Civil Works - Tech Specs - Sewerage

TECHNICAL
SPECIFICATION FOR
MINOR CIVIL WORKS

Revision. January/2010

SECTION 1
GENERAL
Section 1 - General
TABLE OF CONTENT

Page
1.0 GENERAL 1-1

1.1 Materials 1-1
1.2 Standards 1-1
1.3 Samples and Tests 1-1
1.4 Test Certificates 1-2
1.5 Independent and Local Tests 1-2
1.6 Testing Facilities 1-2
1.7 Access Road 1-2
1.8 Environmental and Social Protection Requirements 1-3
1.9 Health, Safety and Environmental 1-7
1.10 The Site 1-13
1.11 Access to the Site 1-13
1.12 Working Space and Work through Private Land 1-14
1.13 Trespass on Adjacent Property 1-14
1.14 Existing Services 1-15
1.15 Works in Roads and Footpaths 1-15
1.16 Claims for Damage to Person or Property 1-15
1.17 Amenities to be Preserved 1-16
1.18 Works to be Kept Clear of Water 1-16
1.19 Discharge of Water and Waste 1-16
1.20 Temporary Fencing 1-17
1.21 Temporary Works Construction and Design 1-17
1.22 Water Supply 1-17
1.23 Power Supply 1-18
1.24 Temporary Sanitary Conveniences 1-18
1.25 Site to be Kept Tidy 1-18
1.26 General Hygiene and Medical Examination of Contractor's
Employees 1-18
1.27 Temporary Buildings for Use by Contractor 1-19

APPENDIX 1.1: Standard Compliance

Section 1 - General
GENERAL

1.1 Materials

The term 'materials' shall mean all materials and articles of every kind whether raw, processed or
manufactured to be supplied by the Contractor for incorporation in the Works. Except as may be
otherwise specified for particular parts of the Works, the provisions in this section of the
Specification shall apply to materials and workmanship for any part of the Works.

All materials other than natural or pretreated materials shall be new and of the kinds and qualities
described in the Contract and shall at least be equal to approved samples, where applicable.

Materials shall be transported, handled and stored in such a manner as to prevent deterioration,
damage or contamination.

1.2 Standards

All workmanship, materials and components throughout shall where applicable and unless otherwise
stated in the Contract comply either (a) with the relevant Malaysian or British Standard or Code of
Practice current on the date fixed for receipt of tenders or (b) with other Standards or Codes of
Practice proposed by the Contractor at the time of submitting his tender provided that these Standards
or Codes of Practice are equivalent or superior to the relevant Malaysian.

1.3 Samples and Tests

The Contractor shall submit samples of such materials as may be required by the S.O. and shall carry
out the specified tests directed by the S.O. at the place of manufacture or on the Site or at a laboratory
approved by the S.O.

Samples shall be submitted and tests carried out sufficiently early to enable further samples to be
submitted and tested if required by the S.O. The Contractor shall prepare the necessary test pieces and
supply all labour, appliances, testing apparatus and everything necessary for the carrying out of all the
specified tests.

Unless otherwise provided for separately in the Bill of Quantities, the cost of the samples and of
conducting all the specified tests on the samples shall be included in the Contract Rates.

The Contractor shall give the S.O. fourteen days notice in writing of the date on which any of the
samples will be ready for testing or inspection at the place of manufacture or at a laboratory approved
by the S.O. and unless the S.O. shall attend at the appointed place within the said fourteen days the
test may proceed in his absence. Provided that the Contractor shall in any case submit to the S.O.
within seven days of every test such number of certified copies (not exceeding six) of the test
readings as the S.O. may require.

Approval by the S.O. as to the placing of orders for materials or as to samples or tests shall not
prejudice any of the S.O.s powers under the Contract.

Specifications for Minor Civil Works 1-1
Issue 01 / Revision 01
January 2010

Section 1 - General
1.4 Test Certificates

Certificates shall be provided by the Contractor in respect of materials to be used in the Works giving
the results of the specified tests. The required copies of submission shall be as per project specific
requirement (refer General Specification of Tender Document). The material shall be suitably marked
to enable it to be identified from references on the certificates.

No materials subject to test shall be incorporated into the Works until the receipt by the S.O. of a
satisfactory Test Certificate.

In case of any items of the Works which have not been inspected at the manufacturer's works, the
Contractor shall obtain from the manufacturer and supply to the S.O. certificates signed by the
manufacturer giving the results of the tests as carried out and certifying that the items have been
manufactured in accordance with this Specification.

1.5 Independent and Local Tests

The S.O. reserves the right to carry out any independent or local tests he may deem fit on any
material to be used in the Works, at any stage of manufacture or delivery. Any samples of materials
which may be required for such tests shall be provided by the Contractor at no extra cost to the
Employer.

The cost of making any such independent tests shall be borne by the Employer, unless it can be
shown that the workmanship or materials under test are not in accordance with the Specification in
which case the costs of the tests shall be borne by the Contractor. Any materials or completed items
of the Works which are shown by such independent tests to be not in accordance with the
Specification shall be rejected notwithstanding any previous certificate which may have been
provided.

1.6 Testing Facilities

The Contractor shall at his own expense arrange with the suppliers or manufacturers to supply the
necessary gauges and prepare all test pieces and supply all labour and apparatus for testing which
may be necessary or which may be required by the S.O for carrying out the tests and requirements of
this Specifications at the Contractors premises or at the place of manufacture, and shall also provide
all test pieces required. If the Contractor fails to perform any of the foregoing obligations, the S.O.
shall be at liberty to perform the said obligations or any of them which the Contractor has failed to
perform, either at the Contractors premises, places of manufacture or elsewhere and charge the costs
and expenses thereof to the Contractor.

1.7 Access Roads

The access roads to and within the Site shall be completed for the readiness of the civil works to
permit plant erection and for easy access to the Employer and to others. The access roads shall be
maintained to permit good and reasonable access at all times to complete the various sections of
works as specified.

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The works to be completed shall also include all culverts, drains, manholes and all turfing necessary
to prevent erosion and deposition of silt on the roads. The Contractor shall maintain and make good
any damage of the roads for easy access to the Site and to areas within the Site.

The Contractor shall maintain and make good any damaged areas to the satisfaction of the S.O. until
all construction and erection works are completed notwithstanding whether the damages of the access
roads are due to the Contractors own doing or by others.

1.8 Environmental and Social Protection Requirements

The civil construction and ancillary works is anticipated to generate both beneficial and adverse
impacts of varying degree on the existing environment. It is important to implement strategies and
techniques to control the extent of environmental impacts to acceptable levels. The Contractor is
required to take necessary actions or mitigation measures to eliminate or minimise adverse
environmental impacts. The mitigation measures identified by S.O. shall be implemented by the
Contractor during the construction Stage.

The Contractor shall comply in all respects with the Conditions of Approval issued by Jabatan Alam
Sekitar as detailed in EIA Approval letter if any.

(a) Soil Erosion

One of the major impacts identified during site clearance and related earthworks activities is soil
erosion and related problems such as increased silt loads and sedimentation rates. The extent of soil
erosion as a result of these activities shall be minimised through the implementation of the following
mitigation measures.

The approach taken to erosion and sediment control shall incorporate:

- exposure of the smallest practical area of land for the shortest time possible;

- application of adequate erosion and sediment control measures within the Site boundary and
downstream areas; and

- implementation of a thorough maintenance and follow-up programme to ensure the
effectiveness of the control measures.

Selective Clearance

The foremost approach to counter soil erosion problems shall be to undertake land clearance in
sections or stages, thereby reducing the surface area exposed to the weather at any one time. In
addition, by compartmentalising the felling of trees from high to low ground, the remaining
vegetation can act as silt barrier. This strategy shall be best approached through advance planning of
the works especially in the coordination between clearing works, supply of equipment and materials
and execution of construction works to avoid undue delays of the project schedule.

Stormwater Diversion

Temporary stormwater diversion ditches shall be adequately installed prior to the construction works
to divert stormwater from any exposed areas which may otherwise aggravate soil detachment leading
to soil erosion and landslides.

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Upon completion of the construction works and when demobilisation activities take place, the
diversion ditches which are not submerged by the reservoir shall be revegetated.

Silt Traps and Sedimentation Ponds

Wherever required, silt traps and sedimentation ponds shall be strategically installed prior to land
clearance activities and earthworks. These silt control structures are essential to intercept any run-off
from the site before entering the receiving waterways thus reducing sediment loads into the
watercourses.

Any discharges from the sedimentation ponds into the watercourses shall not contain suspended
solids of more than 50 mg/l. Regular desilting and maintenance of the silt traps and sedimentation
ponds is necessary to ensure effectiveness of the silt control measures. These structures when no
longer in use, shall be removed and the ground reinstated and revegetated.

Revegetation/Ground Cover

During land clearance and construction stages, topsoil, turf and other suitable vegetation shall be
placed as immediate temporary cover on all exposed surface areas which are not going to be
inundated. Methods such as coconut matting and hydroseeding shall be adopted. This will minimise
erosion of stripped or cut soil while making provision for permanent ground cover. In addition,
plastic, PVC covers or other protection structures which are impervious to water shall also be
temporarily used on all exposed surfaces, particularly on sloping areas.

(b) Materials Handling and Disposal of Waste Material

Soil contamination at the material storage and vehicle maintenance areas shall be avoided through
proper storage and handling of materials such as fuel, lubricants and chemicals. During the
demobilisation stage, all equipment and vehicles used during the construction activities shall be
removed from the Site. Liquid wastes are also required to be removed from the Site and disposed in a
proper manner by a licensed waste collector.

Civil construction works is expected to generate substantial quantities of waste material. Necessary
actions shall be adopted to reduce and dispose of unwanted materials, the waste material shall be
disposed at a pre-selected disposal site as approved by the local authority.

(c) Landuse and Aesthetics

During the construction phase, temporary structures and exposed areas such as the storage and borrow
areas, shall be minimised in order to reduce the impact on the aesthetics of the general environment.
The project site will need to be rehabilitated at the end of the construction phase. Therefore, the
arrangement of temporary structures shall be considered during the planning stage incorporating
detailed rehabilitation plans for these areas.

Surplus excavated material and construction waste generated from the excavation works shall be
disposed of. As much of the material as possible shall be processed for use in the construction works.
It should be noted that the disposal of spoil requires written consent from the DOE as legislated in
Section 24 of the Environmental Quality Act 1974 (Act 127). In general, the selected sites for the
disposal of spoil shall be located where they will not cause siltation problems in the streams. Where
necessary, the waste piles shall be levelled and turfed or landscaped to prevent erosion.

Strategic locations shall be opted for construction of temporary access or haul roads to the
construction siter. The construction of access roads to the construction sites shall be limited as much

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as possible to avoid excessive land conversion. This will also minimise the short term visual and soil
erosion impacts on the existing environment.
It is expected that re-establishment of vegetation will occur in the areas previously cleared during the
construction stage. Exposed slopes shall be immediately revegetated, both for erosion control and to
maintain a visually pleasing appearance at the site.

(d) Road and Traffic

The road and traffic impacts shall be mitigated by adopting the following measures:

- provide temporary and permanent drainage works along with the road construction activities to
avoid localised flooding;

- provide adequate manpower, sign boards and advance notices of imminent inconvenience to the
public road users to reduce traffic flow interruptions and to regulate the traffic movements;

- appoint authorised personnel to co-ordinate with the local traffic and road authorities to plan
and control the movement and schedule of the construction vehicles; and

- immediate turfing, hydromulching or other slope protection measures need to be carried out to
reduce slope failures or landslides.

(e) Air Quality, Noise and Vibration

The potential air quality impacts of construction civil works are mainly related to dust particles
expected to be generated during the construction stage. The air quality impacts shall be mitigated by
implementing the following dust suppression measures:

- maintaining and upkeeping all major haul routes;

- wetting of stockpiles, exposed and uncompacted areas;

- wetting of all access routes and spraying vehicle wheels at the construction route before
entering into the main road;

- covering construction material loads of the transporting vehicles with PVC sheets or other
means of coverage; and

- turfing and revegetating of all exposed areas.

Face masks shall be provided for the construction site workers and personnel.
Necessary actions are required to be taken to minimise noise and vibration impacts through the
adoption of the following measures:

- provide safety goggles and protective hearing devices for construction workers when handling
equipment with potential noise hazards;

- limit operating hours for isolated high noise activities such as pile driving, rock blasting and
tree cutting, etc.;

- install warning signboards to indicate high noise areas; and

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- transportation of heavy loads of construction materials, machineries, etc. to be undertaken
preferably during off-peak traffic hours.
-
(f) Hydrology and Hydraulics Regime

Installation of silt traps and sedimentation ponds shall be carried out before the land clearance to
reduce the silt loads which can potentially alter the hydrology and hydraulic regime of rivers adjacent
to the construction site.

The land clearance and earthwork activities shall be carried out in sections to reduce the area exposed
to rain and wind action which may increase soil erosion rates. Frequent desilting of the silt traps shall
be undertaken to ensure efficient performance. Revegetation of bare earth shall be carried out to
control surface runoff, silt loading, slope protection as well as landscaping purposes.

Culvert and cofferdams shall be installed at strategic locations during the construction period to
control construction floods. These structures shall be designed for a 1 in 25 year return period.
Proper temporary and permanent drainage shall also be provided prior to the construction activities
and continuously maintained up to operational phases of the project to ensure efficient removal of
stormwater.

(g) Water Quality

Implementation of slope protection measures and soil erosion control can minimise the siltation of
waterways during the site preparation period. The loading of high silt concentrations into the rivers
downstream of the Site shall be reduced by constructing silt traps at the outlet of water discharge
points from the construction sites. This will safeguard the deterioration of water quality in the rivers
downstream of the Site. Proper sanitation facilities that comply to the specifications set by the
Ministry of Health shall be provided at the construction workers camp.

As much as possible of the vegetation in the proposed reservoir area shall be removed to reduce the
possibility of the decomposition of residual vegetation leading to anaerobic conditions in the reservoir
water.

In order to maintain river water quality, wastewater generated during the construction phase shall be
treated before discharging into the receiving waters. Since there are water supply intakes located
downstream of the project sites, the wastewaters shall have to be treated to Standard A of the
Environmental Quality (Sewage and Industrial Effluents) Regulations of 1978 prior to discharge.

(h) Aquatic Resources

The biodiversity of aquatic organisms are influenced by the water quality of the river system. As
such, the proposed mitigating measures undertaken to reduce the impacts on river water quality will
also be beneficial for the sustenance of the aquatic ecosystem.

During reservoir impounding compensation flows shall be released to maintain flows in the
downstream river channel in consideration of the aquatic life and other riparian users.

(i) Terrestrial Fauna

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The reservoir area shall be cleared of its vegetation in such a manner that the animals and birds can be
driven up the slopes and be allowed to escape into adjacent forest reserve areas. To be effective in
driving the animals and birds out of the reservoir area, clearing work shall begin at the dam site
working up the valley towards the upper parts of the Sg. Jus catchment.

(j) Public Health

In order to avoid potential health problems during the construction period, the following mitigation
measures shall be adopted:

- screen all construction workers for communicable diseases;

- provide a sufficient supply of clean water to the construction site and base camps;

- provide adequate sanitation facilities at the construction site to prevent bacteriological
contamination of downstream river water;

- provide proper waste disposal systems to prevent the breeding of mosquitoes, rats and other
pests; and

- carry out periodic vector surveys at the construction site.

1.9 Health, Safety and Environmental

Occupational Safety and Health Act 1994

The Contractor shall comply with the relevant requirements of this Act.

Compliance with the requirements of this section of the Specification by the Contractor shall not
relieve the Contractor from responsibility to comply fully with the provisions of the Act, and for the
safety of his workers and employees and those of his sub-contractors.

Failure to Comply

In the event that the Contractor fails to comply with the requirements of the Act or with the
Specification in respect of safe working conditions or practices on the Site, the S.O. shall have the
authority to instruct the Contractor to stop work in any particular location until the unsafe conditions
or practices have been rectified to the satisfaction of the S.O. In this event, the Contractor shall be
responsible for all costs and delays resulting from complying with such instruction by the S.O. and
for the actual costs incurred on rectification of the unsafe conditions or practices.

Contractors Safety Plan

The Contractor shall establish a health and safety plan as may be required by the S.O. to show how
the Contractor will carry out the Works in a safe and hygienic manner and complying with all laws,
regulations, codes of practice and other things relevant to health and safety that may from time to
time apply to the Works. Within fourteen (14) days of the date of the Letter of Award the Contractor
shall produce and submit to the S.O. an outline Health and Safety Plan. Within twenty-one (21) days
thereafter the Contractor shall submit to the S.O. for approval a detailed Health and Safety Plan that
shall take proper account of the S.O.s comments on the outline Health and Safety Plan. The
Contractor shall implement the procedures set out in the approved Health and Safety Plan.

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The Contractor shall prepare and submit to the S.O. for approval a Safety Plan as may be required by
the S.O specific to the work to be carried out under the Contract. The Contractor shall carry out all
work on the Site in accordance with the approved Safety Plan.

The Safety Plan must include the safety objectives and the proposed outline for carrying out this
objectives. The safety plan must also include procedures for training of site personnel on all safety
procedures and induction courses for new staff. The system for accident reporting and investigation
must be fully elaborated in the safety plan.

First Aid Facilities

The Contractor shall provide a complete first aid outfit for all his work site(s). The outfit shall be in
the charge of either the Contractors Safety Officer or some other responsible person who will also be
on the site during all working hours to ensure that the first aid outfit is available without delay at all
times when work is in progress. The Safety Officer or another senior member of the Contractor staff
shall be trained in simple first aid duties including resuscitation of persons rescued from drowning.

The Contractor shall comply fully with all rules and regulations form time to time issued and orders
given by the Health Ministry or the local medical or sanitary authorities.

Overhead Hazards

Every place where persons are required to work or to pass that is normally exposed to falling material
or objects shall be provided with suitable overhead protection, and where no one is required to work
or to pass but employees are at work in the vicinity such exposed area shall be roped off or other-wise
guarded against inadvertent entry.

Falling Hazards

Every hole into or through which a person may fall shall be covered by a temporary cover fixed
securely in position or guarded by an effective barrier to prevent falls except where free access is
required by work actually in progress. In such a case where work is in progress, the barrier shall be
maintained in position to the extent possible, and suitable warning signs shall be erected.

Drowning Hazards

Where the work involves filling tanks with water leaving an open surface, the Contractor shall
provide at all times and at suitable locations equipment for promptly rescuing persons from the water
and resuscitating rescued persons.

Slipping Hazards

The Contractor shall not suffer or permit an employee to use a passageway, or a scaffold, platform or
other elevated working surface which is in a slippery condition. Oil, grease, water and other
substances causing slippery footing shall be removed, sanded or covered to provide safe footing.

Tripping Hazards

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All passageways, platforms and other places of work shall be kept free from accumulations of dirt and
debris and from other obstructions that may cause tripping. Sharp projections shall be removed or
covered.
Access to Workplace

Temporary stairways, ramps or runways shall be provided as the means of access to working levels
above or below ground except where the nature or progress of the work prevents their installation, in
which case ladders or other safe means shall be provided. The Contractor shall not assume that access
arrangements provided by another Contractor or by the Employer will necessarily remain in place
after the time that the Contractor commences work in a particular area.

Dust and Gases

Dust and gases shall be controlled by ventilation or otherwise so as to prevent concentrations tending
to injure health or obstruct vision or from exceeding safe levels.

Corrosive Substances

All alkalis, acids and other corrosive substances shall be so stored and used so as not to endanger
employees. Suitable protective equipment for the use of such substances shall be provided. Clean
water supply shall be readily available for washing off any spillage of any corrosive substance on the
employees.

Eye Protection

Suitable eye protection equipment shall be provided for and shall be used by employees while
engaged in welding or cutting operations or in chipping, cutting or grinding any material from which
particles may fly, or while engaged in any other operation which may endanger the eyes.

Respirators

Where required the Contractor shall provide and the employee shall use a respirator suitable for the
type of operation for which it is to be used. The Contractor shall maintain such respirator in good
repair and shall furnish the means for its continued efficient working condition. The Contractor shall
provide regular inspection, cleansing and sterilisation of such equipment. Such equipment when not
in use shall be store in a closed container.
The equipment shall be either of the escape set type, where it is provided for possible emergency use,
or self contained breathing apparatus where work has to be carried out in conditions where toxic
gases are present or where there is a deficiency of oxygen.

All persons who may be required to use equipment shall be adequately trained and shall have
certificates to that effect.

Work in Confined Spaces

Where work is required to take place in a confined space, defined as an enclosed space with limited
access and where there is no natural ventilation, the Contractor shall provide equipment for
monitoring the quality of the air within the space. The equipment shall be used to check the
atmosphere before personnel enter, and shall remain in place while work is in progress to ensure that
the confined space is free of harmful or noxious gases. The Contractor shall not permit anyone to
enter or work in a confined space, including personnel from other Contractors, the S.O. staff or the
Employers staff if harmful or noxious gases are detected. Any personnel inside shall be evacuated
immediately.

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All personnel working in such conditions shall be provided with escape sets. The Contractor shall
provide a top-man who shall be stationed immediately outside the entrance to the confined space,
and who shall maintain communication with personnel working inside the confined space, and who
shall have means for raising the alarm in case of any emergency inside the confined space. Harnesses
and ropes etc. shall be provided to enable unconscious personnel to be brought out of the confined
space in an emergency.

The Contractor shall provide adequate ventilation for workers carrying out work inside a confined
space, pipeline or chamber or other enclosed areas by using blowers or other suitable means. Trolleys
attached to ropes shall be provided for persons moving within the pipeline.

Protective Clothing

Every employee shall be provided with a safety helmet of a type tested and approved by SIRIM, and
shall be required to wear it while working on the Site, except in the Contractors office.

Every employee required to work in water, wet concrete or other wet footing shall be provided with
suitable waterproof boots.

Every employee required to use or handle alkaline, acid or other corrosive substances shall be
provided with appropriate protective clothing.

Electrical Hazards

Before work commences, the Contractor shall ascertain by inquiry or direct observation, or by
instruments, where any part of an electric power circuit exposed or concealed is so located that the
performance of the work may bring any person, tool, or machine into physical or electrical contact
therewith. The Contractor shall post and maintain proper warning signs to his employees of the
location of such lines, the hazards involved and the protective measures to be taken and shall, if
practicable, de-energise the electric power circuit.

The Contractor shall not suffer or permit an employee to work in such proximity to any part of an
electric power circuit that he may contact the same in the course of his work unless the employee is
protected against electric shock by de-energising the circuit and earthing it or by guarding it, by
effective insulation or other means acceptable to the S.O. or relevant authority. In work areas where
the exact location of underground electric power lines is unknown, employees using jack-hammers,
bars or other hand tools which may contact a line shall be provided with insulated protective gloves
and footwear.

Power Driven Saws

All portable power-driven hand operated saws shall be equipped with guards above the base plate
which completely protects the operator from contact with the saw blade when in motion and with
self-adjusting guards below the base plate which completely covers the saw to the depth of the teeth
when the saw is removed from the cut.

Public Vehicular Traffic

Whenever any work is being performed over, on or in proximity to a highway or any other place
where public vehicular traffic may cause danger to men at work, the working area shall be so

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barricaded as to direct traffic away from it or the traffic shall be specially controlled by persons
designated for that purpose.

All vehicles used at the worksite must be roadworthy and registered with the appropriate authority.
No person shall drive a vehicle at the worksite unless he is the holder of the appropriate driving
licence.

Stability of Structures

No section of the plant or other structure or part of a structure shall be left unguarded in such
condition that it may fall, collapse or be weakened due to wind pressure or vibration.

Storage of Materials and Equipment

All materials shall be stored or stacked in a safe and orderly manner so as not to obstruct any
passageway or place of work. Material piles shall be stored or stacked in such a manner as to ensure
stability.

Disposal of Debris

Debris shall be handled and disposed of by a method which will not endanger persons. Debris shall
not be allowed to accumulate so as to constitute a hazard.

Excavations

No employee shall be permitted to enter any excavated area, including areas excavated by other
contractors on the Site, unless sheet piling, shoring or other safeguard that may be necessary for his
protection is provided.

Where any employee in an excavation is exposed to the hazard of falling or sliding materials from
any bank or side more than 1.5 m high above his footing, adequate piling and bracing shall be
provided against the bank or side to eliminate such hazard. The excavation and its vicinity shall be
checked by a designated person after every rain storm or other hazard-increasing occurrence and the
protection against slides and cave-ins increased if necessary.

Shoring adequate to support the overhanging material shall be provided where banks are undercut.

Excavated material and other superimposed loads shall be placed at least 1 m back from the edge of
open excavations and trenches and shall be so shored or retained that no part thereof can fall into the
excavation, or cause the banks to slip or cause the upheaval of the excavation bed. Banks shall be
stripped of loose rock or other materials which may slide, roll or fall upon persons below.

Open slides of excavations where a person may fall more than 3 m shall be guarded by adequate
barricades, and suitable warning signs shall be put up at conspicuous positions.

No employee shall be suffered or permitted to work where he may be struck or endangered by an
excavating machine or by material dislodged by it or falling from it.

Ladders, Step Ladders and Access Platforms

Every ladder, step-ladder and access platform shall be of good construction, sound material and
adequate strength for the purpose of which it is used. Ladders, step-ladders and access platforms shall
not stand on loose bricks or other packing, but shall have a levelled and firm footing.

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Positioning of Machinery

No person shall be permitted to position or operate machinery in a manner likely to endanger himself
or others.

Cranes

Cranes shall be so constructed, positioned and operated as to be stable. No crane shall be loaded
beyond the safe working load except by an approved person or an inspector for the purpose of testing
such machine.

Every crane including all blocks, shackles, sheaves, wire ropes and the various devices on the mast
and jib shall be thoroughly inspected by an approved person at intervals not exceeding 12 months.
Cranes shall be inspected before being first erected or operated on each job or after any major repair.
Inspection and repair of crane jib shall be made only when the jib is lowered and adequately
supported.

Outriggers and counter-weights shall be provided and used as specified by the manufacturer of the
crane or by an approved person. Counter-weights shall be properly placed and secured. Levelling
jacks or other suitable means shall be provided and used with outriggers of truck mounted mobile
cranes.

Firm and uniform footing shall be provided for cranes. When such a footing is not otherwise supplied
it shall be provided by substantial timber, or other structural members sufficient to distribute the load
so as not exceed the safe bearing capacity of the underlying material.

Every power-operated crane shall be provided with efficient brake or brakes or other locking devices
which will prevent the fall of the load when suspended and by which the load can be effectively
controlled whilst being lowered. Hand or foot-operated bakes shall be provided with a substantial
locking device to lock the brake in engagement.

No load-bearing part of any crane shall be replaced by another part, and no such machine shall be
modified by the addition thereto or removal therefrom of any load bearing part, unless the
replacement or modification shall be certified by either the manufacturer or the approved person who
tested the crane.

A capacity chart shall be provided for every crane. Such chart shall be posted and maintained in a
place clearly visible to the operator and shall set forth the safeloads for various lengths of jib at
various jib angles and radial distances. Where outriggers are provided such loads shall be set forth
with and without the use of outriggers.

Unless furnished by the manufacturer or builder of the crane, a capacity chart shall be prepared and
certified by an approved person.

A crane shall not lift any load that exceeds the corresponding safe working load specified by its
capacity chart.
Every crane having a jib shall be provided with an accurate indicator which shows, clearly to the
operator, the radius of the jib and the safe working load corresponding to that radius at all times and
gives warning signal when the radius is unsafe.

Before hoisting any load at a new job site, the jib shall be operated to its maximum height.

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Crane cabs shall be locked when the operator is not present and no unauthorised person shall enter the
cab or remain immediately adjacent to any crane in operation. If locking of a crane cab is
impracticable, the operating mechanism shall be locked so as to prevent the crane from being
operated by an unauthorised person.

No crane shall be operated in such a location that any part of the cane or of its load in any position of
jib or swing may come within 3 metres of live power lines.

Attachment of Loads

Where a sling is employed to hoist long-length material, a lifting beam shall be used to space the sling
legs for proper balance. When load is suspended at two or more points with slings, the eyes of the
lifting legs of the slings shall be shackled together and this shackle or the eyes of the lifting legs may
be shackled directly on the hoisting block or balance beam. The eyes may be placed on the lifting
hook without shackles if the hook is of the safety type.

Each container or receptacle used for raising or lowering loose material of any kind shall be so
enclosed, constructed or designed as to prevent the accidental fall of such material.

Crane loads shall be raised vertically so as to avoid swinging during hoisting.

No crane shall travel with a suspended load except upon a safe runway. During travel without loads,
cranes falls shall be secured or place so as to prevent accidents or damage by swinging.

1.10 The Site

The limits of the lands available to the Contractor for the purpose of the Works are shown on the
Drawings or as specified. The Contractor shall be deemed to have inspected the Site in accordance
with Clause 15 of the Conditions of Contract to ascertain the site conditions such as the topography,
vegetation, drainage, weather conditions, means of access and any other contingency liable to affect
his construction of the Works. Claims will not be entertained by the S.O. for any extra costs incurred
by the Contractor in carrying out the Works on the ground of ignorance of the site conditions, or the
conditions under which the Works will be executed.

1.11 Access to the Site

Access to the site can be gained from the existing roads from where access roads shall be constructed
under the Contract or temporary access roads constructed by the Contractor.

January 2010

Section 1 - General
1.12 Working Space and Work through Private Land

Land Acquisition for Permanent Works

In the case where Works are to be constructed through private land, the Employer will make available
the land and the limits of the land which will be available for the construction of the Works are shown
on the Drawings. The Contractor will not be allowed to exceed the limits of the land shown on the
Drawings.

Temporary Access

The Contractor shall be responsible for obtaining the consent of the owner, tenant, or occupier of
private land to the use of such land or private roads for temporary access to the work site or for other
temporary purposes. Before entering upon private land for the purpose of commencing construction
the Contractor shall confirm in writing to the S.O. that he has obtained this consent.

The Contractor shall pay all costs, expenses, rentals, compensation or other disbursement which may
be incurred by him in negotiations with the owner, tenant or occupier and during the subsequent use
by him of such private land or roads for these purposes. No reimbursements will be made to the
Contractor in this respect.

The full cost thereof shall be deemed to be included in the Contract Rates. The Contractor shall note
that his responsibility shall apply to the whole of the land occupied or used by him for the purpose of
the Works, whether within or without the working space defined above.

The Contractor shall be held responsible for all damage which he may do to land or property lying
outside the working space as defined above. Compensation for damage to such land or property
caused by the Contractor will be assessed by the Collector of Land Revenue for settlement by the
Contractor through the Employer.

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

1.13 Trespass on Adjacent Property

In carrying out the Works, due regard shall be paid to the amenities of adjacent property and to the
interests of owners, tenants and occupiers. The Contractor shall take adequate steps to prevent
trespass by his employees and shall be wholly responsible for making good any loss or damage
caused by such trespass.

January 2010

Section 1 - General
1.14 Existing Services

The Contractor shall be responsible for the security of all water, electricity, telephone, sewerage and
other services, drains, pipes and other apparatus belonging to or under the control of any public
authority, company or person, which may be, or be liable to be, interfered with, by or in connection
with the execution of the Works. The Contractor shall fully indemnify the Employer against any
claim, action, expense, loss, damage or injury arising in this respect.

1.15 Works in Roads and Footpaths

Where work is carried out in or adjacent to public or private roads, footpaths or verges the Contractor
shall comply with the regulations in force in the place. If the Contractor's work will cause
unavoidable interference with access to adjoining property the Contractor shall give seven days notice
in writing of such interference to the occupier of such property and shall, before interfering with the
existing access provide temporary means of access for vehicles and pedestrians.

Where the Contractor wishes to obtain any partial or complete road closure he shall make all the
proper arrangements with the appropriate persons or authorities. The Contractor shall also provide all
apparatus and men required for adequate traffic control lighting, watching and fencing to the
satisfaction of the S.O., local authority and police. The Contractor shall note that the works may be
required to be executed outside the normal working hours as required and such works as carried out
shall not be considered as ordered overtime working. He shall comply fully with all requirements of
these authorities before commencing and during any excavation in roads.

Any damage to the roads and paths caused by the Contractor's vehicles shall be made good at his own
expense. The Contractor shall carry out such maintenance as to keep the roads and paths clean and
clear of any loose materials, debris, earth and the like deposited by his vehicles.

In respect of this Clause, the Contractor shall bear the full responsibility for all the costs of any such
arrangement and these costs shall be deemed to have been included in the Contract Rates and shall
indemnify the Employer against any claim whatsoever arising therefrom.

1.16 Claims for Damage to Person or Property

Any claim received by the Employer or S.O. in respect of matters in which the Contractor is required
under the Contract to indemnify the Employer will be passed to the Contractor who shall likewise
inform the S.O. of any such claim which is submitted directly to him by a claimant. The Contractor
shall do everything necessary, including notifying the insurers of claims received, to ensure that all
claims are settled properly and expeditiously and shall keep the S.O. informed as to the progress
made towards settlement, failing which the Employer shall be entitled to make direct payment to
claimants of all outstanding amounts due to them in the S.O.'s opinion and without prejudice to any
other method of recovery to deduct by way of set-off the amounts so paid from any sums due or
which shall become due from the Employer to the Contractor. Nothing contained therein above shall
relieve the Contractor of his obligations and responsibilities under the Contract.

If the Contractor receives a claim which he considers to be in respect of matters in which he is
indemnified by the Employer under the Contract he shall immediately pass such claim to the
Employer.

January 2010

Section 1 - General
1.17 Amenities to be Preserved

The Contractor shall not cause interference with existing amenities, whether natural or man-made. No
trees shall be felled except on the instructions of the S.O. and clearance of vegetation of any sort shall
generally be kept to the minimum necessary for the Works and Temporary Works.

1.18 Works to be Kept Clear of Water

The Contractor shall keep the Works clear of water at all times during construction and erection of
plant by others and at all such times during the Defects Liability Period as shall be required by the
S.O.

The Contractor shall construct, operate and maintain all temporary dams, cofferdams, watercourses
and other works, and shall carry out all pumping, that may be necessary to exclude water from the
Works while construction and erection is in progress. All such temporary works shall be removed at a
time approved by the S.O. when the Works are completed.

Notwithstanding any approval by the S.O. of the arrangements made for the exclusion of water, the
Contractor shall be held responsible for the sufficiency thereof, and shall be liable for keeping the
Works safe during all floods, and for making good at his own expense any damage to the Works that
may be attributed to floods. Any loss of production, additional overheads, or additional costs of any
kind that may result from floods shall be at the Contractor's own risk. Floods shall not be deemed to
be an "excepted risk".

All costs incurred by the Contractor in complying with the requirements of this Clause shall be
deemed to be included in the Contract Rates.

1.19 Discharge of Water and Waste

The Contractor shall make provision for the discharge or disposal from the Works and temporary
works of all water and waste products howsoever arising and the methods of disposal shall be to the
satisfaction of the S.O. and of any Authority or person having an interest in any land or watercourse
over or in which water and waste products may be so discharged. The requirements of this Clause
shall not limit any of the Contractor's obligations or liabilities, particularly as to Clause 32 of the
Conditions of Contract.

January 2010

Section 1 - General
1.20 Temporary Fencing

The Contractor shall erect, maintain and remove suitable and approved temporary fencing to enclose
such areas of the Works, Temporary Works and all areas of land occupied by the Contractor within
the Site as may be necessary to meet his obligations under Clause 32 of the Conditions of Contract
and as directed by and to the satisfaction of the S.O. Where any temporary fence has to be erected
around the Site, alongside a public road, footpath, etc, it shall be of the type required by and shall be
erected to the satisfaction of the authority concerned.

1.21 Temporary Works Construction and Design

The Contractor shall submit to the S.O. for approval drawings and full particulars of all Temporary
Works which he intends to construct as may be required by the S.O. Adequate time shall be allowed
for checking such drawings and particulars before it is desired to commence constructing such works.
The submission to or approval by the S.O. of any such proposals by the Contractor shall not relieve
the Contractor of any of his responsibilities for the sufficiency of the Temporary Works for their
intended purposes.

The Contractor shall provide, maintain and remove on completion of the works all necessary
temporary works including but not limited to temporary traffic diversions, roadways, crossings,
footpaths, accesses, drains, stagings, scaffoldings and other temporary supports to enable the
constructional operations to be performed in the appropriate sequence. All temporary works proposed
shall be properly designed and constructed to carry out the loads to which they will be subjected and
all drawings and calculations pertaining thereto shall be forwarded to the S.O. for approval.

Notwithstanding the approval by the S.O. of any submitted design for any temporary works the
Contractor shall remain wholly responsible until the removal of such works for their efficiency,
security and maintenance and for all obligations and risks in relation to such works specified or
implied in the Contract and shall reinstate the same at his own expense should any mishap or accident
occur causing damage or injury thereto subject to any provisions of the Conditions of Contract as may
be applicable in case of such damage or injury.

Except where specific provision is made in the Bill of Quantities for payment to the Contractor for
temporary works the cost of complying with the requirements of this clause shall be deemed to be
included in the tender rates and prices.

1.22 Water Supply

All water for use on the Works shall be fresh and free from harmful impurities to the satisfaction of
the S.O. The Contractor shall make adequate arrangements to deliver sufficient water to the Site for
drinking, washing, sanitation and general cleaning down, in addition to any required for the
construction, watertightness testing, sterilisation and flushing.

January 2010

Section 1 - General
1.23 Power Supply

The Contractor shall make his own arrangements for the supply of electricity to and about the Site for
the construction, of the Works and for his own use during the Defects Liability Period.

The Contractor shall comply with all local authority regulations applicable to the use and storage of
diesel oils, petrol, paraffin and other inflammable fuels and engine driven generators used by him on
the Site, and shall ensure that adequate precautions are taken against fire. Permanent fencing and
other safeguard required to be erected around electrical equipment shall be to the standards required
by the Tenaga Nasional Berhad before any connection to the public supplies can be made.

1.24 Temporary Sanitary Conveniences

The Contractor shall provide all proper temporary conveniences for his workmen as may be required
by the S.O. These conveniences shall consist of flush system closets and the sewerage shall be
discharged to septic tanks or Imhoff tanks. All such arrangements shall meet all the requirements as
stipulated by the local Health Authority and the Contractor's proposals shall be submitted to and

The Contractor shall maintain the Site and all working areas in a hygienic condition and in all matters
of health comply with the requirement of the local Health Authority.

1.25 Site to be Kept Tidy

Throughout the progress of the Works, the Contractor shall keep the Site and all working areas in a
tidy and workmanlike condition and free from rubbish and waste materials. Any temporary works,
construction plant, materials or other things which for the time being are not required for use by the
Contractor may with the consent of the S.O. be removed from the Site but otherwise shall be
dispersed about the Site in an orderly fashion and shall be properly and securely stored thereon. The
Contractor shall make safe and reinstate all areas affected by temporary works.

1.26 General Hygiene and Medical Examination of Contractor's
Employees

Before commencing work on the Site the Contractor shall ensure that all his employees are instructed
in the necessity for the prevention of pollution. The Contractor shall immediately dismiss and remove
from the Site any employee or representative of the Contractor who has been polluting or fouling the
Site or any of the water supply installations and shall take appropriate remedial measures to prevent a
repetition of the occurrence and to disinfect the areas concerned all to the satisfaction of the S.O.

The Contractor shall not employ upon the Site, or on periodic visits thereto, persons who are known
to have any disease which could be water-borne or who is suffering from an illness associated with
looseness of the bowels or who are carriers of typhoid bacillus or other potential pathogenic
organisms or who are otherwise unsuited on medical grounds to be employed in or around water
supply installations. The Contractor shall if and when required to do so, arrange for his employees to
be examined and tested in the manner approved by the Government's Medical Officer of Health.
The Contractor shall immediately remove from the Site any such employees who as a result of such
examination and testing may in the opinion of the Medical Officer or the S.O. constitute a danger to
water supplies or who refuse to undergo an examination.

January 2010

Section 1 - General

January 2010

1.27 Temporary Buildings for Use by Contractor

The Contractor shall provide such temporary offices, buildings, tanks, etc, as may be necessary and
proper for his general use in connection with the Works, and for the use of persons employed by him.
(deleted last sentence)

The Contractor shall maintain all offices, buildings, tanks, etc, referred to in this and succeeding
clauses in good condition and comply with all the requirements of the Local Authorities in whose
area they are situated.

SECTION 2
EARTHWORKS

Section 2 Earthworks

TABLE OF CONTENT

Page
2.0 EARTHWORKS 2-I

2 2. .1 1 D De ef f i i n ni i t t i i o on ns s 2 2- -1 1
2.2 Levels to be Recorded 2-2 2.2 Levels to be Recorded 2-2
2.3 Disposal of Materials 2-3 2.3 Disposal of Materials 2-3
2.4 Excess Excavation to be Made Good 2-3 2.4 Excess Excavation to be Made Good 2-3
2.5 Site Clearance 2-3 2.5 Site Clearance 2-3
2.6 Trees 2-4 2.6 Trees 2-4
2.7 Stumps 2-4 2.7 Stumps 2-4
2.8 Stripping Topsoil 2-4 2.8 Stripping Topsoil 2-4
2.9 General Excavation 2-5 2.9 General Excavation 2-5
2.10 Excavation of Cuttings (Bulk Excavation) 2-5 2.10 Excavation of Cuttings (Bulk Excavation) 2-5
2.11 Excavation below Embankments and below Formation Level
in Cuttings 2-6
in Cuttings 2-6
2.12 Trench Excavation 2-6 2.12 Trench Excavation 2-6
2.13 Trench Excavation in Roads, Road Shoulders and Footpaths 2-7 2.13 Trench Excavation in Roads, Road Shoulders and Footpaths 2-7
2.14 Trench Excavation in Fields, etc. 2-7 2.14 Trench Excavation in Fields, etc. 2-7
2.15 Rock and Other Materials in Excavations 2-8 2.15 Rock and Other Materials in Excavations 2-8
2.16 Supporting Excavation 2-8 2.16 Supporting Excavation 2-8
2.17 Trimming Excavations 2-9 2.17 Trimming Excavations 2-9
2.18 Inspection of Excavation 2-9 2.18 Inspection of Excavation 2-9
2.19 Filling to Embankments and Backfilling to General Excavation 2-9 2.19 Filling to Embankments and Backfilling to General Excavation 2-9
2.20 Earthworks to be Kept Free of Water 2-11 2.20 Earthworks to be Kept Free of Water 2-11
2.21 Trenches Not to be Left Open 2-11 2.21 Trenches Not to be Left Open 2-11
2.22 Refilling Trench Excavation 2-12 2.22 Refilling Trench Excavation 2-12
2.23 Spoil Tips on the Site 2-13 2.23 Spoil Tips on the Site 2-13
2.24 Treatment of Material from Excavation 2-13 2.24 Treatment of Material from Excavation 2-13
2.25 Surface Reinstatement in Road Verges, Fields, etc. 2-13 2.25 Surface Reinstatement in Road Verges, Fields, etc. 2-13
2.26 Works in Roads and Road Reserves 2-14 2.26 Works in Roads and Road Reserves 2-14
2.27 Surface Reinstatement in Roads and Footpaths 2-14 2.27 Surface Reinstatement in Roads and Footpaths 2-14
2.28 Other Structures in the Pipeline 2-15 2.28 Other Structures in the Pipeline 2-15
2.29 Land Drains 2-15 2.29 Land Drains 2-15

2.30 Care of Existing Services 2-15 2.30 Care of Existing Services 2-15
2.31 Hedges, Fences and Walls 2-16 2.31 Hedges, Fences and Walls 2-16
2.32 Crossing Watercourses, etc 2-16 2.32 Crossing Watercourses, etc 2-16
2.33 Top Soiling 2-16 2.33 Top Soiling 2-16
2.34 Turfing 2-16 2.34 Turfing 2-16


January 2010

2.0 EARTHWORKS

2.1 Definitions

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

"Topsoil" M Me ea an ns s a an ny y s su ur rf fa ac ce e m ma at te er ri ia al l, , s su ui it ta ab bl le e f fo or r u us se e i in n s so oi il li in ng g a ar re ea as s t to o b be e g gr ra as ss se ed d o or r
c cu ul lt ti iv va at te ed d. .

Unsuitable
Material
Unsuitable material, shall include :-

i) running silt, peat, logs, stumps, perishable or toxic material, slurry or mud, or

ii) any material
- consisting of highly organic clay and silt;
- which is clay having a liquid limit exceeding 80% and/or a plasticity index exceeding
55%;
- which is susceptible to spontaneouse combustion;
- which has a loss in weight greater than 2.5% on ignition;
- containing large amounts of roots, grass and other vegetative matter.
- which is soft or unstable because it is too wet or too dry for effective compaction for its
intended use.

Suitable
Material
Suitable material shall comprise all that which is acceptable in a natural or processed
state in terms of its intended use to the approval of the S.O.

Rock"

Granular
Fill

Means material which in the opinion of the S.O. would normally have to be loosened
either by blasting or by the use of pneumatic tools (excluding clay spades worked on
an air compressor) or by other rock quarrying methods or, if excavated by hand, by the
use of wedge and sledge hammers. An isolated solid boulder or detached piece of rock
shall qualify as Rock only if it exceeds 0.30 cubic metre in volume.

Granular fill shall conform to the grading limits given below :-

BS Sieve
Size

Percentage by
Weight Passing

10mm
5mm
2mm
600mm
75mm

100
85 to 100
50 to 100
10 to 90
0 to 5


January 2010

Free
Draining
Material

Free draining material shall consist of hard, clean, crushed rock or gravel having the
grading limits specified below. The aggregate crushing value of the material shall not
exceed 30%.

BS. Sieve
Size

Percentage by
Weight Passing

63mm
37.5mm
20mm
10mm

100
85 to 100
0 to 20
0 to 5

"Bulk
Excavation
Means excavation in open cut (excluding Trench Excavation and Incidental
Excavation) down to levels specified on the Drawings or otherwise as being the
general levels after completion of excavation.

"Trench
Excavation
Means excavation of trenches into which pipes, tubes, cables or drainage materials are
to be laid to levels and limits specified in the Drawings or otherwise directed by the
S.O.

"Incidental
Excavation
Means excavation below or outside the limits of Bulk Excavation and Trench
Excavation.

Excess
Excavation
Means excavation outside the limits specified or shown on the Drawings or directed
by the S.O. for Bulk or Trench Excavation.

All reference to excavation or excavations shall apply to Bulk, Trench and Excess Excavation(s)
except where clearly stated to the contrary.

2.2 Levels to be Recorded

Before the surface of any part of the Site is disturbed or the Works thereon are begun the Contractor
shall take and record levels of any such part as may be required by the S.O, in the manner specified
or as agreed with the S.O. in the presence of the S.O. and such levels when agreed shall form the
basis for measurement.

The Contractor shall obtain the S.O.s prior approval to the proposed methods of obtaining and
recording this information and shall afford the S.O. all facilities to attend and check each survey and
recording. The Contractor shall give to the S.O. notice of his intention to carry out such survey work
at least 24 hours in advance of the commencement of the survey. The Contractor shall carry out, to
the satisfaction of the S.O., all extra surveys required to resolve any doubts which may arise as to the
correctness of any survey or record and the S.O.s decision shall be final regarding what shall be
recorded as the correct survey.

A A s si im mi il la ar r p pr ro oc ce ed du ur re e s sh ha al ll l b be e a ad do op pt te ed d t to o r re ec co or rd d a an ny y r ro oc ck k s su ur rf fa ac ce e l li im mi it ts s a an nd d l le ev ve el ls s b be ef fo or re e t th he ey y a ar re e
b bl la as st te ed d o or r e ex xc ca av va at te ed d. .

January 2010

Each survey drawing with agreed data shall be referred to as a Record Survey which shall be
signed by the Contractor and the S.O. and shall form the basis for preparation of record drawings of
the appropriate work. The Contractor shall supply four copies of each Record Survey to the S.O.

2.3 Disposal of Materials

All requirements herein for the disposal by the Contractor of materials arising from site clearance or
from excavations are subject to the provisions of the Specification.

Suitable materials intended for re-use should be used as soon after excavation as possible. With the
approval of the S.O., certain materials may be allowed to be stock piled for re-use. If this is the case,
they shall be stock-piled at a location approved by the S.O.

Temporary stockpiling shall be such that the properties and composition of materials intended for
use as construction materials at a later stage will not change.

The influence of stockpiling on ground water, drainage and adjacent structures and services shall be
investigated and where necessary suitable measures should be taken.

Areas used for temporary stockpiling shall be kept clean and orderly and shall be restored to their
original condition before completion of works.

U Un ns su ui it ta ab bl le e m ma at te er ri ia al ls s a an nd d s su ui it ta ab bl le e m ma at te er ri ia al l n no ot t i in nt te en nd de ed d f fo or r r re e- -u us se e s sh ha al ll l b be e r re em mo ov ve ed d f fr ro om m t th he e w wo or rk k s si it te e
a an nd d d di is sp po os se ed d o of ff f a at t a a l lo oc ca at ti io on n a ap pp pr ro ov ve ed d b by y t th he e S S..O O. . M Ma at te er ri ia al ls s s sh ha al ll l b be e d di is sp po os se ed d o of ff f i in n a ac cc co or rd da an nc ce e w wi it th h
l lo oc ca al l a an nd d n na at ti io on na al l l la aw ws s a annd d r re eg gu ul la at ti io on ns s i in nc cl lu ud di in ng g t th he e p pa ay ym me en nt t o of f r ro oy ya al lt ti ie es s, , f fe ee es s e et tc c. . w wh hi ic ch h m ma ay y b be e
i im mp po os se ed d b by y t th he e r re el le ev va an nt t A Au ut th ho or ri it ti ie es s. .

2.4 Excess Excavation to be Made Good

T Th he e C Co on nt tr ra ac ct to or r a at t h hi is s o ow wn n e ex xp pe en ns se e s sh ha al ll l r re em mo ov ve e f fr ro om m t th he e S Si it te e a al ll l m ma at te er ri ia al l r re es su ul lt ti in ng g f fr ro om m E Ex xc ce es ss s
E Ex xc ca av va at ti io on n a an nd d s sh ha al ll l m ma ak ke e g go oo od d t th he e s sa am me e w wi it th h s su uc ch h k ki in nd d o of f f fi il ll l m ma at te er ri ia al l o or r i in n s su uc ch h c cl la as ss s o of f c co on nc cr re et te e
a as s m ma ay y b be e r re ea as so on na ab bl ly y r re eq qu ui ir re ed d b by y t th he e S S. .O O. . h ha av vi in ng g r re eg ga ar rd d t to o t th he e c ci ir rc cu um ms st ta an nc ce es s. .

2.5 Site Clearance

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

All open burning shall be subject to the prior approval of the relevant Authorities. The Contractor
shall obtain the necessary Contravening Licence from the Director-General of Department of
Environment, all the burning shall be carried out in conformity with all pertinent regulations.

Burning shall only be conducted at times when conditions are considered favourable for burning and
at locations approved by the S.O. Materials to be burns shall be heaped neatly and, when in a suitable
condition, shall be burnt completely. Heaping for burning shall be done in such manner and at such
locations as to cause the least fire risk. A break of 10 m minimum width shall be cleared first along

January 2010

the perimeter of the area to be cleared, to prevent any accidental fire spreading beyond the limits of
the areas to be cleared at all times. Then before any burning may commence, another fire break of 20
m minimum width shall be constructed around the perimeter of the heaped piles.

No boundary stones, survey pegs, reference markers or temporary bench marks and site investigation
markers shall be disturbed from its original position by the Contractor in the course of site clearance
and should such stones/markers be disturbed as a result thereof, the Contractor shall be required to
reimburse the Government the cost of re-survey and materials etc., which shall be deducted by way of
set-off from any sums due or which shall become due from the Government to the Contractor.

2.6 Trees

T Tr re ee es s s sh ha al ll l b be e u up pr ro oo ot te ed d o or r c cu ut t d do ow wn n a as s n ne ea ar r t to o g gr ro ou un nd d l le ev ve el l a as s p po os ss si ib bl le e. . B Br ra an nc ch he es s a an nd d f fo ol li ia ag ge e s sh ha al ll l b be e
r re em mo ov ve ed d a an nd d d di is sp po os se ed d o of f o of ff f t th he e S Si it te e. . U Us se ef fu ul l t ti im mb be er r w wi it th hi in n G Go ov ve er rn nm me en nt t r re es se er rv ve e s sh ha al ll l r re em ma ai in n t th he e
p pr ro op pe er rt ty y o of f t th he e G Go ov ve er rn nm me en nt t a an nd d s sh ha al ll l b be e c cu ut t i in nt to o s su ui it ta ab bl le e l le en ng gt th h a an nd d s st ta ac ck ke ed d p pr ro op pe er rl ly y. .

2.7 Stumps

S St tu um mp ps s a an nd d r ro oo ot ts s w wh he et th he er r e ex xi is st ti in ng g o or r r re em ma ai in ni in ng g a af ft te er r t tr re ee e f fe el ll li in ng g s sh ha al ll l w wh he er re e d di ir re ec ct te ed d b by y t th he e S S. .O O. . b be e
g gr ru ub bb be ed d u up p a an nd d u up pr ro oo ot te ed d a an nd d d di is sp po os se ed d o of f o of ff f t th he e S Si it te e. . T Th he e r re es su ul lt ti in ng g h ho ol le e s sh ha al ll l b be e f fi il ll le ed d w wi it th h a ap pp pr ro ov ve ed d
m ma at te er ri ia al l d de ep po os si it te ed d i in n 2 22 25 5m mm m l la ay ye er rs s a an nd d c co om mp pa ac ct te ed d t to o t th he e s sa am me e d dr ry y d de en ns si it ty y a as s t th he e a ad dj jo oi in ni in ng g s so oi il l. . F Fo or r
r re es se er rv vo oi ir r c cl le ea ar ri in ng g b be ef fo or re e i im mp po ou un nd di in ng g, , s st tu um mp ps s w wi it th h d di ia am me et te er r m mo or re e t th ha an n 0 0. .6 6 m m a at t 1 1m m a ab bo ov ve e g gr ro ou un nd d
l le ev ve el l c ca an n b be e l le ef ft t i in n p pl la ac ce e p pr ro ov vi id de ed d t th he ey y d do o n no ot t p pr ro oj je ec ct t m mo or re e t th ha an n 1 1. .2 2m m a ab bo ov ve e g gr ro ou un nd d. .

2.8 Stripping Topsoil

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

Where applicable, turf intended for re-use, as agreed with S.O., shall be taken up in strips of a
constant breadth with an approved turfing tool and stock piled in a location approved by the S.O.
where it shall be neatly stacked and regularly watered and tended until required for relaying at
approved locations.

T Th he e r re em ma ai in ni in ng g t to op p s so oi il l a an nd d t tu ur rf f s sh ha al ll l b be e d di is sp po os se ed d o of ff f t th he e S Si it te e a as s d di ir re ec ct te ed d b by y t th he e S S. .O O. . a an nd d i in n
a ac cc co or rd da an nc ce e t to o t th he e r re eq qu ui ir re em me en nt ts s o of f t th he e r re el le ev va an nt t a au ut th ho or ri it ti ie es s. .


January 2010

2.9 General Excavation

General excavation shall mean excavation required for structures but not include Trench Excavation.

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

W Wh he er re e n no om mi in na al l ' 'p pa ay ym me en nt t' ' l li im mi it ts s o of f e ex xc ca av va at ti io on n a ar re e n no ot t s sh ho ow wn n o on n t th he e D Dr ra aw wi in ng gs s o or r o ot th he er rw wi is se e s sp pe ec ci if fi ie ed d
t th he ey y s sh ha al ll l b be e d de ee em me ed d t to o b be e t th he e m mi in ni im mu um m n ne et t l li im mi it ts s w wh hi ic ch h w wo ou ul ld d a al ll lo ow w t th he e o ou ut tl li in ne e o of f t th he e c co om mp pl le et te ed d
s st tr ru uc ct tu ur re e t to o b be e l lo ow we er re ed d v ve er rt ti ic ca al ll ly y f fr ro om m g gr ro ou un nd d l le ev ve el l i in nt to o i it ts s f fi in na al l p po os si it ti io on n. . T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l m ma ak ke e
h hi is s o ow wn n a al ll lo ow wa an nc ce e f fo or r a an ny y w wo or rk ki in ng g s sp pa ac ce e r re eq qu ui ir re ed d, , a an nd d a an ny y e ex xc ca av va at ti io on n o ou ut ts si id de e t th he e a af fo or re es sa ai id d l li im mi it t s s
w wh hi ic ch h h ha as s n no ot t b be ee en n o or rd de er re ed d b by y t th he e S S. .O O. . w wh he et th he er r i it t b be e e ex xc ca av va at te ed d t to o s su ui it t t th he e C Co on nt tr ra ac ct to or r s s m me et th ho od d o of f
w wo or rk ki in ng g o or r u un na av vo oi id da ab bl le e o ov ve er rb br re ea ak k o or r d du ue e t to o h hi is s c ca ar re el le es ss sn ne es ss s o or r e er rr ro or r, , s sh ha al ll l b be e h he el ld d t to o b be e E Ex xc ce es ss s
E Ex xc ca av va at ti io on n. .

2.10 Excavation of Cuttings (Bulk Excavation)

(i) The excavation of cuttings shall be carried out in accordance with the Drawings and to the
slopes, levels, depths, widths and heights shown thereon.

(ii) Erosion protection measures as described in Clauses 2.36 and 2.37 shall be carried out as
soon as is practicable following trimming of the cut slope, and in any event within 5 days.
This time limit applies to each part of a slope or slopes as it is trimmed. The S.O. will not
allow excavation of the cutting to progress below any bench until the erosion protection
measures have been carried out to his satisfaction on the slope above that bench.

(iii) Hauling of material from cuttings or the importation of fill material to the embankments or
other areas of fill shall proceed only when sufficient compaction plant is operating at the
place of deposition to ensure compliance with the requirements of Clause 2.20.

(iv) Any over excavation below formation level tolerance shall be made good by backfilling with
suitable material of similar characteristics, removed and compacted in accordance with
Clause 2.20.

(v) Where the material below the formation level of a cut area is deemed to be unsuitable as
subgrade material by the S.O. it shall be removed to a depth to be determined by the S.O. and
replaced with suitable material in layers not exceeding 300mm and compacted to 95% (for
cohesive material) or 100% (for cohesionless material) of the maximum dry density
determined in accordance with BS. 1377, Test 13.

(vi) The slopes of cuttings shall be cleared of all boulders or rock fragments which move when
prised by a crow-bar. Any resultant voids in the slope shall be made good using Class 10/20
concrete, rubble pitching or other means to the satisfaction of the S.O.

(vii) Constructional traffic shall not use the surface of the bottom of a cutting which has reached
formation level unless the cutting is in rock or the Contractor maintains the level of the
bottom surface at least 300mm above formation level. Any damage to the subgrade arising
from such use of the surface shall be made good by the Contractor at his own expense with
material having the same characteristics as the material which has been damaged.


January 2010

in Cuttings

(i) Where any material below the natural ground level under embankments, under culvert
bedding, or below formation level in cuttings is required to be excavated, it shall be removed
to such depth and over such areas as are indicated on the Drawings or as the S.O. shall direct
and disposed of in a manner depending on its nature and condition at the time. The resultant
excavation shall be backfilled with suitable material deposited in layers of thickness
appropriate to the material and compaction plant to be used and compacted in the manner
specified for the forming of embankments.

(ii) If after the removal of material as specified in Sub-Clause (i), the Contractor allows the
material so exposed to reach a condition where compaction of backfilling complying with
Clause 2.20 is impracticable, he shall make good at his own expense either by additional
excavation and filling in the manner specified, or by waiting until the condition of the
exposed material is fit to receive the approved backfill.

2.12 Trench Excavation

The line and level of trenches shall be as shown on the Drawings or as directed by the S.O. Before
commencing Trench Excavation, the route of the trench shall be pegged out accurately and the
existing ground levels shall be agreed with the S.O. Strong sight rails shall then be fixed and
maintained at each change of gradient and at as many intermediate points as may be necessary. On
these rails shall be marked the centre line and the level to which the excavation is to be carried out,
such rails being not more than 25 metre apart.

T Tr re en nc ch h E Ex xc ca av va at ti io on n s sh ha al ll l b be e c ca ar rr ri ie ed d o ou ut t b by y s su uc ch h m me et th ho od ds s a an nd d t to o s su uc ch h l li in ne es s d di im me en ns si io on ns s a an nd d d de ep pt th hs s a as s
s sh ha al ll l a al ll lo ow w f fo or r t th he e p pr ro op pe er r c co on ns st tr ru uc ct ti io on n o of f t th he e W Wo or rk ks s, , p pr ro ov vi id de ed d a al lw wa ay ys s t th ha at t, , u un nl le es ss s s sh ho ow wn n o ot th he er rw wi is se e i in n
t th he e D Dr ra aw wi in ng gs s o or r t th he e S S. .O O. . p pe er rm mi it ts s o ot th he er rw wi is se e a an nd d s su ub bj je ec ct t t to o a an ny y s sp pe ec ci if fi ic c r re eq qu ui ir re em me en nt ts s o of f t th he e
S Sp pe ec ci if fi ic ca at ti io on n, , n no o T Tr re en nc ch h E Ex xc ca av va at ti io on n s sh ha al ll l b be e l le es ss s t th ha an n t th he e w wi id dt th hs s s st ta at te ed d b be el lo ow w: :- -

D Clear width of trench for
backfill with excavated
material
Clear width of trench for sand
surround or sand backfill
Not exceeding 500mm D + 600mm D + 600mm
Exceeding 500mm but not
exceeding 750mm
D + 750mm D + 750mm
Exceeding 750mm D + 900mm D + 750mm

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

Notwithstanding the foregoing, any rock in trench excavation shall be so excavated that the clearance
between the pipe when laid and the rock sides and bottom of the trench is kept to the minimum limits
necessary to provide for the specified thickness of bedding haunching and surround to the pipe. Any
excavations outside these limits whether for working space or due to overbreak shall be held to be
Excess Excavation.

The sides of Trench Excavation shall be vertical unless the S.O. permits otherwise. The Contractor
shall be responsible to take the necessary precaution and safety measure to ensure such excavation is
safe for working.

January 2010

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

Any widening or deepening of Trench Excavations necessary to accommodate curves, joints or bends
in the pipe or to provide extra working space for the construction thereof shall be held to be Excess
Excavation.

Trench Excavation shall wherever practicable be carried out in such a way that every part of the
excavation is at least 600mm clear of the existing edge of the carriageway. In any event the
Contractor shall take special precautions, which shall include the continuous support of the sides of
the excavation, from the time when excavation is begun until the refilling of the trench is placed, to
ensure that there is no disturbance of the adjacent road or road foundation. For the purpose of
measuring certain work in connection with Trench Excavation "nominal limits" of Trench
Excavation are stated above and any excavation outside these limits, which have not been ordered by
the S.O. shall be held to be Excess Excavation.

2.13 Trench Excavation in Roads, Road Shoulders and Footpaths

All Trench Excavation and other work carried out within the limits of any road reserve shall be
completed as rapidly as possible and not more than half of the width of the carriageway shall be
obstructed at one time. A minimum width of 4 m wide of traffic lanes shall have to be kept clear for
flow of traffic and where necessary the shoulder should be strengthened to the satisfaction of relevant
Authorities at the Contractors own cost. Road drains and grids shall be kept free from obstruction.

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

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

T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l t ta ak ke e s sp pe ec ci ia al l p pr re ec ca au ut ti io on ns s, , i in nc cl lu ud di in ng g t th he e c co on nt ti in nu uo ou us s s su up pp po or rt t o of f t th he e s si id de es s o of f t th he e
e ex xc ca av va at ti io on n f fr ro om m t th he e t ti im me e e ex xc ca av va at ti io on n i is s b be eg gu un n u un nt t i il l r re ef fi il ll li in ng g o of f t th he e t tr re en nc ch h i is s c co om mp pl le et te ed d t to o e en ns su ur re e t th ha at t
t th he er re e i is s n no o d di is st tu ur rb ba an nc ce e o of f t th he e a ad dj ja ac ce en nt t r ro oa ad d o or r r ro oa ad d f fo ou un nd da at ti io on n. . T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l a al ls so o p pr ro ov vi id de e
b ba ar rr ri ic ca ad de es s t to o f fe en nc ce e o of ff f t th he e w wo or rk ks s a an nd d a ap pp pr ro ov ve ed d r ro oa ad d s si ig gn n b bo oa ar rd ds s p pl la ac ci in ng g a at t r re eg gu ul la ar r i in nt te er rv va al ls s t to o e en ns su ur re e
s sa af fe et ty y o of f t th he e p pu ub bl li ic c a an nd d v ve eh hi ic cl le es s. .

Special care shall be taken trench excavation for the laying of sewer pipes near or at slope areas to
ensure that the existing earth slopes are not disturbed. The length of excavation shall be limited to the
length of sewer pipes that can be laid within each work period.
Trenches shall be backfilled as soon as possible on completion of pipe laying to avoid leaving them
open over extended periods of time, hence compromising the intensity of the slopes.

2.14 Trench Excavation in Fields, etc.


January 2010

The term "fields" includes fields, plantations, padi, grass verges and the like. The Contractor shall
have particular regard to the safety of livestock in fields or which may be introduced to the fields, and
shall ensure that all excavations, access routes and steep or loose slopes arising from the Contractors
operations in these fields are adequately fenced and protected.

After the erection of temporary fencing the Contractor shall remove topsoil to such depth and over
such area as may be necessary to provide sufficient material to ensure adequate surface reinstatement
of the working areas occupied by the Contractor for construction of the pipeline.

2.15 Rock and Other Materials in Excavations

Any material in the excavations which the Contractor considers may be classified as Rock as defined
in Section 2.1 shall be notified to the S.O. before commencement of excavation of the material. The
quantities of Rock or material alleged to be Rock excavated from within the nominal limits of
excavation shall be recorded by the S.O. and the Contractor each day or at such shorter intervals as
the S.O. may require. Only such proportion of material so notified, recorded and signed shall qualify
for additional payment as Rock. Overbreak (that is excavation outside the nominal limits of
excavation) shall be kept to a minimum and shall be held to be Excess Excavation.

Materials classified as Grade III or weaker (as defined in Table 10 of BS 5930) shall be classified as
Rock within the meaning of Section 2.1 only if in the opinion of the S.O.:

a) a) the material in Bulk Excavation is incapable of being loosened by ripping with a tracked
machine, in good working condition and operated by experienced and skilled personnel, of 24
tonne minimum weight and net horse power rating of 240 hp or more, drawing a mounted
parallelogram type ripper recommended by the tractor or ripper manufacturer; the ripper shall
have a single shank in first class condition with a sharpened cutting point;
the material in Bulk Excavation is incapable of being loosened by ripping with a tracked
machine, in good working condition and operated by experienced and skilled personnel, of 24
tonne minimum weight and net horse power rating of 240 hp or more, drawing a mounted
parallelogram type ripper recommended by the tractor or ripper manufacturer; the ripper shall
have a single shank in first class condition with a sharpened cutting point;

b) b) the material in Trench Excavation is incapable of being excavated at a rate of 4 cu.m. per
hour by hydraulic excavator of minimum net horse power rating of 120 hp, in good working
condition and operated by experienced and skilled personnel.
the material in Trench Excavation is incapable of being excavated at a rate of 4 cu.m. per
hour by hydraulic excavator of minimum net horse power rating of 120 hp, in good working
condition and operated by experienced and skilled personnel.

2.16 Supporting Excavation

The Contractor shall well and effectively support the sides and ends of all excavations to prevent any
fall or run from any portion of the ground outside the excavation and to prevent settlement or damage
to structures adjacent to the excavation. Any extra excavation necessary to provide space for such
support or other working space shall be held to be Excess Excavation. If, for any reason, any portion
of the bottoms, sides or ends of any excavations shall give way the Contractor shall at his own
expense take all necessary remedial measures including the excavation and removal of all the ground
thereby disturbed both within and beyond the nominal limits of excavation and such extra excavation
shall be held to as Excess Excavation.
W Wh he er re e t th he e C Co on nt tr ra ac ct to or r e el le ec ct ts s a an nd d i is s p pe er rm mi it tt te ed d b by y t th he e S S. .O O. . t to o p pe er rf fo or rm m e ex xc ca av va at ti io on ns s w wi it th h s sl lo op pi in ng g f fa ac ce es s
( (o ot th he er r t th ha an n s sl lo op pi in ng g e ex xc ca av va at ti io on ns s s sh ho ow wn n o on n t th he e D Dr ra aw wi in ng gs s o or r r re eq qu ui ir re ed d a as s p pe er rm ma an ne en nt t f fe ea at tu ur re es s o of f t th he e
W Wo or rk ks s) ) a an nd d w wi it th ho ou ut t s sh ho or ri in ng g, , t th he e e ex xc ca av va at te ed d f fa ac ce es s s sh ha al ll l b be e t to o s st ta ab bl le e s sl lo op pe es s a an nd d h he ei ig gh ht ts s a an nd d t th he e
r re es su ul lt ti in ng g e ex xt tr ra a e ex xc ca av va at ti io on n s sh ha al ll l b be e h he el ld d t to o b be e E Ex xc ce es ss s E Ex xc ca av va at ti io on n. .


January 2010

2.17 Trimming Excavations

W Wh he en n e ex xc ca av va at ti in ng g t to o s sp pe ec ci if fi ie ed d l le ev ve el ls s f fo or r t th he e f fo ou un nd da at ti io on n o of f a an ny y s st tr ru uc ct tu ur re e o or r p pi ip pe es s o or r t to o s sp pe ec ci if fi ie ed d l li im mi it ts s
f fo or r t th he e f fa ac ce es s o of f a an ny y s st tr ru uc ct tu ur re e r re eq qu ui ir re ed d t to o a ab bu ut t a ag ga ai in ns st t u un nd di is st tu ur rb be ed d g gr ro ou un nd d t th he e C Co on nt tr ra ac ct to or r s sh ha al ll l n no ot t
e ex xc ca av va at te e t th he e l la as st t 1 15 50 0m mm m u un nt ti il l i im mm me ed di ia at te el ly y b be ef fo or re e c co om mm me en nc ci in ng g t th he e c co on ns st tr ru uc ct ti io on na al l w wo or rk k, , e ex xc ce ep pt t
w wh he er re e t th he e S S. .C C. . s sh ha al l l l p pe er rm mi it t o ot th he er rw wi is se e. . S Sh ho ou ul ld d t th he e C Co on nt tr ra ac ct to or r h ha av ve e e ex xc ca av va at te ed d t to o w wi it th hi in n 1 15 50 0m mm m a ab bo ov ve e
t th he es se e s sp pe ec ci if fi ie ed d l le ev ve el ls s o or r t to o w wi it th hi in n 1 15 50 0m mm m o of f t th he es se e s sp pe ec ci if fi ie ed d l li im mi it ts s b be ef fo or re e h he e i is s r re ea ad dy y o or r a ab bl le e t to o
c co om mm me en nc ce e t th he e c co on ns st tr ru uc ct ti io on na al l w wo or rk k h he e s sh ha al ll l, , w wh he er re e r re eq qu ui ir re ed d b by y t th he e S S. .O O. ., , e ex xc ca av va at te e f fu ur rt th he er r s so o a as s t to o
r re em mo ov ve e n no ot t l le es ss s t th ha an n 1 15 50 0m mm m o of f m ma at te er ri ia al l i im mm me ed di ia at te el ly y b be ef fo or re e c co om mm me en nc ci in ng g t th he e c co on ns st tr ru uc ct ti io on na al l w wo or rk k
a an nd d s su uc ch h f fu ur rt th he er r e ex xc ca av va at ti io on n s sh ha al ll l b be e h he el ld d t to o b be e E Ex xc ce es ss s E Ex xc ca av va at ti io on n. . B Be ef fo or re e c co om mm me en nc ce em me en nt t o of f a an ny y
c co on ns st tr ru uc ct ti io on na al l w wo or rk k a al ll l s sh ha at tt te er re ed d a an nd d l lo oo os se e m ma at te er ri ia al l s sh ha al ll l b be e r re em mo ov ve ed d f fr ro om m t th he e e ex xc ca av va at ti io on ns s b by y h ha an nd d
s so o a as s t to o e en ns su ur re e t th ha at t t th he e w wo or rk k r re es st ts s o on n a a s so ol li id d a an nd d p pe er rf fe ec ct tl ly y c cl le ea an n f fo ou un nd da at ti io on n o or r a ab bu ut ts s a ag ga ai in ns st t s so ol li id d
g gr ro ou un nd d. .

2.18 Inspection of Excavation

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

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

2.19 Filling to Embankments and Backfilling to General Excavation

Forming Of Embankments And Other Areas Of Fill:

(i) Where embankment is to be constructed against an existing embankment or on existing
ground with a cross-slope of 1 vertical to 10 horizontal or steeper the existing ground shall be
excavated, irrespective of the type of material (including rock), to form benches with
horizontal and vertical surfaces on/against which the embankment will be constructed. The
benches shall be contiguous beneath the full width of the embankment and shall be of a width
suitable to accommodate construction equipment such as motor graders, trucks, compactors,
etc.

(ii) All earthwork material placed in or below embankments, below formation level in cuttings or
elsewhere in the Works shall be deposited and compacted as soon as practicable in layers of
thickness appropriate to the compaction plant used. Embankment shall be built up evenly
over the full width unless otherwise indicated in the Contract and shall be maintained at all
times with adequate camber or slope and surface sufficiently even to enable surface water to
drain readily therefrom. During the construction of embankments the Contractor shall control
and direct constructional traffic uniformly over their full width. Damage to compacted layers
by constructional traffic or water erosion shall be made good by the Contractor at his own
expense.


January 2010

( (i ii ii i) ) G Gr ra an nu ul la ar r f fi il ll l a an nd d f fr re ee e d dr ra ai in ni in ng g m ma at te er ri ia al l f fo or r d de ep po os si it ti in ng g i in n w wa at te er r i in n t th he e a ar re ea as s s sh ho ow wn n o on n t th he e
D Dr ra aw wi in ng gs s s sh ha al ll l c co on nf fo or rm m C Cl la au us se e 2 2. .1 1 a an nd d s sh ha al ll l b be e d de ep po os si it te ed d w wi it th ho ou ut t t th he e a as ss so oc ci ia at te ed d u us se e o of f
c co om mp pa ac ct ti io on n p pl la an nt t d de es sc cr ri ib be ed d t to o t th he e r re eq qu ui ir re em me en nt ts s o of f C Cl la au us se e i in n C Cl la au us se e 2 2. .2 21 1. . H Ho ow we ev ve er r, ,
s su ub bs se eq qu ue en nt t t to o t th he e c co om mp pl le et ti io on n o of f f fi il ll li in ng g t to o t th he e s sp pe ec ci if fi ie ed d l le ev ve el ls s, , t th he e g gr ra an nu ul la ar r f fi il ll l s sh ha al ll l, , w wh he er re e
s sp pe ec ci if fi ie ed d, , b be e c co om mp pa ac ct te ed d b by y v vi ib br ro oc co om mp pa ac ct ti io on n. .

(iv) Compaction of embankments and other areas of fill shall be undertaken to the requirements of
Clause 2.21. The embankment shall be constructed to a sufficient width to permit adequate
compaction at the edges before trimming back.

(v) If the material deposited as fill subsequently reaches a condition such that it cannot be
compacted in accordance with the requirements of the Contract the Contractor shall at his
own expense, either :-

(a) make good by removing the material off the embankment either to tip or elsewhere
until it is in a suitable physical condition for reuse, and replacing it with suitable
material; or

(b) make good the material by mechanical or chemical means; or

(c) cease work on the material until its physical condition is again such that it can be
compacted as described in the Contract.

(vi) Isolated boulders each within the range 0.2m
3
to 0.1m
3
in size may be incorporated in earth
embankments at the discretion of the S.O. provided that the specified compaction
requirements are met. No stone exceeding 0.02m
3
shall be placed less than 0.5m below
formation level of carriageway or hard shoulders.

(vii) Work on embankments and/or cuttings in areas required for the construction of bridges and
other structures shall not be carried out until the S.O. agrees that construction of such
structures is sufficiently advanced such that there is no risk of interference or damage to
them. However, where piling for a structure is required through the embankment, the
embankment shall be built up to a level not less than the elevation of the soffit of the pile cap
or to conform to Clause 2.38 in the case of soft ground prior to any piling.

The Contractor shall arrange the timing and rate of placing fill material around or upon any
completed or partially completed structure in such a way that no part of the Works is over-stressed,
weakened, damaged or endangered. All fill materials adjacent to complete structures shall be so
placed as to maintain adequate drainage and to prevent accumulation of water. In particular, the
placing of fill materials around the walls of basements, and tanks shall commence only after the walls
and floor have been completed and have attained their full specified strength. Fill around the walls of
reservoirs shall not commence until after satisfactory completion of testing.
Fill material behind walls fixed at the top to the roof shall not be placed until the roof has been
completed and if made of concrete, has attained its full specified strength and had the temporary
supports removed. The materials shall be placed so as to exert a uniform pressure around the walls of
a structure, and each layer shall be placed with a fall to prevent the accumulation of water.


January 2010

T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l w wh he en n p pl la ac ci in ng g t th he e f fi il ll li in ng g o or r b ba ac ck kf fi il ll li in ng g m ma ak ke e d du ue e a al ll lo ow wa an nc ce e f fo or r a an ny y s se et tt tl le em me en nt t
t th ha at t m ma ay y o oc cc cu ur r b be ef fo or re e t th he e e en nd d o of f t th he e D De ef fe ec ct ts s L Li ia ab bi il li it ty y P Pe er ri io od d. . W Wh he er re e n ne ec ce es ss sa ar ry y, , t th he e C Co on nt tr ra ac ct to or r s sh ha al ll l
a at t t th he e e en nd d o of f t th he e D De ef fe ec ct ts s L Li ia ab bi il li it ty y P Pe er ri io od d r re em mo ov ve e a an ny y e ex xc ce es ss s m ma at te er ri ia al l o or r m ma ak ke e u up p a an ny y d de ef fi ic ci ie en nc cy y o of f
b ba ac ck kf fi il ll li in ng g o or r f fi il ll li in ng g t to o t th he e s sp pe ec ci if fi ie ed d l le ev ve el ls s. .

2.20 Earthworks to be Kept Free of Water

(i) The Contractor shall arrange for the rapid dispersal of water shed on to the earthwork or
completed formation during construction, or which enters the earthwork from any source, and
when practicable the water shall be discharged into the permanent outfall for the pipe
drainage system. The Contractor shall provide adequate means of trapping silt in temporary
systems discharging into permanent drainage systems. The arrangements shall be made in
respect of all earthwork including excavation whether for pipe trenches, foundations or
cuttings.

(ii) The Contractor shall provide, where necessary, temporary watercourses, ditches, drains,
pumping or other means of maintaining the earthwork free from water. Such provision shall
include carrying out the work of forming the cuttings and embankments in such a manner that
their surfaces have at all times a sufficient minimum crossfall and, where practicable, a
sufficient longitudinal gradient to enable them to shed water and prevent ponding.

(iii) In pumping out excavations and in any lowering of the water table the Contractor shall pay
due regard to the stability of all structures.

2.21 Trenches Not to be Left Open

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

The Contractor shall furnish, install and operate all necessary machinery, appliances, and equipment
to keep the excavation sufficiently free from the water during construction of the work to permit
proper laying and jointing, and shall dispose of water so as not to cause nuisance, injury to persons or
damage to public or private property. Particular care shall be exercised when carrying out dewatering
activities adjacent to existing structures or slopes to ensure that no damage is caused.

Pipelaying shall follow closely upon the progress of Trench Excavation, and the Contractor shall not
permit the carrying out of Trench Excavation in unreasonably excessive lengths until pipelaying
matches up with the progress of Trench Excavation. The Contractor shall take precautions to prevent
flotation of pipes in locations where Trench Excavations may be flooded and these precautions may
include the partial refilling of the trench leaving pipe joints exposed while awaiting tests of the joints.
I If f t th he e S S. .O O. . c co on ns si id de er rs s t th ha at t t th he e C Co on nt tr ra ac ct to or r i is s n no ot t c co om mp pl ly yi in ng g w wi it th h a an ny y o of f t th he e f fo or re eg go oi in ng g r re eq qu ui ir re em me en nt ts s h he e
m ma ay y p pr ro oh hi ib bi it t f fu ur rt th he er r T Tr re en nc ch h E Ex xc ca av va at ti io on n u un nt ti il l h he e i is s s sa at ti is sf fi ie ed d w wi it th h t th he e p pr ro og gr re es ss s o of f l la ay yi in ng g a an nd d r re ef fi il ll li in ng g
o of f T Tr re en nc ch h E Ex xc ca av va at ti io on n. .


January 2010

2.22 Refilling Trench Excavation

T Tr re en nc ch h E Ex xc ca av va at ti io on n s sh ha al ll l n no or rm ma al ll ly y b be e r re ef fi il ll le ed d u us si in ng g s su ui it ta ab bl le e m ma at te er ri ia al ls s s se el le ec ct te ed d f fr ro om m e ex xc ca av va at ti io on ns s o or r
i im mp po or rt te ed d f fi il ll l m ma at te er ri ia al ls s. .

Excavated material for trench refilling shall be soft granular material free from stones of all kinds to
be deposited in 150mm layers and thoroughly rammed under and around the pipe with suitably
shaped rammers working alternately on either side of the pipe (particular care being taken to avoid
damage to the pipe and any sheathing) until the trench has been refilled up to the swell of the pipe,
and thereafter until the soft filling has been carried up at least 300mm above the top of the pipe. The
soft filling however shall not be muddled or unsuitable material.

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

The coarse filling shall be carried up to the level at which surface reinstatement is to commence or to
such level at which the surface reinstatement of the whole of the topsoil, will leave the finished work
sufficiently "proud" to allow for future settlement to the original ground level. The reinstated surface
shall be rolled with a two-tonne roller when the material is dried. Any part of the reinstated surface
that settled beyond the adjacent original ground level the Contractor shall have to make good of the
settlement to avoid formation of drains or gullies within the refilled trenches.

Sand material for trench excavation backfilling shall be deposited in 150mm layers on both sides of
the pipe simultaneously and thoroughly compacted and around the pipe working alternately on either
side of the pipe unless shown otherwise in the Drawing, until the trench has been filled up to 150mm
above the top of the pipe unless shown otherwise in the Drawing except for pipes laid in roads where
the sand backfill shall be brought up to the base course formation level. The sand filling material
shall be compacted either by a suitable mechanical vibrator and/or by an approved system of water
jet. The topping of the refilling shall be in accordance with the remainder of the refilling for trench
excavation as described above for backfill with excavated material.

Sand (Class X) filling materials falling within the grading limits as shown in Appendix 2.1 shall be
accepted for use. Quarry dust shall not be considered for use as filling material.

Where necessary the Contractor shall adjust the moisture content of the refill material, as determined
in accordance with BS 1377 Test 13, either by drying out or by adding water to assist the compaction
of the material. Should the material to be placed as refilling, while acceptable at the time when
approved, become unacceptable to the S.O. due to exposure to weather conditions or due to flood or
have become muddled, soft or segregated during the progress of the Works, the Contractor shall not
use such material for refilling trenches and shall only use fresh material approved by the S.O.

Compaction of trench refilling shall be undertaken to the requirements of Section 2.21. In particular,
the Contractor shall demonstrate that the compaction is to 95% of maximum dry density by carrying
out field density testing in accordance with BS 1377 Test 15.

T Tr re en nc ch h E Ex xc ca av va at ti io on ns s s sh ha al ll l b be e r re ef fi il ll le ed d w wi it th h c co on nc cr re et te e t to o t th he e h he ei ig gh ht ts s a an nd d l li im mi it ts s a as s s sh ho ow wn n o on n t th he e D Dr ra aw wi in ng gs s
a an nd d w wh he er re e d di ir re ec ct te ed d b by y t th he e S S. .O O. .


January 2010

2.23 Spoil Tips on the Site

The limits and finished levels of spoil tips shall be as shown in the Drawings or as directed by the
S.O. Spoil tips may be used to store excavated material as required and shall be arranged by the
Contractor subject to the S.O.s approval having regard to any particular requirements of the
Contract.

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

The spoil tips shall be so shaped as to maintain stability and good drainage at all times.

2.24 Treatment of Material from Excavation

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

Where the nature of the excavated material is suitable the Contractors temporary storage as aforesaid
shall include for the separate storage as the S.O. may direct of any of the various grades of material
hereinafter specified for the refilling and surface reinstatement of excavations, namely, soft granular
material, coarse granular material, hard material and topsoil.

The Contractor shall ensure that no excavated material which is suitable and is required for re-use in
the Works is disposed off outside Site, unless it is surplus for use in the Works.

A An ny y e ex xc ca av va at te ed d m ma at te er ri ia al l n no ot t r re eq qu ui ir re ed d o or r n no ot t s su ui it ta ab bl le e f fo or r u us se e i in n t th he e W Wo or rk ks s s sh ha al ll l b be ec co om me e t th he e l li ia ab bi il li it ty y o of f
t th he e C Co on nt tr ra ac ct to or r a an nd d h he e s sh ha al ll l b be e e en nt ti ir re el ly y r re es sp po on ns si ib bl le e f fo or r i it ts s r re em mo ov va al l f fr ro om m t th he e S Si it te e a an nd d f fo or r i it ts s u ul lt ti im ma at te e
d di is sp po os sa al l. . T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l c co om mp pl ly y w wi it th h a al ll l t th he e r re eg gu ul la at ti io on ns s f fo or r t th he e d di is sp po os sa al l o of f s su ur rp pl lu us s e ex xc ca av va at te ed d
m ma at te er ri ia al ls s o of ff f t th he e s si it te e i in nc cl lu ud di in ng g t th he e p pa ay ym me en nt t o of f r ro oy ya al lt ti ie es s, , f fe ee es s, , e et tc c, , w wh hi ic ch h m ma ay y b be e i im mp po os se ed d b by y t th he e
r re el le ev va an nt t A Au ut th ho or ri it ti ie es s. .

2.25 Surface Reinstatement in Road Verges, Fields, etc.

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

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


January 2010

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

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

Any damage to the metalled road due to excavation work alongside road verges or shoulders shall be
reinstated to the satisfaction of the S.O. and the Authorities concerned at no extra cost to the
Employer.

2.26 Works in Roads and Road Reserves

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

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

T Th he e A Au ut th ho or ri it ti ie es s m ma ay y i im mp po os se e c ch ha ar rg ge es s f fo or r w wo or rk ks s c ca ar rr ri ie ed d o ou ut t o on n r ro oa ad d v ve er rg ge es s a an nd d m me et ta al ll le ed d r ro oa ad ds s a an nd d t th he e
C Co on nt tr ra ac ct to or r s sh ha al ll l p pa ay y t th he e A Au ut th ho or ri it ti ie es s a an nd d r re ec co ov ve er r t th he e cco os st t u un nd de er r t th he e a ap pp pr ro op pr ri ia at te e i it te em ms s i in n t th he e B Bi il ll l o of f
Q Qu ua an nt ti it ti ie es s. .

2.27 Surface Reinstatement in Roads and Footpaths

Surface reinstatement of roads and footpaths shall be restored to the approval of the S.O. and to the
requirements of the Authorities concerned or the party concerned. Any settlement or defects prior
to final surface reinstatement shall be made good by the Contractor to the satisfaction of the S.O.
Where the pipe trench crosses or is along tarmacadam roads and footpaths belonging to private
owners or Authorities, the pipe shall be surrounded with sand and topped up with 375mm thick of
crusher run material followed by 100mm thick of dense bituminous mix comprising 60mm thick
binder course and 40mm thick wearing course unless otherwise specified or shown in the drawings.
The compacted crusher run and binder course surfaces shall receive a layer of prime coat and tack
coat respectively before the application of binder course material and wearing course materials. All
fill materials shall be compacted by approved means.
The consolidated surface shall be brought up to the same level of the adjoining road. Any
subsidence shall be filled in by the Contractor using the same materials. The road shall be kept
continuously at its proper level to the satisfaction of the S.O. and the Authorities from the date of
filling in the trench until the surface is finally restored. All materials for this reinstatement and
subsequent maintenance shall be supplied by the Contractor.

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


January 2010

2.28 Other Structures in the Pipeline

T Th he e C Co on nt tr ra ac ct to or r s sh ha al ll l c ca ar rr ry y o ou ut t f fu ur rt th he er r e ex xc ca av va at ti io on n a as s m ma ay y b be e n ne ec ce es ss sa ar ry y t to o a ac cc co om mm mo od da at te e s st tr ru uc ct tu ur re es s
s su uc ch h a as s t th hr ru us st t b bl lo oc ck ks s a an nd d v va al lv ve e c ch ha am mb be er rs s. . S Su uc ch h e ex xc ca av va at ti io on n s sh ha al ll l i in nc cl lu ud de e f fo or r d di is sp po os sa al l o of f s su ur rp pl lu us s
m ma at te er ri ia al l a an nd d, , w wh he er re e a ap pp pr ro op pr ri ia at te e, , f fo or r b ba ac ck kf fi il ll li in ng g r ro ou un nd d t th he e s st tr ru uc ct tu ur re es s. .

2.29 Land Drains

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

The drain on either side of the Trench Excavation shall be cut-back for at least 300mm and temporary
pipes of suitable length and diameter shall be joined to the existing drain and laid resting with the
ends on solid ground with suitable stopping to prevent the subsequent run of land drainage water into
the trench. During trench re-filling, the refill material shall be carefully placed and thoroughly
compacted under the temporary pipes to give them adequate support.
Should any existing sub-soil or field drains be uncovered during general excavation, the Contractor
shall either carefully replace them when backfilling, or if this is impracticable shall divert them to
new drains or ditches, or otherwise relay them as the S.O. may direct.

A At t t th he e a ap pp pr ro op pr ri ia at te e s st ta ag ge e o of f r re ef fi il ll li in ng g t th he e T Tr re en nc ch h E Ex xc ca av va at ti io on n t th he e d dr ra ai in ns s s sh ha al ll l b be e p pe er rm ma an ne en nt tl ly y
r re es st to or re ed d t to o t th he e s sa at ti is sf fa ac ct ti io on n o of f t th he e S S. .O O. .

2.30 Care of Existing Services

Information relating to the positions of all existing mains, cables, culverts, pipes, drains or services
of any kind shall be ascertained by the Contractor. Notwithstanding any information which may be
furnished by the Employer or the S.O., the Contractor shall be responsible for ascertaining the
positions of all utilities including all mains, pipes and cables whether underground or overhead,
within or near the Site by pilot trenching, radio detection, including using current detectors, ultrasonic
detectors, metal detectors, etc and from his own inspection of the site and from the respective utility
authorities and other public authorities. Where services are shown on the drawings or where there is
evidence of services in the ground, the Contractor shall also determine their exact positions. In
addition the Contractor shall watch for and determine the position of any service which may not have
been marked.

Where Trench Excavation is carried out close to or across the line of sewers, pipes, cables and other
services the Contractor shall provide temporary adequate supports to secure the services and where
such sewer, pipe, cable or other service is temporarily displaced or disturbed it shall be restored to its
original state. If restoration of any service to its original state cannot be achieved then it shall be
replaced and made good. The cost of excavating around any service which crosses the trench, and of
temporarily supporting it while pipelaying is undertaken, shall be deemed to be included in the rates
for excavation.

All damage to services shall be made good to the satisfaction of the S.O. and the Authorities
concerned. The cost of making good any damage shall be deemed to be included in the rates for
excavation. In the event that any damaged service shall only be repaired by the Authority concerned,
all costs whatsoever relating to the repairing of the damaged service undertaken by the Authority

January 2010

shall be at the Contractors expense. Where damage to a service had already existed prior to
excavation or other work, repair of the damaged service shall be undertaken by the Contractor, if so
ordered by the S.O. and the Contractor shall be paid on Daywork for repairing such service.

Where in the opinion of the S.O., construction of the pipeline cannot reasonably be carried out unless
the sewer, pipe, cable or other service is permanently severed or permanently diverted or permanently
supported the Contractor shall undertake such work if so ordered by the S.O. Any such work if
carried out shall be to the satisfaction of the S.O. and of the Authority concerned and shall be paid for
at Daywork where necessary and at the appropriate Contract Rates.

W Wh he er re e p pi ip pe es s a ar re e l la ai id d u un nd de er r c cu ul lv ve er rt ts s t th he ey y s sh ha al ll l, , s su ub bj je ec ct t t to o o ot th he er r p pr ro ov vi is si io on ns s i in n t th he e C Co on nt tr ra ac ct t a an nd d t to o t th he e
S S. .O O. . s s i in ns st tr ru uc ct ti io on ns s, , b be e g gi iv ve en n a a c co on nc cr re et te e s su ur rr ro ou un nd d e ex xt te en nd di in ng g f fo or r 6 60 00 0m mm m c cl le ea ar r o on n e ea ac ch h s si id de e o of f t th he e
c cu ul lv ve er rt t, , a an nd d a a c co on nc cr re et te e h ha al lf f h ha au un nc ch h t to o t th he e c cu ul lv ve er rt t s sh ha al ll l b be e p pr ro ov vi id de ed d o ov ve er r t th he e w wi id dt th h o of f t th he e t tr re en nc ch h c ca as st t
d di ir re ec ct tl ly y o on n t to op p o of f t th he e c co on nc cr re et te e s su ur rr ro ou un nd d. . T Th he e c co os st t o of f a al ll l w wo or rk k i in n r re em mo ov vi in ng g a an ny y p pi il le es s a an nd d c co on nc cr re et te e b be ed d
u un nd de er r c cu ul lv ve er rt ts s a an nd d o of f t te em mp po or ra ar ri il ly y s su up pp po or rt ti in ng g t th he e c cu ul lv ve er rt t d du ur ri in ng g p pi ip pe el la ay yi in ng g s sh ha al ll l b be e d de ee em me ed d t to o b be e
c co ov ve er re ed d b by y t th he e r ra at te es s f fo or r t th he e i it te em ms s i in n t th he e B Bi il ll l o of f Q Qu ua an nt ti it ti ie es s f fo or r p pi ip pe es s c cr ro os ss si in ng g u un nd de er r c cu ul lv ve er rt ts s. .

2.31 Hedges, Fences and Walls

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

A Af ft te er r t tr re en nc ch he es s h ha av ve e b be ee en n r re ef fi il ll le ed d a an nd d s su ur rf fa ac ce es s r re ei in ns st ta at te ed d, , t th he e C Co on nt tr ra ac ct to or r s sh ha al ll l c ca ar rr ry y o ou ut t w wo or rk k a as s t th he e
S S. .O O. . m ma ay y o or rd de er r f fo or r p pe er rm ma an ne en nt t r re es st to or ra at ti io on n o of f s su uc ch h b ba ar rr ri ie er rs s. . I In n t th he e c ca as se e o of f a a h he ed dg ge e t th he e s se ec ct ti io on n r re em mo ov ve ed d
s sh ha al ll l b be e r re ep pl la ac ce ed d b by y n ne ew w p pl la an nt ts s o of f t th he e a ap pp pr ro op pr ri ia at te e v va ar ri ie et ty y a an nd d w wh he er re e o or rd de er re ed d b by y t th he e S S. .O O. . t th he e p pl la an nt ts s
s sh ha al ll l b be e p pr ro ot te ec ct te ed d f fr ro om m l li iv ve es st to oc ck k o on n b bo ot th h s si id de es s b by y a an n a ad de eq qu ua at te e p po os st t a an nd d b ba ar rb be ed d w wi ir re e f fe en nc ce e. . D Du ur ri in ng g t th he e
D De ef fe ec ct ts s L Li ia ab bi il li it ty y P Pe er ri io od d a al ll l h he ed dg ge es s r re ep pl la an nt te ed d i in n t th he e a ab bo ov ve e m ma an nn ne er r s sh ha al ll l b be e i in ns sp pe ec ct te ed d a an nd d a an ny y d de ea ad d
p pl la an nt t r re ep pl la ac ce ed d b by y t th he e C Co on nttr ra ac ct to or r t to o t th he e s sa at ti is sf fa ac ct ti io on n o of f t th he e S S. .O O. .

2.32 Crossing Watercourses, etc

W Wh he er re e t th he e p pi ip pe el li in ne e c cr ro os ss se es s u un nd de er rn ne ea at th h r ri iv ve er rs s c cu ul lv ve er rt ts s a an nd d o ot th he er r w wa at te er rc co ou ur rs se es s t th he e C Co on nt tr ra ac ct to or r s sh ha al ll l b be e
d de ee em me ed d t to o h ha av ve e a al ll lo ow we ed d f fo or r a al ll l t th he e a ad dd di it ti io on na al l m me ea as su ur re es s n ne ec ce es ss sa ar ry y f fo or r t th he e p pr ro op pe er r c co on ns st tr ru uc ct ti io on n o of f t th he e
p pi ip pe el li in ne e i in nc cl lu ud di in ng g m ma ai in nt ta ai in ni in ng g t th he e f fu ul ll l f fl lo ow w o of f w wa at te er r. .

2.33 Top Soiling

T To op ps so oi il l s sh ha al ll l b be e e ev ve en nl ly y s sp pr re ea ad d a an nd d t tr ri im mm me ed d o ov ve er r e em mb ba an nk km me en nt ts s a an nd d o ot th he er r a ar re ea as s t to o t th he e s sl lo op pe es s a an nd d
l le ev ve el ls s s sh ho ow wn n o on n t th he e D Dr ra aw wi in ng gs s o or r o or rd de er re ed d b by y t th he e S S. .O O. . T Th he e d de ep pt th h a af ft te er r s sp pr re ea ad di in ng g a an nd d t tr ri im mm mi in ng g s sh ha al ll l
b be e 7 75 5m mm m u un nl le es ss s o ot th he er rw wi is se e d di ir re ec ct te ed d, , m me ea as su ur re ed d n no or rm ma al l t to o t th he e s su ur rf fa ac ce e. . A Al ll l c cl lo od ds s a an nd d l lu um mp ps s s sh ha al ll l b be e
b br ro ok ke en n u up p a an nd d a an ny y r ru ub bb bi is sh h, , s st to on ne es s, , r ro oo ot ts s a an nd d w we ee ed ds s s sh ha al ll l b be e r re em mo ov ve ed d. .

2.34 Turfing

The Contractor shall establish grass by continuous conventional turfing or by hydroseeding as
directed.

January 2010

Conventional (closed) Turfing

Prior to conventional (Closed) turfing an approved pre-turfing fertiliser with N:P:K of 10:15:10 shall
be worked into the top 50mm of the topsoil at the rate recommended by the manufacturer. The areas
thus prepared shall be close turfed and lightly beaten to a well-bonded pattern with no gaps in
between the turfs.

Where turf is laid on slopes steeper than 1 on 3, each turf shall be securely pegged down with two
cleft wooden pegs 150mm long.

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

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

Spot Turfing

Alternatively where indicated on the Drawings, the areas shall be spot turfed with each turf
approximately 200mm by 200mm by 50mm thick and the distance between the centre lines of divots
in the form of a triangular pattern shall not exceed 500mm. Turf shall be laid immediately after
delivery to Site.

Grass Maintenance

A Al ll l g gr ra as ss s s sh ha al ll l b be e r re eg gu ul la ar rl ly y w wa at te er re ed d u un nt ti il l t th he e v ve eg ge et ta at ti io on n i is s s sa at ti is sf fa ac ct to or ry y e es st ta ab bl li is sh he ed d t to o t th he e s sa at ti is sf fa ac ct ti io on n
o of f t th he e S S. .O O. . A An ny y d de ea ad d g gr ra as ss s b be e r re ep pl la ac ce ed d a at t t th he e C Co on nt tr ra ac ct to or r s s o ow wn n e ex xp pe en ns se e. .

The Contractor shall be responsible to maintain the turfed area in good conditions by cutting,
trimming and weeding at monthly intervals until the end of the Defects Liability Period. Where turf
fails to establish itself, the Contractor shall grass the effected area again at no extra cost to the
Employer until the grass establishes itself and thereafter the monthly maintenance aforesaid shall be
continued.

SECTION 3
CONCRETE

Section 3 - Concrete

TABLE OF CONTENT

Page
3.0 CONCRETE 3-I

3.1 Scope 3-1
3.2 Construction Joints and Lifts Joints Layout and Formwork
Lines for Concrete Placing 3-1
3.3 Cement 3-1
3.4 Storage of Cement 3-2
3.5 Aggregates 3-2
3.6 Storage of Aggregates 3-3
3.7 Water 3-3
3.8 Admixtures 3-3
3.9 Test Equipment 3-4
3.10 Grades of Concrete 3-5
3.11 Free Water/Cement Ratio 3-5
3.12 Limits of Salt Content 3-5
3.13 Workability 3-6
3.14 Design of Concrete Mixes 3-6
3.15 Trial Mixes 3-7
3.16 Material Batching 3-8
3.17 Mixing Concrete 3-9
3.18 Ready-mixed Concrete 3-9
3.19 High Alumina Cement 3-9
3.20 Preparing for Concreting 3-10
3.21 Transporting Concrete 3-10
3.22 Placing concrete 3-10
3.23 Concreting in Hot Weather 3-10
3.24 Compaction 3-11
3.25 Attendance of Steel Fixer and Carpenter 3-11
3.26 Curing of Concrete 3-11
3.27 Construction Joints 3-12
3.28 Built in Pipes and Plant 3-12
3.29 Installation of Precast Concrete Units 3-13


3.30 Precast Concrete Products 3-13
3.31 Sampling and Testing of Aggregate 3-13
3.32 Quality Control: Sampling and Testing of Concrete 3-14
3.33 Compliance with Specified Requirements 3-14
3.34 Non-Compliance 3-14
3.35 Cutting and Testing of Core Samples 3-15
3.36 Inspection Procedures 3-15
3.37 Machinery Bases and Grouting In 3-15

Section 3- Concrete
3.0 CONCRETE

3.1 Scope

This section covers the supply of materials for concrete, design of concrete mixes, mixing,
transporting, placing and curing of concrete, testing of concrete and quality control of concrete.

3.2 Construction Joints and Lifts Joints Layout and Formwork
Lines for Concrete Placing

The Contractor shall submit to the S.O. for his approval as may be required by the S.O , as soon as is
practicable after the acceptance of his tender and not less than three weeks before the commencement
of concreting, drawings showing his proposals for placing concrete on which the position of all
construction joints and lifts shall be shown. No concreting shall be started until the S.O. has approved
the method of placing, the positions and form of the construction joints and the lifts. The construction
joints shall be located so as not to impair the strength of the structure.

Rebates, keys or notches shall be formed and waterstops inserted as the S.O. may require. The
position of construction joints and the size of formwork panels shall be so co-ordinated that where
possible the line of any construction joint coincides with the line of a formwork joint and that in any
case all construction joint lines and formwork joint lines appear as a regular and uniform series.

For all exposed horizontal joints and purposely inclined joints, a uniform joint shall be formed with a
batten of approved dimensions to give a straight and neat joint line.

3.3 Cement

The cement used for any particular mix shall comply with whichever of the following standards is
relevant:-

a. Ordinary and Rapid-hardening Portland cement BS EN 197-1
b. Sulphate resisting cement BS 4027
c. Portland Blastfurnace cement BS EN 197-4
d. High Slag Blastfurnace cement BS 4246
e. Portland Polverished-Fuel Ash cement BS EN 197-1
f. High Alumina cement BS 4550-6 & BS 14647

January 2010


General:

In addition to the requirements for soundness of cement given in the relevant British Standard for the
type of cement being used, the cement shall also be tested for soundness in accordance with ASTM
C151-77 'Standard Test Method for Autoclave Expansion of Portland Cement'. The expansion of the
cement bar resulting from this test shall not exceed 0.8 %.

The Contractor shall provide from each consignment of cement delivered to the Site such samples as
the S.O. may require for testing. Any cement which is, in the opinion of the S.O., lumpy and partially
set shall be rejected and the Contractor shall promptly remove such cement from the Site. Cement
which has been stored on the Site for more than forty days and cement which in the opinion of the
S.O. is of doubtful quality shall not be used in the Works unless it is retested and the test results show
that it complies in all respects with the relevant standard.

All concrete shall be produced with cement that is resistant to attack by chlorides and sulphates,
durable in a high humidity environment and not subject to alkali silica reaction. The cement to be
used throughout the works shall be Portland Blastfurnace Cement or equivalent complying with MS
1389:1995 (BS EN 197-4:2004). The cement shall be produced by blending with Ordinary Portland
Cement conforming to BS EN 107-1 and Ground Granulated Blastfurnace Slag (GGBS) conforming
to BS EN 15167 (MS 1387:1995). The blend shall contain not less than 36% GGBS and not more
than 65% GGBS by mass of combination.

3.4 Storage of Cement

Immediately upon arrival at the Site, cement shall be stored in silos designed for the purpose or in dry
weather-tight and properly ventilated structures with floors raised 500mm above ground level with
adequate provision to prevent absorption of moisture. All storage facilities, if provided at site, shall be
subject to approval by the S.O and shall be such as to permit easy access for inspection and
identification. Each consignment of cement shall be kept separately and the Contractor shall use the
consignments in the order in which they are received.

Cement of different types and from different sources shall be kept in clearly marked separate storage
facilities. Cement delivered to the Site in drums or bags provided by the supplier or manufacturer
shall be stored in the unopened drums or bags until used in the Works.

Any cement in drums or bags which have been opened on the Site shall be used immediately or shall
be disposed off.

3.5 Aggregates

Aggregates for concrete shall be obtained from an approved source and shall conform with
the requirements of BS EN 12620.

Sampling and testing of aggregates shall be carried out as required by the S.O. in accordance with the
requirements of the appropriate clauses of BS 81 Water absorption of aggregates when tested in
accordance with the standard procedure prescribed in Part 2 of BS 812, shall not exceed 3%.

The aggregates to be supplied shall not give rise to any alkali reaction with the cement, whether silica
or carbonate. Potential reactivity or otherwise of aggregates shall be determined in accordance with
ASTM C 289.

Specification for Minor Civil Works 3-2
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In addition, the soluble chlorides and sulphates content of the aggregates shall be such that the
concrete mix as a whole complies with the specified limits of salt content.

Tests for chlorides and sulphates and for potential alkali reaction shall be carried out when required
by the S.O.

Notwithstanding any provisions contained herein, limestone aggregates shall not be used in
underground and water retaining structures.

3.6 Storage of Aggregates

The Contractor shall provide means of storing the aggregates at each point where concrete
is made such that:

(i) Each nominal size of coarse aggregate and fine aggregate shall be kept separated at all times;
(ii) Contamination of the aggregates by the ground or other foreign matter shall be effectively
prevented at all times;
(iii) Each heap of aggregate shall be capable of draining freely.

The Contractor shall ensure that graded coarse aggregates are tipped, stored and removed from store
in a manner that does not cause segregation.

Wet fine aggregate shall not be used until, in the opinion of the S.O., it has drained to a constant and
uniform moisture content, unless the Contractor measures the moisture content of the fine aggregate
continuously and adjusts the amounts of fine aggregate and added water in each batch of concrete
mixed to allow for the water contained in the fine aggregate. If necessary to meet the requirements of
this clause, the Contractor shall protect the heaps of fine aggregate against inclement weather.

3.7 Water

Water for washing aggregates and for mixing concrete and curing shall be clean and free from
harmful matter and shall satisfy the recommendations to BS EN 1008. When required by the S.O. the
Contractor shall take samples of the water being used or which it is proposed to use for mixing
concrete and test them for quality, including determining the concentration of sulphates and chlorides,
which shall be such that the concrete mix as a whole complies with the specified limit for salt content.

3.8 Admixtures

Admixtures shall mean material added to the concrete materials during mixing for the purpose of
altering the properties of the concrete mix.

Admixtures containing calcium chloride shall not be used.

Admixtures shall not be used unless the S.O. has given his prior approval in writing for each instance.
Both the amount added and the method of use shall be to the approval of the S.O. who shall also be
provided with the following information:

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(i) the typical amount added and the detrimental effects if any, due to an increase or
decrease in this amount;

(ii) the chemical name(s) of the main active ingredient(s) in the admixture;

(iii) whether or not the admixture leads to the entrainment of air when used at the amount the
manufacturer recommends.

Any approved admixture shall conform to whichever of the following standards is appropriate:-

- air entraining admixtures BS EN 934-6
- water reducing admixtures BS EN 934-6
- retarding admixtures BS EN 934-6
- fly ash and raw or calcined natural
pozzolans for use as a mineral admixture ASTM C 618

When more than one admixture is used in a concrete mix the compatibility of the various admixtures
shall be ascertained by standard tests and certified by the manufacturers.

Admixtures shall be used in accordance with the manufacturer's instructions.

3.9 Test Equipment

The Contractor shall furnish all equipment and materials necessary for collecting samples and
carrying out field laboratory tests on materials for concrete and on fresh and hardened concrete as
may be required by the S.O. Laboratory equipment shall be housed in a suitable laboratory building
on the Site as may be required by the S.O, which shall also incorporate space for storage of field test
equipment and for curing of concrete test cubes in an orderly manner so that they are readily
accessible for testing on the due date. The Contractor shall also furnish all weights, containers and
other equipment necessary for testing the weigh-batching equipment for concrete materials and the
dispensers for admixtures.

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3.10 Grades of Concrete

Grades of concrete for use in the Work shall be as shown in the table below:

Concrete
Grade
Maximum
aggregate
size (mm)
Characteristic
strength at
28 days
(N/sq.mm)
Minimum
Cement
content
(kg/cu.m)
Maximum free
Water/cement
ratio
*C35A/20 20 35 370 0.50
*C35A/40 40 35 350 0.50
C25/20 20 25 330 0.55
C20/20 20 20 250 0.60
# C15/20 20 15 225 0.65

Note : * All water retaining structures shall use Grade C35A concrete. Grade C35A/40 is
recommended for thick section.
# Only for blinding purpose
Concrete grade is that number which represents its 28 day characteristic strength expressed in
N/sq.mm.

Characteristic strength is that value of cube crushing strength below which none of all test results fail.
This condition shall be deemed to be satisfied when test results comply with the specified test
requirements. Maximum free water/cement ratios shall be based on aggregates being in a surface-dry
condition.

3.11 Free Water/Cement Ratio

In designing and establishing approved mixes of concrete for any part of the Works the Contractor
shall keep strictly within the limitations on free water/cement ratios which may be shown on the
Drawings or expressly stated elsewhere as applying to concrete for particular parts of the Works.

3.12 Limits of Salt Content

No concrete shall contain more than the following total quantities of substances expressed as
percentages by weight of cement:

(a) For mixes containing ordinary Portland cement to BS EN 197:
Total water soluble
chlorides 0.4% (as chloride ions)

(b) For mixes containing cements complying with BS 4027:
Total chlorides 0.2% (as chloride ions)

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(c) For mixes used for prestressed concrete (all cement types):
Total chlorides 0.1% (as chloride ions)

(d) For all mixes:
Total acid soluble
sulphates 4.0% (as SO3 ions)

Tests shall be carried out in accordance with the following standards:

- chlorides in aggregates ASTM D 1411
- sulphates in aggregates BS 1377 Test 9
- chloride ion in mixing water ASTM D 512
- sulphates in mixing water ASTM D 516

3.13 Workability

The workability of each grade of concrete shall be such that satisfactory compaction can be obtained
when the concrete is placed and vibrated and that there is no tendency to segregate when it is handled,
transported and compacted by the methods which the Contractor proposes to use in the Works.

For reinforced concrete, the compacting factor, determined by the method described in BS 1881, shall
not be less than 0.85 nor greater than 0.9. For unreinforced concrete the compacting factor shall be not
greater than 0.85. Where pumping of concrete is permitted, the compacting factor may be increased to
0.95, provided that the conditions in clause 3.16 are not varied.

3.14 Design of Concrete Mixes

Each mix design shall be such that:

(i) The aggregate shall comprise both fine aggregate and coarse aggregate with a combined
grading consistent with the production of dense concrete. The maximum size of coarse
aggregate shall be 20mm or 40mm as approved by the S.O.

(ii) The cement content shall not be below the minimum specified for the grade of concrete or as

(iii) The maximum free water/cement ratio shall be the maximum water/cement ratio when the
aggregate is saturated but surface dry.

(iv) The mixes shall be designed to produce a targeted mean concrete cube strength at 28 days
after manufacture and shall be greater than the characteristic strength at 28 days by a margin
of at least 5 N/sq.mm for grade C15 and 7.5 N/sq.mm for grades C20, C25 and C35A.

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(v) Where sufficient data can be produced by the Contractor to show that the standard of
acceptance for characteristic strength can be maintained using a lower margin, the mix may be
redesigned to have such reduced margin. Sufficient data shall consist of cube test results from
at least 40 separate batches of concrete produced over a period exceeding 5 days but not
exceeding 6 months by the same plant under similar supervision. The reduced margin shall be
1.64 times the standard deviation of the test results considered, but not less than 5 N/sq.mm
for grade C15 and 3.75 N/sq.mm for grades C20, C25, and C35A.

For any concrete containing admixtures, the strengths shall not be less than those specified but the
mixes for the grade of concrete shall be separately designed to take account of the effects of the
admixtures, and shall have separate trial mixes made and tested.

3.15 Trial Mixes

As soon as the S.O. has approved each of the concrete mix designs as may be required by the S.O,
two batches from a trial mix as may be required by the S.O for each grade shall be produced in
laboratory using cement and surface dry aggregates known to be typical of the proposed source of
supply. The proposed mix proportions of each grade shall be approved only if both batches have the
correct cement content and a free water cement ratio at or below the maximum value for the proposed
degree of workability.

When mix proportions have been approved by the S.O., three further batches of concrete for each
grade shall be made at Site under full scale production conditions using the same mixing time and
handled by means of the same plant which the Contractor proposes to use in the Works.

The proportions of cement, aggregates and water, shall be carefully determined by weight in
accordance with the Contractors approved mix design, and sieve analyses shall be made, by the
method described in BS 812, of fine aggregate and each nominal size of coarse aggregate used.

The compacting factor of each batch of each trial mix shall be determined immediately after mixing
by the method described in BS 1881 and shall not be outside the limits specified in Section 3.19.
Three 150mm compression test cubes from each of the three batches shall be made by the Contractor
in the presence of the S.O. from each trial mix. The cubes shall be made, cured, stored and tested at
28 days after manufacture in accordance with the method described in BS EN 12390-1. If the average
value of the compressive strength of the nine cubes taken from any trial mix is less than the target
mean strength used in the mix design or if any individual cube test result falls below 85% of the target
mean strength, the Contractor shall re-design that mix and make a further trial mix and set of test
cubes.

A full scale test of the workability of each trial mix of each grade of concrete shall be made by the
Contractor in the presence of the S.O. The trial mix of each grade of concrete shall be batched, mixed
and then transported for representative distance in the manner that the Contractor proposes to batch,
mix and transport the concrete to be placed in the Works. After discarding the first batch so made, the
concrete from later batches shall be placed and compacted in trial moulds both for reinforced and
mass concrete with dimensions typical of the Works in accordance with the procedures described in
later clauses, the sides of the moulds being capable of being stripped without undue disturbance of the
concrete placed therein. The sides of the moulds shall be stripped after the concrete has set and the
workability judged by the surface appearance and compaction obtained. If the workability test shows

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that the workability required is not attained for any trial mix for any grade of concrete, the trial mix
shall be re-designed by the Contractor and a further full scale workability test undertaken for that trial
mix.

The re-design of the concrete mixes and the making and testing of trial mixes of concrete as may be
required by the S.O shall be repeated for each grade of concrete until trial mixes of concrete have
been established which meet the specified requirements and have the required workability as
demonstrated in the full scale workability test described above.

If at any time during the construction of the Works the S.O. approves a change in the source of
cement or aggregate or if the grading of the aggregate alters to such an extent that the fraction of
aggregate retained on any sieve cannot be maintained within 2% of the total quantity of fine and
coarse aggregate when adjusted as specified for sampling and testing of aggregates, then further trial
mixes of concrete shall be made, tested and approved for use.

3.16 Material Batching

All cement used in the manufacture of concrete shall be measured by weight either with an approved
weighing machine or by making the size of each batch of concrete such as to require an integral
number of complete bags or drums of cement.

For concrete of grades C20, C25, and C35A, the fine aggregate and the several nominal sizes of
coarse aggregate shall be measured singly or cumulatively by weight using weigh-batching machines.

For concrete of grade C15, the fine and coarse aggregate shall be measured separately either by
weight using weigh-batching machines or by volume in gauge boxes.

Weigh-batching machines shall provide facilities for the accurate control and measurement of the
aggregates either singly or cumulatively and shall be capable of immediate adjustment by semi-skilled
operators in order to permit variations to be made to the mix. All weigh dials shall be easily visible
from the place at which filling and emptying of the hoppers is controlled.

Every concrete mixing machine shall be fitted with a device to measure added water by weight and
shall be so constructed that the water inlet and outlet valves are interlocked so that either one of them
cannot be opened unless the other is fully closed. The weighing device shall be provided with an
overflow with a cross-sectional area at least four times that of the inlet pipe and with its discharge
point clear of the mixing plant. The entire water system shall be maintained free of leaks at all times
and the measuring device shall be fitted with a drain pipe which allows the full quantity of water
being measured to be drained off for checking the measurement. The outlet arrangement of the
measuring device shall be such that between 5 and 10 % of the water enters the mixer before the other
materials and a further 5 to 10 % of the water enters the mixer after the other materials. The
remainder of the water shall be added at a uniform rate with the other materials. The water measuring
device shall be readily adjustable so that the quantity of water added to the mixer can, if necessary, be
varied for each batch.

Where volume batching is permitted by the Specification, gauge boxes shall be soundly constructed of
timber or steel to contain exactly the volume of the various aggregates required for one batch of each
mix. They shall have closed bottoms and shall be clearly marked with the mix and aggregate for
which they are intended. When calculating the size of the gauge box for fine aggregate, an allowance
shall be made for the bulking of the fine aggregate due to the average amount of moisture contained in
the stockpiles on the Site. Before the Contractor puts any gauge box into use on the Site he shall
obtain the approval of the S.O. of the size and construction of such gauge box.

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Any admixtures which may be used shall be measured separately in calibrated dispensers. The
Contractor shall submit details of the admixtures to the S.O. for his approval before such admixtures
are allowed to be used in the Work.

All mixing and batching plants shall be maintained free of set concrete or cement and shall be clean
before commencing mixing. The accuracy of calibration of any weighing plant, water measuring plant
and admixture dispenser, shall be checked before carrying out trial mixes, before mixing concrete for
inclusion in the Works, after each service or adjustment to the mixing plant, and in any case at least
once per month.

3.17 Mixing Concrete

Concrete shall be mixed in batches in plant capable of combining the aggregates, cement and water
(including admixtures, if any) into a mixture uniform in colour and consistency, and of discharging
the mixture without segregation.

On commencing work with a clean mixer, the first batch shall contain only half the normal quantity
of coarse aggregate to compensate for the adhesion of the other materials to the drum.

The moisture contents of the aggregates shall be determined before the commencement of each day's
concreting and at such intervals during each day as may be necessary. The Contractor shall make due
allowance for the water contained in the aggregates when determining the quantity of water to be
added to each mix, and shall adjust the amount of water added to each mix to maintain constant the
approved free water/cement ratio of the mixed concrete.

3.18 Ready-mixed Concrete

In case of non compliance, the S.O. reserves the right to rescind the approval of ready mixed concrete.

The Contractor shall satisfy the S.O. that ready-mixed concrete complies with the Specification in all
respects, and that the manufacturing and delivery resources of the proposed supplier are adequate to
ensure proper and timely completion of each concreting operation.

The specified requirements as to the sampling, trial-mixing, testing and quality of concrete of various
grades shall apply equally to ready-mixed concrete.

Any additional facility, which the S.O. may require for the supervision and inspection of the batching,
mixing and transporting of ready-mixed concrete shall be provided by the Contractor. In any case no
ready-mixed concrete shall be allowed to be used after 45 minutes of initial mixing.

3.19 High Alumina Cement

The composition of high alumina cement shall comply with BS 4550 6 & BS 14647. It shall consist
of a minimum of 32% of alumina and the minimum compressive strengths of mortar cubes at one and
three days shall be 42 N/sq.mm and 48 N/sq.mm respectively.

High alumina cement shall not be used in structural concrete including foundations under tropical
conditions where substantial reduction in strength has been experienced.

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3.20 Preparing for Concreting

Before placing concrete the Contractor shall remove from the surface of the foundations or previously placed
concrete, all oil, loose fragments of rock, earth, mud, timber and other debris, and standing water, to the
satisfaction of the S.O.

Where specified and elsewhere as ordered by the S.O., the excavated surfaces shall be prepared as specified
under concrete protection.

3.21 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 or drying out and ensure that the concrete is of the required
workability at the time of placing. If segregation has nevertheless occurred in any instance, the
materials shall be remixed or rejected.

3.22 Placing concrete

Concrete shall be placed and compacted before the initial set has occurred and, in any event, not later
than 45 minutes from the time of mixing.

When pneumatic placers are used, if the end of the placer pipe is not equipped with an energy
absorbing device, it shall be kept as close to the work as practicable. Mortar or water used at the
beginning or end of a run shall be discharged outside the formwork.

When pumps are used, the end of the supply pipe shall be kept immersed in the concrete during
placing to assist compaction. Mortar and water used at the beginning or end of a run shall be
discharged outside the formwork.

3.23 Concreting in Hot Weather

In hot weather, the Contractor shall take steps to ensure that the temperature of the concrete as placed
shall not exceed 32 deg. C and that the maximum internal temperature attained during setting does not
exceed 70 deg. C.

To achieve this, the Contractor shall provide sun shades over stockpiles of aggregate, cement silos,
mixing water tanks and pipelines, and in addition shall carry out the first and as necessary other of the
following procedures which shall be submitted to the S.O. for approval:

(i) Cool the mixing water and replace part of the water by chipped ice. The ice shall be
completely melted by the time mixing is completed.

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(ii) Spray clean cool water over the aggregate stockpiles. The Contractor shall carry out regular
tests on the aggregates to ensure that concentrations of sulphates or chlorides do not rise to
unacceptable levels, and to ensure that moisture content determinations allow for such
spraying.

(iii) Shade or wet the outside of the formwork.

(iv) Apply a fine moisture (fog) spray of clean cool water to shaded areas immediately prior to
placing concrete.

(v) Pour concrete at night.

3.24 Compaction

All concrete placed in-situ shall be compacted with power driven internal type vibrators supplemented
by hand spading and tamping, except as otherwise approved by the S.O. The vibrators shall at all
times be adequate in number, amplitude and power to compact the concrete properly and quickly
throughout the whole of the volume being compacted. Spare vibrators shall be readily on hand in case
of breakdown.

Vibrators shall be inserted into the uncompacted concrete vertically and at regular intervals. Where
the uncompacted concrete is in a layer above freshly compacted concrete the vibrator shall be allowed
to penetrate vertically for about 100mm into the previous layer. In no circumstances shall vibrators
be allowed to come into contact with the reinforcement or formwork nor shall they be withdrawn
quickly from the mass of concrete but shall be drawn back slowly so as not to leave voids. Internal
type vibrators shall not be placed in the concrete in a random or haphazard manner nor shall concrete
be moved from one part of the work to another by means of the vibrators.

The duration of vibration shall be limited to that required to produce satisfactory compaction without
causing segregation. Vibration shall on no account be continued after water or excess grout has
appeared on the surface.

3.25 Attendance of Steel Fixer and Carpenter

During the concreting of all reinforced concrete, including prestressed concrete, a competent steel
fixer and carpenter shall be in attendance on each concreting gang, to ensure that the reinforcement,
formwork and embedded fittings are kept in position as work proceeds.

3.26 Curing of Concrete

Concrete shall be cured by protecting the surface from the effects of sunshine, drying winds, frost,
rain, running water or mechanical damage for a continuous period of four days when the cement used
in the concrete is sulphate-resisting Portland cement and seven days when the cement used is the
ordinary Portland Cement. The protection shall be applied as soon as practicable after completion of
placing by one or more of the following methods as approved by the S.O.:

(a) by water sprays in continuous operation;

(b) by covering with hessian or similar absorbent material, or sand, kept constantly wet;

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(c) after thorough wetting, by covering with a layer of waterproof fabric kept in contact with the
concrete surface.

(d) by the application of an approved non-staining liquid curing membrane which is either
self-removing or easily removed following curing period and which has a 75% moisture
retention standard. The liquid shall be applied to formed surfaces immediately after stripping
the formwork.

Liquid curing membranes (d) shall not be used on Class U1 surfaces where laitance is to be removed
and aggregate exposed to provide a satisfactory bond for placing further concrete or mortar screeds or
on surfaces where the S.O. is of the opinion that the appearance of the concrete surface will be
affected.

3.27 Construction Joints

A construction joint is defined as a joint in the concrete introduced for convenience in construction at
which special measures are taken to achieve subsequent continuity without provision for further
relative movement.

Concrete placed to form the face of a construction joint shall have all laitance removed and the large
aggregate exposed prior to the placing of fresh concrete.

The laitance shall wherever practicable be removed when the concrete has set but not hardened by
spraying the concrete surface with water under pressure or brushing with a wire brush sufficient to
remove the outer mortar skin and expose the large aggregate without being disturbed. Where the
laitance cannot be removed due to hardening of the concrete, the whole of the concrete surface
forming the joint shall be treated by high pressure water jet, sand blasting, use of a needle gun or a
scaling hammer to remove the surface laitance.

Before concreting is resumed, all loose matter on the existing concrete surface shall be removed and
the surface slightly wetted.

3.28 Built in Pipes and Plant

Wherever possible, pipes and other items of Plant passing through concrete structures shall be
installed and connected to the remainder of the pipework system to ensure proper fit, and shall be
built into the structure as work proceeds.
Where this procedure is impracticable due to programme or other requirements, holes shall be formed
for the items of Plant to allow them to be built in later after complete installation of the Plant.

In no case shall individual pipes of a complicated pipework system including flanged joints be built
into concrete structures before accurate fit of the whole system can be checked after complete
installation.

Where holes are formed these shall be of size and shape sufficient to permit proper placing and
compaction of concrete or grout. The surfaces of the holes shall be treated to produce a 'bonded'
surface before installation of Plant.
Before building-in commences the Plant shall be adequately supported in position to prevent
movement or damage during building-in.

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Concrete used for building-in shall be of the same grade as concrete of the member into which the
plant is being built, except that the mix shall also incorporate an approved expanding additive used in
accordance with the manufacturer's instructions. Concrete, mortar and grout shall be carefully placed
and compacted around the Plant to avoid damaging or moving the Plant.

3.29 Installation of Precast Concrete Units

At all stages and until completion of the work, precast members shall be adequately protected to
preserve all permanently exposed surfaces, arrises and architectural features.

The protection shall not mark or otherwise disfigure the concrete.

All units shall be laid, bedded, jointed and fixed in accordance with the lines, levels and other details
shown on the Drawings.

Dry-pack mortar jointing for packing shall consist of one part by volume ordinary Portland cement
and two and half parts by volume of fine aggregate passing a 1mm sieve. The mortar shall be mixed
with only sufficient water to make the materials stick together when being moulded in the hands. The
mortar shall be placed and packed in stages, wherever possible from both sides of the space being
filled, using a hardwood stick hammer until the mortar is thoroughly compacted.

Any precast concrete structural member which is found to be cracked, damaged or otherwise inferior
in quality either before or after erection, shall be rejected and replaced by the Contractor.

3.30 Precast Concrete Products

Precast concrete products shall where appropriate be constructed in accordance with British Standards
as follows, being hydraulically pressed where possible:

Type of Unit Standard
Concrete blocks BS EN 1170-1
Concrete kerbs etc. BS EN 1339 & BS EN 1340
Concrete flags BS EN 1339 & BS EN 1340
Concrete sills BS 5642
Concrete lintels BS 5977

The concrete shall comply in every aspect with the provisions of the Specification whether such
products are manufactured on the Site or obtained from other manufacturers.

3.31 Sampling and Testing of Aggregate

The Contractor shall sample and carry out a mechanical analysis of the fine aggregate and each
nominal size of coarse aggregate in use employing the methods described in BS 1881 at least once in
each week when concreting is in progress and at such more frequent intervals as the S.O. may require.

The grading of all aggregates shall be within specified limits and should the fraction of aggregate
retained on any sieve differ from the corresponding fraction of aggregate in the approved mix by more
than 2% of the total quantity of fine and coarse aggregate, the S.O. may instruct the Contractor to alter
the relative proportions of the aggregates in the mix to allow for such difference.

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January 2010


3.32 Quality Control: Sampling and Testing of Concrete

The Contractor shall provide the equipment necessary to determine the compacting factor of freshly
mixed concrete at each place where concrete is being made and shall determine the compacting factor
of the freshly mixed concrete by the method described in BS 12350 on each occasion that a set of test
cubes is made and not less than once a day or as the S.O. may direct.

For each grade concrete, works test cubes shall be made whenever required by the S.O. but not less
frequently than as follows unless otherwise particularly specified:

for concrete one set of cubes per 25 cu.m
of grades C25, or part thereof concreted
C35A per day;

for concrete one set of cubes per 50 cu.m
of grade C15 or part thereof concreted
or C20: per day.

Each set of cubes (six cubes per set) shall be made from a single sample taken from a randomly
selected batch of concrete. Three cubes shall be tested 7 days after manufacture and three cubes 28
days after manufacture.

3.33 Compliance with Specified Requirements

The concrete shall be deemed satisfactory provided that:-

(i) The average 28 days strength determined from any group of four consecutive sets of three test
cubes exceeds the specified characteristic strength by not less than 5 N/sq.mm for grade C15
concrete and 3.75 N/sq.mm for grades C20, C25, and C35A.

(ii) The average of each set of three test cube results is greater than 100% of the specified
characteristic strength.

If only one set of three cube results fails to meet the second requirement, those results may be
considered to represent only the particular batch of concrete from which the cubes were taken,
provided that the average strength of the group satisfies the first requirement.

If more than one set of three cube results in a group fails to meet the second requirement or if the
average strength of any group of four consecutive sets of three test cubes fails to meet the first
requirement then all the concrete in all the batches represented by all such cubes shall be deemed not
to comply with the strength requirements.

3.34 Non-Compliance

When the average strength of four sets of three consecutive test cubes fails to meet the first
requirement, no further concrete from that mix shall be placed in the work and the Contractor shall
establish the cause of the failure and apply such remedies as are necessary. The Contractor shall

Issue 01 / Rev 01
January 2010


demonstrate by trial mixes and test cube results that the revised mix is in accordance with the
specified requirements.
The Contractor shall within 24 hours of the date of test make proposals for agreement with the S.O.
about action to be taken in respect of any concrete represented by test cubes which fail to meet either
of the requirements. These proposals may include, but shall not be limited to, cutting and testing
cores.

Concrete which is ultimately found not to comply with any of the requirements of the Specification
shall be rejected and shall be broken out and replaced or otherwise dealt with as agreed with the S.O.

3.35 Cutting and Testing of Core Samples

As and where directed by the S.O. cylindrical core specimens of 150mm nominal diameter shall be
cut normal to the face of the hardened concrete for the purpose of examination and testing. The
procedure for drilling, examination, measurement and testing for compressive strength shall be in
accordance with BS 12390. Prior to preparation for testing, the specimen shall be made available for
examination by the S.O. If the crushing strength of the specimen determined in accordance with
paragraph 114 of BS 12390 is less than the characteristic strength at 28 days for the grade
requirements in other respects, the concrete in that part of the Works of which it is a sample shall be
considered not to comply with the specified requirements.

3.36 Inspection Procedures

Before any concrete is placed, the Contractor shall carry out an inspection to ensure that all
preparations are complete, including the provision of the necessary equipment and personnel, and
shall ensure that sufficient materials are available to complete the work proposed.

After completion of this inspection the work shall be offered for inspection by the S.O., sufficient
time being allowed for inspection and correction of any defects. No concrete shall be placed until the
S.O. has inspected and approved the surfaces upon which the concrete is to be placed, the formwork
and the reinforcing steel.

Where required by the S.O. the Contractor shall institute a 'pour card' system in which a card is made
out for each lift of concrete and is initialled by the Contractor and S.O. indicating that the inspections
have been carried out.

The 'pour card' shall include spaces to identify the concrete being placed and to signify completion of
the inspections by the Contractor and S.O. of the following items:

- preparation of surface on which concrete is to be placed;
- formwork;
- reinforcement;
- ready for concrete placing;
- inspection after removal of formwork (any remedial work shall be agreed and noted);
- curing procedures;
- completion of remedial work (if any).

3.37 Machinery Bases and Grouting In

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Issue 01 / Rev 01
January 2010

Bases to take machinery and associated pipeworks shall be constructed in fair faced concrete to the
dimensions shown on the approved machinery drawings or as ordered by the S.O. The mounting
surface of the base shall be steel floated to true and level planes.

The structural concrete on which the bases are to be erected shall be prepared by hacking and cleaning
off.

Bases shall be tied to the structural concrete with vertical reinforcement. Horizontal reinforcement
shall also normally be provided at the level of the pockets for the holding down bolts.

Bolt pockets and lead-ins for grout shall be formed by a means which shall have the approval of the
S.O. Polystyrene formers will not be permitted. Where expanded metal is used as a former it shall be
left in.

When the machinery has been erected the bolt pockets shall on approval of the S.O. be completely
filled using a mixture of 2 parts of cement to 3 parts sand by volume with sufficient water to form a
thick creamy consistency.

The machinery shall be run under the supervision of the Contractor and witnessed by the S.O. after
the grout has hardened. When so directed the Contractor shall complete the grouting operation by
filling the space between the top of the concrete and the underside of the machinery base plate.

SECTION 4
FORMWORK

Section 4 - Formwork
TABLE OF CONTENT

Page
4.0 FORMWORK 4.1
4.1 Scope 4-1
4.2 Materials 4-1
4.3 Erection of Formwork 4-1
4.4 Removal of Formwork 4-2
4.5 Building in Plant 4-2
4.6 Dry-pack Mortar 4-3
4.7 Defects in Formed Surfaces 4-3
4.8 Movement Joints 4-4
4.9 Inspection and Testing 4-5


4.0 FORMWORK

4.1 Scope

This section covers the supply, erection and removal of formwork, the finishes to be attained and the
remedial action to be taken to the finished concrete after removal of formwork.

4.2 Materials

Formwork shall be constructed of timber, sheet metal or other approved material. The Contractor shall
also furnish all struts, braces and ties to withstand the placing and vibrating of concrete, all
construction loads and the effects of weather.

Form ties shall be of rod and cone or other approved proprietary type. They shall be designed so that
no part remaining embedded in the concrete after formwork has been removed shall be nearer than
50mm from the surface in the case of reinforced concrete and 150mm in the case of unreinforced
concrete.

Form ties for use in water-retaining structures shall incorporate a diaphragm not less than 50mm
diameter welded to the mid point of the tie, designed to prevent water passing along the tie.

4.3 Erection of Formwork

All formwork shall be soundly constructed, firmly supported, adequately strutted, braced and tied to
withstand the placing and vibrating of concrete, construction loads and the effects of weather.
Formwork shall not be tied to or supported by reinforcement.

Faces of formwork in contact with concrete shall be free from adhering foreign matter, projecting
nails and the like, splits or other defects, and all formwork shall be clean and free from standing
water, dirt, shavings, chippings or other foreign matter. Joints shall be sufficiently watertight to
prevent the escape of mortar or the formation of fins or other blemishes on the face of the concrete.

All exposed exterior angles on the finished concrete of 90 deg. or less shall be given 20mm by 20mm
chamfers.

Formwork shall be provided for the top surfaces of sloping work where the slope exceeds 15 deg.
from the horizontal (except where such top surface is specified as spaded finish) and shall be anchored
to enable the concrete to be properly compacted and to prevent air being trapped.

Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil prior to
reinforcement and concrete placement to prevent adherence of the concrete. Care shall be taken to
prevent the oil from coming in contact with reinforcement or with concrete at construction joints.
Surface retarding agents shall not be used unless specified.

Where ties are built into the concrete for the purpose of supporting formwork, the whole or part of
any such supports shall be capable of removal so that no part remaining embedded in the concrete
shall be nearer than 50mm from the surface in the case of reinforced concrete and 150mm in the case
of unreinforced concrete.

January 2010

Holes left after removal of such supports shall be neatly filled with well rammed dry-pack mortar.
Openings for inspection of the inside of the formwork, for the removal of water used for washing
down and for placing concrete shall be provided and so formed as to be easily closed before or during
placing concrete. Before placing concrete all bolts, pipes or conduits or any other fixture which are to
be built in shall be held fast by fixing to the formwork or otherwise. Holes shall not be cut in any
concrete without prior approval of the S.O.

4.4 Removal of Formwork

Formwork shall be so designed as to permit easy removal without resorting to hammering or levering
against the surface of the concrete.

The periods of time elapsing between the placing of the concrete and the striking of the formwork
shall be as approved by the S.O. after consideration of the loads likely to be imposed on the concrete
and shall in any case be not less than the periods shown in the following table. Where soffit formwork
is constructed in a manner that allows the removal of the majority of the formwork and the retention
during and after such removal of a sufficient number of adequate supporting props in an undisturbed
condition, the Contractor may with the agreement of the S.O. remove the formwork at the earlier
times listed below provided that the props are left in position and are not disturbed during removal of
the majority of the formwork.

Position Time for striking using ordinary Portland
cement normal weather days

Beam sides, walls and columns

1
Slabs (props left under) 5
Props to slabs 14
Beam soffits (props left under) 10
Props to beams 21

Notwithstanding the foregoing, the Contractor shall be held responsible for any damage arising from
removal of formwork before the structure is capable of carrying its own weight and any incidental
loading.

4.5 Building in Plant

The Contractor shall erect all formwork, struts and other temporary work to enable Plant to be built in,
and such formwork shall be designed to allow placing of the concrete, mortar or grout so as to fill the
voids completely, and to enable air to escape from any cavities during filling. The formwork shall be
sealed against pipework and other items of Plant to prevent leakage of grout. Formwork shall be
supported independently of all Plant and pipework. The Contractor shall use such templates and
moulds as are necessary to achieve the accurate positioning of such items.

January 2010

4.6 Dry-pack Mortar

Dry-pack mortar for filling holes and repairing surface blemishes shall be made from one part by
weight of cement and three parts fine aggregate passing a 1mm sieve. The colour of the mortar shall
match that of the surrounding concrete. The mortar shall be mixed with only sufficient water to make
the materials stick together when being moulded in the hands.

The dry-pack material shall then be placed and packed in layers having a thickness not greater than
15mm. The compaction shall be carried out by use of hardwood stick and hammer and shall extend
over the full area of the layer, particular care being taken to compact the dry-pack against the sides of
the hole. After compaction the surface of each layer shall be scratched before further loose material is
added. Holes shall not be over filled and the surface shall be finished by laying the hardwood block
against the dry-pack fill and striking the block several times. Steel finishing tools shall not be used
and water shall not be added to facilitate finishing.

4.7 Defects in Formed Surfaces

Workmanship in formwork and concreting shall be such that concrete shall require no making good,
surfaces being perfectly compacted and smooth.

Any surface blemishes shall be repaired by the Contractor, at his expense, to the satisfaction of the
S.O. immediately after removal of formwork. Any remedial treatment to concrete surfaces shall be
agreed with the S.O.

No rendering of finished surfaces to make good shall be allowed.

Any concrete the surface of which is found to have been treated before inspection by the S.O. shall be
rejected.

Remedial measures may include, but shall not be limited to, the following:

- holes left by the formwork supports shall be thoroughly cleaned out to remove all loose
material and the sides shall be roughened, if necessary, to ensure a satisfactory bond: they shall
then be filled with an approved proprietary epoxy resin mortar or with dry-pack mortar if agreed
by the S.O.;

- fins, pinhole bubbles, surface discolouration and minor defects may be rubbed down with
sacking and cement immediately the formwork is removed;

- abrupt and gradual irregularities may be rubbed down with carborundum and water after the
concrete has been fully cured;

- small defects and minor honeycombing shall be chipped out normal to the face of the concrete
to a depth of at least 25mm and filled with an approved proprietary epoxy resin mortar or with
dry-pack mortar if agreed by the S.O.

Where deeper or more extensive defects occur, the Contractor shall obtain the approval of the S.O. to
the methods of repair proposed which may include, but shall not be limited to, cutting out to a depth
of 25mm with a diamond saw to give a regular edge to the repair and further chipping to form a hole
with dovetail shape to sound concrete or to a total depth of 75mm whichever is the greater.

January 2010

If reinforcing steel is exposed, the concrete shall be removed to a depth of 25mm beyond the back
side of the reinforcement. Steel mesh reinforcement shall then be sprung into the dovetail. The void
shall be refilled with concrete or suitable approved epoxy resin mortar.

The Contractor shall thoroughly clean any hole or defective area that is to be filled and where the
surface has been damaged the Contractor shall break out any loose, broken or cracked concrete or
aggregate.

Where the remedial work is to be carried out using dry-pack mortar or concrete, the concrete
surrounding the hole shall be thoroughly soaked after which the surface shall be dried so as to leave a
small amount of free water on the surface. The surface shall then be dusted lightly with cement by
means of a small dry brush until the whole surface that will come into contact with the dry-pack
mortar has been covered and darkened by absorption of the free water by the cement. Any dry cement
in the hole shall be removed.

Dry-pack mortar shall be mixed and placed as specified.

Where concrete is to be used, the concrete mix shall be approved by the S.O. and shall be placed and
compacted into the hole, using formwork as necessary.

Where the remedial work is to be carried out using epoxy resin mortar or other specialist material, the
surface of the cleaned hole shall be prepared and primed and the repair material placed, compacted
and finished in accordance with the manufacturer's instructions.

Where in the opinion of the S.O., the defect is too extensive to permit satisfactory repair, either from
the point of view of structural integrity or appearance, the concrete containing the defect shall be
broken out and replaced.

4.8 Movement Joints

Movement joints for expansion and contraction shall be constructed in accordance with the details and
to the dimensions shown on the Drawings or where otherwise ordered by the S.O. and shall be formed
of the elements specified.

The Contractor shall pay particular attention to the effects of climatic extremes about the Works on
any material which he may desire to use in any movement joint and shall submit for approval by the
S.O. his proposals for the proper storage handling and use of the said materials having due regard for
any recommendations in this connection made by manufacturers.

Waterstops shall be incorporated into all expansion and contraction joints in units which retain or
exclude liquids.

Different types of waterstop material shall not be used together in any complete installation.

Waterstops shall be fabricated into the longest practical units at the supplier's works and shall be
continuous throughout the structure below highest water level. Intersections and joints shall be factory
made where possible.

Horizontally placed surface type waterstops shall have an interposing sliding plane.

January 2010

January 2010
Waterstops shall be carefully maintained in the position shown on the Drawings supported on
accurately profiled stop boards to create rigid conditions.

Joint filler shall be either cork joint filler or cellular joint filler.

Cork joint filler shall be waterproof and rotproof and shall not extrude as a result of compression.
Cork joint filler shall compress to less than 50% of its original thickness with immediate recovery to
80% or more of its original thickness.

Cellular joint filler shall be a preformed low-compression joint filler made from foam rubber. Cellular
joint filler shall recover to its original thickness after each loading and unloading.

The joint filler shall be fixed to the required dimensions of the joint cross section and shall provide a
firm base for the joint sealer. Where the depth of joint between the concrete surface and the water stop
does not exceed 500mm a filler shall be placed in single depth sections.

Sealing of movement joints shall be carried out only when adjacent concrete surfaces are perfectly
dry.

Immediately before the application of the joint sealer the groove protection batten shall be removed in
such lengths as represent a single days work for sealing the joints.

The joint grooves shall be cleaned, adequately primed and filled with approved sealer strictly in
accordance with the manufacturer's instructions.

On permanently exposed areas of structures joint sealing is to be carried out with the aid of masking
tape to form neatly defined surface limits to the sealer.

4.9 Inspection and Testing

Before concrete is placed against any formwork, the formwork shall be inspected and approved by the
Contractor and offered for inspection by the S.O.

If a "pour-card" system is in operation, the card shall be signed by the Contractor and submitted to the
S.O. with the request for inspection of the formwork.

SECTION 5
STEEL REINFORCEMENT

Section 5 Steel Reinforcement
TABLE OF CONTENT
Page
5.0 STEEL REINFORCEMENT 5.1
5.1 Scope 5.1
5.2 Steel Reinforcement 5.1
5.3 Accessories 5.1
5.4 Detailing 5.1
5.5 Cutting and Bending of Reinforcement 5.1
5.6 Storage of Reinforcing Bars and Fabric 5.2
5.7 Fixing of Reinforcement 5.2
5.8 Inspection and Testing 5.2

Section 5 Steel Reinforcement
5.0 STEEL REINFORCEMENT

5.1 Scope

This specification covers detailing, fabricating, supplying and placing of reinforcing steel and
accessories for all cast in place and precast concrete.

5.2 Steel Reinforcement

Steel for reinforcement shall be of the following kinds as may be specified or detailed on the
Drawings:

Type R - hot-rolled plain round mild steel bars conforming to BS 4449.

Type T - either, hot-rolled deformed high yield steel bars conforming to BS 4449 (with
geometrical classification Type 2).

- or, cold-rolled deformed high yield steel bars conforming to BS EN 10268
(with geometrical classification Type 2).

Fabric - welded hard drawn steel wire and other cold worked high bond bar fabric
conforming with BS 4483.
5.3 Accessories

The Contractor shall supply all accessories such as reinforcing steel supports, hold-downs, spreaders,
hangers, tie wire and all other incidentals necessary to complete an acceptable installation of all steel
reinforcement. All accessories shall be of steel with the exception of spacers to maintain concrete
cover to reinforcement against formed or blinded surfaces which shall be of concrete of same texture,
colour and composition as cast-in-place concrete. Concrete spacers shall be in the form of a truncated
cone or pyramid and shall be used with the larger face towards the reinforcing steel. The smaller face
of a truncated cone or pyramid shall have a maximum dimension of 50mm.

5.4 Detailing

Steel reinforcement shall be as shown on the Drawings. The Contractor shall be responsible for
checking the Drawings before cutting and bending reinforcement. When any information relating to
reinforcement is missing or apparently incorrect, the Contractor shall advise the S.O. and remedy the
missing or incorrect information to the approval of the S.O.

5.5 Cutting and Bending of Reinforcement

Bars shall be cut and bent in accordance with the provisions of BS 8666 and BS EN ISO 3766. All
bending shall be done cold with the use of an approved bending machine. Rebending of bars will not
January 2010
Section 5 - Steel Reinforcement

January 2010

be permitted. Cut and bent bars shall be bundled and labelled for positive identification with the
Drawings and bending schedules, until they are incorporated into the work.

5.6 Storage of Reinforcing Bars and Fabric

The Contractor shall stack separately and label different types of reinforcement for positive
identification.

Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil,
grease, earth, paint, or any other material which may impair the bond between the concrete and the
reinforcement.

Reinforcing steel shall be stored and fabricated under cover on wooden or concrete supports such that
the steel is elevated from the ground surface by a minimum of 150mm.

5.7 Fixing of Reinforcement

All reinforcement shall be securely and accurately fixed in positions shown on the Drawings using
approved spacer blocks or chairs. All intersections of bars shall be secured with No. 16 gauge
(1.60mm) soft iron wire, the ends being turned into the body of the concrete. The Contractor shall
ensure that all reinforcement is maintained in position at all times, particular care being taken during
placing of concrete.

Concrete cover to reinforcement shall be as specified or detailed on the Drawings, and shall be
maintained in accordance with the tolerances specified in BS 8110. Correct concrete cover to
reinforcement shall be maintained with the aid of approved spacer pieces. Top reinforcement in slabs
shall be maintained in position by means of chairs, the diameter and quantity being sufficient to
ensure security of the reinforcement in shape and position.

No part of the reinforcement shall be used to support formwork, access ways, working platforms, or
the placing equipment or for the conducting of an electric current.

5.8 Inspection and Testing

When required by the S.O., the Contractor shall take samples from reinforcement delivered to site and
shall arrange for the samples to be tested by an approved testing agency. Test certificates from that
agency shall be submitted to the S.O.

The S.O. or his authorised representative may require to witness such testing and also routine testing
at the manufacturer's works.

The Contractor shall be responsible for all checking and inspection of reinforcement before
preparations for placing concrete are offered for inspection by the S.O.

SECTION 6
STRUCTURAL STEELWORK

Section 6 Structural Steelwork
TABLE OF CONTENT

Page
6.0 STRUCTURAL STEELWORK .....................................................................6-1
6.1 General .............................................................................................6-1
6.2 Materials ...........................................................................................6-1
6.3 Surveys and Setting Out .................................................................6-1
6.4 Drawings...........................................................................................6-1
6.5 Workmanship ...................................................................................6-1
6.6 Connections .....................................................................................6-2
6.7 Bolting ..............................................................................................6-2
6.8 Welding.............................................................................................6-3
6.9 Holing................................................................................................6-4
6.10 Slab Bases and Caps.......................................................................6-5
6.11 Gusseted Bases and Caps..............................................................6-5
6.12 Compression Joints and Stanchion Splices .................................6-5
6.13 Stiffeners ..........................................................................................6-5
6.14 Clearances........................................................................................6-6
6.15 Marking .............................................................................................6-6
6.16 Protective Painting and Coatings...................................................6-6
6.17 Erection ............................................................................................6-8
6.18 Erection Tolerances.........................................................................6-9
6.19 Grouting............................................................................................6-9
6.20 Inspection.......................................................................................6-10
6.21 Fire Protection ...............................................................................6-10

APPENDIX 6.1: Table 18 and 19 of British Standard 5135

LIST OF TABLE

Table: 6.1: Weld Test Requirements
Table: 6.2: Painting And Coating

Specification for Minor Civil Works
January 2010

6.0 STRUCTURAL STEELWORK

6.1 General

Any ambiguities in or discrepancies between the Contract Documents shall be reported to the S.O.
immediately.

6.2 Materials

Unless otherwise specified all structural steel shall comply with the requirements of the current issues
of British Standards where appropriate.

The grade of steel to BS 7668 shall be as specified on the drawings.

Steel shall be marked in accordance with BS 7668. Where steels of different grades are used they shall
with the exception of Grade 43A have additional markings as specified by the S.O.

Unless specified or approval otherwise stainless steel shall be austenitic stainless steel grade 304 or
316 complying with BS EN 10051.

Cold formed sections shall be manufactured from steel complying with BS 1449 or BS EN 10143.

All steel shall be free from loose mill scale rust and shall be straight unless required to be curvilinear
form, and shall be free from twists.

When required by the S.O., the Steelwork Contractor shall submit test certificates relating to the steels
used in the work. The tests shall be those described in the appropriate British Standards.

6.3 Surveys and Setting Out

The Steelwork Contractor shall be responsible for the survey of the site so far as it applies to the
steelwork.

6.4 Drawings

The steelwork Contractor shall prepare all necessary calculations (including those relating to
connections, plates, etc), detail arrangements and workshop drawings.

Workshop drawings shall be prepared taking full account of the support and dimensional requirements
of cladding and other specialist sub-contractors.

6.5 Workmanship

The workmanship throughout is to comply in all respects with the recommendations of BS 5950 and
be to the satisfaction of the S.O.
Fabrication tolerances shall comply with the requirements of BS 5950 Part 2.
January 2010


Unless noted otherwise the ends of all tubular sections are to be sealed against the ingress of moisture.

Permissible variation in the specified camber of beams or trusses regardless of cross section shall not
exceed - 0mm or + 6mm.

6.6 Connections

The steelwork contractor shall design all the connections, including holding down assemblies, to
BS 5950, except those specifically detailed, to resist the forces and moments as given on the
drawings.

Unless otherwise specified by the S.O., all shop connections are to be formed by arc welding and all
site connections with High Strength Friction Grip (HSFG) bolts or black bolts. All site bolts are to be
sheradised.

Should the Steelwork Contractor elect to use any alternative form of connection these shall be
submitted to the S.O. for his approval.

The Contractor shall allow in his rates for all welding, bolts, cleats, end plates, gussets and stiffeners,
unless these are specifically measured in the Contract Documents.

Unless noted otherwise or specifically approved by the S.O., connections shall be formed with a
minimum of 2M20 8.8 grade bolts, 6mm fillet weld and 8mm thick plate.

6.7 Bolting

The dimensions of black bolts shall conform to the requirements of BS 3692 and BS 4190.

In connections which rely on the shear strength of the bolts, the correct length of bolt is to be used to
avoid any thread portion of the bolt being within the thickness of the parts bolted together.

Washers are to be provided under all nuts except when it is necessary to rotate the head of the bolt. In
this instance the washer is to be provided beneath the head. Where necessary, washers shall be tapered
or otherwise suitably shaped to give the nuts and heads of bolts a satisfactory bearing.

Where High Strength Friction Grip bolts are specified or their use approved by the S.O. they shall be
in accordance with the requirements of the current British Standard BS 4395.

Unless otherwise specified, all High Strength Friction Grip bolts are to be used in conjunction with
load indicating washers and the following procedure for fixing strictly adhered to:

(a) Ensure that the surfaces in contact are clean and free from grease, loose rust, loose scale and
paint.

(b) Ensure that the bolts used are of the High Strength Friction Grip type. (3 radial lines on the
bolt head in the case of Grade 8.8 bolts. In the case of Grade 10.9 bolts 3 radial lines and
109 marked in addition on the bolt head.)

(c) Wherever possible, the load indicating washer must be placed under the head of the bolt with
January 2010


the protrusions towards the head. A hardened steel flatwasher should be placed under the nut
which should then be tightened until the gap between the bolt head and the washer is
0.375mm.

(d) Where it is not possible to fit a load indicating washer under the bolt head, then it may be
placed at the nut end of the bolt with a special 'nut faced washer' fitted between the load
indicating washer (protrusions in contact with the NF washer) and the nut. Care must be taken
to ensure that the NF washer is fitted the right way round (sharp corner up to the nut) and is
concentric with the nut.

(e) If the nut is to be tightened against an inclined face then a hardened steel tapered washer must
be placed under the nut. If the bolt head is on the inclined face and this slope is less than 3
degree (which covers all universal beams) then a tapered washer is not required.

All the foregoing is based on the assumption that the nut will be tightened. Should, for any reason, the
bolt head be rotated, then the load indicating washer should be placed under the nut with the
protrusions towards the nut and with a NF washer. If the bolt head is to be tightened against an
inclined face greater than 3 degree, then a tapered washer will be required under the head.

Should there be more than four bolts per group of HSFG bolts, then the bolts are to be tightened in
sequence, from the centre of the group to the outside. When the whole group is tightened, the first
bolts tightened should be checked to make sure that the gap is still 0.375mm and if necessary further
torqued to bring the gap to this dimension.

If any bolt is found to have been tightened so that the gap is less than 0.375mm, then no attempt is to
be made to slacken off the bolt to reach the desired dimension and it must be left as it is. If, for any
reason an HSFG bolt has to be removed or loosened after it has been torqued up, then it is to be
discarded together with the load indicating washer, and new bolts and washers used.

The facing surfaces of a HSFG connection must be in contact along the whole length of the joint as
the load is transmitted via friction through the bearing surfaces. If a joint is poorly aligned then this
member shall be corrected or a tapered pack for the full length of the joint used. The pack must be in
contact with the full length of the joint.

Should the Steelwork Contractor elect to adopt alternative types or methods of fixing HSFG bolts in
accordance with BS 4604, then a Specification shall be submitted to the S.O. together with a proposed
method of testing, prior to their use on site.

6.8 Welding

Welding shall be in accordance with the following British Standards:

BS 1011-1 Specification for Process of Arc Welding of Carbon and Carbon Manganese Steel.

Site welding will, in general, only be permitted in cases where factory fabrication is
impractical, in which case minor site welding will be allowed.

Site welding shall not be carried out in adverse weather unless adequate protection has been
provided from the rain and wind.

All welds shall be tested by visual examination by the steelwork contractor. Should more rigorous
January 2010


methods of weld testing be required they are described in Table 7.1 and the Contractor is to include in
his rates for carrying out all these tests.

Table: 7.1 Weld Test Requirements

Test
Weld
Type
Extent
Acceptance Criteria to
BS 5135
Tables 18 & 19*
A) Shop Welding

Visual All 100% Category B

Magnetic Particle Fillet 100%
10% of all welds in
each batch

Ultrasonic Butt 20% of all welds in
each batch

B) Site Welding

Magnetic Particle Fillet 100% Category B

Ultrasonic Butt 100%

Note 1 Final examination of a welded joint shall be carried out not less than 16 hours
from the time of completion of the weld.
2. Visual inspection to be in accordance with BS 6072.
3. Magnetic particle inspection to be in accordance with BS 6072.
4. Ultrasonic examination to be in accordance with BS EN 1714.
* Updated Standard shall be BS EN 1011
** Refer Appendix 7.1
Should it be shown that 5% or more of the welds tested are unsatisfactory then the steelwork
Contractor shall test all welds at no additional cost to the Contract.

All welds failing to comply shall be redone and tested at no cost to the contract.

Any welds failing to comply with additional tests on site as instructed by the S.O. shall be redone and
retested at no cost to the contract.

6.9 Holing

All work in connection with holing of members is to be carried out in accordance with BS 5950
unless otherwise specified by the S.O.

The Steelwork Contractor shall provide such holes in the members as may be required or specified by
the S.O. for other trades to fix to or pass their work through.

January 2010


Holes to be used for bolted or riveted connections shall not be formed by a gas cutting process.

Finished holes shall be not more than 2mm in diameter larger than the diameter of the black bolts
passing through them unless specified by the S.O.

Holes for HSFG bolts are to be as specified in BS 4604 Part 1.

6.10 Slab Bases and Caps

Slab bases and slab caps, except when cut from material with true surfaces, shall be accurately
machined over the bearing surfaces and shall be in effective contact with the end of the shaft. A
bearing face which is to be grouted direct to a foundation need not be machined if such a face is true
and parallel to the upper face.

Baseplates that are to be grouted direct to a foundation are to be drilled with 10mm diameter breather
holes at a spacing of one hole per 0.05m or part thereof. The holes shall be set away from the edge of
the baseplate.

6.11 Gusseted Bases and Caps

Ends of compression members depending on contact bearing shall be machined true and at right
angles to the shaft after having the component parts (i.e. gusset plates, angles etc) fixed permanently
to the shaft. Care shall be taken in fixing the component parts to ensure that the minimum thickness of
material has to be removed to obtain a true and level surface. In cases when it is impractical to
machine the ends of the compression members, then connections capable of carrying the full load are
to be provided.

6.12 Compression Joints and Stanchion Splices

Ends of compression members meeting at a splice or bearing on a slab division plate, except when
machine sawn true and square, shall be accurately machined over the full bearing area of the member.

Unless otherwise specified flange and web cover plates are to be provided sufficient to hold the
connected members accurately in place. The length of the flange cover plates are not to be less than
the breadth of the stanchion flange.

Unless otherwise shown on the drawings or otherwise noted, stanchion splices are to be
approximately 500mm above floor level.

6.13 Stiffeners

Load bearing stiffeners shall be provided in the webs of all beams and girders at all points where the
concentrated load exceeds the carrying capacity of the web and at other points that may be specified
by the S.O. The stiffeners shall be arranged symmetrically about the web where possible. The ends of
the stiffeners shall be fitted to provide a tight and even bearing upon the loaded flanges and sufficient
weld provided between the web and stiffeners to carry the full load. Stiffeners which are welded to the
webs need not be prepared for bearing on the flanges provided that the welds between the stiffeners
January 2010


and flanges are capable of sustaining the full load. Stiffeners shall not be joggled but shall be packed
out solid from the web.

Should intermediate stiffeners be provided it is not necessary for the ends of these stiffeners to be
prepared for bearing but they are to be of sufficient length to extend from flange to flange.

6.14 Clearances

The erection clearance for cleaned ends of members connecting steel to steel shall not be greater than
2mm at each end.

The erection clearance at ends of beams without web cleats shall be not more than 3mm each end.

6.15 Marking

Each piece of steelwork shall be distinctly marked before delivery in accordance with a marking
diagram.

Where steelwork is to remain exposed in the finished structure, markings should be painted on, so as
not to impair the finished appearance. Hard stamping or the use of welded erection marks may only be
used with the approval of the S.O.

6.16 Protective Painting and Coatings

When omitted from the protection summary Table 7.2 decorative painting of steelwork is to be
carried out as specified by the S.O.

When protection of the steelwork from corrosion is specified, the type of treatment and preparation of
the steelwork to receive same, is to be in accordance with BS 5493 and ISO 12944, and the surface
finish of blast-cleaned steel in accordance with BS EN ISO 8501-1 and BS EN ISO 8503. The
maximum time lag between cleaning steel and applying primer shall be four hours.

The minimum specific protection requirements shall be able to withstand C4 environment and a high
durability (> 15 years design life) coating system in accordance with ISO 12944. The proposed
protection system is listed in the attached protection summary tables. The Contractor shall furnish the
S.O. manufacturer's data sheets for the paints he proposes to use.

Wherever possible paint colours or shades shall be chosen so that successive coats are of different
hues and readily distinguished.

When contact surfaces are to be painted they are to be brought together while the paint is still wet.

Surfaces which are to be jointed with HSFG bolts must not be painted but are to be prepared as
specified in BS 4604.

Site painting shall not be done when humidity is such as to cause condensation on the surface to be
painted.

January 2010


Galvanising is to be carried out in accordance with BS EN ISO 1461 'Zinc Coatings on Iron and Steel
Articles'. Modifications made to members and fittings to facilitate galvanising are to be approved by
the S.O.

The top of the flanges of steel beams for use in composite construction are to remain unpainted. No
primer that is deleterious to the welding operation will be permitted on this surface.

All shop welds and shop bolted connections shall be blast cleaned and painted to the same standard as
the adjacent steel. All weld slag and spatter shall be removed.

Any areas where paint has been damaged shall be made good to a standard equivalent to that of the
adjacent paintwork. If damage has exposed parent metal local re-blasting may be required. The
maximum time lag between cleaning steel and applying primer shall be two hours.

All materials shall be stored and applied strictly in accordance with the manufacturers instructions.

January 2010


Table: 7.2 Painting and Coating

ELEMENT - All structures

SURFACE
PREPARATION - Abrasive blast clean to Sa 2.5 (ISO 8501-1) or SSPC-SP 10

A) Works Protection

Primer min. 50 microns DFT Epoxy Zinc Rich Primer
(minimum 85% epoxy zinc content)

Intermediate min. 125 microns to 150 microns DFT Micaceous Iron Oxide
(shall have 60% solids content and indefinite overcoating time).
Finish min. 50 microns DFT High Solids Polyurethane

B) Site Protection

Repair all welding joints and damage by power tool cleaning to St 2 of ISO 8501-1

Touch up Primer 125 microns DFT High Solids epoxy
Finish 50 microns DFT High Solids polyurethane

Note: DFT Dry Film Thickness

6.17 Erection

The delivery programme of the steelwork and the rate of delivery shall conform to an erection
sequence which shall be prepared and submitted to the S.O. at the start of the Contract as may be
required by the S.O. The sequence shall be prepared in collaboration with the General Contractor.

The Steelwork Contractor shall provide all equipment necessary for the erection of the steelwork, and
shall be responsible for all claims in respect of any patent devices in connection therewith.

During erection, the steelwork shall be securely bolted or otherwise held to ensure that no part of the
structure is over-stressed or liable to collapse. Any damage to steel members resulting from neglect of
the above shall, on the instructions of the S.O., be repaired or replaced by the Steelwork Contractor at
his own expense.

January 2010


6.18 Erection Tolerances

The following are the maximum deviations permitted in the erection of the steelwork:

a) Plumb of Columns + or - 3mm in 3,000

b) Horizontal Members + or - 3mm from specified level at supports

c) Section Discontinuity + or - 3mm

d) Overall Dimension + or - 10mm in 30,000

e) Connection to Concrete

Bolts cast in rigidly + or - 3mm in any direction
Bolts cast in sleeves + or - 5mm in plan
Projection of the bolt + 25 or - 5mm ends

f) Position of Column Bases

Plan about axis + or - 5mm
Level of base plate + or - 5mm

Rectification of work not constructed within the permissible deviations set out above will be to the
approval of the S.O. and entirely at the expense of the Steelwork Contractor.

Notwithstanding the above the positioning and levelling of all steelwork, the plumbing of stanchions
and the placing of every part of the structure shall be to the satisfaction of the S.O.

6.19 Grouting

At all places where steel members are subsequently required to transmit load to concrete, the latter
shall be fair finished at the requisite level and if specified provided with anchor bolts in accordance
with the drawings. The space between the concrete and steel shall be not less than 25mm and not
more than 50mm unless otherwise specified or approved by the S.O.

After the steelwork is set on steel packings in its final position, levelled and plumbed, and the
grouting space thoroughly cleaned out, the holding down bolts and space beneath the base plate shall
be filled with an approved premixed non-shrink cementitious grout mixed and placed in accordance
with the manufacturers instructions.

Where the use of liquid grout is impracticle the space shall be filled with semi-dry mortar composed
of three parts sand, one part Portland Cement and an approved non-shrink additive, rammed in with a
suitable tool against properly fixed supports. Semi-dry mortar shall only be used with the prior
consent of the S.O.

The grouting or packing shall be done by the Specialist.

January 2010


January 2010

6.20 Inspection

The S.O. shall have full liberty at all reasonable times, to enter the Works where the steelwork is
being fabricated or treated for the purpose of inspecting the work. Any work found to be defective or
which is not in accordance with the drawings or this Specification, shall be made good or rejected.

The Contractor is to allow for providing access for the S.O. to inspect or carry out any independent
tests on the structure on site.

6.21 Fire Protection

Fire rating to all structural steel shall be 2 hours. Blast clean all structural steel members to second
quality (Preparation Grade Sa2.5) in accordance with BS EN ISO 8501 and BS EN ISO 8503.

Apply approved primer at a minimum thickness of 75 microns DFT before applying intumescent
coating.

Apply intumescent to BS 476 and ISO 834 at the specified DFT for the individual member and
according to manufacturer's specifications. Approved finishing coat is required for external exposed
steelworks. Apply approved finishing coat at 60 microns DFT (minimum 50 to maximum 70
microns). The finish should be compatible with the intumescent coating.

All intumescent material for use on the structural steel must be tested and assessed at a recognised
accredited laboratory in accordance with approved national standards as a complete system. In
addition, it shall be assess by a recognised independent thirty party and have an accreditation listing.
The intumescent system has to comply with local Regulations and Building Codes and certified by
BOMBA, Malaysia.


APPENDIX 6
TABLE 18 AND 19 OF BS 5135
January 2010

APPENDIX 6.1 - TABLE 18 and 19 OF BRITISH STANDARD
5135

Table 18: Guidance on acceptance levels for butt joints

Notation:
t is parent metal thickness
l is length of defect
h is height of defect
w is width of defect

Quality
category
A B C D

Minimum
amount of
volumetric non-
destructive
testing
100% 10 % each welder
a
10 % overall
a
None
100% visual only
Cracks Not permitted
b
Not permitted
b
Not permitted
b
Not permitted
b

t 20 mm: l 10 mm
h 2 mm
t > 20 mm: l 15 mm
Lack of fusion
Lack of root
penetration
Not permitted
b

h 2 mm
l 25 mm in any
100mm
length of weld
or h 0.2 t
l 25 % of length
of weld (applicable
only to joints
welded from one
side)
t 18 mm : l t/2 6 mm t 20 mm: l 12 mm
w 1.5 mm w 1.5 mm
t > 18mm 75 mm : t > 20 mm: l 20 mm
l t/3 w 1.5 mm
w 1.5 mm
t > 75 mm: l 25 mm
Individual slag
inclusions
w 1.5 mm
l 25 mm in any
100mm
length of weld
w 1.5 mm
Not applicable
Linear group of
inclusions
Aggregate length 8 % of
length of group which in
turn is not to exceed 12 t
in length
Any length of group
provided adjacent
groups are separated by
a distance of at least 4
times the length of
longest defect for t 20
mm and by a distance of
at least 6 times the
length of longest defect
for t > 20 mm
Any length of
group provided
adjacent groups
are separated by a
distance of at least
4 times the length
of longest defect
Not applicable
January 2010


Table 18: Guidance on acceptance levels for butt joints (cont)

Quality
category
A B C D

Porosity
c
Individual pores: 2 mm
diameter.
Localized: 2 % by area
d
for t 50mm then pro
rata for greater
thicknesses
Individual
pores: 2.5mm
diameter.
Localized: 3 % by
area
d

Individual pores:
3 mm diameter
0.25 t diameter.
Localized: 4 %
by area
d

Surface porosity
Individual
pores: 3 mm
diameter 0.25 t
diameter
Localized: 4 % by
area
d

Undercut Intermittent, 0.5 mm
maximum in depth
Intermittent, 0.5 mm
maximum in depth
Intermittent, 0.5
mm maximum in
depth
Depth 0.1 t
1 mm
l 10 % of length
of weld
a
When random volumetric non-destructive testing reveals unacceptable defects in a joint, two further joints in the
group represented by this joint should be tested similarly. If the results on these two further joints are acceptable then
the original weld should be repaired and retested by similar non-destructive means. If the repair is satisfactory then the
group of joints should be accepted.
If the non-destructive testing of the two further joints reveals unacceptable defects, each joint in the group should be
non-destructively tested. Unacceptable defects should be repaired and retested by similar non-destructive means.
b
This does not mean that the whole joint is rejectable, merely that attention be given to the particular area, e.g. local
repair or grinding without welding.

c
If found during ultrasonic examination, then check-radiography should be applied.
d
The area to be considered should be the length of weld affected by porosity times the maximum width of weld.

Table 19: Guidance on acceptance levels for fillet welds

Quality category A B C D

Minimum amount of
surface non-destructive
testing (either liquid
penetrant or magnetic
particle testing)

100 % of weld
surface and 10 mm of
Random 10 % of
weld surface and 10
mm of adjacent
parent metal each
side of weld
adjacent parent metal
each side weld
Randomly 5 % of
weld surface and 10
mm of adjacent
parent metal each
side of weld
None
100 % visual only
Cracks
Lack of fusion
Not permitted
a
Not permitted
ab
Not permitted
ab
Not permitted
ab

Undercut
c
Intermittent, 0.5mm
maximum in depth
Intermittent, 0.5mm
maximum in depth
Intermittent, 0.5mm
maximum in depth
Some undercut 1
mm maximum in
depth
Fit-up For partial penetration T-joints the results of inspection of joint preparation and fit-up
to be recorded
Throat thickness Total throat thickness to be not less than that specified
a
This does not mean that the whole joint is rejectable, merely, that attention be given to the particular area, e.g. local
repair or grinding without welding
b
If cracks or lack of fusion are found, there may be a need to carry out up to 100% examination.
c
The acceptability of undercut should be at the discretion of the contractor's quality control department in consultation
with the designer and any inspecting authority.

January 2010


January 2010

SECTION 7
SEWERS, FORCE MAINS,
PIPELAYING, MANHOLES AND
APPURTENANCES

Section 7 - Sewers, Force Mains, Pipelaying, Manholes And Appurtenances

TABLE OF CONTENT

Page
7.0 SEWERS, FORCE MAINS, PIPELAYING, MANHOLES AND
APPURTENANCES 7-1
7.1 General for Pipeline 7-1
7.1.1 Test Certificates 7-1
7.1.2 Pipe Marking 7-1
7.2 Vitrified Clay Pipes 7-1
7.2.1 General 7-1
7.2.2 J oints 7-2
7.3 Reinforced Concrete Pipe (RCP) and Fittings 7-2
7.3.1 General 7-2
7.3.2 Materials 7-3
7.3.3 Permissible Variations in Dimensions 7-3
7.3.4 Workmanship and Finish 7-3
7.3.5 Rejection 7-3
7.3.6 J oints 7-4
7.3.7 Marking 7-4
7.4 Polyethylene Pipes (PE) and Fittings 7-4
7.4.1 Materials 7-4
7.4.2 Solid Wall PE Pipes 7-4
7.4.2.1 Sizes and Classes 7-5
7.4.2.2 Joints 7-5
7.5 Unplasticized PVC Pipes and Fittings 7-6
7.5.1 General 7-6
7.5.2 J oints 7-6
7.6 Ductile Iron Pipes and Fittings 7-7
7.6.1 General 7-7
7.6.2 Thickness, Diameter and Length 7-7
7.6.3 External Coating 7-8
7.6.4 Internal Lining 7-8
7.6.5 Fittings 7-8
7.6.6 J oints 7-8
7.6.7 Marking 7-10
7.7 Steel Pipes 7-11
7.7.1 General 7-11
7.7.2 Dimensions 7-11
7.7.3 Painting 7-11
7.8 General for Pipeline Installation 7-11
7.8.1 Scope of Works 7-11
7.8.2 Definitions 7-11
7.8.3 Tools for Pipe Installation 7-12

7.8.4 Handling, Stor0age and Protection during Transit 7-12

7.8.5 Inspection at Time of Installation 7-13
7.9 Installation of Pipes 7-13
7.9.1 General Installation Work 7-13
7.9.2 Pipe Laying 7-14
7.9.3 Closures and Short Sections 7-15
7.9.4 Pipe Bedding for Sewer Pipes 7-15
7.9.5 Concrete Protection of Sewer Pipes 7-16
7.9.6 Protection of J oints for Force Mains 7-16
7.9.7 Tolerances of Alignment and Invert Levels 7-16
7.10 Changes In Line and Grade 7-17
7.10.1 Deflection at Certain J oints 7-17
7.11 Stream and River Crossing 7-17
7.12 Connection to Existing Sewer Mains 7-18
7.13 Cleanliness of Sewers and Force Mains 7-18
7.14 Liability in Pipe Installation 7-18

LIST OF TABLE

Table: 7.1: Pipe Diameter Vs Minimum Crushing Strength
Table: 7.2: Stiffness of PE Pipes
Table: 7.3: Sampling Procedure of PE Pipes
Table: 7.4: Stiffness of GRP Pipes
Table: 7.5: Dimensions of ABS Pipe
Table: 7.6: Classification of ABS Pipe
Table: 7.7: Nominal Diameter Vs Thickness of Wall and Lining of Pipes
Table: 7.8: Hydrostatic Test Pressure

January 2010

7.0 SEWERS, FORCE MAINS, PIPELAYING, MANHOLES
AND APPURTENANCES

7.1 General for Pipeline

Included in this section is the supply and factory testing of pipeline materials for gravity sewers and
force mains. Specifications are included for different materials for both gravity sewers and force
mains. Unless otherwise specified vitrified clay for sewers ranging in size from 100mm diameter to
450mm in diameter and reinforced concrete pipe for sizes pipe shall be used 600mm and greater in
diameter.

The Contractor shall satisfy himself that the pipes included in his tender will be available to him in the
specified quality and in the quantity to meet his construction schedule.

Unless otherwise approved by the S.O., a single manufacturer or supplier shall supply each type of
pipe and its related fittings.

All pipes shall be design and manufactured to have a minimum expected life span of 50 years under
the specified service.

7.1.1 Test Certificates

If required the Contractor shall submit to the S.O. duplicate copies of test certificates, signed by the
manufacturer giving the results of the factory tests on each pipe and special or batch of pipe and
specials as required before dispatch and certifying that each item or batch of items complies with the
requirements of the specification and the relevant standard. The cost of providing test certificates
shall be deemed to be included in the Contract Rates.

7.1.2 Pipe Marking

The following shall be clearly marked on each pipe and fitting delivered to site:

a. The date of manufacture
The name and trademark of the manufacturer
Length, diameter, branch diameter for tees and angles for bends
The material and weight of the pipe or fitting
The strength category that the pipe or fitting conforms to
Factory test pressure (as relevant)
g. Manufacturing standard compliance
h. SIRIM or other certification logo as approved

7.2 Vitrified Clay Pipes

7.2.1 General

All vitrified clay pipes and fittings shall be in accordance with MS 1061 or BS EN 295 with required
crushing as shown below:

Table 8.1: Pipe Diameter Vs Minimum Crushing Strength

Material used for manufacture of vitrified clay pipe shall comprise of blends of naturally available
clays.

All clayware pipes and fittings shall be tested at the factory after manufacture and shall satisfy all the
performance requirements stipulated for Class Number 120 pipes and fittings in BS EN 295. Each
pipe and fitting shall carry the SIRIM acceptance logo or equivalent. Test Certificates shall be
provided.

Pipes and fittings shall be transported to and stored at the Site in a satisfactory manner to prevent
breakages.

The Contractor will be at liberty to use pipe lengths up to the maximum shown in Table 2 of BS EN
295. Some shorter pipes with flexible joints may be required to permit the required levels, positions
and lengths to be accurately obtained.

7.2.2 Joints

The pipes shall be provided with pre-fitted `O' rings spigot/socket joints or skid-type sealing joints.
Vitrified clay pipes shall be jointed strictly in accordance with the manufacturer's instructions.
Spigots, sockets, rubber rings and all sealing faces shall be free from dirt and shall be coated with the
manufacturer's lubricant during jointing.

Rubber rings and vitrified clay pipes with pre-fitted sealant shall be properly stored out of direct
sunlight prior to their use. Rings shall comply with BS 2494 and BS EN 682. The O ring or fitted
sealant shall be made of 100% natural rubber and shall not turn brittle in the sun or creep under
pressure or deteriorate during transit or storage. It shall be able to be precisely fitted to provide a
durable watertight and long lasting joint system.

7.3 Reinforced Concrete Pipe (RCP) and Fittings

7.3.1 General

Pipes shall be of reinforced concrete constructed by the centrifugal spun method or the vibro-cast
method or type, size, strength and quality as indicated on the drawings or as specified. Pipe sections
shall be in minimum lengths of 3m or as specified by the S.O., except where shorter lengths may be
required to meet special conditions.
The manufacturer shall supply certificates of strength. Pipe shall be in accordance with MS 881 or BS
5911 : Part 1 and the applicable provisions of these Specifications and internal diameters shall be as
shown on the drawings.

RCP and fittings from manufacturers with relevant ISO 9000 certifications only shall be acceptable.
January 2010

Pipe Diameter (mm)
Minimum Crushing
Strength (kN/m)
Class No.
150 24 -
225 36 160
January 2010

7.3.2 Materials

a. Aggregates shall conform to the requirements for concrete aggregates as set forth in these
Specifications. The maximum size of the coarse aggregates shall vary with the size of the
clear opening between reinforcing bars or between the bars and the inside or outside surface
of the pipe wall. The maximum size aggregate consistent with proper placing shall be used.

b. Portland Cement shall conform to the requirements as set forth in BS EN 197-1. Ordinary
Portland Cement shall be used unless otherwise indicated.

c. Mix of concrete in which the aggregate shall be sized, graded, proportioned and thoroughly
mixed in a batch mixer with such proportions of cement and water as will produce a
homogenous concrete mixture of such quality that the pipe will conform to the test and
design requirements of these Specifications.

d. Placing of concrete shall be done in the forms by means of the centrifugal spun method or the
vibro-cast method.

e. Curing of concrete pipes shall be done by steam injection, mechanically controlled watering
or by any other established method that will keep the pipe moist during the specified curing
period.

f. Reinforcement shall consist of hard drawn steel wire, steel wire fabric or steel bars. Hard
drawn steel wire for concrete reinforcement shall conform to the requirements as set forth in
BS 4482. Steel wire fabric for concrete reinforcement shall conform to the requirements as
set forth in BS 4461 respectively.

g. Placing of reinforcement shall be done in accordance with BS 5911 : Part 1.

h. Design and reinforcement shall be of the size, and spacing to withstand the loadings specified
in the Drawings.

7.3.3 Permissible Variations in Dimensions

Variations of the internal diameter of the pipe and other variations in dimensions shall conform to the
requirements as set forth in BS 5911 : Part 1.

7.3.4 Workmanship and Finish

Concrete pipe shall be substantially free from fractures, large or deep cracks, and surface roughness.
The planes of the ends of the pipe will be perpendicular to their longitudinal axis.

7.3.5 Rejection

Pipe shall be subjected to rejection on account of failure to conform to any of the specified
requirements or on account of any of the following:

a. Fractures or cracks passing through the shell, except that a single end crack that does not
exceed the depth of the joint shall not be cause for rejection. If a single end crack that does
not exceed the depth of the joint exists in more than 10 % of the pipe inspected, however, the
defective pipe shall be rejected.

January 2010

b. Defects that indicate defective mixing and moulding.

c. Surface defects indicating honeycomb or open texture.

d. Spalls deeper than half the depth of the joint or extending more than 100mm around the
circumference or spalls smaller than half the depth of the joint or less than 100 mm around
the circumference exist in more than 10 % of the pipe.
e. Exposed reinforcement which indicates that the reinforcement is misplaced.

7.3.6 Joints

All reinforced concrete sewer pipes shall have spigot and socket or rebated joints with rubber ring
joint, or approved equivalent.

7.3.7 Marking

In addition to the requirements of clause 8.1.2, circular pipe with elliptical reinforcement shall have
the letter T clearly on the inside at the top and bottom at the correct place to indicate the proper
position when laid.

7.4 Polyethylene (PE) Pipes and Fittings

7.4.1 Materials

The quality of the starting raw material shall closely monitored at the resin-manufacturing site.
Certifications shall be produced by pipe and fitting manufacturer documenting important physical
properties such as melt index, density, environmental strength crack resistance (ESCR), stabilizer tests
and tensile strength as may be required by the S.O. The resin shall stabilized against thermal
oxidation. The resin shall supplied in either the natural state which is normally blended at the
extrusion facility to add pecitized colour and UV stabilizers or in the pre-coloured form. The colour
depends on the intended application and the requirements of the relevant authorised bodies. Carbon
black is the most common pigment used for sewerage application.

The materials used for sewer pipes and fittings shall come from a single compound manufacturer and
shall be made from natural polyethylene (PE) compounds conforming to the minimum cell
classifications as defined in BS 3412 or DIN 16961. Compounds that have different cell
classifications from those specified shall also be acceptable when one or more properties are superior
to those of the specified compound. The PE compound can be in the form powders, granules or
pellets. Some carbon blacks or titanium dioxide about 2-3% shall be added as ultraviolet stabiliser that
makes the pipe resistant to UV degradation. Other additives normally added are lubricants,
antioxidants and pigments.

Design of PE pipes and fittings shall be based on the use of sand backfill compacted to not more than
75% of maximum dry density. Pipes shall be designed to have an expected life span in excess of 50
years under the specified service.

7.4.2 Solid Wall PE Pipes

Solid wall PE pipes to be used for sewerage application shall comply with material, workmanship and
test requirements in accordance with MS 1058. PE solid wall pipe is available locally in diameters up
to 1,000 mm and in standard lengths of 6m and 12m. Pipe size of 160mm or less may be flange
jointed or electrofusion jointed. Solid wall PE pipe is classified by pressure rating with static working
pressures up to 1.6MPa which is normal during servicing.

January 2010

Since PE pipes are flexible, the design of the pipe/trench system is critical. Compared to rigid pipes,
the stability of flexible pipes relies more on the side support of the earth backfill around the pipe.
Consequently, in an urban environment, where the side support may be removed during future
adjacent construction of underground services, pipe failures could be more frequent. Ground
conditions that do not provide good pipe support are not suitable for flexible PE pipe.

Solid wall PE pipe are suitable for buried sewer and buried vacuum sewer installations. Butt fusion
joints shall be used for solid wall PE pipe. Solid wall pipe for pressure main application shall be of
minimum PN10 rating. The use of specific strength shall depend on the depth and nature of the soil as
confirmed by the Qualified Person. Solid wall pipes for vacuum sewer shall be minimum PN8 and at
least PN10 for heavy vehicle loading.

7.4.2.1 Sizes and Classes

The dimensions and tolerances of the PE pipe are determined and set during the sizing and cooling
operation. The sizing operation holds the pipe in its proper dimensions during of the molten materials.
For solid wall pipe, the process is accomplished by drawings the hot material from the die through a
sizing sleeve and into a cooling tank. Sizing is accomplished by either using vacuum or pressure
technique.

Nominal Outside Diameter (OD)

of solid wall PE is a numerical of size to the PE piping system other
than flanges and components designated by the thread size. The nominal outside diameter is fixed and
represented by a round number which is convenient for reference purposes. The internal diameter of
solid wall PE, however, shall vary with the class of pipes depending on the pipe thickness. The
increment is not constant and the sizing follows the adopted international standards for thermoplastic
pipe for pressure application.

Standard length of solid wall PE pipe indicates the overall effective length of the pipe. The standard
length varies with the diameter of the pipes and generally is between 6m to 12m for 100-1000mm
OD. The pipes normally can be cut on site using most types of saws.

Class of solid wall PE pipes is determined by the material types, PE 80 and PE 100, which correspond
to the level minimum design strength at 20
0
C for up to 50 years. PE 80 and PE 100 show the
capabilities of the pipes to withstand 80 bar (8Mpa) and 100 bar (10Mpa) of strength respectively.
The maximum design stress is obtained applying a design coefficient of 1.25 to the strength.

Solid wall PE pipe is normally available in various compounds of different density and this alters the
allowable stress the pipe can stand. Higher the allowable stress means thinner wall for the same
working pressure. Ring stiffness of 8 kN/m
2
(8000Mpa) is generally taken as the minimum stiffness
for smaller diameter pipe. Hence PE 80 with typical resin density of 950 to 955 kg/m
3
is
recommended for use in pressure sewerage. The required working pressure as intended for the
specific working and site conditions shall be achieved by increasing the wall thickness. The pipes at
the joint, however, shall have the same pressure class to ensure the pipe bores align.

7.4.2.2 Joints

Solid wall PE pipes shall be jointed using reliable approved methods. The common methods for
jointing are as follows: -

Spigot-socket joint is performed with one end of the pipe opened up to act as the socket of a moulded
fitting and thereafter the butt fusion welding is carried.

January 2010

7.5 Unplasticized PVC Pipes and Fittings

7.5.1 General

Unplasticized PVC pipe shall not be used for main sewers. The use of uPVC shall be restricted to
house connection sewers.

Where permitted to be used, unplasticized PVC pipes, joints and fittings shall comply with the
relevant provisions of BS 3505, BS 4514, BS 4660, BS 5481, AS 2032 or equivalent approved
standards and codes of practice with respect to the handling, transportation and storage of uPVC pipes
and fittings. Where long term storage racks are to be provided, the racks shall be built to
accommodate four to seven layers of pipe, depending on the diameter and wall thickness of the pipes.

Reference shall be made to BS 5955: Part 6 for further guidance on the use of uPVC pipes and
fittings.

7.5.2 Joints

All uPVC pipes shall be cut using only methods and tools approved by the S.O. Cut pipe ends shall
be chamfered and cleaned of any burrs prior to jointing. Joints shall be made with solvent cement
unless otherwise shown on the Drawings or as directed by the S.O.

Solvent cements for jointing uPVC pipes and the method of jointing shall comply with BS 4346, Part
3 or AS 2032 and the following:

(a) For laying of a buried pipeline, the solvent jointed pipe shall be long enough to ensure a
sealed joint.
(b) For joints which have a rubber ring supplied integrally with the pipe, the fitting shall not be
used if the ring is displaced, and
For pipes and fittings complying with BS 4660, solvent cement may comply with BS 6209.
Unsatisfactory joints shall be re-made before proceeding with further pipelaying.

January 2010

7.6 Ductile Iron Pipes and Fittings
7.6.1 General

Ductile Iron pipes and fittings shall comply with the requirements of BS 4772, BS EN 598 and BS EN
545. All pipes and specials shall be provided with a zinc spray coating and a bituminous varnish at the
factory before delivery to Site. All pipes and specials shall be hydraulically tested at the factory after
manufacture to a test head as given in Clause 8.8.5.

The ends of each pipe and special shall be suitably protected against damage during transit to the Site
by hessian wrapping or other superior means of protection. All flanges shall have wooden discs
securely bolted on and the bolts used for this purpose shall be expendable and additional to those
provided for subsequent permanent jointing. Joints shall be stored in hessian sacks and protected
against sunlight until required for use.

7.6.2 Thickness, Diameter and Length

The nominal and outside diameters and thicknesses of the wall and cement mortar lining of pipes and
fittings shall be as shown in the Table below unless otherwise stated: -

Table No. 8.7: Nominal Diameter Vs Thickness of Wall and Lining of Pipes

Nominal
Diameter
DN
(mm)
Outside
Diameter
OD
(mm)
Standard Wall
Thickness
(mm)
Cement
Nominal
Thickness
Mortar (mm)
Minimum
Mean
Value
Lining
Minimum
Value at A
Point
150 170 6.3 5.0 4.5 3.5
100 118 6.1 5.0 4.5 3.5

Pipes shall be supplied in standard lengths of between 5 and 6 metre.
January 2010

7.6.3 External Coating

The external surface of pipes and the internal surface of sockets shall be protected against corrosion
by a molten zinc spray coating (minimum deposit 130g/sq.m and a coating of bitumen complying
with BS 4164 or a coating of bitumen complying with BS 4147 Type I Grade D or BS 3416 Type 2.
The coating shall have a minimum thickness as specified in Table 9 of BS 534. Fittings shall have a
bitumen coating only.

Dipping, brush, spray or roller may be used to apply bituminous coatings. Surfaces to be coated shall
be clean, dry and free from rust. Coatings shall dry rapidly with good adherence and not flake off and
shall not flow when exposed to a temperature of 76 degrees centigrade. Where internal surfaces of
pipes and fittings are coated, the coating shall not have any water soluble or toxic constituents or
impart any colour, taste or smell to the water.

In additional to the above coatings, all pipes and fittings shall be installed with a polyethylene sleeve,
200 microns thick minimum. The procedures for sleeving shall be as laid down by the pipe
manufacturer and generally in accordance with ANSI A 21-5.

7.6.4 Internal Lining

All pipes and fittings shall unless otherwise specified, be lined internally with sulphate resisting or
high alumina cement mortar to the thicknesses given in the BS 4772. The materials used in the mortar
shall comply with paragraph 33.3 of BS 534. Portland blast furnace cement complying with BS 146
may also be used.

The mortar shall contain at least one part of cement to 3.5 parts of sand by mass. The cement, sand
and water shall be thoroughly mixed to a standard consistency to provide a dense and homogeneous
lining. Surfaces to be lined shall be free from all loose scale, dirt or foreign material detrimental to
good contact between the metal and the lining.

Pipes shall be spun lined or centrifugally spray lined with an applicator head. Fittings shall be
centrifugally spray lined and finished to a comparable standard to that specified for straight pipes. The
process of lining shall be controlled to produce a continuous layer of cement mortar over the bore of
the pipe in a single pass. The inside of sockets and faces of flanges shall be free from cement mortar.

The surface of the lining shall be substantially smooth, free from laitance, with minimal sand
segregation and comply with paragraph 33.3 of BS 534. Isolated shrinkage cracks not exceeding
0.8mm wide shall be acceptable. Curing shall be carried out at not less than 4 degree C and in such a
manner as to produce a properly hydrated, hard and durable cement mortar lining. Subject to the
S.O.s prior approval, curing may be effected by application of bitumen coating complying with BS
3416 Type 2 while the lining is still moist.

Small areas of damaged linings may be repaired by cutting back the lining to the metal surface,
thoroughly wetting the exposed surfaces of metal and lining, and patching with fresh stiff cement
mortar worked in thoroughly to ensure a good bond with the exposed surfaces.

7.6.5 Fittings

Standard fittings without branches shall be Class K12 and those with branches shall be Class K14.
They shall be flanged or socket ended and generally conform to the dimensions given in the
respective tables of BS 4772.
7.6.6 Joints

January 2010

All flexible joints shall be supplied complete with bolts, nuts, glands, washers, rubber gaskets, locking
rings and other accessories.

The gasket shall be of elastomeric material complying with BS 2494 and compatible with the fluid to
be conveyed in the main. It shall provide a positive seal within the manufacturers range of maximum
joint deflection and withdrawal, and in the range of pressures likely to occur in the pipeline including
those below atmospheric pressure where applicable. The Contractor shall state the material, type and
quality of the rubber gaskets offered.

(b) Flanged joints (Only for Force Mains)

Flanges shall have a nominal pressure rating of 16 bars. They shall be integrally cast on square to, and
concentric with, the longitudinal axis of the pipe or fitting. They shall be of the raised face type and
truly faced over their whole width, but may also be supplied as cast where particularly accurate
moulding processes are used subject to the approval of the S.O. The finish on flange joint surfaces
shall be in accordance with Clause 4.4 of BS 4504. Bolt holes shall be drilled off centre lines,
concentric and truly in line end to end with the longitudinal axis. However, where particularly
accurate machine moulding processes are used that produce equivalent functional quality, bolt holes
may be cored.

Flange and neck thickness shall comply with Table 11 of BS 4772 while diameters of flange raised
face and drilling shall comply with Table 16/3 of BS 4504.

Each set of flange jointing materials shall be supplied complete with nuts, bolts, washers and joint
gaskets. Joint gaskets shall be of the flat section 4.5 mm thick medium rubber to BS 1154 Class Y3
reinforced with two-ply fabric in accordance with BS 5292, and shall not extend beyond the bolt pitch
circle. Each bolt shall be supplied with a nut and two washers and shall be of sufficient length to show
two threads past the nut when installed. Bolts and nuts shall be of mild steel with galvanized surfaces,
hexagonal and in accordance with BS 4190 unless otherwise specified.

Bolts, nuts, ragbolts and spring washers shall be stainless steel for joints in wet wells, other locations
where the joint is within the splash zone or subject to submergence in liquid or otherwise exposed to a
corrosive atmosphere. Stainless steel nuts, screws, washers and bolts shall be manufactured from
Grade 316 S31 steel complying with BS 970: Part 1 or BS 1449 : Part 2. Where bolting is
incompatible with the material being fixed, suitable isolating washers and sleeves shall be used.

Flanges shall be properly aligned before any bolts are tightened.

(b) Mechanical flexible couplings and adaptors (Only for Force Mains)

Joints using mechanical flexible couplings and adapters shall be made in strict accordance with the
instructions given by the manufacturer.

After the pipe ends have been examined, prepared and painted as specified in the Specification, the
flanged portions of the flexible coupling shall be placed over the ends and rotated to check circularity,
following which the rubber rings shall be placed into position at 25 mm or so back from their final
location.

The central sleeve, with the taper plug gauge screwed into position, shall then be placed over the end
of the fixed pipe, and the end of the free pipe entered into it and pushed home so that the plug gauge
shall set the pipe ends the correct distance apart. At this stage it should be possible to rotate the
central sleeve freely. The rubber rings shall then be eased forward into position without disturbing
the setting of the central sleeve, the flanges brought into position, and the bolts inserted and tightened,
working in sequence around the joint. The plug gauge should be slackened and removed before the
January 2010

securing bolts and nuts are fully tightened. These bolts and nuts shall be tightened in regular
sequence starting on opposite side of the bolt circle and going around at least twice to ensure that they
are all tight so that an even tension all rounds the joint is obtained.

7.6.7 Marking

In addition to the requirements of Clause 8.1.2 ductile iron pipes shall be marked with two-socket
penetration lines on the spigot end for use with a push-in flexible joint.

January 2010

7.7 Steel Pipes

7.7.1 General

Steel pipe shall only be used for pressure pipe. Steel pipes, fittings and specials shall be made from
mild steel by the longitudinal electric fusion welded process or the spiral seam welded process. Pipes
and specials shall be protected internally with High Alumina or Sulphate Resisting cement mortar
lining and externally either by reinforced coal tar enamel or bitumen coating or with two coats of red
lead oxide paint as approved by the S.O. Pipes and specials shall be supplied either flanged, or with
plain ends truly circular for collar welded joint or mechanical couplings. All pipes and specials shall
be suitable for the maximum working pressure to which the pipe or special will be exposed with due
allowance for the effects of surge etc. The ends of all pipes and specials shall be suitably covered and
protected against damage during transit to the Site by Hessian wrapping or other superior means of
protection. All flanges shall have wooden discs temporarily bolted on. None of the packing or
protection shall be returnable.

The design and manufacture of the pipes and specials shall be in accordance with the requirements of
BS 10:1962, BS 534:1990, BS 3601:1987. The steel used shall be made by the open-hearth process
or other approved process, and shall have a minimum tensile strength of 400 mega Pascal.

7.7.2 Dimensions

The pipe diameters given refer to the outside diameters (O.D.) of uncoated pipes in accordance with
BS 534:1990. Flanges are specified by flange size designation (Nominal bore of pipe) in accordance
with Table 10/5 of BS 3601.

7.7.3 Painting

All pipes, couplings etc. to be laid above ground shall be painted with one coats of red lead oxide
paint.

7.8 General for Pipeline Installation

7.8.1 Scope of Works

The Contractor shall be responsible for the installation of pipelines as delineated in this specification,
and for providing all materials, labour and equipment necessary for the installation of those works.

7.8.2 Definitions

The following terms shall have the meanings hereby assigned to them except where the contract
clearly renders these meanings inapplicable:

Pipe : means pipes or pipes, bends, junctions and other specials and
fittings and includes joints and jointing parts.

January 2010

Installation : means supplying, hauling, handling, placing, fixing. Jointing
in position, and testing whether in trench or elsewhere in the
Works.

Pipeline : means those parts of the Works comprising pipe, manholes,
and fittings.

7.8.3 Tools for Pipe Installation

The Contractor shall supply all necessary tools for cutting, chamfering, jointing, testing and for any
other requirement for satisfactorily installing the pipelines.

7.8.4 Handling, Storage and Protection during Transit

During storage, handling, and transporting, every precaution shall be taken to prevent damage to the
pipe and fittings. Pipe shall be handled by means of approved hooks on ends of sections, by means of
fabric slings, or other methods strictly in accordance to the manufacturers recommendation for the
type of pipe used and as approved by the S.O. Dropping or bumping of pipe will not be permitted.
Damaged pipe shall be replaced or repaired by the Contractor at his expense and such repairs shall be
to the approval by the S.O. Pipes shall not be dragged over the ground and, if rolled shall be rolled
only over adequate timber bearers to prevent damage.

Pipes may be stored in the open, but shall be placed on adequate timber bearers to prevent damage to
sheating or sockets. Pipes may be stacked one above the other up to the height as recommended by
the manufacturer subject however to the approval of the S.O, provided suitable protective packing is
placed between them. If any pipes or fittings shows signs of corrosion or deterioration during storage
they shall immediately be treated at no extra charge by the Contractor as the S.O. directs to arrest and
prevent the corrosion.

Coated pipes shall be lifted and moved only by wide non-abrasive slings or other means acceptable to
the S.O. Wire ropes, chains and hooks shall not be permitted to come into contact with the coating.
Coated pipes shall not be rolled or dragged along the ground.

Coated pipes shall be stacked in one layer only at pipe storage yards approved by the S.O. or strung
along the pipeline route and in such manner that the coating is not damaged. The Contractor shall
supply adequate packing between pipes for this purpose. Coated pipes shall be kept clear of the
ground and rested on padded sleepers or supports.

Care shall be taken with elastomer joint rings or gaskets and washers to ensure that they are kept in
weatherproof storage away from direct sunlight. They shall not be stored at low temperature to
prevent them from becoming rigid and losing their flexibility.

The ends of all pipes and fittings shall be suitably protected against damage during transit with straw
contained in hessian secured to the pipe ends. All flanges shall have wooden discs temporarily bolted
on. Pipes and fittings shall be wrapped or cushioned so that no load is taken directly on the external
coating.

The Contractor shall be responsible for the disposal of all materials used for the protection of pipes
and fittings during transit.

January 2010

7.8.5 Inspection at Time of Installation

Pipes and fittings including any sheathing, lining or protective paintwork, shall be inspected by the
Contractor immediately before and after installation and any damage shall be repaired by the
Contractor as directed by the S.O. before the pipe or fitting is installed or jointed as the case may be.
Any specified material required for the repair of pipe, sheathing or lining shall be obtained by the
Contractor at his cost from the pipe supplier and shall be used with due regard to his recommendation.
The S.O. may himself, and without thereby relieving the Contractor of any of his obligations, inspect
and test the pipe and appurtenances by any means he considers appropriate and the Contractor as
aforesaid shall repair any damage discovered by such inspection. The Contractor shall remove from
the Site any pipe or appurtenance which in the opinion of the S.O. is so badly damaged as to be unfit
for incorporation in the Works.

7.9 Installation of Pipes

Installation of pipes shall include both gravity sewers and force mains. Trench excavation shall be
carried out strictly in accordance to Section 2 of this Specification, Clauses 2.13 to 2.37 inclusive.

7.9.1 General Installation Work

Unless specified otherwise, pipe shall be installed singly and shall not be jointed until after they have
been installed. Except where otherwise shown in the drawings, all sewer and force main pipes shall
have flexible joints.

In the case of force main all above ground crossings, section of all fittings and bends, the joints shall
be all flanged joints. The line and levels of the pipelines are shown approximately on the drawings.

The contractor shall provide evidence to show that benchmarks used for control of line and level are
cross-referred with permanent benchmarks established by Jabatan Ukur Malaysia as may be required
by the S.O. The pipe shall be accurately installed to the lines, levels, grades and positions set out by
the Contractor from data given on the drawings or supplied to him by the S.O. Pipe and specials that
are required to be fixed onto or built into other structures shall be positioned as shown on the
drawings or as directed by the S.O.

Brackets, steelwork cradles and the like fixings shall be in accordance with typical details shown on
the drawings, or if not so detailed shall be as approved by the S.O. Pipe shall rest on a solid and even
foundation or bedding for the full length of the pipe barrel. Suitable additional excavation shall be
made to accommodate sockets or collars. Except where directed or shown otherwise, the minimum
cover to the laid pipes, measured at the highest point at the joint, shall be 1.2m in roadways and
0.75m in open fields.

The Contractor shall keep the interior of pipes clean and free from water, dirt, stones or other foreign
matter as installation proceeds. At the end of the days work or whenever the work ceases for any
reason, or at other times when installation work is not proceeding, the unfinished/open ends of pipes
shall be securely closed or sealed off by wooden plug or a tight fitting plug or other approved stopper.
The pipe trench shall be kept free from water at all times.

January 2010

The Contractor shall take all necessary precautions to prevent the pipe from floating due to water
entering the trench from any source, and shall assume full responsibility for any damage due to this
cause. The Contractor shall restore and replace the pipe to its specified condition and grade if it is
displaced due to float at ion. All pipelines adjoining concrete structures (including manholes) shall
have a mechanical (flexible) joint within or 600mm length (for pipe up to 300mm diameters) or
900mm length (for pipes greater than 300mm diameter) of the outside face of such structures.

The Contractor shall, after excavating the trench and preparing the proper bedding for the pipe,
furnish all necessary facilities for properly lowering and placing sections of the pipe in the trench
without damage and shall properly install the pipe. The section of pipe shall be fitted together
correctly and shall be laid true to line and grade in accordance with the bench marks established by
the Contractor.

7.9.2 Pipe Laying

Each pipe shall be carefully lowered onto its prepared bed by means of necessary slings and tackle. A
recess shall be left in the prepared bed to permit the sling to be withdrawn. If the prepared bed is
damaged the pipe shall be raised and the bed made good before pipe laying is continued. Pipe shall be
laid upgrade unless otherwise authorized by the S.O. In general socket and spigot pipes shall be laid
with socket ends upstream.

No pipe shall be rolled into place prior to lowering into the trench except over suitable timber
planking free from roughness likely to damage any coatings. Before laying, each pipe shall be
cleaned out and inspected for defects.

Before any pipe is lowered into place, the bedding shall be prepared so that each length of pipe shall
have a firm and uniform bearing over the entire length of the barrel. The pipes shall be laid in straight
lines, both in the horizontal and vertical planes, between manholes or, where directed in the case of
force mains and larger diameter sewers to regular curves.

Each pipe shall be plumbed to its correct line and directed and accurately sighted by means of boning
rods and sight rails fixed to secure posts which shall be set up and maintained at each end of the sewer
to be laid and not more than 70 m apart. Sight rails shall be clearly painted in contrasting colors and
be not less than 150mm deep, straight and level. Boning rods shall be of robust construction clearly
painted and accurately made to the various lengths required, the lower end being provided with a shoe
of sufficient projection to rest on the invert of the pipes as laid. The boning rod shall be complete
with a vertical spirit level. Boning rods and sight rails shall not be removed until the pipeline has
been checked and approved by the S.O.

Any pipe which is not true alignment, both vertical and horizontal, or shows any undue settlement
after laying, shall be taken up and relaid correctly by the Contractor at his own expense, when so
ordered by the S.O. No pipe shall be laid which is damaged, cracked, checked, or spalled or has any
other defect deemed by the S.O. to make it unacceptable, and all such sections shall be permanently
removed from the work.

Where sub-soil water is encountered it shall be kept below the sockets when jointing by pumping or
other means. In no case shall pipes be jointed before being lowered into position. If any damage
should occur to any pipes through failure of the Contractor to comply with these conditions, the
damage shall be made good at the Contractors expense.

January 2010

Pipe sections shall be joined in such a manner that the offset of the inside of the pipe at any joint will
be held to a minimum at the invert. The maximum offset at the invert of pipe shall be 1 % of the
inside diameter of the pipe or 9.4mm whichever is smaller. Unavoidable offsets shall be distributed
around the circumference of the pipe in such a manner that the minimum offsets occurs at the invert.
After the joints have been made, the pipe shall not be disturbed in any manner.

The interior of each pipe, after being laid, shall be thoroughly cleaned. Pipe will be carefully
inspected in the field before and after laying. If any cause for rejection is discovered in a pipe after it
has been laid, it shall be subjected to rejection. Any corrective work shall be approved by the S.O. and
shall be at no cost of the Employer.

7.9.3 Closures and Short Sections

For the purpose of reducing the angular deflections at pipe joints, and for closure sections, the
Contractor shall be permitted to install pipe sections of less than standard length. Closing courses and
short sections of pipe shall be fabricated in accordance with approve cutting procedure and installed
by the Contractor as found necessary in the field. Where closing pieces are required, the Contractor
shall make all necessary measurements and shall be responsible for the correctness thereof.

7.9.4 Pipe Bedding for Sewer Pipes

The surface shall be firm and true to grade. If soft, spongy, unstable, or similar other material is
encountered upon which the bedding material or pipe is to be placed, this unsuitable material shall be
removed to a depth ordered by the S.O. and replaced with suitable densified crushed rock bedding
material.

Bedding shall be in accordance with details on the drawings. Except where concrete or one of the
following materials is specified, bedding material supporting the pipe or conduit shall be gravel,
disintegrated granite, crushed aggregate, native granular material, or other material approved by the
S.O. Limestone shall not be used.

After trimming, granular bedding material shall be spread in the trench bottom and screeded with a
template. The Contractors rates shall include for provision of suitable material for granular bedding,
and also for removal and disposal of excess material arising from the trench excavations, due to the
granular bedding. Material for granular bedding shall meet the following requirements:

Table 8.8 : Percentage Passing

BS Sieve Size Min. Max.
19mm 100 -
9.5 mm 80 90
4.75 mm 10 25
2.36 mm 0 15

The material shall be tested in accordance with B.S. 812, Section 8 when required by the S.O. and
shall have a 10% fines value greater than 50 kN. Material retained on a 7 mm sieve shall have an
index of flakiness less than 25% and an index of elongation less than 45%.

Whenever the S.O. directs the following test for compaction shall be carried out on the material for
granular bedding in accordance with British Standards CP 312.

January 2010

If through the Contractors neglect any trench bottom is excavated below the grade shown on the
plans, it shall be refilled to grade of pipe invert with bedding material, properly compacted into place
at the Contractors expense.

7.9.5 Concrete Protection of Sewer Pipes

Where sewers are to be laid on concrete bedding or surrounded in concrete, the pipes shall be
temporarily supported on precast concrete bedding blocks positioned at each end of each pipe, clear of
the sleeve joints. The width of the bedding block shall be half the diameter of the supported pipe
subject to a minimum of 115mm. The blocks shall be left in and paid for as concrete bedding. The
blocks shall be set to level allowing for the thickness of the pipe wall, and sight strings shall be used
to check alignment. The greatest care shall be taken to avoid movement of the pipe and to ensure a
continuous support during concreting. Should any pipe become either partially or wholly clogged
before final acceptance of the work, it shall be cleaned out or replaced by the contractor at no extra
cost to the Employer.

All sewers with less than 1.2 metre of cover under roads, or 0.75 metre where not under roads, shall
be surrounded with at least 150mm of concrete Grade 20. The depth of cover shall be measured from
original ground level to the top of the barrel of the pipe.

To ensure flexibility of the sewers concrete protection shall be interrupted over its full cross-section at
each pipe joint by a 12 mm thick board of softwood, or other approved material cut to shape.

7.9.6 Protection of Joints for Force Mains

After the pipelines have been tested and found satisfactory, the protection of joints shall be
completed.

a. Flanged Joints shall be reprimed and painted with aluminium (if above
ground) and two coats of heavy bodied black bituminous paint for joints
below ground.

b. Mechanical Joints (K-Type Joints) shall have similar protection as the Flanged
Joints.

The Contractor shall furnish and install complete all the necessary temporary bulkheads or steel boiler
heads and appurtenances thereto in the pipeline used for backfilling purpose and shall remove such
bulkheads upon completion of the line.

7.9.7 Tolerances of Alignment and Invert Levels

The accuracy of line direction grade and invert levels shall not deviate more than + 50mm for every
100m (or 1/2000) of pipe installed between 2 manholes.

January 2010

7.10 Changes in Line and Grade

In event obstructions not shown on the plans are encountered during the progress of the work which
will require alterations to the drawings, the S.O. shall have the authority to amend the drawings and
order the necessary deviation from the line or grade shown. Contractor shall not make any deviation
from the specified line or grade without approval of the S.O.

7.10.1 Deflection at Certain Joints

Where the S.O. orders or allows a change of direction to deflect force mains from a straight line,
either in the vertical or horizontal planes to avoid obstruction or where long radius curves are
permitted, the amount of deflection allowed shall not exceed that required for satisfactory connection
of the joint and shall be approved by the S.O. Where a change of direction cannot be made by
deflection at the joints of ordinary straight pipes, bends shall be used.

The locations of such bends and other specials are indicated upon the drawings and their exact
positions will be determined by the S.O. on the Site.

7.11 Stream and River Crossing

Work at any crossing of a watercourse shall be carried out as expeditiously as possible to the
satisfaction of the S.O. and any responsible Authority with the minimum interference to the free flow
of the water in the watercourse. Details of any temporary works which may effect the flow of the
watercourse shall be submitted to the S.O. at least 14 days before starting work.

Where the pipeline passes underneath a river, stream or ditch it shall be cased in concrete unless
otherwise approved by the S.O. The minimum thickness shall be 150mm. Unless otherwise shown,
the depth of cover shall not less than 600mm from the bed of the river, stream or ditch to the top of
the concrete. The Contractor shall fill the trench in both banks with rockfill or concrete up to levels as
shown on the drawings or as directed by the S.O. The extent of this work may be varied to suit each
individual crossing.

Unless otherwise ordered, the concrete encasement of the pipe shall extend at least to a section
vertically below the tops of the banks. Protection against erosion to the banks shall be provided by
means of stone pitching or riprap.

7.12 Connection to Existing Sewer Mains

At the locations shown on the drawings the Contractor shall connect to the existing sewer main or
existing manholes. The sewer connections may include back-drops, service diversions, punching
through the wall of the existing manholes and to construct new flow-through fittings in each manhole
base to accommodate the new sewer line as required. Actual connection between the existing piping and
new piping shall not be made until the new work has been approved by the S.O.

January 2010

7.13 Cleanliness of Sewers and Force Mains

The pipes shall be kept thoroughly clean and an adequate supply of expanding rubber plugs shall at all
times be available to ensure that all pipe ends are stopped off. Except when water testing, water shall
not be allowed to flow through the pipes. The Contractor shall make all necessary provision for
disposing of drainage water during the execution of the Works by means of channels, troughs or other
approved methods. Before the issue of the Certificate of Completion, a train consisting of an approved
badger and a circular rubber squeegee shall be passed through each length of sewer, and this shall be
followed by a wooden ball, not smaller than one inch less in diameter than the pipes under inspection.
The Contractor shall remove any obstruction found during these operations.

7.14 Liability in Pipe Installation

Pursuant to the relevant Clause in the Conditions of Contract, the Contractor shall be liable to the
Employer for any damage caused to the pipeline or to pumps and other equipment of the Employer as
a result of foreign matter of any kind not having been cleaned out of the pipeline before it is handed
over to the Employer.

SECTION 8
BUILDING WORKS

TABLE OF CONTENT

Page
8.0 BUILDING WORKS ......................................................................................8-i

8.1 Brickwork .........................................................................................8-1
8.1.1 Bricks ................................................................................................8-1
8.1.2 Mortar ................................................................................................8-1
8.1.3 Bricklaying.........................................................................................8-1
8.1.4 J oints ................................................................................................8-2
8.1.5 Ties ................................................................................................8-2
8.1.6 Wall Reinforcement............................................................................8-2
8.1.7 Damp-Proof Course...........................................................................8-2
8.2 Metalwork .........................................................................................8-4
8.2.1 Aluminium Framed Windows and Doors............................................8-4
8.3 External and Internal Finish............................................................8-5
8.3.2 Finishes to Brickwork.........................................................................8-5
8.4 Roofing .............................................................................................8-7
8.4.1 Metal Roof Decking and Roofing Sheets ...........................................8-7
8.4.2 Interlocking Concrete Roof Tiles........................................................8-7
8.5 Cold Water Plumbing.......................................................................8-8
8.5.1 General..............................................................................................8-9
8.5.2 Isolating Valves..................................................................................8-9
8.5.3 Installation of Taps and Outlets .........................................................8-9
8.6 Hard core........................................................................................8-10
8.6.1 Material and Laying..........................................................................8-10

Section 8 Building Works

Minor Civil Works Specifications 8-1
January 2010
8.0 BUILDING WORKS

8.1 Brickwork

8.1.1 Bricks

Approved Manufacturer Bricks whether facing or common shall be from an approved
manufacturer and shall be hard, sound, well-burnt, machine made wire-cut bricks or pressed bricks of
regular and standard size. Bricks shall be regular in size and shape, with good faces and clean arrises,
sound and free from cracks and any other defects. Facing bricks shall be of the colour selected by the
S.O.

Common Bricks The common bricks, unless otherwise described, shall be wire cut clay bricks,
even in size, smooth in texture and with sharp well defined arrises. Clay bricks shall conform to BS
3921 with a minimum compressive strength of 20 N/mm
2
.

All rejected brick shall be removed from the site forthwith at the Contractors own expenses.

8.1.2 Mortar

Brickwork in buildings shall be set in 1:1:6 cement-line-sand mortar. Brickwork in manholes and
elsewhere shall be set in 1:3 cement sand mortar. Lime for use with mortar shall be semi-hydraulic
(calcium) lime or non-hydraulic (calcium) lime complying with the requirements of BS EN 459-1

Mortar shall be machine mixed on site only as required immediately prior to use, and any mix which
is over 3/4 hour old shall be rejected. Under no circumstances shall a type of sand be changed during
the course of the work.

Where handmixing is permitted, mixing shall be carried out on an approved waterproof platform.

Materials for mortar shall comply with the requirements as follows:-

Sand clean, sharp, best quality bricklayers sand containing not more than 5% of clay and shall be
obtained from approved source.

Cement Portland cement, fresh and of an approved brand complying with BS EN 197-1 Water
Fresh, clean of potable quality, free of vegetation and other deleterious matter, and shall comply with
BS EN 1008.

Materials for mortar for brickwork shall be measured by volume and shall consist of 3 parts sand and
1 part cement.

Plasticising additives shall not be used without prior approval from the S.O.

8.1.3 Bricklaying

Codes of Practice Workmanship shall generally comply with the requirements of BS 5628: Part
3 Use of Masonry subject to any qualifications given below.

Bricklaying shall be carried out such that cutting of bricks is reduced to the minimum by
careful setting out.


January 2010
Brickwork shall be set out accurately to the various dimensions, thickness and heights shown on the
Drawings. Before commencing work, storey rods showing the heights of all courses shall be set out
and these shall be strictly followed.

All brickwork shall be plumb within 5mm of plane and level over a distance of 3 metres in any
direction. Brickwork shall be built English bond for walls one brick thick and over, stretcher bond for
walls half a brick thick.

All bricks shall be well soaked before use and during hot or dry weather to avoid undue absorption of
moisture from the mortar, but shall not be left standing in water or be brought otherwise to a saturated
condition. Bricks shall be damp as necessary and the top of walls left off shall be damp before work
commences.

All walls shall be kept to a fairly uniform height and at no point shall brickwork in the same wall unit
be carried up more than five (5) courses above any adjoining portion.

Before commencing any work, the bricklayer shall confer with other trades to ensure that all pipes,
conduits, bolts, frames or any other materials necessary to be installed in the work at the time it is
built, has been fixed or provided for.

8.1.4 Joints

Beds and vertical joints of brickwork shall be filled solid with mortar, and no vertical joint
shall be allowed to be flushed up from the top but each joint must be filled up as the bricks
are laid. All work found not to comply strictly with this requirement shall be taken down and
rebuilt at the Contractors expenses.

Joints shall not be more than 6mm thick and all joints shall be raked out to a depth of 12mm
to form a key for plastering as the work proceeds. The courses shall be laid truly level and at
the time or bedding all joints shall be neatly struck with a trowel. Suitable pointing of an
approved colour shall be made on all joints with facing bricks.

8.1.5 Ties

All brickwork adjacent to reinforced concrete shall be bonded to the concrete structure with
approved ties set at every fourth course. The ties shall be adequately secured to the main
reinforcement in the concrete.

Where facing brick is required for the external face and common brick is required for the internal face
of brick walls, the two thickness of brickwork shall be bonded together with wall ties spaced 900mm
apart horizontally, 450mm vertically and staggered and with extra ties at reveals and openings.

8.1.6 Wall Reinforcement

Reinforcement shall be of approved galvanised steel expanded metal lath set at every fourth
course. Wall reinforcement shall be lapped with the column ties. Wall reinforcement shall be
laid in continuous long lengths and shall have minimum lap of 350mm at joining and bent
around at angles and intersections. The reinforcement shall be discontinued at control joints.

8.1.7 Damp-Proof Course


January 2010
Damp-proof course shall be of the best quality 6 mm thick three ply bitumen impregnated and
approved by the S.O. Damp-proof course shall be laid in continuous length of appropriate width in a
12mm thick mortar bed one course above ground floor level. A minimum lap of 100mm shall be
provided where necessary.


January 2010
8.2 Metalwork

8.2.1 Aluminium Framed Windows and Doors

Window frames casement, sashes, door frames, etc., unless otherwise specified shall be constructed of
extruded aluminium alloy B6063-T5 sections or equivalent and anodised in bronze colour in
accordance with BS EN12373-1 to give a minimum coating thickness of 10 microns. Aluminium
surfaces shall be anodised with a clean satin sealed finish throughout.

Where polyester powder coating is required, it shall be corro-coat PE-F to BS 6496 in any approved
colour and shall be applied by an approved applicator strictly in accordance with the manufacturers
specification and instructions. The film thickness for the polyester powder coating shall be 65 + 15
microns.

All aluminium window frames shall be supplied with continuous extruded aluminium finger pulls
and complete with approved fixing, locking and hanging devices, handles and/or pegs and stays. The
perimeter of the windows shall be fixed with an approved waterstrip. Windows shall be lourved, top
hung and side opening types and fixed glass types unless otherwise shown on the drawings.

Window frames for fixed glass louvres shall have weathering jambs, heads and sill of minimum 102
x 45 mm with fixed clips to receive minimum 225 mm glass blades and with removable insectproof
screens in aluminium frames at the rear, unless otherwise specified. Adjustable louvers shall
whenever necessary be provided complete with extension arms and cranks to permit adjustment from
shoulder level.

All aluminium frames shall be obtained from an approved manufacturer by the S.O. The whole
assembly by its design, flashing and calking shall be completely waterproof, watertight and
insectproof under in-service condition. Fixed louvers windows and doors shall be provided complete
with insect screens.

The Contractor shall submit designs and samples of the materials and assembly to the S.O. for
approval prior to fabrication.

Operating gear or mechanism to sashes shall be of such design as will adequately and easily control
the airway of an opening sash by manual control within easy reach of the floor.

Satisfactory hardware and operational gear shall be provided to perform the functions for which it is
intended and in such a manner as will ensure adequate safety to the ordinary user in operation. Sashes
shall not be removable from outside of the building.

Screws, nuts, washers, bolts, rivets and other fastening devices incorporated in window units shall be
of stainless steel and shall be of sufficient strength to perform the functions for which they are
required.

Glazing rebates shall be not less than 16 mm deep and sufficiently wide to provide adequate glass
clearance and where glass dimensions exceed 650 mm, neoprene spacers are to be used.

Glazing beads shall be sufficiently heavy to maintain adequate pressure on spacers and shall be held
in position by aluminium or stainless steel screws or by approved snap-in type grooves, all with
provision for adjustment.


January 2010
Hardware shall be designed to perform the functions for which it is intended and shall be securely
attached to the units.

Component parts shall be of bronze, brass, stainless steel or other non-corrosive material compatible
with the parent metal and of sufficient strength for the intended function.

All items of hardware shall be approved by the S.O.

Provision shall be made for hinges, locks, catches, handles, furniture, latches, opening,
devices and pulls required for efficient use and operation.

The provision of trimming members shall be incorporated in the design and construction of units as
necessary to suit the architectural requirements specified.

Expansion and construction of the member of frame must be able to take place freely. Under no
circumstances will the provision for expansion be allowed by slotting the fixing holes in brackets to
allow sliding movement between the brackets and the building structures.

Wherever possible all metal shall be formed, cut, drilled, tapped, welded, fitted or otherwise
fabricated in the shop. Fixing lugs of all metal sub-frames shall be suitably galvanised or primed with
zinc chromate before building in.

The units shall be set plumb, square and level and shall be built into openings prepared for this
purpose and shall be securely held in correct vertical and horizontal alignment.

8.3 External and Internal Finish
8.3.1 Finishes to Brickwork

a) Plastering

Plastering shall consist of two coats; with total thickness 20mm thick. The undercoat shall be 12mm
thick, roughened adequately to form a key for the final coat. The finished coat shall be trowelled with
proper metal floats to an even and smooth surface. All arises shall be slightly rounded to 3mm radius.

The mortar for plastering shall be gauged in the proportion of one (1) part of cement to one (1) part of
lime and three (3) parts of sand. No materials which have started to set or have been affected by damp
or long storage shall be used. All materials shall be proportioned by volume using gauge boxes.


January 2010
b) Rendering

Cement mortar rendering shall consist of two coats; the undercoat shall be 12 mm thick (should not
exceed 16 mm or be less than 10 mm). The undercoat of cement mortar shall be thrown and smoothed
with a wooden float with as little working as possible. Immediately after the initial set has taken place
the surface shall be scored to form a key for the final coat and shall be allowed to dry out for as long
as possible. It shall directed by the S.O. be sprayed with water before applying the final coat.

The finishing coat shall be worked with a proper wooden float, and the face left with an even and
smooth surface. The finishing coat shall be applied onto the undercoat after a minimum lapse of 24
hours and in no case shall the lapse exceed three (3) days. Its thickness shall not exceed l0 mm or be
less than 6mm.

The finished rendering shall be cured for at least four (4) times a day and kept damp for a period of at
least fourteen (14) days after completion.

The mortar for rendering shall be gauged in the proportion of one (1) part of cement to three (3) parts
of sand.


January 2010
8.4 Roofing

8.4.1 Metal Roof Decking and Roofing Sheets

Metal roof decking

i) Metal roof decking shall be the proprietary specialist system described or shown on the
Drawings, and shall generally be coated corrugated steel sheets, free from twist, buckle or
other surface imperfections. Galvanising shall be clean and free of obvious surface
contamination and defects. The Contractor shall provide complete details of the type,
section, sizes, gauge, thicknesses, etc. of the roof decking, including fixing method.
ii) Fascias shall be constructed using similar materials.
iii) Metal roof decking shall be laid such that ribs run parallel to roof framing members, and at
90 degree to purlins. Roof sheets shall be securely fixed by straps, and completely
watertight. No puncturing of the deck would be permitted. Lapping shall be as per
manufacturers instructions.
iv) Galvanised self-drilling screws complete with neoprene washers shall be used in fastening
cladding to steel purlins, girts and other supports. Holes for fasteners shall be drilled
accurately on the centreline of the corrugation directly over the supporting purlin or girt.
Cladding with wrongly positioned holes shall be rejected; no repair of such holes with
bitumastic or other sealant shall be permitted.
v) Suitable ridge capping, side flashing and side capping pieces of the type and size
recommended by the manufacturer shall be supplied and fixed at locations shown on the
Drawings.
vi) Cladding for roof shall be supplied with suitable preformed roof connectors. Ridge ends
shall be fitted with suitable end closers and lined with bitiumastic seal.
Roofing sheets
The roofing sheets shall be a minimum of 0.60mm thick galvanised steel with approved
protective coating of silvery-matt appearance. Steel base shall be a minimum of 0.55mm
thick with minimum yield stress of 300MPa. The roof shall be supplied complete with
acoustic insulation where specified on the Drawings.

The roof shall be laid to fall as shown on the Drawings and shall be secured to zinc coated or painted
steel purlins in accordance with the manufacturer's instructions without the need of puncturing holes
through the roofing sheets.

Roof decks shall be of the profile specified on the Drawings and shall be in continuous lengths
without end joints wherever possible. However, where end joints are necessary they shall be made to
detail conforming with the manufacturer's recommendation.

8.4.2 Interlocking Concrete Roof Tiles

i) Interlocking concrete roof tiles shall be of approved type and colour and conforming to the
requirements of BS EN 14437.

ii) All tiles shall be equal to the samples approved by the S.O. and shall be of a uniform colour.
All broken, chipped or defective tiles shall be immediately removed off the site and replaced

January 2010
with sound tiles.

iii) Tiles shall be laid to the pitch indicated on the Drawings on suitably sized tanalised timber
battens to details as described or shown on the Drawings. Roof tiles shall be laid to broken
joints and to a maximum gauge recommended by the tile manufacturer. Each course shall be
laid so that the tiles are properly set out to suit the slopes.

iv) Each tile in every alternative course shall be nailed by galvanised iron nails. In addition, each
eaves tiles and tiles adjacent to hips, valleys and ridges shall be nailed. All laying including
lap length and fixing shall be carried out strictly in accordance with manufacturers
instruction and recommendation.

v) Eaves shall overhang fascia by minimum 50 mm.

vi) Form cement mortar (1:3) fillet along the full length of verges.

vii) Ridges and hips shall be formed by half round ridge tiles and 1/3 round hip tiles.

viii) Ridges and hips shall be bedded with cement and sand (1:3) mortar at the edges neatly
pointed with tinted cement mortar to match general tilling. End ridge tiles shall be stopped by
standard ridge end tile. Barge tile shall be stopped by using standard barge tile end.

ix) Execute all necessary cutting and fitting at abutments and top edges.

8.5 Cold Water Plumbing


January 2010
8.5.1 General

The service water supply shall be drawn from the service storage tanks.
Pipes and fittings shall be of copper pipes conforming to BS 1387. Copper pipes shall be
painted as specified or ordered by the S.O.

All pipes and fittings shall be thoroughly cleaned before installation and any burrs, fins, etc., shall be
removed.

Where piping is installed above ground, it shall be securely fixed to walls and within roof spaces, wall
cavities, ducts, etc. at maximum intervals of 1800mm and at joints and changes of direction. Pipes
shall be laid to straight lines and uniform grades without sags.

Pipes shall be secured with galvanised steel clips and screws and/or approved pipe hangers. Any pipe
found to be noisy during testing due to insufficient support or loose fixing will be rejected.

Where possible, piping shall be concealed in wall ducts and partitions and not be exposed on internal
or external faces of walls.
8.5.2 Isolating Valves

Where an isolating valve is installed inside a building it shall be placed in an accessible
position. Where access to valves is required through duct walls, in cavities, etc, an opening of
suitable size shall be provided in the wall and covered with a stainless steel plate, fixed with
stainless steel screws to enable easy removal.
8.5.3 Installation of Taps and Outlets

All taps and outlets shall be fixed with wall anchors, lugged tees, elbows, breeching pieces,
etc, all to the satisfaction of the S.O.

Taps to be installed shall be to BS 1010.


January 2010
8.6 Hard core

8.6.1 Material and Laying

When shown and required, approved hard core consisting of good, sound, broken bricks or
stones shall be provided and laid to the thickness shown on the drawings, well rammed,
compacted and blinded with sand. All hard core shall be well watered immediately prior to
the depositing of concrete thereon.

SECTION 9
ROADWORKS

Section 9 - Roadworks

TABLE OF CONTENT

Page
9.0 ROADWORKS......................................................................................................... 9-1 ................................................... 9.0 ROADWORKS..................................... ................. 9-1

9.1 Preparation of Formation to Receive Road Pavement .................9-1
9.2 Earth Subgrade................................................................................9-1
9.3 Sub-Base ..........................................................................................9-1
9.3.1 Sub-base Materials .................................................................9-1
9.3.2 Laying and Compaction of Sub-base......................................9-3
9.4 Road Base ........................................................................................9-3
9.4.1 Road Base Materials...............................................................9-3
9.4.2 Laying and Compaction of Roadbase.....................................9-4
9.4.3 Finished Surface.....................................................................9-5
9.5 Bituminous Material ........................................................................9-5
9.5.1 General ...................................................................................9-5
9.5.2 Cutback Bitumen.....................................................................9-5
9.5.3 Bitumen Emulsion...................................................................9-5
9.6 Bituminous Prime Coat ...................................................................9-5
9.6.1 Material ...................................................................................9-6
9.6.2 Surface Preparation................................................................9-6
9.6.3 Application of Prime Coat........................................................9-6
9.6.4 Spraying Procedure ................................................................9-6
9.6.5 Protection of Prime Coat.........................................................9-7
9.7 Asphaltic Concrete ..........................................................................9-8
9.7.1 Aggregate, Binder and Composition.......................................9-8
9.7.2 Transport.................................................................................9-9
9.7.3 Laying of Asphaltic Concrete.................................................9-10
9.7.4 Bituminous Tack Coat...........................................................9-10
9.7.5 Compaction...........................................................................9-10
9.8 Road Shoulders .............................................................................9-10
9.9 Road Markings ...............................................................................9-11
9.9.1 Thermoplastic Material..........................................................9-11
9.9.2 Preparation of Surface..........................................................9-11
9.9.3 Preparation of Thermoplastic Material on Site......................9-11
9.9.4 Laying...................................................................................9-11
9.9.5 Protection of Markings ..........................................................9-11
9.9.6 Clearing Up...........................................................................9-12


LIST OF TABLE

Table 9.2: Compacting Procedure for Unbound Sub-Base and Roadbase Materials and For Soil-Cement
and Cement-Bound Granular Roadbase

9.0 ROADWORKS

9.1 Preparation of Formation to Receive Road Pavement

The preparation of formation shall be carried out only after completion of all sub-grade drainage,
piped drains, services and ducts or any other drainage work that might affect the works, unless
otherwise approved by the S.O., and such preparation shall be carried out immediately prior to the
laying of the sub-base or the road base where no sub-base is required.

9.2 Earth Subgrade

Where soft spots and unsuitable material occur, they shall be removed and backfilled with approved
suitable material and the formation shall then be checked and the final trimmed surface shall be
compacted to the satisfaction of S.O. prior to the laying of the sub-base or base-course.

The formation shall be so constructed to drain surface water to the side ditches or other drainage
system. If the Contractor allows the moisture content of the completed formation to reach a value
above the permitted maximum for the compacted material, the Contractor shall allow the materials to
revert to an acceptable moisture content and, if directed by the S.O., make good at his own expense
the surface by recompaction before laying the sub-base or road base.

9.3 Sub-Base
9.3.1 Sub-base Materials

The sub-base material shall be hard, durable and clean. It shall be granular material such as laterite or
gravel or crushed rock or sand and shall be free from organic material, clay lumps and any other
deleterious substances.

December 2010

The laterite or crushed rock or gravel shall conform to one of the following gradings:-

BS Sieve Size

Percentage by
(A)

Weight Passing
(B)
40mm (1 1/2 in.) 100 -
25mm (1 in.) 75 - 100 70 - 100
20mm (3/4 in.) 60 - 90 58 - 75
10mm (3/8 in.) 45-75 35-65
5mm (3/16 in.) 30-60 35-65
No. 7 20-50 25-50
No. 36 10-30 15-30
No.200 0-2 0-2

The sand shall conform to the gradings given below :-

BS Sieve Size

Percentage by Weight Passing
10mm 100
5mm 95-100
No. 14 45-80
No. 52 10-30
No. 100 2-10
December 2010

9.3.2 Laying and Compaction of Sub-base

All work on the portion of the subgrade on which the sub-base is to be laid shall be properly shaped
and compacted in accordance with the requirements of the specification before the placing of sub-base
material on that portion. The preparation of the subgrade shall be completed at least 200 metres ahead
of the placing of sub-base material. The sub-base shall be constructed to the full compacted thickness.

The sub-base material shall be laid in layers not exceeding 225 mm in thickness. Where two or more
layers are required, they shall be of approximately equal thickness and none shall be less than 100 mm
compacted thickness. At the time of laying and compaction of sub-base, the formation shall be dry.
Compaction of sub-base shall be carried out by adequate compaction equipment approved by the S.O.

Rolling operations shall begin from the outer edge towards the centre gradually in a longitudinal
direction except on super elevated curves where rolling shall begin at the low side and progress
towards the high side. Sub-base sandy material shall be compacted by use of vibrating equipment.

If necessary the Contractor shall add water to the sub-base material to achieve the required moisture
content.

Sub-base material containing excess moisture shall be dried by harrowing, scarifying, taping, ripping
or mixing prior to or during compaction. The Contractor shall ensure that the subgrade is not
disturbed by the operations carried out to adjust the moisture content of the sub-bases material.

Throughout the laying, adjustment of moisture content and compaction of sub-base material, care
must be taken to maintain a uniform gradation of the material and prevent segregation into coarse and
fine fractions.

The thickness of the finished sub-base shall be on average not less than the required thickness.

9.4 Road Base
9.4.1 Road Base Materials

The crushed rock road base to be placed on top of the subgrade or sub-base shall consist of sound
durable material free from clay lumps, organic matter, objectionable coatings or other foreign matter.

The material shall be crushed rock of hard durable particles or rock crushed to the correct size, well
graded and lie within the following grading limits.

BS Sieve Size

Percentage by Weight Passing
December 2010

50mm (2 in.) 100
40mm (1 in.) 95-100
20mm (3/4 in.) 60-80
10mm (3/8 in.) 40-60
5mm (3/16 in.) 25-40
(2.4mm) (No. 7) 15-30
(600 Micron) (No.25) 8-22
(75 Micron) (No.200) 0-8

NOTE:
1. The particle size shall be determined in accordance with the requirements of BS 1377.
2. The material passing No.36 BS Sieve when tested in accordance with BS1377 shall be
non-plastic.

9.4.2 Laying and Compaction of Roadbase

All work on the portion of the subgrade or sub-base on which the roadbase is to be laid shall be
properly shaped and compacted in accordance with the requirements of the Specification before the
placing of the roadbase material on that portion. The preparation of the subgrade or sub-base shall be
completed at least 200 metres ahead of the placing of the roadbase material.

All material shall be placed and spread evenly to the full width of the roadbase. The maximum
compacted thickness of any one layer shall not exceed 150mm.

Care shall be taken to prevent segregation of the material into the coarse and fine fractions.
Segregated surface areas of a base constructed or base material contaminated to such an extent that it
no longer complies with the Specification shall be removed and replaced with well graded and
satisfactory material at the expense of the Contractor.

The material shall be spread by a motor grader or any other approved mechanical plant.

Tipping of aggregate and laterally spreading by dozer or motor grader can cause segregation between
the coarse and fine fractions resulting in patches with non-uniform gradation during compaction.

Should this occur, all such areas shall be scarified and additional fines added before recompaction, at
the Contractors own expense.

When a roadbase is spread adjacent to concrete kerbs or gutter sections, extreme care shall be
exercised so as not to damage the kerbs or gutters. Any damaged kerbs or gutters shall be removed
and replaced at the Contractors own expense.

Compaction shall be completed as soon as possible after each layer has been spread and shaped
satisfactorily. Each layer shall be thoroughly compacted with suitable compaction equipment to the
requirement specified in Table 9.2. Rolling operations shall begin along the edges and progress
towards the centre gradually in a longitudinal direction. On superelevated curves, the rolling shall
begin at the low side and progress towards the high side. The rolling operation for each layer shall
continue until all rolling marks, ridges or cracks are eliminated.

Any combined irregularities, segregation or loose material which may develop in the surface during
or after construction shall be corrected or removed and the defective areas made good to the full
thickness of layer and recompacted.
December 2010


Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse
joints. On completion of compaction the surface of any layer of material shall be well knitted, free
from movement under compaction plant and from compaction planes, ridges, cracks or loose material.
All loose segregated or otherwise defective areas shall be made good by being removed and replaced
with properly graded material.

Before the laying of each layer of roadbase material a partial width of the shoulder, not less than
300mm wide, shall be constructed to the top of each uncompacted layer of the base to act as a haunch
to support the edges of the roadbase during rolling.

The roadbase material shall be maintained at the correct moisture content as necessary for proper
compaction. Moisture content control of the roadbase material shall be accomplished by sprinkling
with water or drying as required, at the Contractors own expense.

The surface of the aggregate roadbase shall be well drained at all times.

9.4.3 Finished Surface

The finished roadbase surface shall be even, of non-uniform gradation and free from irregularities,
loose material or fines and true to cross-section, lines and level. Any irregularities on the finished
roadbase surface of more than 12mm when measured with a straight edge 3 metres long laid either
parallel to the centre line of the road or laid transversely, shall be corrected by loosening, adding or
removing material, reshaping and recompacting at the Contractors own expense.

9.5 Bituminous Material

9.5.1 General

This section specifies the methods of storage, handling, heating and the procedure to be used for
testing the efficiency of the spraying equipment. Petroleum Bitumen shall comply with the
requirements (for the appropriate grade) given in MS 159 and MS 161.

Petroleum Bitumen shall be intended when material is referred to as "Asphalt Cement" "Straight-run
Bitumen", "Penetration grade bitumen", or by its penetration value (as for example 80 - 100 pen).

9.5.2 Cutback Bitumen

Cutback bitumen shall be of the rapid curing type or the medium curing type and shall comply with
the requirements (for the appropriate grade of cut back bitumen) given in MS 159.

9.5.3 Bitumen Emulsion

Bitumen Emulsion shall be of the slow setting anionic and or cationic type and shall comply with the
requirements (for the appropriate grade) given in MS 161.

9.6 Bituminous Prime Coat

December 2010

9.6.1 Material

The prime coat shall be a medium curing cut-back bitumen of grade RC-70 or MC-70. The actual
grade to be used shall determine the penetration of each grade.

9.6.2 Surface Preparation

Immediately before the application of the prime coat the surface of the road base shall be brushed
clean and free from all dust, dirt, dried or wet mud, organic matter or any other loose material to the
satisfaction of the S.O. If considered necessary by the S.O., the surface of the road base shall be
slightly damped before the application of the prime coat. Moisture control of the road base shall be
carried out by the Contractor using a wetting agent and method approved by the S.O. and to a level of
dampness to the satisfaction of the S.O.

Preparation of the surface as above shall not precede the application of bitumen by more than 450m.
Should any part or parts of the prepared surface become contaminated or unsuitable for the
application of the prime coat, due to lack of care on the Contractors part to protect the surface or due
to prolonged exposure, the surface shall be restored or reprepared to the satisfaction of the S.O. at the
Contractors own expense.

9.6.3 Application of Prime Coat

The prime coat shall be applied uniformly over the full width of the prepared road base by means of
an approved pressure load mobile distributor complying with the requirement of BS 1707. In addition
to the Special Requirements detailed in Section 3 of BS 1707, the pressure feed mobile distributor
shall be fitted with a spray bar through which the hot bitumen can be circulated while the distributor is
not spraying. The jets shall be so arranged in the spray bar that they are effectively preheated in the
same temperature as the circulating bitumen.

The bitumen shall be applied at a temperature in accordance with the table below and at the rate of
spray as directed by or agreed with the S.O. after carrying out Site tests, but not to be less than
440ml/sq.m.

SPRAYING TEMPERATURE FOR BITUMEN PRIME COAT

TEMPERATURE OF APPLICATION GRADE OF BITUMEN
(
o
C )
RC70
MC70
50
o
C 65
o
C

9.6.4 Spraying Procedure

Immediately before any spraying run is begun the spray bar shall be tested by allowing all the jets to
discharge simultaneously for about half a minute with a slotted metal tray placed beneath the spray
bar whilst a visual inspection is made. Any jet which is seen not delivering a uniform spray cone shall
be cleaned or replaced. After testing the spray bar the distributor shall proceed with the spraying run
without delay.

Any areas insufficiently covered shall be resprayed by spray lance to the satisfaction of the S.O. No
spraying of bitumen shall be carried out during, or when rain is imminent, or immediately after rain
until the road base has dried.
December 2010


9.6.5 Protection of Prime Coat

Prime coat shall normally be left undisturbed for at least 24 hours after application and shall not be
opened to traffic until, in the opinion of the S.O., it has penetrated the roadbase and cured sufficiently
so that it will not be picked up by the wheels of vehicles.

The Contractor shall maintain the prime coat until the overlying pavement course is constructed,
which shall not be within 24 hours after the application of the bituminous priming material nor within
such longer period as is required, in the opinion of the S.O., for the prime coat to achieve maximum
penetration of the roadbase and become fully cured.
December 2010

9.7 Asphaltic Concrete

9.7.1 Aggregate, Binder and Composition

This is a general specification for asphaltic concrete road pavement surfacing. The binder course and
wearing course shall have thickness of 75mm and laid in accordance with BS 594987 after
construction of road base and bitumen prime coat or tack coat.

a) Coarse Aggregate

The coarse aggregate shall be hard, clean, durable crushed rock of the granite group or of any other
rock group as may be approved by the S.O. Only granite shall be used for the wearing course.

b) Fine Aggregate

i) The fine aggregate shall consist of crushed rock or of clean sand, substantially all of which shall pass
a 3.35mm BS Sieve. If sand is used, the content of silt, loam and clay shall not exceed 3 per cent by
weight of the fine aggregate, determined in accordance with BS812, method A or B.

ii) If added filler is used in the asphaltic concrete it shall consist of crushed rock, hydrated lime,
Portland cement or other material approved by the S.O. At least 75 per cent of it shall pass a 75 m
(No.200) BS Sieve.

c) Binder

The binder shall be straight run bitumen, which shall have a penetration at 25 deg C, between 80 and
100.

d) Composition of Mixtures

The composition of freshly-mixed material for the asphaltic concrete shall comply with the following
requirements or as instructed by the S.O.

i) BINDER COURSE

Passing BS Sieve
mm.
1 1/2 in. (38mm) nominal size aggregate
% by weight
37.5mm 100
28.0mm 80-100
20.0mm 72-93
14.0mm 58-82
9.0mm 50-75
5.0mm 36-58
3.35mm 30-52
December 2010


Passing BS Sieve
mm.
1 1/2 in. (38mm) nominal size aggregate
% by weight
1.18mm 18-38
425m 11-25
150m 5-14
75m 3-8
Binder content as
found by analysis
4.0 6.0

ii) WEARING COURSE

Passing BS Sieve
mm.
3/4 in. (20mm) nominal size aggregate
% by weight
20mm 100
14mm 80-95
10mm 68-90
5mm 52-72
3.35mm 45-62
1.18mm 30-45
425m 17-30
150m 7-16
75m 4-10
Binder content as
found by analysis
5.0 7.0

NOTE :

(a) Limestone gravel aggregate shall not be permitted for use in wearing course.
(b) Ordinary Portland cement shall be added to the combined aggregate for asphaltic
concrete to serve as an adhesion and anti-stripping agent. The amount of cement
added for this purpose shall be 2% by weight of the combined aggregate.

9.7.2 Transport

The asphaltic concrete shall be transported from the manufacturing plant to the Site in clean vehicles
and shall be protected against adverse weather conditions by means of tarpaulins. The use of coated
dust, oil or water on the interior of vehicles to facilitate discharge of the asphaltic concrete may be
permitted, but the amount shall be kept to a minimum and any excess shall be removed by tipping or
brushing.

It is particularly important that asphaltic concrete which is to be laid warm shall be protected to
minimise loss of heat during transit so that all material is delivered in a condition suitable for
spreading and compacting.
9.7.3 Asphaltic Concrete Layer Thickness and Tolerance

The binder course and wearing course shall be laid in single course each and the compacted thickness
of the individual courses shall be :-

Binder course : 60mm
December 2010

Wearing course : 40mm

9.7.4 Laying of Asphaltic Concrete

On carriageways, narrow strips remaining alongside machine work shall be as far as possible hand
laid and rolled at the same time as the machine laid work and allowance shall be made for extra
compaction of hand laid strips.

Continuous inspection of the finished surface as it is laid shall be carried out and any defects
immediately rectified before any rolling takes place.

9.7.5 Bituminous Tack Coat

The surface of the asphaltic concrete binder course shall be cleaned immediately prior to the
application of the tack coat. The bituminous material shall be applied by means of distributor at the
rates directed by the S.O., but not to be less than 270 ml/sq.m. and at temperatures within the range
required.

9.7.6 Laying Around Manhole Covers

When laying around manhole covers and similar fittings, those parts against which the asphaltic
concrete is to abut shall be cleaned and painted with bitumen or bitumen emulsion prior to laying
operations. The asphaltic concrete shall be tamped so that after final compaction, the finished surface
is level with, or slightly proud of, such fittings.

9.7.7 Compaction

As soon as rolling can be effected without causing undue displacement, the asphaltic concrete shall be
uniformly compacted. Compaction shall be carried out to the satisfaction of the S.O.

Rollers shall not be allowed to stand on newly laid surface while there is a risk that the surface will be
deformed thereby.

Traffic shall not be allowed to pass over the surface until the asphaltic concrete has been completed
and is adequately set.

9.8 Road Shoulders

Road shoulders shall be constructed to the lines, grades, levels, dimensions and cross sections as
directed by the S.O.

The shoulder shall be constructed on a previously approved subgrade as required in the Specification
at the edge of pavement and any other areas as directed by the S.O. The work shall be carried out in
conformity with the requirements for simultaneous construction of sub-base or road base where
required and as approved by the S.O. The material for shoulder construction shall conform to the
requirements as specified in Section 9.2.

December 2010

9.9 Road Markings

Road markings shall be thermoplastic material as specified.

9.9.1 Thermoplastic Material

Thermoplastic material shall comply with the requirements of BS 3262 Part 1. Yellow thermoplastic
material in accordance with standard colour BS 381C No 356 (Golden Yellow) shall be used.

9.9.2 Preparation of Surface

Thermoplastic material shall be applied only on a surface which is clean and dry. It shall not be laid
over loose detritus, mud or extraneous matter or over old material or paint marking incompatible with
the paint being applied.

A tack coat compatible with the marking material shall be applied in accordance with manufacturers
instructions prior to the application of thermoplastic material.

If a primer or undercoat is necessary to ensure proper adhesion of the marking paint to the road
surface without bleeding or other discoloration, the primer or undercoat shall be fully compatible with
the marking paint and the road surface. The rate of application of tack coat, primer or undercoat shall
be in accordance with the manufacturers instruction and to the satisfaction of the S.O.

9.9.3 Preparation of Thermoplastic Material on Site

Thermoplastic material shall be supplied in block or powder form. If the material is supplied in block
form it shall be broken into pieces, each weighing not more than 4 kg, which shall be melted in a
heater fitted with a mechanical stirrer to prevent local overheating.

A thermoplastic of sufficient accuracy shall be used during laying to ensure that overheating of the
material does not occur.

Once molten, hydrocarbon resins be used within 6 hours and wood and gum resins shall be used
within 4 hours. The material shall not be heated beyond the manufacturers specified temperature
during application. Excess material shall be discarded on completion of application.

9.9.4 Laying

Centre lines, lane lines an edge lines shall be marked by approved mechanical means or as directed by
the S.O. Other markings shall be applied by brush, spray, screed, hand-propelled or self-propelled
machine according to the marking configuration and the type of marking material approved for use.
The rate of application of the marking material for each coat shall be that recommended by the
manufacturer unless otherwise specified. When more than one coat is used, the succeeding coat shall
not be applied until the previous coat has fully set.

Road markings of a repetitive nature other than centre lines, lane lines, etc., shall, unless otherwise be
decided by the S.O., be set out with stencils which comply with the size and spacing requirements as
shown on the Drawings.

9.9.5 Protection of Markings

December 2010

All markings shall be protected from traffic until they have dried sufficiently so that no pick-up by
vehicle tyre will occur.

9.9.6 Clearing Up

The Contractor shall clean up all spatters, splashes and smirches of marking material completely to
the satisfaction of the S.O.

December 2010

December 2010

Table 9.2: Compacting Procedure for Unbound Sub-Base and Roadbase Materials and For Soil-Cement and
Cement-Bound Granular Roadbase

Minimum number of passes

Type of compaction Plant
Category
< 110mm
layer
< 150mm
layer
< 225mm
layer

Smooth-wheeled
roller
Force per 100 mm width
kN

2.6-5.2 16 Unsuitable Unsuitable
> 5.2 8 16 Unsuitable

Pneumatic- tyred roller Wheel load (Tonnes)
4-6 12 Unsuitable Unsuitable
6-8 12 Unsuitable Unsuitable
8-12 10 16 Unsuitable
> 12 8 12 Unsuitable

Vibratory roller Static force per 100mm
width (kN)

1.26-1.75 6 16 Unsuitable
1.76-2.3 4 6 10
2.31-2.8 3 5 9
2.81-3.5 3 5 8
3.51-4.2 3 4 7
4.21-4.9 2 4 6

Vibrating- plate
compactor
Static force under base
plate (kN/m2)

17.2-20.7 5 8 Unsuitable
> 20.7 3 6 10

Vibro-tamper Mass (kg)
50-60 4 8 Unsuitable
65-75 3 6 10
> 75 2 4 8

Power rammer on dropping
weight compactor
Mass (kg)
100-500
> 500

5
5

8
8

Unsuitable
12

SECTION 10
DRAINAGE WORKS

Section 10 Drainage Works
TABLE OF CONTENT

..............................................................................................................................Page
10.0 DRAINAGE WORKS..................................................................................10-1

10.1 Stone Pitching 10-1
10.2 Weepholes 10-1
10.3 Gabions 10-1

10.4 Reinforced Concrete Pipes 10-2
10.5 Laying Drain Pipes 10-2
10.6 PVC Pipes 10-2
10.7 Drain Covers and Gratings 10-2

10.0 Drainage Works

During the course of excavations, should the Contractors workmen uncover any cables, ducts, pipe
mains, etc., work shall be stopped immediately and shall not again be started until the matter has been
reported to the S.O., who will issue whatever instructions he deems appropriate.

All pipes, ducts, cables, mains and other services exposed during excavations shall be effectively
supported and the Contractor shall take all necessary precautions to prevent any damage thereto. All
damage shall be made good at the Contractors expense.

Form all stormwater drainage channels to the type, size, alignment and grade as instructed by S.O.

10.1 Stone Pitching

Stone for pitching shall be granite or other clean, hard, dense and durable rock free from cracks,
kaolinished patches organic or other impurities or deleterious materials and shall be approved by the
S.O.

The dimension of each stone measured perpendicular to the face of the pitching shall not be less than
100 mm and shall exceed 225 mm for at least 60% of the pitched area. The exposed face of each stone
shall not be less than 100 square cm in area.

Stone shall be hand placed with closed joints on a layer of gravel or crushed stone to a minimum
finished thickness of 225 mm.

The sides of stones shall be roughly trimmed with a spalling hammer to obtain a reasonably close fit
and the interstices filled with clean coarse aggregate or gravel well rammed and wedged with spalls,
the finished pitching shall show an even surface to the lines and levels shown on the Drawings.

The joints in pitching shall be raked out to a depth of at least 20 mm and sealed with 1:3 cement/sand
mortar finished neatly flushed with the surrounding stones; the stones being left clean of all mortar
stains.

10.2 Weepholes

Where indicated on the Drawings or directed by the S.O., weepholes 75 mm in diameter shall be
formed by embedded uPVC pipes through concrete members or pitching.

10.3 Gabions

Gabions shall be supplied in sizes 1 m x 1 m x 1 m. The mesh size shall be 100 mm and the hot
dipped galvanised wire diameter shall be 3.3 mm.

The gabion filling shall be durable stone of maximum dimension of 300 mm and minimum
dimension of 150 mm.

January 2010

January 2010

After filling, the gabions shall be securely closed and tied to adjacent units with galvanised wire not
less than 2 mm diameter.

10.4 Reinforced Concrete Pipes

Reinforced concrete pipes shall be manufactured and tested in accordance with MS 881. Pipes shall
be spigot and socket ended suitable for rubber ring joints and supplied in standard lengths of 1.52 m.
Rubber rings shall be manufactured in accordance with BS 2494.

All pipes shall be hydraulically tested in the manufacturer's works. The Contractor shall despatch
duplicate copies of test certificates certifying that the pipes comply fully with the Specification.

10.5 Laying Drain Pipes

All drain pipes shall be laid with the sockets leading uphill and shall rest on solid and even
foundations for the full length of the barrel. Socket holes shall be formed in the bed of the trench to
allow sufficient room for the proper making of the joints. Each separate pipe shall be set for line and
level using a boning rod.

10.6 PVC Pipes

PVC drain pipes shall be of Class C unplasticised PVC pipes complying with BS 3505. Pipe ends
shall be suitable for jointing with approved patent joints.

Pipes which are to be used as underdrains under the slabs of the reservoirs or tanks shall be plain
ended suitable for butt joints and shall be perforated. The perforations shall be 15 mm diameter each.
Four perforations shall be made on each cross section of the pipe and shall be spaced equally.
Perforations along the pipe shall be spaced at 150 mm centres.

10.7 Drain Covers and Gratings

Provide mild steel gratings and precast reinforced concrete grade C20 covers to drains.

SECTION 11
MISCELLANEOUES

Section 11- Miscellaneous

TABLE OF CONTENT

Page
11.0 MISCELLANEOUS 11

11.1 Chequer Plating .............................................................................11-1
11.2 Handrailing .....................................................................................11-1
11.3 Ladder .............................................................................................11-1
11.4 Manholes, Surface Boxes, etc ......................................................11-2
11.5 Fencing ...........................................................................................11-2
11.6 Galvanised Metals .........................................................................11-2
11.7 Dissimilar Metals ...........................................................................11-3
11.8 Painting...........................................................................................11-3
11.8.1 General .................................................................................11-3
11.8.2 Painting Procedure................................................................11-3
11.8.3 Painting Timber Surface........................................................11-4
11.8.4 Painting Steel and Ironwork..................................................11-5
11.8.5 Painting Concrete and Cement based Surfaces ...................11-5
11.8.6 List of Approved Paints .........................................................11-6
11.8.7 Painting Colour Code............................................................11-6
11.9 Fibreglass Reinforced Plastic (FRP) Fabrications ......................11-8
11.9.1 General .................................................................................11-8
11.9.2 Products................................................................................11-9

11.0 MISCELLANEOUS

11.1 Chequer Plating

Chequer plating shall be hot-dip galvanised mild steel in accordance to ISO 1461 and shall have a non
slip pattern on its upper face.

Chequer plates shall be securely bolted with countersunk screw studs to frames set in the edges of and
spanning the ducts or opening. Chequer plates for use in valve chambers or manholes shall be hinged
to one side of the frames unless otherwise specified.

The sizes of chequer plates shall be such that no discernible deflection occurs under the weight of a
man standing upon it. Where it is not practicable to provide individual frames to each plate, the plates
shall be stiffened by welding steel angles on their underside to eliminate discernible deflection. The
plate panel sizes shall be such that they can be lifted by two men easily and each panel shall be
provided with suitably sized lifting holes.

The edges of all chequer plates shall be finished straight or to the outline of obstructions and shall be
free of burn marks or irregularities. Chequer plating which has been cut with a torch shall afterwards
be ground to present a straight edge.

Chequer plating shall be painted with one (1) coat of epoxy based red lead primer and finished
with one (1) coat coal tar epoxy paint of approved quality and colour.

11.2 Handrailing

Handrailing shall be made from mild steel hollow section pipe. Any distortions or warping of the
handrails as a result of the hot-dip process is unacceptable and prior to installation all lengths of
handrailing shall be inspected for straightness and approved by the S.O. It shall be painted with one
(1) coat of epoxy red lead primer and 2 coats of an approved gloss paint. Expansion units shall be
provided where the handrailings are more than 15 metre long.

11.3 Ladder

Mild steel ladders shall be hot-dip galvanised in accordance with BS EN ISO 1461. It shall be painted
with two coats of approved two pack coal tar epoxy paint which shall be obtained from an
approved manufacturer. Unless detailed on the Drawings, the Contractor shall submit to the S.O.
detailed drawings of the ladder for approval before placing any orders.

Steel ladders shall be 450mm wide, of welded construction and shall not have an unsupported length
of more than 2 metre unless otherwise specified. Intermediate support between the ends of the ladder
shall be by means of stays securely fixed to the nearest part of the structure.

The steel ladders shall be galvanised before leaving the manufacturers' works and supplying and
fixing steel ladders shall include for painting as specified, and for all nuts, bolts, stays and other things
necessary for fixing the ladders securely in place.

January 2010

11.4 Manholes, Surface Boxes, etc

Ductile iron manhole and access covers, surface boxes, gulley grating and frames unless otherwise
specified shall be obtained from an approved manufacturer and shall comply with BS EN 124.

Access covers and surface boxes exposed to the weather shall incorporate a waterproof seal.

Pan type duct covers to receive a floor finish shall be Broads Stelduct or similar subject to the
approval of the S.O. They shall be partially filled with concrete ready to receive the floor finish
specified.

Frames shall be firmly bedded in 1:3 cement/sand mortar and the tops of all covers and gratings shall
be flush with the finished surface of the surrounding floor, ground or pavement. Four sets of each type
of lifting key shall be supplied by the Contractor.

11.5 Fencing

The boundary of a treatment plant, pumping station and/or sludge treatment facility shall be secured
by perimeter fence. The perimeter fence shall have an entrance by double gates or sliding barrier to
allow access of maintenance vehicles. The gates shall be secured by padlocks and shall comply with
the requirements of the S.O. Where the treatment plant is situated in a building, access to the plant
must be secured.

Brickwall Fencing The fence shall be at least 2.2 meter high solid brick wall, with three strands
of 0.8 meter high barbed wire. Barbed wires shall be PVC coated two ply 2.64mm with 4 point barbs
spaced at 75mm intervals.

Chain link Fencing The fence shall be PVC coated. The fencing mesh shall be 50mm diamond
mesh No. 10 S.W.G. included with 3 strands of straining wire no. 8 S.W.G. and turn buckles.

Installation of fencing shall include for the supply of all materials, excavation, erection of the fencing
complete painting with 1 coat of primer and 1 coat of approved paint, fence posts as per drawing.

11.6 Galvanised Metals

All metals to be galvanised shall be of the full dimensions shown or specified in accordance with ISO
1461 and all punching, cutting, drilling, screw tapping, welding and the removal of burrs shall be
completed before the galvanising process commences.

All galvanising shall be done by the hot-dip process with spelter, not less than 98% of which shall be
pure zinc. Bolts, nuts and washers shall be completely galvanised including the threads but
galvanising removed in the course of nut fixing may be replaced with an approved zinc rich paint.

The galvanising shall be uniform, clean, smooth and as free from spangle as possible. It shall weigh
not less than 6.00 grams per square metre of area covered and be not less than 0.1mm thick.

All galvanised metal parts shall be protected from damage due to electrolytic action, white rust and
abrasion during delivery, storage and erection. Minor damage shall be touched up with an approved
January 2010

zinc chromate or other approved metallic compound but if, in the opinion of the S.O. the damage to
the galvanising is too severe or extensive, the part shall be removed and be re-galvanised.

11.7 Dissimilar Metals

The Contractor shall not use fixtures and fittings for metalwork including pipework in which
dissimilar metals likely to lead to galvanic action are placed in permanent contact with each other.

11.8 Painting
11.8.1 General

Painting shall comply with the requirements of BS 6150 and Recommendations for Painting in
Tropical Climates (Building Research Station Tropical Building Studies No. 4)

All paints and painting materials used in this Contract shall be of the best quality suitable for tropical
climate and approved by the S.O. Undercoats shall be of distinctive tints and finishing colours shall be

Paints shall be delivered to site in their original containers, sealed and intact. All materials and costs
of each type shall be of the same manufacturer.
11.8.2 Painting Procedure

The Contractor shall follow strictly in accordance with the manufacturers instructions and
recommendations based on BS 6150, particularly with regard to:-

a) Preparation of surfaces specified to be painted.

b) Preliminary priming or sealing coat.

c) The number of undercoats and method of application.

d) The finishing coat and method of application.

As the painting work proceeds, each coat of paint shall differ slightly in colour or shade from the
preceding coat. The finishing coat, when dry, shall be the colour selected. The finished surface shall
be uniform in colour and free from brushmarks.

No painting shall be carried out when the atmosphere is dusty or wet or when the surface to be painted
is hot. Adequate ventilation shall be provided for the proper application and curing of the paint-work
and for the safety and health of the painters. Care shall be taken to protect floors, roofs and any other
adjacent areas or installations by covering them with drop cloths or other similar approved means.

Except as required for surfaces on which emulsion or water thinned paints are to be applied, painting
shall be done only on surfaces which are thoroughly clean and dry, and at such humidity and
temperatures of the atmosphere and of the surfaces to the painted as will cause evaporation of
moisture rather than condensation.

Surfaces which have been cleaned, pretreated and/or otherwise prepared for painting shall be primed
as soon as practicable after such preparation has been complete but before deterioration of the
January 2010

prepared surface. Paint shall not be applied to any surface which is excessively hot for the type of
paint being used, and freshly painted surfaces shall be shaded and protected from overheating until
sufficiently hardened to prevent the occurrence of cracking or blistering. Painted exterior surfaces
shall be protected from the weather until the paint is thoroughly dry and hard.

Painted woodwork and metalwork shall be lightly rubbed down with glass paper between coats and
dusted down. At least 24 hours shall elapse between the application of successive coats unless
otherwise specified by the manufactures. Final coats shall only be applied after clearing up and
finishing by all other trades has been completed. On completion of painting, the Contractor shall
remove all paints, spots and shall touch up or re-paint imperfect work.

Unless otherwise specified by the manufacturers, at least 24 hours shall elapse between the
application of successive coats. However, in no circumstances shall the time between coats exceeds
the following:

a) between application of primer - 3 weeks
and undercoat

b) between undercoats or under 2 weeks
coat and first finishing coats

c) between gloss finishing coats 48 hours

Should the above times be exceeded the Contractor shall recoat the work which has been weathered
beyond the specified time, with a coat equal to that previously applied, at his own expense.
11.8.3 Painting Timber Surface

Timber surfaces to be painted shall be examined for sap, grease, and oil, and shall be removed and
cleaned. Any holes, cracks and joints shall then be neatly stopped with putty. All mortar splashes,
excessive roughness, loose edge shall be sanded with sandpaper. All protruding and exposed nails
shall be punched beneath surface and puttied.

All frames and other external timber specified to be painted shall be knotted, stopped and primed with
one coat of an approved aluminium primer before erection. Joinery shall be primed before assembly.
Cut ends must be primed before fixing. End grain faces and covered faces which cannot be painted
further after erection shall be given two coats of aluminium primer.

The sequence of painting timber surfaces after priming shall be

a) one further priming coat

b) one under coat

c) two high gloss finishing coats

of paint suitable for interior or exterior use depending on the recommendation of the manufacturers.

Unless otherwise specified, hardwood shall be stained and treated with two coats of long oil
formulation type of varnish after erection as directed.
January 2010

11.8.4 Painting Steel and Ironwork

Unless galvanised, all steel and ironwork shall be supplied with two coats of two pack epoxy based
red lead oxide primer before leaving the manufacturers works. The Contractor shall examine and
make good any damage in the surface due to delivery, handling and erection.

Steelwork and ironwork to be embedded in concrete shall be painted with an additional coat of similar
primer and made good before it is built into the concrete.

Steelwork and ironwork to be embedded in brickwall shall have two additional coats of bituminous
paint and made good before it is built into the brickwall.

After erection and building in, all exposed surfaces of steelwork and ironwork which are not
completely painted shall be cleaned, filled and painted with one flat undercoat and three coat
semi-gloss high finishing paint approved by the S.O.

Items which will be submerged in water or exposed to outside atmosphere or in manholes shall be
given two coats of approved bituminous epoxy enamel. Where in contact with water, the enamel shall
be taint free, non-toxic and chlorine resistant.

Items which are supplied bitumen primed shall be given two coats of approved metallic sealer. Items
supplied with red lead primer shall be given a further priming coat. In both cases they shall be painted
with one flat undercoat and two coats of high gloss finish.

All galvanised steel to be painted shall be washed with ICI lithoform or other similar approved
material and then applied with an approved etching primer before applying the standard primer. It is
then followed by an undercoat and two coats of epoxy paint.

Aluminium work shall not be painted except those surfaces to be built into concrete, which shall be
cleaned down and given two coats of an approved bituminous paint. The paint shall be thoroughly
dry before placing the surrounding concrete.

All painting works for structural steel works shall strictly refer to Section 7.0 and in accordance to BS
5493.
11.8.5 Painting Concrete and Cement based Surfaces

All concrete and cement based surfaces to be painted shall be dried to the satisfaction of the S.O.
before painting is commenced, and all dust, dirt, plaster splashes or efflorescence shall be brushed off
and removed by dry brushing.

Any cracks, blister or other imperfections shall be rubbed down, smoothed, cut out and made good.
The surfaces excepting the lime silo storage areas shall be given a coat of an approved alkali resisting
primer and one undercoat followed by two finishing coats of approved undiluted super acrylic
emulsion paint with fungicide additive.

The lime silo areas shall be given primer and undercoat as above and followed by two finishing coats
of super gloss paint.

The floor of liquid alum storage area shall be painted with two coats approved epoxy based paint
according to manufacturers specification.
January 2010

11.8.6 List of Approved Paints

The paint shall be of the type and make as approved by S.O.. If the tender is accepted, the Contractor
shall supply and paint the type of building as stated in the Schedule. No substitution shall be allowed
without the prior approval of the S.O.

The colour standard / painting system index for buildings and piping shall comply to IWKs
requirement as shown the Appendix.
11.8.7 Painting Colour Code

Painting shall include all plant and machinery inside buildings, including pipework, grating,
handrailing, internal walls below ground level and all metal work including machinery.

Conduits and piping shall be appropriately named and labelled indicating flow directions and painted
with the following colour codes for easy identification:

Chlorine line - yellow with double green bands
Compressed air line - green
Fuel gas line - orange
Potable water supply line - blue
Raw sewage line - black
Final effluent line - grey
Sludge line - brown
Non-potable water line - blue with double black bands
Other disinfectant lines - yellow with double red bands
Biogas line - yellow

The labels shall be stencilled on the piping in a contrasting colour with the colour coded bands, if any,
located at appropriate and strategic points.

Colour codes selected for general equipment, building and others items in a sewage treatment plant
shall be adhered to colour standards as detailed in the table below. The types of paint and surface
preparation used shall be as recommended by the paint manufacturer.

Painting shall include all plant and machinery inside buildings, including pipework, grating,
handrailing, internal walls below ground level and all metal work including machinery.

January 2010

Painting System Index Colour Standards

Item Colour Equivalent Colour
Guide
Dulux Regal Blue 0013 General Equipment including motors (unless
come with the original manufacturer approved
colour code)
Dark Blue
Par Mandarin Blue
0013
Penstocks/Valves/Manhole Covers Black Par Bituminous Black

Machinery
Guards/Railings/Runways/Overhead
Cranes/Lifting Davit
Dulux Lemon 2024

Yellow

Par Golden Yellow
Light Grey

Dulux Pewter 695 Switchboards
Par Willow Grey
00A05
Green

Dulux A365-13449 Fencing poles/Gates
Par Green 3666
Building and Walls Exterior

Grey
(Weathersheild)
Dulux BS 00A05-
10235
Building and Walls - Interior White
Fencewall Interior and Exterior Grey Dulux BS 00A05-
10235
Floors - Concrete Interior Green Leigh Green 3666

Building Stripes Green Dulux A910-13448

Green
Par Green 3666
Blue Dulux A910-11482

Par Blue 2686
Indah Water Logo
(where applicable)
Green Indah Water
Green

Dulux A365-13449
Par Green 1006
Blue Indah Water Blue
Indah Water Blue
Dulux A365-11483
Par Blue 1007

Notes

The above painting requirements are not applicable to stainless steel, aluminium, galvanised metal
surfaces except where necessary to comply with statutory health and safety requirement.

January 2010


11.9 Fibreglass Reinforced Plastic (FRP) Fabrications
11.9.1 General

Description
The work included in this section comprises furnishing all plant, labour, equipments, appliances and
materials and performing all operations in connection with fibre reinforced plastic fabrications.

Submittals
a) Product data shall include manufacturers catalog data showing dimensions, spacings, and
construction details; design tables showing limits for span length and deflection under
various uniform and concentrated loads; materials of construction.
b) Shop drawings shall detail fabrication and erection of each FRP fabrication including plans,
elevations, sections, and details of FRP fabrications and their connections, anchorages and
accessory items.
c) Samples of each type of FRP product proposed shall be submitted for approval.

Quality Assurance
a) Material shall be furnished by a reputable and qualified manufacturer of proven ability who
has regularly engaged in the manufacture and installation of FRP systems and shall be
approved by the Engineer.
b) Fabricator shall be a firm experienced in successfully producing FRP fabrications similar to
that indicated for this project, with sufficient production capacity to produce required units
without causing delay in the work.
c) Substitution of any component or modification of system shall be made only when
approved by the Engineer and at no additional cost to the Employer.
d) In addition to requirements of these specifications, the Contractor shall comply with
manufacturers instructions and recommendations for work.

Delivery Storage and Handling
a) All systems, sub-systems and structures shall be shop fabricated and assembled into the
largest practical size suitable for transporting.
b) All materials and equipments necessary for the fabrication and installation of the grating,
stair treads, handrails, ladders, weir plates, linings and structural shapes shall be stored in a
manner to prevent cracking, twisting, bending, breaking, chipping or damage of any kind to
the materials or equipment, including damage due to over exposure to the sun.
c) All material which, in the opinion of the Engineer, has become damaged as to be unfit for
use, shall be promptly removed from the site of works and the Contractor shall receive no
compensation for the damaged material, or its removal.
d) All materials, items and fabrications for installation and field assembly shall be identified
and match-marked.
January 2010

January 2010

11.9.2 Products

a) The Contractor shall design, engineer, fabricate, and install the FRP fabrications to
withstand the specified structural loads without exceeding the allowable design working
stress of the materials involved, including anchors and connections. Each load shall be
applied to produce the maximum stress in each respective component of each FRP
fabrication.
b) Materials used in the manufacture of the FRP products shall be new stock of the best
quality, free from all defects and imperfections that might affect the performance of the
finished product.
c) All materials shall be of the kind and quality specified, and where the quality is not
specified, it shall be the best of the respective kinds and suitable for the purpose intended.
d) All FRP products shall be manufactured by a pultruded process using a vinyl ester resin
with flame retardant and ultra-violet (UV) inbibitor additives. A synthetic surface veil shall
be the outermost layer covering the exterior surface and FRP shapes shall achieve a flame
spread of 25 or less in accordance with ASTM test method E84.
e) All FRP items shall be corrosion resistant to a 5% concentration of either sulphur dioxide or
hydrogen sulphide.
f) After fabrication, all cut ends, holes and abrasions of FRP shapes shall be sealed with a
compatible resin coating to prevent intrusion of moisture.
g) FRP products exposed to weather shall contain an ultraviolet inhibitor and shall additionally
receive 25 microns thick U.V. coating to shield from ultra-violet light.
h) All exposed surfaces shall be smooth and true to form.
i) Color shall be OSHA safety yellow or gray as gray as instructed by the S.O.

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