be constructed generally to comply with B.S. 459. Timber which is required to be polished shall be of selected quality, matching grain shade to the C.S.R.s approval. Joinery shall be well protected from the weather during transit and shall be stored under cover, well clear of the ground, on a sound base, level and square. Before leaving the joinery works, all surfaces of joinery to be painted later shall be well primed. All joinery shall be delivered to the site after inspection at the workshops by the C.S.R.

3.7.7

Fixing Accessories (i) Heavy cramps shall be 25mm x 14 gauge 254mm girth one end turned up 50 mm and twice drilled and the whole galvanised after fabrication. They shall be fixed to the joinery with two No. 10 gauge galvanised steel screws, Fixing inserts for casting into concrete shall be Philplug No. 97 or other approved equivalent. Plugs for screws in external positions shall be Rawplugs White Bronze or other approved preformed metal plugs of adequate size. Plugs for screws in internal positions shall be Rawplugs or other approved preformed plugs of adequate size. Dowels shall be 10 mm diameter galvanised steel housed 76 mm into timbers.

(ii) (iii) (iv) (v)

3.7.8

Protection of the Work The Contractor shall protect the materials and assembled units during the progress of the work and provide and maintain this protection to dressed or finished woodwork that might otherwise be damaged during the progress of the work. Doors and other joinery shall not be brought on to site until necessary or before the structure has dried out as far as possible.

3.7.9

Replacing Timbers Any timber which splits during fixing, shrinks or is damaged in any way likely to affect efficiency of finish shall be removed and replaced at the Contractors expense. Doors that are warped and/or show signs of other defects shall be removed and replaced. All doors so replaced shall be guaranteed for a period of one year from the date of replacement. All doors shall be neatly fitted in frames with a minimum of clearance for proper functioning.

3.7.10 Ironmongery Generally 1) All ironmongery shall be fixed with screws which shall be of the same metal and finish as the fittings. All screws damaged when driven by the turnscrew or from any other cause shall be removed and replaced by undamaged ones. 2) All doors shall be provided with locks, rubber tipped bumpers, knob handles, butts and hinges, roses, push plates, hydraulic surface mounted door closer etc. as required to serve the space intended. 3) Locks shall comply with BS 5872 : 1980 or equivalent standard unless otherwise specified and will be supplied complete with striking plates to match furniture. 4) Locks for both internal and external hardwood doors will be chrome or brass cased as Yale or Union. 5) Unless otherwise stated, all furniture locks, bolts push plates, kick plates shall be in anodised aluminium alloy to a first quality Satin Silver finish. 6) All ironmongery shall be fixed temporarily with temporary screws to locate fixing position etc. and shall be permanently fixed with the matching screws supplied. 7) On completion, all ironmongery shall be checked and oiled if necessary and put into perfect working order. All damaged screws shall be replaced by new ones. 8) All locks shall be keyed differently except where there is more than one door to the same room, in which cases these doors shall be keyed alike. Brass hinges for doors shall be 102 mm wide x 4 mm thick type. Corrosion resisting steel pins shall be provided for all hinges throughout the building. 9) All keys including duplicate keys shall be clearly labelled, handed to and a certificate obtained from the C.S.R.

3.8 3.8.1

Metalwork Materials All ferrous metals shall be free from rust, scale and other defects and the various shapes and sections shall be clearly rolled or otherwise formed to uniform sections. All non-ferrous metal shall have uniform finished surfaces machined and buffed, free from defects and all sections shall conform accurately to the sizes and shapes required. Steel shall comply with the requirement of B.S. 15 No. 1 quality and the Contractor shall produce the manufacturers test certificates when so required by the C.S.R. Wrought iron shall be malleable quality, straight and of constant section. Aluminium sheet shall be to B.S. 1470 : 1972. Angles, channels, tees and I sections shall be to B.S. 1161 : 1951. Where stated aluminium shall be anodised either natural or to colours selected by the C.S.R. Bolts generally shall have hexagonal heads and nuts unless otherwise stated. Threads shall be Whitworth and all bolts shall be fitted with washers. Anchors shall be Ramset, Rawi, Sabco, Loxin or other equal and approved expansion tapered nut type anchors for fixing all bolts in brickwork or concrete. Mortices for anchors shall be drilled to the required diameters in accordance with the manufacturers instructions so that no damage is done to the receiving surface.

3.8.2

Ferrous Metal Preparation Unless galvanised or concrete encased, treat all ferrous metalwork with primer paint as specified. Wherever practicable the priming shall be carried out after the metal has been drilled, cut, welded, etc., but before delivery to the site. All parts which will become inaccessible after building in shall receive a further coat of primer on the site.

3.8.3

Galvanising All galvanising to metalwork shall be hot dipped with not less than 610 gm of zinc per square m of surface after welding, drilling, tapping, etc., and fabricating has been completed. All exposed accessories shall be hot dip galvanised.

3.8.4

Chrome Plating Where bronze, copper or brass is specified to be chromium plated this work shall be carried out by an approved firm and shall follow the best trade practice and the work shall be first nickel plated and then heavily chrome plated to a finish specified.

3.8.5

Protective Coating Where extruded or sheet aluminium butt against cement render concrete brick or timber treated with preservative, prime the aluminium with one (1) coat of zinc chromate before fixing. Maintain the protective coating throughout the currency of the job. On completion clean all exposed non-ferrous metal finishes with steel wool and petrol and wipe dry.

3.8.6

Dissimilar Contact Surfaces Where non-ferrous metalwork is connected and/or secured or fastened to dissimilar metal parts such non-ferrous metal shall be thoroughly insulated from direct contact with any steel ferrous metal or masonry and timber by a heavy shop coat of primer made with a synthetic resin vehicle. At the same time of connection and/or installation of all securement devices when securement and fastening devices are in place they shall again be coated with a thorough application of paint.

3.8.7

Workmanship (i) General The whole of the fabrication, welding, bolting, priming and erection shall be carried out by skilled tradesmen in accordance with best trade practice. All non-ferrous work required by the drawings indicated herein or specified shall be as detailed on drawings, of suitable thickness and of approved gauge to ensure the necessary rigidity when erected, free from bends or waves or other surface imperfections, true and straight vertically and horizontally. All arises, profiles and moulded surfaces shall be true and sharp. All joints and mitres shall be carefully and accurately assembled and machined so as to provide close smooth connections that will not be noticeable and weather-and water-tight. Screws and bolt heads shall be concealed wherever possible and counterwork finishing flush on exposed surfaces. Provision shall be made for appropriate expansion and contraction joints in all long runs of horizontal and vertical exposed members and be subject to C.S.R.s inspection prior to forming and/or installation. Architectural non-ferrous metal work shall be the products of outstanding recognised manufacturers and fabricators of highest grade architectural alloy metal products and shop assembled in a shop where the grade of metalwork is of the highest grade and quality and acceptable to the C.S.R. Faces of metal in contact shall have hair line joints. Work shall be assembled with concealed fittings insofar as practicable. Exposed joints shall be water-tight. Mouldings shall be in true alignment at joints, straight, tightly and neatly fitted. (ii) Welding Welded joints shall be dressed smooth, free from porosity, cracks and blow holes and finished to match adjacent surfaces. When welding and dressing operations are completed all welding flux shall be removed without delay. Welding shall be carried out by Company approved welders in strict accordance with PTS 20.104, Structural Steelwork. (iii) Fixing The various members of metalwork shall be properly and neatly assembled and connected together with approved fixings. Fastenings which are exposed shall be of the same materials, colour and finish as the metal to which applied unless otherwise specified. (iv) Cuttings, Drilling and Fitting Furnish all materials and services and perform all labour in connection with all tapping, drilling, cutting and fitting of the work specified herein and/or to accommodate the work of other trades in connection therewith providing all tap holes, bolts and screws, anchors, lugs, reinforcement and any other correcting devices, subframes, supports, stiffeners or items required or necessary to install the work permanently and securely in place.

3.8.8

Holdfasts Provide galvanised mild steel holdfasts to the back of timber door frames built in brickwall/blockwall unless otherwise stated. Holdfasts shall be 32 mm x 5 mm galvanised mild steel flat, twice bent, one end fishtailed and built into joints of brickwork and other end screw fixed to the door frame.

3.8.9

Adjustable Metal Louvred Windows The adjustable louvre shall be Naco or other equal and approved pattern metal louvre framing with clips for 150 x 6 mm thick louvres. Fix metal adjustable louvres including assembling, screwing and spotwelding to mild steel framing.

3.8.10 Roller Shutter Provide and fix Diethelm aluminium roll-up grilles or other equal and approved to the position and size as indicated on the drawings. The colour and design of grilles shall be approved by the C.S.R. before being installed.

3.8.11 Balustrades, Railings, Burglar Bars and Built-in Ladders etc. Balustrades, etc. shall be mild steel and where stated, shall be galvanised. Such items of fabricated metal work shall be in accordance with the detail drawings. Form all necessary fish tails for building in. All ungalvanised mild steel is to be primed before leaving the workshop.

3.8.12 Clothes Line & Framing Steel tubes shall be galvanised and comply with B.S. 1387. Clothes lines wire shall be 10 SWG galvanised iron wire. All fittings shall be galvanised.

3.8.13 Division Strips, Water Bars All such components shall be galvanised mild steel, unless otherwise stated. Division strips shall be set flush with the floor finish.

3.8.14 Matwell Frames Matwell frames shall be galvanised mild steel, unless otherwise stated, and shall be welded up true and square. The frames shall be provided with fixing lugs, and shall be set flush with the floor finish.

3.8.15 Chequered Plate Chequered plate shall be galvanised mild steel to the thickness and sizes stated. Frames and other fittings shall be galvanised mild steel. The frames shall be true and square and the chequered plate shall fit firmly. Lifting holes shall be provided for removal of the chequered plate so that each section of plate is readily removable.

3.9 3.9.1

Ceiling General The ceiling workers shall cooperate with other trades in the preparation of ceiling layouts and during installation. Airconditioning outlets, fire detectors, lights and similar ceiling outlets shall be located at the centre of solid panels and not at the intersection of ceiling panels or grid suspension. No additional point loads shall be carried by the ceiling or suspension system without prior discussion with and approval of the C.S.R. The Contractor shall particularly note that where modular ceilings are specified and scheduled, allowance must be made for all make-up tiles of non-standard size in order to conform with the ceiling layouts. The tiles shall rest on anodised aluminium grid suspension systems in strict accordance with the specification to a grid pattern to suit the ceiling layout. The tile sizes shall not dictate the ceiling layouts.

3.9.2

Aluminium Framed Suspension System (i) General A permanent, uniformly level and rigid system of securement shall be achieved to hold each and every tile in the same place with no projection, dropped or sagged tile edges at any time. Individual tiles shall be able to be quickly removed and replaced without injury to any surface. (ii) Hangers for Aluminium Framed Ceilings Hangers shall be 5 gauge hard drawn aluminium flat of various lengths to suit depth of false ceiling. (iii) Support Rails Support rails shall consist of aluminium tees at not more than 1.22 m centres drilled for bolt fixings of hangers and properly supported at ends against masonry etc. (iv) Scrap in Rails Scrap in rails shall be aluminium at 300 or 600 mm centres to suit size of tiles and so formed as to provide positive support for tiles when these are placed in position. Scrap in rails shall be firmly fixed to support rails and full details must be submitted for approval.

3.9.3

Metal Ceiling Where indicated in the drawings, metal ceiling shall be Luxalon, aluminium ceiling or other approved equivalent. The whole ceiling shall be suspended via adjustable hangers and the perforated metal sheeting shall be supported by an aluminium profile, all done in accordance with the manufacturers specification.

3.9.4

Timber Slatted Ceiling The timber slate shall be wrought kapur 76 mm wide x 12 mm thick battens and spaced with 12 mm gap between and nailed to Joists at 152 mm centres. Framings to receive the battens shall consists of 102 mm x 50 mm kapur Joists at 610 mm centres and 50 mm x 50 mm nogging at 610 mm centres unless otherwise specified. A layer of approved bird proved nest shall be secured to the soffit of the Joists before the battens are nailed to them or unless otherwise specified. All timber used shall conform with the specification for carpentry,

3.9.5

Softboard Ceiling Soft board linings shall be of termite proof fibre building board 16 mm thick unless stated otherwise. Softboard for ceiling linings shall have maximum density of 400 kg per cubic metre and shall be fixed in 1220 x 1220 mm panels. All boards shall be supported on framing at 610 mm maximum centres with cross framing at 610 mm maximum centres and shall be fixed with 32 mm long galvanised clout headed nails at 150 mm centres on all supporting framework. The nails shall be punched below the surface and the holes filled up flush with an approved plaster filler. Edges of boards shall be butted up tight and slightly chamfered to give a neat V joint. Access panels in ceilings shall be 762 mm square 10 mm plywood. The opening in the ceiling shall be lined with 38 mm wide x 75 mm deep rebated lining. Nogging pieces shall be fixed to the lining to support edges of ceiling panels.

3.10

Plastering And Tiling

3.10.1 General All work shall be completed in a neat and workmanlike manner, and all angles and corners shall be true and straight and plumb. The C.S.R. shall order the removal of any work which he considers to be not in accordance with this specification.

3.10.2 Gauging The materials for plastering and rendering shall be determined by the volume. Gauge boxes are to be supplied, kept clean and properly maintained.

3.10.3 Lime The lime for plastering shall be as rich as obtained and shall be first quality lime. It must be freshly burnt and shall be slaked in a sheltered place at least one month before use by drenching with water, be well broken-up and mixed, and the wet mixture shall be passed through a sieve of ten meshes to a square cm. Lime putty consist of freshly slaked lime as above described, saturated with water until semi-fluid and passed through a fine sieve; it shall then be allowed to stand until the superfluous water has evaporated and it has become the consistency of thick paste, in no case for a shorter period than one month before being used, during which it must be kept damp and clean and no portion of it allowed to become dry.

3.10.4 Sand, Cement, Water The sand, cement and water used in plastering shall be in all ways conform to that specified for concrete work, but shall be fine and of as light a colour as possible to comply with BS 1199.

3.10.5 Storage of Material All plasters, lime and cement shall be stored in a properly roofed, weatherproof, dry, well ventilated shed, used exclusively for this purpose, with a wooden floor not less than 300 mm clear above the earth.

3.10.6 Preparation of Surfaces for Plastering. Surfaces to receive plastering shall be dry brushed to remove all loose particles, dust, efflorescence, etc. and any projecting fins on concrete surfaces shall be hacked off. All traces of mould oil shall be removed from concrete surfaces by scrubbing with water containing detergent and rinsing with fresh clean water. Surface shall be wetted and re-wetted as required to equalise suction before the first coat of plaster is applied. In particular, dense hard concrete surfaces shall be wetted and re-wetted as required before bonding plaster is applied.

3.10.7 Preparation of Surface For Pavings And Screeds The concrete sub-floor shall be brushed with a stiff broom before it has hardened to remove laitance and give a roughened surface. Alternatively, the surface shall be thoroughly hacked if so directed by the C.S.R. at the Contractors expense.

3.10.8 Dubbing Out Dubbing out shall be in the same mix as the subsequent coat and shall not exceed 12 mm in thickness in one application. Should a greater thickness be required than usual, then it shall be obtained by dubbing out in cement and with a mortar of approx. the same mix as the mortar for blockwork (one part cement four parts sand).

3.10.9 Mixing of Material All materials shall be thoroughly mixed in the proportions described. No mixes of plasters other than those described shall be used. Bunkers and gauge boxes shall be thoroughly cleaned after each mix and due care and attention shall be given at all times to their cleanliness. The water content of the mix must be the minimum required to give a workable mix. The paving must be thoroughly rammed within 30 minutes of laying and the surface trowelling must be delayed until the paving has stiffened sufficiently to prevent liatance being brought to the surface by the trowel. The paving shall be rubbed down, if necessary, to produce a smooth even surface.

3.10.10 Retempering Cement - lime - sand plasters shall be used with 30 min. of the gauging with cement. Gypsum and light weight plasters shall be used within one hour of the addition of water. Plasters shall not be re-tempered except as is permissable for class C gypsum plaster, and the use of the water brush shall be kept to a minimum. All tools shall be kept clean. Fresh plaster shall not be contaminated with set plaster.

3.10.11 Period Between Coats Cement - lime - sand undercoats shall be allowed to dry out thoroughly before a further coat is applied. With gypsum and light weight plaster undercoats, the subsequent coats shall be applied as soon as the undercoat has set and has developed reasonable suctions.

3.10.12 Finish All undercoats shall be scratched to provide an adequate key for the next coat. Unless otherwise described all finishing coats in cement - lime - sand shall be finished with a wood float and finishing coats in gypsum and light weight plasters with a steel trowel. All plastering and rendering shall be finished straight and true to fill a 2 m straight edge in every direction. All internal and external angles shall be either horizontal or vertical.

3.10.13 Arises and Junctions Unless otherwise described all arises shall be pencil rounded. A neat cut shall be made with the edge of the trowel through all coats of the wall plaster at the junction with the ceiling plaster.

3.10.14 Composition of Coats 3.10.14.1 Internal rendering shall be composed of one part Portland cement, one part lime and six parts sand well trowelled, hard and smooth to a total thickness of 20 mm in two coats of 10 mm thick each. It is important that the rendering coat develops its full strength before the finishing coat is added. The rendering coat shall be liberally treated with fresh water until it is hard and there is no powder present. Setting coat plaster shall be class C anhydrous plaster trowelled to a hard dense smooth surface, thickness not more than 6 mm, levelling with straight edge if necessary. 3.10.14.2 External rendering shall be in two coats composed of one part Portland cement one part lime and six parts sand trowelled with at to a wood flood to a smooth even surface of 20 mm in total thickness in two coats of 10 mm thick each. All concrete surfaces to be rendered shall be carefully and thoroughly hacked to provide an adequate and suitably keyed surface. All brick work shall have joints raked out and surfaces hacked as above to provide a keyed surface. Unless directed by the C.S.R. all making good shall be cut out to rectangular shape with undercut edges to form a dovetail key and finished flush with surrounding. 3.10.14.3 Curing All render shall be kept wet for seven days after being applied. No paint or other decoration shall be applied to rendered surfaces until the Contractor has satisfied the C.S.R. that the walls and render are thoroughly dry.

3.10.16 Glazed Wall Tiles 108 x 108 glazed wall tiles shall have cushioned edges and shall be 6 mm thick tiles unless otherwise specified. Tiles used shall be sat straight joint on 1:3 cement sand rendering. Tiles shall be neatly pointed on completion in white cement. The glazed wall tiles shall be forwarded to the C.S.R. for approval, and all tiles supplied shall be of equal colour and quality to the approved samples which shall be retained by the C.S.R. Special accessory tiles shall be provided to match wall tiles at all external and internal angles, skirtings, junctions, etc.

3.10.17 Screeding to Receive other Finishes Screeds for walls shall be of cement and sand (1:3); the thicknesses and surface textures are to suit the paving or tiling they are to receive. Water used in the mix shall be kept to a minimum. Screeds shall be covered to avoid too rapid drying out and be protected from damage until the laying of the wall finishes.

3.10.18 Ceramic Wall Tiles Ceramic wall tiles shall be Buchtal tiles of 11 mm thick. All ceramic tiles and accessories shall be laid in strict accordance with the manufacturers specification. The Contractor has to confirm the colour of the tiles with the C.S.R. before placing any order for materials. 3.10.19 Shanghai Plaster Paving Shanghai plaster paving shall consist of 16 mm thick layer of 1:3 cement sand render coat and 10 mm thick finishing coat. The finishing coat shall be composed of 2 parts of cement and 5 parts of granite chippings (to pass 10 mm mesh and graded to 5 mm). The finishing coat shall be applied to the rendering before the latter commences to set; when the finishing coat is about to set the surface shall be gently brushed with a soft, wet brush to expose the stone chippings. The concrete surfaces to receive shanghai plaster shall be thoroughly cleaned and wetted before the render coat is applied.

3.11

Paving

3.11.1 Preparation of Concrete Surface Concrete floors that are to receive pavings or screeds shall have their upper surfaces hacked and well roughened and shall then be brushed to remove all dust and loose particles and be thoroughly wetted. Immediately before laying pavings or screeds the clean wet surface shall be given a coat of pure cement grout brushed on with a stiff brush.

3.11.2 Floor and Roof Screeds All screeds shall be 1:3 cement/sand. Screeds shall be laid to the thickness stated and shall be brought to a true and smooth surface. Where stated the screeds shall be laid to falls. Screeding shall be carried out in bays not exceeding 10 sq.m. Where specified that the surface of the screeds is to be divided into panels. This shall be done by pressing a cord into the surface whilst the screed is still green. The panels shall be regular in size as instructed by the C.S.R. and shall be parallel to walls. Where cement/sand screeds are left plain as floor finishes, the paving shall be sprinkled with fine carborundum grit (Mesh size No. 12 to No. 26) whilst the surface of the paving is still green and the grit lightly worked into the surface using a steel float. The rate of application shall be at least 0.820 kg. per square meter. Any oil proofing or chemical resistant additives required to screeds shall be as described separately.

3.11.3 Waterproof Screeds Any screeds described as waterproof shall have an approved waterproofing agent added to the mix in accordance with the manufacturers instructions. (Refer C1. 3.6.5 of this specification).

3.11.4 Floor Drains In all rooms where floor drains are required as shown on the drawings the floors shall be sloped gently towards the floor drain.

3.11.5 Mosaic Tile Flooring Mosaic tiles shall be approved first quality vitreous unglazed. The pattern and colour and pointing shall be to the requirements of the C.S.R. Screeds to receive mosaic tile flooring shall be true and even shall be well wetted before mosaic is laid. The mosaic shall be laid on a bed of cement sand (1:3) and shall be pointed in 1:1 cement sand mortar. The finished mosaic flooring shall be true and even and where specified shall be laid to falls. On completion the surface of the mosaic shall be thoroughly cleaned off to remove any bedding or pointing material. Unless stated otherwise a 100 mm high mosaic tile skirting shall be provided to all areas where mosaic flooring is specified, bedded and pointed in a similar manner to the flooring. The perimeter row of mosaic floor tiles shall be set at an angle of 45 from the floor at junctions with mosaic skirtings. Where mosaic tiles are specified for stair treads, non slip nosing tiles shall be provided in colour to match mosaic. Traffic shall be kept off the floor for at least 3 days after grouting while the floor is kept wet by sprinkling.

3.11.6 P.V.C. Flooring P.V.C. flooring shall be 2 mm pure flexible vinyl asbestos floor tiles of MW range manufactured by Messr. Marleyflex International or equal and approved tiles and shall be laid by an approved specialist team in accordance with the manufacturers specification. The floor screed shall have a steel float finish, and shall be clean and dry to the satisfaction of the floor layer who is to guarantee his work. Sheeting and tiles are to be laid on Marley No. 3 adhesive or equal and shall have tight straight joints well stuck down. Surplus adhesive must be removed immediately from the floor finish.

3.11.7 Cill Tiles Where cill tiles are indicated on drawings they shall be clay cill tiles of appropriate size and shall be bedded & pointed in 1:3 cement sand mortar. External cill tiles shall be provided with throating and shall be laid to fall away from the building. All exposed arises shall be rounded.

3.11.8 Granolithic Flooring Granolithic flooring shall consist of one part cement to two and a half parts of aggregate. The aggregate shall be granite (or other approved hard stone) which shall be graded from 10 mm down with not more than 20% passing a 200 mesh B.S. sieve. The water cement ratio shall be kept as low as possible compatible with workability. The granolithic flooring shall be laid to the thickness stated and shall be laid whilst the concrete subbase is still green. The granolithic shall be finished with a steel trowel perfectly true and smooth surface, and laid to falls where stated. The granolithic shall be laid in bays as specified for screeds in Clause 3.11.2. Where the flooring is described as non-slip, and to all stair treads, these areas shall be evenly sprinkled with carborundum dust or other approved material, which shall be lightly trowelled into the surface before final trowelling.

3.11.9 Quarry Tile Flooring Quarry tiles and floor tiles shall conform to BS 6431 and unless otherwise stated shall be 150 x 150 x 16 mm in an approved colour. The tiles shall be thoroughly wetted before laying. The tiles shall be bedded and pointed in cement/sand (1:3) 10 mm thick. Covered skirtings to match tiles shall be 150 mm high and shall have bullnose top and cove at bottom and internal angles and rounded external angles. The tiles shall be laid true and level.

3.11.10 Terrazzo Paving Terrazzo shall be composed of 3 parts of marble chippings and 1 part of coloured cement. The marble chippings shall unless otherwise stated, be graded 10 mm down to 3 mm. The terrazzo shall be 16 mm thick and shall be laid on a 1:3 cement sand screed 19 mm thick and laid while the screed is still green. The terrazzo shall be rolled and trowelled to a dense even surface, and ground down on completion to an approved polished surface, first by using a coarse abrasive, and finally by using a suitable fine abrasive. The paving shall be divided into sections not exceeding 1.5 sq.m. with ebonite dividing strips 3 mm. wide fixed flush with the surface of the finished paving. Joints in the screed and in the terrazzo shall coincide with any joints in the concrete sub floor. The whole construction of Terrazzo paving shall be in accordance with BS 4131, 1973. 3.11.11 Oil Proofing and Chemical Resistant Hardeners Where oil proofing and chemical hardeners are used, the type used shall be subject to the approval of the C.S.R. and shall be used strictly in accordance with the manufacturers instructions. 3.11.12 Sundry Labours All finishes shall be neatly worked up to, or cut around, plinths, channels, gratings, duct covers, gulleys, manhole frames pipes and the like. Floor finishes and screeds shall be continued into recessed manhole covers to match the surrounding areas.

3.11.13 Aluminium Diving Strips Aluminium dividing strips between different floor finishes are to be 25 mm x 3 mm finished flush with flooring.

3.11.14 Samples The Contractor shall prepare sample squares of paving, plastering and tiling as directed until the quality texture and finish required is obtained and approved by the C.S.R., after which all paving, plastering and tiling works shall conform to the respective samples.

3.12

Glazing

3.12.1 Glass All glass shall be of approved manufacture and free from flaws, waves or other defects and shall be of uniform thickness in accordance with B.S. 952. Glass shall be delivered in proper containers with makers name, guarantee, type of glass and thickness or weight of glass attached to the outside of the containers. Plain sheet glass shall be of selected quality. Polished plate glass shall be glazing glass. Except where otherwise specified all glass for doors and windows shall be heat reflective laminated safety glass of 12 mm thick, or 30 kg/m2 with the interlayer film 1.5 mm thick. The obscure glass shall be of an approved pattern. Glass to all Bathrooms and Toilet windows shall be obscure glass. Wired glass shall be Geogian Wired Polished Plate glass. Unless stated otherwise it shall be 6 mm thick. It shall be fixed with wires parallel with the frame and straight wires vertical. Where translucent wired glass is specified it shall be 6 thick Geogian Wired Cast Glass fixed as described above. Where decorative and special glass is required it shall be as specified in the Additional Clauses. Mirrors shall be of 6 mm. thick selected quality clear plate glass, free from all blemishes, with all exposed edges ground smooth and slightly rounded. The silver shall be protected by an electro copper backing followed by a coating of shellac varnish. The silvering and protective backing shall be taken to the extreme edge of all mirrors. Mirrors shall be drilled during manufacture for screws and shall be fixed with chromium plated dome headed screws, plugged to walls with plastic washers under all screw heads and rubber buffers at back.

3.12.2 Putty Putty for glazing to wood shall comply with B.S. 544 and to metal frames to be of approved manufacture, tropical quality.

3.12.3 Workmanship All glazing and beads in wood shall be sealed or primed before glazing is commenced. All glass shall have clean cut edges. Glazing in putty shall be executed with proper bed and back putties, springs, clips etc. and with splayed and mitred front putties. Back putties shall be trimmed off level with tops of rebates; front putties shall be finished 3 mm. back from sight line to allow for sealing between glass and putty with paint. Glazing fixed in beds shall have both glass and beads bedded and back puttied with the putty trimmed off flush. Beads to be properly mitred and fixed with brass screws. All labour and other incidental materials such as glazing compound, shims, glazing clips, securing devices, felt, etc., not specified but required to complete a satisfactory and approved installation shall be provided. Glazing strips shall be 3 mm. thick approved Neoprene U shaped glazing strip neatly mitred at angles. Actual glass sizes required shall be determined by measuring all frames to receive glass. All glass shall be factory labelled on each pane and the label shall not be removed until final approval. Glass required and not particularly mentioned or described shall be the same as indicated for other similar or corresponding locations. In all cases for either clear or glare and heat reducing glass, in cutting glass for setting, the draw shall appear when set in the horizontal position in all sash units. Glazing must be carried out in such a manner that if draw lines exist they shall not cause any visual distortion. Glass in metal windows shall be secured in place with appropriate type glazing stops or beads sat in approved type cushions that will permit normal expansion and contraction. In glazing metal windows, the Contractor shall follow the instructions of metal window manufacturers as approved by the C.S.R. relative to bedding for installation of glass and setting in glazing compound if so required and approved. On completion of the works, all broken or cracked glass shall be replaced and all glass cleaned both sides to the satisfaction of the C.S.R.

3.13

Plumbing And Sanitary Fittings

3.13.1 General The work shall include all jointing materials, copper nails, lead wedges, wall hooks, tacks, fastening and all other things necessary to make the installation complete in all respects. The whole of the plumbing work shall be tested in such manner as the C.S.R. shall direct and to his satisfaction. On completion, the whole of the installation shall be left for inspection and testing thereafter shall be left in a clean and proper condition.

3.13.2 Materials The Contractor shall supply all pipings, fittings and all sanitary ware as shown on the drawings and in the schedules. They shall be of the best quality and shall be of approved manufacture.

3.13.3 Rainwater Pipes and Fittings 3.13.3.1 Cast Iron Gutters, external down pipes and fittings shall conform to B.S. 460 and shall be to the sizes shown on the drawings. Gutters shall be half round, and shall be jointed with red lead putty and gutter bolts. They shall be fixed to fall not less than 250 mm in 30 m. on galvanised mild steel brackets screwed to the fascia board with rust-proofed screws. Down pipes shall be spigot and socketted and shall be jointed with red lead putty and shall be screwed to the wall with galvanised mild steel straps, plugged and screwed to brickwork or screwed direct to timber framed walls. Internal cast iron down pipes shall conform to B.S. 416 and shall be jointed with yarn and molten lead or approved cold caulking compound. Internal pipes shall be fixed to the structure as described for external pipes. All internal rainwater pipes, gutter brackets and fittings shall be prepared and painted one coat of primer before fixing. 3.13.3.2 Plastic Balloons Plastic gutters, down pipes and fittings shall be P.V.C. and shall be of an approved make. They shall be of the sizes shown on the drawings. Gutters shall be half round and fixed on P.V.C. brackets to a minimum fall of 250 mm in 30 m. The brackets shall be screwed to the fascia board with rust-proof screws. Down pipes shall be fixed with proprietary straps supplied by the manufacturer of the pipes. The whole of the Rainwater Installation shall be installed in accordance with the manufacturers instruction. 3.13.3.3 Access for Cleaning Internal Rainwater Pipework All internal rainwater pipework shall be provided with an adequate number of access plates, cleaning eyes etc. to ensure that the system is fully accessible for cleaning. 3.13.3.4 Wire Balloons All outlets from gutters shall be fitted with galvanised mild steel wire balloon grating of approved design to fit securely into the outlet. 3.13.3.5 Roof and Balcony Outlets Roof and balcony outlets shall be coated cast iron of an approved type. The outlets shall be provided with a luting flange to receive the roof or balcony finish. Roof outlets shall be provided with a coated cast iron done grating. Balcony outlets shall be provided with a coated cast iron flat grating.

3.13.4 Hot & Cold Water Supply The Hot and Cold Water Supply installation shall be carried out in compliance with the By-laws of the Water Authority. 3.13.4.1 Workmanship The whole of the Plumbing work shall be executed in a neat and workmanlike manner to the satisfaction of the C.S.R. All internal piping shall be in the shortest possible runs to fall slightly to the outlets and vertical runs shall be truly vertical. Sweeps and small radius curves shall be avoided. All possible precautions shall be taken against air locks.

All cold and hot supply tubing shall not be surface mounted but properly embedded in the wall, before plastering or tiling in such a way that the outside edge of the pipe fittings or lagged pipe are 13 mm below the final surface unless stated otherwise in the schedule of Finishings. 3.13.4.2 Piping Work General Where reductions in the diameters of the pipes are necessary reducing fittings will be used and not pushed fittings. Where practicable, pipework will follow the line of the walls, vertically and horizontally and pipes shall be set round obstructions in one piece, fittings shall not be used for this purpose. All pipework and joints shall be properly assembled and shall be complete in all respects. The pipe runs shall be done in a workmanlike manner and adequately fixed with proper clips, hangers and brackets. No joints shall be made within the thickness of walls, floors or ceilings, sleeves shall be provided with plates of sufficient diameter to allow free movement of the pipe for expansion and contraction. Ample provision shall be made in the form of unions for future dismantling for cleaning etc. 3.13.4.3 Internal Distribution Cold and hot supplies unless otherwise stated, shall be in hard drawn copper tubing in as long length as possible, carefully bent, jointed by welding or approved couplings; no threaded junctions shall be used. All fittings required to complete the work shall be provided. The Contractor shall thoroughly test the system to the satisfaction of the C.S.R. 3.13.4.4 Hot Water Lagging Hot water supply lines shall be lagged with jute wrapping only where embedded in walls. The insulation shall be smoothed and left ready for plastering. 3.13.4.5 Copper Tubing and Fittings Where copper tubing is specified, it shall conform to BS 2871, and all fittings shall be an approved compression type conforming to B.S.864 Type A or approved capillary type fittings conforming to B.S. 864. The tubing where concealed shall be fixed with copper clips. The tubing where exposed shall be fixed with polished brass pips rings of approved type. The centres of the fixings shall be as described for galvanised mild steel tubing. Underground copper pipes will conform to BS 2871. The fittings will be manipulative gun metal fittings. 3.13.4.6 Galvanised Mild Steel Pipes and Fittings Galvanised mild steal tubing where specified shall conform to B.S.1387 (Class C). Fittings shall be galvanised malleable cast iron to conform to B.S. 1256. All pipes and fittings shall be suitable for screwing to B.S. 21 pipe threads. Jointing shall be by means of screwed joints made with white hemp and an approved non-tainting leadless jointing compound. Reducing pieces shall be provided when jointing pipes of different sizes. All pipework shall be fixed to walls and ceilings with galvanised malleable iron brackets. conforming with B.S. 1494 table 6(a)/7(a) with screwed backplates or tails for building in. Where required extended brackets shall be used which shall consist of galvanised malleable iron pipe rings as Table 13 (a) it screwed galvanised mild steel rods split for building in or with screwed backplates as table 10 (a). Brackets shall be fixed in accordance with the following table on straight runs and in addition at all bends and fittings.

Diameter of tube mm 13 & 19 25 32 38 & 51 64 & 76 102

Centres in m. Vertical 1.83 2.44 3.05 3.66 4.58 4.58 Horizontal 1.07 1.68 2.44 3.05 3.66 3.96

3.13.4.7

Brass Work Brass taps and valves will conform to B.S. 1010.

3.13.4.8

Pipe Sizing Unless stated otherwise supply pipe sizes shall be as follows:Final connections to all fittings except long baths shall be 13 mm diameter. Connections to long baths shall be 19 mm diameter. The sizes of distribution pipes from which these connections are taken shall be as follows:-

Number of Fittings Served 2 3,4 5,6,7 8, 9, 10, 11, 12 13, 14, 15, 16, 17, 18

Diameter of Distribution Pipe, mm 19 25 32 38 51

3.13.4.9

Supply to Sinks & Drinking Fountains All cold water supplies to domestic sinks, drinking fountains and drinking water taps shall be taken directly from the rising main.

3.13.4.10 Stopvalves, Gate Valves & Draining Taps Stopvalves shall be brass, and conform to B.S.1010. Gatevalves shall be brass, and shall conform to B.S.1952. Draining taps shall be brass and conform to B.S.2879. An adequate number of valves and draining taps shall be provided so as to permit the various section of the installation to be isolated and drained down. The following rules shall apply to all installations:i) A stopvalve shall be fitted to the rising main at a height of 305 mm above the point of entry into the building.

ii) iii) iv) v) vi) vii) 3.3.4.11

A draining tap shall be fitted to the rising main immediately above the stopvalve. A stopvalve shall be provided to the rising main as close as possible to the storage cistern. A gatevalve shall be provided to the down supply pipes from all cold water storage cisterns, and electrical water heater as close as possible to each cistern or heater. A stopvalve shall be provided to the branch supply pipe for each range of sanitary fittings at the junction with the main down supply. A draining tap shall be provided at the lowest point of each branch supply pipe to enable the whole of the installation to be drained down. A stopvalve shall be provided to the supply pipe to all electrical water heaters.

Cold Water Storage Cisterns Cold Water Storage Cisterns shall be galvanised mild steel to conform to B.S.417. Grade A or plastic (polyolefin or olefin copolymer) to conform to B.S. 4213 or approved glass reinforced plastic. The cistern shall be of the sizes stated and in the positions shown on the drawings and where galvanised shall be painted inside with 2 coats of non tainting bituminous paint. The cisterns shall be provided with a brass ball valve to conform to B.S.1212 Part 1 with plastic or copper float conforming with B.S. 2456. Each cistern shall be fitted with a 25 mm diameter outlet for connection to wash-out pipe and a stoptap shall be fitted to the wash-out pipe. The end of the wash out or connector shall not project into the cistern. The wash out pipe shall be run to a position to be directed.

3.13.5 Internal Drainage The internal drainage installation shall be carried out in compliance with the relevant By-Laws of Malaysia and BSCP 2005 - Sewerage. 3.13.5.1 Cast Iron Unless stated otherwise soil and ventilating pipes and fittings shall be coated cast iron to conform with B.S. 416. The pipes and fittings shall be jointed with a hemp gasket and molten lead, and be fixed as follows:(i) (ii) To walls with mild steel straps, plugged and screwed, and to ceilings with malleable iron pipe rings to B.S. 1494. Table 13(a) and screwed galvanised mild steel suspension rods split for building in or with screwed back plates as Table 10(a).

3.13.5.2

Galvanised Steel Waste overflow and antisyphonage pipes shall be galvanised mild steel tubing to conform to B.S.1387. Fittings shall be galvanised malleable cast iron to conform to B.S.1256. All pipes and fittings shall be suitable for screwing to B.S.21 pipe threads. Jointing shall be by means of screwed joints made with white hemp and red lead, or approved jointing compound. Waste and antisyphonage pipes shall be fixed as described in Clause 3.13.4.6 of this Specification. All junctions to waste systems shall be made with sweep tees.

3.13.5.3

Access for Cleaning Soil & Waste Pipework The soil and waste system shall be fitted with sufficient access plates or eyes, to ensure that the system is fully accessible for cleaning.

3.13.5.4

Wire Balloons All soil and ventilating pipes shall be fitted at the top with a galvanised mild steel wire balloon grating of approved design to fit securely into the pipe.

3.13.5.5

Floor Gullies Floor gullies shall be coated cast iron, with 89 mm trapped outlet and shall be fitted with a galvanised flat grating of an approved type.

3.13.5.6

Layout of Pipework The positions and runs of soil, waste and water supply pipework shall be approved by the C.S.R. before the installation is commenced. Pipework where exposed shall be set out to give a neat appearance.

3.13.5.7

Builders Work All holes, chases etc in reinforced concrete to accommodate pipework and fittings shall be formed as the structural work proceeds. No cutting into reinforced concrete will be allowed. All holes and chases in walls, floors and ceilings etc. shall be made good on completion of plumbing work and before decoration. Any damage caused to finished work shall be rectified to the satisfaction of the C.S.R.

3.13.5.8

Painting All exposed pipework straps, brackets etc. shall be painted in accordance with the Painting Specification.

3.13.6

Sanitary Fittings All sanitary fittings shall be of Armitage Shanks manufacture, or other approved equivalent, supplied and fixed by the Contractor and unless otherwise stated shall be as described below:-

3.13.6.1

Pedestal W.C. Pans Pedestal W.C. pans shall be of white glazed vitreous china syphonia. They shall have P Q or S traps as required. Where pans are fixed to timber floors they shall be jointed to the drain pipe with hemp gaskin and red lead putty. Where pans are fixed to concrete floors, they shall be jointed to the drain pipe with cement/sand mortar (1:2). The pans shall be screwed to wood floors with rust-proofed screws, and shall be plugged and screwed to concrete floors with rust proofed screws. Where antisyphonage pipes are required, the traps shall be provided with antisyphonage outlets. W.C. seats shall be black plastic and shall comply with B.S. 1254.

3.13.6.2

Squat Type Toilet Squat type toilets shall comprise a closet of white vitreous china as claywood for sinking into the floors and integral or separate tread plates in matching material. The closet shall have P Q or S trap as required. The traps shall be provided with antisyphonage outlets, where required. The closets and tread plates shall be set into a concrete bed with the top surface level with the floor finish.

3.13.6.3

Flushing Cisterns Flushing cisterns shall be black plastic complying with B.S.1125 or white vitreous China complying with B.S.1125 and shall be single flushing type. They shall be fitted with a nylon or brass ball valve to B.S.1212 with a plastic float to B.S.2456 and connections for 12 mm. diameter supply and 19 mm. diameter overflow pipes. Flush pipes shall be provided, which shall be to B.S.1125 and shall be of galvanised mild steel. They shall be jointed to the bottom

of the cisterns by means of watertight unions which allow for easy removal and shall be jointed to W.C. pans by means of approved rubber cone connectors. The cisterns shall be fixed to walls with sherardised steel screws which shall be plugged to concrete, blockwork or brickwork. High level cisterns shall be provided with chromium plated chains with rubber pull handles and shall be fixed at a height of 1.52 m. to the underside of the cistern. Flush pipes shall be 32 mm. diameter and shall be fixed with pipe clips which shall be screwed to walls. Low level cisterns shall be, provided with chromium plated lever flushing handles and shall be fixed at a height of 610 mm. to the underside of the cistern. Flush pipes shall be 35 mm diameter. 3.13.6.4 Toilet Roll Holder Toilet roll holder shall be white vitreous china as Armitage Shank semi-recessed in walls 150 x 150 mm. 3.13.6.5 Towel Rails Towel rails brackets shall be white vitreous china as Armitage Shank complete with CP towel rail 610 mm. long. 3.13.6.6 Paper Hand Towel Dispenser Paper hand towel dispenser shall be approved Molnlycke make manufactured in Sweden, or other approved equivalent. 3.13.6.7 Lavatory Basins Lavatory basins shall be white vitreous china size 635 x 455 mm. overall as Armitage Shanks Avon. Each basin shall be provided with a 32 mm. chromium plated brass waste outlet and rubber plug with chromium plated chain and stay. Provide and fix a 32 mm. trap to each lavatory basin having a 38 or 76 mm. deep seal as necessary. Provide and fix one or two Sovereign 12 mm. pillar taps as required. Where one tap only is required, provide and fix one tap hole stopper to match the basin. The pedestals shall match the basin and shall be to the same B.S. and make. 3.13.6.8 Baths Baths shall be in Trolex fully reinforced acrylic as Armitage Shanks Sheraton 2. Each bath shall be provided with a 38 mm. chromium plated brass waste outlet, and rubber plug with combined chromium plated chain and stay and overflow. Provide and fix a 38 mm. trap to each bath with 38 or 76 mm. deep seal as necessary and with overflow connection. Provide fix Starlite 19 mm. bath and shower mixed with flexible tube and handspray. 3.13.6.9 Sinks Ceramic sinks shall be white glazed fireclay size 610 x 457 x 254 mm deep and shall conform to B.S. 1206 and shall have overflow in centre at back. Each sink shall be provided with a 38 mm. chromium plated brass waste outlet and rubber plug with chromium plated chain and stay. Provide and fix a 38 mm. trap to each sink having a 38 mm. or 76 mm. deep seal as necessary. Provide and fix one or two 12 mm. pillar or bib taps, as required. Pillar taps shall have 152 mm. raising pieces and bibs shall have extension pieces of adequate length. Unless otherwise specified each sink shall be fixed on two cast iron brackets to B.S.1255 plugged and screwed to wall. Metal sinks shall be stainless steel as Bristle manufacture to the sizes stated and shall conform to B.S.1244. They shall be provided with waste outlet, overflow, plug, chain and stay, trap and taps as described for ceramic sinks. Where one tap only is required, a tap hole stopper to match the sink shall be provided. Unless supported on a sink unit or fitting, the sinks shall be provided with suitable legs and bearers in cast iron or galvanised steel with painted finish.

Cleaners sinks shall be white glazed fireclay 533 x 457 x 178 mm. deep with a 152 mm. high back, hardwood pad and chromium plated or polished cast brass bucket grating and shall comply generally with B.S.1206. Each sink shall be provided with a 38 mm. chromium plated brass waste outlet with grating. Provide and fix a 38 mm. trap to each sink, having a 38 mm. or 76 mm. deep seal as necessary. Provide and fix one or two 12 mm. bib taps as required with extension pieces of adequate length. The sinks shall be fixed on two cast iron brackets, plugged and screwed to wall, at a height of 559 mm. from the bucket grating to finished floor level. Laboratory sinks shall be white vitreous china to B.S.3402 size 559 x 356 x 229 mm. deep and shall be provided with a 38 mm. waste outlet, standing waste and overflow all in acid-proof material. They shall be fixed into laboratory benches in accordance with the detail drawings. Provide and fix laboratory water and/or gas supplies as specified. 3.13.6.10 Taps All taps shall conform to B.S.1010. Taps shall be of the following type as appropriate, and where necessary shall be provided with extension pieces. Pillar taps : Chromium plated brass with cross heads ; 12 mm. diameter for basins and sinks, 19 mm. for baths. Bib taps: Unless otherwise stated, 12 mm. diameter chromium plated brass with cross heads, complete with backplate elbow or wall flange. Bib taps to stand pipes shall be 12 mm. diameter, unplated brass, and shall have an extended nozzle suitable for hose connection.

Where hot and cold water is supplied to any one fitting the taps to that fitting shall be provided with suitable markings to indicate Hot or Cold. 3.13.6.11 Drinking Fountains Drinking fountains shall be white vitreous china as Armitage Shank Aqualon. They shall be fitted with a self closing non-concussive valve with chromium plated toggle action lever. The jet nozzle shall be hooded so that it cannot be touched by mouth or contaminated by mouth swilling. They shall be fitted with a 25 mm. diameter chromium plated waste outlet and trap and shall be fixed to walls with concealed cast iron fixing brackets bolted through the fittings. 3.13.6.12 Showers Shower trays, shall be white glazed fireclay size 762 x 762 x 178 mm. deep as Armitage Shanks Moray. They shall be provided with 38 mm. diameter chromium plated brass waste outlet and grating. The tray shall be bedded in cement mortar and the joint between the walls and the tray shall be pointed with approved non-hardening mastic compound. Shower fittings shall be comprised of a 102 mm. diameter adjustable chromium plated brass inclined shower head with rose and 12 mm. diameter supply pipe(s) with 12 mm. diameter stop valve(s) to control the water supply. Where hot and cold water is supplied, a stop valve shall be fitted to both the hot and cold water supply pipes which shall then be connected to a tee junction from which the supply pipe to the shower head is to be connected. The stop valves shall be fixed at a height of 915 mm. above the bottom of the shower tray, shall be chromium plated, shall have back plates and be securely screwed to the wall. Where hot and cold water is supplied, the valves shall be provided with suitable markings to indicate Hot or Cold. The shower head shall be fixed at a height of 1.83 m, above the bottom of the shower tray or finished floor level. All exposed pipework and fittings serving the showers within the shower area shall be chromium plated and fixed with chromium plated holderbats.

Where hot and cold water is supplied, the layout of the plumbing shall be such that the water pressures to the hot and cold supply pipes are balanced so that water can be obtained from the head at all temperatures from cold to maximum heat. All shower trays shall be fitted with a 38 mm diameter traps having a 38 mm or 76 mm deep seal as necessary. 3.13.6.13 Slab Urinals Urinal slabs shall be white glazed fireclay and shall have end screens. All urinals shall have a white glazed fireclay floor channel and white glazed fireclay fluted treads set flush with the floor finish. The channel shall have a 38 mm diameter chromium plated brass outlet with hinged grating. The urinal slabs, channel and floor treads shall be bedded in cement mortar and jointed and pointed with white cement. The flushing cistern shall be a white glazed fireclay automatic flushing cistern, complete with cover, and shall be fixed on white porcelain, enamelled cast iron brackets plugged and screwed to walls. Flush pipes and spreaders shall be chromium plated and shall be fixed to walls with chromium plated holderbats. Provide a 38 mm diameter trap with 38 mm or 76 mm deep seal as necessary. 3.13.6.14 Bowl Urinals Urinals bowls shall be white vitreous china as Armitage Shanks Sanura with lipped basin and flushing rim. They shall be plugged and screwed to walls with brass screws. Flushing cisterns, flush pipes and spreaders shall be as described for slab urinals. The bowl urinals shall be complete with chromium plated brass outlet and trap. 3.13.6.15 Traps Traps shall be of the following types:Traps for sinks, lavatory basins, baths and drinking water fountains Copper, brass, or aluminium, to BS 1184 with cleaning eye. Traps to baths shall have an overflow connection. Traps for shower trays with suspended drainage Copper, brass or aluminium, to B.S. 1184 with cleaning eye and shall have the inlet of an appropriate length. Traps for shower trays with buried drainage 76 mm diameter cast iron to B.S. 1130 Figure 59. They shall be fitted with cast iron connectors with top drilled and threaded to receive outlet from shower tray. Traps for urinals with suspended drains 76 mm diameter cast iron to B.S. 416 Table 14. They shall be fitted with cast iron connectors with top drilled and threaded to receive outlet from urinal. Traps for urinals with buried drainage 76 mm diameter cast iron to B.S. 1130 Figure 59. They shall be fitted with cast iron connectors with top drilled and threaded to receive outlet from urinal. 3.13.6.16 Testing After completion of the works the whole of the installation shall be flushed out and water tested to the satisfaction of the C.A.R. 3.13.6.17 Supervision All plumbing shall be carried out by or under the supervision of a plumber duly licensed by the Water Authority.

3.14

Painting And Decoration

3.14.1 Materials All paints and finishes shall be of an approved type, colour and manufacture. They shall be obtained from Company approved firms and be delivered to the site in the makers containers unopened. All paints shall be applied strictly in accordance with the manufacturers directions and used without adulteration. Any work found to be carried out with adulterated materials shall be removed and reinstated at the Contractors expense. Mixing of paints of different brands before or during application will not be permitted. Undercoats and finishing coats shall be of the same brand. Paint used externally shall be of external quality and all paints shall be anti-fungus type. All paints used shall comply with BSCP 231.403 Painting and distempering Portland Cement Concrete and Cement Plaster. Knotting Knotting shall consist of shellac dissolved in methylated spirits or other approved type. Stopping Stopping shall be of an approved type and for external joinery shall be waterproof. Oil Oil for joinery shall be best clear boiled linseed oil. Filler Grain filler shall be water soluble of an approved type. Varnish (Lacquer) Varnish (Lacquer) shall be clear matt finish polyurethane internal or external quality as appropriate. Wax polish & special polishes Wax polish and special polishes shall be an approved type. Stains Stains shall be water or spirit stains of approved type and colour.

3.14.2 Workmanship - General Every possible precaution shall be taken to keep down dust before and during painting processes. No paint shall be applied to surfaces structurally or superficially damp and all surfaces shall be free from condensation, efflorescence, etc. before the application of each coat. No cleaning or painting will be permitted in wet weather unless carried out under adequate cover approved by the C.S.R. Primed or undercoated woodwork and metal-work shall not be left in an exposed or unsuitable situation for a long period before completion of the painting process. No exterior or exposed painting shall be carried out under adverse conditions, such as rain. Metal fittings such as ironmongery, etc. not required to be painted shall first be fitted and then removed before the preparatory processes are commenced. When all the painting is completed the fittings shall be cleaned and refixed in position.

The Contractor shall be required to repaint at his own expense any work on which the paint shall be found to be incorrectly applied. The Contractor shall be responsible for protecting from damage the paint work and all other work during and after painting operations including the provision of all necessary dust sheets, covers, etc. All coats of paint shall be rubbed down with fine waterproofing abrasive where necessary and be thoroughly dry before subsequent coats are applied. Each coat of paint is to be of a separate and distinct tint.

3.14.3 Preparation of surfaces All surfaces shall be thoroughly dry and free from dust when decoration is carried out. 3.14.3.1 Plaster & Rendering Clean down thoroughly, cut out large cracks, with edges undercut, and make good with stopping. Fill in small cracks, holes and other surface blemishes with stopping. 3.14.3.2 Fair Face Brickwork Clean down thoroughly with a wire brush to remove all dust and mortar droppings. Rake out any cracked or loose mortar and re-point before decoration commences. 3.14.3.3 Fair Face Concrete Clean down thoroughly with a wire brush to remove all dust, dirt and loose material and if necessary wash down with detergent solution to remove shuttering oil. Fill all cracks, and holes with cement mortar neatly trowelled flush. 3.14.3.4 Preparation of galvanised iron surfaces If hot dip galvanised steel is supplied unprimed, all grease, dirt, salt and moisture must be cleaned from the surface before paint is applied. Before new galvanised work can be painted, the surface should be treated with a special solution such as Lithoform or with self-etching primer. The method of using Lithoform is as follows:(a) Remove oil or other foreign substances from the surfaces to be treated, ensuring that the cleaner leaves no residue. All old paint must be removed, by scoring the surface with fine abrasive if necessary. (b) Brush a generous coating of undiluted Lithoform with a scrubbing motion on to the metal surface, which will become dark grey in 2 or 3 minutes. Any bright spangles or light spots remaining should be retouched with Lithoform to make the surface as uniform as possible. (c) Wash the treated surface thoroughly with clean fresh water, before the Lithoform has dried. (d) Allow the treated surface to dry, using clean rags, air-drying or dry in an oven. No moisture should remain in joints or around screw heads, bolts, etc. Lithoform has a covering capacity of 20 m /litre. The treatment of galvanised surfaces with chemicals such as hydrochloric acid or copper sulphate solution before painting is not recommended.

3.14.3.5

Preparation of Aluminium or zinc Surfaces A surface treatment recommended for use before painting aluminium or zinc surfaces is the self-etching or wash primer. This primer is supplied as two liquids to be mixed just before use. The coat of wash primer, which by itself provides only temporary protection, should be regarded as a pretreatment for subsequent coats of paints. It is not intended as a substitute for one of the normal priming coats. Wash primer may be applied by brushing or spraying; the covering power is approximately 8 m/litre. It is dry to the touch in 15 minutes and may be followed with a coat of normal primer in 1 hour.

3.14.3.6

Preparation of Steelwork & Other Metalwork Where structural steel is to be bolted together or built into walls, the parts to be joined together shall be given a coat of approved zinc chromate primer or Red oxide primer. All oil, dirt, etc. must be removed and a perfectly clean surface obtained. All surfaces of structural steelwork shall be prepared as described in Clause 3.4 of this Specification.

3.14.3.7

Preparation of Woodwork to Be Painted Woodwork shall be well seasoned before being painted. Surfaces shall be cleaned to remove grease and dirt. In the case of teak the surface shall be cleaned with white spirit to remove free oil. Knots shall be treated with knotting and the surface primed. When the priming is hard, all cracks, holes, open joints, etc. shall be made good with hard stopping rubbed down with fine glass paper and washed down with fresh water. All holes and cracks shall be stopped as follows :(a) Internal woodwork, hard board and plywood shall be putty tinted to match that of undercoat. (b) External woodwork shall be white lead paste tinted to the colour of undercoat. (c) Clear finished woodwork shall be stopping tinted to match surrounding work. All stoppings shall be allowed to harden and the surface then rubbed down again to a smooth finish suitable to receive paint or finish. The priming paint shall be well worked into the surface by brush and 2 coats shall be applied to end grain. The bottom and top edges of doors are to be primed and painted.

3.14.3.8

Insulating Boards Thoroughly clean down to remove all dust, grease etc.

3.14.4 Application of various finishes The types of finishing paint shall be applied as follows:(a) Emulsion Paint & Seals This may be applied by brush or roller. Paint one coat of primer lime sealer as a primer sealer and two coats of Pentalite emulsion paint undiluted as finishing coat. (b) Alkyd Enamel (ICI - DULUX) The paint shall be applied by brush and used directly from the container without the addition of any thinner. At least 24 hours must be allowed for drying between coats. Prime one coat wood primer, one undercoat and two finish coats shall be applied over properly.

(c) I.C.I. Dulux Weathershield Exterior Wall Finish This may be applied by brush or roller direct onto the new unpainted surfaces. 3 coats of Dulux weathershield shall be applied to the new concrete surfaces as per manufacturers instructions. (d) I.C.I. Dulux Epoxy Chemical Resistant Finish F430-Line The paint shall be applied by brush or roller. Paint one coat of epoxy primer and 3 coats of Dulux Epoxy Chemical Resistant Finish F430-line as finishing coats as per Manufacturers Specification. (e) Teak Oil This shall be applied using a piece of padded cloth, rubbing the teak oil onto the surface with considerable pressure. 2-4 coats should be applied to get the desired appearance.

3.14.5 Paint Schedule for New Work The following paint schedule shall be adhered to:Exterior (a) Cement plastered brick-walls, exposed concrete of beams, columns, lintels, asbestos cement sheets:(b) I.C.I. Dulux weather shield exterior wall finish, or other approved equivalent.

Exposed woodwork:Alkyd enamel paint.

(c)

Steel window frames, door frames, doors, gutters, downpipes, brackets, roof support pipes etc: Alkyd enamel paint.

Interior (a) Plaster brickwalls, exposed concrete, lintels, fair face brickwork and concrete (excluding floors):Prepare and apply one coat of Emulsion Paint thinned with 50% of water and two full coats of Emulsion Paint. (b) Woodwork including Plywood, Chipboard & Blockboard Unless otherwise stated, all exposed woodwork shall be painted as follows:Prepare and apply one coat of aluminium primer. Apply one undercoat, rub down with fine glasspaper and apply one finishing coat of gloss alkyd enamel paint. (c) Non-galvanised Metalwork (NOT STRUCTURAL STEELWORK) All concealed iron and mild steelwork not galvanised shall be painted with 2 coats of bitumastic paint, one before and one after fixing. Exposed mild steelwork (not galvanised) and iron work shall be painted with 2 zinc chromate primer coats (Primocon) and finished off with one undercoat, rub down with fine glass paper, and apply one finishing coat of gloss alkyd enamel paint.

(d)

Galvanised metalwork Prepare and apply:(i) (ii) (iii) (iv) First coat: Second coat: Third coat: Fourth coat: a thin coat of self-etching primer or Lithoform. zinc chromate primer. aluminium paint or gloss alkyd enamel paint. aluminium paint or gloss alkyd enamel paint.

(e)

Fibreboard (Softboard & Medium Hardboard) Internal only Prepare and apply two coats of emulsion paint.

(f)

Structural Steelwork After sandblasting the structural steel surfaces, apply one coat of red oxide primer in the shop. On arrival at site, apply one coat of undercoat of Dulux alkyd Speed Undercoat, and one coat of approved gloss alkyd paint before erection. After erection, paint all steel surfaces with one finishing coat of approved gloss alkyd enamel paint.

3.14.6 The following items shall not be painted, but shall be treated as described:(a) Insides of cupboards, wardrobes, etc. shall be left clean, but the inside face of doors shall be painted. (b) Internal floors shall be waxed as hereinafter described and external floors shall be left clean. (c) Draining boards shall be oiled as hereinafter described. (d) Worktops shall be varnished as hereinafter described. (e) Furniture shall be varnished as hereinafter described. Where finishes other than painting are required they shall be as follows:(a) Varnishing: Prepare and apply one coat varnish thinned with appropriate thinner, and two full coats varnish. Varnish is to be rubbed down with fine glass paper between coats. (b) Polishing: Prepare and apply two coats of wax, or other approved polish, well rubbed into the surface. (c) Oiling: Prepare and apply two coats oil, well rubbed into the surface.

3.14.7 Repainting (i) Cleaning Down Surfaces previously painted or varnished shall be washed down with Teepol or Shirlan solution or approved solvent to remove dirt grease, mould, etc. All flaking or loose paint or varnish shall be removed and all surfaces shall be rubbed down with glass paper, rinsed down with clean water and allowed to dry. Unless stated otherwise all previously decorated surfaces shall be decorated as follows in colours to match existing, in accordance with the specification for new work.

(ii)

Surfaces previously Gloss Painted After cleaning down, the surfaces shall be prepared as necessary, as described for new work. Any bare patches shall be primed and undercoated to bring forward to the general surface. The whole surface shall then be rubbed down smooth and painted with one undercoat and one finishing coat of gloss paint as specified for New Work.

(iii)

Surfaces previously Emulsion Painted After cleaning down, the surfaces shall be prepared as necessary, as described for new work. Any bare patches shall be painted one mist coat and the whole surface shall be painted two coats of emulsion paint as necessary to obtain a uniform colour.

(iv)

Surfaces previously Cement Painted After cleaning down, the surfaces shall be prepared as necessary as described for new work. Any bare patches shall be painted with sealer and one coat cement paint. The whole of the surface shall then be painted one coat of cement paint to obtain a uniform colour.

(v)

Surfaces previously varnished After cleaning down, the surfaces shall be prepared as necessary, as described for New Work. All bare patches shall be stained to match the colour of the existing material and the whole surface shall be given two coats of varnish, including rubbing down after the first coat.

(vi)

Surfaces previously polished All surfaces shall be sanded down to remove existing polish. The surfaces shall be thoroughly cleaned and surface blemishes then made good. Apply two coats of polish as specified for New Work.

(vii)

Steelwork All rusty parts of the steel works must be thoroughly cleaned by machine wire brush before applying red oxide metal primer. 2 coats of red oxide metal primer & 2 coats of gloss alkyd paint should be applied to bare metal. Paint work on steel work which is still in good condition should be cleaned before applying another coat of gloss alkyd paint.

3.14.8 Colour The colour scheme shall be advised later by the C.A.R. in writing.

3.14.9 Leave Clean on Completion On completion wash off paint and stains from walls, floors etc. Clean away all rubbish and superfluous materials and leave the whole of the premises fit and ready for immediate occupation.

3.15

Sewerage The whole of the drainage installation shall be carried out in compliance with the Relevant By-laws.

3.15.1 Excavation Excavation work shall be carried out generally as described in Excavation. The following additional requirements shall be applicable to Excavation for drainage:(i) Excavation for drain trenches shall be first carried down to approximately 76 mm. above the required level. The remaining 76 mm. shall be excavated immediately prior to laying the pipes. The width and depth of trenches shall be in accordance with the following schedule:-

(ii)

Nominal size of pipes in mm 100 150 229 305 381 457 533 610

Nominal width of trench in mm 610

Extra depth of trench below the Pipe-invert in mm 165

686 762 991 1067 1143 1219

191 216 229 241 254 279

Supporting Collars shall be left in the bedding and trench width increased at each joint (in case of A.C. pipes only) to allow adequate working space for assembly and inspection of joints. (iii) The first 305 mm. of back-filling shall be screened free from large stones and shall be hand-packed, watered if necessary, and well rammed on either side of the pipe.

3.15.2 Sundry Materials Hardcore shall be as specified in Excavation. Cement, aggregates and water shall be as described in Concretework. Sand for brickwork, pipe jointing and pipe bedding shall be as described in Brickwork. Sand for rendering shall be as described in Plastering for external rendering. Concrete and reinforcement generally shall be as described in Concretework. Brickwork generally shall be as described in Brickwork and shall consist of Kiln bricks bedded and jointed in cement/sand mortar (1:3).

3.15.3 Glazed Stoneware Pipes & Fittings Glazed Stoneware Pipes and fittings shall be spigot and socketed and shall comply with B.S. 65 for soil drainage they shall be British Standard quality, and for storm drainage British Standard Surface Water quality. Stoneware pipes and fittings shall be jointed with a tarred gaskin lightly caulked and cement/sand mortar (1:1) well rammed to the full depth of the socket and finished off with a 45 fillet, or shall be jointed with approved rubber ring flexible joints.

3.15.4 Concrete Pipes and Fittings Concrete drain pipes and fittings shall be spigot and socket and shall comply with BS 5911 (Part 1 & 3). Jointing of concrete pipes and fittings shall be as described for Glazed Stoneware, except that the spigots and sockets shall be well wetted before jointing.

3.15.5 Porous Pipes Porous pipes for Land Drainage and Septic Tank effluent shall be clayware Field Drain Pipes complying with B.S. 1196. They shall be laid unjointed and surrounded with a minimum of 150 mm broken stone or other approved material.

3.15.6 Gulleys and Traps Gulleys and Traps shall comply with the relevant British Standards as follows:Glazed Stoneware Cast Iron BS 437

Jointing of gulleys and traps shall be as described for the pipes of the same material. Gulley gratings, unless otherwise specified shall be coated cast iron.

3.15.7 Drainlaying All drains shall be laid in straight lines and to even gradients to the levels stated. Unless otherwise stated the drains shall be laid to gradients within the following limits:-

100 mm. dia. -

Maximum gradient Minimum gradient

- 1 in 30 - 1 in 60 - 1 in 50 - 1 in 120 - 1 in 70 - 1 in 200 - 1 in 100 - 1 in 300

150 mm. dia. -

Maximum gradient Minimum gradient

229 mm. dia. -

Maximum gradient Minimum gradient

305 mm. dia. -

Maximum gradient Minimum gradient

All drains shall be kept free from earth, debris etc. and immediately after jointing each pipe shall be cleaned out to remove any excess mortar or other jointing materials. Before backfilling of trenches or placing of concrete haunchings or surrounds to pipes the drainage system shall be tested and approved by the C.S.R. as described in Clause No. 3.15.27 hereinafter.

3.15.8 Beds, Haunchings and Surrounds Beds, haunchings and surrounds shall be provided to drain pipes and fittings as follows :-

Flexible Jointed Pipes The trench excavated as per Clause 3.15.1 shall be filled with sand, full width, up to a height of half the diameter of the pipes to be laid. Suitable supporting collars made of cement-sand mix shall be placed under the pipes to correct level and alignment (two collars under each pipe). Each pipe shall be carefully lowered and placed in position, suitable tackle being used for the purpose where necessary, and each shall be accurately boned into the line and level with the travelling rod between the sight-rails. Pipe laying shall commence at the down-stream end of each section. Piled concrete rafts, concrete bed or concrete surround shall be provided in accordance with the drawings if so directed by the C.S.R.

Glazed Stoneware (with cement and sand joints) Pipes shall be laid on a concrete bed (1:2:4 mix 19 mm max aggregate) 150 mm thick and 305 mm wider than the external diameter of the pipe. Unless otherwise stated the pipes shall be haunched both sides with similar concrete after jointing. The haunching shall be carried up for the full width of the bed to the level of the horizontal diameter of the pipe and from this level carried up at 45 to meet the pipe barrel. Where pipes are specified to be surrounded, the concrete shall be carried up from the bed in a square section with a minimum of 150 mm thickness over the barrel of the pipe.

Cast Iron Generally as described for Glazed Stoneware.

Concrete Generally as described for Glazed Stoneware.

Gulleys Gulleys shall be set on and surrounded with 150 mm concrete (mix as described above). Where external gullies occur next to walls, they shall be surrounded with a concrete curb 100 mm x 75 mm.

3.15.9 Types of Drain Pipes Unless otherwise stated the following types of drain pipes and fittings shall be used :-

Rainwater Drainage All drains, except where under buildings or above ground shall be glazed stone-ware.

Soil Drainage Main drain runs (i.e. between manholes septic tanks etc.) except where under buildings or above ground, shall be asbestos cement. Branch drains (i.e. from the buildings to the main runs), shall be glazed stone-ware, except where under buildings.

Drains under Buildings All drains under buildings shall be cast iron which shall extend 915 mm beyond the external face of the external wall.

3.15.10 Drains Under Roads, Hardstanding etc. All drains under roads, hardstanding etc. having less than 1.22 m cover above round of pipe shall be surrounded with concrete as described.

3.15.11 Shallow Drains All drains with ground cover of less than 915 mm shall be surrounded with concrete as described.

3.15.12 Drains in Filled Ground All drains (including surface water block drains) laid on filled ground shall be laid on beds as specified together with any additional foundations and/or piling shown on the detail drawings or specified. The approval of the C.S.R. is to be obtained before drainage work in filled ground is commenced. 3.15.13 Drains Above Ground Level Where drains are laid above ground, cast iron pipes and fittings shall be used and shall be supported on brick or concrete piers on suitable foundations for non made-up ground. Where drains are laid above filled ground special foundations and/or piling shall be carried out in accordance with the detail drawings or specification.

3.15.14 Manholes (External) Manholes, circular or rectangular, unless otherwise stated shall be constructed as follows : Walls shall be 229 mm thick kiln-brick as described in brick-layer or 150 mm thick R.C. concrete (1:2:4 mix 19 mm maximum aggregate) reinforced with B.R.C. No. 65 or equivalent. The base-slab shall project 150 mm beyond the external face of the walls and shall be concrete (1:2:4 mix, 19 mm maximum aggregate). It shall be 150 mm thick for manholes up to 1.83 m

depth and 229 mm thick for manholes over 1.83 m depth up to 2.44 m depth and shall be reinforced with one layer of B.R.C. No. 61, or equivalent, reinforcement placed centrally. Channels and junctions shall be formed in the benching which shall consist of concrete (1:1 :3 mix, 10 mm maximum aggregate) and shall be rendered with cement and sand (1:3) 12 mm thick and trowelled smooth with a steel-trowel. Drainpipes and branches shall be built into the walls and manholes and solidly bedded in cement-sand mortar (1:3). The junctions shall be formed so that the invert meets the main channel at a height above the invert level of the main channel equivalent to > of the diameter of the main channel, and the top of the benching shall be sloped 1 to 6 towards the main channel. When A.C. pipes are used for drain-laying the length of pipe to be embedded in the walls of the manholes shall not exceed 991 mm to allow for differential settlement. For soil-manholes the internal face of brick work shall be rendered with 19 mm cement-sand 1:3 rendering. For storm-water manholes the internal face of brick work shall be flush pointed. The internal face of concrete manholes shall be fair-face. To manholes exceeding 762 mm depth galvanised mild steel step-irons 762 mm girth shall be built into the walls at 406 mm intervals from the top of the manhole and shall be staggered and located under the cover-frame for easy access. The cover-slab shall be 150 mm thick cement concrete (1:2:4 mix 19 mm aggregate) and shall be reinforced with 19 mm diameter mild steel bars spaced at 150 mm centres in both directions and placed at bottom of slab with 50 mm cover. It shall have an opening to suit the size of the cover frame. Build two to five (maximum) courses of brick work on the top of the concrete slab to receive the cover frame which shall bedded in 1:3 cement-sand mortar so that the top is level with the finished ground-level or paving-surface. The internal and external surfaces of the brick work are to be rendered in 1:3 cement-sand mortar and the brick work is to be corbelled over to receive cover.

3.15.15 Manholes (Internal) Manholes within the building shall be constructed generally as for external manholes with the following exceptions:i) In place of open channels and junctions, coated cast iron access pipes with bolted on covers and the requisite number of branches shall be provided. They shall be bedded in concrete up to the underside of the cover plate. In reinforced concrete floor slabs, the opening for the cover frame shall be formed in the floor slab in accordance with the structural details. In un-reinforced concrete floor slabs the cover slab shall be as described for external manholes. The cover frame shall be bedded directly on to the cover slab. (Which shall be rebated if necessary) and set flush with the finished floor level.

ii) iii) iv)

3.15.16 Size of Manholes The size of manholes shall be as follows:a. Up to 610 mm deep - 686 mm x 686 mm b. Over 610 mm but not over 1.22 m deep - 1.22 x 0.92 m or 1.22 m diameter c. Over 1.22 m but not over 2.44 m - 1.22 x 1.22 m or 1.22 m dia.

d. Over 2.44 m deep to be constructed as per detailed drawings.

3.15.17 Piling for Manholes Where piling is specified under the manholes base it shall be carried out by using five numbers of 150 mm diameter Bakau piles (four number to be equally spaced in a circle of 1.07 m diameter and one number in the centre of the circle) to be driven as specified, cut off 50 mm below the bottom level of the manholes base and topped with 50 mm thick lean concrete before laying the manhole base. 3.15.18 Manhole Covers and Frames Manhole covers and frames shall be cast iron and shall comply with B.S. 497. The types of covers and frames shall be as follows :-

Location Roads, Hardstandings, Car Parks: Footpaths, paved areas and grassed areas. Within buildings

Type Heavy duty with 559mm diameter clear opening and weighing 127 kg Medium duty Grade B, Ref. B5-24/18 with 610 x 457 mm clear opening and weighing 143 kg. Light duty Grade C. Single-seal recessed type Ref. C8/24/18 with 610 x 457 mm clear opening and weighing 54.5 kg. Covers shall be fixed with 12 mm x 32 mm brass screws.

External Manhole covers shall be set into the frames in a mixture of heavy grease and sand. Internal Manhole covers shall be screwed. Manhole covers in floor tiling or external paving shall be positioned to line up with the joint lines of such materials. 3.15.19 Back Drops to Manholes Back drop to manholes shall comprises cast-iron tees, pipe work and bends encased in concrete 150 mm thick all round and shall be to the depth stated. A short length of pipe shall be fitted to the tee-junction and shall be provided with a screwed access-plate on the inside face of the manhole. In case of manholes where the drop exceeds 1.22 m an extra step-iron shall be provided for a man to stand inside the manhole for easy clearance of drain-blockages. Where invert-levels are not stated or back-drops are not sufficiently indicated the contractor shall make allowance in his tender for providing a sufficient number of back-drops in suitable position so that the maximum falls for drains (as stated in clause 3.15.8) is not exceeded.

3.15.20 Different Types of Manholes Construction of Manholes with precast R.C. rings, precast R.C. pipes or prefabricated P.V.C. materials etc. may be allowed to be carried out in accordance with the detailed drawing and specifications to be approved by the Company Engineer.

3.15.21 Ventilation Each main soil drainage run shall be provided with ventilating pipes in positions shown on the drawings and in accordance with the relevant by-laws. The ventilating pipes shall be as specified in Plumbing.

3.15.22 Septic Tanks, Filter Beds and Cesspools Septic tanks, filter beds and cesspools shall be constructed in accordance with the detail drawings.

3.15.23 Soakaways Soakaways shall be formed by excavating pits to the sizes and positions shown and filling to within 305 mm of the finished ground level with broken brick or stone, minimum size 76 mm. Top with 305 mm thickness of topsoil, level off and make good to ground surface.

3.15.24 Concrete Surface Water Channels Channels shall be of concrete (1:2:4 mix 12 mm max aggregate) reinforced with B.R.C. No. 65 mesh (or equivalent) reinforcement to the sizes shown on the drawings. The channels shall be laid to suitable falls and the sides of the channels shall be extended up to ground level in insitu concrete of the same mix. Where sizes are not indicated the channels shall be 229 mm diameter half round with 76 mm thick base and sides. All channels shall be rendered internally with 1:3 cement/sand and finished smooth. All channels shall be laid on a 100 mm thick bed of hardcore.

3.15.25 Concrete Block Surface Water Drains Concrete block drains shall be precast concrete (1:2:4 mix 12 mm max aggregate) to the sizes shown on the drawings. They shall be reinforced with one layer B.R.C. No. 65 mesh (or equivalent) reinforcement and shall be cast in units 610 mm long. The units shall be jointed with cement/sand mortar (1:3 mix). The internal surfaces shall be perfectly smooth from the mould. No rendering of the inside surfaces to give a smooth face will be permitted and any units so treated will be rejected. The drains shall be laid in trenches on solid ground which shall be compacted if required to the satisfaction of the C.S.R. The drains shall be laid to the levels and falls shown on the drawings. Where cascade drains are required the units of block drain shall be stepped and overlapped to form a cascade. Each unit shall be laid horizontally, commencing at the lowest level and 229 mm. thickness of concrete (1:2:4 19 mm max. aggregate) shall be placed at the back of each unit extending up to the underside of the unit above.

3.15.26 Inspection and Testing Close inspection shall be maintained at every stage of the drainage work to ensure that pipes and fittings are laid as specified and that the drainage system is kept clean during the works. All lengths of drain shall be thoroughly cleaned out before testing. The system shall be tested twice:The first test shall be carried out as soon as practicable after laying (but not less than 48 hours after jointing) and before haunching or surrounding pipes and before backfilling trenches. The second test shall be carried out on completion of the works. The tests shall be carried out, where possible to a complete section of drainage between manholes. Short branch drains shall be tested with the main drain run. Long branch drains shall be tested separately. The Contractor shall carry out the tests in the presence of the C.S.R. and all necessary remedial work shall be to his satisfaction.

The drains shall be tested by water tests, which shall be carried out as follows:For gravity drains, the lower end, and the ends of all branches to the length of drain to be tested shall be plugged. Where the higher end of the length to be tested is connected to a manhole, the drain and the manhole shall be filled with water to a height 1.22 m above the invert of the manhole. Where the higher end of the length of drain to be tested is not connected to a manhole, a temporary stand pipe shall be constructed and the drain then filled with water to a height of 1.22 m above the invert level of the highest point of the drain. If any leaks are immediately visible, the contractor shall remedy these and when the remedial works have been completed the testing procedure shall recommence. The drain shall remain under test for 30 minutes and if the loss of water during that period exceeds 0.91 litres per hour per 30 linear metre per 25 mm of nominal internal dia of pipe, the drain under test shall be deemed to have failed the test. For Force Mains (i.e. drains under pressure), after the pipe has been laid to correct grade and alignment, and thrust blocks have been installed at the bends, but before back filling has commenced, the force main shall be subjected to a hydrostatic leakage test. The lower end of the pipe shall be fitted with a suitable blank cap or flange adequately shored, the other end of the pumping main shall be fitted with a suitable cap adequately shored and fitted with an air vent, a pressure gauge, and tapped to receive the coupling from a standard hand operated pipe testing pump. The force main shall be filled with clean water, all air expelled and a pressure of 50% in excess of the working pressure applied. All pipes, fittings, valves and joints shall be examined carefully for defects. All visible leaks shall be repaired and made water tight. The pressure shall be maintained at the test pressure over a period of one hour and the water necessary to keep up the pressure shall be measured. The hourly leakage for the various sizes of force main shall not exceed that indicated in the table below. 102 mm pipe 152 mm pipe 203 mm pipe 229 mm pipe 254 mm pipe 305 mm pipe 381 mm pipe 533 mm pipe - 9.1 litres per hour - 13.6 litres per hour - 1 8.2 litres per hour - 22.7 litres per hour - 22.7 litres per hour - 27.3 litres per hour - 31.8 litres per hour - 40.9 litres per hour

Should any length fail a test, the Contractor shall search for and remedy all defects and the drain shall then be re-tested. The C.S.R. may carry out any additional tests which he considers necessary to ensure that the works have been carried out in accordance with the specification. The Contractor shall provide all labour, water, other materials and equipment required for testing and these shall all be to the satisfaction of the C.S.R.

3.16

Gas Installation

3.16.1 General: The Installation shall be carried out in accordance with CP 331.

3.16.2 Gas Piping Gas Piping shall be of galvanised steel tubing complying with B.S. 1387 Class C or copper tubing complying with B.S. 659.

3.16.3 Pipe Fittings and Joints in Piping Fittings to steel shall be galvanised malleable cast iron to conform to B.S. 1256. All steel pipes and fittings thereto shall have ends screwed to B.S. 21 and all male ends shall be tapered. Joints shall be made with an approved jointing compound which is resistant to L.P. gas and which remains plastic. The jointing compound shall be applied to the male ends only. Hemp and similar materials shall not be used in jointing. Fittings to copper tubing shall be approved capillary type fittings conforming to B.S. 864, or compression type fittings conforming to B.S. 864 type A.

3.16.4 Fixing Piping Surface fixed steel pipes shall be fixed to walls or ceilings or in ducts with galvanised malleable iron brackets conforming to B.S. 1494 table 6(a)/7(a) with screwed bradplates or tails for building in. Brackets shall be fixed in accordance with the following table on straight runs and in addition at all bends, elbows and fittings.

Diameter of Pipe in mm 12 19 & 25 & 32 38 & 50

Centres in m. Vertical 2.4 3.0 3.7 Horizontal 1.3 2.4 3.0

Surface fixed copper tubing shall be fixed with copper clips where concealed and polished brass pipe rings of approved type where exposed. The centres of fixing shall be as described for steel pipes. Pipes buried in chases shall be fixed below the surface and the chase shall be completely filled with cement and sand mortar (1:3) No pipes shall be bent, all changes in direction shall be made by use of fittings. No bushing shall be used, all reductions in sizes shall be made with reducing tees, elbows or couplings. 50 mm diameter gas line shall be connected from 50 mm off-take on 102 mm diameter main line near the road-side. A main control valve shall be fitted as near as practicable to the gas supply and a control plug cock shall be fitted to each branch supply serving a fitting or range of fittings at the junction with the main supply pipe. In addition to the foregoing additional plug cocks and valves shall be fitted as required by good engineering practice.

3.16.6 Layout of Piping and Positions of Outlets etc: The layout of piping and positions of outlets etc shall be as shown on the drawings or, where not shown, shall be agreed with the C.S.R. before work commences.

3.16.7 Underground Piping Underground pipes shall be laid in an 500 mm wide trench 600 mm deep and shall be backfilled in accordance with the specification in Excavation.

3.16.8 Road Crossings At road crossings the pipe shall be laid through 150 mm dia. steel pipe sleeves.

3.16.9 Builders Works All holes chases etc. in reinforced concrete work to accommodate piping or fittings shall be formed as the structural work proceeds. No cutting into reinforced concrete work will be allowed. All holes and chases shall be made good on completion of the gas installation and before decoration. Any damage caused to finished work shall be made good to the satisfaction of the C.S.R.

3.16.10 Painting All exposed pipework and fittings shall be painted in accordance with the painting specification.

3.16.11 Testing After completion, the whole installation is to be tested as follows: The ends and outlets of the system are to be capped or suitably sealed with the exception of one which is to be fitted with a tee piece having a cock on one outlet and a pressure gauge on the other. Air shall then be pumped into the installation pipe system through the cock on the tee piece until a pressure of 305 mm water column is registered on the pressure gauge. The cock shall then be shut and, if after the expiration of one minute from the time of shutting off the cock, no fall of pressure is registered on the pressure gauge in the following two minutes, the system shall be deemed to have complied with the test. All equipment and labour necessary for testing shall be supplied by the Contractor at his cost and the testing shall be carried out in the presence of the C.S.R.

3.17

Electrical

3.17.1 General This Section shall govern the minimum requirement for standard of workmanship and construction techniques for electrical installations. All electrical work shall be executed strictly in accordance with the drawings and project engineering specifications. Deviation from the drawings or specifications shall be permitted only with approval of the Company Site Representative (C.S.R.). The C.S.R. shall be advised in writing of any conflict arising from the drawings or specifications.

3.17.2 Standards and Codes The following standards and codes shall be applied and all works, shall be carried out in accordance with these publications. (a) The Institute of Electrical Engineers (IEE) Regulations for Electrical Installations. (Latest edition). (b) British Standard Code of Practice CP-1013 - earthing. (c) PETRONAS Manual. PTS. 33.64.10.10 - Electrical Engineering Guidelines (d) Relevant British Standards (e) Local Regulations