ANNEX -I

SPECIFICATIONS

1 GENERAL- DI PIPES, FITTINGS

,SPECIALS, ACCESSORIES AND
VALVE

2 DI PIPES & FITTINGS

3 MECHANICAL COUPLINGS, REPAIR

CLAMPS & FLANGE ADAPTORS

4 VALVES

5 TECHNICAL SPECIFICATION FOR

GENERAL BUILDING WORK

6 STEEL WORKS
 Section 1

SPECIFICATIONS FOR DI PIPES, FITTINGS, SPECIALS, ACCESSORIES,

DI VALVES.

GENERAL

TABLE OF CONTENTS PAGE NUMBER

1 Suitability for Potable Water 2

2 Definitions 2

3 Flanges 2

4 Protection during Delivery 2

5 Storing handling and hauling of Pipes, Fittings, Valves and Specials 2

6 Quality and workmanship 3

7 Final Acceptance at site 3

1
 GENERAL

1 Suitability for Potable Water

Pipes and pipeline components, including their protective coatings and joint materials,
that will or may come into contact with potable water shall not constitute a toxic
hazard; shall not support microbial growth; shall not cause taste or odour, cloudiness
or discolouration of the water.

2 Definitions

The definitions given in the relevant standards which are referred to in the
specification shall apply for the terms used in this specification.

3 Flanges

All flanges dimensionally shall be in accordance with BSEN 1092-1 : 2007

Specification for Steel Flanges - Metric Series. The screw threads in all pipes and
fittings shall comply with ISO Metric Screw Threads.

4 Protection during Delivery

The Contractor shall provide protection, to the approval of the Engineer, for the ends
of all pipes and fittings prior to the pipes and fittings leaving the place of manufacture
and shall maintain such protection until the items reach their destination in order to
guard effectively against damage during transit and storage and the ingress of foreign
matter inside the pipes and fittings.

All valves and fittings shall be securely packed in crates and boxes to prevent damage
during delivery. The cost of packing shall be deemed to be included in the Contract
Rates and crates will not be returned.

Each box and package therein shall be clearly labeled stating the number, size and
description of the contents.

All details of the proposed method of providing such protection shall be submitted at
the time of tendering.

5 Storing, Handling and Hauling of Pipes, Fittings, Valves and Specials

All materials shall be stored in an approved location and in such a manner as to

preserve their quality and condition.

Storage shall be in accordance with the manufacturers recommendation.

2
6 Quality and Workmanship

All pipes, fittings, accessories, valves, shall be manufactured in compliance with the
ISO 9001 : 2008 Quality Management System requirements. Quality Management
system certificate should be from an organization accredited to issue such
certification and the manufacturer shall have this certificate valid during the supply
and delivery of the materials. This certificate shall clearly indicate the location of the
place of manufacture of goods.

7 Final Acceptance at site

All pipes, fittings, valves and accessories shall conform to the specification at site.
Engineer shall carryout necessary inspections at site prior to final acceptance.

3
 Section 2

SPECIFICATIONS FOR DI PIPES, FITTINGS, SPECIALS, ACCESSORIES,

DI VALVES.

DUCTILE IRON PIPES AND FITTINGS

TABLE OF CONTENTS PAGE NUMBER

1 Scope 5

2 Reference Standards 5

3 Definitions 7

4 Classes of Pipes & fittings and Pressure Rating 7

5 Dimensions of Pipes and Fittings 7

6 Method of Manufacture of Pipes and Fittings 7

7 Coating and Lining 8

8 Flange Joints for pipes and pipeline fittings 8

9 Gaskets for flanged joints 8

10 Nuts, bolts and washers 9

11 Tolerances 9

12 Tensile properties of pipes and fittings 9

13 Hardness of pipes and fittings 10

14 Works Leak Tightness Test for pipes and fittings 10

15 Works Leak Tightness Test for pipe joints and fitting joints 10

4
 DUCTILE IRON PIPES AND FITTINGS

1 Scope

This section covers the requirement for the supply of Ductile Iron pipes and fittings.

2 Reference Standards

The following standards are referred to ;

ISO 2531 : 1998 Ductile iron pipes, fittings and

accessories for pressure pipe lines

BS EN 545 : 2006 Ductile Iron pipes, fittings, accessories and their joints
for water pipelines. Requirements and test methods.

.
BS 7874 : 1998 Method of tests for microbiological deterioration of
Elastomeric scales for Joints in pipe work and pipe
lines.

BSEN 681 -1 : 1996 Elastomeric seals- material requirement for pipe joint
seals used in water and drainage application.
(Vulcanized rubber)

BSEN 681 -2 : 2000 Elastomeric seals- material requirement for pipe joint
seals used in water and drainage application.
(Thermoplastic elastomers)

ISO 4633:2002 Rubber seals – Joint rings for water supply drainage and
sewerage pipe lines – specification for materials.

BS 3416 : 1991 Bitumen based coatings for cold application, suitable

for use in contact with potable water.

BSEN 10 300 : 2005 Steel tubes & fittings for onshore and offshore pipe
lines. Bitumen hot applied material for external coating.

BSEN 1092-1 ;2007 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN Designated, steel
flanges.

BS 14399 : Part 1 : 2005 Specification for high strength structural bolting

assemblies for pre-loading. General requirements.

BSEN 14399 : Part 2: 2005 Specification for high strength structural bolting
assemblies for pre- loading. Suitability test for Pre-
loading.

5
BS 1514: Part 1:1997 Dimensions of non-metallic Flanges and their joints.
Dimensions of gaskets for PN designated flanges. Non
metallic flat gasket with or without inserts gaskets for
pressures up to 64 bar.

BS 4320: 1968 Metal washers for general engineering purposes metric

series.

ISO 9001 : 2008 Quality Management System Requirement

ISO 4179 : 2005 Ductile iron pipes for pressure and non pressure
pipelines Centrifugal cement mortar lining.

ISO 6600 : 1980 Ductile iron pipes centrifugal cement mortar lining
(composition controls for freshly applied mortar).

JIS G 5528: 2006 Epoxy powder coating for interior of DI pipes and
fittings

ANSI A214 Cement Mortar lining for cast iron and Ductile iron
pipes and fittings for water.

ISO 8179 : 2004:Part 1 Metallic Zinc with finishing layer.

ISO 8179:1995: Part 2 Zinc rich paint with finishing layer

BS EN 12329 : 2003 Corrosion Protection of metals. Electrodeposited

coatings of Zinc with supplementary treatment on Iron
or Steel

BS EN 14161 : 2003 Code of practice for Pipe Lines. Pipelines on land :

design, construction and installation. Ductile Iron

BS EN 10088: Part 2: 2005 Stainless steel – Technical delivery conditions for

sheet/plate and strip of corrosion resisting steels for
general purposes.

BS 6076:1996 Polymeric film for use as a protective sleeving for

buried iron pipes and fittings (for site and factory
application)

The year of publication of the standards referred to in the following clauses shall be
the year as given above.

6
3 Definitions

The definitions given in the relevant standards which are referred to in the
specification, shall apply for the terms used in this specification.

4 Classes of Pipes & fittings and Pressure Ratings

Ductile iron pipes and fittings shall be in accordance with ISO 2531 : 1998 or with
BS EN 545:2006. The standard class designation of pipes and fittings shall be as
follows unless otherwise stated.

- Pipes with Integral Flanges K 12

- Pipes with factory welded flanges K 9

- Pipes with screwed flanges K 9 or K 10

- Fittings except tees K 12

- Tees K 14

- Flanges PN 16

The allowable operating pressures shall comply with Annex A of BS EN 545 : 2006
or ISO 2531 : 1998 unless otherwise stated.

5 Dimensions of Pipes and Fittings

Dimensions of standard pipes and fittings shall be to ISO 2531:2009 or BS EN

545 : 2010 unless otherwise shown on the Drawings or required for special purposes.

6 Method of Manufacture of Pipes and Fittings

All straight pipes shall be spun or centrifugally cast and fittings and joint components
shall be cast in sand moulds. Prior approval of the Engineer shall be required for any
alternative casting methods.

At all stages of manufacture, rigid control shall be exercised and the pipes and fittings
shall be sound and free from surface or other defects.

Foundries shall comply with the requirements of ISO 9001:2008 Quality Management
Systems.

Manufacturing process of Pipes and Fittings shall comply with the ISO 9001: 2008
quality management system requirements and such quality management system
possessed by the manufacturer should be from an organisation accredited to issue such
certification. Documentary evidence regarding accreditation together with the scope

7
 of certification should be provided. Certificate shall clearly indicate the name and
address of the location of factory
7 Coating and Lining
All ductile iron pipes and fittings shall be protected internally and externally against
corrosion. The external protection shall comprise a coating of metallic zinc or zinc
rich paint complying with ISO 8179 : Part 1 : 2004 and ISO 8179 Part II followed
by two coats of bituminous based black paint complying with BS 3416 : 1991 Type II
or an approved coat of epoxy. The internal protection shall be a cement-mortar lining
complying with specified thickness in Table 8 of BSEN 545 : 2006 or relevant Table
in ISO 4179 : 2005 or ISO 6600 : 1980.

All such coatings and linings shall be applied under factory conditions, in complying
with BSEN 545 : 2006 or ISO 4179 : 2005/ ISO 6600 : 1980.

8 Flanged Joints for Pipes and Pipeline Fittings

Flanges for pipes and pipeline fittings shall unless otherwise stated comply with
BS EN 1092 – 1: 2007. Flanges shall be of PN 16 nominal pressure rating and shall be
raised faced, unless otherwise stated.

Note: Flanges in accordance with BS EN 545 and ISO 2531 are dimensionally
compatible with BSEN 1092-Part 1:2007

Flanged joints shall be complete with all nuts, bolts, gaskets and two washers per bolt.

The flanges of all fittings shall be integrally cast. The flanges of flanged pipes shall
either be integrally cast or screwed or factory welded unless otherwise stated.
‘Factory welded’ means that the flanges are welded to the pipes at the point of
manufacture under factory conditions with inspection agency certification.

The Contractor shall be responsible for checking and ensuring that mating flanges are
compatible in all cases, including where connections are required to pipe work and
valves associated with pumping plant and inlet/outlet pipe work at service reservoirs
or other structures.

9 Gaskets for Flanged Joints

Gaskets for flanged pipe joints shall be of the inside bolt circle type and the
dimensions shall comply with BSEN 1514 – Part 1 : 1997.

The physical properties of gaskets shall comply with Table 2 of BSEN 681-1:1996.
The Gaskets shall also comply with the relevant provisions in BSEN 681-1:1996 for
effects on water quality and resistance to microbiological deterioration.

The Gasket material shall be EPDM/SBR and shall be of average hardness of 76-84.

The Gaskets shall be supplied by the manufacturer and shall suit for PN 16 flanges
unless otherwise stated.

8
 Each gasket shall be marked clearly and durably in accordance with the following
information in a manner that does not interfere with the sealing function of the gasket,
in complying with clause 10 of BSEN 681-1:1996.

a). The nominal size

b). Manufacturer’ s identification

c). The number of the BS or BS EN with seal type designation.

d). Abbreviation for the elastomer

10 Nuts, Bolts and Washers

The nuts, bolts and washers for flanged joints shall be of high tensile steel and shall
comply with BSEN 14399 – Part II – 2005.

The bolting shall comply with the relevant provisions of BSEN 1092- 1: 2007.

The Bolt lengths shall be sufficient to ensure that nuts are full threaded when
tightened in their final position with two threads showing.

Two washers per each bolt shall be supplied for providing under the head of the bolt and
under the nut.

11 Tolerances

Tolerances on wall thickness weights and lengths shall be in accordance with BS EN

545 and/or ISO 2531, and the specific references for compliance are as follows.

BS EN 545 : 2006 ISO 2531 : 1998

Wall thickness Table 8 Table 1

Weights - Table Table 3

Lengths 6 Table 4 & 5

The tolerances on flange thickness and flange diameter shall be in accordance with
BSEN 1092-1 : 2007.

12 Tensile properties of pipes and fittings

The tensile properties and testing methods shall be in accordance with BS EN 545 or
ISO 2531 and the specific references for compliance are as follows:

9
 BS EN 545:2006 ISO 2531 : 1998
Tensile Properties Table 7 Table 6

Test methods Clause 6.3 Clause 4.3.1

Clause 6.3

13 Hardness of Pipes and Fittings

The Hardness of pipes and fittings shall not exceed the following superficial values,
when tested in accordance with brinell hardness tests complying with clause 6.4 of
BS EN 545 : 2006 or clause 4.3.2. of ISO 2531 : 1998.

Superficial Hardness
Pipes 230 HB

Fittings & accessories 250 HB

14 Works Leak Tightness Test for Pipes and Fittings

All pipes and fittings shall comply with works leak tightness requirements of BS EN
545 : 2006 and ISO 2531 : 1998 and the specific references for compliance are as
follows:

BS EN 545 : 2006 ISO 2531 : 1998

Method of testing Clause 6.5.2 and Clause 6.5.2 and
Clause 6.5.3 6.5.3

Minimum work test pressures Table 14 Table 10

15 Work Leak Tightness Test for Pipe Joints and Fitting Joints

A Pipe joint, connecting two pipes shall be tested at a test bench at the factory for the
leak tightness of the pipe joint for the same test pressures for work leak tightness test
for pipes & fittings.

10
 Section 3

SPECIFICATIONS FOR DI PIPES, FITTINGS, SPECIALS, ACCESSORIES,

DI VALVES.

TABLE OF CONTENTS
PAGE NUMBER

MECHANICAL COUPLINGS AND

FLANGE ADAPTORS

1 Mechanical Couplings, Repair clamps and Flange Adaptors 12

11
 1 MECHANICAL COUPLINGS, REPAIR CLAMPS AND FLANGE
ADAPTORS

All mechanical couplings, repair clamps and flange adaptors shall comply with ISO
9001:2008 quality Management system requirement . Quality Management system
certificate should be from an organisation accredited to issue such certificate.
Documentary evidence regarding accredition together with the scope of certification
should be provided. This certificate shall indicate the location of the factory.

Mechanical couplings and repair clamps shall comply with WIS 4-21-02 or equivalent
and shall be PN 16 pressure rated unless otherwise stated.

All these fittings shall be protected against corrosions by the application of Polymeric
anti-corrosion coatings in accordance with WIS 4-52-01 Class B. (both internal and
external) with the coating thickness of not less than 250 microns. Engineer’s approval
shall be obtained for any other type of coating, prior to order.

The mechanical couplings and repair clamps shall be designed for a safe allowable
angular deflection of 6° without leakage while it shall be 3° for flange adaptors.

All fastners of couplings, clamps and adaptors shall be electroplated to BS EN

12329:2000 grade Zn 10 or equivalent followed by a suitable primer and then with
Polymeric anti-corrosion coatings in accordance with WIS 4-52-01 Class B. to a
thickness of 60 – 120 microns.

Gaskets and rubber rings shall be of EPDM/SBR and the physical properties shall
comply with table 2 of BSEN 681-1:1996. Gaskets shall be of the inside bolt circle
type and the dimensions shall comply with BSEN 1514 – Part 1 : 1997. The hardness
range for Gaskets is 76-84 IRHD.

Prior to the commencement of the manufacture the Contractor shall submit to the
Engineer, for approval, detailed drawings of all mechanical couplings repair clamps
and flange adapters.

12
 Section 4

SPECIFICATIONS FOR DI PIPES, FITTINGS, SPECIALS, ACCESSORIES,

DI VALVES

VALVES

TABLE OFCONTENTS PAGE NUMBER

1.0 General
1.1 Scope 14
1.2 Definitions 14
1.3 Reference Standards 14
1.4 Records and Drawings for Materials to be supplied 15
1.5 Materials of Manufacture 16
1.6 Testing 16
1.7 Coating 19
2.0 Types of Valves
2.1 Sluice Valves 19

13
 VALVES
1.0 General

1.1 Scope

This section covers the requirements for the supply of valves.

Accessories associated with the valves are also specified.

1.2 Definitions

The definitions given in the relevant standards, which are referred to in the
specification, shall apply for the terms used in this specification.

1.3 Reference Standards

The following standards are referred to in this section;

BSEN ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel
articles. (Specifications & test methods)

BSEN 1982 : 2008 Copper and copper alloys. Ingots and castings.

BSEN 1092-2:2003 Flanges and their joints- Circular flanges for

pipes, valves, fittings and accessories, PN designation

BSEN 1171 : 2002 Industrial Valves. Cast Iron Gate Valves.

BSEN 12334:2001 Industrial valves, Cast iron check valves

BS EN 1563:1997 Specification for Spheroidal graphite cast iron.

BSEN 593 : 2004 Industrial Valves Metallic Butterfly valves.

BS 5163 : 2004 Predominantly Key-operated cast iron gate valves for

waterworks purposes.

BS 750 : 2006 Underground fire hydrants and surface box frames and
covers

BSEN 10293: 2005 Steel castings for general engineering purposes

14
 BSEN 558: 2008 Industrial Valves. Face to face and centre to face
dimensions of metal valves for use in flange pipe
systems. PN and class designated valves.

BSEN 1074 –1: 2000 Valves for water supply. Fitness for purpose
requirements and appropriate verification tests. General
Requirements.

BSEN 1074 –2: 2000 Valves for water supply. Fitness for purpose
requirements and appropriate verification tests. Isolating
valves.

BSEN 1074 –3: 2000 Valves for water supply. Fitness for purpose
requirements and appropriate verification tests. Check
valves.

BSEN 1074 –4: 2000 Valves for water supply. Fitness for purpose
requirements and appropriate verification tests. Air
valves.

1.4 Records and Drawings for Items(Valves and other Ancillary items) to be
Supplied

The following records and drawings of all types of valves shall be made available by
the supplier for inspection.
- Drawings showing overall dimensions, valve construction and settings

- Data related to pressure ratings, weights and materials of manufacture (each

component)

- Test certificates of works tests

- Performance data of air valves

- Seating design and the seating materials of butterfly valves

15
1.5 Materials of Manufacture

All materials of manufacture shall be suitable for use with water at temperatures up to
45 deg. C.

Valve body casting shall be ductile iron complying with BS EN 1563 :2004 for
diameters above DN 150, while CI valve body casting is acceptable for below DN
150 and shall be capable of withstanding the test pressures specified. The castings
shall be close grained, sound, smooth and symmetrical, and shall be carefully cleaned
and dressed off. No stopping or plugging will be permitted in the case of air holes
appearing in the castings.

Unless otherwise specified, all standard valves shall be flanged type where flanges
shall be of PN 16 and complying with BSEN 1092-1 :2007.

The direction of closing of valves shall be “clockwise” and hand wheels shall be
permanently marked with the words "open" and "closed" and a direction arrow.

All materials shall comply with the appropriate British Standards or equivalent. All
castings shall be free of blowholes and other defects.

Sluice valves and butterfly valves shall be suitable for flow in either direction.

All standard valves shall be suitable for frequent operation and for infrequent
operation after long periods in the open or closed condition.

All non-metallic materials to be provided shall be listed in the current "Water Fittings
and Materials Directory" published by the Water Research Centre, UK, or approved
equivalent publication, as having passed full tests of effect on water quality under the
requirements for the testing of non-metallic materials for use in contact with potable
water.

The Engineer shall have the right to reject any casting, forging, bearing etc and the
contractor shall replace any such defective parts at his own expense.

1.6 Testing

(i) Performance Test

Each valve, gate and appurtenance shall be shop-operated three times from the
fully closed to the fully opened position, and the reverse, under a no-flow
condition, to demonstrate that the complete assembly is workable.

16
(ii) Leakage Test (Closed Position)
(a) For Internal Pressure
Valves, gates and appurtenances shall be shop-tested for leaks in the closed
positions. The hydrostatic pressure shall be applied to one face of the disc for
the full test duration at the working pressure when the valve is in closed
position. This shall be repeated to the other face of the valve too. The length of
test shall be at least 3 minutes and there shall be no indication of leakage past
the valve during the test period. The test pressure shall be given in the Table
below.

PN Test Pressure (PFA) (Bars) Duration (Minutes)

16 25 3

25 35 3

(b) For External Pressure

Valves shall be leak tight to ingress of air, water or any other foreign matter.

a. Hydrostatic Test
Valves specified shall be hydrostatically tested. Hydrostatic tests shall
conform to the following;
With the valve disc in fully open and a slightly open position, internal
hydrostatic pressure equivalent to 150% of the specified working pressure a
specified in the table below shall be applied to the inside of the valve body of
each valve for a period of 3 minutes. During the hydrostatic test, there shall be
no leakage through the metal, the end joints, or the valve shaft seal; nor shall
any part be permanently deformed. While undergoing testing, the valve body
shall be struck with a hammer several times.

PN Test Pressure (PFA) (Bars) Duration (Minutes)

16 25 3

25 35 3

17
(iv) Seat Tightness Test

Type of valve Test Procedure

Sluice valve 1. Fill in the valve cavity including if appropriate, the
Ball float valve bonnet cavity with water.
2. Move the obturator to the closed position.
3. Apply the test pressure, which is 1.1 times the
allowable differential pressure at room temperature,
and maintain the test pressure for 3 minutes.
4. Determine the leakage rate.
5. Repeat 3 and 4 inclusive for the other side of the valve.
See NOTES 1,2,3 and 4
Butterfly Valve 1. Fill the valve cavity with water.
2. Move the obturator to the closed position.
3. Apply the test pressure, which is 1.1 times the
allowable differential pressure at room temperature in
the direction to unseat the obturator and maintain the
test pressure for 3 minutes.
4. Determine the leakage rate.
See NOTE 5
Check Valve 1. Fill in the downstream valve cavity including, if
appropriate, the cover cavity with water.
2. The test pressure, which is 1.1 times the allowable
differential pressure at room temperature in the
direction tending to close the obturator and maintain
the test pressure for 3 minutes.
3. Determine the leakage rate.

NOTE
1. The procedure described may not ensure pressurization of the integrate
space of double seated valves and may not therefore permit verification of
the leakage rate of the downstream seat. When such pressurization is a
requirement of the product or performance standard or is required by the
purchaser, it is necessary to carry out step 3 before step 2.
2. Valves which incorporate “double block and bleed” design feature have the
bleed plug removed prior to the test in order to prove the “double block and
bleed” capability.
3. Valves with independent double seating (such as two piece obturator or
double-seated valves) may be tested by applying the test pressure between
the seats and checking each side of the closed valve.
4. Soft seated ball float valves previously subjected to a liquid seat test
pressure may have a reduced performance capability in some subsequent
services at low differential pressures. If a liquid seat test pressure is
specified and is carried out before a low pressure gas seat test, it may be
necessary to allow time for the seat material cover.
5. Valves with symmetrical seating may be tested in either direction.

18
 (v) Field Testing
When the valves, gates and appurtenances have been completely installed and
as soon as operation conditions permit, they shall be given a field test by the
Engineer to demonstrate that they have been suitably installed, that they meet
all requirements, are in good operating condition and are, in every way,
adequate for the service intended.

1.7 Coating

All exposed cast iron or ductile iron components of valves to the external
environment or to the water contained in the valve shall be fully coated to provide
protection against corrosion.
The external and internal surfaces except mating surfaces of all valves shall be treated
with an epoxy coating, a bitumen solution or any other material acceptable to the
purchaser at the place of manufacture. Threaded and exposed machined surfaces
liable to rusting shall be adequately protected in accordance with BS 5163 : 2004.

2.0 Types of Valves

2.1 Sluice Valves

The sluice valves for pipeline installation shall comply with the BSEN 1074:1-2000
and BSEN 1074 : 2 – 2000 or BS 5163-1:2004 for diameters up to and including 600
mm and BSEN 1171:2002 for diameters above 600 mm and shall be of PN 16
pressure rating, for potable water applications.

Sluice valves shall be standard inside screw, wedge gate valves with resilient seating
for diameter from DN 50 – DN 300 inclusive and metal to metal seating from
diameters above DN 300. The valve body shall be ductile iron or cast iron upto and
including DN 150 complying with BS 5163-1 : 2004 and BSEN 1563 : 2004. For
diameters above 150mm, the valve body shall be ductile iron complying with BSEN
1563: 2004. Valves shall have stainless steel stems, machined bronze or gunmetal
mating faces securely fixed to the valve body, stuffing box and gland type or
approved type stem seal, EPDM / SBR seals at joints between castings.

All Tee-Key operated valves shall be provided with valve cap as per BS 5163 : 2004.
By pass arrangement shall be provided for valves of DN 300 and above. Directions of
closure of the valves shall be ‘clockwise”. In case of hand wheel operated valves, the
hand wheels shall be indelibly marked with words “open” and “close” with direction
arrows.
The maximum differential pressure in operation for valves shall be as given in items
description of the valves in the BOQ or as given in the drawings. Where necessary
valves above 300mm diameter shall be provided with gearing to achieve the designed
manual operation of valves where it should be assumed that the maximum torque
exerted by one man is 130 Nm.

Motorized (Motor operated) valves shall be provided for diameters 500mm and above
as given in the item description of BOQ or as given in the drawings.

19
Valve spindles shall be of the internal non-rising type. Hand wheels shall be made of
cast iron and shall have arrows and words ‘open’ and ‘close’ cast on to indicate
direction of rotation for opening and closing the valve.

All sluice valves shall be subjected to all type testing in accordance clause 1.6 above
including 'open ended' works test of which the test certificates issued by the
manufacturer to this effect, shall be submitted.

The face-to-face (FTF) dimensions of the sluice valves as specified in BSEN

558:2008 shall be as follows.

Sluice Valves - Series 3

FTF dimension (mm)
Diameter (mm) PN 10/PN 16 PN 25
10 102 -
15 108 140
20 117 152
25 127 165
32 140 178
40 165 190
50 178 216
65 190 241
80 203 283
100 229 305
125 254 381
150 267 403
200 292 419
250 330 457
300 356 502
350 381 572
400 406 610
450 432 660
500 457 711
600 508 787
700 610 -
800 660 -
900 711 -
1000 813 -

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 Section 5

TECHNICAL SPECIFICATION FOR GENERAL BUILDING WORK

TABLE OFCONTENTS PAGE NUMBER

1.0 Excavation and earthwork

1.1 General 22
1.2 Examine the site 22

1.3 Ground level 22

1.4 Excavation & preparation of foundation for concrete 22

1.5 Shoring 22

1.6 Surplus excavated materials 22

1.7 Rates to include for excavation items 22

1.8 Measurements for excavation 23

2.0 Concrete

2.1 General 23

2.B Materials 24

2.C Mixing and placing of concrete 25

2.D Construction joints 27

2.E Tests for concrete 28

2.F Vibration of concrete 28

2.G Grade of concrete 28

2.H Form work 29

2.I Steel reinforcement 29

21
 1.0 EXCAVATION AND EARTHWORK :

1.1 GENERAL

The excavation will generally refer to open excavation of foundation wet or dry and in
all sorts of soils.

1.2 EXAMINE THE SITE

The Contractor shall visit and ascertain the nature of the ground to be excavated and
the work to be done and shall accept all responsibility for the cost of the work involved.

1.3 GROUND LEVEL

Before commencement of excavation spot levels on an approved grid covering the entire
plot shall be taken by the Contractor in consultation with the Engineers representative.

1.4 EXCAVATION & PREPARATION OF FOUNDATION FOR CONCRETE

Excavation shall include removal of all materials of whatever nature at all depths and
whether wet or dry necessary for the construction of foundation.

1.5 SHORING

The sides of the excavations should be timbered and supported in such a way as is
necessary to secure these from falling in, and the shoring shall be maintained in
position as long as necessary. The contractor shall be responsible for the proper design.
.

1.6 SURPLUS EXCAVATED MATERIALS:

All excavated materials certified as surplus and not useful shall be removed by the
Contractor from the site in an approved manner.

1.7 RATES TO INCLUDE FOR EXCAVATION ITEMS

Apart from other factors mentioned elsewhere in this contract, rates for the item of
excavation shall also include for the following :-

i) Clearing Site

ii) Setting out works as required.

iii) Providing shoring and shuttering to avoid sliding of soil and to protect adjacent
structures and subsequently by removing the same, if not started separately in the
schedule of quantities.

iv) Bailing and pumping out water as required and directed.

22
 v) Excavation at all depth (unless otherwise specified in the Schedule of quantities)
and removal of all materials of whatever nature wet or dry and necessary for the
construction of foundation underground reservoir etc. and preparing bed for laying
concrete.

vi) Sorting out useful excavated materials and conveying beyond the structure and
stacking them neatly on the site for back filling or re-use as directed.

vii) Necessary protection works involving, labour, materials, and equipment to ensure
safety and protection against risk or accident.

viii) Drilling of small holes as directed to explore the nature of substrata if necessary.

1.8 MEASUREMENT FOR EXCAVATION

Excavation for foundation of columns, base shall be measured and paid net as per
drawing, dimensions of concrete (bed concrete where so specified) and the lowest level
in regard to length and breadth and depth shall be computed from the excavation levels
and ground levels taken before excavation for that area. Any additional excavation
required for working space, form work, planking, shuttering for concrete work,
dewatering and strutting etc. shall not be measured and shall not be paid for separately
but rates quoted for excavation shall include for all these factors. No increase in bulk after
excavation shall be allowed.

2.0 CONCRETE

2.1 GENERAL

A.1 SUPERVISION

Contractor shall employed a competent person approved by the Engineer for supervise
all stages in the preparation and placing of the concrete. All cubes should be made and
necessary site tests carried out under his direct supervision in the presence of
Engineer’s representative.

A.2 APPROVAL OF CONCRETING ARRANGEMENT ETC.

Before commencement of construction the contractor shall submit detailed

arrangements for concreting, system of form work and all other devices which he
proposes to use for the construction of structural frame work for approval of
Engineer’s representative.

A.3 SAMPLE AND TESTS

Every facility shall be provided by contractor at site to enable the Engineer’s

representative to select samples, get contractor to collect samples and carry out tests on
the materials and construction. At least l0% of the cube tests should be carried
out in Laboratory/ Institution approved by the Engineer’s representative. If those

23
 tests shows that strength of cubes do not comply with the acceptance criteria of
specifications, the contractor will be responsible for replacement of the defective
construction. The necessary cost of all such sampling and testing has to be borne by the
contractor.

A.4 REJECTED MATERIALS

All materials which have been damaged, contaminated or have deteriorated or do not
comply in any way with the requirements of this specification, shall be rejected and
shall be removed immediately from the site at the Contractor's own expense.

A.8 EQUIPMENT

The contractor shall keep at work site testing equipment for aggregate and concrete, viz.
test sieves, balance, slump cones, concrete cube testing machine etc all items required.

2.B MATERIALS

All materials shall be of approved quality as per relevant specifications/or as

specified in the contract.

B.1 CEMENT

a) Ordinary portland cement and Portland Slag Cement shall conform to the BS
standards..

b) Cement at site shall be stored in dry weather shed built at the cost of the
contractor. Cement must not be stacked in more than l0 bag height..

c) The contractor shall be fully responsible for the quality of cement brought by him
at the work site.

B.2 AGGREGATE

Aggregate shall conform to BS EN 12620:2013.

B.3 FINE AGGREGATE: SAND

a) The fine aggregate - sand shall be hard, strong, dense, durable clean with
uncoated grains. The maximum size of the particles shall be 4.75 mm and shall
be graded down. The sand shall not contain any harmful materials such as
iron, Pyrites, coal, mica, silt, clay, alkali, sea shells organic impurities, loam etc.
or in case of reinforced concrete work, any materials which might attack the
reinforcement or detrimental to concrete. Aggregate, which are chemically

24
 reactive with the alkalies of the cement,shall not be used. The maximum quantity
of deleterious materials shall not exceed the limit specified in the relevant I.S.
Specifications. The silt content shall be within 8%.

B.4 COARSE AGGREGATE

a) Coarse aggregate shall consist of hard, dense, durable uncoated crushed rock.
Gravel aggregate shall be allowed to be used only if specially specified in the bill
of quantities. Otherwise it shall be taken that only crushed rock shall be permitted
as coarse aggregate.

b) The aggregate shall be free from soft, friable thin or long laminated pieces.
Aggregate shall be free from injurious amounts of alkali, organic matter and
other deleterious materials. Flacky or weathered stones shall not be used. The
maximum percentage of deleterious materials shall not exceed those specified in
the relevant I.S. specification.

c) The contractor shall arrange to supply coarse aggregate of nominmal size

conform to the grading in the limits specified in BS EN 12620:2013.

d) Size of Aggregate :

i) Generally for reinforced concrete work, nominal maximum size of

agreegate be 20 mm graded suitably.

e) In selecting the aggregate, the contractor shall satisfy himself that the source is
suitable for regular supply and a watch shall be maintained that the particles
shape and grading remain reasonably uniform throughout the progress of work.

B.5 WATER

Water used for both mixing and curing shall be clean and free from injurious
amounts of deleterious materials which are likely to affect the strength or durability
of concrete. Water containing any sugar shall not be allowed for use. Water is to be
tested in accordance with BS EN 1008:2002. The pH values of water shall generally
be not less than 6.

2.C MIXING AND PLACING OF CONCRETE

C.1 CEMENT

Cement shall be batched by weight even though a ggr ega t e are batched by volume.

C.2 AGGREGATE

The aggregate shall be batched by volume, the form as used shall be of the correct
sizes to be certified by the Owner/Architects before use. Heaping of aggregates on
25
 the form is prohibited and aggregates shall be filled level in form and struck off
with a horizontal timber or steel rule. Where sand is measured by volume, bulkage
allowance as determined by the Owner/Architects shall be accounted for while
measuring sand.

C.3 WATER

Water shall be measured either by volume in calibrated tanks/vessels having

conical shape narrow at top or water shall be weighed.

C.4 MIXING OF CONCRETE

a) Machine Mixing

Concrete shall be mixed in Mechanical Mixer. Mixing shall be continued until there
is uniform distribution of materials and the mass is uniform in colour and
consistency

b) Hand Mixing

Hand mixing shall not be permitted except for unimportant structural

members. When hand mixing is permitted it shall be taken to ensure that the
mixing is continued until the mass is uniform in colour and consistency

C.5 TRANSPORTING, PLACING, COMPACTION AND CURING OF CONCRETE

C.6 TRANSPORTING

Concrete shall be handled from the place of mixing to the place of final deposit as rapidly
as practicable, by method which will prevent the segregation or loss of any of the
ingredients. If segregation occurs during transport, the concrete shall be remixed
beforeuse. The concrete shall be placed in position and compacted before the initial
set of cement has commenced and shall not be subsequently disturbed. During hot or
cold weather concrete shall be transported in deep container to reduce loss of water by
evaporation during hot weather and loss of heat during cold weather. Deep
containers are specified on account of their lower ratio of surface area to mass.

C.7 DROPPING OF CONCRETE

Concrete shall not be dropped into position from a height greater than l.0 meter
unless directed otherwise by Engineer’s representative.

C.8 DEBRIS ETC. REMOVED

All debris, saw dust etc. shall be removed from the shuttering before any concrete is
placed..

26
C.9 PROTECTION AND PLACING IN LAYERS

Concrete shall be placed into t he forms in layers not exceeding 300 mm (approx) in
thickness. .

C.10 COMPACTION

Concrete shall be thoroughly compacted during operation of placing by the use of

Mechanical Vibrators. Sufficient number of vibrators (including stand by) of adequate
capacities shall be used for compaction of concrete.

C.11 CONTINUOUS CONCRETING

Concreting shall be carried out continuously up to predetermined positions of

construction joints. The position and arrangement, for construction joints shall be
approved by the Engineer’s representative.

C.12 PACKING ROUND REINFORCEMENT

In the case of reinforced concrete work, the concrete shall be carefully consolidated
and packed round the reinforcement and care shall be taken to ensure that
reinforcement is not displaced during the placing and compaction of concrete.

C.13 CURING

All concrete work shall be water cured for a minimum period of 7 days after concreting
or as directed by Owner/Architects. Horizontal surfaces shall be kept covered with
water ponded by means of bunds and vertical surfaces like those of columns, fins etc. by
burlaps kept constantly wet with water sprays.

2.D CONSTRUCTION JOINTS

D.1 GENERAL

a) Location

The position of all construction joints shall be as approved by the Engineer’s

representative.

D.2 CONSTRUCTION JOINTS IN SUPERSTRUCTURES :

a) Column

Joints shall be formed horizontally above top of foundation and 75 mm below the
lowest soffit of the beams meeting at the head of the column.

b) Beams
27
 Concrete in the beams shall be placed throughout without a joint but if the
provision of joint is unavoidable the joint shall be vertical and at positions
approved by the Engineer’s representative.

c) Slab

Where the joint is unavoidable it shall be vertical and parallel to the principal
reinforcement. However, if joints is required to be provided at right angles to
the principal reinforcements it shall be vertical and at l/3rd to l/4th position of
span/at positions approved by the Engineer’s representative.

2.E TESTS FOR CONCRETE

Tests shall be conducted in accordance with BS EN 12390.

2.F VIBRATION OF CONCRETE :

a) Water Cement Ratio

The water cement ratio (by weight) for all vibrated concrete (except controlled
concrete) shall generally conform to relevant BS. provision and it shall not be
varied unless otherwise directed. In respect of "Design Mix" the water cement
ratio shall be as determined in the laboratory mix design suitable for vibrated
concrete.

b) Placing

Concrete shall be placed in layers not over 45 to 60 cm (l8 to 24 inches) deep

and each layer shall be vibrated into places by methods which will not permit
the ingredients to separate. Surfaces shall be smooth and free from voids
caused by stone pockets, where necessary vibration shall be supplemented by
hand spading to secure these results.

c) Number and size of vibrators

Vibrators shall be of sturdy construction, adequately powered. The vibration

shall be sufficiently tense to cause the concrete to flow or settle readily into place

2.G GRADE OF CONCRETE

The concrete shall be of grades designated as Grade 10, Grade 20, Grade 25, of
cube crushing strengths as specified in BS8110.

28
2.H FORM WORK

H.1 MATERIALS AND DESIGN

a) The form work shall be of approved dressed timber of not less than 3.5 cms
thick except where otherwise stated. As an alternative sufficiently rigid steel/ply
board shuttering of approved design may be used.

b) The form work shall conform to the shape, lines and dimensions to suit the
R.C.C. members as shown on drawing. Form work shall be adequately
designed to support the full weight of workers, fresh placed concrete without
yielding to settlement or deflection and to ensure good and truly aligned concrete
finish in accordance with the construction drawings.

2.I STEEL REINFORCEMENT

I.1 MILD STEEL BARS / HIGH STRENGTH DEFORMED BARS

Reinforcement bars shall conform to BS 4449:2005.

I.2 CLEANING OF REINFORCEMENT

Before steel reinforcement is placed in position, the surface of the reinforcement shall
be cleaned of rust, dust, grease and any other objectionable substances.

I.3 BAR BENDING SCHEDULE OF REINFORCEMENT

On receipt of structural drawing, Contractor shall prepare bar bending schedule of

reinforcement.

I.4 PLACING AND SECURITY

Reinforcement bars shall be accurately placed and secured in position and firmly
supported or wedged by precast concrete blocks of suitable thickness at sufficiently
close intervals so that they will not sag between the supports or get displaced
during the placing of concrete or any other operation of the work.

I.5 BINDING WIRE

The reinforcement shall be securely bound wherever bars cross or whenever required
for with 20 gauge soft black annealed steel wire.

29
 Section 6

TECHNICAL SPECIFICATION FOR STEEL WORK

TABLE OFCONTENTS PAGE NUMBER

1. General 31

1.2 E r e c t i o n 31

2. Steelwork 31

2 . 1 Structural Steelwork 31

2.2 O t h e r Steel work 33

2.3 S t e e l Ladders 33

2.4. Hand railing 34

2.5 Bolts and Nuts 35

2.6 Submissions by Contractor 35

2.7 Manufacturing and Workmanship 36

2.8 Painting and Protective Coatings 38

2.9 Inspection and Tests 42

2.10 Corrosion Resistant Materials 42

2.11 Box and Tubular Sections 43

2.12 Paint Systems 43

30
 1. General

Fabricate, Supply and installation of steel Aerator structure

Cascade type steel Aerator shall be fabricated with mild steel to meet the requirement shown
in drawings and accordance with specifications and erection the structure as shown in the
drawings.

1.2 E r e c t i o n
The steel structure to be erected on top of the concrete foundation b y u sing u niver sa l
b eams as shown in drawings and fasten to the concrete with 16mm steel anchors bolts
d r i v e n in to the concrete.

2. Steelwork

2 . 1 Structural Steelwork

This Section specifies the provision, fabrication, erection, connection, grouting, galvanizing and
shop painting of structural steelwork.

Rolled structural steel sections shall be mild steel complying with the requirements of BS EN
10025 Grade S275 and which shall include test certification, subject to the additional
requirements of BS 449. The dimensions, tolerances and properties of the structural sections
shall conform to BS 4 or BS EN 10056. Structural steel shall not be manufactured on site
without prior approval.

Where the use of proprietary product designs of prefabricated building frames is proposed, the
standards to which they are manufactured shall be equivalent to those stated above.

For each batch of steel supplied to the Works, certified mill test reports or certificates issued by
the mill, as evidence of compliance with the specified material standards for chemical
composition and mechanical properties, shall be provided. If authorized by the Engineer, the
steel shall be tested by an independent testing authority for compliance with the specified
material standard.

Shop drawings shall be prepared for structural steelwork showing relevant details of each
assembly, component and connection, together with information relevant to fabrication, surface
treatment, and erection; including

• identification marks and orientation of members;

• steel type and grade;

• dimensions, cambers as applicable;

• fabrication methods (e.g. hot or cold forming, post-weld heat treatment); 31

• location, type and size of welds or bolts; and categories;

• Required fixings for adjoining building

elements;

• location of temporary connections;

• surface preparation methods and coating system;

• procedures for shop and site assembly; and erection including temporary bracing;

• lifting and support points, and temporary bracing if required, for handling and transport.
5 days shall be provided for inspection of the shop drawings by the Engineer, and fabrication
shall not commence until approval has been provided by the Engineer to the Contractor.

Structural members shall be provided in single lengths unless otherwise required or approval for
splicing is obtained. If beam members have a natural camber but within the straightness
tolerance, then erect them with the camber up.

Edges of steel shall be treated with all burrs and sharp arises removed by light grinding. Prior
blast cleaning, remove loose mill scale and rust, clean off oil, grease, dirt, loose weld metal and
slag, and other foreign matter. All structural steelwork shall be abrasive blast cleaned and
followed by galvanised zinc coated to the BS standards as specified above for structural steel.
Zinc coating shall be free of lumps, blisters, grit, uncoated areas, acids and black spots, flux or
other imperfections.

Inspections, with 3 days notice to the Engineer, shall be made on completion of fabrication prior
to surface preparation, after surface preparation, after protective coating on delivery, and on
completion of erection prior to cladding. Structural steel members shall be suitably marked for
identification, setting out, location, bolting categories, and connection to other steelwork.

Structural steel shall be fabricated and erected in a safe manner without interfering with or
damaging other adjacent structures. Temporary connection cleats shall not be attached without
prior approval, unless shown on shop drawings. Temporary connections shall be removed on
completion and surfaces restored. Thermal expansion and contraction movements shall be
allowed for during erection. Bolt holes shall be pre-drilled, and not hand flame cut without
prior approval.

The structural steelworks comprise mainly the fabrication and erection of the following
constructions:

columns and beams;

roof purlins;
Steel water storage tanks
other structural steelwork associated with the specified mechanical and electrical plant.
32
 2.2 O t h e r Steel work

The Contractor shall fabricate, supply, deliver and install all other steelworks shown on the
drawings or as necessary for the installation of all mechanical and electrical equipment such as
listed below and all other associated parts in accordance with the Specification and his
approved shop Drawings, and shall comply with the requirements of the relevant Standards,
unless otherwise specified or instructed by the Engineer.

The steelworks shall comprise of the following main items:

• open mesh, gratings and frames;

• covers to channels;

• Hatch opening covers and frames;

• chequerplate flooring, support angle frames and anchors;

• GMS flanges and bolted connections, if any;

• anchorings and fixings;

• step irons, ladders and pipe inserts;

• staircases, landings and platforms;

All items to be cast-in concrete, such as anchor bolts, steel frames and tie bars, etc., shall be
fixed and cast in by the Contractor in accordance with the prior approved shop drawings.
The Contractor shall ensure that all of the fabrications and items as mentioned above are on-
site in due time in order to avoid interruptions during the execution of concrete works. If
recesses are provided, these shall be sufficiently larger in size than the dimensions of the
fabrication or items to be cast in.

2.3 S t e e l Ladders

Steel ladders shall generally comply with BS 4211 except where otherwise specified. Ladders
shall be fabricated of solid mild steel sections as shown on the Drawings. The stringers shall be
flat section and shall be flanged and drilled for fixing at both ends. Ladders over 3 metres long
shall have additional intermediate stays at not more than 2.5 metre centres.

Rungs shall be solid, equally spaced, shouldered at each end, and securely rivetted into
countersunk holes.

All ladders rising more than 2.50 metres from lower platform or ground level to the top rung shall
have safety cages which shall be constructed of three flat verticals supported by flat hoops with
a diameter of 750 mm. The hoops shall be approximately 700 mm centres and the first hoop
shall be 2.4 metres above ground or platform level.
33
 2.4. Hand railing
Hand railing shall consist of solid (parallel) galvanised mild steel section satisfying the
requirements of BS (449, 4360) with handrails and standards designed to withstand a horizontal
force at handrail level of 740 Newton per metre run. The deflection of rails shall not exceed 0.8
percent of their span between posts and the deflection of posts shall not exceed 0.8 percent of
their height. Posts and handrails shall be not less than 40 mm in diameter, or as shown on the
Drawings. The Contractor shall ensure that unless specified to the contrary all hand railing shall
be of uniform appearance and manufacture.

Horizontal mounting flanges shall be drilled for not less than three bolts with two bolts on a line
parallel to and on the walkway side of the line of the handrailing. Vertical mounting flanges shall
be drilled for not less than two bolts the line through the bolts being vertical. Fittings shall be
screwed or secured with grub screws. The posts shall be set at not more than 1.5 m centres, or as
shown on the drawings. When provided in sections, hand-railing shall be gained together with
purpose made fittings secured by screws or grub screws.

Openings for ladders, etc., shall be closed with two galvanised mild steel hanging chains which
shall be secured at one end and detachable at the other.

Bolts, nuts and washers shall be hot-dip galvanized.

The grouting under hand-railings shall be executed with a synthetic resin mortar based on
epoxy and to be approved by the Engineer.

Detailed drawings of handrailing shall be submitted by the Contractor for the approval of the
Engineer.

2.5 Bolts and Nuts

Steel bolts and nuts for structural steelwork shall be high strength friction grip bolts conforming
to BS 4395 or black bolts conforming to BS 4190 as detailed on the Drawings. Washers shall
conform to BS 4320. High strength friction grip bolts shall be used in conjunction with approved
proprietary load indicating washers. They shall be hot-dipped galvanised commercial bolts, nuts
and washers, unless otherwise shown on the drawings. Sizes shall be M20 unless otherwise
shown.

For roofing, purlin connections shall be by standard purlin bolts as supplied by the roofing
manufacturer. Masonry anchors shall be standard hot dipped galvanised chemical anchors.
Foundation bolts shall be supplied with 2 hexagonal nuts and 2 oversize flat washers, and with
sufficient thread to permit the levelling nut to be set below the base plate. Anchor bolt groups
shall be provided with accurate set-out templates when casting in

34
 2.6 Submissions by Contractor
Prior to the manufacture of any of the items, or steelwork fabrication the Contractor shall submit
full fabrication details, drawings and calculations required, and full details of his proposed
procedure, qualification and methods of fabrication to the Engineer for approval.

This information shall include (but not be limited to) the following details where they
are relevant:

(i) The method of plate forming

(ii) Joint design

(iii) Proposed welding procedure and proof of competence of welders

(iv) Method of straightening, sizing and hydrostatic testing.

(v) Quality control and inspection procedures.

Prior fabrication, the Contractor shall submit to the Engineer for his approval working drawings
of the steelworks and general arrangement, with each component clearly marked. Structural
calculations shall accompany the working drawings for verification of details on the
Employer’s Drawings or for additions by the Contractor; for approval of the Engineer for
beams, columns, mounting plates, unequal angle supports, stiffening plates, welds, anchors and
bolting.

In the event of unavailability of certain materials and steel sections, deviations from the original
design can be made provided they are approved by the Engineer. In such cases the Contractor
shall submit to the Engineer his calculations for the proposed design together with copies of the
corresponding working drawings.

The Contractor shall submit to the Engineer for his approval calculations of weights of all
relevant steel structural components. The basis for the calculations shall be the measurements of
items as indicated on the approved working drawings multiplied by their number and the
specific weight of steel (= 7850 kilograms/cubic metre) or specific weight per metre and/or
square metre.

These calculations shall be submitted in two copies together with two copies of corresponding
working drawings.

35
 2.7 Manufacturing and Workmanship

All Facilities shall wherever possible be carried out in covered and well equipped workshops.
Where work must be carried out on Site, and as approved by the Engineer, the Contractor shall
take adequate measures to protect work against damp, draughts and extremes of temperature.
The Contractors proposed measures shall be submitted to the Engineer for approval before any
metal delivery commences. Welding shall be carried out as specified below. Unless shown
otherwise welds shall be 6mm continuous fillet welds.

The Specification shall apply to all manufacturing, delivery, storage and workmanship.

2.7.1 Fabrication Tolerances

The general tolerance on all dimensions shall be A 2 mm. Holes shall be aligned such that
fasteners can be freely inserted through the members at right angles to the contact face. Where
holes in members cannot be aligned without damaging or distorting the structure or (unless the
Engineer shall permit) reaming holes, the member or members shall be rejected.

A structural member shall not deviate from straightness (or from the specified shape) by more
than:

• 1/1,000 of the lengths between lateral restraints in the case of compression members
and beams, or

• 1/500 of the overall lengths (maximum 25 m) in the case of other members.

A structural member shall not deviate from its intended length by more than:

• A 1 mm in the case of compression members faced at both ends for bearing, or

• 0 + 0.4 mm in the case of other members.

Lengths of components shall be such that cumulative variations do not prejudice the accurate
alignment of the completed structure.

Where two steel surfaces are required to be in contact to effect a bearing or frictional contact,
the surfaces shall be prepared so that at least 90% of the area is touching before any clamping
force is applied.

2.7.2 Welding

All welding carried out during fabrication or erection shall be in accordance with the
requirements of BS EN 1011 and as shown on the approved detail shop drawings. All
connections shall be welded in such a manner as to make the finished connections neat and
36
smooth in appearance and suitable for coating and painting. All slag shall be removed and all
sharp projections shall be round smooth.

Before welding is commenced either in the fabrication shop or on Site, weld procedure tests
shall be carried out in accordance with BS EN ISO 15607 where directed by the Engineer. All
welding procedures shall be qualified, and prior approved by the Engineer. Other than any site
welds shown on the approved shop drawings, if any, all welding shall be carried out in the
fabrication shop, unless otherwise approved by the Engineer.

All welders employed either in the fabrication shop or on Site shall pass qualification tests
relevant to the weld procedures in use in accordance with BS 4871. Welders shall have
satisfactory evidence of having been engaged in welding for at least 9 months in the preceding
12 month period. If the work of any welders employed on the Contract is unsatisfactory, the
Contractor shall find further candidates and carry out further welder qualification tests as are
necessary to ensure that the welding is up to required standard.

Welds shall be subjected to non-destructive testing by processes which may include but shall
not necessarily be limited to radiographic, ultrasonic, magnetic particle, or dye penetrant
methods, depending on the type of weld and its position in the structure. The standards of
acceptance shall be as defined in BS 5500: Table 5.7, unless specified otherwise. Fabrication
shops shall have quality procedures to ensure all works completed to standard. The Contractor
shall examine all welds (or shop tests) prior to issuing notification of the completion of
fabrication to the Engineer.

If any work shows defects or fails to comply with the requirements of the Drawings or
Specification for any reason it shall be repaired or rejected, even though it may have been
carried out by qualified welders using approved procedures.

Welding Consumables

All welding consumables (electrodes, wire, filler rods, flux, shielding gas and the like) shall
comply with the requirements of BS EN 1011.

Weld electrodes for metal arc welding shall conform to BS EN ISO 2560 and comply with the
requirements of the appropriate weld procedure.

2.7.3 Dissimilar Metals

Where metals dissimilar to those specified above are used in close proximity to structural steel
members or their connections, contact between such metals and the steel shall be avoided
unless the Contractor can demonstrate to the satisfaction of the Engineer that contact between
the dissimilar metals will not lead to galvanic corrosion.

Contact between aluminium or aluminium alloy and galvanized mild steel will be permitted.
For fixing aluminium to steel structures, bolts, nuts, washers and screws shall be galvanized.
37
Where galvanized parts might otherwise become sacrificial anodes to the main structure, or
where the electrolytic potential difference exceeds 250 mV, the parts shall be separated by an
insulating medium of adequate strength.
2.8 Painting and Protective Coatings

All work shall be carried out in accordance with DIN EN, BS or equivalent
standard.

Where blast cleaning is specified prior to painting, the cleaned surfaces shall have maximum
amplitude not exceeding 100 micron.

All coating shall be obtained from one approved manufacturer and applied strictly in accordance
with the manufacturer's instructions. The source of supply shall not be altered without the
Engineer's approval. The colour of the coats used shall be approved by the Engineer and where
possible alternate layers shall be of different colours.

Where surfaces are joined during fabrication, they shall be brought together while the final
protective coat is still wet.
After welding and fabrication, all welded areas shall be thoroughly cleaned and touched up as
specified with the appropriate priming system. Application methods shall be as recommended
by the manufacturer depending on the items to be protected.
2.8.1 Paint General

All paints shall be complying with the following specification,

.
1. The Epoxy Paint should be satisfied the maximum concentrations prescribed in ASTM F
963 (2003) which prescribes limits for toxic elements in paints to be used for toys.

2. The Epoxy Paint should be no toxic

3. Non Volatile Content should be 97% or more.

4. Should be applicable on Oil stain or water wetted surface using Brush, Roller, and Sprayer

5. Possibility of application without sand blasting

6. Should be able to obtain minimum 100 Microns thickness in one application

7. Should resist to water with Alum - Al2(SO4)3, and Chlorine (Cl)

8. Viscosity : Resin – Thixotropic Medium viscosity

Hardener – 170 ± 20 CPS at 200 -300C

9. Tack free condition should be obtained from 4-5 hours (200 -300C)

10. Minimum Coverage should be 70Sq.feet / kg at 100 microns thickness

38
 2.8.2 Painting General
Preparation, application and conditions of work shall be in accordance with appropriate painting
techniques and relevant standards and specifications.

2.8.3 Preparation of Surfaces to Receive Paint

Before paint is applied to any surface, the appropriate surface preparation, as described in the
Contract, shall be carried out in accordance with the following and shall comply with the relevant
standards and specifications.

(a) Blast Cleaning

Blast cleaning shall be carried out in accordance with the correct techniques and relevant
standards unless stated elsewhere, using fine chilled iron grit or shot as necessary.

The abrasive used for blasting shall be free from contamination and any recovered materials
shall be cleaned to the satisfaction of the Engineer. The maximum amplitude (peak to trough)
of the blast cleaned surface shall not exceed 100 microns.

Surfaces shall be protected within four hours of having been blast cleaned.

(b) Pickling

Steel shall be pickled by a suitable method in accordance with relevant standards and
specifications. The first priming coat of paint shall be applied as soon as the steel has dried and is
still warm.

(c) Flame Cleaning

The flame cleaned surface shall be cleaned of all loosened material. The first priming coat shall
be applied while the steel is still warm. The sequence of operation for flame cleaning steel work
shall be planned and controlled to avoid the risk of distortion and buckling.

(d) Mechanical Cleaning

Mechanical cleaning shall be carried out by power driven tools such as abrasive grinding discs,
chipping hammers or needle guns, followed by steel wire brushing and dusting to remove all
loosened material. Excessive burnishing of the metal through prolonged application of rotary
wire brushes shall be avoided.

Surfaces shall be protected within four hours of having been mechanically cleaned.

Note: Methods of surface protection utilising (b), (c) or (d) will only be permitted with
the written permission of the Engineer.

(ii) Welds and Weld Affected Areas

Unless otherwise described in the Specification, welds and surfaces, which have been affected
by welding, shall be prepared for painting by the same process as described in the Contract 39
for
the adjoining metal.

(iii) Painted Surfaces

Painted surfaces shall be cleaned of all dust immediately prior to the application of further paint.
Any loose paint and rust shall be removed. Areas contaminated by oil and grease shall be
cleaned with oil and grease solvents. Where required by the Engineer, the whole surface shall
then be cleaned by washing down with a solution of an approved liquid detergent, followed by
rinsing with clean fresh water and allowed to dry thoroughly before paint is applied. Old painted
surfaces shall be abraded to provide a key for subsequent coats.

2.8.4 Application of Paint

Preparation, application and conditions of work shall be in accordance with an appropriate

painting technique and with relevant standards and specifications.

All primers, undercoats and finishes shall be applied by brush or airless spray, except where
otherwise specified.

Consecutive coats shall be in distinct but appropriate shades. All paint shall be supplied from
the store to the painters, ready for application, and addition of thinners or any other material
shall be prohibited. Any instructions given by the paint manufacturer shall be strictly followed.

All painting shall be carried out by the painters under supervision. Paint shall be applied to the
dry surface, which has been prepared in accordance with Clause 2.8.3. Paint shall not be
supplied under the following conditions:

(i) When relative humidity rises above 90%.

(ii) During rain, fog or mist.

(iii) When condensation has occurred or is likely to occur on the steel.

Two-pack paints of epoxy resin type shall not be applied when the temperature falls below 5 °C
or as required by the paint manufacturers, nor shall it be applied when the temperature is likely
to fall below the specified minimum during the curing period. Unless otherwise agreed by the
Engineer, each coat of paint shall be applied by the method described in these Specifications to
produce a continuous film of uniform and even thickness.

As soon as the first priming coat has dried, an extra stripe coat of paint shall be applied by
brush, to edges, corners, crevices, bolt heads, rivet heads and welds, using paint of similar
composition to the priming coat but of a contrasting shade. Successive coats shall have
different shades for identification and each coat shall be thoroughly dry before the application of
a further coat.
The dry paint film thickness shall be measured by Elcometer or other instruments approved by
the Engineer. In order to obtain the dry film thickness specified, the Contractor shall ensure that
the coverage rate given by the paint manufacturer will enable this thickness to be obtained. Wet
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film thickness gauges may be used for checking but shall not be used after the expiration of the
"pot life" stipulated by the manufacturer and the paint of limited "pot life" shall not be mixed
with fresh paint or have thinners added to them. Strength of adhesion shall be measured with
an adhesion tester and this value shall not be less than 10 kg/cm2. Painted fabricated
steelwork which is to be stored prior to erection shall be kept clear of the ground and shall be
laid out or stacked in an orderly manner that will ensure that no pools of water or dirt can
accumulate on the surface. Suitable packings shall be laid between the stacked materials.
Where cover is provided, it shall be ventilated.

Where primed painted steel work is to be stored outdoor before being over coated it shall not be
exposed for periods longer than the following:

Period
Etch primers
Ni
l

Etch primers on metal coatings Two weeks

Chromate paint Two weeks

Zinc chromate primers Two weeks

Zinc rich primers 25/37 microns thick Four weeks

2.8.5 Repairs to Damaged Surfaces

Areas of paint, which have been damaged, shall be cleaned to bare metal or metal coatings
where this has been applied and the edges of the undamaged paint bevelled with sand paper.
Where a metal coating has been damaged, the affected areas shall be rubbed down to remove
excessive rust, cleaned and an additional coat of an approved primer applied. The full specified
painting system shall then be re-applied and new paint shall overlap the existing paint by at
least 50 mm all round the affected part.

2.8.6 Painting of Existing and Previously Painted Surfaces

In general, all surfaces shall be suitably prepared by cleaning, abrading and degreasing, etc and
may be repainted with the finishing systems as detailed in these Specifications. Decorative
paints, such as gloss finish or similar type finishes, may be applied to clean, dry and well-
prepared surfaces direct without primer, as approved by the Engineer.

Exposed surfaces should be primed and brought forward in the normal manner, that is: prime
where necessary followed by undercoat and gloss finish as detailed in these Specifications, but
sound surfaces may in general be recoated with the finishing paints only. Where two pack
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materials have been used and where adhesion of the new paint may be difficult, the weakness
in adhesion may be overcome with the use of an etch primer. Care should be taken to
avoid over application of this primer since this can create additional problems.

2.8.7 Paint Specifications

The Contractor shall give full details of the preparation, type of materials, methods
and sequences he proposes to use to comply with the requirements for the protection of
the equipment against corrosion. In the case of materials he shall submit details of the basic
raw materials source, volatile matter content, nature of solvent, number of constituents
including the percentage of epoxy resin, type of application, coverage, time interval
between coats, recommended number of coats, toxic properties, shelf life and details of
`patch' repairing.

No thinners shall be used unless approved by the paint manufacturer. To prevent loss
of adhesion and solvent entrapment, the paint manufacturer's instructions shall be rigidly
followed particularly with respect to the minimum and maximum periods between
coats and the permissible temperature and humidity range for application.

Care shall be taken to maintain the full paint thickness at all corners and edges and special
attention shall be given to the application of protective coatings after welding. Primer
and subsequent coats shall be in different colours.

Power tool cleaning may only be carried out on metal surfaces, which may be difficult to
blast because of their location or shape. These surfaces shall be 100% disc cleaned to a
surface finish equivalent to one that has been sand or grit blasted. Where welds occur
within these areas or where these areas cannot accommodate a power disc, an air hammer
shall be used. Power tool cleaning will only be permitted after review by the Engineer.

The Contractor shall submit for review an overall colour scheme for the exposed surfaces of
all equipment. All final coats shall be in the colours thus approved.

2.9 Inspection and Tests

The plant and equipment shall be inspected and reviewed at the various stages of the coating
application both at the Manufacturer's Works and at the site of the work. Samples may be
taken from the paints as delivered and submitted to such tests as are deemed necessary.
The completed paint systems
shall be tested by instruments to ensure that the protection is of adequate thickness and is
free from pinholes and the direct measurement of adhesion shall be checked by the removal
of a small section of the coating. The Contractor shall supply
all instruments and apparatus required for carrying out such tests required by the Engineer.
2.10 Corrosion Resistant Materials
No blast cleaning or painting shall be applied to corrosion resistant materials such as
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stainless steels, Ni-resist cast iron, bronze and other metals used for seals, hot dip galvanized
surfaces, bearings, lighting fittings etc. All pipes with various diameters within the water
treatment facilities shall be protected by cathodic protection according to international
standards.

2.11 Box and Tubular Sections

Box and tubular sections shall be permanently sealed. All such sections shall be
thoroughly dried out using hot dry air before final sealing and painting is carried out.
After sealing, all sections shall be tested for air tightness.

2.12 Paint Systems

The following paint systems shall be used for the items of plant
listed.
The coatings shall be in accordance with the standards shown below and approved by the
Employer, and systems shall be designed to give a maintenance free period of at least ten
years.

USES: Steelwork exposed to weather and exposed to water from time to time.

PREPARATION: SA 2.5 Abrasive blast or equivalent cleaning to DIN EN ISO 8501:

2002-03
Standard.

PAINTING:

(a) Apply two-pack epoxy primer containing anti-corrosive pigment, two coats to a
total
100 micron DFT.

(b) Apply one coat epoxy undercoat to a 50 - 100 microns DFT.

(c) Apply two coats of two-pack epoxy finishing coat to a total DFT of 100

microns. Total DFT = 250 - 300 microns.

USES: Steelwork exposed to weather, such as platforms, ladders, hand railing, etc.

PREPARATION: SA 2.0 Abrasive blast or equivalent cleaning to DIN EN ISO 8501:

2002-03
Standard.

PAINTING:

(a) Apply alkyd based primer (long chain oil) with oxidised drying containing

43
 anti- corrosive pigment, two coats to a total 80 micron DFT.

(b) Apply two coats of alkyd based (medium chain oil) with oxidised drying finishing
coat to a total DFT of 80 microns.

Total DFT = 160 microns.

Note: This system can be used for galvanised works exposed to weather for decorative
purposes.

USES: Steelwork exposed to humid weather and requiring hard maintenance and
repairs.

PREPARATION: SA 2.5 Abrasive blast or equivalent cleaning to DIN EN ISO 8501: 2002-
03
Standard. PAINTING:

(a) Apply two-pack epoxy primer containing anti-corrosive pigment, two coats to a
total
100 microns DFT.

(b) Apply two coats of two-pack epoxy finishing coat to a total DFT of 100

microns. Total DFT = 250 microns.

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