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Engineering Spec

'Typical Civil and Structural engineering specification for Sewerage Works' aims to minimise variation of works quality whilst enhancing functionality of end product. It is applicable to both new and refurbishment projects. References have been made to various internationally accepted codes of practice and standard, adapting them to local conditions.

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0% found this document useful (0 votes)

462 views304 pages

Engineering Spec

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ENGINEERING WORKS SPECIFICATION

Typical Civil and Structural

Engineering Specification for
Sewerage Works

PED/SDQS/SPEC-CWS/SPEC/0808(017)

PREFACE
Indah Water Konsortium Sdn. Bhd. (IWK) is the national sewerage services company responsible to
plan, design, operate and manage the national sewerage infrastructure in Peninsular Malaysia. Since
its inception in 1994, IWK had seen through the steep improvements in the countrys lagging
standards in the sewerage sector.
Series of procedures, guidelines, standards, specifications and best practices had been developed and
introduced over the past decade to enhance the standards in the sewerage industry. This has resulted
in a better planned and well organised development of new sewerage systems to fulfil the whole life
infrastructure obligations. This continual effort is important in moving the industry to higher
standards which will uplift the image of our local sewerage industry.
This document contains the key Engineering Specification deliberately catering to the needs of Civil
and Structural works of sewerage facilities. It sets out the typical requirements of engineering works
detail aiming to minimise variation of works quality whilst enhancing the functionality of end product
in the construction of sewage treatment plant, pump station, sewer network etc. It is applicable to
both new and refurbishment projects.
The Typical Civil and Structural Engineering Specification for Sewerage Works is presented in
twelve (12) sections as follows:
Section 1.0
Section 2.0
Section 3.0
Section 4.0
Section 5.0
Section 6.0
Section 7.0
Section 8.0
Section 9.0
Section 10.0
Section 11.0
Section 12.0

: General
: Earthworks
: Concrete
: Formwork
: Steel Reinforcement
: Piling
: Structural Steelwork
: Sewers, Force Mains, Pipelaying, Manholes and Appurtenances
: Building Works
: Roadworks
: Drainage Works
: Miscellaneous

In the preparation of this document, references have been made to various internationally accepted
codes of practice and standard, adapting them to local conditions. Considerable assistance and
valuable advice have also been derived from panel of experts and such assistance is hereby
acknowledged.
Whilst complying with this specification is strongly encouraged, engineering discretion and best
advice need to be sought for betterment in case to case application.
It is IWKs hope and vision to see a better and sustainable sewerage infrastructure in the coming
years.

Prepared by
Planning and Engineering Department
Indah Water Konsortium Sdn. Bhd.
October 2008

Typical Civil and Structural Engineering Specification for Sewerage Works

Issue 01 / Rev 0
August 2008

ACKNOWLEDGEMENT
This document was a cooperative effort between IWK Planning & Engineering Department (PED),
IWK Capital Works & Refurbishment (CWRD), IWK Operation & Maintenance Department (OMD),
and SMHB Sdn. Bhd. To all, Planning and Engineering Department (PED) would like to express
recognition and appreciation to the following members in developing this document.

Ir. Abdul Rashid Abdul Rahman IWK OMD

Ir. Mohd Adnan Md Dom IWK PED
Ir. Moghan Muniandy SMHB Sdn. Bhd.
Ir. Mohd Taufik Salleh IWK PED
Ir. Tan Kok Hong IWK CWRD
Ir. Teh Teik Ho IWK OMD
Ir. Yam Soong Yeong IWK CWRD
Jamaiatul-Lailah bt Mohd. Jais IWK PED
Khor Bee Chin IWK PED
Ng Mee Weng SMHB Sdn. Bhd.
Stephanie Sim Lee Gaik IWK PED
Zakaria Mohd Yassin SMHB Sdn. Bhd.

Typical Civil and Structural Engineering Specification for Sewerage Works

Issue 01 / Rev 0
August 2008

Copyright Indah Water Konsortium Sdn Bhd,

2008

All rights reserved.

This publication is protected by copyright.

No part of this publication may be reproduced, distributed, transmitted, stored in a retrieval system, or
reduced to any electronic medium without the written authority of the company.

Typical Civil and Structural Engineering Specification for Sewerage Works

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iii

Table of Contents

TYPICAL CIVIL AND STRUCTURAL ENGINEERING SPECIFICATION FOR

SEWERAGE WORKS
Section 1

General

Section 2

Earthworks

Section 3

Concrete

Section 4

Formwork

Section 5

Steel Reinforcement

Section 6

Piling

Section 7

Structural Steelwork

Section 8

Sewers, Force Mains, Pipelaying, Manholes and Appurtenances

Section 9

Building Works

Section 10 Roadworks
Section 11 Drainage Works
Section 12 Miscellaneous

Typical Civil and Structural Engineering Specification for Sewerage Works

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Section 1 - General

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..............................................................................1-3

1.7

As-Built Survey ................................................................................1-3

1.8

Programme of Work.........................................................................1-4

1.9

Access Roads ..................................................................................1-6

1.10

Environmental and Social Protection Requirements....................1-7

1.11

Health, Safety and Environmental ................................................1-11

1.12

The Site...........................................................................................1-18

1.13

Access to the Site ..........................................................................1-18

1.14

Working Space and Work through Private Land.........................1-18

1.15

Trespass on Adjacent Property ....................................................1-19

1.16

Existing Services ...........................................................................1-19

1.17

Works in Roads and Footpaths ....................................................1-19

1.18

Claims for Damage to Person or Property...................................1-20

1.19

Amenities to be Preserved............................................................1-20

1.20

Works to be Kept Clear of Water ..................................................1-20

1.21

Discharge of Water and Waste .....................................................1-21

1.22

Temporary Fencing........................................................................1-21

1.23

Temporary Works Construction and Design ...............................1-21

1.24

Water Supply..................................................................................1-22

1.25

Power Supply .................................................................................1-22

1.26

Temporary Sanitary Conveniences ..............................................1-23

1.27

Site to be Kept Tidy .......................................................................1-23

1.28

General Hygiene and Medical Examination of Contractor's

Employees.......................................................................................1-23

1.29

Temporary Buildings for Use by Contractor ...............................1-23

1.30

Temporary Offices for the S.O. and His Staff ..............................1-24

1.31

Transport for S.O. and His Staff ...................................................1-24

APPENDIX 1.1:

Standard Compliance

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1.0 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.
As soon as practicable after receiving the order to commence the Works, the Contractor shall inform
the S.O. of the names of the suppliers from whom he proposes to obtain any materials, but he shall not
place any order, without the approval of the S.O. which may be withheld until samples have been
submitted and satisfactorily tested. The Contractor shall thereafter keep the S.O. informed of orders
for and delivery dates of all materials.
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.
Appendix 1.1 provides a list of standard compliance tabulating the relevant standards that need to be
complied with for the design and execution of specified civil works.
The acceptance of a tender based upon a Standard or Code proposed by the Contractor shall only
signify the S.O.s general approval to the use of such Standards or Codes and shall not make the S.O.
liable to accept a Standard or Code subsequently found to be inferior to the corresponding Standard or
Code.
Where the relevant standard provides for the furnishing of a certificate to the S.O. stating that the
materials supplied comply with all aspects with the standard, the Contractor shall obtain the certificate
and forward it to the S.O.

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

Typical Civil and Structural Engineering Specification for Sewerage Works

Approvals required from statutory authorities and agencies

Testing of sections of the Works (e.g. hydraulic testing of pipelines and leakage testing of
water retaining structures)
Mobilisation, time on site and removal of major items of Contractors Plant and temporary
facilities

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Dates when civil structures are specified to be available to commence plant installation

Off-site activities such as prefabrication of components

Plant and equipment installation, testing and commissioning

10.

Maintenance, operation and training

Each of the activity in the Overall Works Programme shall have the following information:
1.

Activity code, description, duration and the sequence with other activities

The earlier and latest start and finish dates with available float

The party responsible for each activity

The cost weightage for each activity with respect to the total cost of all the activities in the
Programme. The total weightage of all activities must add up to 1.

The installation quantities and forecast manhour requirements.

The six months Working Programme shall contain the sub-items which are breakdowns of the major
work items by area or zones, such that no activity shall have a duration exceeding 30 days. The
detailed Working Programme shall indicate the major activities involved in the sub-items, e.g.
formwork, reinforcement and casting and curing of concrete. The Programme shall identify the main
quantities of materials and other agreed relevant information.
The Contractor shall provide a concise master network diagram. The Contractor shall analyse the
CPM network using the precedence diagram method. The work breakdown structure will be the same
as that for the Overall Works Programme, and each major activity shall relate to the price breakdown
headings.
The activities presented in the programme shall be capable of indicating the required information
similar to that required for the Overall Works Programme.
The Contractor shall provide the S.O. with the six (6) months Working Programme and Weekly
Detailed Working Programme. The Contractor shall immediately report to the S.O. details of all
critical activities in delay and any delays the Contractor can foresee to future critical activities. If
necessary the Contractor shall consult the S.O. and submit a revised programme for his approval and
shall report the likely effect of these delays on the programme and the remedial action the Contractor
proposes to rectify the delay such as, but not limited to:
1.
2.
3.

increasing resources
increasing the hours worked
carrying out activities in parallel

The approval by the S.O. of any revised programme shall not be deemed to be consent to any
amendments of the completion dates or relieve the Contractor of his obligations under the Contract.
Within twenty-eight (28) days of the Commencement Date, the Contractor and the S.O. shall agree to
a schedule for weekly progress meetings covering the first six (6) months of the Works. The

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Contractor shall make himself available for any other meetings called for by the S.O. outside the
schedule.
The Contractor shall prepare the following programmes with increasing detail to demonstrate the
Contractors shorter term and detailed planning of the execution of the activities:
1.
2.

Six (6) Months Working Programme

Weekly Detailed Working Programme

The Six (6) Months Working Programme shall be submitted to the S.C. for approval monthly to cover
the period for the next six (6) months planned work. The hard copy of the programme must also
include the previous one (1) months progress. The electronic copy of the programme must also
include progress for the period from the beginning of the Contract.
The Weekly Detailed Working Programme shall be submitted to the S.O. for approval weekly and
must show at least the previous weeks progress and the future two (2) weeks planned work.
The Contractor shall issue relevant short-term programmes with method statements required in the
Contractor project Quality Assurance Plan. To accurately reflect the status of the Works, the
Contractors shall monitor, update, revise the programmes, and submit them to the S.O. in the
monthly or weekly progress meetings or at such other times as instructed by the S.O. All the
programmes submitted to the S.O. shall be in the electronic format using a project management
software to be approved by the S.O. Upon approval by the S.O., the programmes shall become the
current Working and Detailed Working Programmes.
In addition, the Contractor shall develop within 30 days of award of the Contract, S-curves for
cumulative financial and physical progress for the Works. These curves shall be up-dated monthly to
show actual progress versus planned progress including a schedule of outstanding commitment
figures. The Contractor shall provide explanations if the actual and planned progress differ
significantly.

1.9

Access Roads

The access roads to and within the Site shall be completed for the readiness of the civil works as
shown in the programme of work to permit plant erection and for easy access to the Employer and to
others. For this purpose, the access roads shall be completed up to the binder coarse which will
permit good and reasonable access at all times to complete the various sections of works as specified.
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.
It is intended that the final top wearing course shall be laid towards the later part of the Contract
period after the main construction and erection activities have been completed. Before laying the top
wearing course, the road surfaces shall be cleaned and all damaged portions including the road base
and sub-base shall be made good to the satisfaction of the S.O.
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.

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1.10 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.
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
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.

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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
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 dam site.
(d) Road and Traffic

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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

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.

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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
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;

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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.

1.11 Health, Safety and Environmental

Occupational Safety and Health Act 1994
The Contractor shall comply with the relevant requirements of this Act. The Contractor shall appoint
a Safety Officer and set up Safety Committee.
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 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.
The Contractor shall prepare and submit to the S.O. for approval a Safety Plan 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.
Contractors Safety Officer

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The Contractor shall appoint a qualified and experienced Safety Officer for the duration of the
Contract. The full time duty of the Safety Officer shall be the prevention of accidents and enforcement
of the requirements of legislation in force. The name and qualifications of the Safety Officer so
designated shall be submitted to the S.O. by the Contractor for approval within two (2) weeks of the
date of the Letter of Award. The Safety Officer shall attend full time on site during normal working
hours and whenever work is in progress during out of hours working, public and national holidays
approved by the S.O. and available by phone and cellular phone during non-working hours.
The Safety Officer shall be registered with DOSH and shall possess, as a minimum requirement,
certificates of attendance at relevant safety training courses operated under the auspices of the
Factories & Machinery Department or similar government bodies.
In the absence of such certificates of formal relevant training the proposed Safety Officer will be
required to attend and complete a Short Course in Safety Training operated under the auspices of the
National Institute of Occupational Safety and Health (NIOSH).
Contractors Safety Committee
The Contractor shall set up a Safety Committee comprising the Safety Officer, project manager, site
agent, S.O.s site representatives and foremen for the Contract. The committee shall meet weekly and
minutes shall be recorded and a copy shall be submitted to the S.O. The S.O. shall be invited to be
present at the Safety Committees meetings.
Site Safety Committee
The Contractor shall appoint a representative, whose appointment shall be approved by the S.O, to the
Site Safety Committee which shall be set up to coordinate safe working practises of the various subcontractors. Unless otherwise permitted by the S.O., the Contractors representative shall be the
Contractors full time safety officer or part time safety officer as appropriate.
The composition of the Site Safety Committee shall be:
-

the S.O. or his representative

Project Manager
Site Agent
Safety Officer

The purpose of the meetings will be to discuss and resolve safety aspects of the various parts of the
work, including possible areas of conflict or difficulty. Where different sub-contractors are working in
the same area of adjacent areas, or where the work of one may impinge upon the work of another, the
meetings will consider what action needs to be taken to ensure each sub-contractor is aware of the
safety requirements of others.
First Aid Facilities
The Contractor shall provide a complete Red Crescent first aid outfit and shall keep it in a metal box
in his site office. 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 Contractor shall also
provide a first aid outfit in the office for the S.O. There shall be provided at all times and at suitable
locations equipment for promptly rescuing persons from the water and resuscitating rescued persons.

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The Safety Officer and 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
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.

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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.
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

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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 selfadjusting 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
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

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

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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.

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1.26 Temporary Sanitary Conveniences

The Contractor shall provide all proper temporary conveniences for his workmen. 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 approved by the S.O.
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.

1.27 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.

1.28 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.

1.29 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.
The nature of the offices, buildings, tanks, etc, and the positioning of them shall be subject to the prior
approval of the S.O.

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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.

1.30 Temporary Offices for the S.O. and His Staff

The Contractor shall supply, paint and furnish temporary site offices for the S.O. and his staff in
approved locations to be provided by the Contractor. The site offices as approved by the S.O. shall be
constructed and maintained by the Contractor.

1.31 Transport for S.O. and His Staff

The Contractor shall provide and keep available at all times during the period of execution of the
Works and such times until issuance of the Certificate of Practical Completion as shall be required by
the S.O. for the sole use of the S.O. and his staff in the performance of their duties the motor vehicles
as described in Bill of Quantities.

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Section 2 - Earthworks

2.0

EARTHWORKS

2-1

2.1

Definitions

2-1

2.2

Levels to be Recorded

2-2

2.3

Explosives and Blasting

2-3

2.4

Disposal of Materials

2-4

2.5

Excess Excavation to be Made Good

2-4

2.6

Site Clearance

2-4

2.7

Trees

2-5

2.8

Stumps

2-5

2.9

Stripping Topsoil

2-5

2.10

General Excavation

2-5

2.11

Excavation of Cuttings (Bulk Excavation)

2-6

2.12

Excavation below Embankments and below Formation Level

in Cuttings

2-6

2.13

Trench Excavation

2-7

2.14

Trench Excavation in Roads, Road Shoulders and Footpaths

2-8

2.15

Trench Excavation in Fields, etc.

2-8

2.16

Rock and Other Materials in Excavations

2-9

2.17

Supporting Excavation

2-9

2.18

Trimming Excavations

2-9

2.19

Inspection of Excavation

2.20

Filling to Embankments and Backfilling to General Excavation 2-10

2.21

Compaction of Embankments and Other Areas of Fill

2-11

2.22

Earthworks to be Kept Free of Water

2-13

2.23

Embankments on Soft Soil

2-13

2.24

Trenches Not to be Left Open

2-14

2.25

Refilling Trench Excavation

2-14

2.26

Spoil Tips on the Site

2-15

2.27

Treatment of Material from Excavation

2-15

2.28

Surface Reinstatement in Road Verges, Fields, etc.

2-16

2.29

Works in Roads and Road Reserves

2-16

2.30

Surface Reinstatement in Roads and Footpaths

2-17

2.31

Other Structures in the Pipeline

2-17

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2.32

Land Drains

General Filling

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Section 2 - Earthworks

2.0 Earthworks
2.1

Definitions

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

Means any surface material, suitable for use in soiling areas to be grassed or
cultivated.

Unsuitable
Material

Unsuitable material, shall include :-

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"

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

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

BS Sieve
Size

10mm
5mm
2mm
600m
75m

Percentage by
Weight Passing

85
50
10
0

100
to 100
to 100
to 90
to
5

Free draining material shall consist of hard, clean, crushed rock or gravel having the

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Free
Draining
Material

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, 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 similar procedure shall be adopted to record any rock surface limits and levels before they are
blasted or excavated.

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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

Explosives and Blasting

The S.O. shall have power to regulate, restrict or prohibit blasting if in his opinion it is necessary to
do so for the safety of persons or property or to safeguard the Works. No blasting shall be carried out
in any part of the Works without the permission in writing of the S.O. Such permission shall not
absolve the Contractor from any of his obligations or liabilities under the Contract and he shall take
all necessary precautions including the use of blasting nets to avoid damage, loss or injury to persons
and to public or private property.
The Contractor shall keep the S.O. fully informed at all times when blasting is proposed to be carried
out and of any details that may be required concerning strength of charges and their positions.
Explosives shall not be used within 15 metre, or such greater or lesser distances as the S.O. may
direct, of concrete placed in the Works, of any existing structure, water main, electric cable, sewer or
other services.
Notwithstanding the above, all excavations into rock by blasting to prepare foundations for any
structures in close vicinity of existing structures shall be carried out with extreme care. Before any
rock blasting commences, the Contractor shall submit a detailed controlled blasting plan for the
approval of the S.O.
The purpose of the control of blasting operations is to eliminate any possibilities of damage to the
existing structures.
Approval of the Contractors proposal shall not absolve him from responsibilities in the event that the
existing structures are damaged as a result of the blasting method used.
All details regarding the type of explosives or chemicals, strength, spacings, depths, positions of
charges, detonation delays used and the method of monitoring the magnitude of vibration generated
shall be supplied to the S.O.
Pilot tests to assess the effectiveness of the controlled blasting shall be conducted at an approved
location within the site before the method is approved. The Contractor shall provide vibration
measuring instruments to monitor the magnitude of vibration caused by the proposed arrangements
with respect to explosive charges, spacings, detonation delays, etc. The instrument shall be able to
measure resultant peak particle velocities from measurement in X, Y and Z planes and record
measurements digitally. Sensors shall be mounted at different positions on the existing structures as
instructed by the S.O. The instrument shall be a triaxial vibration recorder or similar and shall be
capable of measuring velocities in the range of 10-70mm/sec.
Blasting operations shall be carried out and supervised only by personnel qualified in and fully
conversant with the handling and use of explosive.

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The Contractor shall be responsible for determining the danger zone likely to be created during
blasting operations and he shall be responsible for evacuating this area of personnel and placing the
necessary safety barriers. The Contractor shall also ensure, by placing heavy blasting mats, or taking
similar precautions, when necessary, such that no damage is caused to personnel and property on or
off site during blasting operations.
The Contractor shall obtain the necessary permits and licences for the use, storage, transport and
handling of explosives including providing a store or stores suitable for explosives in accordance with
local and national regulations, laws and standards.

2.4

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.
Unsuitable materials and suitable material not intended for re-use shall be removed from the work site
and disposed off at a location approved by the S.O. Materials shall be disposed off in accordance with
local and national laws and regulations including the payment of royalties, fees etc. which may be
imposed by the relevant Authorities.

2.5

Excess Excavation to be Made Good

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

2.6

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.

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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
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.

2.7

Trees

Trees shall be uprooted or cut down as near to ground level as possible. Branches and foliage shall be
removed and disposed of off the Site. Useful timber within Government reserve shall remain the
property of the Government and shall be cut into suitable length and stacked properly.

2.8

Stumps

Stumps and roots whether existing or remaining after tree felling shall where directed by the S.O. be
grubbed up and uprooted and disposed of off the Site. The resulting hole shall be filled with approved
material deposited in 225mm layers and compacted to the same dry density as the adjoining soil. For
reservoir clearing before impounding, stumps with diameter more than 0.6 m at 1m above ground
level can be left in place provided they do not project more than 1.2m above ground.

2.9

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.
The remaining top soil and turf shall be disposed off the Site as directed by the S.O. and in accordance
to the requirements of the relevant authorities.

2.10 General Excavation

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

2.11 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.

2.12 Excavation below Embankments and below Formation Level

in Cuttings

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(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.

2.13 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.
Trench Excavation shall be carried out by such methods and to such lines dimensions and depths as
shall allow for the proper construction of the Works, provided always that, unless shown otherwise in
the Drawings or the S.O. permits otherwise and subject to any specific requirements of the
Specification, no Trench Excavation shall be less than the widths stated below:D

Clear width of trench for

backfill with excavated
material
Not exceeding 500mm
D + 600mm
Exceeding 500mm but not
D + 750mm
exceeding 750mm
Exceeding 750mm
D + 900mm

Clear width of trench for sand

surround or sand backfill
D + 600mm
D + 750mm
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.
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

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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.

2.14 Trench Excavation in Roads, Road Shoulders and Footpaths

All Trench Excavation and other work carried out within the limits of any road reserve shall be
completed as rapidly as possible and not more than half of the width of the carriageway shall be
obstructed at one time. A minimum width of 4 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.
The Contractor shall take special precautions, including the continuous support of the sides of the
excavation from the time excavation is begun until refilling of the trench is completed to ensure that
there is no disturbance of the adjacent road or road foundation. The Contractor shall also provide
barricades to fence off the works and approved road sign boards placing at regular intervals to ensure
safety of the public and vehicles.
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.

2.15 Trench Excavation in Fields, etc.

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

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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.

2.16 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)

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 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.

2.17 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.
Where the Contractor elects and is permitted by the S.O. to perform excavations with sloping faces
(other than sloping excavations shown on the Drawings or required as permanent features of the
Works) and without shoring, the excavated faces shall be to stable slopes and heights and the resulting
extra excavation shall be held to be Excess Excavation.

2.18 Trimming Excavations

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When excavating to specified levels for the foundation of any structure or pipes or to specified limits
for the faces of any structure required to abut against undisturbed ground the Contractor shall not
excavate the last 150mm until immediately before commencing the constructional work, except where
the S.C. shall permit otherwise. Should the Contractor have excavated to within 150mm above these
specified levels or to within 150mm of these specified limits before he is ready or able to commence
the constructional work he shall, where required by the S.O., excavate further so as to remove not less
than 150mm of material immediately before commencing the constructional work and such further
excavation shall be held to be Excess Excavation. Before commencement of any constructional work
all shattered and loose material shall be removed from the excavations by hand so as to ensure that the
work rests on a solid and perfectly clean foundation or abuts against solid ground.

2.19 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.

2.20 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.

(iii)

Granular fill and free draining material for depositing in water in the areas shown on the
Drawings shall conform Clause 2.1 and shall be deposited without the associated use of
compaction plant described to the requirements of Clause in Clause 2.21. However,

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subsequent to the completion of filling to the specified levels, the granular fill shall, where
specified, be compacted by vibrocompaction.
(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 0.2m3 to 0.1m3 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 0.02m3 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.
The Contractor shall when placing the filling or backfilling make due allowance for any settlement
that may occur before the end of the Defects Liability Period. Where necessary, the Contractor shall at
the end of the Defects Liability Period remove any excess material or make up any deficiency of
backfilling or filling to the specified levels.

2.21 Compaction of Embankments and Other Areas of Fill

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(i)

All materials used in embankments and as fill elsewhere shall be compacted as soon as
practicable after deposition. Unless otherwise stated on the Drawings, suitable materials shall
be laid in layers not greater than 300mm loose depth and shall be compacted with appropriate
compaction equipment. Compaction of each layer shall only be undertaken when at least 75%
of the samples taken at a rate of one sample per 500m2 for a length not exceeding 100m show
a moisture content within the limits of optimum moisture content + 3% as determined in
accordance with BS. 1377, Test 13. The fill shall be processed by scarifying, grading, mixing,
wetting, aerating, drying or other approved method so that the material is brought within the
above designated limits.

(ii)

The Contractor shall submit to the S.O. for approval his proposals for the compacting of each
main type of material to be used in the embankments. These shall include proposals for the
number of passes in relation to the loose depth and the type of plant for each material. The
Contractor shall carry out compaction trials, supplemented by any necessary laboratory
investigations, as required by the S.O., using the procedures proposed by the Contractor for
the earthworks and shall satisfy the S.O. that all the specified requirements regarding
compaction can be achieved. Compaction trials with the main types of material likely to be
encountered shall be completed before any permanent work using any of these materials will
be allowed to commence.

(iii)

Filter material shall be compacted in layers not exceeding 150mm by passes of a smoothwheeled vibrating roller. One pass shall consist of as many journeys of the roller as shall
ensure that the bearing width of the roller completely covers the layer once. An overlap of
450mm between the adjacent paths of the roller shall be maintained.
All filter materials shown on the Drawings as vertical layers or layers whose surface is
inclined at a slope steeper than one horizontal to three vertical shall be described as filter
material in vertical layers. The Contractor shall ensure that the filter material so placed will
comply with the specified requirements.

(iv)

Earthmoving plant shall not be accepted as compaction equipment under this Clause.

(v)

The requirements for compaction of embankment fill are as follows and shall apply equally to
all clayey, silty, sandy or gravelly materials placed in the embankment.

(vi)

The Contractor shall ensure that the embankment and other areas of fill are compacted to 95%
of maximum dry density for the 900mm below formation and 90% of maximum dry density
elsewhere. The maximum dry density shall be determined in accordance with BS 1377, Test
13.
The Contractor shall demonstrate compliance with Clause 2.21 (v) for material within 900mm
of formation by carrying out field density tests in accordance with BS 1377, Test 15 at a rate
of not less than one test per 2,000 cubic metres.

(vii)

The S.O. may at any time order or carry out field density tests on material which he considers
has been inadequately compacted. If the test results confirm this to be the case then the
Contractor shall carry out such further work as the S.O. may approve to comply with the
requirements of the Contract.

(viii)

Without prejudice to the relevant Clause in the Jabatan Kerja Raya Conditions of Contract
and in order that the S.O. may make proper provision for the supervision and testing of
compaction in the permanent work, the Contractor shall, not less than 24 hours before he

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proposes to carry out earthwork compaction during periods of overtime, apply in writing to
the S.O. for permission to do so.

2.22 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.

2.23 Embankments on Soft Soil

(i)

The construction of embankments on soft soil shall be carried out in accordance with the
methods, sequence, and rates of filling indicated on the Drawings and other sections of the
Specification. In each case the method of construction shall be reflected in the Contractors
programme submitted with the tender, and in the subsequent works programme.

(ii)

The compaction of all embankment material including any portion placed to make up
anticipated settlements shall be in accordance with the requirements of Clause 2.21.

(iii)

During the construction of embankments on soft soil, the Contractor shall carefully monitor
pore water pressures, settlements and horizontal displacements of the embankment material as
indicated by the piezometers, rod settlement gauges and displacement markers.

(iv)

Unless otherwise instructed by the S.O. such readings shall be taken twice weekly during
filling operations and weekly during rest periods. Plotted records shall be submitted, in a
format agreed with the S.O., within 24 hours of the readings being taken.
For the computation of the volume of fill that has settled below the original level of the
ground on which the embankment is constructed, the measured settlement of each marker
shall be used for the purpose following the method shown on the Drawings.

(v)

Should the S.O. so direct, filling operations shall be immediately suspended and shall not
resume until directed by the S.O.

(vi)

Drainage Layer
When shown on the Drawings or as directed by the S.O., Geotextile complying with the
requirements of Clause 10.5 shall be placed on the cleared and graded subsoil foundation

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prior to the deposition of free draining material as defined in Clause 2.1 of the Specifications.
Free draining material shall be deposited without the associated use of compaction plant to the
thickness shown on the Drawings.
No construction plant shall travel directly over the geotextile layer until a sufficient thickness
of material has been placed to prevent damage to the geotextile or to avoid heave of the
foundation soil.
A second layer of geotextile shall be laid on top of the free draining material before
commencement of deposition of embankment fill.

2.24 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.
If the S.O. considers that the Contractor is not complying with any of the foregoing requirements he
may prohibit further Trench Excavation until he is satisfied with the progress of laying and refilling of
Trench Excavation.

2.25 Refilling Trench Excavation

Trench Excavation shall normally be refilled using suitable materials selected from excavations or
imported fill materials.
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.

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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.
Trench Excavations shall be refilled with concrete to the heights and limits as shown on the Drawings
and where directed by the S.O.

2.26 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.

2.27 Treatment of Material from Excavation

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2.34 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.
After trenches have been refilled and surfaces reinstated, the Contractor shall carry out work as the
S.O. may order for permanent restoration of such barriers. In the case of a hedge the section removed
shall be replaced by new plants of the appropriate variety and where ordered by the S.O. the plants
shall be protected from livestock on both sides by an adequate post and barbed wire fence. During the
Defects Liability Period all hedges replanted in the above manner shall be inspected and any dead
plant replaced by the Contractor to the satisfaction of the S.O.

2.35 Crossing Watercourses, etc

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

2.36 Top Soiling

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

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

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Section 2 - Earthworks

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.
Hydroseeding
Seeding or hydroseeding shall be carried out as soon as practicable on slopes and other areas as shown
on the Drawings and/or directed by the S.O.
The Contractor shall submit to the S.O. for his consideration and approval, at least (4) weeks in
advance of the proposed work, full details of his proposed method of seeding or hydroseeding. The
information submitted shall include, but not necessarily be limited to, a full description of the
following aspects of the work:
i.

the preparation of the areas to be seeded or hydroseeded, including if appropriate the amount
of topsoil to be used and its method of application;

ii.

the details and results of investigations to determine which types of grass and legume are
compatible with the soil in the areas to be seeded;

iii.

the types of grass and legume (if any) and strains of seed to be used, and the function, root
and growth characteristics of each type;

iv.

the rates of application of the grass and legume seeds;

the composition of fertiliser to be used at the time of seeding, and its rate of application;

vi.

the composition of fertiliser to be used after seeding, the times of application after seeding,
and the rates of application;

vii.

the type of mulch to be used and its method and rate application;

viii.

the amounts of lime or other chemicals (if any) to be applied to improve the soil before,
during and/or after seeding;

ix.

the type and amounts of binding agent to be applied with the seeds, mulch fertiliser, etc., as
appropriate;

the proportions and methods of preparation of the seeding mix;

xi.

the equipment and methods to be used in preparing and placing the seeding mix and other
materials;

xii.

the cultivation and after-care of the seeded areas, including rates and frequencies of watering,
fertilising, grass cutting and general maintenance for at least 1 year after seeding;

xiii.

the time after seeding required for establishing permanent, dense growth of grasses, which
will require minimal maintenance; and

xiv.

guarantees of success of seeding work.

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Grass Maintenance
All grass shall be regularly watered until the vegetation is satisfactory established to the satisfaction of
the S.O. Any dead grass be replaced at the Contractors own expense.
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.

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Appendix - 2.1

GRADATION CURVES FOR FILTERS, AND RIP-RAP MATERIALS

FOR GENERAL FILLING

GRADATION CURVES FOR CRUSHER RUN

Civil Work Specifications

Final Document (June 2008)

App2-1

Section 3 - Concrete

3.0

CONCRETE

3-1

3.1

Scope

3-1

3.2

Concrete Production at the Site

3-1

3.3

Test Certificates

3-1

3.4

Aggregate Samples

3-1

3.5

Records of Concreting

3-1

3.6

Concrete Mixes Submission of Design

3-2

3.7

Construction Joints and Lifts Joints Layout and Formwork

Lines for Concrete Placing

3-2

3.8

Cement

3-2

3.9

Storage of Cement

3-3

3.10 Aggregates

3-3

3.11 Storage of Aggregates

3-4

3.12 Water

3-11

3.28 Concreting in Hot Weather

3-11

3.29 Compaction

3-12

3.30 Attendance of Steel Fixer and Carpenter

3-12

3.31 Curing of Concrete

3-12

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3.49 Epoxy Protective Coating for Concrete Surfaces

3-23

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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

Concrete Production at the Site

At the commencement of the Contract the Contractor shall submit for the approval of the S.O. a
method statement detailing with regard to the requirements of this Specification his proposals for the
organisation of concreting activities at the Site.
The method statement shall include the following items:
(a)
(b)
(c)
(d)
(e)

plant proposed;
layout of concrete production facility;
proposed method of organisation of the concrete production facility;
quality control procedures for concrete and concrete materials;
method of transport and placing of concrete;

3.3

Test Certificates

Unless otherwise directed by the S.O., manufacturer's test sheets shall be supplied with each
consignment of cement and admixture certifying compliance with the relevant standard.
The Contractor shall also submit to the S.O. certificates of calibration for the weighing and dispensing
equipment on the concrete batch mixing plant, certified test results for all tests carried out on
aggregate, water, fresh concrete and hardened concrete, all as specified.

3.4

Aggregate Samples

Prior to the commencement of the trial mixes of concrete the Contractor shall submit for approval
samples 50kg in weight of each aggregate which he proposes to use. The source of each aggregate
shall be clearly marked on the container of each sample.
Certified test results demonstrating compliance with the relevant quality standard shall be submitted at
the same time. Samples approved by the S.O. shall remain preserved at Site for reference.

3.5

Records of Concreting

An accurate and up to date record showing dates, times, weather and temperature conditions when
various sections of the Works are concreted shall be kept by the Contractor and shall be available for
inspection by the S.O. The Contractor shall also record the results of all tests of concrete and shall
identify these results with the parts of the Works of which the sampled material is representative.

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For each grade of concrete, the Contractor shall submit to the S.O., not later than twenty-four hours
after concreting, a daily return of the number of batches mixed, the number of batches and total
volume of concrete placed, the number of batches wasted or rejected and the weight of cement used.
The return shall also include specific details of each location in the Works where concrete is placed,
together with the grade of concrete, total volume of concrete placed and the number of batches used
for each location.

3.6

Concrete Mixes Submission of Design

At the commencement of the Works the Contractor shall design a mix for each grade of concrete
which will be required for use in the Works and shall submit full details of the mix designs to the S.O.
for his approval. Each mix design shall be according to the requirements of BS 5328.

3.7

Construction Joints and Lifts Joints Layout and Formwork

Lines for Concrete Placing

The Contractor shall submit to the S.O. for his approval, 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.

3.8

Cement

The cement used for any particular mix shall comply with whichever of the following standards is
relevant:a.
b.
c.
d.
e.
f.

Ordinary and Rapid-hardening Portland cement

Sulphate resisting cement
Portland Blastfurnace cement
High Slag Blastfurnace cement
Portland Polverished-Fuel Ash cement
High Alumina cement

BS EN 197-1
BS 4027
BS EN 197-4
BS 4246
BS EN 197-1
BS 4550-6 & BS 14647

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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.

3.9

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 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.

3.10 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.

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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.

3.11 Storage of Aggregates

The Contractor shall provide means of storing the aggregates at each point where concrete is made
such that:
(i)
(ii)
(iii)

Each nominal size of coarse aggregate and fine aggregate shall be kept separated at all times;
Contamination of the aggregates by the ground or other foreign matter shall be effectively
prevented at all times;
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.

3.12 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.

3.13 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:
(i)

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

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(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.

3.14 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.
Laboratory equipment shall be housed in a suitable laboratory building on the Site, 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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3.15 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)

C50/20
C40/20
*C35A/20
*C35A/40
C30/20
C25/20
C20/20
# C15/20

20
20
20
40
20
20
20
20

Characteristic
strength at
28 days
(N/sq.mm)
50
40
35
35
30
25
20
15

Minimum
Cement
content
(kg/cu.m)
410
410
370
350
350
330
250
225

Maximum free
Water/cement
ratio
0.45
0.45
0.50
0.50
0.50
0.55
0.60
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.

3.16 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.

3.17 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
sulphates in aggregates
chloride ion in mixing water
sulphates in mixing water

ASTM D 1411
BS 1377 Test 9
ASTM D 512
ASTM D 516

3.18 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.

3.19 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
approved by the S.O.

(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, C30, C35A and
C40.

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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.

3.24 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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3.25 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.

3.26 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.

3.27 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.

3.28 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.

(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.

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(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.

3.29 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.

3.30 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.

3.31 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;

(c)

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

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(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.

3.32 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.

3.33 Dimensions and Surfaces of Finished Concrete

Workmanship in formwork and concreting shall be such that concrete shall require no making good,
surfaces being perfectly compacted, smooth and with no irregularities. Concrete surfaces for the
various classes of unformed and formed finishes shall in any event not exceed the maximum permitted
tolerances which shall be as shown in the table below except where expressly stated otherwise in the
Specification or Drawings.
In the table "line and level" and "dimension" shall mean the lines, levels and cross-sectional
dimensions shown on the Drawings.
Surface irregularities shall be classified as "abrupt" or "gradual". Abrupt irregularities include, but
shall not be limited to; offsets and fins caused by displaced or misplaced formwork, loose knots and
other defects in formwork materials, and shall be tested by direct measurement.
Gradual irregularities shall be tested by means of a straight template for plane surfaces or its suitable
equivalent for curved surfaces, the template being 3.0m long for unformed surfaces and 1.5m long for
formed surfaces.
Maximum tolerance in mm:

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Class of
Finish
U1
U2
U3
F1
F2
F3

Line and level

Abrupt irregularity

Gradual irregularity

Dimension

+/- 12
+/- 6
+/- 6
+/- 12
+/- 6
+/- 3

6
3
3
6
6
3

+/- 6
+/- 3
+/- 3
+/- 6
+/- 6
+/- 3

+12, -6
+12, -6
+/-6

3.34 Unformed Surfaces

Finishes to unformed surfaces of concrete shall be classified as U1, U2, U3, 'spaded' or 'bonded
concrete' or such other special finish as may be particularly specified. Where the class of finish is not
specified, the concrete shall be finished to Class U1.
Class U1 finish is the first stage for Class U2 and U3 finishes and for a bonded concrete surface.
Class U1 finish shall be a levelled and screeded, uniform plain or ridged finish, which (unless it is
being converted to Class U2, U3 or bonded concrete) shall not be disturbed in any way after the initial
set and during the period of curing, surplus concrete being struck off immediately after compaction.
Where a bonded concrete surface is specified, the laitance shall be removed from the Class U1 finish
surface and the aggregate exposed while the concrete is still green.
A spaded finish shall be a surface free from voids and brought to a reasonably uniform appearance by
the use of shovels as it is placed in the Works.
Class U2 finish shall be produced by manual or mechanical floating of the concrete surface after the
initial set has taken place and the surface has hardened sufficiently. The concrete shall be worked no
more than is necessary to produce a uniform 'sandpaper' finish free from screed marks.
Class U3 finish shall be a hard smooth steel-trowelled finish. Trowelling shall not commence until the
moisture film has disappeared and the concrete has hardened sufficiently to prevent excess laitance
from being worked into the surface. The surface shall be trowelled under firm pressure and left free
from trowel marks.
The addition of dry cement, mortar or water will not be permitted during any of the above operations.

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3.35 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.
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.

3.36 Structural Precast Concrete

Structural units of precast concrete shall be manufactured in the grade of concrete and to the sizes and
details shown on the Drawings. The concrete shall comply in every aspect with the provisions of the
Contract whether such units are manufactured on the Site or obtained from other manufacturers.
All cement, aggregate and other materials for precast concrete units with faces which are exposed
either internally or externally shall be from the same sources throughout. Exposed surfaces of the
units shall be uniform in colour and in texture.
Formwork and unformed surfaces for precast concrete units shall comply with the requirements for F3
formed surfaces and U3 unformed surfaces except that the dimensional variations shall not exceed the
values listed below, unless otherwise detailed on the Drawings.
Length

+/- 6mm

Cross-section

+/- 6mm each direction

Straightness

6mm (deviation from intended line)

Flatness

3mm (deviation from a 1.5m straight edge placed in any position on a nominally
plane surface).

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Squareness

when considering the squareness of a corner, the longer of the two adjacent sides
being checked shall be taken as the baseline, and the shorter side shall not vary in its
distance from the normal so that the differences between the greatest and the shortest
dimension exceeds 6mm. When the nominal angle is other than 90 degrees, the
included angle between the check lines shall be varied accordingly.

Twist

any corner on any nominally plane surface shall not be more than 6mm from the
plane containing the other three corners.

The positions of individual connecting bolts, bolt holes, projecting steel and other devices in any
associated group (e.g. the joint of two precast units) shall be within 3mm of their true position in the
group in which they are cast. The location of any such group shall be within 6mm of its true position
in the unit in which it is cast, provided that such deviation does not adversely affect the proper
assembly of the whole structure.
The Contractor shall submit to the S.O. for approval, full details of his proposed method of carrying
out all operations connected with the manufacture and assembly of precast concrete structural
members, including:
-

a description of the types of casting bed, mould and formwork for the various types of
members;

the procedure for concrete casting and the method of curing the concrete;

the procedure for transporting, handling, hoisting and placing of each type of precast structural
member;

full details of temporary supports necessary to ensure adequate stability during erection, due
account be taken of construction loads, including wind.

3.37 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.

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3.38 Prestressed Concrete

The Contractor shall submit to the S.O. for approval his proposed method of carrying out all
operations connected with prestressed concrete work and his proposals for handling, hoisting and
placing in position any precast prestressed concrete units.
Prestressed concrete work whether precast or cast in-situ shall be as detailed on the Drawings and the
Contractor shall provide full details of his proposed method of carrying out all operations connected
with prestressing including:(a)

Design of concrete mix.

(b)

Description of concrete casting and curing operations.

(c)

Procedure for prestressing and method of checking and recording the

extension and anchorage slip.

(d)

Procedure for handling, hoisting and placing of any precast units.

(e)

Grouting of ducts.

prestress, wire

All tendons, duct forming devices, anchorages and other components shall be kept free of mud, oil
(except water soluble oil applied for protection), paint, retarders, loose rust, or other foreign matter.
They shall be placed with a tolerance of +/- 3mm in concrete dimensions of 300mm or less or +/6mm in concrete dimensions over 300mm.
The bearing surfaces between anchorages and concrete shall be normal to and concentric with the
tendons and the line of action of the prestressing force.

3.39 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
Concrete blocks
Concrete kerbs etc.
Concrete flags
Concrete sills
Concrete lintels

Standard
BS EN 1170-1
BS EN 1339 & BS EN 1340
BS EN 1339 & BS EN 1340
BS 5642
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.

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3.40 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.

3.41 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
of grades C25,
C30, C35A, C40

one set of cubes per 25 cu.m

or part thereof concreted
per day;

for concrete
of grade C15
or C20:

one set of cubes per 50 cu.m

or part thereof concreted
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.

3.42 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, C30, C35A and C40.

(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.

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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.

3.43 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
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.

3.44 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.

3.45 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.

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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).

3.46 Concrete Protection Systems

Where required all structural concrete in contact with the ground shall be protected by one of the
methods specified below. Unless otherwise specified or detailed on the Drawings, in-situ concrete
surfaces which are to be protected shall have either U2 or F2 finish as appropriate.
(a)

Prefabricated membrane tanking:

The membrane shall be preformed consisting of 1.5mm thick rubber/bitumen compound formulated
for use in hot climates, backed with 0.3mm thick PVC sheet. The membrane shall adhere with
watertight joints to itself at overlaps and to concrete surfaces prepared with suitable priming
compound.
The membrane and primer shall be applied in accordance with the manufacturer's instructions to
horizontal, inclined and vertical surfaces.
After the blinding concrete has hardened, the membrane shall be applied, bitumen face downwards,
and shall extend at least 150mm beyond the outer limits of the structure. As soon as the membrane has
been applied and before any reinforcement or structural concrete is placed, the membrane shall be
covered by a sand/cement screed 50mm thick, extending over the whole area of the base of the
structure. The membrane projection of 150mm shall be temporarily protected with a layer of board as
specified below to prevent mechanical damage.
After the concrete structure has been constructed up to ground level and curing is completed, the
surfaces which will be in contact with the ground, or as detailed otherwise on the Drawings, shall be
primed with the material supplied by the membrane manufacturer. The vertical membrane shall be
bonded onto the projection of the base membrane and terminated in a chase at the top. Fillets and
reinforcing strips shall be used.
Completed areas of vertical membrane shall be protected from mechanical damage during backfill
operations by 12mm thick cardboard, fibreboard or chipboard secured with suitable adhesive, or by
concrete blockwork.
(b)

Made-in-place membrane tanking:

As an alternative to prefabricated membrane tanking on horizontal surfaces, the Contractor may

propose to design, supply and install a made-in-place membrane of bitumen asphalt concrete laid on a
tack coat placed on clean original ground.
The bitumen asphalt concrete shall comprise bitumen or asphalt and coarse and fine aggregates.

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The Contractor shall demonstrate to the S.O. by testing, by trial and by experience that made-in-place
membrane tanking exhibits characteristics which are in all respects equal to or better than
prefabricated membrane tanking. The system shall be:
-

waterproof during life of protected structure;

robust during preparation for concreting;
durable during life of structure;
flexible in differential settlement;
incompressible under weight of structure.

Made-in-place membrane tanking may be used in place of blinding concrete provided that the
Contractor shall also have demonstrated to the S.O. the practicability of this system by testing, by trial
and by experience.
Vertical or sloping concrete surfaces shall be protected by prefabricated membrane tanking as
specified which shall overlap and adhere to made-in-place membrane tanking over a width of 150mm.
(c)

Bituminous latex emulsion:

This material shall only be used as an alternative to membrane tanking where the S.O. has specifically
agreed that satisfactory membrane tanking cannot be carried out.
The emulsion shall be a rubber-rich bituminous emulsion suitable for use in hot climates and capable
of building up a film with minimum dry thickness of 1.0mm, which is impermeable to water
penetration and possessing a high degree of flexibility.
A priming mixture shall be made by thoroughly mixing 1 part emulsion with 6 parts fresh water.
Coats other than priming coat shall not be diluted.
Application rates shall be as follows:
Surface
Horizontal

Vertical

Coat
1st (priming)
7
2nd
3rd
1st (priming)
7
2nd
3rd
4th

Application rate
(sq.m/litre)
1
1.5

2
2
2

or as necessary to build up a minimum dry film thickness of 1.0mm.

Overcoating shall take place as soon as the previous coat has dried. Immediately the final coat has
been applied to vertical surfaces, bituminised building paper shall be applied to the fresh emulsion
and pressed into close contact over the whole area of the protection.
Horizontal and vertical surfaces shall be protected from mechanical damage during subsequent
construction work by screed or boarding as specified for membrane tanking.

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(d)

Polyethylene sheet

250 micron polyethylene sheet shall be placed against vertical or sloping surfaces of excavated
ground before placing concrete directly against such surfaces.
Backfilling with sand against protected surfaces shall be carried out in such a manner that the
protection is not damaged. Nevertheless, if such damage occurs, the damage shall be made good to the
satisfaction of the S.O.

3.47 Concrete Protection Procedures

Details of concrete protection shall be shown by the Contractor on the preliminary working drawings.
Such details shall include corners overlaps, brick or board protection and details for curved faces, etc.
Concrete protection systems proposed for use in the Works shall be demonstrated by the Contractor to
the S.O. for approval before submission of preliminary working drawings showing use of such
systems in the Works.

3.48 Machinery Bases and Grouting In

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.

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3.49 Epoxy Protective Coating for Concrete Surfaces

General
The descriptions on the epoxy protective coating covers all labour, materials, equipment and services
necessary to complete its application concrete surfaces. The following standards shall be used for
reference and in the event when a conflict arises which requires for more detailed information: 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

ASTM D638 Tensile Properties of Plastics.

ASTM D790 - Flexural Properties of Unreinforced and Reinforced Plastics.
ASTM D695 Compressive Properties of Rigid Plastics.
ASTM D4541 Pull-off Strength of Coatings Using Portable Adhesion Tester.
ASTM D2584 Volatile Matter Content.
ASTM D543 Resistance of Plastics to Chemical Reagents.
ASTM C109 Compressive Strength Hydraulic Cement Mortars.
ASTM C579 Compressive Strength of Chemically Setting Silicate and Silica Chemical
Resistance Mortar.
SSPC The published standards of the Society of Protective Coatings, Pittsburgh, PA.
SSPC SP-13/NACE No.6 - Surface Preparation of Concrete.

Material Specifications
The epoxy to be used must be safe for handling and does not pose a danger to health and the
environment. It must be an approved type by SIRIM, JPP, IWK and other relevant bodies. It must be
suitable for repair and coating of new and existing manholes, pumping stations, concrete holding and
mixing tanks, etc. The epoxy can be either a coal tar or non-coal tar type. Coal tar epoxies are
essentially a mix of coal tar and epoxy resins and only come in a tar black colour.
It must be readily applied to damp concrete surfaces and able to provide a strong bond to the concrete
to prevent the ingress of water. It must be low viscosity for ease of application within confined areas,
non-blushing and non-water spotting.
The epoxy coating must have excellent chemical, corrosion and abrasive resistance against
wastewater. Also, it must be smooth, glossy and easy to clean to ensure a long maintenance-free life.
It must be solvent free and of high-build epoxy system. Coal tar epoxies shall be of the amine cured
and not amide cured system.
The Contractor shall warranty all works against defects in materials and workmanship for a period of
one (1) year, unless otherwise stated, from the date of final acceptance of the project. The Contractor
shall, within a reasonable time after receipt of written notice thereof, repair defects in materials or
workmanship which may develop during the warranty period and any damage to other work caused
by such defects or repairing of same at his own expenses and without cost to the Owner.
The protective coating must be able to provide a maintenance-free life and last until the next
maintenance inspection which normally will be carried out after 5 years from the date of application.
Submittals:
Prior to use, the Contractor must submit the product data to the S.O. for approval. The information
required includes:
a)

Technical data sheet on each product to be used.

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b)
c)
d)
e)
f)

Material Safety Data Sheet (MSDS) for each of the product to be used.
Copies of independent testing performed on the coating product indicating the product meets
the requirements as specified therein.
Technical data sheet and project specific data for materials to be top-coated with the coating
product(s) including application, cure time and surface preparation procedures.
Current documentation from coating product manufacturer certifying the Contractors training
and equipment complies with the quality assurance requirements specified therein.
At least (5) recent references of the Contractor indicating successful application of coating
product(s) of the same material type as proposed.

Quality Assurance
a)

b)
c)

e)
f)
g)

Epoxy coating product(s) shall be capable of being applied and cured properly within a
manhole or confined environment. Coating product(s) shall be resistant to all forms of
chemical or bacteriological attack found in municipal sanitary system and capable of adhering
to the manhole structure substrates.
Repair product(s) shall be fully compatible with epoxy coating product(s) including ability to
bond effectively forming a composite system.
The Contractor shall utilize equipment for the spray application of the epoxy coating products
which has been approved by the manufacturer. The Contractor shall also have received
training on the operation and maintenance of said equipment from the manufacturer.
The Contractor shall be trained or have their training approved and certified by the epoxy
coating product manufacturer for the handling, mixing, application and inspection. Only
competent and certified applicator(s) shall be allowed to carry out the coating application.
Inspectors shall be trained in the use of testing or inspection instrumentation and
knowledgeable of the proper use, preparation and installation of the coating product(s).
The Contractor shall initiate and enforce quality control measures consistent with the epoxy
coating product manufacturer recommendations.
Prior to epoxy coating application, a pre-construction meeting shall take place. At the
meeting, important issues regarding materials and application need to be addressed.

Delivery, Storage and Handling

a)
b)

Materials shall be kept dry, protected from weather and stored under waterproof cover.
Epoxy materials shall stored between 10oC and 32o C. The epoxy materials shall not be stored
near flame, heat or strong oxidants.
c)
Epoxy materials shall be handled properly according to the material safety data sheets.
Surface Preparation
Appropriate actions shall be taken by the Contractor to comply with the local, state and federal
regulatory and other applicable agencies with regard to environment, health and safety during work.
All structures to be coated shall be made readily accessible by the Contractor. The standard Portland
cement or new concrete (not quick setting high strength cement) must be cured a minimum of 28 days
prior to application of the epoxy coating. Any active flows shall be dammed, plugged or diverted as
required to ensure all liquids are maintained below or away from the surfaces to be coated. The
temperature of the surface to be coated should be maintained between 5oC and 50oC.
Prior to commencing surface preparation, the Contractor shall inspect all surfaces specified to receive
the coating and notify the S.O., in writing, of any noticeable disparity at the site, structure or surfaces
which may interfere with the work, use of materials or procedures as specified.

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The concrete surface must be clean, dry and free from laitance and loose particles. Contaminants such
as oil, grease, wax, dust, efflorescence and organic growth shall be removed. Incompatible previous
coating also must be removed from the concrete surface prior to application of the epoxy which may
affect the performance and adhesion of the epoxy coating to the substrate. Infiltration shall be stopped
by using a material which is compatible with the repair products and is suitable for top-coating with
the epoxy material(s).
Choice of surface preparation method(s) shall be based upon the condition of the structure and
concrete or masonry surface, potential contaminants present, access to perform work and required
cleanliness and profile of the prepared surface to receive the coating product(s). Surface preparation
method or combination of methods that may be adopted include high pressure water cleaning, high
pressure water jetting, abrasive blasting, hot water blasting, etc. Whichever method(s) used, they shall
be performed in a manner that provides a uniform, sound clean neutralized surface suitable for the
specified epoxy coating.
For repairing and resurfacing works, repair products shall be used first to fill voids, bug holes and/or
smooth the transition between the components prior to the installation of the epoxy coating. Repair
materials must be compatible with the specified coating and shall be used and applied in accordance
with the manufacturers recommendations. Resurfacing product shall be used to fill large voids, lost
mortar in masonry structures, smooth deteriorated surfaces and rebuild severely deteriorated structures
in order to provide a concrete or masonry substrate suitable for the epoxy coating. These products
shall be installed to minimum thickness as recommended by the manufacturer.
Repair and resurfacing products shall be handled, mixed, installed and cured in accordance with
manufacturers guidelines. All repaired or resurfaced surfaces shall be inspected for cleanliness and
suitability to receive the epoxy coating. Additional surface preparation shall be performed prior to
coating application, if necessary.
The following criteria shall be used in selecting and accepting compatible repair and resurfacing
products for use within the specifications:

100% solids, solvent-free epoxy grout specifically formulated for epoxy top-coating
compatibility.
Factory blended, rapid setting, high early strength, fibre reinforced, non-shrink repair mortar
that can be trowelled or pneumatically spray applied may be approved if specifically
formulated to be suitable for top-coating with the specified coating product(s).

Epoxy coating application shall only be carried out using the manufacturers approved plural
components spray equipment. Hand tools may be used on hard to reach areas, primer application and
touch-up works.
Application
Application procedures shall conform to the recommendations of the epoxy coating manufacturer
including environmental controls, product handling, mixing, application equipment and methods.
The spray equipment shall be specifically designed to accurate ratio and apply the coating and shall be
in proper working order. Only competent and certified applicator(s) shall perform all aspects of epoxy
coating installation.

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Prepared surfaces shall be coated by spray application of the coating product(s) to the minimum wet
film thickness. The thickness for coal tar epoxy shall be up to 35 mils (875 microns) in two coats. For
epoxy resins based, the thickness per coat shall be at least 8 mils (200 microns) of dry film and wet
film each. Top-coating or additional coats of the epoxy coating shall occur within the products recoat
window. Additional surface preparation procedures will be required if the recoat window is exceeded.
The coating thickness may vary depending on substrate and manufacturers recommendation based on
project assessment.
The epoxy coating shall interfere with adjoining construction materials throughout the manhole
structure to effectively seal and protect concrete or masonry substrate from infiltration and attack by
corrosive elements. Procedures and materials necessary to effect the interface shall be as
recommended by the product manufacturer. Sewage flow shall be stopped, bypassed or diverted for
application of the epoxy coating to the invert of manholes and interface with pipe materials.
Testing and Inspection
During application of the protective coating, measurement shall be taken, verified and documented by
the Contractor for submission to the S.O.
Holiday Detection is recommended for coating systems installed in corrosive environment, when it
can be safely and effectively performed. Structure size and active flowing liquids, however, may
restrict the use of holiday detection. After the coating product(s) have set in accordance with
manufacturer instruction, all surfaces shall be inspected for holidays with high-voltage holiday
detection equipment. Reference can be made from NACE RPO 188-99 for performing holiday
detection. All detected holidays shall be marked and repaired by abrading the coating surface with
grit disk paper or other hand tooling method. After abrading and cleaning, additional coating can be
hand applied to the repair area. All touch-up/repair procedures shall follow the coating manufacturers
recommendations. Contractor shall provide documentation on areas tested, results and repairs made to
S.O.
Adhesion Testing is a destructive test method and should be used in moderation as an evaluation tool.
A minimum of 10% of the manholes coated shall be tested for adhesion/bond of the coating to the
substrate. Testing shall be conducted in accordance with ASTM D4541 as modified herein. The S.O.
shall select the manholes to be tested. A minimum of three 20 mm dollies shall be affixed to the
coated surface at the cone area, mid section and at the bottom of the structure. The adhesive used to
attach the dollies to the coating shall be rapid setting with tensile strengths in excess of the coating
product and permitted to cure in accordance with manufacturers recommendations. The coating and
dollies shall be adequately prepared to receive the adhesive. Failure of the dolly adhesive shall be
deemed a non-test and require retesting.
Prior to performing the pull test, the coating shall be scored to within 30 mils of the substrate by
mechanical means without disturbing the dolly or bond within the test area. Two of the three adhesion
pulls shall exceed 200 psi or concrete failure with more than 50% of the subsurface adhered to the
coating. Should a structure fail to achieve two successful pulls as described above, additional testing
shall be performed at the discretion of the S.O. The S.O. shall evaluate any areas detected to have
inadequate bond strength. Further bond tests may be performed in that area to determine the extent of
potentially deficient bonded area and the Contractor shall make repairs.
The S.O. shall make a visual inspection. Any deficiencies in the finished coating shall be marked and
repaired according to the procedures set forth herein by the Contractor.

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Section 4 - Formwork

4.0

FORMWORK

4-1

4.1

Scope

4-1

4.2

Submissions

4-1

4.3

Materials

4-1

4.4

Design and Detailing

4-1

4.5

Formed Surfaces - Class of Finish

4-1

4.6

Erection of Formwork

4-2

4.7

Removal of Formwork

4-3

4.8

Building in Plant

4-3

4.9

Dry-pack Mortar

4-4

4.10 Defects in Formed Surfaces

4-4

4.11 Movement Joints

4-5

4.12 Sliding Planes and Joints

4-6

4.13 Inspection and Testing

4-6

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Section 4 - Formwork

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

Submissions

The Contractor shall submit calculations and designs for formwork including layout of panels, before
fabrication commence.

4.3

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.

4.4

Design and Detailing

The Contractor shall be responsible for the adequacy and safety of formwork.
On formwork to external faces which will be permanently exposed, all horizontal and vertical
formwork joints shall be so arranged that joint lines shall form a uniform pattern on the face of the
concrete. Where the Contractor proposes to make up the formwork from standard sized manufactured
formwork panels, the size of such panels shall be approved by the S.O. before they are used in the
construction of the work. The finished appearance of the entire elevation of the structure and
adjoining structures shall be considered when planning the pattern of joint lines caused by formwork
and by construction joints to ensure continuity of horizontal and vertical lines.

4.5

Formed Surfaces - Class of Finish

Finishes to formed surfaces of concrete shall be classified as F1, F2 or F3 as specified in Section 3.

Where the class of finish is not specified the concrete shall be finished to Class F1.

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Section 4 - Formwork

Formwork for class F3 finish shall be lined with panels of non-staining material with a smooth
unblemished surface such as sanded plywood or hard compressed fibre board. The panels shall be as
large as possible and shall be arranged in a uniform approved pattern and fixed to back formwork by
oval nails. Unfaced wrought boarding or standard steel panels will not be permitted.
Ribbed finishes shall be formed by a backing of sanded plywood or hard compressed fibre board, as
described for a Class F3 finish, against which timber battens are fixed. Battens shall have clean sharp
arises at base and be stopped with a waterproof filler and be sanded to give a smooth surface. Battens
shall be securely fixed to the backing by adhesive and screws to prevent the penetration of grout
behind them.
Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or plywood or
metal panels arranged in a uniform approved pattern free from defects likely to detract from the
appearance of the surface.
Formwork for Class F1 finish shall be constructed of timber, sheet metal or any suitable materials
which will prevent loss of grout when the concrete is vibrated. Surfaces subsequently to be rendered,
plastered or tiled shall be adequately scabbled or roughened as soon as the formwork is removed to
reduce the irregularities to not more than half the thickness of such rendering, plastering or bedding
for tiles and to provide a satisfactory key.

4.6

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.
Holes left after removal of such supports shall be neatly filled with well rammed dry-pack mortar.

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Section 4 - Formwork

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.

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Section 5 - Steel Reinforcement

5.0

STEEL REINFORCEMENT..........................................................................5-1
5.1

Scope ................................................................................................5-1

5.2

Submissions ....................................................................................5-1

5.3

Steel Reinforcement ........................................................................5-1

5.4

Steel Wires and Bars for Prestressing...........................................5-1

5.5

Accessories......................................................................................5-2

5.6

Detailing............................................................................................5-2

5.7

Cutting and Bending of Reinforcement .........................................5-2

5.8

Storage of Reinforcing Bars and Fabric ........................................5-2

5.9

Storage of Prestressing Wire and Bars .........................................5-2

5.10

Fixing of Reinforcement..................................................................5-2

5.11

Inspection and Testing....................................................................5-3

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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

Submissions

The following submissions are required to be submitted by the Contractor.

(1)

Test certificates
Manufacturer's test certificate for each delivery of reinforcing steel. Each certificate
shall show the country of origin and test.

(2)

Data
Manufacturer's data on accessories and mechanical couplings.

5.3

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).

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

Fabric

5.4

Steel Wires and Bars for Prestressing

Prestressing steel wire or bars shall be of the following kinds as specified or detailed on the Drawings:
(a)

Cold drawn wire or cold drawn and stress relieved wire conforming with BS 5896.

(b)

Stress relieved seven-wire strand conforming with BS 5896.

(c)

Stress relieved nineteen-wire strand confirming with BS EN10218-1.

(d)

Cold worked high tensile alloy steel bars conforming with BS 4486.

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Section 5 - Steel Reinforcement

5.5

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.

5.6

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.

5.7 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
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.

5.8

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.

5.9

Storage of Prestressing Wire and Bars

In addition to complying with the above storage requirements, the Contractor shall ensure that
prestressing wire and bars are protected from mechanical damage by storing on timber supports above
a concrete slab, and shall ensure that during storage the wire and bars are kept properly coated with
water soluble oil inside protective wrappings.

5.10 Fixing of Reinforcement

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Section 5 - Steel 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.

5.11 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.

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Section 6 - Piling

6.0

PILING .........................................................................................................6-1
6.1

General .............................................................................................6-1
6.1.1 Ground Conditions ...............................................................6-1
6.1.2 Setting Out.............................................................................6-1
6.1.3 Piling Equipment...................................................................6-2
6.1.4 Programme ............................................................................6-2
6.1.5 Pile Driving ............................................................................6-2
6.1.6 Trial and Working Piles ........................................................6-4
6.1.7 Load Tests .............................................................................6-4
6.1.8 Ultimate and Design (Working) Loads ................................6-4
6.1.9 Piling Personnel ....................................................................6-5
6.1.10 Piling Records .......................................................................6-5

6.2

Precast Reinforced Concrete Piles ................................................6-5

6.2.1 General...................................................................................6-5
6.2.2 Pile Casting ...........................................................................6-6
6.2.3 Curing, Stripping and Stacking............................................6-6
6.2.4 Handling Storage and Transport of Piles............................6-6
6.2.5 Pitching and Driving .............................................................6-7
6.2.6 Plant for Pile Driving.............................................................6-7
6.2.7 Measuring Pile Set ................................................................6-8
6.2.8 Extending Piles .....................................................................6-8
6.2.9 Preparation of Pile Heads.....................................................6-8
6.2.10 Load Tests .............................................................................6-8

6.3

Steel Sheet Piles ..............................................................................6-9

6.3.1 General...................................................................................6-9
6.3.2 Section and Properties .........................................................6-9
6.3.3 Storage and Protection.........................................................6-9
6.3.4 Piling Crew ..........................................................................6-10
6.3.5 Plant and Equipment ..........................................................6-10
6.3.6 Alignment of Sheet Piles ....................................................6-10
6.3.7 Lifting and Pitching.............................................................6-11
6.3.8 Pile Driving ..........................................................................6-11

6.4

Treated Timber Piles......................................................................6-11

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Section 6 - Piling

6.4.1 General.................................................................................6-11
6.4.2 Treatment of Piles ...............................................................6-12
6.4.3 Delivery and Stacking of Piles ...........................................6-12
6.4.4 Pile Driving and Jointing ....................................................6-12
6.4.5 Load Tests ...........................................................................6-13
6.5 Steel H-Piles..............................................................................................6-14
6.5.1 General.................................................................................6-14
6.5.2 Handling, Storage and Transport of Piles.........................6-14
6.5.3 Pitching and Driving ...........................................................6-14
6.5.4 Measuring Pile Set ..............................................................6-15
6.5.5 In-situ Lengthening of Piles ...............................................6-15
6.5.6 Welding ................................................................................6-15
6.5.7 Welding Personnel..............................................................6-16
6.5.8 Reuse of Cut-off Piles.........................................................6-16
6.5.9 Cutting of Pile Head ............................................................6-16
6.5.10 Load Tests ...........................................................................6-16
6.6

Prestressed Spun Concrete (PSC) Piles......................................6-17

6.6.1 Standard ..............................................................................6-17
6.6.2 Shape ...................................................................................6-18
6.6.3 Aggregates ..........................................................................6-18
6.6.4 Water ....................................................................................6-18
6.6.5 Cement.................................................................................6-18
6.6.6 Admixtures ..........................................................................6-18
6.6.7 Prestressing Steel...............................................................6-18
6.6.8 Reinforcement .....................................................................6-19
6.6.9 Reinforcement Details ........................................................6-19
6.6.10 Concrete ..............................................................................6-19
6.6.11 Curing ..................................................................................6-19
6.6.12 Level of Prestress ...............................................................6-19
6.6.13 Transfer of Prestress ..........................................................6-20
6.6.14 Pile Ends..............................................................................6-20
6.6.15 Manufacturing of Piles........................................................6-20
6.6.16 Splicing ................................................................................6-21
6.6.17 Marking of Piles...................................................................6-21

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6.8

Micro Piles......................................................................................6-37
6.8.1 General.................................................................................6-37
6.8.2 Submission by the Contractor ...........................................6-37
6.8.3 Equipment ...........................................................................6-37
6.8.4 Materials ..............................................................................6-37
6.8.5 Method of Construction......................................................6-37
6.8.6 Grout Mix .............................................................................6-38
6.8.7 Rejected Micropiles ............................................................6-38

6.9

Pile Testing.....................................................................................6-38
6.9.1 General.................................................................................6-38
6.9.2 Test Load and Kentledge ...................................................6-38
6.9.3 Settlement Measurement....................................................6-39
6.9.4 Equipment and Personnel for Load Test ..........................6-39
6.9.5 Procedure of Testing ..........................................................6-39
6.9.6 Records of Test ...................................................................6-40
6.9.7 Interpretation of Test Results ............................................6-40

6.10

Rejection of Piles...........................................................................6-40

6.11

Dynamic Pile Load Test Method ...................................................6-41

6.11.1 General.................................................................................6-41
6.11.2 Measurements .....................................................................6-41
6.11.3 Field Data Processing.........................................................6-41
6.11.4 Measurement Devices ........................................................6-42
6.11.5 Hammer................................................................................6-42
6.11.6 Preparation of Pile Head.....................................................6-42
6.11.7 Personnel.............................................................................6-42
6.11.8 Preliminary Results.............................................................6-43
6.11.9 Detailed Report....................................................................6-43
6.11.10 Defective Piles...................................................................6-44

6.12

Piling Records................................................................................6-44

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Section 6 - Piling

6.0 PILING
6.1

General

Unless otherwise specified, all piling shall conform in all respects to the Civil Engineering Code of
Practice BS 8004 `Foundations' issued by the `British Standards Institution, London'.
The type of pile to be used at each structure, where piling is required, shall be as indicated on the
Drawings or as directed by the S.O.

6.1.1 Ground Conditions

Soil investigation including boreholes have been carried out by the Employer on the Site and the soil
investigation report with borehole logs and samples are available for examination by the Contractor at
the Employers office and the Contractor shall be deemed to have inspected them before preparing his
tender.
The results of the soil investigation are solely for the purpose of assisting the Contractor in the
preparation of his tender. Neither the Employer nor the S.O. bears any responsibility for the
correctness of the result.
It shall be the Contractors responsibility to carry out further sub-surface investigation if he has any
doubt about the available information or if he considers further information necessary or desirable.
Such investigation by the Contractor shall be entirely at his own expense and shall have the
Employers prior approval in writing.
The S.O. shall be supplied free of charge with two (2) copies of the results of all such investigation by
the Contractor.
In addition to submitting the records required, the Contractor shall report immediately to the S.O. any
circumstances which indicate that the ground conditions differ from those expected by the Contractor
from his interpretation of the results of soil investigation carried out by the Employer and which affect
adversely the bearing capacity of the pile or proposed foundation.
The Contractors attention is, however, drawn to the fact that suitable founding strata may be
encountered at depths which require the actual installation of different lengths of pile and which may
give rise to considerable variation within any particular site or pile groups.

6.1.2 Setting Out

The pile layout and the number of piles shown on the Drawings are provisional only. The Contractor
shall, before commencing any part of the piling work ascertain from the finalised S.O. the layout of
the piles required.
The Contractor shall set out the piles from the main grid lines of the proposed structure or such base
lines as shall be agreed with the S.O. The main setting out for piles shall be completed prior to
commencement of piling. Secondary or individual pile setting out shall be completed and agreed with
the S.O. not less than 24 hours prior to commencing work on the piles concerned. All main setting
points, lines, stations and the like shall be suitably protected, maintained and undisturbed.

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Section 6 - Piling

For a pile cut-off at or above ground level the maximum permitted deviation of the pile centre from
the centre point shown on the Drawings shall not exceed 75mm in any direction. For a pile cut off
below ground level an increase in the verticality tolerance is permitted up to 1 in 75 from the finished
pile.

6.1.3 Piling Equipment

The piling equipment shall be capable of speedily and efficiently installing piles of the specified
types, sizes, lengths and safe working loads.
The type of piling equipment shall be suitable for the type of piles to be installed and shall be that of a
system which produces minimum noise during pile installation.
The Contractor shall provide sufficient number of units to ensure completion of piling work according
to programme.
Before any piling work is commenced, the Contractor shall submit to the S.O. full details of the pile
driving equipment and the method of carrying out the work which he intends to use. Such
information shall include a full description of the piling frame, hammer, helmet and packing and of a
method of handling and pitching piles and supporting them during driving, and of the proposed
driving procedure set to give penetration to the required level and of the proposed set for the working
load on the pile and the method of calculating it.
Any revisions to these proposals which, in the light of ensuing experience, appear desirable, shall also
be submitted for the approval of the S.O. prior to implementation of said revisions.
The piling frame shall be of sturdy construction, supported on an adjustable base, securely guyed and
with ample toggle connections to leaders so that the pile is firmly held at all times. The type and
weight of hammer shall be to the approval of the S.O. and the weight of the hammer shall be at least
half that of the pile or otherwise specified. In general, a heavy hammer with a short drop should be
used in preference to a light hammer with a longer drop. Single or double acting diesel or airoperated hammers may also be employed.
The Contractor shall submit confirmation of hammer energy per blow to the satisfaction of the S.O.
All plant being used shall be maintained in a satisfactory condition and any items suffering wastage or
damage shall be promptly replaced or repaired.
No piling shall be carried out without the approval in writing of the S.O. of the equipment and method
of working and any revisions to these as described above, and the Contractor shall submit all of his
proposals at least three weeks before the date on which he intends to use the plant on the Site.

6.1.4 Programme
The Contractor shall submit to the S.O. his proposed programme for the execution of the piling work
at least seven days before commencement of the work. In addition, the Contractor shall inform the
S.O. daily of the programme of piling for the following working day and shall give adequate notice of
his intention to work outside normal hours, if this has already been approved by the S.O.

6.1.5 Pile Driving

Unless otherwise specified, pile driving shall be as specified hereunder.

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Section 6 - Piling

The driving equipment to be used shall be of such type and capacity to the approval of the S.O. If
drop hammer is used, it shall be of a free fall type and the weight of the hammer shall be as specified
in BS 8004.
Piles shall be pitched accurately in the positions as shown on the Drawings or to the layout approved
by the S.O. At all stages during driving and until the pile has set or driven to the required length, all
exposed piles shall be adequately supported and restrained by means of leaders, trestles, temporary
support or other guide arrangements to maintain position and alignment and to prevent buckling and
damage to the piles.
Each pile shall be driven continuously until the specified set and/or depth has been reached.
However, the S.O. may permit the suspension of driving if he is satisfied that the rate of penetration
prior to the cessation of driving will be substantially re-established on its resumption or if he is
satisfied that the suspension of driving is beyond the control of the Contractor.
A follower (long dolly) shall not be used for driving end bearing piles. It may be used for driving
frictional piles with prior approval of the S.O.
The Contractor shall inform the S.O. without delay if an unexpected change in driving characteristics
is encountered.
Where required by the S.O. set shall be taken at approved intervals during the driving to establish the
behaviour of the piles. A set shall be taken only in the presence of the S.O. unless otherwise approved.
The Contractor shall provide all facilities to enable the S.O. to check driving resistances.
Redrive checks, if required, shall be carried out in accordance with an approved procedure.
A detailed record of the driving resistance over the full length of each pile shall be kept. The log shall
record the number of blows for every 300mm of pile penetration.
The final set of a pile other than a friction pile, shall be recorded either as the penetration in
millimetres per 10 blows or as the number of blows required to produce a penetration of 25mm.
When a final set is being measured, the following requirements shall be met:(a)

The exposed part of the pile shall be in good condition, without damage or distortion;

(b)

The dolly packing shall be in sound condition;

(c)

The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and
at right angle to the pile and hammer axis;

(d)

The hammer shall be in good condition and operating correctly;

(e)

The temporary compression of the pile shall be recorded if required.

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral
displacement of the ground.
When required, levels and measurements shall be taken to determine the movement of the ground or
any pile resulting from the driving process. If any pile rise occurs as a result of adjacent piles being

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Section 6 - Piling

driven, the Contractor shall submit to the S.O. his proposals for correcting this and to avoid the same
in subsequent work.

6.1.6 Trial and Working Piles

A trial pile is a pile installed at the Site before the commencement of the main piling work for the
purpose of establishing the driving criteria for subsequent working piles and for confirming the
adequacy of the pile design, dimensions and bearing capacity. This pile shall be treated as a working
pile unless failure or excessive settlement has occurred. Trial piles shall be of the same materials and
driven or formed with the same plant and in the same manner as the working piles.
A working pile is a pile which is installed as part of the permanent foundation works. No work on
working piles shall proceed until the testing of the trial pile has been completed to the satisfaction of
the S.O.

6.1.7 Load Tests

The Contractor shall submit to the S.O. for approval complete details of the testing equipment he
intends to use for testing piles. All loading tests shall be carried out and comply with the conditions
as described in Clause 6.9 of the Specification on pile testing.
The S.O. will select the location of the trial test piles and the working piles to be load tested.
The S.O. will decide upon the necessity for testing working piles, and may select for testing one or
more working piles which the Contractor shall drive in advance of the remaining piles at the Site.
Piles selected for this purpose shall be constructed or driven, with the same equipment as proposed for
the main piling work, to the depths required by the S.O. The remaining piling at the Site shall not
proceed until the testing of the advance working pile has been completed to the satisfaction of the
S.O. and meets the requirements for acceptance specified herein. The S.O. will also instruct the testing
of further piles during the course of the piling work.

6.1.8 Ultimate and Design (Working) Loads

Where pile test is carried out the ultimate load is defined as the constant load at which the pile
continues to settle at a steady rate or the load at which the maximum settlement of the pile top during
one continuous loading cycle is one tenth of the pile base diameter or least dimension, whichever is
the lesser.
Where pile test is not carried out the ultimate load is defined as the calculated ultimate load, derived
from appropriate static bearing capacity calculations.
The design load or working load shall be defined in relation to a pile loaded in isolation, without
nearby piles being loaded, except those providing test reaction.
Where the ultimate load is not measured by means of pile tests, the design load is the lesser of the
following:(a)

The calculated ultimate load for the pile divided by the specified factor of safety.

(b)

The calculated ultimate load of the pile base together with the calculated shaft adhesion, as
derived from appropriate static bearing capacity calculations divided by a factor of safety of
3.0.

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Unless otherwise specified, the factor of safety shall be taken as not less than 2.0 for piles in
compression and not less than 3.0 for piles in tension.

6.1.9 Piling Personnel

Piling work shall be carried out under the direction of a competent supervisor experienced in the
particular system of piling to be used.
He shall be employed full time for the duration of the piling operations and his appointment shall be
subject to the approval, in writing, of the S.O. before the commencement of piling work.
The Contractor shall also employ at each site a specially qualified foreman together with the
necessary gang of trained personnel and labour experienced in the installation of the piles.

6.1.10 Piling Records

The Contractor shall keep a record of all piles installed at the Site.
The record shall contain such details as specified or otherwise as required by the S.O.
The Contractor shall also submit to the S.O. within 24 hours a copy of the field record of the piling
work done each day.
On completion of all piling work at each site, the Contractor shall prepare and submit to the S.O. two
(2) complete sets of drawings showing details of all piles installed at the Site.
All pile test records shall be considered as confidential and shall not be disclosed by the Contractor to
any third party without the permission in writing of the Employer.

6.2

Precast Reinforced Concrete Piles

6.2.1 General
Precast reinforced concrete piles shall conform to the details shown on the Drawings. Concrete
reinforcement and formwork shall be in accordance with the appropriate Clause of the Specification.
Main reinforcing bars shall be supplied in one complete length; should this prove impracticable
separate lengths shall be effectively coupled mechanically or lapped as specified. Spacer forks shall
be of cast iron, mild steel or other material or type and shape approved by the S.O.
Pile shoes shall consist of "chill-hardened" cast iron points and mild steel straps cast into the points
and be in accordance with the Drawings or otherwise approved by the S.O.

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After pile driving and load tests have been completed to the satisfaction of the S.O., the top of each
pile shall be cut down to the correct level, and the steel reinforcement exposed and bent into the
required positions, prior to construction of the pile cap.
Where the length of pile left above the required level exceeds the length of pile cap reinforcement
required, the excess length of pile may first be cut at the level which provides the required length of
reinforcement.

6.2.10 Load Tests

The Contractor shall carry out load tests on precast concrete piles by the Maintained Load Method as
detailed in Clause 6.9.

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Tests shall be carried out on trial piles and working piles, as defined in Clause 6.1.7 and as directed
by the S.O.

6.3

Steel Sheet Piles

6.3.1 General
The work comprises the supply, delivering and driving of steel sheet piles with matching corner and
junction steel piles and the cutting of excess lengths of sheet piles all in accordance with the Drawings
or as directed by the S.O.
The Contractor shall provide all labour, plant, equipment, guide walings, timber trestles, temporary
stores, and the like necessary for the execution of work and remove them on completion.

6.3.2 Section and Properties

The steel sheet piles shall be `U' type with interlocking connection with one another to form a
continuous watertight wall after driving.
Special sections shall be used for all corners, junctions and at change of directions. Special sections
shall be fabricated as instructed or of an approved rolled section.
Each single pile shall have a minimum weight and section of modulus as described in the Drawings.
The weight shall be exclusive of rolling margins, which shall not exceed 2.50% of the theoretical
weight.
The Contractor shall furnish manufacturer's certificates for sheet piles supplied by him as proof of the
quality of steel for acceptance by the S.O. before any materials are brought to the Site.
The S.O. may at his discretion, require additional tests to be made on samples taken from the Site.
In the event of any steel sheet piles being found to be not in accordance with the relevant Standard the
whole batch of steel piles from which the test samples are taken may be rejected by the S.O. and shall
be removed from the Site at the Contractors own expenses, notwithstanding any previous acceptance
on the strength of the manufacturer's certificates.
The cost of all tests required by the Specification or the relevant British or other approved Standards
shall be deemed to be included in the Contract Rates, except where specifically mentioned otherwise.
Steel sheet piles may be purchased from different agents but shall be from the same rolling mill.

6.3.3 Storage and Protection

Sheet piles supplied by the Contractor shall be transported, handled and stored on the Site in such a
manner and location so as to prevent damage, distortion or corrosion.
If in the opinion of the S.O., piles are damaged in the process of handling, storing and transporting,
such that the structural value of such sheet piles are likely to be impaired, they shall be replaced as
directed by the S.O. at the Contractors own expenses.
When corrosion coating is specified, surfaces of steel sheet pile shall be suitably protected against
corrosion by cleaning, priming and coating with high build coal tar epoxy. Surfaces shall be prepared

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to ISO 8501-1 Sa 2.5 by sand blasting or St 3 by mechanical means. Primer shall be compatible with
the protective coating material. The coal tar epoxy shall be applied in three (3) coats to give a total
finished dry film thickness of 400 microns.

6.3.4 Piling Crew

The Contractor shall maintain on the Site a specially qualified experienced pile driving foreman,
together with the necessary gangs of trained labour capable of carrying out the Works and dealing
with all pile driving contingencies.
The Contractor shall supply to the S.O. full description and particulars of the proposed driving crew
and inspectors and such crew and/or inspectors shall be replaced, if the S.O. deems that they are not
suitable for the works.

6.3.5 Plant and Equipment

The Contractor shall provide and maintain all plant, equipment and vehicle, including frame-lifting
and driving devices, temporary guide walings, supply of fuel and lubricants and other equipment
necessary for execution and completion of the Works.
Before commencement of piling, the Contractor shall submit to the S.O. full details of his working
programme including the number and types of frames and hammers and/or rams which he intends to
use and the S.O. reserves the right to order the Contractor, at no additional cost to the Employer, to
provide any additional equipment and plant which the S.O. considers necessary for carrying out the
Works.
The S.O. may order the removal and/or replacement of any equipment and/or plant whenever he
considers that such equipment and/or plant is not suitable for the Works.
Notwithstanding any approval of the Contractors proposals by the S.O., the Contractor shall remain
solely responsible for the successful and timely installation of the sheet piles.
It shall be the responsibility of the Contractor to provide hammers of sufficient weight to control the
drop so as to ensure that no piles are damaged during piling and that the piles are driven to the
required penetration depth.
In general, the pile hammer shall be adequately supported and located during driving. Hammer
suspended from jib shall be fitted with proper guide attachments and hammer supported on frames
shall be located to sit squarely on the piles at all times during driving and the frames shall be of a rigid
and strong construction.
The Contractor shall not remove any of his equipment or plant from the Site until the S.O. has
certified in writing that all steel sheet piling has been satisfactorily completed.

6.3.6 Alignment of Sheet Piles

Piles shall be driven in the positions indicated on the Drawings.
The Contractor shall be responsible for the true and proper setting out of the piles and correctness of
the position, levels, dimensions and alignments of all parts of the work and for the provision of all
instruments, appliances and labour in connection therewith.

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The setting out and the checking of the correctness of position, levels, dimensions and alignments of
the works shall be carried out by an experienced surveyor employed by the Contractor before
commencing, during and after completion of piling work.

6.3.7 Lifting and Pitching

Piles shall be lifted and pitched accurately to their positions shown on the Drawings. Where piles have
been damaged due to improper handling, lifting and/or pitching, the Contractor shall replace the
damaged piles at his own expense.

6.3.8 Pile Driving

Sheet piles shall be pitched to form panels before driving. The piles shall be prevented from leaning
and/or tilting and in this respect the Contractor shall allow for temporary guide walings, leg guides to
the satisfaction of the S.O.
Temporary guide walings, leg guides, back guides, and the like shall consist of substantial timbers
and/or other approved materials spaced apart at a distance equal to the overall width of the piling with
timber spacer blocks or other approved material to fit the profile of the piles.
The piles shall be driven with the driving equipment suitable for the work.
The heads of piles are to be protected by an approved type of helmet and dolly during driving and the
hammer rope shall not be "snatched" before the hammer has completed it full drop.
Driving of sheet pile shall commence by driving a pair of piles to part penetration and as vertical as
possible. A minimum of ten piles are then interlocked and pitched ready for driving. The last pair of
piles in the panels are driven to part penetration and the remaining pairs of piles are then driven to
finished level in stages. The procedure shall then be repeated with a further panel of piles with the
half driven last pair of the first panel forming the first pair of the second panel.
Piles shall be driven in pairs or otherwise as directed.
The interlock of the piles shall be lubricated with an approved grease.
When driving, adjustments are to be made to compensate centres of sheet piling to fit into the overall
length of sheet piling panels.
Sheet piles shall be driven to the length and depth indicated on Drawings or as directed by the S.O. to
achieve a satisfactory anchorage.

6.4

Treated Timber Piles

6.4.1 General
Timber used for the piles shall not be of a lesser quality than the Selected Structural Grades specified
in Clause J (Stress Grading) of Part III of the Malayan Grading Rules for Sawn Hardwood Timber.
The timber shall be free from rot, fungal or pest attack and any other defects not permitted for its
grade.

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The dimensions of sawn timber piles shall be within the range of 2mm less and 6mm greater than their
specified cross-sectional dimensions. The centroid of any cross-section of a sawn timber piles shall
not deviate by more than 25mm from the straight line connecting the centroids of the end faces of the
standard length of pile.
Where applicable the standard of workmanship shall conform to BS 5268.
Before commencement of any work, the Contractor shall notify the S.O. the name of the supplier and
manufacturer for approval. All piles supplied shall be SIRIM approved and bear the SIRIM
acceptance logo.
Piles shall be supplied in one single length of 6 metres, unless otherwise approved.

6.4.2 Treatment of Piles

6.5.4 Measuring Pile Set

The Contractor shall provide suitable means of measuring and recording the pile set under each
hammer blow.
This may be achieved by using a fixed straight edge held against a sheet of paper affixed to the pile,
and running a pencil along the straight edge at the moment of impact to record on the paper the elastic
and plastic sets resulting from the blow. The straight edge shall be attached to a fixed frame of heavy
timber standing close to the pile.

6.5.5 In-situ Lengthening of Piles

Where it becomes necessary to splice or lengthen a pile, the top of the pile and the bottom of the
extension pile shall be prepared for manual Vee butt and fillet welding by metal arc welding process.
Suitable means shall be employed to ensure straightness of the spliced or lengthened piles.
After each pile has been lengthened or spliced and prior to further driving the Contractor shall clean
the pile at the joint and paint the surface with a suitable primer followed by two coats of coal tar
epoxy paint or equivalent. Pile driving shall continue only when the coating has hardened.

6.5.6 Welding
All electric arc welding equipment shall be to the approval of the S.O. and shall comply with BS EN
ISO 2560 applicable to welding of piles rolled from steel manufactured to BS 7668 Grade 43A.
All welding electrodes shall comply with BS EN ISO 2560 applicable to welding of Grade 43A steel.
The Contractor shall also comply with the requirements of BS EN 1011-1 including stress relief for
welding of high tensile steel and shall submit details of the welding procedure which he proposes to
adopt for the S.O.s approval, including:
(a)

Make, type and gauge of electrodes

(b)

Size, shape and number of runs in weld joint

(c)

Direction of welding

(d)

Welding current

(e)

Length of run per metre of electrode

Only procedures approved in writing by the S.O. shall be adopted in welding on the steel piles.
Welding shall be carried out in accordance with the details shown on the Drawings.
The portion of the piles to be welded shall be cleaned to a bright metallic finish before welding. The
weld shall be of the complete full penetration butt weld and convex full fillet type.
Welds shall be subject to inspection by the S.O. and shall comply with the requirements for fusion,
penetration, soundness and freedom from undercutting.

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6.5.7 Welding Personnel

Only the most highly skilled welders shall be employed on the works and every welder before
commencing any joint welding shall prepare specimens for testing in accordance with API Standard
1104 or similar for each welding procedure proposed by the Contractor.
The S.O. will advise the Contractor in writing which welders pass the performance qualification test.
Only these welders will be allowed to joint steel piles. The S.O. shall be at liberty to withdraw his
approval of any welder responsible for making joints which fail to meet the required standard.

6.5.8 Reuse of Cut-off Piles

Cut-off piles may be reused for the Works provided:
(a)

The cut-off piles are of good condition and not less than 4 metres long.

(b)

When used to make up full length piles or extension piles there will be no extra costs for
spliced joints required for the make-up pile.

(c)

Such make-up piles shall be used only in locations to the direction of the S.O.

6.5.9 Cutting of Pile Head

After the pile has been driven to the required level and set, the pile shall be cut, if required, to the
finished level as shown on the Drawings and to the satisfaction of the S.O.

6.5.10 Load Tests

The Contractor shall carry out static load tests on piles as directed by the S.O.
The loading platform shall be strongly built and suitable arrangements made to prevent over-turning.
The load shall be applied so that its magnitude can be determined accurately. Concrete or metal
blocks, bags of sand, structural steel or water in a tank may serve this purpose.
The test piles shall be selected by the S.O. The pile selected for testing may form part of the
foundation to the structure.
Piles selected by the S.O. shall be tested by the Contractor as follows:
(i)

The test load shall be applied using a jack by a method approved by the S.O. and shall be
measured within an accuracy of 2%. Settlement recovery shall be measured within an
accuracy of 0.05mm from a datum that will not itself be affected by any movement of the
ground due to the test loading or other causes. The S.O. may require independent checks on
the level of the datum by an accurate levelling instrument.

(ii)

The jack shall be properly calibrated by an approved testing station and the appropriate
certificate produced before any tests commence. The measuring equipment and supports
employed shall be adequately protected from the sun and elements and the readings of the air
temperature shall be made and recorded at the same time as those on the gauges of the several
measuring instruments used.

(iii)

The test load shall be applied in equal increments of one-tenth of the working load up to the
working load and thereafter at 20% of the working load up to twice the working load.

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(iv)

The load shall be kept constant after each increment or reduction until the rate of settlement
does not exceed 0.25mm per hour.

(v)

The load shall be applied and removed gradually and without shock. Other work that might
cause vibration or any other disturbance to the ground conditions at the test site or affect the
plant or apparatus being used in the test shall be suspended during the period of the test.

(vi)

The safe working load shall be maintained for at least 12 hours and the full test load of 2
times the working load shall be maintained until the rate of settlement ceases to be apparent
but for not less than 48 hours.

(vii)

The amount of settlement and recovery shall be read and recorded immediately after the
change of loading and at 10 minute intervals thereafter. Readings under working load, full
test load and during recovery at zero load need not be taken and recorded more frequently
than at 1 hour intervals.

(vii)

The Contractor shall, within 48 hours of the completion of the test, submit to the S.O. for each
pile tested a detailed record of testing together with graphs prepared to suitable scale,
showing:

(viii)

6.6

(a)

load and settlement plotted above and below a common base line of time;

(b)

settlement and recovery plotted vertically against a base line of load.

For acceptance, the settlement of the pile under the test load and the recovery of the pile after
their subsequent removal of the test load shall not exceed the following values:
(a)

residual settlement

6mm

(b)

settlement under working load

12mm

(c)

settlement under twice the working load

38mm

Prestressed Spun Concrete (PSC) Piles

6.6.1 Standard
Piles shall be manufactured to comply with the requirements of:
-

BS 8004

British Standard Code of Practice for Foundation

BS 8110

Standard use of concrete

BS 5400 Part 7 :

Specification for materials and workmanship, concrete,

reinforcement and prestressing tendons

BS 5400 Part 8 :

Recommendation for materials and workmanship, concrete,

reinforcement and prestressing tendons.

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6.6.2 Shape
The PSC piles shall be made of hollow cylinders of external diameter with a wall thickness sufficient
to support the working loads indicated on the drawings. They shall be provided with an appropriate
steel joint which will have the same performance as the main body. The external diameter and
thickness of the hollow cylinder shall be constant over the entire length of the pile and coaxial with
the steel casing at each end.

6.6.3 Aggregates
Coarse aggregates shall be clean granite and shall not contain any deleterious materials, dust, mud,
salts or organic matter other requirement of BS EN 12620. The maximum size of the coarse
aggregate shall be less than 20mm, and shall be less than 2/5 of the thickness of the PSC piles. Fine
aggregates shall be clean river sand. Sea or beach sand shall not be used.

6.6.4 Water
The water shall be free of oil, acid, salts, organic matter or other substances that be deleterious to
concrete or steel and shall conform to the requirement of BS EN 1008.

6.6.5 Cement
Shall be ordinary Portland cement meeting the requirement of BS EN 197 - 1.

6.6.6 Admixtures
Admixtures shall be such as not to produce any defects to the concrete and/or to the reinforcement.
Calcium chloride shall not be used. Admixtures permitted to be used shall meet the requirement of BS
5057.

6.6.7 Prestressing Steel

(a)

General

Wires or bars shall be free from grease or other materials likely to impair the bond. The steel should
not be pitted.
(b)

Materials

The prestressing steel should be one of the following:

(i)

Plain hard-drawn steel wire complying with the requirements of BS 2691, "Steel for
Prestressed Concrete Part 1 Plain Hard-drawn Steel Wire".

(ii)

Indented or crimped hard-drawn steel wire complying with the requirements of

BS 2691 in all respects except for the bend test.

(iii)

High tensile steel bars of open hearth steel with sulphur and phosphorus contents each
below 0.05 per cent.
Bars whether plain or deformed should have a tensile strength of not less than
930MPa with a 0.25 per cent proof stress of not less than 75 per cent or more than 92

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per cent of the actual ultimate strength. Methods of testing shall be in accordance to
BS 10002 - 1, "Tensile Testing of Metals".
(iv)

Such other wires, strand or bars having properties not inferior to those laid down in
BS 2540 in sub-clause (iii) above respectively.

6.6.8 Reinforcement
Steel reinforcement should comply with the requirements of BS 8110 "Structural Use of Concrete".

6.6.9 Reinforcement Details

The total sectional area of prestressing tendons and axial reinforcement arranged in a straight axial
direction shall not be less than 1%. The net space between the prestressing tendons and the axial
reinforcement shall be more than the larger of their diameters and more than 4/3 of the maximum size
of the coarse aggregate.
The spiral and ring reinforcement shall be arranged on the outside of the prestressing steel and axial
reinforcement. Such spiral and ring reinforcement shall be more than 3mm in diameter and shall have
a pitch no greater than 150mm.
The cover shall be not less than 30mm.
The prestressing steel and reinforcement shall be free of loose rust or any material which will reduce
bond.

6.6.10 Concrete
The 150mm x 150mm test cube strength of the concrete for the manufacture of the PSC piles shall not
be less than 78.5MPa at 28 days.

6.6.11 Curing
The PSC piles shall be cured under moist conditions for at least 6 days after they have been removed
from the moulds. If steam curing is used, the curing period may be reduced to 3 days.
When low pressure steam curing is performed, the following requirements must be complied with:
(a)

Steam shall be introduced so that the temperature in the curing chamber is raised uniformly.

(b)

Steam curing shall not be performed until at least two hours have elapsed after the mixing of
the concrete.

(c)

The rate at which the temperature in the curing chamber is raised shall not be greater than
20oC per hour and the maximum temperature shall not be greater than 70oC.

(d)

The piles shall be taken out of the curing chamber only after the temperature in curing
chamber has been gradually reduced to that prevailing outside.

6.6.12 Level of Prestress

The prestress after allowing for losses should satisfy the following conditions:

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(a)

Prestress to cover handling, transporting and lifting conditions, for this purpose it may be
assumed that only 75% of the full loss of prestress will have occurred within 2 months of a
casting.

(b)

Prestress in kgf/cm of not less than 0.7 times the ratio of the length of the pile to its least
lateral dimension, and not less than 50kgf/cm.

(c)

Minimum prestress related to the ratio of effective weight of hammer to weight of pile to be
in accordance to BS 8004.

6.6.13 Transfer of Prestress

The transfer of prestress shall be in accordance with BS 8004.

6.6.14 Pile Ends

Both ends of each length of pile are to be provided with a casing made from steel plate of at least
16mm thickness. The ends of the prestressing tendons shall be fixed to the steel casing such that the
full prestressing force shall be flush with the top plate of the steel casing. The end surface of the steel
casing shall be in a plane which is at right angles to the longitudinal axis of the pile.
The barrel of the steel casing shall be flush with the barrel of the concrete shaft of the PSC pile, with a
chamber to accommodate the welding when two lengths of pile are jointed.

6.6.15 Manufacturing of Piles

Piles shall be manufactured by the centrifugal casting process. Metal forms shall be used and they
shall be well braced and stiffened against deformations caused by the hydrostatic pressure of the wet
concrete while spinning. The metal forms shall have smooth joints and inside surfaces. The forms
shall be accessible for adequate cleaning.
The portions of the forms which form the end surfaces of the pile sections must be a true plane
perpendicular to the axis of the section within the following tolerances: maximum allowable deviation
of 1.5mm for abutting end surfaces, 5mm for pile head end surfaces and 25mm for pile tip end
surfaces.
The concrete mix shall provide the most uniform possible distribution of aggregates across the wall of
the pile sections. Fine and coarse aggregates shall have as nearly as possible the same specific
gravity. The water ratio by weight shall not exceed 0.35. The concrete shall be Grade 78.5 (in
conformance to BS 5400: Part 7) and have a minimum compressive strength of 78.5MPa at twentyeight (28) days.

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The wall thickness of the spun pile shall be within the following tolerance:
- 3mm, +9mm
Pretension reinforcing wires shall be centred in the pile wall. The transfer of prestress shall be in
accordance with BS 8004.
The spiral reinforcement shall be wrapped outside the longitudinal reinforcement and shall have the
minimum cover as required in the Codes. The spiral cage shall be securely held in position during the
casting and spinning operation.
The piles may be initially steam cured. Steam shall not be applied until 60 minutes have elapsed
following casting. The section may then be steam cured between 55oC and 70oC. Steam shall be so
introduced that the temperature in the curing chamber is raised uniformly. After the section has been
steam cured for a minimum of (3) hours, the forms may, if the concrete has reached sufficient strength
to sustain all handling stresses, be removed from the section. The pile shall not be taken out of the
curing chamber until the temperature in the curing chamber has been gradually reduced to the
prevailing temperature outside. The curing shall be carried out by such a method that may not affect
adversely the quality of the product.
The method of handling of the pile sections shall be such that no damage to the concrete will occur.
However, the minimum prestress in the concrete after all losses shall be adequate to resist stresses
induced by handling.
The main body of the prestressed concrete pile shall, when subjected to the bending test, not develop
crack of width more than 0.05mm under a bending moment as specified.
The bending strength test shall be performed by supporting the pile section at points located 1/5L
from its ends (where L is the length of the pile section). The vertical load shall be applied at the
centre of the span. Two piles from each lot shall be so tested. If one of the two does not meet the test
criteria, four other pile sections shall be further sampled and tested. If all four satisfy the test, then all
piles in the lot will be accepted; otherwise all piles in that lot shall be rejected.
Both ends of each length of pile are to be provided with a steel end plate. The ends of the PC tendons
shall be fixed to the steel end plate such that the full prestressing force is transmitted over to the steel
end plate. The ends of the PC tendons shall be flushed with the top of the steel end plate. The end
surface of the steel end plate shall be in plane which is at right angles to the longitudinal axis of the
pile.
The barrel of the steel casing welded to the end plate shall be flushed with the barrel of the concrete
shaft of the pile, with a chamber to accommodate the required depth of welding when two lengths of
pile are jointed.

6.6.16 Splicing
When two lengths of pile are joined, the end plates must bear over their complete areas. Shims for
packing will not be accepted.
The two end plates are to be welded around their entire periphery.

6.6.17 Marking of Piles

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Each pile shall have marked on its side, within 300m from the head, the length of pile, the date of
casting, and identification number. The marking shall be in indelible paint which is not injurious to
the concrete and the letters shall be at least 75mm high.
In addition the pile shall be marked by indelible paint as above perpendicular to its lengths
commencing at 5 metres from the toe at every 200mm up to the head. Just above each line, i.e. on the
side further from the toe, the distance of each such line from the toe shall be painted.

6.6.18 Handling and Stacking

Prestressed piles shall not be lifted or handled until fully stressed.
Piles shall be lifted, supported and pitched at the positions indicated by the manufacturer.
For the stacking of piles, heavy sill logs shall be well bedded on the ground or on a prepared surface,
and shall be flattened to give a bearing width not less than 200mm, and a minimum clearance of
300mm above ground. Piles may be stacked on top of each other up to six layers. Each layer shall be
separated from the next layer by timber bearers, each 100mm wide and 75mm high.
The bearers shall be placed centrally above the sill logs, and above one another, so that no additional
bending in any pile in the stack.

6.6.19 Joints
The bending strength of a joint between two lengths of pile shall be equal or more than the bending
strength of the concrete shaft. When two lengths of pile are jointed, the end plates must bear over
their complete areas. Shims for packing will not be accepted. The two end plates are then welded
along their entire periphery with weld size as specified in the drawing or where not shown in drawing,
to the requirements of the pile manufacturer.

6.6.20 Welding of Joints

All welding shall be carried out in accordance with requirements of BS EN 1011: Metal-Arc Welding
of carbon and carbon-manganese steel. The Contractor shall supply the S.O. with full details of his
proposed method of welding and shall if required, arrange for a demonstration, and the Contractor
shall employ not less than two teams of welders.

6.6.21 Tests for Approval of Welders

Welders shall be qualified in accordance with the requirements of AWS (American Welding Society)
Code D1.1. Only welders who pass the qualifying tests for the type of weld shall be employed on the
Works.

6.6.22 Examination of Welds

Fillet welds between the end plates of the joints shall be tested using magnetic particle or dye
penetrant test methods. Copies of these test records and reports shall be furnished to the S.O.
Where such examination reveals defects in the welds, the joints shall either be rejected or repaired. If
repeat tests show the weld to be still defective, the joint shall be rejected. The defective weld shall be
removed, replaced with a fresh weld, and re-examined.

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For the purpose of this Clause, cracks, leaks, laminations, lack of complete fusion, undercutting or
reduction in wall thickness adjacent to the weld shall constitute a defect.

6.6.23 Driving Piles

The Contractor shall submit full details of his proposed pile driving equipment and methods to the
S.O. for approval before commencing pile driving operations.
Each pile shall be driven continuously until the specified set and/or depth has been reached.
However, the S.O. may permit the suspension of driving if he is satisfied that the rate of penetration
prior to the cessation of driving will be substantially re-established on its resumption or if he is
satisfied that the suspension of driving is beyond the control of the Contractor.
The follower (long dolly) shall not be used without prior written approval from the S.O. If use of the
follower is permitted by the S.O., its dynamic stiffness must be at least as large as the dynamic
stiffness of the pile.
The Contractor shall take every precaution in pitching and driving or sinking the piles to ensure that
no damage occurs to them and that they are pitched and driven sunk in the positions shown on the
drawings.
The piles shall be driven down or sunk to such depths as to be capable of carrying the specified loads.

6.6.24 Pile Hammers

Pile hammers shall be of size and type able to deliver consistently and effective dynamic energy
suitable to the piles to be driven and the material into which they are to be driven. Hammers shall be
provided with proper driving helmets suited for the piles. Any indication of collapse of hoses,
stripping of hose lining or any erratic action of the hammer shall be cause for immediate shutdown
until the problem has been corrected.
Pile hammers shall be operated at the full rated efficiency and capacity and in the manner specified by
the manufacturer, except as directed otherwise by the S.O., or noted herein below under reduction of
Hammer Energy.
When a steam or air hammer is used for driving any type of piles, both the volume and pressure of
steam or air recommended by the manufacturer of the hammer shall be maintained at all times to
ensure full energy of the driving blows. Before the pile driving is started, the Contractor shall provide
written certification to the S.O. that the pile hammer, compressors and valves have been inspected and
found to be in good working condition.

6.6.25 Reduction of Hammer Energy

When the pile is set in a pre-jetted or pre-drilled hole or when the point of a prestressed concrete pile
is passing through soft soil so that there is little or no resistance to penetration of the pile, there is a
possibility that longitudinal tensile stresses may be set-up in the pile shaft by the elastic shock waves
travelling up and down the pile.
For such driving conditions, the length of stroke of the hammer shall be reduced. Failure of the piles
due to longitudinal tensile stresses caused by excessive driving shall be the Contractors
responsibility.

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6.6.26 Pile Cushion Block

The heads of all prestressed concrete cylinder piles shall be protected with a soft wood cushion block
at least 15cm thick to effectively and uniformly distribute hammer blow energy. The block shall be
composed of layers of 25mm plywood or approved equivalent, and of such dimensions as to
completely cover the concrete cross-section of the pile. The cushion block shall be inspected
periodically during driving and no driving shall be done with a block that has been unduly worn and
compressed with use. Cushion blocks must be replaced when compressed to 1/2 their original
thickness, when badly worn or when burning.

6.6.27 Driving
The piles shall be driven to the driving resistance or tip elevation as determined by the S.O. from pile
load tests. The maximum allowable variation at the butt end of the pile shall be 150mm in any
direction from the location shown on the Drawings or as directed by the S.O.

6.6.28 Cutting Off and Capping Piles

Top of foundation piles shall be embedded in the concrete footing or pile cap, a minimum depth of
75mm (measured at centre line of pile). When the top elevation of a pile is below the elevation of the
bottom of the cap, the pile shall, if approved by the S.O., be built-up from the butt of the pile to the
elevation of the bottom of the cap by an approved method. The cuts shall be made accurately in
clean, straight line; care shall be exercised to avoid damaging the remaining pile and to ensure full
bearing between the footings (or caps) and piles.
The inside of the pile shall be roughened (by sand blasting or bush hammering) in order to improve
the bonding strength between the cast-in-situ concrete cap and the precast concrete pile.
The cast-in-situ concrete cap shall not be poured until the inside of the precast pile has been inspected
by the S.O. and his approval is obtained.

6.6.29 Re-driving
Re-drive checks, if required, shall be carried out in accordance with an approved procedure.

6.6.30 Jetting
Jetting shall be carried out only when the Contractors detailed proposal have been approved.

6.6.31 Pile Shoes

Pile shoes of a type which seal off the core shall not be used on spun concrete piles.

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6.7

Cast-in-situ Bored Piles

6.7.1 Description
This Clause gives the requirements for the installation and testing of bored piles. This work shall
comprise the boring or grabbing, with or without casing, and subsequently filling the hole with plain or
reinforced concrete to form bored cast-in-situ piles, all in accordance with this Specification and to the
details shown on the Drawings.

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

6.7.3 Approval of Proposal

Before any piles are installed, the Contractor shall submit to the S.O. for approval the description of the
method he proposes to adopt for installing the bored piles giving full particulars of the drilling and the
plant and equipment to be employed. Notwithstanding the approval of the Contractors proposals by the
S.O., the Contractor shall be and remain solely responsible for the successful installation of the piles.

6.7.4 Shaft Diameter

The diameter of the shaft shall not be less than the specified designed diameter as shown in the
Drawings, at any level throughout its length. Temporary casing used to control the shaft diameter
shall have a nominal inner diameter 25mm greater than the required shaft diameter.

6.7.5 Length of Piles and Cut-off Level

The cut-off level of piles shall be as shown in the Drawings. The lengths of piles shown in the Drawing
are indicative. The actual length of pile shall be decided by the S.O. based on examination of the material
recovered from the pile excavation, results of in-situ test at the bottom of the pile excavation and the
results of preliminary pile load tests.

6.7.6 Pile Layout

The pile layout and the number of piles required are as shown in the Drawings. If necessary inclined
piles have to be provided with a ratio of 1 : 10 or 1 : 8 or 1 : 6 maximum.

6.7.7 Setting Out

Setting out shall be carried out using the data and reference points as shown on the Drawings.
Immediately before installation of the pile, the pile position shall be marked with suitable identifiable
pins, pegs or markers.

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6.7.8 Equipment
The Contractor shall provide all plant, tools appliances and temporary works required for the
installation of bored piles. All plant, materials and methods employed in the formation of the piles
shall be such as to ensure that the completed piles are of the desired cross sections.

6.7.9 Soil Information

The Contractor shall, prior to starting the work, satisfy himself of the adequacy and accuracy of the
information contained in available soil reports by such additional borings and other tests as he may deem
necessary.

6.7.10 Temporary Casings

Temporary casing shall be of appropriate size and of approved quality. They shall be free from
significant distortion and shall have sufficient strength to withstand handling stresses and external
pressures of the caving soil or water. They shall be of uniform cross section through out each continuous
length and shall be free from internal projections and encrusted concrete and lumps of soil which might
prevent the proper formation of the pile.

6.7.11 Permanent Casing

Permanent casings, if required as part of the designed pile shall be as specified or shown in the
Drawings.

6.7.12 Reinforcement
The reinforcement shall be as specified in Section 5.

6.7.13 Concrete
Materials for concrete shall be as specified in Section 3. Where ready-mixed concrete is used, with the
approval of the S.O., it should be in accordance with BS 8500.

6.7.14 Supply of Drilling Fluids

Drilling fluid shall be bentonite suspension and shall be of approved quality and shall comply with the
specification No. DF CP4 of the Oil Companies Materials Association, London (Drilling Fluid Materials
- Bentonite). A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
powder, showing the properties of each consignment delivered to site. This certificate shall be made
available to the S.O. on request.

6.7.15 Mixing of Drilling Fluids

Bentonite shall be mixed thoroughly with clean fresh water to make a suspension which will maintain
the stability of the pile excavation for the period necessary to place concrete on completion of the
excavation. Preparation of the suspension shall comply with the manufacturer's instructions.
Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to
modify the bentonite suspension or prehydrate the bentonite in fresh water so as to render it suitable in
all respects for the construction of piles.

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6.7.16 Tests of Drilling Fluids

The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by
the Contractor prior to the commencement of the work. The frequency may subsequently be varied as
required, depending on the consistency of the results obtained.
Control tests shall be carried out on the bentonite suspension, using suitable apparatus. The density of
freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension
being formed. The measuring device shall be calibrated to read to within 0.005g/ml. Tests to determine
density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pile boring
and the results shall generally be within the ranges stated in table below. The tests shall be carried out
until a consistent working pattern has been established, account being taken of the mixing process, any
blending of freshly mixed bentonite suspension and previously used bentonite suspension and any
process which may be used to remove impurities from previously used bentonite suspension. When the
results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and
tests to determine density and viscosity shall be carried out as agreed with the S.O. In the event of a
change in the established working pattern, tests for shear strength and pH value shall be reintroduced for
a period if required.
Property to be
Measured

Range of Results at
20oC

Test method

Density

Less than 1.10g/ml

Mud Density
Balance

Viscosity

30-90s or

Mash Cone Method

Less than 20cP

Fann Viscometer

Shear
Strength
(10 minute gel
strength)

1.4 - 10N/mm2
or 4-40N/mm2

Shearometer
Fann Viscometer

9.5 12

pH indicator
Paper Strips or
Electrical pH Meter

Where the Fann viscometer is specified, the fluid sample should be screened by number 52
sieve (300m) prior to testing.

6.7.17Setting Out
The Contractor shall check the position of each pile during and immediately after placing the casing and
it shall be checked and approved by the S.O. before the boring starts.

6.7.18 Method of Boring

Boring shall be carried down to the depth as required and as directed by the S.O. The boring shall be
carried out by power auger. Where caving conditions are encountered or where excess water begins

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seeping into the borehole, no further drilling shall take place until the Contractor takes all necessary
precaution and selects an approved method of preventing the ground movements or ingress of water or
foreign material. Where instructed by the S.O., the Contractor shall place a temporary casing or advance
the drilling by stabilising the borehole by use of drilling fluid of appropriate properties.
Where practicable, the bottom of the casing should be kept sufficiently far below the borehole to prevent
the inflow of soil and the formation of cavities in the surrounding ground, which can release water into
the pile concrete when the casing is withdrawn. Where the casing cannot practically be advanced below
the bottom of the borehole, for example in compacted sand and gravel, it will be necessary to use other
expedients.
The S.O. shall be informed of any unforeseen ground conditions encountered during boring.
Where hard stratum is encountered during boring, the Contractor shall advance the borehole by means of
chiselling or use of pneumatic tools or rock coring buckets with tungsten carbide tip teeth or other
equivalent approved means with the approval of the S.O. For purposes of payment of advancing
borehole through hard stratum, hard stratum shall be defined as material with Standard Penetration test
value of 200 and above.
Soil, rock or ground water samples shall be taken and appropriate soil identification tests carried out
while boring at every 1.5m intervals or change of strata as per the directions of the S.O. The taking of
samples and all subsequent handling, transportation and testing shall be carried out in accordance with
BS 5930. The rate of boring shall include for sampling and testing of soil samples.

6.7.19 Use of Drilling Fluid for Stabilising Pile Borehole

Where drilling fluid is used to stabilize the borehole, level of the fluid in the excavation shall be
maintained so that the fluid pressure always exceeds the pressures exerted by the soils and external
ground water and an adequate temporary casing shall be used in conjunction with the method to ensure
stability of the strata near ground level until concrete has been placed. The fluid level shall be
maintained at a level not less than 1m above the level of the external ground water.
In the event of rapid loss of bentonite suspension from the pile excavation, the excavation shall be
backfilled without delay. Before resuming excavation at that location the approval of the S.O. shall be
obtained.

6.7.20 Spillage and Disposal

All reasonable steps shall be taken to prevent spillage of bentonite suspension on the site in areas outside
the immediate vicinity of boring. Discarded bentonite shall be removed from the site without undue
delay. Any disposal of bentonite shall comply with regulations of the local controlling authority.

6.7.21 Boring Near Recently Cast Piles

Piles shall not be bored so close to other piles which have recently been cast and which contain workable
or unset concrete, such that a flow of concrete could be induced from or damage caused to any of the
piles.

6.7.22 Pumping from Pile Bores

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Pumping from a borehole shall not be permitted unless a casing has been placed into a stable stratum
which prevents the flow of water from other strata in significant quantities into the boring, or, unless it
can be shown that pumping will not have a detrimental effect on the surrounding soil or property.

6.7.23 Standard Penetration Test

When the Contractor has bored to the designed depth or any lower depth as instructed by the S.O.,
Standard Penetration Tests shall be carried out at the bottom of pile excavation to assist in confirming the
founding level. The number and depth at which these tests are carried out shall be at the discretion of the
S.O. The cost of carrying out such tests shall be deemed to be included in the Contract Rates.

6.7.24 Proof Coring

Where bedrock is encountered during boring, the Contractor shall if instructed by the S.O. bore a further
600mm to establish a proper socketing for the pile. He shall affirm the soundness of the bedrock by
coring through the bedrock by a diamond core drill and to determine the rock quality designation and
total core recovery in accordance with BS 5930 to a depth of 5 times the diameter of the pile or to the
designed pile depth whichever is less. All drill-holes shall be cement grouted on completion. The
Contractor shall maintain a diamond core drill at site for this purpose.

6.7.25 Depth of Bored Pile

Upon completion of the Standard Penetration Test (SPT) or the drill-hole, the Contractor shall
immediately furnish the results to the S.O. After assessing the results the S.O. may instruct the
Contractor to proceed with the installation of the bored pile or may instruct the Contractor to further
advance the depth of the boring until further SPT or drilling confirms that sound founding level is
reached.]

6.7.26 Cleaning of Pile Bore

On completion of boring, loose, disturbed material or remoulded soil shall be removed from the base of
the pile and the hole shall be cleaned to the satisfaction of the S.O. On final approval of the boring by
the S.O., the final depth of borehole shall be measured.

6.7.27 Inspection of Pile Bore

Each pile borehole shall be inspected and measured prior to the placing of concrete in it. The excavation
must be examined by the inspector or any other representative of the S.O. and permission shall be
obtained by the Contractor before proceeding with concreting. The Contractor shall provide at his own
cost all the apparatus necessary for inspection, including any electrical apparatus, if required.
For dry boreholes, each hole shall be inspected prior to the placing of concrete in it. The inspection shall
be carried out from the ground surface in the case where the borehole diameter is less than 750mm.
Torches or other approved means of lighting, measuring tapes and a means of measuring verticality shall
be provided. Where the borehole diameter exceeds 750mm, adequate equipment conforming to BS 8008
shall be provided by the Contractor to enable the Contractor and the S.O. to descend into the borehole for
the purpose of inspection.
For wet boreholes, i.e. holes filled with drilling fluid or water, a suitable probe shall be provided to
ascertain the evenness and cleanliness of the pile base. In the event that the soil characteristics at the
bottom of the borehole is significantly impaired due to ingress of water or is filled with loose disturbed
or remoulded soil or foreign material as a result of the Contractors prolonged delay in placing of

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concrete, he shall clean the hole again or advance the hole further to a stratum of at least the same soil
characteristic as before. The additional cost for boring, carrying out the Standard Penetration Test, and
the additional concrete shall be borne by the Contractor.

6.7.28 Disposal of Spoil

The Contractor shall be responsible for the disposal of the spoil removed from the pile hole as per the
directions of the S.O.

6.7.29 Placing of Reinforcement

The steel reinforcement cage consisting of longitudinal bars and spiral reinforcement or lateral ties shall
be securely assembled prior to placing in the borehole.
Necessary cover blocks shall be provided for the reinforcement cage to ensure a clear cover of at least
75mm to the reinforcement.
The reinforcement cage shall be made so that there is no relative displacement of the reinforcement
during the construction of the pile and shall be sufficiently strong enough to withstand the impact of
falling/discharging concrete.

6.7.30 Continuity of Construction

A pile constructed in a stable cohesive soil without the use of temporary casing or other form of support
shall be bored and concreted without prolonged delay and in any case soon enough to ensure that the soil
characteristics are not significantly impaired.

6.7.31 Concreting - General

The method of placing and workability of the concrete shall be such that a continuous monolithic
concrete shaft of full cross section is formed. The concrete shall be placed without such interruption as
would allow the previously placed batch to have hardened. The method of placing shall be approved by
the S.O.
The Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid
arching of the concrete in the casing. No spoil, liquid or other foreign matter shall be allowed to
contaminate the concrete.

6.7.32 Workability of Concrete

The workability of the concrete shall be determined by the slump test as describe in Section 3.
The concrete shall have slumps of 100mm to 150mm in dry shaft without temporary casing and 150mm
to 200mm for concrete placed in dry shaft with temporary casing and 175mm to 225mm slump for
concrete placed by tremie under water or drilling fluid. The slump shall be measured at the time of
discharge into the borehole. The concrete is to be rejected if the required slump is not met.

6.7.33 Minimum Cement Content

The cement content in any mix shall be not less than 350kg/m3. Where concrete is to be placed under
water or drilling mud by tremie, the cement content shall be not less than 380kg/m3, or where the pile
will be exposed to sea water 400kg/m3.

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6.7.34 Cube Tests

Tests cubes shall be taken from each batch of the concrete used in the concreting or as required by the
S.O., to determine and control the strength of the concrete in the piles. Test cubes shall be taken in
accordance with Section 3.0. The Contractor shall submit certified copies of the result of all tests to the
S.O.

6.7.35 Compaction
Internal vibrators shall not be used to compact concrete unless the method of use has been approved.
Rodding shall be done in the top one metre of the shaft.

6.7.36 Concreting in Dry Boring

Approved measures shall be taken to avoid segregation and bleeding and to ensure that the concrete at
the bottom of the pile is not deficient in grout. The concrete shall be placed by the use of a hopper with a
length of pipe to ensure that the concrete falls centrally to the full depth without striking the
reinforcement steel or the sides of the pile excavation.

6.7.37 Concreting Under Water or Drilling Fluid

Concrete to be placed under water or drilling fluid shall be placed by tremie unless otherwise approved
and shall not be discharged freely into the water or drilling fluid.
Before placing concrete, measures shall be taken in accordance with Clause 6.7.27 to ensure that there is
no accumulation of silt or other material at the base of the borehole and the Contractor shall ensure that
heavily contaminated bentonite suspension, which could impair the free flow of concrete from the pipe
of the tremie, has not accumulated in the bottom of the hole.
A sample of the bentonite suspension shall be taken from the base of the boring using an approved
sampling device. If the specific gravity of the suspension exceeds 1.25 the placing of concrete shall not
proceed. In this event the Contractor shall modify or replace the bentonite as approved to meet the
Specification.
During and after concreting, care shall be taken to avoid damage to the concrete from pumping and
dewatering operations.
The hopper and pipe of the tremie shall be clean and watertight throughout. The tremie pipe shall extend
to the base of the borehole and a sliding plug or barrier shall be placed in the pipe to prevent direct
contact between the first charge of concrete in the tremie and the water or the drilling fluid. The pipe
shall at all times penetrate the concrete which has previously been placed and shall not be withdrawn
from the concrete until completion of concreting. At all times a sufficient quantity of concrete shall be
maintained within the pipe to ensure that the pressure from it exceeds that from the water or drilling
fluid.
The internal diameter of the pipe of the tremie shall be not less than 150mm for concrete made with
20mm aggregate and not less than 200mm for concrete made with 40mm aggregate. The internal face of
the pipe of the tremie shall be free from projections.

6.7.38 Extraction of Casing - General

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The extraction of temporary casings to pile shafts shall be carried out in such a manner that no damage
shall be sustained by pile being cast or by adjacent piles or structures. A sufficient head of concrete shall
be maintained above the bottom of the linings at all times to prevent entry of ground water or the
reduction of cross-section of the pile shaft.
The casing extractor shall be placed in position before any concrete is placed within the casing so that
the extraction may commence as soon as concrete is placed. Casing shall be extracted within two (2)
hours of placing concrete. Extraction of casing shall be done by vertical lift, continually plumb, and
shall proceed in such a manner as to allow continuous observation of the interior slumping of the
concrete.

6.7.39 Workability of Concrete During Casing Extraction

Temporary casing shall be extracted while the concrete within them remains sufficiently workable to
ensure that the concrete is not lifted.

6.7.40 Vibrating Extractor

The use of vibrating casing extractors will be permitted subject to the condition that work shall be carried
out in such manner and at such times as to minimise nuisance and disturbance to adjacent structures or
newly completed pile.

6.7.41 Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it, to
ensure that the pressure from external water, drilling fluid or soil is exceeded and that the pile is neither
reduced in Clause nor contaminated.
No concrete is to be placed in the boring once the bottom of the casing has been lifted above the top of
the concrete, it shall be placed continuously as the casing is extracted until the desired head of concrete is
obtained.
Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could be
caused as the casings is withdrawn because of the displacement of water or fluid by the concrete as it
flows into its final position against the wall of the pile shaft. Where double casings are used in the
boring, the proposed method of working shall be with the approval of the S.O.
The following checks are to be followed when the extraction of casings commences:i)

Reduced level of the top of the casing and the top of the concrete shall be measured before
extraction commences.

ii)

Reduced level of top of concrete shall be measured after casing is extracted.

The reduced level of top of concrete shall be checked at intervals during extraction by suitable means to
be agreed on site.

6.7.42 Water Level

In the event of ground water level being higher than the required pile head casting level shown on the
Drawings, the Contractor shall submit his proposals for approval prior to placing concrete. The pile head
shall not be left below the ground water level unless approved precautions are taken.

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6.7.43 Preparation of Pile Heads

The top of the pile shall be brought above the cut-off level of the pile to permit all laitance and weak
concrete to be removed and to ensure that it can be properly keyed into the pile-cap. Pile heads shall be
constructed to the details shown on the Drawings.

6.7.44 Temporary Backfilling After Casting

After each pile has been cast, any empty pile hole remaining shall be protected and shall be carefully
backfilled as soon as possible with approved materials.

6.7.45 Tolerances
The bored pile must be installed so that the axis of the shaft at the top of the shaft is not more than 75mm
from its plan location. Piles that are to be installed vertically must be within 2% of plumb for the total
length of the shaft.

6.7.46 Existing Services

Before the work commences the Contractor shall investigate the site for the presence of electrical cables,
water mains and other services that may be damaged in the course of installing bored piles.

6.7.47 Tidy Site

The Contractor shall keep the site clear of all unnecessary obstructions such as spoil heaps, discarded
wire ropes and reinforcement rods, etc.

6.7.48 Public Safety

The Contractor shall ensure that all open boreholes be adequately covered during non-working hours.

6.7.49 Daily Records

The Contractor shall supply to the S.O. in duplicate a complete records of all piles installed in the day
signed not later than noon of the next working day after the pile has been installed. The record shall
include the following:(a)

Identification Number of pile

(b)

Location

(c)

Ground Level

(d)

Diameter of shaft

(e)

Top and bottom elevation of shaft and cut-off level

(f)

Depth of boring

(g)

Depth of rock coring, RQD etc.

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(h)

Details of all strata bored

(i)

Depth of water table

(j)

Details of in situ tests like SPT carried out at various levels and at bottom of boring

(k)

Details of temporary casing

(l)

Details of drilling fluid used

(m)

Volume of concrete used in forming the pile shaft

(n)

Length, diameter and other details of reinforcement cage

(o)

Elevation of top of rebar cage before and after concrete is poured

(p)

Date and time of starting, stopping, delays, if any and finishing of pile shaft

(q)

Any unusual occurrences that could affect the integrity of the bored pile construction

The signed record shall be part of the record for the Works.

6.7.50 Integrity Testing of Piles - General

Piles shall be tested for detection of major faults, necking, discontinuation, pile length and cross sectional
area of the pile. The integrity testing of piles shall be carried out by a specialist agency to be appointed
by the Contractor subject to the approval of the S.O. The results of the test shall be fully recorded and
interpreted for submission to the S.O. for further analysis. No pile caps shall be constructed on piles
selected for integrity testing until the Contractor submits the integrity test report. The Contractor shall
make due allowance in his programme of work for such integrity tests. The delay in carrying out
integrity test, submission of report and any necessary rectification of the pile shall not entitle the
Contractor to any extension of time.
The Contractor shall provide the testing team with a site plan showing the pile layout and a list of the
piles to be tested with the date of concreting, total length, length of casing (if any), diameter and volume
of concrete used, plus any other relevant factors.

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6.7.50.1 Shock Test

a) Preparation of Pile Head for Shock Test

The pile head shall be clearly exposed, free from debris, etc. and not more than 1.0m above or below
ground level, otherwise the surrounding soil shall be built up or excavated to meet this condition.
The pile head shall be smooth over its complete
perpendicular to the vertical axis of the pile.

cross-section, free from irregularities and shall be

The pile head shall consist of sound concrete. This shall be achieved during the concreting of the pile by
flushing out all weak mortar, etc. from the top of the pile head and carefully screening off to provide a
smooth level surface in sound concrete. Alternatively if the pile head is prepared after concreting, all
weak mortar, broken concrete, etc. shall be removed from the pile head, to expose sound concrete and
the head left horizontal over its complete cross-section. After cleaning it off to ensure a sound bond, a
very thin screed (maximum 1cm) of strong sand/cement mortar rapid hardening or a compound such as
FEBFLOR shall be spread to provide a smooth working surface for the shock test equipment. The
mortar shall be allowed to harden before testing. The soundness shall be tested by means of light blows
from a small hammer.
The pile head shall be free from any structure, building concrete or concrete spillage prior to testing.
Any reinforcement or other inclusions protruding from the pile head shall not prevent the testing team
from giving the pile the required impact force over the center of the pile and the placing of a 5cm
diameter (approximately) electronic pick-up at about 10cm from the periphery of the pile. Access shall
be provided for the service van within 30m of the pile.
b) Shock Test Equipment
The shock which is to be imparted on to the pile head shall be carried out using a suitable size hand held
hammer or any approved method which is capable of transmitting vibration to the base of the pile shaft.
The electronic-pick-ups located on the pile head shall be approved velocity transducers or accelerometers
connected through an approved frequency analyser to an X-Y plotter. The mechanical admittance shall
be plotted on a vertical scale and the frequency on the horizontal scale. Both the horizontal and vertical
scales shall be varied as required. The equipment shall have an independent power supply.
c) Shock Testing
Before testing, the heads of the piles shall be inspected by the testing team for regularity and soundness
and any unsatisfactory pile heads shall be reported to the S.O. They shall be made good by the
Contractor as instructed by the S.O. and smoothed off using a suitable epoxy mortar if necessary.
Preliminary tests shall be carried out to establish the appropriate scales and to check the electronic
circuit.
6.7.50.2 Sonic Logging Method

Selected number of piles shall be tested by Sonic Logging Method to check their integrity. The number
and choice of piles to be tested shall be decided by the S.O.

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Sonic Logging Method is a method of investigation using the lateral transmission of waves consisting of
emission of an ultra sonic vibration in an access tube filled with water and capturing this vibration at the
same level in another tube within the pile shaft. This operation is repeated at a high frequency and at
level sufficiently close to each other in order to get a continuous recording over the entire length of the
pile shaft.
The tubes for integrity tests by sonic logging shall be of internal diameter not less than 50mm with no
internal projections or couplings. They can be of mild steel pipe or G.I. Pipe. Four (4) nos. of tubes are
required for each selected pile of diameter less than 1.3m while six (6) nos. are required for each selected
pile of diameter greater than 1.3m.
The tubes shall be cleaned with non-greasy product before use in order to prevent oil films from causing
problems of adherence between the tube and the concrete. This could cause a variation that might be
incorrectly interpreted as a significant defect in the pile.
The tubes shall be fixed to the vertical bars with equal spacing on the inside perimeter of the links. The
tubes shall be watertight with the bottom of the tube sealed and suitably weighed to prevent floating.
The upper ends of the tubes must be closed and extended to at least 0.5m above the concrete surface to
prevent debris or concrete from falling into the tube. The tubes shall be secured to the internal face of the
reinforcement cage at equal distance from each other on the circumference.
In all cases, the tubes shall rest on the founding level of the pile so that the full length of the pile can be
tested. The type of tube and condition of sealing shall be checked and approved by the S.O. before
installation.
The tube shall be filled with water to provide the necessary acoustic coupling, and then plugged or
capped before concreting. After conducting the tests, all metal tubes shall be grouted and water in the
tubes displaced. The grout shall be dense cement grout with an approved expanding agent. Payment for
the grouting work shall be deemed to have been included in the rate of testing.
6.7.50.3 Records

The time required to carry out the integrity test shall be recorded along with records of starting time and
finishing time.
The results of the tests shall be presented in reported form by the testing firm and must be signed by a
professional engineer. The report shall include comprehensive engineering analysis of the test results for
each pile taking into consideration the soil condition and any other relevant factor. Interim reports of
each pile or group of piles testing in one day shall be submitted to the S.O. within 5 days of the
completion of the test or tests. A final comprehensive report shall be submitted to the S.O. within 10
days of the completion of the last test or tests.

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6.8

Micro Piles

6.8.1 General
The micropiling shall be undertaken by a specialist sub-contractor employed by the contractor, subject
to the approval of the S.O. The specialist sub-Contractor shall satisfy the S.O. that he has the
necessary experience in works of a similar nature and magnitude.

6.8.2 Submission by the Contractor

The following submissions are required from the Contractor:
a) Proposals
Not later than 2 weeks before the date proposed for the commencement of the micropiling the
Contractor shall submit details of his proposals to the S.O. for approval. Such details shall include:
-

equipment to be used including standby capacity and spares

personnel
construction sequence
grouting pressure and techniques
proposed grout mix
any other information requested by the S.O.

b) Drillings and grouting records

Whenever drilling and grouting operations are in progress the Contractor shall submit daily records to
the S.O. which shall detail all aspects of the work carried out in a format to be agreed by the S.O. The
records shall be submitted in duplicate on the morning following the day to which the report refers.

6.8.3 Equipment
The Contractor shall have at his disposal all the necessary equipment for drilling and concreting holes
at least to the depth specified. The equipment provided shall be adequate to carry out the work within
the time scale allowed in the programme.

6.8.4 Materials
Materials shall comply with the relevant requirements in the Specification. Joints in the reinforcement
shall be such that the full tensile and compressive strength of the base is effective across the joint and
made in such a way that there is no relative displacement during subsequent operations.

6.8.5 Method of Construction

The Contractor shall advance the hole using a simultaneous drilling and casing system or method
approved by the S.O., that ensures full support to the hole over its full depth until casing withdrawal.
Grouting of the micropiles shall be carried out in a continuous operation with a tremie tube to ensure
the grout is injected from the bottom of the hole upwards. The quantity of grout shall be recorded.

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Grout shall be mixed on Site and shall be free from segregation, slumping and bleeding. Grout shall
be pumped into its final position in one continuous operation as soon as possible and in no case more
than half an hour after mixing.

6.8.6 Grout Mix

The grout to be used shall be made with non-shrink cement grout and may include chemical
admixtures as approved by the S.O. The water/cement ratio shall not exceed 0.45.
Unless otherwise directed by the S.O. one set of 150mm cubes (six cubes per set) shall be taken daily
during grouting operations from a randomly selected batch; curing and testing shall be in accordance
with BS EN 12390 - 1. Three cubes from each set shall be crushed at 7 days and the remaining three
at 28 days.
The minimum 28 days cube crushing strength shall be 30N/mm.
The Contractor shall propose a suitable mix for approval by the S.O. and test mixes shall be made up
from the variations thereof, to determine the optimum mix to be used in practice. These trial mixes
shall be made and tested well in advance of the time planned for the construction of micropiles.

6.8.7 Rejected Micropiles

If any micropile fails to comply with the specified requirements in any respect which renders it not
measurable for payment, its construction shall still be completed to the satisfaction of the S.O. unless
otherwise permitted by the S.O.

6.9

Pile Testing

6.9.1 General
Unless otherwise specified, pile tests shall be carried out as described in this Clause of the
Specification.

6.9.2 Test Load and Kentledge

The test load shall be applied by means of hydraulic jack of adequate capacity fitted with measuring
devices capable of registering loads in increments not exceeding 5 tons. The hydraulic jack and
measuring devices shall be approved by the S.O. before use.
All measuring devices used shall be provided with calibration certificates. Time lapsed for the
calibration date shall not exceed 12 months.
The kentledge shall be provided by a heavy mass of dead load, exceeding the maximum test load
required, supported centrally over the test pile on suitably constructed temporary staging or by means
of anchor piles.
If anchor piles are used to provide reaction for the jack, these piles shall not be closer to the test pile
centre to centre than 1.5m or 5 pile diameters or equivalent whichever is the larger.
Anchor piles, which later form part of the piled foundation to the structure, shall be appropriately
re-driven to the required set or level as directed by the S.O. all to his full satisfaction.

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6.9.3 Settlement Measurement

Vertical movements of the test pile shall be measured by at least two dial gauges, with a minimum of
25mm travel, graduated in 0.025mm divisions.
The gauges shall be erected on stiff steel beams, the ends of which shall rest on or be fixed to reliable
supports. Such supports shall be located not closer than 1.8m from the test pile, and shall be rigidly
fixed to the ground to a depth of not less than one metre of concrete surround. In addition, the
elevation of the supports shall be checked frequently with reference to a fixed benchmark. The entire
measuring assembly shall be properly protected against rain, direct sunlight and other disturbances
that might affect its reliability. Temperature readings shall be taken when requested by the S.O.

6.9.4 Equipment and Personnel for Load Test

All kentledge staging, anchor piles, equipment, shelter, supports, and the like required for the load test
shall be provided by the Contractor, who shall also provide all necessary facilities to enable the S.O.
to check all readings during the progress of the test.
The S.O. will supervise and direct the whole process of the test and provide skilled staff to assist in
taking and recording all readings.
The Contractor shall provide all other labour required for the proper execution of the test, including
the construction and dismantling of the load staging and handling of the kentledge materials on and
off the load stage, and the like and for the continuous and competent watching of the whole assembly,
all to the full satisfaction of the S.O.

6.9.5 Procedure of Testing

The `MAINTAINED LOAD' method of testing shall be carried out on the test pile. The S.O. may at
his discretion decide to carry out the `CONSTANT RATE OF PENETRATION' method of testing on
completion of the Maintained Load Test.
(a) Maintained load test
The load shall be applied in increments of 25% of the working load until a maximum test load of
twice the working load is reached. Each increment of load shall be applied as smoothly and as
expeditiously as possible.
Settlement readings and time observations shall be taken before and after each new load increment.
A settlement-time graph shall be plotted to indicate when the rate of settlement of 0.05mm in 15
minutes is reached.
A further increment of load shall be applied when this rate of settlement is achieved or until a
minimum time of 2 hours elapsed, whichever is later. The process is repeated until the maximum test
load is reached.
The maximum test load shall then be maintained for a minimum of 24 hours, and time-settlement
readings shall be taken in regular intervals as for the other load stages.

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The test load shall then be decreased in four equal stages and time-settlement readings taken as
described aforesaid until the movement ceases. At least 60-minute intervals shall be allowed between
the unloading decrements.
(b) Constant rate of penetration test
The load shall be applied at a constant rate of penetration of a value varying between 0.75mm per
minute to 1.5mm per minute, the rate to be so chosen as to suit the available pumping equipment.
Both settlement and time readings shall be recorded every minute. Further loading shall be
discounted when the loading varies directly as the penetration in the case of end-bearing piles in sand
or gravel or when the rate of penetration is constant without further increase in the load in the case of
friction piles in clay. Loading shall then be released gradually and rebound readings taken.

6.9.6 Records of Test

The Contractor shall submit two copies of all records of results, not including the original copy,
together with load-settlement and load-time graphs to the S.O. on completion of each test.

6.9.7 Interpretation of Test Results

The S.O.s interpretation and conclusions arrived at on the test results shall be final. When the pile
test as prescribed has been carried out, the pile so tested shall be deemed to have failed if:a)

the residual settlement after removal of the test load exceeds 6mm, or

the total settlement under Design Load exceeds 13mm, or

the total settlement under twice the Design Load exceeds 38mm.

6.10 Rejection of Piles

Piles deviating from position or inclination more than the allowable tolerances shall be liable to
rejection at the discretion of the S.O.
If any pile is rejected, either due to its incorrect position, poor workmanship, poor materials or due to
any other causes, the S.O. shall order an additional or more piles, if necessary, to be installed and
incorporated in the redesigned pile cap.
If at the discretion of the S.O., the Contractor installs an additional pile or piles, the Contractor will
not be paid for the rejected pile but he will be paid for one pile of the average length of the additional
piles. The cost of the second pile, if two are ordered, plus the additional cost of the pile cap over the
original design and all other costs involved in the amendments necessary to the supported structure as
a result of the altered positions of the piles and the special design of the pile cap shall be borne by the
Contractor.

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6.11 Dynamic Pile Load Test Method

6.11.1 General
Dynamic load test for pile shall include: (i)

Monitoring of pile response when the pile is subjected to an impact provided by the pile
driving hammer. Monitoring shall continuous with time and shall be carried out for each
hammer blow until satisfactorily completion of pile installation;

(ii)

Signal matching using TNOWAVE or CAPWAP techniques to match the measured response
with an approved pile-soil model to determine the static pile resistance, the distribution of
shaft resistance, and the base resistance. Signal matching shall be carried out for each hammer
impact to enable determination of the pile resistance with depth.

Dynamic load test for a specified number of working piles shall include monitoring of pile response
when the pile is subjected to an impact provided by the pile driving hammer after the completion of
driving.

6.11.2 Measurements
Measurements of strain, force and acceleration shall be carried out close to the pile head. Such
parameters shall be measured continuously with time and stored on electronic data capture units with
the capability of producing graphs of measured:(i)

Force time;

(ii)

Acceleration time;

(iii)

Velocity time;

(iv)

Displacement time;

during and after pile installation.

The permanent penetration per blow and the temporary compression of the pile and soil system shall
be measured independently of the instrument being used to record the dynamic test data.

6.11.3 Field Data Processing

Immediate field data processing shall be carried out to identify malfunctions. The following
computations shall be carried out during pile installation:(i)

The force measurement shall be continuously balanced except during the impact event;

(ii)

The acceleration must be integrated or displacement must be differentiated over time to obtain
velocity. The resulting velocity shall be continuously zero except during impact;

(iii)

The force and velocity shall be output on a display unit during measurements;

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(iv)

The product of force and velocity shall be integrated over time to obtain the energy
transferred to the top of the pile. The energy shall be continuously zeroed except during
impact;

(v)

The maximum values of force, acceleration, displacement, velocity, energy, force at

maximum velocity and minimum force shall be determined.

6.11.4 Measurement Devices

All instruments for measurements and all equipment for receiving and processing data shall be
suitable for the purpose and to the S.O.s approval. Equipment required to be attached to the pile shall
be appropriately positioned and fixed to the approval of the S.O. No optical measuring device shall
either for strain or velocity measurement shall be permitted. Equipment shall be fixed as follows:(i)

Acceleration shall be measured by suitable transducers attached to the pile at a distance not
less than 1 pile diameter below the top of the pile. At least two accelerometers shall be used at
the pile surface and so arranged to cancel the effects of bending;

(ii)

Accelerometers used shall be linear to at least 1000 x g and 10kHz;

(iii)

In the event force measurements are made using strain transducers, such transducers shall be
securely attached on the pile such that no slippage shall occur. Bolt-on or glue-on transducers
may be acceptable for use. The strain transducers shall be linear over the entire range of pile
strains. The natural frequency when attached to the pile shall be in access of 10kHz.

(iv)

Force transducers shall have an impedance of between 50% to 100% of the impedance of the
pile near the top. The output signal shall be linear up to the maximum axial pile force at the
top of the pile. The connection between the force transducers and the pile top shall have the
smallest possible additional mass.

6.11.5 Hammer
The hammer and all site equipment shall be capable to delivering an impact force sufficient to
mobilize the equivalent specified test load without injury to the pile.

6.11.6 Preparation of Pile Head

The preparation of the pile head for the application of the dynamic load test shall include, where
appropriate, trimming the head, cleaning and building up the pile using materials which will at the
time of testing safely withstand the impact stress. The impact surface shall be flat and right angle to
the pile axis. The pile head shall be exposed for a minimum length of 3 times the pile diameter below
the pile top. The sides of the pile head must be easily accessible for the installation of gauges or
transducers.

6.11.7 Personnel
All personnel involved in Dynamic Load Testing shall be person experienced in the task.

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6.11.8 Preliminary Results

The following preliminary results shall be provided to the S.O. within 24 hours of the completion of
the pile test. These shall include the following:(i)

The assumed damping factor;

(ii)

The assumed wave speed;

(iii)

The maximum force applied to the pile head;

(iv)

The maximum head velocity;

(v)

The maximum energy impact to the pile;

(vi)

The maximum tension experience by the pile;

(vii)

The field estimated static resistance;

(viii)

The maximum driving resistance.

6.11.9 Detailed Report

Subsequently a full detailed report shall be given to the S.O. in triplicate within 10 days of the
completion of testing for all piles. These shall include the following:(i)

Report all information given in preliminary report;

(ii)

Information of pile size and working load;

(iii)

Date of pile installation

(iv)

Date of test;

(v)

Pile identification number and location;

(vi)
(vii)

Length of pile below commencing surface;

Total pile length including projection above commencing surface at time of test;

(viii)

Length of pile from instrumentation position to pile toe;

(ix)

Hammer type and other relevant details;

(x)

Blow selected for report;

(xi)

Estimate of static pile capacity including distribution of shaft resistance and base resistance;

(xii)

Pile integrity;

(xiii)

Force/velocity versus time trace;

(xiv)

Upward travelling wave versus time trace;

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(xv)

Displacement versus time trace.

6.11.10 Defective Piles

Defective piles, which are not ordered by the S.O. to be replaced by additional piles, shall however be
remedied by a method proposed by the Contractor and approved by the S.O.

6.12 Piling Records

The Contractor shall keep a record of all piles driven at the Site.
A copy of the field record of the piling work done each day shall be given to the S.O. within 24 hours.
The Contractor shall record the number of blows for each 300mm of penetration of the advance piles
and submit the following information to the S.O.:
(a)

Serial number of pile on plan

(b)

Pile size

(c)

Date driven

(d)

Details of hammer and strokes

(e)

Penetration of pile

(f)

Sequence of driving in groups

(g)

Details for the final 300mm penetration including final set

(h)

Details of any interruption in driving

(i)

Details of re-driving

(j)

Position and level of pile joints

(k)

Elastic compression of pile Cp, and quake of sub-soil Cq for the last 10 blows
On completion of all piling work, the Contractor shall prepare and submit to the S.O. two sets
of complete records including drawings showing details of all piles driven at the Site relative
to the Survey Department level.

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7.0

STRUCTURAL STEELWORK .....................................................................7-1

7.1

General .............................................................................................7-1

7.2

Materials ...........................................................................................7-1

7.3

Surveys and Setting Out .................................................................7-2

7.4

Drawings...........................................................................................7-2

7.5

Workmanship ...................................................................................7-2

7.6

Connections .....................................................................................7-3

7.7

Bolting ..............................................................................................7-3

7.8

Welding.............................................................................................7-4

7.9

Holing................................................................................................7-6

7.10

Slab Bases and Caps.......................................................................7-6

7.11

Gusseted Bases and Caps..............................................................7-6

7.12

Compression Joints and Stanchion Splices .................................7-6

7.13

Stiffeners ..........................................................................................7-7

7.14

Clearances........................................................................................7-7

7.15

Marking .............................................................................................7-7

7.16

Protective Painting and Coatings...................................................7-7

7.17

Erection ............................................................................................7-9

7.18

Erection Tolerances.......................................................................7-10

7.19

Grouting..........................................................................................7-10

7.20

Inspection.......................................................................................7-11

7.21

Subletting .......................................................................................7-11

7.22

Required Information from the Contractor ..................................7-11

7.23

Fire Protection ...............................................................................7-12

APPENDIX 7.1:

Table 18 and 19 of British Standard 5135

LIST OF TABLE
Table: 7.1 Weld Test Requirements
Table: 7.2 Painting And Coating
Table: 7.3 - Summary Of Information Required From The Contractor For Approval

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7.0 STRUCTURAL STEELWORK

7.1

General

The works shall be constructed strictly in accordance with the drawings.

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

7.2

Materials

Unless otherwise specified all structural steel shall comply with the requirements of the current issues
of the following British Standards where appropriate:BS 4

Parts 1 and 2: Structural Steel Sections

BS 10002-1

Tensile Testing of Metallic Materials. Method of Test at Ambient

Temperature

BS 5950

Structural Use of Steelwork In Building

BS EN ISO 1461

Hot Dip Galvanized Coatings on Fabricated Iron and Steel Articles

BS 1449-1.1

Steel plate, sheet and strip: Carbon and Carbon-manganese Plate,

Sheet and Strip

BS EN 10051

Specifications For Continuous Hot-Rolled Uncoated Plate, Sheet And

Strip of Non Alloy And Alloy Steel

BS EN 10143

Continuously hot dip zinc coated and iron zinc alloy coated steel

BS 3692

Isometric Precision Hexagonal Bolts Screws and Nuts

BS 4190

Isometric Black Hexagon Bolts, Screws and Nuts

BS 4320

Metal Washers for General Engineering Purposes

BS 7668

Weldable Structural Steel Hot Finished, Structural Hollow Section in

Weather Resistant Steels

BS 4395

High Strength Friction Grip (HSFG) Bolts for Structural Engineering

BS 4604

The Use of High Strength Friction Grip (HSFG) Bolts in Structural

Steelwork

BS EN 10210-2

Hot Finished Structural Hollow Sections of Non-Alloy and Fine

Grain Structural Steel

BS EN 10056-1

Specification for Structural Steel Equal and Unequal Angles

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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.
The Contractor shall supply the S.O. with the Manufacturer's Mill Certificate in accordance with
BS 7668.
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.

7.3

Surveys and Setting Out

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

7.4

Drawings

The steelwork Contractor shall prepare all necessary calculations (including those relating to
connections, plates, etc), detail arrangements and workshop drawings. Two copies of these to be
submitted to the S.O. for approval prior to fabrication. The phasing of drawing submissions and the
time allowed for inspection of drawings shall be agreed with the S.O.
Workshop drawings shall be prepared taking full account of the support and dimensional requirements
of cladding and other specialist sub-contractors.
The S.O.'s approval shall relate only to the adequacy of the connections and shall not relieve the
Steelwork Contractor from any responsibility of rectifying, at his own expense, errors in the steelwork
due to drawing office errors subsequently discovered.

7.5

Workmanship

Fabrication shall not commence without the S.O.'s consent.

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

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

7.6

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.
Site welding and alterations to steelwork on site shall not be permitted without the detailed approval
of the S.O.

7.7

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.)

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(c)

Wherever possible, the load indicating washer must be placed under the head of the bolt with
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.

7.8

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.
The Steelwork Contractor shall provide evidence to the satisfaction of the S.O. that the welding
operators are capable of passing the tests specified in BS EN 287 and BS 4872.
The Steelwork Contractor shall supply details of his proposed welding procedure for all full strength
butt welds and for any other welds specifically required by the S.O.

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Section 7 - Structural Steelwork

The information supplied shall include:

Type size and manufacturer of electrode

Current and arc voltage
Number and arrangement of runs in multiweld runs
Position of welding
Pre or post heating
Preparation of surfaces and welding sequence
Use of backing plates or back gouging
Plus any further relevant information

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
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

Weld
Type

Test

Extent

Acceptance Criteria to
BS 5135
Tables 18 & 19*

A) Shop Welding
Visual

All

100%

Magnetic Particle

Fillet

100%
10% of all welds in
each batch

Ultrasonic

Butt

20% of all welds in

each batch

Magnetic Particle

Fillet

100%

Ultrasonic

Butt

100%

Category B

B) Site Welding

Note

1
2.
3.
4.
*
**

Category B

Final examination of a welded joint shall be carried out not less than 16 hours
from the time of completion of the weld.
Visual inspection to be in accordance with BS 6072.
Magnetic particle inspection to be in accordance with BS 6072.
Ultrasonic examination to be in accordance with BS EN 1714.
Updated Standard shall be BS EN 1011
Refer Appendix 7.1

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Section 7 - Structural Steelwork

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.

7.9

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.
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.

7.10 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.

7.11 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.

7.12 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.

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Section 7 - Structural Steelwork

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.

7.13 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
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.

7.14 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.

7.15 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.

7.16 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.

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Section 7 - Structural Steelwork

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.
Paint thickness tests are to be carried out at the works and Test Certificates are to be forwarded to the
S.O.
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.
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.

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Section 7 - Structural Steelwork

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

Works Protection

Primer

min. 50 microns DFT

Intermediate

min. 125 microns to 150 microns DFT Micaceous Iron Oxide

(shall have 60% solids content and indefinite overcoating time).
min. 50 microns DFT High Solids Polyurethane

Finish

Epoxy Zinc Rich Primer

(minimum 85% epoxy zinc content)

Site Protection

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

125 microns DFT

50 microns DFT

High Solids epoxy

High Solids polyurethane

Note: DFT Dry Film Thickness

7.17 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. 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.

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Section 7 - Structural Steelwork

7.18 Erection Tolerances

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

Plumb of Columns

+ or - 3mm in 3,000

Horizontal Members

+ or - 3mm from specified level at supports

Section Discontinuity

+ or - 3mm

Overall Dimension

+ or - 10mm in 30,000

Connection to Concrete
Bolts cast in rigidly
Bolts cast in sleeves
Projection of the bolt

+ or - 3mm in any direction

+ or - 5mm in plan
+ 25 or - 5mm ends

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.

7.19 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.

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Section 7 - Structural Steelwork

7.20 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.

7.21 Subletting
The Steelwork Contractor shall only be permitted to sublet the fabrication, treatment and erection of
the structural steelwork with the prior approval of the S.O.

7.22 Required Information from the Contractor

A summary of information required from the Contractor for approval is given in Table 7.3.
Table: 7.3

Summary of Information Required From the Contractor for Approval

Item

When Required

Clause Ref (1)

Steel Tests Certificates

Before fabrication

7.2

Shop Drawings
Calculations

Before fabrication

7.4

HSFG Tightening

At start of Contract

7.7

Welder Qualifications

Before fabrication

7.8

Welding
Information

Before fabrication

7.8

Painting System

Before painting

7.16

Erection Sequence

At start of Contract

7.17

and

Process

Date Req'd

Note:
(1)

This column will be completed at the start of the contract.

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Section 7 - Structural Steelwork

7.23 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.

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Appendix - 7.1

APPENDIX 7.1 - 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

100%
Minimum
amount of
volumetric nondestructive
testing

10 % each weldera

10 % overalla

Cracks
Not permittedb
Lack of fusion Not permittedb
Lack of root
penetration

Not permittedb
t 20 mm: l 10 mm
h 2 mm
t > 20 mm: l 15 mm

Not permittedb
l 25 mm in any
100mm
length of weld
or h 0.2 t

h 2 mm
Individual slag t 18 mm : l t/2 6 mm t 20 mm: l 12 mm
inclusions
w 1.5 mm
w 1.5 mm

None
100% visual only

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

Civil Work Specifications

Final Document (June 2008)

App7-1

Appendix - 7.1

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

Quality
category

Porosityc

Individual pores: 2 mm
diameter.
Localized: 2 % by aread
for t 50mm then pro
rata for greater
thicknesses

Individual
pores: 2.5mm
diameter.
Localized: 3 % by
aread

Undercut

Intermittent, 0.5 mm
maximum in depth

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

Surface porosity
Individual
pores: 3 mm
diameter 0.25 t
diameter
Localized: 4 % by
aread
Intermittent, 0.5 Depth 0.1 t
mm maximum in 1 mm
depth
l 10 % of length
of weld

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

Minimum amount of 100 % of weld

surface non-destructive surface and 10 mm
testing (either liquid of adjacent parent
penetrant or magnetic metal each side weld
particle testing)
Cracks
Not permitteda
Lack of fusion
Undercutc
Intermittent, 0.5mm
maximum in depth
Fit-up
Throat thickness

B
Random 10 % of
weld surface and 10
mm of adjacent
parent metal each
side of weld
Not permittedab

Randomly 5 % of
None
weld surface and 10 100 % visual only
mm of adjacent
parent metal each
side of weld
Not permittedab
Not permittedab

Intermittent, 0.5mm Intermittent, 0.5mm Some undercut 1

maximum in depth maximum in depth mm maximum in
depth
For partial penetration T-joints the results of inspection of joint preparation and fit-up
to be recorded
Total throat thickness to be not less than that specified

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.

Civil Work Specifications

Final Document (June 2008)

App7-2

Section 8 - Sewer, Force Mains, Pipelaying, Manholes and Appurtenances

Page
8.0

SEWERS, FORCE MAINS, PIPELAYING, MANHOLES AND

APPURTENANCES .....................................................................................8-1
8.1

General for Pipeline .........................................................................8-1

8.1.1 Test Certificates ................................................................................... 8-1
8.1.2 Pipe Marking .......................................................................................... 8-1

8.2

Vitrified Clay Pipes ..........................................................................8-2

8.2.1 General ..................................................................................................... 8-2
8.2.2 Joints ........................................................................................................ 8-2

8.3

Reinforced Concrete Pipe (RCP) and Fittings...............................8-3

8.3.1 General ..................................................................................................... 8-3
8.3.2 Materials .................................................................................................. 8-3
8.3.3 Tests .......................................................................................................... 8-4
8.3.4 Permissible Variations in Dimensions ........................................ 8-4
8.3.5 Workmanship and Finish.................................................................. 8-4
8.3.6 Rejection .................................................................................................. 8-4
8.3.7 Joints ........................................................................................................ 8-5
8.3.8 Cementitious Lining ........................................................................... 8-5
8.3.9 Marking..................................................................................................... 8-5

8.4

Polyethylene Pipes (PE) and Fittings.............................................8-5

8.4.1 Materials .................................................................................................. 8-5
8.4.2 Solid Wall PE Pipes ............................................................................. 8-5
8.4.2.1 Sizes and Classes....................................................8-6
8.4.2.2 Fittings......................................................................8-7
8.4.2.3 Joints ........................................................................8-8
8.4.2.4 Quality Control and Quality Assurance Testing ...8-9
8.4.3 Profile PE Sewer Pipes ...................................................................... 8-9
8.4.4 Dimensions and Tolerances............................................................ 8-9
8.4.5 Fittings.................................................................................................... 8-10
8.4.6 Joints ...................................................................................................... 8-11
8.4.7 Mechanical Properties ..................................................................... 8-11
8.4.8 Quality Control Test .......................................................................... 8-12
8.4.9 Visual Inspection................................................................................ 8-14
8.4.10 Information to be Provided ............................................................ 8-14

8.5

Glass Fibre Reinforced Plastic (GRP) Pipes and Fittings ..........8-15

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8.5.1 Materials ................................................................................................ 8-15

8.5.2 Dimensions ........................................................................................... 8-16
8.5.3 Fittings.................................................................................................... 8-16
8.5.4 Joints ...................................................................................................... 8-16
8.5.5 Stiffness ................................................................................................. 8-17
8.5.6 Strain Corrosion Resistance ......................................................... 8-17
8.5.7 Quality Assurance Tests................................................................. 8-17
8.5.8 Information to be Provided ............................................................ 8-17
8.6

Unplasticized PVC Pipes and Fittings..........................................8-18

8.6.1 General ................................................................................................... 8-18
8.6.2 Joints ...................................................................................................... 8-18

8.7

ABS Pipe.........................................................................................8-19
8.7.1 Materials ................................................................................................ 8-19
8.7.2 Sizes/Classes....................................................................................... 8-19
8.7.3 Fittings.................................................................................................... 8-20
8.7.4 Joints ...................................................................................................... 8-20

8.8

Ductile Iron Pipes and Fittings .....................................................8-21

8.8.1 General ................................................................................................... 8-21
8.8.2 Manufacture and Testing ................................................................ 8-21
8.8.3 Process of Manufacture .................................................................. 8-21
8.8.4 Thickness, Diameter and Length ................................................ 8-22
8.8.5 Tolerances ............................................................................................ 8-23
8.8.6 Works Tests ......................................................................................... 8-23
8.8.7 External Coating ................................................................................. 8-23
8.8.8 Internal Lining ..................................................................................... 8-24
8.8.9 Fittings.................................................................................................... 8-24
8.8.10 Joints ...................................................................................................... 8-25
8.8.11 Marking................................................................................................... 8-26

8.9

Steel Pipes......................................................................................8-26
8.9.1 General ................................................................................................... 8-26
8.9.2 Testing .................................................................................................... 8-27
8.9.3 Dimensions ........................................................................................... 8-27
8.9.4 Straight Pipes ...................................................................................... 8-27
8.9.5 Specials .................................................................................................. 8-27
8.9.6 Joints ...................................................................................................... 8-27

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Section 8 - Sewer, Force Mains, Pipelaying, Manholes and Appurtenances

8.9.7 Protection .............................................................................................. 8-29

8.9.8 Lining ...................................................................................................... 8-29
8.9.9 Coating ................................................................................................... 8-29
8.9.10 Painting .................................................................................................. 8-30
8.9.11 Marking and Transportation .......................................................... 8-30
8.9.12 Repair of Lining and Coating ........................................................ 8-30
8.10

General for Pipeline Installation ...................................................8-31

8.10.1 Scope of Works .................................................................................. 8-31
8.10.2 Definitions ............................................................................................. 8-31
8.10.3 Dimensions of Pipes......................................................................... 8-32
8.10.4 Specialists, Inspection and Testing ........................................... 8-32
8.10.5 Tools for Pipe Installation .............................................................. 8-32
8.10.6 Handling, Storage and Protection during Transit ................ 8-32
8.10.7 Inspection at Time of Installation................................................ 8-33
8.10.8 Laying Diagrams ................................................................................ 8-33

8.11

Installation of Pipes .......................................................................8-33

8.11.1 General Installation Work ............................................................... 8-33
8.11.2 Pipe Laying ........................................................................................... 8-34
8.11.3 Closures and Short Sections ........................................................ 8-35
8.11.4 Pipe Bedding for Sewer Pipes...................................................... 8-35
8.11.5 Concrete Protection of Sewer Pipes.......................................... 8-36
8.11.6 Protection of Joints for Force Mains ......................................... 8-37
8.11.7 Tolerances of Alignment and Invert Levels ............................ 8-37

8.12

Special Laying Methods: Jacking.................................................8-37

8.12.1 Pipe Jacking - Procedures ............................................................. 8-37
8.12.2 Alternative Trenchless Pipe Installation Methods ............... 8-38
8.12.3 Type of Pipe Used for Jacking ..................................................... 8-38
8.12.4 Alignment Control and Tolerances ............................................ 8-39
8.12.5 Joints for Jacking Pipes ................................................................. 8-39
8.12.6 Joints Performance Test................................................................. 8-39
8.12.7 Jacking and Receiving Pits ........................................................... 8-39
8.12.8 Jacking Records................................................................................. 8-39

8.13

Changes In Line and Grade ..........................................................8-40

8.13.1 Deflection at Certain Joints ........................................................... 8-40

8.14

Stream and River Crossing...........................................................8-40

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Section 8 - Sewer, Force Mains, Pipelaying, Manholes and Appurtenances

8.15

Connection to Existing Sewer Mains ...........................................8-40

8.16

Manholes ........................................................................................8-41

8.17

Testing Pipelines ...........................................................................8-42

8.17.1 Testing Gravity Sewers ...................................................8-42
8.17.2 Testing of Force Main (Hydraulic Testing)........................8-43

8.18

Sewer Inspection, Condition Assessment and Classification ...8-45

8.19

Test for Straightness .....................................................................8-45

8.20

Cleanliness of Sewers and Force Mains......................................8-45

8.21

Temporary Surfacing.....................................................................8-46

8.22

Liability in Pipe Installation...........................................................8-46

8.23

Maintenance in Pipe Installation Work.........................................8-46

8.24

Sewer Connections to Existing Properties..................................8-46

LIST OF TABLE
Table: 8.1 Pipe Diameter Vs Minimum Crushing Strength
Table: 8.2 Stiffness of PE Pipes
Table: 8.3 Sampling Procedure of PE Pipes
Table: 8.4 - Stiffness of GRP Pipes
Table: 8.5 Dimensions of ABS Pipe
Table: 8.6 Classification of ABS Pipe
Table: 8.7 Nominal Diameter Vs Thickness of Wall and Lining of Pipes
Table: 8.8 - Hydrostatic Test Pressure

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8.0 Sewers, Force Mains, Pipelaying, Manholes and

Appurtenances
8.1

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.

8.1.1 Test Certificates

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.

8.1.2 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)

Manufacturing standard compliance

SIRIM or other certification logo as approved

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Section 8 - Sewer, Force Mains, Pipelaying, Manholes and Appurtenances

8.2

Vitrified Clay Pipes

8.2.1 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
Pipe Diameter
(mm)

Minimum Crushing
Strength (kN/m)

Class No.

150
225
300
375
450
500
600

24
36
48
45
54
60
72

160
160
120
120
120
120

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.

8.2.2 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.

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8.3

Reinforced Concrete Pipe (RCP) and Fittings

8.3.1 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.

8.3.2 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.

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

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.

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

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.

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.

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

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

The contractor shall submit for approval detailed shop drawings of the pipes, joints,
reinforcement, cage assemblies prior to manufacture of the pipe.

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8.3.3 Tests
Concrete pipes may be tested by the S.O. by one or more of the following tests. The Contractor shall
furnish without charge all necessary equipment and samples for making the tests. All tests shall be
made in accordance with BS 5911 : Part 1. Any pipe tested shall not be used in the sewer mains.
a.

Absorption Test is to determine the amount of moisture absorbed by the concrete.

Three-Edge Bearing Strength Test may be made to determine the ultimate strength of the pipe
and the works proof load which the pipe will withstand.

Sand Bearing Test may be used in place of the three-edge bearing test to determine the
strength of the pipe.

Core or Cube Test may be used to determine the strength of the concrete in the pipe. Cores
may be cut from the concrete of the pipe or test cubes cast from the concrete.

Visual Inspection and Test may be made by the S.O. before and/or after delivery of the pipe,
for the purpose of determining the placement of the reinforcement, the size, shape, fractures,
spalls, honeycomb or other imperfections or damage. The Contractor shall notify the S.O. not
less than 24 hours in advance of beginning manufacture of the pipe. The S.O. shall have
access to all operations of the manufacture and may inspect and test any or all equipment,
materials and operation used in the manufacturing, handling and curing of the pipe.

8.3.4 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.

8.3.5 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.

8.3.6 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.

Defects that indicate defective mixing and moulding.

Surface defects indicating honeycomb or open texture.

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.
Exposed reinforcement which indicates that the reinforcement is misplaced.

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

8.3.8 Cementitious Lining

All Reinforced Concrete Pipe, unless otherwise shown, shall be lined during manufacture with a
12.5mm thick high sulphate resisting lining consisting of High Alumina Cement (one part), granite
dust passing No. 100 BS Sieve (one part), and 2.5 parts of fine aggregate with sufficient clean water
to ensure maximum density. Sulphate Resisting Cement shall be in accordance with BS 4550-6 and
BS EN 14647. Lining and testing of lining shall be in accordance with BS 4550-6 and BS EN 14647.
Plastic liner plate shall not be used

8.3.9 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.

8.4

Polyethylene (PE) Pipes and Fittings

8.4.1 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. 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.

8.4.2 Solid Wall PE Pipes

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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 1,0000mm 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.
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.
8.4.2.1 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 200C 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.

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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/m2 (8000MPa) is generally taken as the minimum stiffness
for smaller diameter pipe. Hence PE 80 with typical resin density of 950 to 955 kg/m3 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.
8.4.2.2 Fittings

Various fittings are available which increase the overall use of the solid wall PE pipe system. PE
fittings may be injection moulded, fabricated or thermoformed. The following section briefly
describes the operations of each technique.
a)

Fabricated Fittings

Fabricated fittings for solid wall PE pipes are normally available 200mm diameter and above.
Fabricated fittings can be constructed by joining sections of pipe, machine blocks or moulded fittings
together to produce the desired configuration. Components shall be joined by heat fusion, hot gas
welding or extrusion welding techniques. Use of either hot gas or extrusion welding for pressure
service fittings is not recommended since the joint strength is significantly less than of a heat fusion
joint.
Fabricated fittings designed for full pressure service are joined by heat fusion and must be designed
with additional material in areas subject to high stress. The normal practice is to increased wall
thickness in high-stress areas by using heavy-wall pipe sections. The increased wall thickness may be
added to the nominal Outside Diameter (OD) which provides for a full-flow nominal Inside Diameter
(ID); or it may be added to the ID which slightly restricts ID flow.
This is similar to moulded fittings that are moulded with a larger OD, heavier body wall thickness. If
heavy-wall pipe sections are not used, the pressure rating of the fitting needs to be reduced
accordingly. The lowest pressure rated component shall determine the operating pressure of the pipe
system.
Very large diameter fitting shall be handled with great care during unloading and installation.
Precautions shall be taken to prevent bending moments that could stress the fitting during these
operations. These fittings can be wrapped with reinforcement materials such as rubber or fibreglass
for protection.
b)

Injected Moulded Fittings

Injection moulded solid PE fittings can be manufactured in sizes trough various sizes. Typical
moulded fittings are tees, 45O and 90O elbows, reducers, couplings, caps, flange adapters and stub
ends, branch and service saddles, and self-tapping saddles tees. Very large parts may exceed common
injection moulding equipment facilities so these are usually fabricated.
c)

Thermoformed Fittings

Thermoformed fittings are manufactured by heating a section of pipe and then using a forming tool to
reshape the heated area. Examples are sweep elbows, swaged reducers and forged stub ends. The area
to be shaped is immersed in a hot liquid bath and heated to make it pliable. It is then removed from
the heating bath and reshaped in the forming tool. The new shape shall be held until the part has
cooled.

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Electrofusion Couplings

Electrofusion couplings and fittings for solid wall PE pipe can be manufactured by either moulding in
a similar manner as butt and socket fusion fittings or manufactured form pipe stock. A wide variety of
couplings and other associated fittings are available. Electrofusion fittings are manufactured with coillike integral heating element. These fittings shall be installed utilizing a fusion processor which
provides the proper energy to provide a fusion joint stronger than the joined pipe sections.
8.4.2.3 Joints

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

Thermofusion Welding

Thermofusion welding is also known as fusion welding. This method uses heated tools to weld the
joint faces together and can be applied to specially made mould socket fittings for spigot-socket
jointing and also to those made for butt jointing.
Butt fusion joint is suitable for jointing of the solid wall PE pipes. It is carried out by heating the faces
of the components to be joined against a heated flat plate which are usually coated with PTFE. Theses
faces are then brought together under control pressure. Butt welding normally leaves a raised bead on
the joint inside the pipe which will interfere with the flow. The internal bead but shall be removed
using suitable tools before inspection.
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.
b)

Electrofusion

Electrofusion is simpler to carry out than butt fusion but it is applicable for small diameter of solid
wall PE pipe normally up to 315mm only.
The heating and the timing operations are all automatically taken by a control unit of the following
procedures:
-

Electrofusion coupling slipped over the ends of the pipe to be joined

Resistance wires in the coupler are heated by a controlled electric current

The coupler and pipe are melted and fused to each other

The setback of this method of jointing its greater cost compared to thermofusion welding.
c)

Flange Joint

Flange joint can be used where require for jointing to fitting or pipes of other material and most
commonly used for larger diameter pipes. It consists of either a full face or stub flanges welded to the
pipe or alternately can be formed on the pipe. The rotational flexibility provided by this type of
jointing is compensated by the longitudinal flexibility of the PE pipe.
d)

Mechanical Metal Coupling

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Mechanical metal couplings do not provide the strength or long-term performance as compared to a
properly made fusion joint. This jointing method is normally considered for repair operations. There
are wide ranges of small diameters plastic pipes e.g. acetal and GRP fittings use mechanical
(compressed rubber seal) joints.
8.4.2.4 Quality Control and Quality Assurance Testing

Quality shall be engineered into pipe product during the entire manufacturing process of solid wall PE
pipes and fittings. The three (3) phases of quality control for the pipe manufacturer involve the
incoming raw material, the pipe or fitting production and the finished products. Combination of all
three areas can ensure that the final product fulfils the requirements of the specification to which it
was made.
Testing of the incoming resin is crucial and the first step in the quality control program. The resin
shall be checked for contamination, melt index, density, tensile strength and environmental stress
crack resistance (ESCR). Any resin that does not meet the raw material specification shall not be used
for the production.
During the manufacturing stage, the pipe producer shall routinely perform quality assurance tests on
samples. This can verify that proper production procedures and controls are implemented during
operation. Once the product has been produced, it shall undergo a series of quality control tests to
ensure that it meets the minimum specifications as required.
Quality inspections for solid wall PE pipes and fittings typically include knit line strength, voids,
dimensions and pressure tests. A knit line is formed when the shot flows around a core pin and joins
together on the other side. Voids can form from materials shrinkage during cooling, particularly in
heavier sections. Voids can be detected non-destructively by using x-ray scans. If this is not feasible,
samples shall be cut into thin sections and inspected visually.

8.4.3 Profile PE Sewer Pipes

A profiled wall pipe consists of an outer ribbed or corrugated wall fused to a smooth inner wall with
sizes based on controlled inside diameter. The ribs or corrugation shall be normally either aligned
circumferentially or helically. These corrugated or ribbed profiles optimize the pipe ring stiffness to
weight ratio and improve static load bearing capacity. The pipe shall be designed with double-wall
profile or triple-wall profile. It must be able to withstand high pressure jetting up to 120 bars as
commonly used for sewer servicing.
Corrugated PE pipe is available normally in a range of size from 100mm to 3000mm nominal
diameter and in standard 6m lengths. The standard joint is normally flexible spigot-socket with rubber
seal. Only approved PE pipes from licensed manufacturer shall be used for gravity sewers especially
where special circumstances maximize the benefit of such pipes.

8.4.4 Dimensions and Tolerances

The average inside diameter of the pipe shall meet the requirements given in Table 2 of DIN16961.
The average inside diameter can be measured by taking a series of at least six (6) inside diameter
measurements at equally spaced intervals using appropriate measuring devices such as calipers, inside
micro meters or telescoping gauges and calculating the average inside diameter by taking the average
of all theses measurements.

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The finished dimensions of all pipes, fittings-couplings, specials or other components shall be
compatible with their assembly into a completed system satisfying all requirements of the Contract
and, in particular, the specified requirements for water tightness and joint flexibility.
The dimensions of PE pipes shall be to DIN 8074/75 for pipes up to and including 1000mm nominal
diameter. For pipes exceeding 1000mm nominal diameter, dimensions and tolerances shall be as
given below. Profile wall pipes shall comply with the dimensional tolerances of DIN 16961.
a.

Pipe Diameter for PE Pipe, the Contractor shall state the manufacturing size which is to be
supplied. The manufacturing size shall be the target internal pipe diameter to which the
manufacturer works and shall not differ from the specified nominal internal diameter by more
than 1%.
A manufacturing tolerance of 1% deviation from the manufacturing size is permitted for
pipes up to and including 600mm nominal diameter, and of 0.5% for pipes of nominal
diameter greater than 600mm.

Standard lengths shall be 3 or 6 m and at least 90% of pipe supplied, other than specified
specials, shall be of standard length. The remaining pipes shall have lengths of not less than
1.5m. Where the length of special pipes is specified a tolerance of 25mm will be allowed
on the specified length.

Deviation from straightness of the bore of the pipe shall not exceed 0.3% of the effective length of the
pipe or 15mm whichever is the smaller. This requirement shall NOT be limited to the straightness of
the pipe when measured at its place of manufacture.

8.4.5 Fittings
Bends and Fittings shall be equal or superior in performance to the corresponding pipes. Mitred
bends and fittings or mitring at sections of straight pipes shall be manufactured from pipes which have
passed the appropriate hydraulic test and shall have a smooth internal surface free from weld run
projection.
The angle of deviation of bends shall be within 1 of the specified angle where the nominal
diameter does not exceed 600mm and within 0.5 where the nominal diameter is greater than
600mm.
The overall length of fittings shall be within 10 mm of that specified or stated in advance by the
manufacturer, and the length from the point of inter-section of junctions to any end shall be within 5
mm of that specified or stated in advance.
All welds shall be in accordance with approved standards. Dimensions of bends and fittings shall
comply with the angle of deviation and tolerances on length set as given above. Only qualified and
competent personnel shall carry out weld on pipes and manufacturer shall produce certificate and
other related documents as evidence.

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8.4.6 Joints
Joints of PE pipes and fittings shall be provided with bell and spigot joints suitable for external
extrusion welding. In addition for pipes greater than 1000 mm diameter, the joints shall be internally
welded. The method of extrusion welding shall be to the S.O.s approval. Friction welding will not
be permitted.
The completed welded joints shall provide a smooth internal bore to the pipe, which shall be
accurately aligned and without internal projections due to weld run or distortion. The completed
joints shall have a longitudinal strength of not less than that of the main pipe barrel, i.e. a weld factor
of not less than 1.0 and shall be capable of withstanding the specified internal test pressure.
Alternatively, PE pipes and fittings with a nominal internal diameter less than 1000 mm shall be
jointed using a socket-spigot assembly sealed by an elastomeric sealing ring. The socket or bell shall
be formed integrally with the barrel of the pipe or fitting, and the complete joint shall be capable of
accommodating a relative longitudinal movement (telescopic draw) of not less than 1% of the
effective length of the longer pipe or fitting at any point.
Elastomeric gaskets shall be manufactured from material that complies with the physical property
requirements specified in DIN 16961 and shall not leak. The dimensions shall be in accordance with
the manufacturers standard design dimensions and tolerances. The elastomeric gasket shall be the
sole element depended upon to make the joint flexible and watertight under all combinations of joint
and gasket tolerances. The gasket shall be a continuous ring in nature.
The joint components shall be of such design that they will withstand the joining forces by the
compression of the elastomeric gasket without cracking or fracturing. All surfaces of the joint upon or
against which the gasket may bear shall be smooth and free from cracks or fractures and imperfections
that could adversely affect the performance of the joint. Where a spiral-winding seam exists, it shall
not be regarded as a crack as long as it shows evidence of a continuous bond. Lubricants, if required,
shall be suitable for lubricating the parts of the joint in assembly. The lubricants shall have no adverse
effect on the gasket and PE pipe materials.

8.4.7 Mechanical Properties

The stiffness of the pipes when defined as EI/D3 where E is the bending modulus of the pipe wall in
the circumferential direction (N/m2), I is the moment of inertia of the pipe wall per unit length (m4/m)
and D is the nominal internal diameter of the pipe (m), shall not be less than the following:
Table 8.2: Stiffness of PE Pipes
Stiffness
2

Initial stiffness N/m

Stiffness at 24 hrs N/m2

Light Duty

Medium Duty

1,250
450

1,500
675

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Stiffness testing shall be carried out in accordance with the methods set in DIN 16961 Part 2, ASTM
D-2412 or similar. The applied tests load per unit length of pipe shall be that corresponding to a pipe
deflection of 3% of the diameter when the pipe stiffness is taken as the 24 hour value specified above.
The initial stiffness shall be calculated by measuring the deflection immediately after application of
the test load and using the formula EI/D3 = 0.019 load/deflection. The test shall then be continued for
24 hours, at the end of which time the deflection of the pipe shall not exceed 3% of the diameter.
Pipes used for the stiffness test shall not be included in any delivery for incorporation into the works.
Pipe deflection on PE Pipe, on completion of a 24 hours stiffness test, the test load shall be
progressively increased until a pipe deflection of 20% the diameter is reached. The pipe shall then
sustain this load for a period of one minute without visible signs of damage or distress. The load
corresponding to this deflection shall be recorded and notified in the pipe test report.

8.4.8 Quality Control Test

Prior to initial commencement of delivery, and prior to commencement of delivery following any
change in design, materials or methods of manufacture the following shall be carried out:
-Inspection of manufacturers works
-Deflection to failure test
The following tests shall be carried out regularly at the frequencies specified in Table 8.2:
a)

Pipe Compression Strength

There shall be no evidence of splitting, cracking or breaking when tested in accordance with DIN
16961. One specimen of PE pipe, about 300 mm in length if NPS-18 or over, or about 150 mm in
length if under NPS-18, shall be flattened between parallel plates in a suitable press until the distance
between the plates is 40% of the original outside diameter of the pipe.
The rate of loading shall be uniform and such that the compression is completed within 2 to 5
minutes. For closed profile pipe, the loading force shall rise continuously and the specimen shall
retain a smooth, elliptical form up to the point of 60% compression.
Upon removal of the load, the specimen shall be examined for evidence of splitting, cracking, or
breaking. For closed profile pipes only, test records or loading charts shall be examined for any
discontinuity in the acceptance of the load by the specimen. Small tears initiated at the cut end of the
corrugation shall not constitute failure when they are less than or equal in length to 10% of the
nominal diameter of the individual test specimen, up to a maximum length of 75 mm.
If the specimen fails by splitting, cracking or breaking or in the case of closed profile pipe exhibits
discontinuous acceptance of the load, two more specimen shall be tested. If both pass, the material
shall be acceptable. If one the retest specimen fails, the materials shall be rejected.
b)

Pipe Impact Resistance

Test specimen shall be cut from the sample and numbered. The cut shall be square and free form large
chips or other imperfections. The length of the specimen shall be between 300 mm and 325 mm. For
spirally corrugated PE pipe samples, the sample length may vary such that samples are of sufficient
length to have included at least three full corrugation profiles.
After conditioning the specimen in accordance to the requirement, five specimens shall be tested. Test
impact energy shall be as specified. The impact energy shall occur on top of the corrugations, with the
tup striking at the centre of the corrugation crown. When two or more specimens fail, the product

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does not meet the impact requirement. When only one specimen fails, an additional five specimens
shall be tested. To meet the specified impact requirement, none of the five specimens shall fail.
Failure shall be defined as any crack or split on the inside or outside of the waterway wall that was
created by the impact and that can be seen by the naked eye. Separation of the corrugations from the
waterway wall shall constitute a failure. Damage to the waterway wall shall constitute a failure but
cracking or breaking of corrugations shall be acceptable. Lighting devices shall be used to assist in the
examination for cracks and splits in the waterway wall of the pipe specimen.
c)

Air Tightness of Spirally Wound Pipe

Each length of PE pipe shall be tested for air tightness for the minimum dwell period specified in DIN
16961. The following shall the test procedure:
i)

The pipe ends shall be sealed with a suitably restrained closure.

ii)

The pipe shall be pressurized with air to 24.1 kPa (3.5 psi) and the air source cut-off. Pipe
may be pressurized above this level before the dwell period commences.

iii)

Timing of the dwell period shall commence and monitored

iv)

If the pressure falls below 23.3. kPa within the designated test period, the pipe shall be
rejected.

Weld Integrity of Welded Bells and Spigots

Each weld connecting bells or spigots, or both, to pipe shall be checked or integrity and continuity by
air testing or alternatively, by subjecting the weld to an industry-accepted test such as spark testing or
ultrasound testing. Test frequency and procedure shall be in accordance with the manufacturers
standard practice.
e)

Pipe Stiffness

Where the number of units produced in batches, the sampling procedures shall be in according to the
following table: Table 8.3: Sampling Procedure of PE Pipe

No. of unit
in batch

No. of unit
in first
sample

0-25
26-150
151-280
281-500
501-1200

2
5
8
13
20

No. of Defective unit in

sample
Accept
Reject batch
batch
0
0
0
1
2

1
2
3
4
5

No. of unit
ins second
sample
5
8
13
20

No. of Defective in both

sample
Accept
Reject
batch
batch
1
3
4
6

2
4
5
7

The second samples are only taken where the number of detective units in the first sample lies
between the numbers stipulated for acceptance or rejection of the batch. In no case shall sample unit
founds defective be included in accepted batch. Batch is defined as a number of units of a particular
specification, size or stiffness produced under uniform conditions during one continuous production

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period by the same process. For the purpose of Batch definitions, the continuous production period
shall not exceed 24 hours: within this limit any size batch may be chosen.
The unit tested in accordance with the requirements of this Clause shall in every respect be
representative of the units supplied for incorporation into the works.
The S.O. or his designated Representative shall be permitted, at all reasonable times, to visit the place
of manufacture for the purpose of witnessing any of the above tests.

8.4.9 Visual Inspection

Checks of dimensional accuracy will be carried out by the S.O. or his Representative as required, both
at the place of manufacture and on site. Any units founds at any time failing to meet the specified
dimensional, or quality criteria, shall be either be destroyed immediately or indelibly marked as
rejected, and removed from the site.
Whether or not there shall exist any physical evidence of damage any pipe which has undergone a
deflection of more than 5% at any time will be automatically rejected and shall be clearly and
indelibly marked as such. If on site pipes so affected shall immediately be destroyed or removed from
the site.

8.4.10 Information to be Provided

The Tenderer shall provide with the Tender the following information to the S.O. wherever the use of
such pipes are specified or otherwise proposed to him. Prior to manufacture of any items, the
Contractor shall inform the S.O. of any changes to this information.
a.

Name of manufacturer and address of factory at which units are to be made.

In the case of pipes or components made under license, the name and address of the company
granting the license.

Date of manufacture of pipe or date coding

Whether pipe manufacture is already subject to independent quality control, inspection and
certification procedures. (Such as the SIRIM acceptance logo or equivalent)

Designation of any national or international specifications normally worked to. (If other than
BS or ASTM a copy of the specification should be provided).

Name and address of polyethylene manufacturer. In addition the following information

regarding the polyethylene shall be provided, from the manufacturer:
1.

General description, name and type

2.
3.

Details of any pigments, stabilizers fillers, modifiers and other additive incorporated
into the material
Density (DIN 53479 or similar)

Melt index (DIN 53735 or similar)

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Yield stress, elongation at yield, ultimate tensile strength and elongation at break
(DIN 53455, ISO RS 27 or similar)

Coefficient of Thermal linear expansion (DIN 52328, ASTM DS96 or similar)

Flexural Modulus (DIN 53452 or similar)

Creep rupture strength (DIN 8075)

The pipe manufacturer will be required to provide evidence of continuing quality control
procedures to ensure that the above characteristics of the material are maintained within the
ranges stated by the polyethylene manufacturer and required by the pipe manufacturer:g.

Actual stiffness of pipes offered.

Details of pie or component design.

Method of manufacture to be used.

Full details of the proposed jointing systems, including materials to be used, equipment
required and full instructions for jointing.

Any changes to any of the above matters which are proposed to take place before the manufacture and
supply of pipes for this Contract are completed shall notify the S.O. who may withdraw his approval
of the manufacturer if not satisfied with the new arrangements.

8.5

Glass Fibre Reinforced Plastic (GRP) Pipes and Fittings

8.5.1 Materials
a.

Resins used in the manufacture of pipe and fittings shall comply with the requirements of BS
3532 for polyester resin system or of BS EN 61558 for expoxide resin systems, and finished
product shall in addition conform to BS EN ISO 5210 and BS EN ISO 5211.

Glass fibre reinforcement shall be type E glass which satisfies the following specifications:
-

Glass fibre roving BS EN 14020

Glass fibre chopped strand

Glass fibre woven fabric BS 3396

Glass fibre woven roving fabric BS 3749

Surface tissues for the inner and outer layers shall incorporate either type C glass, synthetic
organic fibres or type E glass.
c.

All aggregates, inert fillers, additive and colorants shall be used in accordance with BS EN
ISO 5210 and BS EN ISO 5211.

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Preformed thermo-plastic liners, if used, shall comply with BS 3505 or BS 3506 for
unplasticised PVC liners and BS 4991 for polypropylene liners. The minimum liner wall
thickness shall be 1.5mm.

8.5.2 Dimensions
a.

The finished dimensions of all pipes, fittings, couplings and other components shall be
compatible with their assembly into a completed system satisfying all the requirements of the
Contract and of BS 5480 : Part 2 where applicable.

Pipe Diameter for GRP Pipe, the Contractor shall state the manufacturing size which is to
be supplied. This manufacturing size shall be the target internal pipe diameter to which the
manufacturer works and shall not differ from the specified nominal internal diameter by more
than -3.5% or + 1%.
A deviation from the manufacturing size is permitted by limited to the tolerances specified
as follows: + 1.5mm for pipes up to and including 150mm nominal diameter.
+ 3mm for pipes over 150mm up to and including 600mm nominal diameter.

Effective length of pipe shall be as defined in BS 5480 : Part 1. Effective lengths acceptable
are 3m and 6m unless specified otherwise on the Drawings. 95 % of all pipes supplied in any
one diameter category shall conform to these effective lengths with a tolerance of + 25mm.
The remaining pipes shall have the lengths of not less than 1.5 metres.

All pipes shall fall within the Out-of-Square limits specified in BS 5480 : Part 1.

The deviation from straightness of the bore of the pipe shall not exceed 0.3% of the effective
lengths of the pipe or 15mm, whichever is the smaller. This requirement shall NOT be limited
to the straightness of the pipe when measured at its place or manufacture.

8.5.3 Fittings
a.

All fittings made from GRP, such as bends, tees, junctions and reducers, shall be equal or
superior in performance to pipes of the same classification. All fittings shall be smoothly
finished internally and comply with the dimensional tolerances stated in BS 5480: Part 1.

Fittings made from materials other than GRP may be used provided they have compatible
jointing systems and are equal or superior in performance to the GRP pipe of the same
classification. Where applicable, such fittings shall comply with the relevant British Standards
or, if these are not available, they shall fall within the same tolerance as those specified for
GRP fittings above. In this respect, the Contractor shall provide the S.O. with a copy of the
manufacturers specifications when proposing the use of fittings made from materials other
than GRP, and he shall obtain prior approval of the S.O. for the incorporation of such fittings
into the works,

8.5.4 Joints
a.

Joints may be rigid or flexible (mechanical)

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Rigid joints such as flanged joints, butt and overwrap, socket and spigot with bonding
compound, screwed joints, etc. shall be equal or superior in performance to pipes of the same
classification in both the circumferential and the longitudinal directions.

Flexible (mechanical) joints such as rolling or restrained O ring or clamped joints shall be
equal or superior in performance to pipes of the classification of the main pipe barrel in the
circumferential direction only, up to the limits of angular deviation or straight draw indicated
by the manufacturer of the joint.

8.5.5 Stiffness
The stiffness of the pipe when defined as EI/D where E is the bending modulus of the pipe wall in the
circumferential direction (N/m2). I is the moment of inertia of the pipe wall per unit length (m4/m) and
D is the nominal internal diameter of the pipe (m), shall not be less than the following:
Table 8.4: Stiffness of GRP Pipes

Initial Stiffness (N/m2)

Light Duty
1,250

Medium Duty
1,500

Initial Stiffness shall be tested in accordance with Appendix J of BS 5480 : Part 2.

8.5.6 Strain Corrosion Resistance

All pipes supplied and used in this Contract shall fulfill the strain corrosion resistance requirements
specified in 5480 : Part 2. The Contractor shall produce documentary evidence of such compliance if
requested by the S.O.

8.5.7 Quality Assurance Tests

Testing for initial stiffness and leakage shall be carried out using double sampling procedures
stipulated in BS 6001 for attaining a maximum of 10 % defective at an inspection level of S3 as
described therein. The units used for testing shall be representative of the units supplied for
incorporation into the works.
a.

Stiffness Test, the initial stiffness of the pipe shall be determined in accordance with
Appendix J of BS 5480: Part 2.

Leakage Test, the pipe shall be able to withstand a hydrostatic pressure of 150 kPa without
leakage when tested in accordance with Appendix G of BS 5480: Part 2.

Checks on dimensional accuracy will be carried out by the S.O. or his Representative as required,
both at the place of manufacture and on site. Any units found at any time failing to meet the specified
dimensional tolerances described in the Clause on Dimensions for GRP Pipes shall be either
destroyed immediately or indelibly marked as rejected, and removed out or the site.

8.5.8 Information to be Provided

The Tenderer shall provide the following information to the S.O. when submitting his tender.

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Name of manufacturer and address of factory at which units are to be made.

In the case of pipe or components made under license, the name and address of the company
granting the license.

Whether pipe is already subjected to independent quality control, inspection and certification
procedures (such as the SIRIM acceptance logo or equivalent).
Designation of any national or international specifications normally worked to (if other than
BS or ASTM a copy of the relevant specification should be provided).

Specifications of materials used in manufacture of the GRP pipe and the sources of these
materials. Also state details of any pigments, stabilizers, filters, modifiers and other additives
used.

Details of the pipe/component design.

Description of the manufacturing process

Physical properties of the finished product as follows :

1.
2.
3.
4.
5.
6.

Initial Hoop Tensile Strength

Initial Longitudinal (Axial) Tensile Strength
Flexural Modulus
Coefficient of Thermal Linear Expansion
Density or Specific Gravity
Stiffness

Prior to manufacturer and supply of any item, the Tenderer if successful, shall notify the S.O. of any
changes to the information that he has provided. The S.O. may in consequence of this withdraw his
approval of the proposed manufacturer if he is not satisfied with the new arrangements.

8.6

Unplasticized PVC Pipes and Fittings

8.6.1 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.

8.6.2 Joints

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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

(c)

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.

8.7

ABS Pipe

8.7.1 Materials
Material compositions of ABS pipes consist of a copolymer of the monomers acrylonitrile,
butadiene and styrene. For pipe applications for pressure sewerage system, appropriate quantities of
each monomer shall be selected to optimise the performance properties of tensile strength, chemical
resistance, ductility and weatherability. Material suitable for pressure pipe applications shall be Type
12142 in conformance with MS ISO 2580-1.

8.7.2 Sizes/Classes
Nominal size (DN) shall be used as a numerical designation of the diameter of ABS pipe. The ABS
pipe without couplings shall conform to the dimensions recommended in MS 1419:Part 1-1997 as
given in Table 8.4 below.

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Table 8.5: Dimensions of ABS Pipe

Nominal Size
(DN)
10
15
20
25
32
40
50
80
100
150
200

Mean Outside Diameter, Dm

Min
Max
17.0
17.3
21.2
21.5
26.6
26.9
33.4
33.7
42.1
42.4
48.1
48.4
60.2
60.5
88.7
89.1
114.1
114.5
168.0
168.5
218.8
219.4

Pipe lengths show the standard overall length of the pipe, exclusive of coupling, of 6 + 0.05, -0m. All
measurements shall be adjusted to an equivalent length at 20oC. The ABS pipe can be cut at site to the
desirable length. However, care must be taken to ensure squareness of cut ends.
Classes of ABS for force main are defined according to maximum static working pressure at a pipe
material temperature of 20oC, as Table 8.5 below:
Table 8.6: Classification of ABS Pipe
Class of Pipe
Class 4.5
Class 6
Class 9
Class 12
Class 15
Class T

Maximum Static Working Pressure, Mpa

0.45
0.60
0.90
1.2
1.5
1.2 after threading

8.7.3 Fittings
Purpose made ABS fittings shall be used for making of junction connections and shall be suitable for
pressure applications.

8.7.4 Joints
The methods of jointing ABS pipes shall be one of the following :
1.
2.

Spigot-socket with solvent cement welding joint

Stub flange joint with flange solvent cemented onto spigot end

The jointing of ABS pipe shall be carried out only by specially trained jointers.
Solvent cement shall consist of one or more solvents and a sufficient quantity of base ABS material
dissolved in the solvents to give the cement the body and consistency required for proper application.
Inert fillers shall be used to control shrinkage during drying.

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8.8

Ductile Iron Pipes and Fittings

8.8.1 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.

8.8.2 Manufacture and Testing

The manufacture and testing of ductile iron pipes and fittings shall comply with the current edition of
BS 545, BS 598 and BS 969 unless otherwise specified. Pipework shall generally be lined internally
with cement mortar and coated externally with a zinc spray coating and a bituminous varnish.
Ends of pipes and fittings shall generally be socket and spigot suitable for forming flexible joints of
the "push-in" type or "mechanical" type. Flanged ends where specified shall be suitable for jointing to
valves and flanged pipework.
Iron to be used for castings shall be made from pig iron or molten iron, iron or steel scrap, with such
ferro-alloy and other additives as shall be necessary to produce in the resultant castings, a ductile iron
complying with the mechanical properties as specified in Table 1 of BS 4772.
Before dispatch of the Goods to the Site, the suppliers shall forward to the S.O., results of all specified
tests and copies of test certificates stating that the pipes and fittings comply fully with the
requirements of the Contract.

8.8.3 Process of Manufacture

Ductile iron pipes shall be manufactured by one of the following process :(a)
(b)
(c)
(d)

centrifugal casting in lined or unlined metal moulds,

centrifugal casting in sand moulds,
casting in sand moulds,
casting in metal moulds.

Ductile iron fittings shall be manufactured by one of the following processes :(a)
casting in sand moulds,
(b)
casting in metal moulds.
"Sand" shall include mineral based materials used in the foundry trade irrespective of the type of
bonding agent used.
After casting, pipes and fittings may be subjected to heat treatment in order to achieve the required
mechanical properties.

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Pipes and fittings shall be sound and free from surface or other defects likely to be detrimental to their
use. Cracks and tears are specifically excluded from repair. Castings showing slight surface
imperfections inseparable from the method of manufacture and in no way affecting their use, shall be
accepted. On his own responsibility, the manufacturer may remedy such defects in a suitable manner.
Subject to the S.O.'s approval, minor cavities and certain defects may be repaired by a proven process
such as welding.
Castings shall be capable of being cut, drilled, tapped or machined. If the S.O. considers that their
quality does not comply with this requirement, Brinell hardness tests shall be carried out on them in
accordance with BS 240:Part 1 except that the period of application shall be 15 + 1 seconds. The
superficial hardness shall not exceed 250 HB for centrifugally cast pipes and 250 HB for all other
castings.

8.8.4 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)
1200
1100
1000
900
800
700
600
500
450
400
350
300
250
200
150
100
80

Outside Standard Wall

Diameter
Thickness
OD
(mm)
(mm)
1253
1150
1048
945
842
739
635
532
480
429
378
326
274
222
170
118
98

15.3
14.4
13.5
12.6
11.7
10.8
9.9
9
8.6
8.1
7.7
7.2
6.8
6.4
6.3
6.1
6

Cement
Nominal
Thickness

Mortar (mm)
Lining
Minimum
Minimum
Mean
Value at A
Value
Point

6.0
6.0
6.0
6.0
6.0
6.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0

5.5
5.5
5.5
5.5
5.5
5.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5

4.5
4.5
4.5
4.5
4.5
4.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
2.5

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

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8.8.5 Tolerances
(a)

Tolerances on standard mass

The supplier shall specify the standard masses of pipes and fittings for each type of joint.
These shall be calculated using the nominal mass of 7050 kg/m3. The tolerances on the
standard mass shall be in accordance with BS 4772.
(b)

Tolerances on dimensions

The supplier shall specify the dimensions of pipes and fittings for each type of joint. The
outside diameter of pipes is fixed as a function of the nominal diameter and is independent of
the pipe wall thickness which shall be changed only by modification in relation to forces
acting in each point of the castings, particularly to local stresses induced by internal pressure.
Increases or decreases in wall thickness of fittings may be obtained by modification to either
the outside or inside diameter. The tolerances on diameter, length, thickness, ovality and
straightness shall be in accordance with BS 4772.

8.8.6 Works Tests

Before being lined or coated, each pipe and fitting shall be hydrostatically tested at the manufacturer's
works in accordance with BS 4772. The hydrostatic test pressure shall be as follows: Table No. 8.8: Hydrostatic Test Pressure
Nominal
Diameter

Test

Pressure

Leak-Tightness Test Pressure for fittings and for

pipes not Centrifugally Cast

(mm)

(bar)

80-300

350-600

700-800

900-1200

Tensile tests on the castings shall also be carried out at the works in accordance with BS 4772. The
break faces of the test pieces shall show a regular, tight, light grey grain and shall not have any
unfileable parts.

8.8.7 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.

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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.

8.8.8 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.

8.8.9 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. The Contractor shall submit drawings showing all details and
dimensions of the fittings offered.

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8.8.10 Joints
The Contractor shall submit drawings showing all details, dimensions and the maximum joint
deflections of the "push-in" and "mechanical" type deflection joints. 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 manufacturer's 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.
(a)

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.

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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 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.
Internal protection to the joint is to be effected by pouring hot bitumen into the annular space
between the pipe ends against an inflated mandrel. The mandrel shall be coated with lime
wash before inserting into the joint and then inflated to the appropriate pressure (about 13.8
kPa). The two screwed plugs shall be removed from the sleeve and a funnel and vent shall be
screwed in. Bitumen shall be heated up to 250 degrees Celsius and poured into the funnel
until the annular space between the pipe ends is filled. After the joint has cooled and set, the
funnel, vent and mandrel shall be removed and the plugs replaced and tightened.
The external protection of the pipe is to be effected by enclosing the joints with run bitumen
compound, in accordance with the manufacturer's instructions. Before casing, the ends of the
pipes are to be coated with a suitable preparation to ensure adhesion of the covering.

8.8.11 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.

8.9

Steel Pipes

8.9.1 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.

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8.9.2 Testing
Samples of the steel plate supplied for the manufacture of pipes and specials, and test pieces cut from
the pipes themselves shall be tested in accordance with BS 534:1990 and BS 3601:1981. The
Manufacturer shall submit certificates in duplicate from the steel manufacturer stating the results of
the tests specified on samples and test pieces, and also the steel used, the process of manufacture and
chemical analysis.
Before lining and coating, all pipes and specials shall be tested hydraulically at the factory as
specified in Clause 14.4 of BS 3601: 1987 at a pressure not less than twice the maximum working
pressure.

8.9.3 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.

8.9.4 Straight Pipes

Straight pipes shall be supplied in standard lengths of 9 metres as defined in the relevant British
Standards. The variation in length from the nominal standard length shall be kept as small as possible
within the normal methods of manufacture. Straight pipes shall be supplied in half lengths and
quarter standard lengths as required. These pipes will be required for cutting to exact lengths during
laying to form closing lengths.

8.9.5 Specials
Specials conform generally to the appropriate dimensions given in BS 534:1990 and BS 4504:1990
unless otherwise stated. Where it will not be practicable to carry out the factory hydraulic test on the
completed specials, the specials may be fabricated by welding together sections out from straight
pipes which have been satisfactorily tested, lined and sheathed. In all respects, the specials shall be
fabricated and tested in accordance with Clause 20 of BS 534:1990. The lining and coating shall be
repaired by hand after welding and testing.

8.9.6 Joints
(a)

Collar joints

Collars shall be truly circular, and shall conform to Clause 25 of BS 534:1990. They shall be
at least equal in thickness and quality to the adjoining pipes.
(b)

Mechanical couplings

Mechanical couplings shall be of approved type. Each coupling and adaptor shall be capable
of withstanding twice the working pressure. Couplings shall be without the centre register
and shall be supplied with three removable locating plugs fitting into holes drilled and tapped
on the centre line of the sleeve. Couplings and adaptors shall be supplied complete with all
necessary couplings rings, nuts, bolts, washers and rubber rings. Couplings connecting pipes
of different outside diameters shall be stepped and suitable for the particular purpose required.

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(c)

Flanged joints

Flanges shall be of steel and welded to the pipe by the metal-arc process or other approved
method. Flanges shall be truly faced over their whole width and the bolt holes drilled off
centre and truly in line end to end with the longitudinal axis. Flanges shall be in accordance
with table 10/5 of BS 4504:1989.
(d)

Welded joints

Where jointing of steel pipes and specials by welding is approved by the S.O. it shall be by
means of an external circumferential electric arc weld at each joint.
The weld shall be of the convex full fillet type, the length of each leg being not less than the
thickness of the metal of the pipe. The weld shall be made manually by the metalled arc
process using approved types of electrodes, and shall be carried out in two stages, one root
pass followed by one or more weave cover passes. Each time the arc is started it shall be
manipulated to obtain complete fusion of the weld metal with the pipe metal and any
previously deposited weld metal. All slag shall be completely removed and the weld metal
and the adjacent pipe metal shall be cleaned by wire brushing.
All welds shall be subject to visual inspection by the S.O. and shall comply with the
requirements of BS 5950 : Part 1 : 2000, BS EN 1011 and BS 4872 for freedom from
undercutting, fusion penetration and soundness.
(i)

Welding procedure

All electric arc welding equipment shall comply with BS 638. The Contractor shall submit
details of the welding procedure which he proposes to adopt for the S.O.'s approval. Details
shall include: (I)
(II)
(III)

Make, type and gauge of electrodes

Size, shape and number of runs in welded joint.
Current strength

The Contractor shall demonstrate his chosen welding technique on a pipe and joint of the
same metal and thickness as the pipeline to be welded. Bare steel shells and joints shall be
supplied by the Contractor free of charge for this purpose. Test specimens shall be prepared
and tested in accordance with BS 2633. Only procedures approved in writing by the S.O.
shall be adopted in welding on the pipelines, and change from one procedure to another will
not normally be permitted without submitting the new procedure for re-testing.
(ii)

Welding personnel

Only competent and certified welders shall be employed on the Works, and every welder
before commencing any joint welding shall prepare specimens for testing in accordance with
BS 2633 for each welding procedure proposed by the Contractor.
The Contractor shall make test specimens which shall be tested in the presence of the S.O. for
each welding procedure proposed.
The S.O. will advise the Contractor in writing which welders the S.O. considers produce
satisfactory test specimens. Only these welders will be allowed to joint pipes in position and

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the S.O. shall be at the liberty to withdraw his approval to any welder responsible for making
joints which fail to meet the required standard.
The Contractor shall supply all materials and labour for preparing the test specimens and shall
allow for their cost and for laboratory test charges in the unit rates for welding.
(iii)

Radiographic examination of welded joints

Welded joints for large diameter pipes of 1200 mm diameter and above shall be radiographed
at random as directed by the S.O. At least 2 strips each for internal and external welds shall
be sampled for quality check for a slip joint. The contractor shall make all the necessary
arrangement apparatus and equipment and a specialist to carry out the test. The analytical
report in duplicate shall be submitted to the S.O. three days after the test. If the weld does not
meet the requirements of the Specification, the weld will have to be gouged out and made
good. The repaired welds shall be radiographed again at no extra cost to the Employer. The
frequency of radiographic examination for welded joints shall be one in every fifty.
(iv)

Completion of coating of welded joints

After each length of pipeline has been laid the external coating shall be made good.
Bare metal shall be thoroughly cleaned to a bright metallic finish and it shall be immediately
coated with a primer solution. The primer shall be applied cold by brush.
As soon as the primer has set, the coating shall be completed by running hot coal tar enamel
or bitumen, whichever is compatible with the external coating, into an aluminium mould
placed over the joint and overlapping the coating by 75mm.

8.9.7 Protection
Before internal lining and external protection, all pipes and specials shall be cleaned to remove all
scale rust, oil, grease or other foreign matter, by an approved method in accordance with Clause 28 of
B.S. 534: 1990. A priming coat shall be applied immediately if cleaning is done by sand or shot
blasting.

8.9.8 Lining
The internal lining of all plain-ended pipes and specials shall be extended to the ends and finished
square with the ends. All steel pipes and specials shall be protected internally with cement mortar
lining using sulphate resisting or high alumina cement in accordance with Clause 33 of BS 534:1990.

8.9.9 Coating
Steel pipes and specials shall be protected against external corrosion by coating and wrapping in a
neat and workmanlike manner. All coating and wrapping shall be able to withstand the attack of soil
and ground water with sulphate content as high as 0.34% and a pH as low as 3.1.
Within 15 minutes of each pipe or special being cleaned to base metal, a uniform thin coat or primer
compatible with the coating material to be used shall be cold applied by flood coating, spraying or
brushing. The primer shall be allowed to dry properly before the coating material is applied but if
more than 96 hours elapses before coating or if the primer becomes dead, powdery or crumbly it shall
be cleaned off and the pipe or special shall be reprimed. The coating material shall conform with the
requirements of either sub-clauses (a) or (b) hereinafter specified.

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(a)

Bitumen coating: The pipes and specials shall be coated with appropriate layers of bitumen
containing a mineral filler complying with Type 2 of BS EN 10300. The coating shall be
applied hot to have a total thickness of 6.5 mm and shall be reinforced with an inner wrap and
an outer wrap.

(b)

Coal tar enamel coating: The pipes and specials shall be coated with appropriate layers of
plasticised coal tar pitch base enamel complying with Clause 30.6 of BS 534:1990. The
coating shall be applied hot to have a total thickness of 6.5 mm and shall be reinforced with
an inner wrap and an outer wrap.

The wrapping materials shall be spirally wound onto the pipes and specials simultaneously with the
coating material. Each wrap shall be from 300 - 450 mm wide and the edges shall overlap by 15mm
to 25 mm. Care shall be taken to ensure that the inner wrap does not come in contact with the pipe
metal or with the outer wrap.
Inner wrap: The inner wrap shall be a glass fibre resin bonded tissue reinforced in the longitudinal
direction with parallel glass threads spaced 10 mm apart. The nominal thickness shall be 0.5 mm and
the minimum weight shall be 46 gms per sq. metre.
Outer wrap: The outer wrap shall be a glass fibre resin bonded tissue reinforced in the longitudinal
direction with parallel glass threads spaced 10 mm to 25 mm apart. It shall be impregnated with a
material fully compatible with the coating material to give a finished thickness of 0.75 mm.
All coated pipes and specials shall be inspected for defects. Thickness shall be determined by a pit
gauge, continuity with a holiday detector and coating quality by cutting out 75 mm x 75 mm samples.
The whole coated surface area of all pipes and specials shall be tested for pinholes or other invisible
defects in the coating using an approved holiday detector at a potential of 14,000 volts.
Any lengths on which the coating is poorly applied shall be cleaned to bare metal and re-coated.
Touching up can be used to repair minor defects. All repairs shall be checked for thickness and
continuity.

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

8.9.11 Marking and Transportation

In addition to the requirements of clause 8.1.2 for steel pipes, sized pipes shall be marked with two
longitudinal parallel bands throughout their whole length.

8.9.12 Repair of Lining and Coating

Only specially competent and skilled men shall be employed to carry out repair work to damaged
linings and coating.
Small cracks and flaws in the internal concrete lining of steel pipes and specials may, with the prior
approval of the S.O. and if they are accessible, be repaired on Site. Such cracks may be repaired by
cutting out a 10 mm x 10 mm dovetailed key and making good with a semi-dry mortar (proportion 1

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part cement to 2 parts coarse sand) well tamped into the groove, and cured by keeping it damp for 7
days. Alternatively, small cracks may be caulked with an epoxy resin filler.
The external coating of steel pipes and specials shall be made good wherever the steel has been
exposed or the thickness of the coating does not adhere tightly to the steel. Where the steel has been
exposed all rust and dirt shall be removed carefully by wire brushing or otherwise, and when perfectly
clean and dry, a coat of special quick drying priming paint applied before re-fettling. Small stones
which may have become embedded in the coating shall be picked out and the coating refettled by
heating locally with a blow lamp and smoothing over with a fettling knife. Additional external
jointing material shall be added wherever necessary. The compound used for repairing coatings shall
be compatible with the coating material and shall be approved by the S.O.
All defects to linings and coating shall be made good to the entire satisfaction of the S.O.

8.10 General for Pipeline Installation

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

8.10.2 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.

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.

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8.10.3 Dimensions of Pipes

The Contractor shall submit to the S.O. all technical information, the internal, external and other
necessary dimensions of the pipes prior to the purchase and supply of the pipe to the work site.

8.10.4 Specialists, Inspection and Testing

The Employer may, at his cost, employ the services of a specialist firm to assist the S.O. as he may
require in any matter connected with pipe, manholes, and fittings including the inspection of materials
and workmanship and the witnessing of tests at any stage (including manufacture) during the
execution and maintenance of the works. Such independent tests may be carried out at any stage
during the execution and maintenance of the Works, but they shall not relieve the Contractor of any of
his own obligations under the Contract. To the extent ordered by the S.O., the Contractor shall
provide labour, plant and materials (but not special testing equipment) for direct assistance to the
specialist firm in their inspection and independent testing and for any further work of investigation
and repair which the S.O. considers necessary as a result of such inspection or testing. The cost of
providing labour, plant and materials as aforesaid shall be borne by the Contractor where in the S.O.s
opinion the inspection test or further investigation shows that materials and workmanship provided by
the Contractor do not comply with the specified requirements, but otherwise shall be borne by the
Employer.

8.10.5 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.

8.10.6 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.

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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.

8.10.7 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.

8.10.8 Laying Diagrams

The Contractor shall submit for approval detailed laying diagram showing the following :
a.

Location, length, design and designation by number of each pipe section and pipe special to
be furnished and installed.

b.
c.

Station and elevation of pipe invert at all changes in grade.

All data on curves and bends for both the horizontal and vertical alignment.

All applicable provisions of these Specifications shall apply to the preparation and submittal of said
drawings, and their subsequent approval and possible revision. In the event that the final As-Built
condition varies from the original approved shop drawings, the Contractor shall revise the shop
drawings and laying diagrams to the As-Built condition.

8.11 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.

8.11.1 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.

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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. 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.
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.

8.11.2 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.

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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.
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.

8.11.3 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.

8.11.4 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,

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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
19mm
9.5 mm
4.75 mm
2.36 mm

Min.
100
80
10
0

Max.
90
25
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.
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.

8.11.5 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.

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8.11.6 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.

For Welded Joints, the exposed surfaces shall be cleaned by sand blasting or
through wire brushing, primed by tar primes and spiral wrapped with coal tar
and coal tar saturated with asbestos felt so that a continuous sheathing free
from detect is formed and given a coat of white wash.

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.

8.11.7 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.

8.12 Special Laying Methods: Jacking

The jacking method of pipelaying shall be employed where indicated on the Drawings or as directed
by the S.O.
Unless otherwise specified or as shown on the Drawings the method and equipment to be used for this
purpose shall be proposed by the Contractor but a detailed description of his proposal as well as the
safety measures which he will be taking shall be submitted to the S.O. for prior approval before
commencement of pipejacking works. Approval of the Contractors proposal by the S.O. shall not
relieve the Contractor of the responsibility for making a satisfactory installation which meets the
technical criteria set forth hereunder. One single approved manufacturer shall supply pipes and pipe
joints used in pipe installation by jacking method.

8.12.1 Pipe Jacking - Procedures

Where a steel shield is utilized during the jacking operation, this steel shield shall be bolted to or by
other approved means joined to the first piece which is being jacked.
The Contractor shall be required to use a jacking ring. The jacking ring may be either steel or
concrete construction and shall be used at all times when pipe is being jacked. This jacking ring will
allow the jacking pressure to be distributed evenly around the wall of the pipe.
The Contractor shall also be required to use a jacking frame during all operations. The jacking frame
shall be designed to distribute the stresses from the jacks evenly to the jacking ring.

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After the jacking operation has begun, the Contractor shall work continuously (24 hours per day) until
the complete length of jack pipe is installed.
The pipes shall be jacked into place true to line and level. The maximum tolerance allowable in the
displacement of the centreline of the laid pipe from the design centreline is 50mm in the horizontal
plane and 25mm in the vertical plane but there shall be no back fall at any point. Any pipe that is not
laid in its correct position must be removed and re-laid or adjusted to obtain its correct position.
There shall be provision to prevent the relative movement between pipes at the joints by the use of
steel gaiters or other approved methods during jacking operation. A packing piece of compressible
material shall be provided at each joint and shall be securely held before the pipes are lowered into the
thrust pit. Details of proposals shall be submitted to the S.O. for approval.
The Contractor shall be required to furnish, install and remove to the extent required thrust blocks or
whatever provisions that may be required for backing up the jacks employed in driving the pipe
forward. The jacking pit shall also be equipped with steel rails or beams embedded in concrete.
These rails or beams will be used for placement and alignment of each pipe during the jacking
operation.
The Contractor shall be fully responsible for the design and construction of jacking and receiving pits,
thrusting wall, installation of jacking equipment, sheeting, bracing etc. and for the efficient execution
of the jacking operation. Full details of his proposals, including plant, shield machine equipment,
operating procedures, jacking pit and intermediate jacking stations shall be submitted to the S.O. and
shall be fully satisfactory to him before construction. However, review of the plans shall not relieve
the Contractor from his responsibility to provide a safe and satisfactory jacking pit.
The Contractor shall be required to monitor closely the progress of the jacking operation. Daily site
records of thrusting pressures and the line and level measurements shall be properly maintained and
shall be available to the S.O. at all times.
It is the responsibility of the Contractor to ensure that the completed pipes are watertight. Pipe testing
shall be carried out strictly in accordance to the requirements of Clause 8.17. If leakage is detected at
any time before the end of the Maintenance Period, the Contractor shall carry out any remedial work
as necessary to make the works watertight all at his own expense.

8.12.2 Alternative Trenchless Pipe Installation Methods

The contractor shall take into full consideration all geological conditions in which the proposed pipe
jacking will be carried out and shall modify the methods of pipe installation as appropriate subject to
the approval of the S.O. Alternative methods of trenchless pipe installation such as micro tunnelling
or rock boring methods may need to be used. The contractor shall satisfy himself with respect to the
suitability of the machines he propose to use for the purposes of installing the pipe in the ground
conditions expected to be encountered.

8.12.3 Type of Pipe Used for Jacking

All pipes used shall fulfil the Specifications set out in this Contract. Pipes used for jacking shall be
mild steel, reinforced concrete or vitrified clay pipes and it shall be the responsibility of the
Contractor to ensure that the pipes used are able to withstand the laterally induced jacking stresses
without damage. The Contractor shall submit calculations showing that the structural strength of the
pipes meet requirement for the entire jacking operations. Shop drawings of all pipes shall be
submitted for evaluation before the commencement of pipe manufacture.

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Unless otherwise specified or directed by the S.O., the types of joints permitted for jacked pipelines
are butt joints and spigot and socket joints, but where a butt joint is used the butting surfaces should
be modified to accommodate the rubber ring or similar sealing device to make the joint watertight.
Any leakage detected shall be resealed to the satisfaction of the S.O. The concrete pipe used shall be
adequately protected against corrosion from sewage with high alumina or sulphate resisting cement
lining as specified. The pipes shall also satisfy the cracking strength requirements.
Where pipe jacking is carried out using a larger concrete pipe as a sleeve and vitrified clay pipes are
inserted through the sleeve, all details including pipes, joints, sandfilling and grouting shall be as
shown on the drawings and as approved by the S.O.

8.12.4 Alignment Control and Tolerances

In order to maintain a high level of accuracy of line and grade, extreme care shall be exercised by the
contractor when setting out the guide rails for the pipe and during actual jacking operations. The
jacking frame if used must be aligned perpendicularly to the direction of pipe travel. During the
course of jacking, the Contractor shall carry out regular checks to ensure that the pipe adheres to the
pre-determined alignment and he shall make modifications to the jacking procedure to correct any
deviation detected.
Accuracy of line direction and grade shall be kept at +50mm from the designed alignment for every
100 metres of pipe installed but up to a maximum deviation of 100mm.

8.12.5 Joints for Jacking Pipes

Pipes to be used in jacking shall have joints which are manufactured to close tolerances of within
+2mm of manufacturers specified dimensions. The types of joints to be employed shall be approved
by the S.O. prior to supply of pipes to the site. Stainless steel 304 collars shall be used and shall be
manufactured to tolerances of +2mm. The joints shall be flexible and watertight. The Contractor
shall be responsible for the proper functioning of the joints.
Spigot and socket shall be used to join pipes using pipe-sleeve jacking method. This method normally
used when the smaller pipe is non-jacking pipe. The smaller pipe shall be pushed along the invert
inside the bigger pipe sleeve progressively. The void space inside the pipe sleeve shall be filled with
sand or cement grout to keep the inner pipe in position. This method of jacking is not commonly used
nowadays since the jacking pipes are also manufactured in small diameters for different types of
pipes.

8.12.6 Joints Performance Test

All joints of pipes installed by jacking shall be subjected to and pass the Leakage Test as described
under Clause 25.8 (Tests for flexible joints) of BS 5911 (Part 1): 2002.

8.12.7 Jacking and Receiving Pits

The Contractor shall submit details of his proposed jacking pit and receiving pit to the S.O. for prior
approval before commencement of jacking works. All material excavated during the construction of
the jacking and receiving pits shall be removed from the Site. Only approved backfill material shall
be permitted to be used for backfilling such excavations upon completion of jacking works.

8.12.8 Jacking Records

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The Contractor shall maintain accurate and complete jacking records which shall be submitted to the
S.O. after completion of each jacked sections.

8.13 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.

8.13.1 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.

8.14 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.

8.15 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.

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8.16 Manholes
At each change of gradient or direction, at each intersection with other sewers and at such other points
as shown on the drawings or as directed by the S.O., a manhole shall be constructed to the form and to
the dimensions shown on the drawings. Manholes are to be constructed in circular precast reinforced
concrete sections as shown on the drawings and as directed by the S.O.
The bases of all manholes sections shall consist of concrete of the full thickness shown on the
drawings. Channel inverts shall be accurately laid to meet pipe invert elevations at the same time as
the sewer pipes are laid, the bends being as slow as possible by siting the manholes off-center at
changes in direction. Short lengths of pipe with flexible joints (not more than 1m) shall be provided
immediately upstream of the inlet cut pipe and immediately downstream of the outlet cut pipe for
flexibility.
Precast concrete manhole sections shall conform in all respects to BS 5911. The dimensions of the
chambers and the shafts shall be as shown on the drawings. All joints in precast manhole sections
shall be made with cement mortar. Manhole floors shall be constructed with concrete formed to the
required shapes with concrete channel inverts including half round concrete channels, bends, tapers,
junctions and double junctions. The top of the in-situ benching shall be sloped back at 1 in 12.
Precast manholes shall be encased with concrete as shown on the drawings. Rough shuttering shall be
used for the concrete surround to manholes. All concrete used in manholes shall be made using
sulphate resisting cement unless otherwise shown on the Drawings or directed by the S.O.
Full evidence of compliance shall be provided to the S.O. prior to the ordering and delivery of the
chamber ring and cover slab sections. On site casting of these sections is unacceptable. The manhole
cover slab sections shall be heavy duty and provided with an opening tapered by 50mm over which
the manhole cover and frame will be set. The slabs shall be provided with built-in lifting rings.
Provision shall be made for future sewer connections to manholes by providing a box-out sealed with
bricks where shown on the drawings or where ordered by the S.O. The pipes shall be laid at the levels,
slopes and in the directions instructed by the S.O. Ductile iron covers, to BS EN 124 shall be laid with
their frames bedded on the concrete slab of the manhole cover. Manholes covers generally shall be set
to the road profile and be flush with the road surface. Manhole covers located in unpaved areas shall
be set at an elevation such as to prevent the entry of surface water as directed by the S.O.
Where drop manholes are indicated they shall be as shown on the drawings and shall be formed where
the upstream length of sewer enters a manhole at a higher level than the manhole invert level. All
pipes and fittings in drop connection shall be the same material and of the same size as the fitting in
drop connection shall be the same material and of the same size as the connecting pipeline shown on
the Drawings. All manholes shall be watertight on completion and where leakage is discovered the
Contractor shall perform such work and provide all materials as are necessary to render such faulty
work watertight.
The Contractor is warned that he should expect rubbish and debris to be deposited in the manholes
during the course of construction and he should take the necessary measures to ensure that the
manholes are not used as rubbish and waste dumps. The Contractor shall keep pipelines and manholes
clear of such rubbish and debris.
Manhole openings and covers shall be located taking into account the relative orientation of the
manholes, ladders, landings, sewers and benching below such that access and sewer maintenance are
facilitated.

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8.17 Testing Pipelines

The Contractor shall submit for the S.O.s approval details of his proposed methods and programme
for testing (including details of test equipment) and shall arrange for all tests to be witnessed by the
S.O. or other person appointed by the S.O. The Contractor shall provide all things necessary for
carrying out testing and cleaning including pumps, gauges, pipe connections, stop ends, and all other
temporary works. Pipelines shall be properly completed and supported before being put under test
except as hereinafter detailed.
No testing will be permitted until ten days after thrust blocks and other holding down works have
been completed. Trenches shall be left open prior to testing pipelines except as permitted by the S.O.
who may lay down certain restricting conditions.
In addition to any tests of individual joints or other interim tests which may be specified elsewhere the
Contractor shall submit all parts of the pipelines to a final test. Notwithstanding the foregoing the
Contractor may at any stage of construction, carry out such other tests as he considers desirable to
check materials and workmanship on the pipeline but this shall not relieve the Contractor of his
obligations to achieve successful test under the Contract.
All tests shall be conducted in accordance with the requirement of MS 1228:1991 or in accordance to
this section of Specification as directed by the S.O.

8.17.1 Testing Gravity Sewers

Unless otherwise directed by the S.O., all sewers shall be tested immediately upon completion of not
more than 300m of sewers.
One or more of the following tests for leakage due to internal pressure and infiltration shall be carried
out on all gravity sewer mains. The test method shall be submitted to the S.O for approval. The
Contractor shall, at his own expense, furnish all equipment and materials for making the test. Tests
shall be performed before backfilling is commenced and again after backfill and compaction is
completed, and after all utilities are in the ground including sewer laterals, but prior to placing of
permanent resurfacing.
Tests shall be performed in the presence of the S.O., and shall include the main and laterals as a unit.
All pipes are to be clean and empty at the time of testing. When leakage of infiltration exceeds the
amount allowed by the specifications, the Contractor shall re-open the trench and repair the defect or
defects until the length of sewer pipes has been retested in order to reduce the leakage or infiltration to
the specified limits to the satisfaction of the S.O. However, any individual detectable leaks shall be
repaired, regardless of the results of the test. Leakage tests shall be made on completed gravity sewer
lines as follows:
a.

Leakage Due to Internal Pressure (Air Pressure Method), the Contractor shall
plug all pipe outlets with suitable plugs, and brace each plug securely where
needed. The input air supply shall be regulated by a pressure regulating valve so
as to not exceed 34 kPa gauge pressure. The air test equipment is to be approved
by the S.O. prior to testing, the test shall be performed as follows:

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Air shall be added slowly to the pipe until the internal air pressure is raised to 27
kPa gauge pressure, at which time the flow of air into the pipe shall be shut off
and the input supply hose disconnected completely from the testing equipment.
After the internal pressure of 27 kPa is obtained, two minutes shall be allowed
for the air temperature to stabilize within the pipe. Sufficient air is admitted as
needed only to reattain a pressure of 27 kPa, timing shall start and the seconds
counted until the pressure has decreased to 17 kPa. Minimum permissible
pressure holding times for sewer mains, with or without laterals, are listed in the
N.C.P.I. Air Test Tables, as published in the latest National Clay Pipe Institute:
Low Pressure Air Test and Sanitary Sewers (Procedures and Tables).
b.

Leakage Due to Internal Pressure (Water Pressure Method), the S.O. may require
in some cases to have certain sections of sewer pipes tested by water pressure in
lieu of the Air Pressure Method. This test shall be performed as follows:
The pipeline to be tested shall be plugged at all pipe outlets with suitable plugs,
and each plug securely braced where needed. The pipeline shall be filled with
water, and sufficient time will be permitted to elapse between the filling and
testing of the line to permit absorption of water by the pipe walls. A hose shall
connect the plug with a standpipe (30 cm diameter approximately). The
standpipe will be filled to a level not less than 1.2m above the level of the sewer
at the upper end and positioned to permit the addition of 3.8 additional litres of
water. 3.8 litres of water shall be added and the time measure for the water level
to return to the mark measured. The time so measured shall not be less than that
computed by the following formula which provide for minimum allowable
leakage of 20 litres per milimetre diameter per kilometer per day.
Minimum Time (minutes)

273,500
Diameter(mm)xTest Length(m)

Leakage Due to Infiltration, in the construction of a section of sewer of any size,

excessive groundwater is encountered, a test for infiltration shall be conducted if
ordered by the S.O. The upper end of the sewer shall be closed sufficiently to
prevent the entrance of water, and pumping of water shall be discontinued for at
least 3 days prior to the test for infiltration.
The infiltration shall not exceed 20 litres per millilitre diameter per kilometer per
day of that portion of main line sewer in groundwater being tested and does not
include the length of house laterals entering that section. This test may be
conducted in lieu of, or in addition to the other tests, as determined by the S.O.

8.17.2 Testing of Force Main (Hydraulic Testing)

When a section of pipeline of about 300 metres has been laid, jointed and partly
backfilled as specified, it shall be prepared for testing by sealing the open ends
temporarily with caps. For this purpose the contractor shall prepare test end
units consisting of short lengths of pipe permanently fitted with caps to the
satisfaction of the S.O. These units shall be jointed to the section of pipe to be
tested with a standard coupling which can be easily removed when the tests have
been completed thus enabling the test end unit to be provided with a valve
outlet complete with pressure gauge shall be tested commences at a sluice valve,

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the valve may be used in place of the test end section to close this end of the
section during test.
The ends of the section of pipe under test shall be braced to withstand the end
thrust which develops from water pressure; temporary thrust blocks shall be
provided by the contractor for this purpose.
The thrust blocks specified for the pipeline shall be permanently constructed in
place and the concrete properly cured before the test is made. No temporary
bracing will be permitted in place of thrust blocks since the purpose of the test
includes the testing of permanent thrust blocks and fittings in addition to pipes.
b.

The section of pipe to be tested shall be filled with water of fair quality, free
from sediment from a source approved by the S.O. The water shall be
introduced into the pipeline through the valve in test end unit at the lower end
of the pipeline.
During filling, provision shall be made for air to escape from all high spots in the
pipeline and from the valve in the upper test end unit. If the pipeline is on a
level grade, it may be necessary to provide temporary tees and air valves on the
main at several points to ensure the escape of air. The tees shall be blanked off
after the test is applied.
If the main runs up-hill, the pressure gauge used during tests should be situated
at the bottom of the section, otherwise excessive pressure may be imposed upon
the lower part of the pipeline and there will be a risk of damage to anchorages
designed to withstand the specified test pressure. This pressure shall be applied
by means of force pump at the highest convenient point on the main so as to
minimize the pressure against which the pump will have to operate.
The test section shall be completely filled with water for at least 24 hours prior to
testing to allow for absorption of water into the pipes and/or jointing material.

Water shall be pumped into the main raising the pressure slowly in increments of
1 bar, with pauses of one minute between each increment. Should any
appreciable drop in pressure be noted during one of these pauses the test shall be
stopped until the cause of the pressure drop has been investigated and rectified.
The pipes shall be tested to one and a half times the working pressure.
The pressure/strength test shall be considered to have been passed when the
pressure gauge shows no reduction from the test pressure during the period of ten
minutes after full pressure has been attained.

The leakage test shall then follow. The pressure shall be held at one and a half
times the working pressure and maintained as constant as possible for a period of
twenty-four hours by pumping in make-up water if necessary.
The leakage test shall be considered to have been passed if the measured quantity
of make-up water pumped into the pipe to maintain the test pressure does not
exceed 0.1 litre per millimetre (mm) of pipe diameter per Kilometre (km) of
pipeline per day (24 hours) for each 3 bars of pressure applied.

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Only sufficient backfilling of the trench to prevent snaking of the pipes shall be
allowed before the satisfactory completion of these tests detailed above.

Every section of the pipeline shall be tested and connected with all previously
tested sections so that no element of the pipe line is left untested.

All ductile iron pipes and fittings within pump stations shall also be similarly
tested for strength and leakage, but the Contractor shall take adequate
precautions to strengthen and secure joints, bends, tees, etc. so that they are not
damaged during the tests. All pipes and fittings which prove defective shall be
remedied or repaired and tests repeated until satisfactory result are obtains. The
contractor shall repair any damage resulting or caused by these tests at his own
expense. Pumps to be used in the works shall not be subjected to hydrostatic
pressure during the tests.

8.18 Sewer Inspection, Condition Assessment and Classification

All network sewers shall be 100% internally inspected after all other tests on the sewer have been
completed and prior to hand-over. Sewers 1200mm diameter and larger may be inspected manually
by man entry. Otherwise all sewers shall be examined by closed-circuit television (CCTV)
inspection. Sewer inspection shall also comply with all the relevant requirement of MS 1228. Only
certified operators shall carry out CCTV inspection. Valid calibration certificates shall be produced
for all CCTV equipment to be used for the inspection.
The sewer condition assessment and classification report shall be endorsed and submitted by an
accredited assessor. The assessment and classification shall be strictly in accordance to the Manual of
Sewer Condition Classification (4th Edition) published by WRC, United Kingdom.
Acceptance or otherwise of the sewers shall be based on the requirements of Malaysian Sewerage
Industry Guidelines Volume 3. Any sewer found not meeting the acceptance standard shall be
repaired and the reinspected. This process shall be repeated until the repaired sewers meets the
acceptance for the sewer. Old sewers shall be Grade 2 or better while new sewers shall be Grade 1.

8.19 Test for Straightness

Tests for straightness for pipes equal to or less than 750mm diameter shall be applied on a section of
pipeline between two manholes by means of a mirror at one end of the sewer and a lamp at the other.
The sewer will have passed the test if a full circle of light is observed. For pipes having diameters
greater than 750mm, the permissible deviation from true alignment shall not be more than 50mm
measured from plan.

8.20 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

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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.

8.21 Temporary Surfacing

Temporary surfacing 38mm thick shall be furnished, installed, maintained, removed and disposed of
in accordance with the applicable portions of Section 306-1.12 of the Standard Specifications for
Public Works Construction, 1970 Edition for all trenches where traffic is allowed to drive over or
along the excavated and backfilled areas prior to permanent resurfacing. All costs of furnishing and
installing the temporary surfacing are considered to be included in the unit rates for pipe and no
additional compensation will be allowed.

8.22 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.

8.23 Maintenance in Pipe Installation Work

One month before the end of the Contract Maintenance Period, the Contractor shall inform the S.O. of
the expiry date and arrange for the leaning up and ventilation of the Works and the provision of all
necessary ladders, etc., required for inspection of the works by the S.O. accompanied by the
Contractor or his representative. Any default resulting from faulty materials or workmanship used in
the execution of the works shall be rectified by the Contractor at his own cost to the satisfaction of the
S.O.

8.24 Sewer Connections to Existing Properties

The Contractor will not be permitted to start work on the sewer connection to any property until all
the downstream sewers, pumping stations, pumping mains, and disposal facilities are sufficiently
completed to receive the flow to the satisfaction of the S.O. The S.O.'s judgement shall be final and
no claim for delay or additional monies will be entertained resulting from the incomplete status of the
Permanent Works downstream.
All sewer connections shall be constructed of vitrified clay pipe unless otherwise instructed by the
S.O.
The Contractor shall lay new sewers and house connections and construct new chambers and
manholes, as required to divert sewage and waste-water flows from existing properties as shown on
the Drawings or as instructed by the S.O. to the main sewers constructed under this Contract.
The work shall be carried out in accordance with the details shown on the Drawings or as directed by
the S.O. on site. The location of sewers, manholes and chambers to be constructed under this
Contract is indicated on the Drawings and will be confirmed by the S.O. on site.

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In general, the existing properties to be connected under this Contract have existing septic tank
facilities. The location of these tanks, where known, is indicated on the Drawings. The Contractor
shall confirm the location of each septic tank. Precise connection arrangements will be as directed by
the S.O. on site. The Contractor should allow for modifications to the sewerage arrangements to
individual properties in those instances where no septic tank is in existence.
After the diversion works for each group of buildings have been finished, the Contractor shall remove
and dispose of the contents of the existing septic tanks, and break out the slabs and walls of the tank
to a depth of at least 500 mm below ground level. The Contractor shall backfill the tanks with
approved compacted backfill and reinstate the surface with turf, topsoil, concrete and macadam or
otherwise as directed by the S.O. to its original condition. The Contractor shall remove all debris
from the Site and leave the area in good condition to the satisfaction of the S.O.

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Section 9 - Building Works

9.0

BUILDING WORKS .....................................................................................9-1

9.1

Brickwork .........................................................................................9-1
9.1.1 Bricks .....................................................................................9-1
9.1.2 Mortar.....................................................................................9-1
9.1.3 Bricklaying.............................................................................9-2
9.1.4 Joints .....................................................................................9-2
9.1.5 Ties.........................................................................................9-2
9.1.6 Wall Reinforcement...............................................................9-3
9.1.7 Damp-Proof Course ..............................................................9-3
9.1.8 Lintels ....................................................................................9-3
9.1.9 Building-In .............................................................................9-3
9.1.10 Chases in Brickwork.............................................................9-3
9.1.11 Protection of Finished Work ................................................9-3

9.2

Stone Work.......................................................................................9-3
9.2.1 Stone ......................................................................................9-4
9.2.2 Mortar.....................................................................................9-4
9.2.3 Uncoursed Square Rubble ...................................................9-4

9.3

Carpentry and Joinery.....................................................................9-4

9.3.1 Codes of Practice..................................................................9-4
9.3.2 Materials ................................................................................9-4
9.3.3 Fixings and Fastenings ........................................................9-5
9.3.4 Workmanship ........................................................................9-6
9.3.5 Timber Architraves ...............................................................9-7
9.3.6 Timber Doors.........................................................................9-7
9.3.7 Hardware................................................................................9-8
9.3.8 Partitions .............................................................................9-10
9.3.9 Toilet Partitions ...................................................................9-10
9.3.10 Bench and Cupboard Fitments ..........................................9-10
9.3.11 Overhead Shelving..............................................................9-11

9.4

Metalwork .......................................................................................9-11
9.4.1 Aluminium Framed Windows and Doors ..........................9-11
9.4.2 Double Glazed Windows ....................................................9-13
9.4.3 Security Grilles to Window of All Stores...........................9-13

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9.4.4 Roller Shutter Doors ...........................................................9-13

9.4.5 Acoustic Doors....................................................................9-14
9.5

External and Internal Finish..........................................................9-14

9.5.1 Suspended Ceilings............................................................9-14
9.5.2 Finishes to Brickwork.........................................................9-16
9.5.3 Ceramic and Glass Mosaic.................................................9-17
9.5.4 Glazed Wall Tiling ...............................................................9-17
9.5.5 Acrylic Spray Tile and Coating ..........................................9-17
9.5.6 Sound Absorbent Wall Lining ............................................9-18
9.5.7 Floor Finishes - General .....................................................9-18
9.5.8 Preparation of Applied Finishes ........................................9-18
9.5.9 Marble Slabs ........................................................................9-18
9.5.10 Carpet Tiles .........................................................................9-18
9.5.11 Raised Modular Floor .........................................................9-18
9.5.12 Ceramic Tiles.......................................................................9-18
9.5.13 Homogeneous Tiles ............................................................9-19
9.5.14 Granolithic Finish................................................................9-19
9.5.15 Pebble Washed Finish ........................................................9-19
9.5.16 Quarry Floor Tiles ...............................................................9-20
9.5.17 Concrete Floor Hardener ....................................................9-20
9.5.18 Mosaic Tiling .......................................................................9-21
9.5.19 Terrazzo Tiling.....................................................................9-21
9.5.20 Vinyl Tiles ............................................................................9-22
9.5.21 Slate .....................................................................................9-22
9.5.22 Skirting.................................................................................9-22

9.6

Roofing ...........................................................................................9-22
9.6.1 Roof Waterproofing ............................................................9-22
9.6.2 Roof Insulation Material .....................................................9-23
9.6.3 Metal Roof Decking and Roofing Sheets ..........................9-23
9.6.4 Interlocking Concrete Roof Tiles .......................................9-24
9.6.5 Asbestos Cement Roofing Sheets.....................................9-25
9.6.6 Roof Fascia..........................................................................9-25
9.6.7 Roof Drainage......................................................................9-25

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9.7

Glazing............................................................................................9-26
9.7.1 Glazing and Fixing Glass ...................................................9-26
9.7.2 Frameless Glass..................................................................9-26
9.7.3 Mirrors..................................................................................9-26
9.7.4 Cleaning and Replacement ................................................9-27

9.8

Sanitary Plumbing .........................................................................9-27

9.8.1 General.................................................................................9-27
9.8.2 Fixture Outlet.......................................................................9-27
9.8.3 Jointing and Supporting Pipes ..........................................9-28
9.8.4 Sanitary Fixtures .................................................................9-28
9.8.5 Testing Sanitary Plumbing .................................................9-29
9.8.6 Floor Waste .........................................................................9-29
9.8.7 Sanitary Fittings ..................................................................9-29

9.9

Cold Water Plumbing.....................................................................9-29

9.9.1 General.................................................................................9-29
9.9.2 Isolating Valves ...................................................................9-30
9.9.3 Installation of Taps and Outlets.........................................9-30
9.9.4 Ironmongery ........................................................................9-30

9.10

Hard core ........................................................................................9-30

9.10.1 Material and Laying.............................................................9-30

9.11

Building Acoustic Treatment ........................................................9-30

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9.0 BUILDING WORKS

9.1

Brickwork

9.1.1 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/mm2.
Facing Bricks
The facing bricks shall be hard, well burnt, machine made, wire cut Clinker
bricks with a vitreous finish, of size 215 mm x 102.5 mm x 65 mm approximately and from an
approved source. They shall all possess the same colour and texture and shall not exhibit any
efflorescence.
Calcium Silicate Bricks
Calcium silicate bricks shall comply with the requirements of BS EN
771-2, Class 3 with a minimum compressive strength of 20.5 N/mm2.
S.O. Approval
Before bricks are ordered, samples shall be submitted to the S.O. for
approval. The approved samples shall be kept on the site for reference. Delivery shall be kept strictly
to the approved samples. On delivery to Site, bricks shall be stacked to the approval of the S.O.
All rejected brick shall be removed from the site forthwith at the Contractors own expenses.

9.1.2 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.

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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.

9.1.3 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.
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.

9.1.4 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.

9.1.5 Ties

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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.

9.1.6 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.

9.1.7 Damp-Proof Course

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.

9.1.8 Lintels
Unless otherwise shown all brickwork over openings shall be supported on precast concrete lintels in
accordance with the dimension shown on the Drawings or as directed by the S.O.

9.1.9 Building-In
Generally and wherever practical, all items shall be built in as work proceeds. The Contractor shall
ensure all built in items are preprimed as required, set and braced into correct position, have all
building-in provisions properly fixed, reinforced to prevent distortion and protected against damage.

9.1.10 Chases in Brickwork

Chases shall be cut in brickwork where instructed by the S.O. to accommodate cables and conduits for
electric lighting, power and instrumentation.

9.1.11 Protection of Finished Work

All decorative elements, finished surfaces, particularly corners and jambs shall be protected with
timber casing or other suitable means as soon as they are built.
Newly erected brickwork shall be protected against weather to prevent the mortar from being washed
out of the joints. Should any brickwork become damaged by sun or rain the brickwork so damaged
shall be removed by the Contractor and rebuilt at no extra cost to the Contractor.

9.2

Stone Work

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9.2.1 Stone
Stone material, selected colour and texture shall be approved by the S.O.

9.2.2 Mortar
The material for mortar shall be as previously specified for brickwork. The fine aggregate shall
preferably be composed of crushed stone of the stone type selected.

9.2.3 Uncoursed Square Rubble

Stone work shall be in uncoursed square rubble. It shall be roughly dressed, square laid with all
horizontal joints. Maximum height for stone shall not exceed 250 mm.

9.3

Carpentry and Joinery

9.3.1 Codes of Practice

Carpentry works shall generally comply with the requirements of BS 5268 subject to any qualification
given below.
Joinery works shall generally comply with the requirements of BS 1186 and BS EN 942, subject to
any qualification given below.

9.3.2 Materials
Where specified, codes and standards shall be taken as a guide only as minimum in quality and
performance. Any materials which do not comply with these requirements or which in the opinion of
the S.O. are defective or damaged by exposure or other causes shall be removed from the site.
a)

Timber

Timber for use in permanent work shall be primary hardwood first class Chengai, Merbau,
Bakau or Resak or as specified on the Drawings and shall be the best quality suitable for the
particular purpose and shall in all cases be thoroughly seasoned, sound, dry straight and free
from large loose or dead knots, injurious shakes, sap, shakes, dogmarks or other defects. Well
seasoned and tanalised meranti may be used for furniture and wall panels.
Moisture content of all timber shall not exceed 15%.
Timber shall be sawn into scantlings not less than one month before use, such that the
scantlings will be of the specified dimensions after planning and preparing. Unless otherwise
directed, all woodwork exposed to view shall be wrought and prepared for painting unless
otherwise specified. All timber shall be unused and shall be properly stacked and protected
from the weather.
All defects appearing in joinery work such as warping, twisting, opening of joints, etc. shall
be remedied either by refitting or by substitution as required, at no extra charge.

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All timber for permanent works shall, except where otherwise specified, be pressure
impregnated with an approved wood preservative after planning and preparing. The
quantity of preservative used per cubic metre of timber shall be fully in accordance with the
manufacturer's recommendations. All surfaces cut after preservative treatment shall be
brushed with two coats of an approved preservative.
All secondary hard wood timber shall also be treated with approved pressure preservative and
all timber shall be primed before delivery to the Site for fixing.
b)

Plywood

All plywood in doors, fitments or panelling shall be manufactured from hardwood and in
compliance with BS 6566: Grade II on both faces and shall be of Weather and Boil Proof
Quality. Marine plywood shall comply with the requirements of BS 1088. Each sheet of
plywood delivered to the site shall bear the following markings:

Manufacturers name or identification

BS EN 636
W.B.P (Weather and Boil Proof)
Grade of Finish
Thickness

Plywood shall comprise resin bonded multiple veneer plywood and of thickness specified,
finished in matched veneers on both sides.
All plywood exposed to weather or in washrooms shall be waterproofed plywood and shall
comply with BS EN 636.

9.3.3 Fixings and Fastenings

All nails, screws, spikes, bolts, etc. are to be of the best quality and of the weights and lengths suitable
for the purpose required.
a)

Nails for carpentry work or for fixing steel to timber shall be galvanised.

Screws shall be countersunk for fixing accessories to timber.

Brass screws shall be chrome plated and countersunk, raised or dome head for fixing
sanitaryware and similar accessories.

Engine bolts shall be hexagonal head for fixing timber to steel.

Masonry anchors shall be of expanding screw type in lead in pre-drilled or formed

holes grouted in cement mortar.

Explosive powered steel pins into concrete or steel may be used only if specifically
approved by the S.O.

Bolts and screws shall be completed with nuts and washers as appropriate.

Proprietary fixing
Various proprietary fixings are available for particular or specialised jobs.
These shall only be used where appropriate in accordance with the manufacturers instructions and to
approval of the S.O. when not specifically detailed.

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Where holes are required for fixings, their formation in metal or synthetic materials shall be by
drilling and in brick, stone or concrete shall be by percussion methods i.e. jumper and hammer.
Where cartridge operated hand tools are used such as Ramset or similar approved, performed holes
are not required. They must not be used on ceramic tiles, hollow blocks, cast iron and other brittle
material, lath and plaster, fibre board and similar soft materials.
Fixing of timber to concrete or brickwork shall be by:
a)

Hardened steel pins direct into concrete or brickwork for fixing small sections such as
skirtings and architraves. The head shall be punched home-and filled.

Preformed plugs such as Rawlplug or similar approved informed holes.

Plastic compounds such as Philplug Fixrite or similar approved in-formed holes

Expanding bolts such as Rawlbolt, Expandabolt or similar approved

Catridge operated hand tools such as Ramset or similar approved but shall not be
used within 50mm of any edge.

9.3.4 Workmanship
a)

Storage of materials

All timber, asbestos-free cement sheeting, etc. shall be stored under a shed, and properly
stacked to enable air to circulate freely around all faces on site and protected from weather
until they are incorporated in the work. Any materials which deteriorate as the result of
storage shall be replaced at the Contractors expense. Storage shall be as follows:

Each grade separately stored, with treated timber separate from untreated.

ii)

On levelled bearers off the ground, permitting free air circulation and preventing
sagging.

iii)

Protected from weather; keep any temporary covers from close contact with the
timber.

Carpentry and joinery

Carpentry and joinery shall be carried out in accordance with the best trade practice using
competent tradesmen, equipment, materials and processes that are adequate for the purpose.
Timber which is to be permanently incorporated into the work shall not be used for any
temporary purpose.
All timber members shall be new and selected for straightness.
Saw cuts to relieve bowed members will not be accepted.
All joints shall be secured by concealed fixings where possible. All slips, fillets, casings,
wedges, blocks, etc, shall be provided where required.

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All carpentry framing shall be jointed as shown or as is most appropriate in the circumstances.
The joints shall be designed and constructed so that they will transmit the loads and resist the
stresses to which they will be subjected. Unless otherwise stated, all joints shall be secured
by means of notching and where necessary strengthened by wood dowels.
c)

Built-in work

Fitments to be built between walls and/or columns shall be based on measurements of actual
completed work on site such that a neat tight junction is achieved.
All joinery which is built-in shall be first primed or sealed on the faces and edges to be
built-in.
Where sink units or other items are built into the joinery, they shall be properly fitted and
fixed prior to leaving the shop.
d)

Finishing

All work shall be thoroughly sand papered leaving no machine marks or sand streaks.

9.3.5 Timber Architraves

Architraves shall be provided and fixed to timber door frames. They shall be of hardwood size 25 x
12mm mitred at corners.
Where door jambs are flush with the face of brickwork, architraves shall be splayed externally 38 x
18mm mitred at corners.

9.3.6 Timber Doors

All hardwood used for doors shall be Grade 'A'. Door frames, unless otherwise indicated shall be of
chengai or merbau, sized 150 x 50 mm rebated as shown to form door stops.
Doors shall be of type, size and thickness as indicated on the Drawings and shall be of first quality
construction. Doors shall be obtained from one manufacturer as approved by the S.O. and shall be
guaranteed against any warp, wind or other defects, other than fair wear and tear. Should any defect or
defects become apparent during the Defects Liability Period, the affected door shall be replaced and
finished to approval at no extra cost.
Unless otherwise specified, all meeting stiles of paired doors shall be rebated.
Timber doors are classified as follows:

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Section 9 - Building Works

Timber flush door

It shall be 38mm thick flush doors which are surfaced with sheets of painted grade plywood fixed to a
skeleton frame. The doors shall be fitted with 10mm thick primary hardwood edge strips all round in
accordance with BS 459 Part 2 with top and bottom rails and styles 100 mm x 50 mm and
intermediate rails 100 mm x 25 mm at 300 mm centres. The frames shall be hardwood and the facing
plywood shall be manufactured with a waterproof adhesive. Door frames unless otherwise shown
shall be hardwood and of minimum finished size 125mm x 75mm.
Timber flush doors unless otherwise specified shall be used for all internal doors. Decorative
laminates shall be provided in accordance to the drawings where necessary or as requested by the S.O.
Timber flush door Timber flush doors that used for doors of toilets, tea rooms, etc, where such doors
are in contact with water shall be surfaced with sheets of waterproof grade plywood on both sides.
Solid Timber Door
It shall be 38mm solid primary hardwood core flush doors lined with waterproof plywood unless
otherwise specified.
All external wooden doors shall be solid timber doors.
Solid Timber Door (1-hour fire rated)
It shall be 1-hour fire resistant doors made of solid primary hardwood and surfaced with plywood all
approved by the Fire Authority. Should timber door is used as internal doors of stores, it shall be 1hour fire rated.
Solid Timber Door (2-hour fire rated)
It shall be 2-hour fire resistant doors made of solid primary hardwood and surfaced with plywood all
approved by the Fire Authority. Should timber door is used as internal doors of electrical switch
rooms, battery rooms, etc it shall be 2-hour fire rated.

9.3.7 Hardware
Hardware shall be fixed with screws and accessories of matching finish in a manner appropriate to the
item and in accordance with the manufacturer's instructions.
a)

Locks, Latches and Door Furniture

Locks

Locksets shall be of `Vachette' of satin stainless steel finish as approved by S.O. The quality
of lock All locks shall be of the appropriate functions and operation as recommended by the
Manufacturer.
Locksets for toilet doors shall be of Whitco or equivalent as approved by S.O. complete
with all necessary accessories.
Each lock shall be supplied with three keys. All locks shall be mastered keyed of two
systems, namely one for external doors and another for internal doors. Four master keys
shall be supplied for each system.

ii) Latches

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Latches shall be heavy duty tubular type of stainless steel as approved by S.O.
iii) Door Furniture
Door furniture shall be of the highest quality, fitted with matching screw and supplied by an
approved manufacturer. Door furniture shall be as follows unless otherwise stated in the
drawings or subject to any modifications as required by the S.O:

External single leave door:

Single cylinder upright mortise nightlatch

Handles on plates
External double leaves door:

Lever handle

Cylinder rim nightlatch, 230mm grip handle on outside of leading leaf, 300 mm
barrel bolt at bottom and top of following lead.
Internal single leave doors:

Lever mortise lock

Lever mortise lockset.

Internal double leave doors:

Leading leaf as for single door.

300 mm barrel bolts at top and bottom of following leaf.

Sliding doors:

With swing leaf - cylinder rim nightlatch. handle on each side of door, 450mm barrel
bolt.

230mm grip

Without swing leaf - cylinder rim nightlatch with sliding locking bar. 230mm grip
handle on each side of door, 450mm barrel bolt.
W.C. door:

Brass indicating bolt

Door closers
Provide and fix Lokwood design or approved equivalent of appropriate types, sizes and
weights to all fire-rated doors and doors of air-conditioned Rooms, Control Rooms,
Evaporator, and Chlorinator Rooms and entrance doors to toilets and tea rooms.

Accessories (Hinges, Bolts, etc.)

Internal doors shall generally be hung on 3 Nos 100mm stainless steel loose pin butt hinges.
Barrel bolts for the tops of doors shall be provided with suitable top plates, and those for the
bottom of doors with cleanable sockets. Internal and external door furniture shall have a satin
anodized aluminium.

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Door stops, door hooks, door and kicking plates shall be provided for each door in materials
compatible with the door furniture.

9.3.8 Partitions
Gypsum board partitions shall be of `Fabwall' slimline demountable partitions or approved equivalent.
Full height partitions shall be covered with selected `3M Scotchgard Tapetex' linen wall covering or
approved equivalent on both sides.
Gypsum boards of half-glazed partitions shall be similarly covered.
All partitions shall be complete with all necessary aluminium door frames, heads, trimmings &
skirtings in anodised finish.
All full height partitions of individual offices including doors shall be sound insulated with approved
heavy density fibreglass blankets.

9.3.9 Toilet Partitions

Toilet partitions shall be `Moflex' partitions of `Ardmoe' model or approved equivalent complete with
all necessary accessories where specified in the Drawings.

9.3.10 Bench and Cupboard Fitments

All cupboard and fitment dimensions shall be determined accurately by the joiner on site. Fitment
dimensions as relevant shall be checked on site.
All work shall be carried out by an experienced joinery firm. All materials and workmanship shall be
of the highest standard.
Generally all exposed finish shall be varnished with three coats of ICI Timber Tone or equivalent
paint. Top of bench and of floor standing shelf shall be finished with selected plastic laminate of
1.2mm thickness.
Unless otherwise directed by the S.O., the construction of cupboards and fitments shall be as follows:a)

Framing and supports shall be ex 75 x 25 mm hardwood timber.

Minimum 25mm thick veneered plywood to be used for tops, bottoms, ends, intermediate
vertical partitions and shelves.
Exposed edges shall be finished smooth and painted.

Backing of all cupboard shall be of 18mm thick plywood.

Each cupboard door shall be hung with brass hinges with approved 75mm `D' pull handles.

Drawers shall generally have fronts ex 25mm timber and sides and backs ex 18mm, all
ploughed to receive 9mm waterproof plywood at bottom.

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Drawers shall be fitted with approved drawer slide runners with stops and `D' pull handles, similar in
pattern as for cupboard doors.

9.3.11 Overhead Shelving

Overhead shelf shall be of 18mm thick waterproof plywood with 10mm deep edge all round, properly
varnished to approved colour. Shelf shall be supported on 4 Nos 150mm x 4mm thick galvanised mild
steel angle brackets concealed behind wall lining. The brackets shall be securely fixed to the wall and
to the under side of the shelf.

9.4

Metalwork

9.4.1 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.
Window frames for fixed aluminium louvres shall have weathering jambs, heads and sills of
minimum 102 x 45 mm to admit sufficient light to interior, unless otherwise specified.
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.

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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.
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.

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Side Hung Aluminium Casement Door and Window Frames:

All aluminium side hung/swing door and 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. All doors shall be hung on approved floor springs and shall be complete with
horizontal aluminium bar openers and approved locks. The perimeter of the windows shall be fixed
with an approved waterstrip.
Top Hung Aluminium Casement Window Frames (Vertically and Horizontally Pivoted
Windows):
All vertically and horizontally pivoted window shall be provided with friction side arms to allow the
opening of the vents in any desired positions without the need for pegs stays. Handles shall be
provided for locking the windows from the inside.

9.4.2 Double Glazed Windows

Double glazed windows shall be hermetically sealed double glazed type in powdered coated
aluminium frames for sound insulation purpose. The sound insulation value shall be not less than 40
dB for frequency of 100-3150 Hz. Tinted glass of 6 mm thickness shall be separated for a distance not
less than 200 mm apart and the surfaces of the interspace shall be lined with sound absorbent material.
The sashes shall be sealed. The Contractor shall submit his design and sound reduction data for
approval by the S.O. before manufacturing.

9.4.3 Security Grilles to Window of All Stores

'Amplimesh' aluminium grilles type 103 panel shape in powder coated finish shall be provided to all
aluminium framed glass windows and louvres of all store rooms and workshops/stores of all buildings
inclusive of the whole of store Building. Amplimesh shall be incorporated to the external faces of top
hung/casement windows. For louvre windows, they shall be incorporated between glass louvres and
removable insect screens with matching aluminium spacers and frames for fixing. The design and
details of incorporation and fixing of security grilles shall be submitted to the S.O. for approval before
manufacturing and incorporation.

9.4.4 Roller Shutter Doors

Roller shutter doors shall be SKB Heavy Gauge Roller Shutter or approved equivalent by the S.O.
Doors shall be operated with push button electric drive system and manual override. Roller shutter
doors shall be of the multiple folds type opening vertical upwards into a roller drum which shall be
housed and concealed in an aluminium cabinet. Side guides, channels and bottom rails shall be
provided. Aluminium sheets used for the door shall not be less than 16 SGW thick.
The door shall be operated mechanically by an endless chain through either a spur or worm reduction
gear running on self lubricating bearings or ball bearings and shall have smooth action.
The door curtain shall be a continuous galvanised sheet steel of 1.0 mm minimum thickness and spray
painted. Where openings exceed 4800mm wide, lift-out or hinged mullions shall be provided so that
access through the doors are not restricted.
The doors shall be provided with locks and each lock shall be supplied with three keys. The locks
shall be of stainless steel.

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9.4.5 Acoustic Doors

The doors shall comprise flush panel steel door leaf not less than 63mm thick and shall be factory
hung in a four sided steel frame, complete with acoustic edge seals and the necessary furniture and
hardware. The door frames shall be pressed from galvanised mild steel not less than 16 gauge (1.5
mm) thick to form a 75mm architrave faced section suitable for a 112mm thick brickwall. The door
faces shall be completely flat and free of buckle. Door hinges shall be of stainless steel. The doors
shall be capable of opening through 180 degrees except where limited by contact of the door or door
closer with the adjacent walls.
Pre-tapped holes in the door and frame shall be provided to accommodate the door hardware, furniture
and door closers as required or as shown on the Drawings.
The doors shall be supplied prime coated after washing down with lithoform and shall be painted after
installation as specified.
The door shall be tested in accordance to BS EN ISO 104 or equivalent standards at the
manufacturer's works, if requested by the S.O. and a copy of the test certificate showing the test
results shall be submitted.
The door shall be tested on site after installation. Testing shall be made with octave bands of random
noise which must show that the insertion loss of the door is equal to or greater than the following
values.

Octave Band Centre

Frequency (Hz)

125

250

500

Door "insertion loss"

(dB)

The doors shall be installed strictly in accordance to the manufacturer's instruction.

The doors shall be provided with locks and each lock shall be supplied with three keys.

9.5

External and Internal Finish

9.5.1 Suspended Ceilings

Suspended ceiling shall be made of material as listed below or other material as approved by the S.O.

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Mineral fibre board ceilings

Unless otherwise specified, the tiles shall be 18mm thick Armstrong Second Look II
mineral fibre boards or approved equivalent, and shall be painted to the approval of the S.O.
The Contractor shall submit a sample to the S.O. for approval prior to installation.
The tiles shall be suitable for use in the local climatic conditions and shall be resistant to
attack by termites, pests or fungal growth.
b)

Aluminium strip ceilings

The aluminium strip ceilings shall be Luxalon aluminium lineal ceilings (without
insulation) or approved equivalent in colour to be selected by the S.O. The ceilings shall be
installed in accordance to the manufacturer's instructions.
c)

Asbestos free fibre cement ceiling boards

The ceilings shall be UAC-UCO Superflex or UAC Decoceal free ceiling sheets or other
approved equivalent. The ceiling sheets shall be 4.5 mm thick in 610 x 1220 mm panel sizes
in patterns to be selected and approved by the S.O.
d)

Sound absorbent ceilings

The ceilings shall be 'Dampa' 300T 300 mm wide perforated aluminium sound absorbent
ceilings or equivalent. The units shall be in long lengths to minimise jointing. The surface
shall be stoved enamelled with sound absorbent textile and perforated with 1 mm holes at 2
mm centres achieving an open area of minimum 22%. The whole ceiling shall be suspended
by galvanised steel hangers, adjustment clips, carriers and splices complete with edge trims
and sufficient number of access hatches, all to manufacturer's specification.
e)

Suspension system

All framework and accessories for supporting the ceiling shall be aluminium. The sizes of
individual members of the system of support shall be such that on completion of the ceiling
the deflection at any point shall not exceed 4mm. The Contractor shall submit details of the
proposed panel layout and of the supporting system to the S.O. for approval before
commencing work.
The suspension system shall be fully concealed proprietary brand and shall comprise hangers
(with threaded adjustment), cold formed primary crossrails, spline rails and sliding locks. The
whole shall carry twice the in-service dead loads without failure or deformations beyond the
tolerances stated below:Ceiling departure from nominal plane
Change in level of adjacent hangers
at more than 1200mm centres
Variation from straight by a grid
member between adjacent hangers
Individual hangers shall carry a load
of 200kg without failure.
f)

+ 3mm
+ 1.5mm
0.001 of
span

Workmanship

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Ceiling grids in place shall be set out accurately parallel to building grid. In every room tiles
shall be set out symmetrically in both directions with or without margin at periphery of 1/2
tile or greater as directed by the S.O.
The ceiling shall be installed strictly in accordance with the manufacturer's fixing instructions.
Opening, etc in ceiling, if required, shall be trimmed to receive recessed light fittings and
neatly cored for vent pipes to exact size.
The ceiling grid shall be erected to the heights shown on the Drawings and to a true and level
plane.
Each board shall be rectangular in shape, measuring 600mm x 1200mm and a minimum of 4.5
mm thick. Except where otherwise approved by the S.O., the panels in any one room shall
be of uniform size and arranged in an orderly and symmetrical pattern. Where this is not
possible, they shall be neatly cut and edging strips shall be provided where necessary.

9.5.2 Finishes to Brickwork

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.
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.

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9.5.3 Ceramic and Glass Mosaic

External tiles of buildings shall generally be of matt glazed ceramic tiles of approved manufacturer,
sized approximately 100 x 48 x 8 mm unless otherwise specified.
External glass mosaic wall tiles shall be of approved imported Italian vitreous glass mosaics, Group I
series, sized 25 x 25 x 4.5mm unless otherwise specified.
Internal ceramic wall tiles to areas indicated in Architectural Drawings shall be 200 x 200 x 8 mm
fully glazed ceramic tiles or approved equivalent laid to selected patterns and colours shall be as
approved by the S.O.
Purpose made internal and external angle tiles shall be used as required.
Tiling shall be set out in an uniform and symmetrical manner. Small make-up pieces should generally
be avoided and for margins, half tile or wider is preferred.
Tiles shall be laid to previous rendered surfaces with full bed of water resistant tile adhesive as
recommended by the manufacturer. Tiles shall not be fixed until surfaces are thoroughly cured and
completely dry. After fixing joints shall be pointed flush with Parian cement.
Concrete benches where shown shall be tiled with 200 x 200 x 8 mm glazed ceramic tiles as approved
by S.O.

9.5.4 Glazed Wall Tiling

Glazed wall tiling shall be in accordance with BS 1281. The tiles shall be l00 mm x l00 mm, true to
shape and free from all blemishes. They shall be set and pointed in Pariah cement or set in approved
tile adhesive and pointed in Pariah cement. The glazed tiles shall be of tinged blue or white colour as
ordered and uniform in size and colour. The pattern and colour of the glazed tiles shall be approved
by S.O. prior to order.
The glazed tiles shall be arranged in a uniformly symmetrical manner. Joints to tiling shall be exactly
in line. External and internal angles shall be radiused and to the dimension shown in BS 1281.

9.5.5 Acrylic Spray Tile and Coating

Acrylic spray tile shall be SKK Acrylic Enamel CT-Tile system or other approved equivalent by the
S.O. The water based granite like acrylic coating is to be SKK Eleganstone Spray Granite Coating
or equivalent as approved by S.O. The system shall have one coat acrylic sealer, one coat texture
compound and two coats acrylic top coats. The acrylic spray tile system shall be carried on 20 mm
rendering work.
The surfaces to be coated shall be clean, dry, smooth, free from defects, cracks and other imperfection
prior to application and damaged area should be repaired before hand. Surfaces to be coated shall be
cured for 28 days before commencement of work. Methods of application shall be in accordance with
manufacturer's specification. The works shall strictly be applied by the manufacturer or their approved
sub- contractors strictly according to their specifications.
The Contractor shall provide a guarantee for a period of five years (commencing from the end of
Defects Liability Period) against peeling, flaking, discolouration, loss of gloss retention, fungus
growth, etc. due to defective material or faulty workmanship.

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9.5.6 Sound Absorbent Wall Lining

The wall lining shall be 'Dampa' 300T 300 mm perforated aluminium absorbent wall lining or
equivalent as approved by S.O. The specification shall be as Clause 9.5.1 (d) except that the wall
lining shall be spaced 100 mm from the wall with galvanised steel spacers and that the sound
absorbent units shall have galvanised steel carriers at 300 mm centres up to window sill height.

9.5.7 Floor Finishes - General

Floor finishes shall not be laid prior to completion of plastering and wall tiling. Where pipes are
brought through floors, the floor finish shall be neatly finished level around metal sleeves and shall
not be finished against the pipes.
Where necessary to grade finished surface to fall, screed thickness may be adjusted with approval
from S.O.

9.5.8 Preparation of Applied Finishes

Concrete surfaces specified to be finished with granolithic, ceramic tiles, or other applied finishes,
shall be thoroughly roughened, brushed with wire brushes to expose a fresh surface and swept clean,
washed with clean water until well soaked. A thin layer of stiff cement grout shall then be well
brushed into the roughened surface a few minutes to ensure that it penetrates all the small holes and
crevices before laying the applied finish.

9.5.9 Marble Slabs

Marble slabs shall be 600 x 600 x 20 mm imported or local marble as specified. Where imported
marble slabs are used, they shall be Italian marble or equivalent. Marble slabs shall be selected by the
S.O. and laid to approved pattern including boarder.
The marble slab shall be protected against weather or damage and staining by other trades. Particular
care must be taken against staining from timber, oil, washing from steel work or scaffolding and other
injurious substances.

9.5.10 Carpet Tiles

Carpet tiles shall be `Versa-Tile' Barklay square carpet tiles or other approved equivalent, unless
otherwise specified. The colour and pattern shall be selected by the S.O.

9.5.11 Raised Modular Floor

Raised modular floor shall be `Atlas Air' raised modular floor or approved equivalent complete with
all accessories such as cable outlets, skirting boards, PVC fascias, panel lifters etc. Panels shall be
600 x 600mm high density processed timber of 33mm thickness sandwiched between 2 sheets of
equal thickness plastic laminates. The sub-structure shall consist of an assembly of rust free load
bearing components capable of providing a support frame work for the floor panels.

9.5.12 Ceramic Tiles

Ceramic floor tiles shall be 300 x 300 x 8 mm or 200 x 200 x 8 mm floor tiles by approved
Manufacturer or approved equivalent.

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9.5.13 Homogeneous Tiles

General
Homogeneous tiles shall be laid absolutely level and set out with the joints
maintained in a regular and continuous manner to the satisfaction of the S.O. All tiles shall be bedded,
jointed and pointed in matching coloured cement and sand mortar.
Floor tiles
Floor tiles shall be 300x 300 x 8 mm approved special colours or standard colours
heavy duty non-slip homogeneous tiles, laid to selected patterns and matt colours as approved by the
S.O.
Wall tiles
Wall tiles shall be 200 x 200 x 8 mm approved special colours polished porcelain
homogeneous tiles laid to selected patterns and colours as approved by the S.O.

9.5.14 Granolithic Finish

Granolithic concrete shall consist of two (2) parts of cement to five (5) parts of granite by volume.
The granite shall be graded in accordance with Table 3 of BS 1201 for all-in aggregate.
The mixing shall be as specified for concrete, and the water content shall be just sufficient to produce
a dense concrete of adequate workability.
Before laying, the base concrete shall be cleaned and prepared as specified in Clause 9.5.7, a thin
layer of stiff cement grout shall then be well brushed into the roughened surface a few minutes before
the granolithic concrete is laid. The granolithic shall be spread, screeded to allow compaction,
thoroughly consolidated by tamping and floated by means of a steel trowel, screeded again if
necessary, to produce an even surface true to within plus or minus 0.80mm of a true plane measured
in any direction.
The granolithic finish shall be laid to a thickness of 40mm in panels not exceeding 2.5 metres square
and to fall where directed to an even graded surface. All panels shall be cast against permanent
aluminium strips of 2 mm thick or using approved ebonite strips. The arrangement of panels shall be
symmetrical wherever possible and as directed by the S.O. The concrete shall be compacted using
wooden straight edges and levelled by very light trowelling. It shall then be allowed to stand until it is
hard enough to withstand a final hand trowelling, in the course of which any laitence collecting on the
trowel shall be removed and not trowelled back.
As soon as the granolithic surface has hardened sufficiently to withstand defacement, it shall be kept
continuously damp for a period of not less than ten (10) days. The surfaces shall not be exposed to
traffic or be worked on during this period.

9.5.15 Pebble Washed Finish

Aggregate shall be of 2mm - 3mm rounded river gravel not produced by crushing, 100% stone and
free of shell grit, dirt, organic material and other matters.
Aggregate colour is to be true and not obtained by colour treatment such as bleaching and dying.
Samples shall be submitted to the S.O. for approval prior to ordering.
Trial finishes are to be prepared for the S.O.s approval prior to fabrication of in-situ paving.

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A Barra Emulsion 57 or other equal and approved bonding agent must be applied to the pebble
washed finish and to ensure a good bonding between aggregate and screed.
The Contractor shall submit shop drawing based on the design drawing for the S.O.s approval prior
to the commencement of works.

9.5.16 Quarry Floor Tiles

Quarry tiles shall generally conform to the requirements of BS 1286. Quarry tiles shall be supplied
and installed where specified or indicated on the Drawings. The tiles shall be of the size, quality,
patterns and colours described or shown in the Drawings as approved by the S.O. The quarry tiles
shall be 6.5 mm minimum thickness homogeneous type which is obtained from an approved source.
The tiles shall be laid to approved patterns and bedded and Before laying, the quarry tiles shall be
well wetted and then laid on a l9mm thick 1:3 cement and sand screed that has been thoroughly
worked into the roughened and cleaned concrete surface. The quarry tiles shall be pointed in a
matching or contrasting cement colour to be selected by the S.O. Quarry tiles with one edge rounded
shall be placed to form a skirting of a single course height.
After laying, the tiled floor shall be pointed and grouted with tinted cement to match and to be
scrubbed with water to remove slurry, dirt, stains, etc. and polished to desired surface finish. After
final polishing, the whole floor is to be washed with hot water and soap waxed strictly in accordance
to the manufacturers instructions. All damaged, defective stained or discoloured floor tiles shall be
rejected and replaced by the Contractor at his own expense.

9.5.17 Concrete Floor Hardener

Concrete floor hardener shall be applied on the flooring at the appropriate buildings as specified and
detailed in the drawings. Typical areas of use include sludge storage building and pumping station.
Approved type shall be used to suit the required function. Concrete floor hardener shall comply with
BS 476, Part 7: 1987. Where a coloured flooring is required, site trial shall be carried out to assess
possible local variations caused by aggregates and sands used in the base concrete. Timing of the
concrete floor hardener is important, hence care shall be taken to ensure adequate labour, machinery
and material is available to complete the whole area while sufficient moisture is available to fully
react to provide a good dense finish. Concrete floor hardener shall not be applied at temperatures
below 10oC or where ambient relative humidity exceeds 80% when tested in accordance with BS
8203 Appendix A or by visual thermohygrometer.
The most important objective for the application of the concrete surface hardener is to achieve a
functional and reliable coating system to withstand the vehicular loading, heavy equipment and the
day-to-day operation. Concrete surface hardener material shall be deep penetrating to the concrete
surface to provide long-term protection against wear. The concrete surface shall be thoroughly
prepared, clean and free from dusts, woods and other foreign substances before concrete hardener is
applied in order to achieve maximum adhesion between the surface hardener and substrate. Oil and
grease penetration shall be removed by hot compressed air.
Any surface irregularities may show through causing excessive wear on high spots and changing the
perceived colour of the surface hardener.
Sanitary sewage is not highly corrosive, but under anaerobic conditions, bacteria may decompose
sanitary sewage and form hydrogen sulphide gas. This gas combines with water or moist air to form
sulfuric acid which may attack the concrete surfaces. The concrete surface hardener shall provide high

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performance and high resistance to this condition. It shall be able to provide water repellence,
abrasion resistance, dust proof easily cleaned surface which is resistant to oils and liquids, feature
easy and quick application and form an impervious finish easily cleaned surface for low maintenance.
Samples of concrete surface hardener proposed to be used shall be submitted to the S.O. for approval
prior to application. The concrete surface hardener shall be applied by specialist applicators or trained
and certified personnel approved by the S.O.

9.5.18 Mosaic Tiling

Mosaic tiles shall be 25 or 20 mm square non-slip ceramic mosaic. The pattern and colour of the
mosaic tiles shall be approved by the S.O. before making the order. The squares shall be uniform in
size and colour and shall be held in position in panels by being gummed onto a piece of paper for
transport to site.
The base concrete surface for receiving the mosaic tiles shall be prepared as specified in Section 9.5.7
and 9.5.8. The panels of mosaic shall then be bedded into a layer of 25mm thick mortar consisting of
1 part cement and 3 parts sand and shall be hand tamped with wooden blocks. As soon as gummed
paper is removed by damping the surface with water before the mortar sets, the groove between the
mosaic tiles shall be adjusted and straightened with straight metal plates.
Any excessive mortar on the surface area shall be cleaned with a piece of clean wet cloth. The mosaic
tiles shall be arranged in an orderly symmetrical manner. The mosaic tiling to floors shall be kept
damp for a period of three (3) days after laying and during this period, the flooring shall not be used
for any traffic.
Mosaic tiling shall be measured by the nett surface area actually laid. The rate shall be deemed to
include for the cost of supply and laying mosaic tiles, preparation of floor, walls and columns, supply
and placing of 25mm thick mortar bedding, forming to channel, openings, pipes, chamfers, tamping
and proper cleaning of the surfaces before handing over. Separate measurement will be made for
skirting to plinths, walls and columns.

9.5.19 Terrazzo Tiling

Terrazzo tile shall be not less than 300mm square and 10 mm thick. The pattern and colour of the tiles
shall be approved by the S.O. before making the order.
The base concrete surface for receiving the terrazzo tiles shall be prepared as specified in Clauses
9.5.6 and 9.5.7.
Terrazzo tile shall be bedded into a layer of 25mm thick mortar, consisting of 1 part cement and 3
parts sand.

The tiles shall be hand tamped with wooden blocks to level and any differences in the thickness of the
tiles shall be made up by the wet mortar bedding. The tiles shall be arranged in an orderly manner
such that joints formed between tiles are in a straight line. The grooves shall be kept as thin as
possible.
Terrazzo tiling shall be measured by the nett surface area actually laid. The rate shall be deemed to
include the cost of supply and laying of the tiles, preparation of floor, supply and placing of 25 mm
thick mortar bedding, forming around services, polishing and washing before handing over.

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9.5.20 Vinyl Tiles

Vinyl asbestos tiles shall be supplied and installed where specified and/or shown on the drawings and
shall be of a pattern and colour approved by the S.O. The tiles shall be bedded on an adhesive to be
supplied by the manufacturer and shall be installed in strict compliance with the manufacturer's
instructions.

9.5.21 Slate
Slate tiling shall be executed by specialist and the Contractor shall be fully responsible for these
works and any defective materials and/or faulty workmanship will not be accepted and shall be made
good and/or re-executed entirely at Contractors own expense.
The slate shall be 10mm thick or large irregular shape and size, bedded in cement and sand (1:3) and
pointed in cement with uniform joints of 13mm width in approved colour to match slate. The slate
shall be properly sealed with an approved sealant on all surfaces.
Samples shall be submitted to the S.O. for approval prior to ordering.

9.5.22 Skirting
All floor finishes shall have 100mm skirtings of the same material on walls vertical to the floor
concerned.

9.6

Roofing

9.6.1 Roof Waterproofing

All concrete surfaces to receive waterproofing, whether flexible sheet materials and brush or sprayapplied coatings shall be finished smooth preferably to wood float finish. Surface to be dry and clean,
free from oil, and swept to remove dust and loose stones. Ensure that all pipe or pipe sleeves are
formed and ready for waterproofing. All surface must be primed before applying the waterproofing
membrane. Apply primers and full coats by brush unless otherwise specified.
Concrete roofs shall be waterproofed by waterproof membranes protected by 1200mm x 1200mm x
50mm cement and sand protective panels reinforced with BMC A98. The membrane shall be turned
up at the kerbs and parapets and turned into a sealing chase and pointed with sealant or mastic.
Membrane collars, sleeves, etc. should be provided and properly seal at areas where pipes, conduits,
etc are found, ensuring water tightness to manufacturers details. Sheet and liquid membranes shall
be protected until covered by subsequent construction or handing over.
The Contractor shall submit a proprietary waterproofing system including description and details for
approval by the S.O. taking into consideration the mechanical strength, watertightness, fatigue
resistance and its suitability under local climatic conditions. Application shall be carried out by
approved specialist applicators, strictly in accordance with the manufacturers specifications.
The Contractor shall, jointly with the manufacturer, provide a minimum 10 year guarantee of the
proprietary waterproof system against leakage due to faulty material and workmanship.

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9.6.2 Roof Insulation Material

Roof insulation shall be installed between the concrete roof tiles and soffit of the building where
specified.
The roof insulation material shall be 50 mm thick fibreglass overlain with a composite insulating
material made up of 2 layers of aluminium foil/polymeric adhesive/2 layers of Kraft paper laminate
bonded together with a flame retardant adhesive and reinforced with a special polypropylene fabric.
The roof insulation shall be laid strictly in accordance with the manufacturers specifications and over
one layer of 50 mm thick fibreglass insulation. It shall have a thermal conductivity of 0.032 0.035
Kcal/mh degree contrigrade at normal room temperature. Insulation quit shall be laid over galvanised
chicken wire mesh, unless otherwise specified. It must also be protected from exposure to rain whilst
laying. Sheets of the materials shall be sealed together with pressure sensitive foil tape to form a
moisture free protective barrier.
The fire rating of the insulation shall comply with the following:
Flammability test to AS 1530 Part 2
Spread Factor
0
Speed Factor
0
Heat Factor
1
Flammability Index* 1
*Note: Shall comply with BS 476 Part 6 1989 Fire Tests on Building Materials and Structures Method of test for fire propagation for product, and BS 476 Part 7: Fire Tests on Building Materials
and Structures Method of Test to determine the classification of the surface spread of flame of
product.

9.6.3 Metal Roof Decking and Roofing Sheets

Metal roof decking

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

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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.

9.6.4 Interlocking Concrete Roof Tiles

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
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.

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.

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ix)

Execute all necessary cutting and fitting at abutments and top edges.

9.6.5 Asbestos Cement Roofing Sheets

Corrugated asbestos cement roofing sheets shall be of the sizes, colour and patterns described,
and of approved quality and weight, free from flaws, broken edges, etc.

ii)

The sheets are to be laid with end laps of minimum 225 mm and 38 mm corrugations side
laps, or as required for the specific type of roofing sheet.

iii)

The sheets shall be fixed with galvanised steel drive screws to timber purlins and properly
secured.

iv)

All cuttings, whether straight, raking or circular on roofing sheets shall be properly and neatly
cut with a hand saw.

9.6.6 Roof Fascia

Roof fascia shall be 0.46mm thick with approved protective coating of coloured appearance. The
profile of the fascia and the installation shall be as shown on the Drawings.

9.6.7 Roof Drainage

Galvanised Mild Steel Gutters, flashings and Cappings:

The galvanised mild steel flashings and Cappings shall be of gauge indicated and shall
generally comply as regard manufacture to the requirements of BS EN 10143.

ii)

Provide 22 gauge galvanised mild steel gutters with soldered seams and joints and fixed to
plywood lining, timber battens or with concealed galvanised mild steel straps.

Rain water down pipe:

UPVC rain water down pipes and fittings shall be obtained from an approved manufacturer. They
shall be formed into required lengths where necessary by an approved method recommended by the
suppliers.
Steel rain water pipes and fittings shall be of hot dipped galvanised 1.25 mm pressed steel sheets and
rectangular in cross section. They shall be formed into required lengths by an approved method of
soldering and properly secured with 50 mm x 0.8 mm galvanised sheet iron straps spaced at
approximately 1800 mm centre.

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After erection, all exposed surfaces shall be cleaned down with lithoform and painted with one flat
undercoat and two high gloss finishing coats of paint of approved quality.

9.7

Glazing

9.7.1 Glazing and Fixing Glass

All glass and glazing shall comply strictly with BS 952 and shall be undertaken by an approved
supplier. Unless otherwise specified, tinted float glass of 6mm thickness shall be used. Glass shall be
free from bubbles, scratches and other defects. Glass shall be accurately cut to fit rebates and
carefully bedded, back puttied, sprigged or pinned (beaded where specified) and evenly trimmed with
all splayed edges straight and smooth. Defective, cracked or damaged glass shall be replaced.
Glass fixed to internal windows shall be held in place by suitable wood beads and soft packing. The
packing shall be wash leather or felt of approved quality. Glass of the control rooms of the Control
Buildings shall be of approved anti-glare quality or with solar control tinting. All glass louvres shall
be of minimum 230mm width to prevent easy breakage.
Putty for glazing shall conform to BS 544. For wooden rebates it shall be Type 1 linseed oil putty.
For metal rebates it shall be Type 2 gold size putty or an approved proprietary make. Glass panes
shall be cut to allow a margin of 3mm to 6mm all round between the glass and the rebate. Back
puttying shall be carried out and pegs, clips or springs shall be inserted as required. The front putty
shall be applied neatly and evenly and shall be carefully bevelled off to a smooth level surface
suitable for painting.
Immediately before completion of the Contract all glass shall be cleaned both inside and outside and
all defective, cracked or damaged panes shall be replaced without extra charge.

9.7.2 Frameless Glass

Provide and fix 12 mm thick tinted frameless float glass where indicated in the Architectural
Drawings.
All joints between adjoining glass panels, and between glass panels and masonry work shall be sealed
with watertight structural sealant to the approval of the S.O.
Prior to the installation of the frameless glass panels, shop drawings indicating clearly the detailed
fixing of the glass panels shall be submitted to the S.O. for approval.

9.7.3 Mirrors
Mirror glass shall be of silvering quality 6mm thick float glass having a layer of silver and a layer of
copper deposited on the back, and covered with a protective paint coating.
Mirrors shall be fixed to masonry walls with waterproof plywood backing & dome headed screws
complete with 12mm natural anodised aluminium trimmings all round.

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The size of mirrors shall be 600 x 300 mm for individual hand basins (without vanity slabs) and 750
mm high across the full width of vanity slab where hand basins are set into them.

9.7.4 Cleaning and Replacement

Immediately before handing over, all glass and mirrors shall be cleaned, polished and replaced if
damaged or broken. During the progress of the work, the glass shall be kept clean by prompt removal
or foreign matter, particularly cement products.
Glass shall be cleaned with clean water with or without detergents added to it. Glass cleaning agents
such as paraffin (kerosene), acid or abrasive cleaners which contain felspar shall not be used for glass
cleaning. Hard objects which may result in cuts, scratches or marks on the surface of the glass shall
not be used for removing cement, paint or labels.
Glass and mirrors with cuts, scratches or marks on their surfaces shall be replaced without extra cost.

9.8

Sanitary Plumbing

9.8.1 General
All soil, waste and vent pipes and sanitary plumbing fittings shall be uPVC as specified on the
Drawings.
Generally uPVC pipes shall be used within buildings and under floors of buildings and clay or pitch
fibre pipes shall be used outside buildings.
All pipes whether shown on Drawings, specified or required shall be installed and concealed in an
approved manner to meet structural and architectural conditions and as far as possible to avoid
interference with work of other trades. Care shall be taken in arranging the exposed pipework to
appear neat and in true alignment.
All pipes and fittings shall be thoroughly cleaned before installation. Any scale, burrs, fins and
obstructions shall be removed.
Unless indicated on the Drawings or approved by the S.O., all soil, waste and vent pipes shall not be
extended on the external face of any wall of any building. When indicated on the Drawings or
approved by the S.O., all pipes on the external face of the buildings shall be extended vertically.
All connections to soil, waste and vent pipes shall be made with approved forty five (45) degree
junctions.

9.8.2 Fixture Outlet

The Contractor shall fix to the outlets of all sanitary fixtures the necessary soil pipes, trap and waste
pipes, soil and anti-syphonage vent pipes. All pipes shall be extended, clipped and supported in
accordance with this Specification and Local By-Laws requirements to connect the soil and waste
pipes to drain and to extend vent pipes to open air.
Soil pipes, waste pipes and vent pipes shall be of the type and size indicated on the Drawings or as
required. Traps shall be of loose ring `P' trap type.

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Soil and anti-syphonage vent pipes shall be completed with cowl and clips, and extended to requisite
heights as required.
Unless otherwise indicated on Drawings or approved by the S.O., all vent pipes shall be extended
vertically.

9.8.3 Jointing and Supporting Pipes

Wherever possible, the number of joints in the pipework shall be kept to a minimum and joints shall
be made only at the supports. Pipe cut-offs shall not be used to fabricate lengths of pipe.
All piping shall be supported at maximum interval of 1800mm by approved pipe clips, and/or hangers
securely fixed to walls, floors and members of building construction to the satisfaction of the S.O.

9.8.4 Sanitary Fixtures

All sanitary fixtures shall be fixed in the positions shown on the Drawings in accordance with the
description, type, and dimensions, complete with all necessary accessories. The fittings and
accessories shall comply with the relevant British Standard.
W.C.s -

Pedestal type shall be Shanks Armitage Unisyla pedestal or equivalent approved WCs
coloured for Administration & Control Buildings & white for the remaining buildings,
with matching cisterns unless otherwise specified.

Squatting type shall be white Shank Armitage Andria or equivalent approved WCs
complete with vitreous china cisterns.

Earthernware plain edge sinks shall be Amitage Shanks or equivalent approved in white
fire clay complete with chrome plated taps.

Metal sinks shall be TML or equivalent approved stainless steel complete with chrome
plated taps.

Toilet Paper
Holders

Toilet paper holders shall be Bobrick or equivalent approved 150 x 150 mm BS EN

15167 stainless steel paper holders.

Urinals -

Urinals shall be coloured Armitage Shanks Santor or approved equivalent with

divisions and water cisterns for Administration and Control Buildings unless otherwise
specified.

Sinks

Where trough urinals are indicated, they shall be Diethelm or equivalent approved
stainless steel type or approved equivalent of the dimensions shown with spreaders and
concealed flush pipes.
Wash

Vanity basins shall be coloured Armitage Shanks Jade type or equivalent approved for
basins Administration and Control Buildings unless otherwise specified.
The remaining ones shall be white Armitage Shanks Dorex types or equivalent
approved.

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Taps

Pillar taps shall be Dorf chrome plated ArrowLine type or DE 120 Duo-Mix basin
mixer as appropriate or equivalent approved.
Laboratory sinks shall be white Diamond 355mm square laboratory sinks complete
with `Daelim' double faucets or equivalent approved.

Shower -

Showers shall be Dorf 90mm chrome plated DE 34A twin ball showers or equivalent
approved.

All sanitary fixtures shall be thoroughly cleaned with non-abrasive cleaner on completion.

9.8.5 Testing Sanitary Plumbing

Sanitary plumbing soil, waste and vent pipes shall be inspected and tested before concealment.
All tests and inspections shall be carried out in the presence of the S.O.

9.8.6 Floor Waste

Each floor waste outlet shall be fixed with screwdown chrome-plated drainage gratings. The gratings
shall be set flush with the floor to permit proper and free drainage of the surrounding areas.

9.8.7 Sanitary Fittings

Sanitary fittings shall comply with one of the following appropriate Standards:
BS 1125, BS 1184, BS 1188, BS 1206, BS 1254, BS 1281, BS EN 997, BS EN 33, BS EN 37.
Sitting type W.C.'s shall have a wash down W.C. pedestal with "S" trap in one piece, a plastic seat
and cover, "low level" flushing cistern of 13.5 litres capacity and lever flushing handle. Squatting
type W.C.'s shall have a wash down W.C.'s trough with "S" trap in one piece, high level flushing
cistern of 9 litres capacity and flushing chain. The cistern shall have a 12mm ball valve with silencer,
a plastic ball and a l9mm diameter overflow pipe. W.C.'s shall be supplied complete with downpipes,
all necessary fittings, and l9mm diameter overflow pipes discharging outside the building.
Internal plumbing for sanitary fittings shall be uPVC.
It shall be noted that locally manufactured sanitary fittings are to be used where possible.
No substitution shall be allowed without the prior approval of the S.O.

9.9

Cold Water Plumbing

9.9.1 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.

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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.

9.9.2 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.

9.9.3 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.

9.9.4 Ironmongery
The ironmongery shall be of the type as proposed in Schedule of Particulars which shall be of an
approved make. If the tender is accepted, the Contractor shall supply and fix the type of ironmongery
as stated in the Schedule.
No substitution shall be allowed without the prior approval of the S.O.

9.10 Hard core

9.10.1 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.

9.11 Building Acoustic Treatment

General

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Description
Furnish all plant, labour, equipment, appliances and materials and performing all
operations in connection with Building Acoustic Treatment.
Submittals
Manufacturers specifications and installation instructions shall be provided for the
type of acoustic treatment. 600 x 600 mm square samples of the type of insulation shall be provided.
Delivery, Storage and Handling
Insulation materials shall be delivered in the manufacturers
unopened containers or packages, fully identified with trade name, type, class and other identifying
information. Delivery shall be sequenced to avoid project delays and to permit proper co-ordination of
the work. Acoustic materials shall be stored above grade and protected from weather and damage
from any source. The building acoustic treatment shall not become wet or soiled and the Contractor
shall comply with other precautions and recommendations of the manufacturer to protect insulation
from deterioration.
b)

Products

Insulation
Rigid plastic insulation, which shall be 50 mm thick on walls and 70 mm on roofs,
shall be extruded rigid closed-cell plystyrene foam board with ship-lapped edges having the following
properties
Property
Density
Five-year aged average
Thermal conductivity
When tested at 24oC
Compressive strength (av)
Water Absorption (av)
Water vapour permeability (av)

Typical Results
35 kg/m3

Test Method

0.032 W/m.k

ASTM C 518 or DIN 52612

280 kPa
1%
0.79 perm.cm

ASTMD 1621 or DIN 53421

ASTM D2842
ASTM C355

Where required for fire rated construction rigid polyester impregnated fibre glass insulation with noncombustible fabric covering shall be provided. It shall comply with FS HH-1-521E, type 1, and be of
the thickness, density and type tested and approved for the required ratings.
Expanded polystyrene insulation which is not manufactured with, or contains chlorofluorocarbons
(CFCs) which are known have harmful effects on earths ozone layer and the environment, shall be
used.
Adhesives that are compatible with the insulation, protection course and substrata materials shall be
used.
For securing fire rated insulation to the ceiling, galvanised steel clamps of suitable size and strength
shall be provided to suit the installation.

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10.0

ROADWORKS ...........................................................................................10-1
10.1

Preparation of Formation to Receive Road Pavement ...............10-1

10.2

Earth Subgrade ..............................................................................10-1

10.3

Subgrade of Rock ..........................................................................10-1

10.4

Pavement Thickness .....................................................................10-2

10.5

Geotextile Filter Membrane...........................................................10-2

10.6

Storage of Geotextile Filter Membrane ........................................10-3

10.7

Laying and Spreading Over the Geotextile Filter Membrane .....10-3

10.8

Sub-Base ........................................................................................10-3

10.9

10.8.1

Sub-base Materials .........................................................10-3

10.8.2

Alternative Sub-base ......................................................10-4

10.8.3

Laying and Compaction of Sub-base ............................10-5

Road Base ......................................................................................10-5

10.9.1

Road Base Materials .......................................................10-5

10.9.2

Laying and Compaction of Roadbase ...........................10-6

10.9.3

Finished Surface .............................................................10-7

10.9.4

Definition and Requirements Associated with Table 10.1 ...10-8

10.10 Bituminous Material ......................................................................10-8

10.10.1 General.............................................................................10-8
10.10.2 Cutback Bitumen.............................................................10-8
10.10.3 Bitumen Emulsion...........................................................10-9
10.10.4 Storage, Handling and Heating-of Bitumen ..................10-9
10.10.5 Depot Tray Test ...............................................................10-9
10.11 Bituminous Prime Coat .................................................................10-9
10.11.1 Material ............................................................................10-9
10.11.2 Surface Preparation ........................................................10-9
10.11.3 Application of Prime Coat ............................................10-10
10.11.4 Spraying Procedure ......................................................10-10
10.11.5 Protection of Prime Coat ..............................................10-10
10.12 Asphaltic Concrete ......................................................................10-11
10.12.1 Aggregate, Binder and Composition...........................10-11
10.12.2 Mixing.............................................................................10-12

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10.12.3 Transport .......................................................................10-13

10.12.4 Sampling and Testing...................................................10-13
10.12.5 Asphaltic Concrete Layer Thickness and Tolerance .10-13
10.12.6 Laying of Asphaltic Concrete.......................................10-14
10.12.7 Bituminous Tack Coat ..................................................10-14
10.12.8 Joints .............................................................................10-14
10.12.9 Laying Around Manhole Covers ..................................10-14
10.12.10 Compaction ...................................................................10-14
10.13 Road Shoulders ...........................................................................10-15
10.14 Laterite Surface............................................................................10-15
10.15 Lateral Shoulder Subsoil-drains.................................................10-16
10.16 Refilling of Excavated Pipe Trenches for Roadways................10-16
10.17 Compliance with Specification ...................................................10-16
10.18 Road Markings .............................................................................10-18
10.18.1 Thermoplastic Material .................................................10-18
10.18.2 Preparation of Surface..................................................10-18
10.18.3 Preparation of Thermoplastic Material on Site...........10-18
10.18.4 Laying ............................................................................10-18
10.18.5 Protection of Markings .................................................10-19
10.18.6 Reflectorisation .............................................................10-19
10.18.7 Thickness ......................................................................10-20
10.18.8 Tolerance on Width.......................................................10-20
10.18.9 Defective Materials or Workmanship ..........................10-20
10.18.10 Clearing Up ....................................................................10-20
LIST OF TABLE
TABLE A:

CLASS A GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS AND DEFECTS.

TABLE B:

CLASS B GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS AND DEFECTS.

TABLE 10.1 :

PLANT AND METHOD SPECIFICATION FOR COMPACTION OF EARTHWORKS AND SUBGRADES

TABLE 10.2:

COMPACTING PROCEDURE FOR UNBOUND SUB-BASE AND ROADBASE MATERIALS AND FOR
SOIL-CEMENT AND CEMENT-BOUND GRANULAR ROADBASE

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10.0 ROADWORKS
10.1

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.
The surface of the formation shall be substantially uniform in density throughout its entire width and
shall conform to the density requirements for compaction. The surfaces in subgrade whether on fill or
on cut ground shall be compacted to the requirements for earth subgrade as specified in Section 10.2
It shall be trimmed to conform to the lines, camber, grades and typical cross sections shown on the
Drawings, or as directed by the S.O. The surface shall be constructed to sufficient accuracy to permit
the construction of subsequent layers of material to the thickness, cross-section surface tolerance and
compaction specified but in no case shall a tolerance of + 10mm and -20 mm from the required levels
shown on the Drawing be permitted. Where ruts or other objectionable irregularities occur as a result
of construction traffic or other causes, the Contractor shall reshape and re-compact the formation to
the required density before the sub-base or road base is placed at his own expense.

10.2

Earth Subgrade

Where soft spots and unsuitable material occur, they shall be removed and backfilled with approved
suitable material and compacted according to the Specification in Table 10.1, "Plant and Method
Specification for Compaction of Earthworks and Subgrades". The material used for subgrade shall
have a soaked CBR value, after the specified compaction, as indicated on the Drawings or if not
indicated, not less than 5. The formation shall then be checked and the final trimmed surface shall be
rolled by one additional pass of a smooth-wheeled roller of not less than 5 tonnes or an equivalent
vibratory roller prior to the laying of the sub-base or base-course.
Notwithstanding the above the top 300mm of the finished embankment shall be compacted to a dry
density equal to at least 95% of the maximum dry density as determined by BS 1377 Compaction Test
(4.5 kg rammer method). Other embankment layers more than 300mm below the underside of the
lowest layer of sub-base and shoulder shall be compacted to a dry density equal to at least 92% of the
maximum dry density as determined by BS 1377 Compaction Test (4.5 kg rammer method).
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.

10.3
a)

Subgrade of Rock
Where the surface of an excavation in rock extends over the whole width of the formation :-

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i)
ii)

the rock surface shall be trimmed to a free draining profile, at or below formation
levels. No high spot shall protrude above the formation levels;
any voids or depression more than 0.5 metre in depth below the formation level shall
be filled up with approved lean concrete having 7 day cube strength greater than 7
N/sq.mm.
The rock surface shall then be brought up to the formation levels with approved
crushed rock or gravel, regulated and blinded.

Where rock outcrop occurs over part of the formation only, the rock outcrop shall be
excavated down to a level not less than 300mm below the formation level. The surface shall
then be brought up to a level with suitable subgrade material.

10.4

Pavement Thickness

The thickness of the various layers of the pavement shall be as shown on the Drawings. However
before the construction of the pavement the S.O. may carry out or direct the Contractor to carry out
soaked California Bearing Ratio (C.B.R.) tests as described in BS 1377 on the prepared subgrade to
determine the strength of the subgrade.
The S.O. may order variations in the thickness of the various layers of the pavement as shown in the
typical cross-section Drawings as a result of the above tests.

10.5

Geotextile Filter Membrane

The geotextile to be used, where specified or shown on the Drawings, for the drainage embankment
blanket filters and sub-base/formation interface shall conform to the following specifications :

CRITERIA
Maximum force sustained
in plain strain

MINIMUM VALUE
8 kN/m (min.)

Maximum force sustained in

grab tension with 50% elongation
(ASTM 1682 - 200mm strip)

0.69kN (min.)

CBR Puncture Resistance

1.6kN (min.)

Minimum flow through geotextile

under 100mm head of water

50 l.p.s./sq metre (min.)

Maximum Pore Size

200 um (max.)

Acid Resistance

pH >= 2 (min.)

Basic (Alkali) Resistance

pH <= 13 (min.)

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CRITERIA
Coefficient of Variation

MINIMUM VALUE
10% (max.)

The geotextile material shall be resistant to general chemical attack, oil, petrol, petroleum bitumen,
cut back bitumen, bacteria, fungi and the like.
Additionally, the geotextile material shall not deteriorate significantly in strength due to exposure to
sunlight. The geotextile material shall retain at least 80% its original strength after an exposure to
10,000 Langley's isolator radiation.

10.6

Storage of Geotextile Filter Membrane

The geotextile material shall be stored according to the manufacturer's recommendation out of
sunlight. The opaque wrapping/packaging around the geotextile shall not be removed until
immediately before use. Any geotextile material deemed by the S.O. to be in damaged or deteriorated
condition shall be replaced by the Contractor at his own expense.

10.7

Laying and Spreading Over the Geotextile Filter Membrane

The geotextile shall be laid on trimmed formation, or compacted embankment bench level, prior to
laying of the sub-base or drainage blanket material.
Following this, the sub-base or drainage blanket material shall be uniformly tipped onto the geotextile
filter membrane.
The thickness of the layer immediately on top of the geotextile shall not be less than 250mm and not
greater than 400mm, or as directed by the S.O. Any tear, puncture or damage to the geotextile shall
be made good by patching with 500mm minimum overlap, by the Contractor at his own expense, to
the satisfaction of the S.O.
The as laid geotextile material shall not be left uncovered and exposed to sunlight for a period greater
than six hours. The S.O. may reject all such material left exposed to sunlight for more than six hours
on the grounds of deterioration due to over-exposure to sunlight. The rejected material shall be
replaced by the Contractor at his own expense.

10.8

Sub-Base

10.8.1 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.

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The sub-base material shall have a CBR value of not less than 30 when compacted to 95% of the
maximum dry density as determined by BS 1377 Compaction Test (4.5 kg rammer method). The
portion passing the No. 36 sieve shall, if it is plastic, have a liquid limit not greater than 35 and a
plasticity index not greater than 11.
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.)

25mm (1 in.)
20mm (3/4 in.)
10mm (3/8 in.)
5mm (3/16 in.)
No. 7
No. 36
No.200

100
75 - 100
60 - 90
45-75
30-60
20-50
10-30
0-2

70 - 100
58 - 75
35-65
35-65
25-50
15-30
0-2

The sand shall conform to the gradings given below :BS Sieve Size

Percentage by Weight Passing

10mm
5mm
No. 14
No. 52
No. 100

100
95-100
45-80
10-30
2-10

10.8.2 Alternative Sub-base

Alternative suitable material may be accepted subject to the prior approval of the S.O. The proposed
sub-base material shall have a laboratory controlled unsoaked CBR value not less than 30% when
compacted to 95% of maximum dry density as determined by the BS 1377 Compaction Test (4.5 kg
rammer method) or modified AASHO compaction test. The material shall be free from vegetative
matter, soft particles or clay lumps and shall conform to one of the following gradings:BS Sieve Size

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. The finished surface
level of the roadbase shall not vary from the level shown on the Drawing by more than 12 mm.

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10.9.4 Definition and Requirements Associated with Table 10.1

Number of passes is the number of times that each point on the surface of the layer being compacted
has been traversed by the compaction plant. The effective width of a pneumatic tyred roller for this
purpose is the sum of the widths of the individual wheeltracks together with the sum of the spacing
between the wheeltracks, provided that each spacing does not exceed 225mm. When the spacing
exceeds 225mm the effective widths shall be taken as the sum of the widths of the individual
wheeltracks only.
The load per 10cm width is the total weight on the roll divided by the total roll width. Where a
smooth-wheeled roller has more than one axle the machine will be assessed on the basis of the axle
giving the highest value of load per 100 mm width.
Wheel load is the weight of the roller divided by the number of wheels. Vibratory rollers are self
propelled or towed rollers having means of applying mechanical vibration to one or more rolls.
i)

The requirements of vibratory rollers are based on the use of the lowest gear on a self
propelled machine and a towing speed of 1.5 - 2.5 km per hour for a towed machine. If
higher gears or speeds are used, an increased number of passes shall be provided in
proportion to the increase in speed of travel.

ii)

Vibratory rollers operating without their vibration mechanism in use will be classified as
smooth wheeled rollers.

iii)

Vibratory rollers shall only be operated with their vibration mechanism operating at the
frequency of vibrating recommended by the manufacturers. All such rollers shall be
equipped with a device automatically indicating the frequency at which the mechanism is
operating.

Combination of different types of plant will be permitted in which case the number of passes for each
type shall follow such proportion of the appropriate number in Table 10.2 as will together produce the
same total compactive effort as any type operated singly in accordance with Table 10.2.

10.10 Bituminous Material

10.10.1 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).

10.10.2 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.

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10.10.3 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.

10.10.4 Storage, Handling and Heating-of Bitumen

Bituminous materials shall be handled and stored with due regard for safety and in such a way that at
the time of use in the work the material conforms to the Specification. In particular, bitumen emulsion
shall be handled with care and not subjected to mechanical shocks or extremes of temperature likely
to cause separation of bitumen. Bitumen emulsion showing signs of separation shall not be used.
Bitumen shall be heated in an approved type of bitumen heater having a capacity commensurate with
the output required. The heater shall be fitted with a thermometer accurately registering the
temperature of the bitumen and so situated as to be readily accessible.
Great care must be ensured that the bitumen be heated to a temperature within the range specified for
its grade. Overheated bitumen shall, if the S.O. so direct, be disposed off at the Contractors expense.

10.10.5 Depot Tray Test

This test shall be carried out prior to using the distributor for the first time in the Contract and at such
intervals thereafter as may be required by the S.O.
As and when required, the Contractor shall provide a set of 50mm wide trough as described in
Appendix "A" of BS 1707 and shall carry out Depot Tray Test A in the presence of the S.O. of the
bitumen distributor in accordance with BS 1707.
Should the quantity of bitumen in any trough or troughs be found to lie outside the prescribed
tolerance from the average, the Contractor shall carry out such adjustments to the distributor, or,
including the replacement of any faulty jets, as may be necessary to achieve compliance with the test
requirements.

10.11 Bituminous Prime Coat

10.11.1 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.

10.11.2 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.

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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.

10.11.3 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
GRADE OF BITUMEN

TEMPERATURE OF APPLICATION
( oC )

RC70
MC70

50oC 65oC

10.11.4 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.

10.11.5 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.

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10.12 Asphaltic Concrete

10.12.1 Aggregate, Binder and Composition
This is a general specification for asphaltic concrete road pavement surfacing. The binder course and
wearing course shall have thickness as shown on the Drawings 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

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.

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.

BINDER COURSE
Passing BS Sieve
mm.
37.5mm
28.0mm
20.0mm
14.0mm
10.0mm
5.0mm
3.35mm

1 1/2 in. (38mm) nominal size aggregate

% by weight
100
80-100
72-93
58-82
50-75
36-58
30-52

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Passing BS Sieve
mm.
1.18mm
425m
150m
75m
Binder content as
found by analysis

ii)

1 1/2 in. (38mm) nominal size aggregate

% by weight
18-38
11-25
5-14
3-8
4.0 6.0

WEARING COURSE
Passing BS Sieve
mm.
20mm
14mm
10mm
5mm
3.35mm
1.18mm
425m
150m
75m
Binder content as
found by analysis

3/4 in. (20mm) nominal size aggregate

% by weight
100
80-95
68-90
52-72
45-62
30-45
17-30
7-16
4-10
5.0 7.0

NOTE :
(a)
(b)

10.12.2

Limestone gravel aggregate shall not be permitted for use in wearing course.
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.

Mixing

The aggregate shall be surface dried, and the aggregate and binder separately heated to the following
temperatures before entering the mixer.
Aggregate
Binder

120 - 148 deg C

130 - 162 deg C

It is particularly important to avoid excessive heating of the binder, and excessively high temperatures
of the aggregate at the time of mixing, as these will adversely affect the quality of the resultant
asphaltic concrete.
The materials, including any added filler, shall be weighed or measured in a mechanical mixer and
thoroughly mixed in such a manner that all particles of the aggregates are completely and uniformly
coated.
The mixing plant shall have a capacity sufficient to supply the paver on the road continuously when
spreading the mix at normal speed and required thickness.

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10.12.3

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.

10.12.4

Sampling and Testing

Sampling and testing of the aggregate and mixed materials carried out shall be in accordance with the
following British Standards as appropriate:a)

BS 812 -

Methods for the sampling and testing of mineral aggregates, sand and fillers.

BS 598 -

Sampling and examination of bituminous mixtures for roads and buildings.

BS EN
ISO 9029 - Crude petroleum. Determination of water distillation method.

10.12.5

Asphaltic Concrete Layer Thickness and Tolerance

The binder course and wearing course shall be laid by machine in single course each and the
compacted thickness of the individual courses shall be :Binder course :
Wearing course :

60mm
40mm

The accuracy of finish in the longitudinal direction shall be determined by measuring the gap under a
3m straightedge, placed in any position on the road surface parallel to the centre line; the gap at any
place between the points at which the straightedge is in contact with the road shall not exceed the
following limits :Binder course :
Wearing course :

5mm
5mm

The transverse profile shall conform to a similar standard of accuracy, using a correctly shaped
template instead of a straightedge.

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10.12.6

Laying of Asphaltic Concrete

The asphaltic concrete shall be laid by machine. Works shall not proceed under unsuitable weather
conditions. The machine shall be of a type preferably self-propelled and capable of laying asphaltic
concrete continuously so as to produce automatically an even, smooth and compact surface to the
required widths, thickness and cross-falls without segregation of the asphaltic concrete.
A fully trained and experienced operator shall be in direct charge of the machine.
The asphaltic concrete shall be supplied continuously to the machine. Material supplied to the
machine shall be laid as soon as possible after delivery.
The machine shall be used only when it is in a serviceable condition. Bituminous material remaining
in the hoppers, conveying and spreading mechanisms, tempers and screeds, shall be cleaned off at the
end of each working day. On no account shall cleaning solvent be allowed to come into contact with
any road surfacing material. Accumulations of material not of the specified quality shall be removed
from the Site. The machine shall be operated to avoid, as far as possible, dragging of the 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.

10.12.7

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.

10.12.8

Joints

When a transverse construction joint is to be made, the material shall be cut back to a vertical face of
the full depth of the course being laid and painted with bitumen or bitumen emulsion before any new
material is laid.
On longitudinal joints a complete bond of the two strips after compaction shall be ensured. If this is
not possible, the edge shall be cut back and painted as above.

10.12.9

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.

10.12.10 Compaction

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As soon as rolling can be effected without causing undue displacement, the asphaltic concrete shall be
uniformly compacted by rolling to a density of not less than 98 % of the Marshall Density of the mix.
Compaction shall be carried out with a roller or rollers of weight not less than 6 tons nor exceed 10
tons, and the width of a roller shall not be less than 1.0m. The asphaltic concrete shall be rolled in a
longitudinal direction, working from the sides to the centre of the carriageway, overlapping on
successive passes by at least one half of the width of the rear roll. The roller shall be fitted with a
quick reverse and smooth acting clutch. If directed by the S.O. suitable pneumatic tyre rollers shall be
provided by the Contractor.
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.

10.13 Road Shoulders

Road shoulders shall be constructed to the lines, grades, levels, dimensions and cross sections as
shown on the Drawings and 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 shown on the Drawings or 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 10.2.

10.14 Laterite Surface

Laterite surface shall be constructed to the lines, grades, levels, dimensions and cross sections shown
on the Drawings and as directed by the S.O.
Laterite surface shall be constructed on an approved subgrade as required in the Specification. The
material for construction shall be of well graded laterite and conforms to the requirements as specified
in Clause 11.8 (sub-base materials) and the following additional requirements.
Minimum Plasticity Index : 10
Maximum Plasticity Index : 30
(Material passing 425 m per sieve).
Laterite surface shall be placed and compacted in layers not exceeding 200mm thickness before
compaction. The layers shall be compacted to 95% of maximum dry density as determined in
accordance with BS 1377 Compaction Test. (2.5kg rammer method).

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10.15 Lateral Shoulder Subsoil-drains

Shoulder subsoil drains shall be constructed along the road shoulders as shown on the Drawings or as
directed by the S.O.
Such lateral shoulder subsoil drains shall be constructed of graded selected fill to provide free
drainage outlet from the pavement sub-base and shall be constructed to the dimensions and material as
shown on the Drawing or as directed by the S.O.

10.16 Refilling of Excavated Pipe Trenches for Roadways

In roads and in all other places where the S.O. considers mechanical compaction is required, the
suitable material above the pipe shall be spread in layers of not greater than 150 mm and thoroughly
compacted by mechanical means as listed out in Table 10.2.
As soon as the compaction of sub-base is completed the roadbase will be laid and compacted, before
proceeding with the laying of the bituminous courses. Any depressions found shall be made up with
material of the same kind as that of the original surface.

10.17 Compliance with Specification

The notes given in Section 10.4 and Tables 10.1 and 10.2 are for guidance only and shall not relieve
the Contractor from his basic obligation to produce work to the requirements of the Specification.
1)

The depth of compacted layer is the height by which an embankment is raised by

each successive compacted layer.

Number of passes is the number of times that each point on the surface of the layer
being compacted has been traversed by the item of compaction plant. In assessing
the number of passes of pneumatic tyred rollers to meet the requirements of Table
10.1 the effective width shall be the sum of the widths of the individual wheel
tracks together with the sum of spacing between the wheel tracks provided each
spacing does not exceed 225mm. The effective width shall be the sum of the widths
of the individual wheel tracks when the spacing exceeds 225mm.

The forces per 100mm width is the total force (weight) on the roll divided by the
total roll width. Where a smooth-wheeled roller has more than one axle the machine
will be assessed on the basis of the axle giving the highest value of force per
100mm width.

For pneumatic tyred rollers, wheel load is the total weight of the roller divided by
the number of wheels.

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Vibratory rollers are self propelled or towed having means of applying mechanical
vibration to one or more rolls.
a)

The requirement for vibratory rollers are based on the use of the lowest
gear on a self-propelled machine and a towed machine. If higher gears or
speeds are used an increased number of passes shall be provided in
proportion to the increase in speed of travel.

Vibratory rollers operating without their vibration mechanism in use will be

classified as smooth wheeled rollers.

Vibratory rollers shall be operated with their vibration mechanism

operating only at the frequency of vibration recommended by the
manufacturers. All such rollers shall be equipped with a device
automatically indicating the frequency at which the mechanism is
operating.

Vibrating-plate compactors are machines having a base-plate to which is attached a

source of vibration consisting of one or two eccentrically weighted shafts.
a)

The static pressure under the plate of a vibrating-plate compactor is

calculated by dividing the total weight of the machine in working order by
the area in contact with compacted soil.

Vibrating-plate compactors shall be operated at the frequency of vibration

recommended by the manufacturers. They shall normally be operated at
travelling speeds of less than 15 m/min but if higher speeds are necessary
the number of passes shall be increased in proportion to the increase in
speed of travel.

Vibro-tampers are machines in which an engine-driven reciprocating mechanism

acts on a spring system, through which oscillations are set up in a base-plate.

Power rammers are machines which are actuated by explosions in an internal

combustion cylinder, each explosion being controlled manually by the operator.
In the case of power rammers one pass will be considered as made when the
compacting shoe has made one strike on the area in question.

For items marked with an asterisk the rollers shall be towed by track-laying
tractors. Self-propelled rollers are unsuitable.

10)

Where combinations of different types or categories of plant are used, the

compaction requirements shall be:
a)

the depth of layer shall be that for the type of plant requiring the least depth
of layer;
and
the number of passes shall be that for the type of plant requiring the
greatest number of passes.

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Section 10 - Roadworks

However, where the Contractor uses a lighter type of plant to provide some preliminary compaction
only, these requirements to assess the effective compaction could be disregarded.

10.18 Road Markings

Road markings shall be as shown on the Drawings and shall be thermoplastic material as specified.

10.18.1

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.

10.18.2

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.

10.18.3

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.

10.18.4

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.

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Section 10 - Roadworks

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.

10.18.5

Protection of Markings

All markings shall be protected from traffic until they have dried sufficiently so that no pick-up by
vehicle tyre will occur.

10.18.6

Reflectorisation

Solid glass beads to be incorporated in marking materials prior to application to road surfaces shall be
Class A glass beads complying with the requirements of Table 1 of BS 6088 (see Table A).
Solid glass beads for additional surface reflectorisation shall be Class B glass beads complying with
the requirements of Table 2 of BS 6088 (see Table B).
TABLE A - CLASS A GLASS BEADS
ROUNDNESS AND DEFECTS.
B.S Sieve

Percentage
Retained

1.18 mm
850 m
425 m

0 to 3
0 to 10
90 to 100

TABLE B -

Min. % Spherical
Beads
by mass as tested
in accordance with
Appendix C
of BS 6088

850
800
300
180
Below
180

Percentage
Retained

0 to 5
5 to 20
30 to 75
10 to
0 to

SIZE

DISTRIBUTION,

Max. % Defective Beads

as tested
in accordance with
Appendix D
of BS 6088

CLASS B GLASS BEADS

ROUNDNESS AND DEFECTS.
B.S
Sieve
(m)

PARTICLE

Min. % Spherical
Beads
by mass as tested
in accordance with
Appendix C
of BS 6088

SIZE

DISTRIBUTION,

Max. % Defective
Beads
as tested
in accordance with
Appendix D
of BS 6088

30
15

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Section 10 - Roadworks

10.18.7

Thickness

The determination of thickness shall be in accordance with BS 3262 Part 3, Appendices B

and C.
Thermoplastic material shall be laid to the following thickness:i)

for synthetic hydrocarbon resin binder -

ii)

for gum or wood resin binders -

10.18.8

screed lines: not less than 2 mm nor more than 5 mm;

sprayed lines other than yellow lines : not less than 1.5 mm;
sprayed yellow edge lines (for no parking, no waiting, etc.) :
not less than 0.8 mm.

screed lines : not less than 3 mm nor more than 5 mm;

sprayed lines other than yellow lines : not less than 2 mm;
sprayed yellow edge lines (for no parking, no waiting, etc.),
not less than 2 mm nor more than 3 mm.

Tolerance on Width

The tolerance on the specified width of the marking shall be within the range of 0% to +10%.

10.18.9

Defective Materials or Workmanship

Materials which are defective or which have been applied in an unsatisfactory manner or to incorrect
dimensions or in a wrong location, shall be removed by approved chemical or mechanical means. To
the extent necessary, the road pavement shall be made good and the markings reapplied all at the
Contractors own expense and to the approval of the S.O.
Where directed by the S.O., existing markings shall be removed in the same manner as above.

10.18.10 Clearing Up
The Contractor shall clean up all spatters, splashes and smirches of marking material completely to
the satisfaction of the S.O.

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Section 10 - Roadworks

TABLE 10.1 : PLANT AND METHOD SPECIFICATION FOR COMPACTION OF

EARTHWORKS AND SUBGRADES Sheet 1/2
Well-graded
granular
& dry cohesive soil
Max depth Min
Max depth Min
of
no. of of
no. of
compacted passes compacted passes
layer
layer
mm
mm
Cohesive Soil

TYPE OF
COMPACTION
PLANT

Smooth-wheeled
roller

Grid-roller

Vibratory
roller

Pneumatic-tyred
rollers

* These rollers shall be towed. Self propelled rollers are unsuitable

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Section 10 - Roadworks

TABLE 10.1: PLANT AND METHOD SPECIFICATION FOR COMPACTION OF

EARTHWORKS AND SUBGRADES Sheet 2/2

TYPE OF
COMPACTION
PLANT

Vibratingplate
compactor

Vibro-tamper

Max depth Min no

of
of
compacted passes
layer
Mm

Max depth Min no

of
of
compacted passes
layer
mm

Max depth Min

of
no of
Compacted
passes
layer
mm

Unsuitable
Unsuitable
Unsuitable
100(4)
150(6)
200(8)

6
6
6

Unsuitable
75(3)
75(3)
125(5)
150(6)
200(8)

10
6
6
5
5

75(3)
100(4)
150(6)
150(6)
200(8)
250(10)

6
6
6
4
4
4

100(4)
150(6)
200(8)

3
3
3

100(4)
125(5)
150(6)

3
3
3

150(6)
200(8)
225(9)

3
3
3

150(6)
275(11)

4
8

150(6)
275(11)

6
12

Unsuitable
Unsuitable

Mass: kg
50-65
65-75
5 more than
75

Power rammer

Cohesive Soil

Well-graded
granular
& dry cohesive soil

Mass : kg
100
more than 500

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Section 10 - Roadworks

TABLE 10.2: COMPACTING PROCEDURE FOR UNBOUND SUB-BASE AND

ROADBASE MATERIALS AND FOR SOIL-CEMENT AND CEMENTBOUND GRANULAR ROADBASE
Minimum number of passes
Type
Plant

compaction
Category

< 110mm
layer

< 150mm
layer

< 225mm
layer

Force per 100 mm width

kN
2.6-5.2
> 5.2

16
8

Unsuitable
16

Unsuitable
Unsuitable

Wheel load (Tonnes)

4-6
6-8
8-12
> 12

12
12
10
8

Unsuitable
Unsuitable
16
12

Unsuitable
Unsuitable
Unsuitable
Unsuitable

Static force per 100mm

width (kN)
0.71-1.25
1.26-1.75
1.76-2.3
2.31-2.8
2.81-3.5
3.51-4.2
4.21-4.9

16
6
4
3
3
3
2

Unsuitable
16
6
5
5
4
4

Unsuitable
Unsuitable
10
9
8
7
6

Static force under base

plate (kN/m2)
13.8-17.2
17.2-20.7
> 20.7

8
5
3

Unsuitable
8
6

Unsuitable
Unsuitable
10

Mass (kg)
50-60
65-75
> 75

4
3
2

8
6
4

Unsuitable
10
8

Power
rammer
on Mass (kg)
dropping
weight 100-500
compactor
> 500

5
5

8
8

Unsuitable
12

Smooth-wheeled
roller

Pneumatic- tyred roller

Vibratory roller

Vibrating- plate
compactor

Vibro-tamper

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Section 11 - Drainage Works

11.0

DRAINAGE WORKS..................................................................................11-1
11.1

Stone Pitching................................................................................11-1

11.2

Weepholes......................................................................................11-1

11.3

Rip-rap ............................................................................................11-1

11.4

Placing Rip-rap ..............................................................................11-2

11.5

Filter Material .................................................................................11-2

11.6

Material for Underdrains and Rubble Drains...............................11-2

11.7

Filter Fabric ....................................................................................11-3

11.8

Reno Mattresses ............................................................................11-4

11.9

Gabions ..........................................................................................11-4

11.10 Porous Concrete Pipes .................................................................11-4

11.11 Salt Glazed Stoneware Pipes and Fittings...................................11-4
11.12 Reinforced Concrete Pipes ...........................................................11-5
11.13 Clayware Field Drain Pipes and Fittings......................................11-5
11.14 Laying Drain Pipes.........................................................................11-5
11.15 PVC Pipes.......................................................................................11-5
11.16 Drain Pipe Test Certificates ..........................................................11-6
11.17 Drain Covers and Gratings ...........................................................11-6

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Section 11 - Drainage Works

11.0

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 shown on the Drawings.

11.1

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
150 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 155 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.

11.2

Weepholes

Where indicated on the Drawings or directed by the S.O., weepholes 75 mm in diameter shall be
formed by embedded asbestos cement, concrete or glazed stone-ware pipes through concrete members
or pitching.

11.3

Rip-rap

Rip-rap shall be hard, sound, broken granite obtained from an approved source, and shall be free from
cracks, kaolinised patches, organic or other impurities or deleterious material. Sand and dust shall not
exceed 1% by weight.
Rock fragments used for rip-rap shall be angular and the greatest dimension of any piece shall not
exceed twice the least dimension. The specific gravity of the rock shall not be less than 2.60.

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Section 11 - Drainage Works

Soundness shall be measured by immersion in a solution of Sodium Sulphate of fragments prepared as

laid down in Clause 5(b) of ASTM C88 "Method of Test for Soundness of Aggregates by use of
Sodium Sulphate or Magnesium Sulphate". The loss in weight after 5 cycles, as defined in ASTM
C88, shall not exceed 5%.
The material shall be well graded and shall conform to the limits shown in Appendix 2.1.

11.4

Placing Rip-rap

Rip-rap shall be tipped or otherwise placed in such manner as to distribute the sizes uniformly
throughout the full thickness of the material; all large voids being filled with smaller rock fragments.
It shall be finished finally by hand to the designed slope and thickness.
The Contract Rates for rip-rap shall be deemed to include the cost of supplying, handling, placing and
any necessary adjustment after dumping to achieve the necessary uniformity of distribution.

11.5

Filter Material

Filter material shall consist of material conforming to the grading limits shown on Appendix 2.1. The
gradings and the materials shall be subject to the approval of the S.O. and they shall not be gap
graded. The Contractor shall supply to the S.O. grading curves, and samples of not less than 20 kg
weight, of each filter material within two weeks after the S.O.s order to commence work. The S.O.
will require simultaneously to see the curves and samples for each category of material which is in
contact with another material in the section of the works concerned.
Filter material shall be compacted in layers not exceeding 225 mm by 4 passes of a smooth-wheeled
vibrating roller. One pass shall consist of as many journeys of the roller as shall ensure that the
bearing width of the roller completely covers the layer once. An over-lap of 450 mm between the
adjacent paths of the roller shall be maintained.
Filter material shall be compacted at the moisture content determined by the S.O. The Contractor shall
be deemed to have allowed in his Contract Rates for placing filter material for any watering necessary
to achieve the required moisture content.
All filter materials shown on the Drawings as vertical layers or layers whose surface is inclined at a
slope steeper than one horizontal to three vertical shall be described as filter material in vertical
layers. The Contractor shall place filter materials in vertical layers in steps not exceeding 1200 mm
deep and shall satisfy the S.O. that the filter material so placed will comply with the specified
requirements.
The Contract Rates shall allow for all necessary work including excavating and backfilling or the use
of temporary formwork to separate different materials or any other operation necessary to comply
with these requirements.

11.6

Material for Underdrains and Rubble Drains

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Section 11 - Drainage Works

Material used for sub-soil drains shall be 9.5 mm to 38 mm graded crushed granite, clean and free
from silt and clay.
Material used for rubble drains shall be graded crushed granite, clean and free from silt and clay as
specified in Section 11.1.

11.7

Filter Fabric

The filter fabric employed in the Works shall be as shown in the Drawings and of a make approved by
the S.O., and shall be handled and laid strictly in accordance with the recommendations of the
manufacturer.
The fabric shall be non-woven needle punched type comprising 100% polypropylene continuous
fibres and resistant to all naturally occurring soil acids and alkalis and to attack by bacteria and fungi.
Fabric manufactured from staples (short) fibres or heat bonded shall not be accepted. The
manufacturer shall certify compliance of this requirement. The filter fabric used in the Works shall be
the following three types as shown below:

Surround to sub-soil drain pipes.

In pipe trench in water logged ground.
Under Reno mattress or rip-rap.

The geotextile delivered to site shall meet or exceed the technical values of the following properties.
Manufacturer must provide Quality Statement to verify compliance of the technical values. Geotextile
not meeting the required technical values shall be rejected.
Property

Test Standard

Unit

Type A

Type B

Type C

Ultimate tensile Strength

EN ISO 10319

kN/m

9.5

11.5

24.0

Tensile elongation @
max strength

EN ISO 10319

75/35

80/40

CBR puncture

EN ISO 12236

1500

1700

3850

Effective opening size

(Wet sieving)

EN ISO 12956

0.12

0.09

Vertical Permeability
(2kPa)

E DIN 60500/4

cm/s

0.3

Vertical water flow

(2kPa)

E DIN 60500/7

1/sq.m

250

200

103

Mass/area

EN 965

g/sq.m

125

155

325

Thickness

EN 964-1

1.2

1.5

2.9

UV resistance

Outdoor testing

Retain > 80% of max tensile strength

after 3 month exposure

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Section 11 - Drainage Works

11.8

Reno Mattresses

Reno mattresses shall be supplied in sizes 5.5 m x 1.8 m in plan with internal diaphragm at 900 mm
centres. The mesh size shall be 60 mm and the hot dipped galvanised wire diameter shall be 2 mm
coated in PVC giving a minimum of 3.3 mm outside diameter.
The mattress filling shall be durable stone graded from a maximum size of 180 mm to a minimum size
of 50 mm.
After filling the mattresses shall be securely closed and tied to adjacent units with hot dipped
galvanised wire not less than 2 mm diameter. Each mattress shall be staked to the ground with a 20
mm galvanised mild steel rod 1200 mm long.
Reno mattresses shall be measured as the net volume laid and shall include the stone filling, securing
stakes and wire.

11.9

Gabions

Gabions shall be supplied in sizes 2 m x 1 m x 1 m. The mesh size shall be 100 mm and the hot
dipped galvanised wire diameter shall be 2.7 mm coated in PVC giving a minimum of 3.8 mm outside
diameter.
The gabion filling shall be durable stone of maximum dimension of 300 mm and minimum dimension
of 150 mm.
After filling, the gabions shall be securely closed and tied to adjacent units with galvanised wire not
less than 2 mm diameter.

11.10

Porous Concrete Pipes

Porous drainage pipes shall be ogee porous concrete pipes complying with BS 5911-114. Porous
pipes shall be laid dry jointed as detailed in the Drawings or as directed by the S.O. and surrounded
by drain material.
Unless otherwise shown on the Drawings, precast concrete channels shall be at least cast in concrete
grade C20 and shall be dense, homogeneous channels with clean true edges and surfaces. The drain
channels shall be reinforced with fabric reinforcement as shown on the Drawings or as required.
Channels shall, unless otherwise stipulated, be bedded on concrete grade C20 base of required
thickness, all joints (6 mm maximum) shall be grouted and pointed in cement mortar (1:3).

11.11

Salt Glazed Stoneware Pipes and Fittings

All salt glazed stoneware drain pipes and fittings shall comply with BS 65 or an equivalent standard.
The pipes shall be laid carefully to the lines and gradients shown on the Drawings or as directed by

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Section 11 - Drainage Works

the S.O. Chemically resistant salt glazed ware drains conforming with BS 65 are required for certain
of the surface water drains.
They shall be well glazed and impervious and free from fire cracks and other defects.
The pipes shall be jointed by first placing into the socket a ring of tarred yarn and then by filling the
remainder of the cavity with 1 to 1 1/2 cement sand mortar. The joint shall be finished with a neat 45o
fillet worked round the outside. The tarred yarn when rammed into position shall not occupy more
than one quarter of the depth of the socket. A suitable scraper shall be drawn through each pipe
immediately after laying to remove any jointing material to leave a clear and unobstructed waterway.
All salt glazed ware pipes shall be bedded and haunched or surrounded with 150 mm thick Grade C20
concrete as directed by the S.O. They shall be fully surrounded in concrete where they are under
buildings and roads or where the cover to the crown of the pipe is less than 1 metre or greater than 2
metre.

11.12

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.

11.13

Clayware Field Drain Pipes and Fittings

All clayware fields drain pipes and fittings shall comply with the requirements of BS 1196: 1971.

11.14

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.

11.15

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.

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Section 11 - Drainage Works

11.16

Drain Pipe Test Certificates

Each batch of pipes supplied shall be accompanied by the manufacturers test Rain water pipes shall
be measured as the net length erected in place and shall include for all works in forming bends where
required, cutting, jointing and building into concrete, providing and erecting support brackets for
holding the pipe in position.

11.17

Drain Covers and Gratings

Provide mild steel gratings and precast reinforced concrete grade C20 covers to drains, to details as
shown on Drawings, and at areas where required.

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Section 12 - Miscellaneous

12.0

MISCELLANEOUS ....................................................................................12-1
12.1

Chequer Plating .............................................................................12-1

12.2

Handrailing .....................................................................................12-1

12.3

Ladder.............................................................................................12-1

12.4

Step-irons .......................................................................................12-2

12.5

Manholes, Surface Boxes, etc ......................................................12-2

12.6

Fencing ...........................................................................................12-2

12.7

Galvanised Metals .........................................................................12-3

12.8

Dissimilar Metals ...........................................................................12-3

12.9

Painting...........................................................................................12-3
12.9.1

General ...........................................................................12-3

12.9.2

Painting Procedure........................................................12-4

12.9.3

Painting Timber Surface ...............................................12-5

12.9.4

Painting Steel and Ironwork .........................................12-5

12.9.5

Painting Concrete and Cement based Surfaces .........12-6

12.9.6

List of Approved Paints ................................................12-6

12.9.7

Painting Colour Code ....................................................12-6

12.10 Sealing Compounds ......................................................................12-8

12.11 Joint filler........................................................................................12-9
12.12 Waterstops .....................................................................................12-9
12.13 Building Paper ...............................................................................12-9
12.14 Interlocking Concrete Pavement Block .......................................12-9
12.15 Anchor Bars .................................................................................12-10
12.16 Fibreglass Reinforced Plastic (FRP) Fabrications....................12-11
12.16.1

General .........................................................................12-11

12.16.2

Products .......................................................................12-12

12.17 Fibreglass Reinforced Plastic (FRP) Gratings

and Stair Treads...........................................................................12-13
12.18 Fibreglass Reinforced Plastic (FRP) Handrails.........................12-13
12.19 Fibre Reinforced Plastic (FRP) Covers ......................................12-14
12.19.1

General .........................................................................12-14

12.19.2

Design...........................................................................12-14

12.19.3

Materials .......................................................................12-19

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Section 12 - Miscellaneous

12.19.4

Workmanship ...............................................................12-21

12.19.5

Inspection and Testing................................................12-23

12.19.6

Water Supply System ..................................................12-27

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Section 12 - Miscellaneous

12.0

MISCELLANEOUS

12.1

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 two coats of two pack epoxy based red lead primer before
delivery. After installation on Site, chequer plates used in valve chambers shall be fully painted with a
further two coats of two pack coal tar epoxy paint. Chequer plates used elsewhere shall be painted on
the lower (hidden) surfaces with two coats of similar coal tar epoxy paint and on the upper (exposed)
surfaces with one undercoat, two coats of semi-gloss high finishing paint of approved quality and
colour.

12.2

Handrailing

Handrailing shall be made from hot-dip galvanised mild steel hollow sections and flats. 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.
After cleaning with lithoform, it shall be painted with two coats of two pack epoxy red lead primer, an
undercoat and a further 2 coats of an approved gloss paint after installation. Expansion units shall be
provided where the handrailings are more than 15 metre long.

12.3

Ladder

Mild steel ladders shall be hot-dip galvanised in accordance with BS EN ISO 1461. After cleaning
with lithoform 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.

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Section 12 - Miscellaneous

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.

12.4

Step-irons

Step irons for use in chambers unless otherwise specified shall be bent from 25mm diameter deformed
high yield steel bars to the shape and dimensions shown on the Drawings and shall be hot-dip
galvanised after bending. Step irons shall be painted with 2 coats of approved two pack coal tar epoxy
paint.

12.5

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.

12.6

Fencing

The boundary of a treatment plant, pumping station and/or sludge treatment facility shall be secured
by 3.0 meter high 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 Commission. Where the treatment plant is situated in a building, access
to the plant must be secured.
Typical details of the fence are as shown in Developer Guideline Volume 4. Fencing shall be as
detailed on the Drawings.
Contractor is required to provide adequate warning/safety and the Commission signboard before
handing over the sewerage system to the Commission.
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 galvanised two ply 2.64mm with 4 point barbs
spaced at 75mm intervals.
Precast Concrete Fencing
The fence shall be 2.2 meter high solid precast concrete wall with
three strands of 0.8 meter high barbed wire.
Mosony Fencing
high barbed wire.

The fence shall be 2.2 meter high masony wall with three strands of 0.8 meter

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Section 12 - Miscellaneous

Gate Chain link for gate shall be PVC coated and consist of hot dipped galvanised 4.06mm wire of
50mm square mesh reinforced with 3 No. 4.06 mm hot dipped galvanised line wires. Fence posts for
gate shall be of 64 mm x 64 mm x 9.4 mm hot dipped galvanised mild steel angles spaced at 3.0 metre
intervals with straining posts at all corners and at intervals of 15 metre. Stays for straining posts shall
be 51 mm x 51 mm x 6.3 mm hot dipped galvanised mild steel angles raked at 45o. All mild steel
angles shall be galvanised and painted in accordance with BS 5493. All fence posts and struts shall be
sunk into post holes 300 mm x 300 mm x 750 mm deep, and filled in with Grade C20 concrete to be
flushed with the ground level unless otherwise shown in the Drawings.
Installation of fencing shall include for the supply of all materials, galvanising, excavation, erection of
the fencing complete painting with 2 coats of approved paint, fence posts, stays corner posts, concrete
support and up stand beam.

12.7

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
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.

12.8

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.

12.9

Painting

12.9.1

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
approved by the S.O.
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.

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12.9.2

Painting Procedure

The Contractor shall follow strictly in accordance with the manufacturer's instructions and
recommendations based on BS 6150, particularly with regard to:a)

Preparation of surfaces specified to be painted.

Preliminary priming or sealing coat.

The number of undercoats and method of application.

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
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

and undercoat

3 weeks

between undercoats or under

coat and first finishing coats

2 weeks

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.
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Section 12 - Miscellaneous

12.9.3

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

one under coat

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.

12.9.4

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 manufacturer's 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.

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Section 12 - Miscellaneous

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.

12.9.5

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 manufacturer's specification.

12.9.6 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.

12.9.7 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

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Section 12 - Miscellaneous

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.
Painting System Index Colour Standards
Item

Colour

Equivalent Colour
Guide

General Equipment including motors (unless

come with the original manufacturer approved
colour code)

Dark Blue

Penstocks/Valves/Manhole Covers

Black

Dulux Regal Blue

0013
Par Mandarin Blue
0013
Par Bituminous Black

Machinery Guards/Railings/Runways/Overhead
Cranes/Lifting Davit

Yellow

Dulux Lemon 2024

Par Golden Yellow

Switchboards

Fencing poles/Gates

Building and Walls Exterior

Building and Walls - Interior
Fencewall Interior and Exterior

Light Grey

Dulux Pewter 695

Green

Par Willow Grey

00A05
Dulux A365-13449

Grey
(Weathersheild)
White
Grey

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Par Green 3666

Dulux BS 00A0510235
Dulux BS 00A0510235

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Section 12 - Miscellaneous

Item

Colour

Equivalent Colour
Guide

Floors - Concrete Interior

Green

Leigh Green 3666

Green

Dulux A910-13448
Par Green 3666
Dulux A910-11482

Building Stripes

Green
Blue

Indah Water Logo

(where applicable)

Green

Indah Water
Green

Par Blue 2686

Dulux A365-13449
Par Green 1006

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.

12.10

Sealing Compounds

Construction and contraction joints

Sealing compounds for horizontal joints shall be hot applied bituminous sealants complying with the
requirements of BS 2499 and BS EN 14188. The sealing compound shall be capable of expanding to
110% of its original thickness between parallel faces without separation.
Horizontal joints to be filled with the sealing compound shall first be thoroughly cleaned and dried
before applying primer compatible with the sealing compound to be used. Both primer and sealing
compound shall be applied in accordance with the manufacturer's recommendations for tropical
climates.
Sealing compounds for vertical and inclined joints shall be bituminous putty of a quality approved by
the S.O. The sealing compound shall be capable of expanding to 110% of its original thickness
between parallel faces without separation. Vertical and inclined joints to be filled with the sealing
compound shall first be thoroughly cleaned and dried before applying an approved primer compatible
with the scaling compound to be used. Both primer and sealing compound shall be applied in
accordance with the manufacturer's recommendations for tropical climates.
b)

Expansion joints

Sealing compounds for expansion joints shall be polysulphide liquid polymer sealants obtained from
approved manufacturers. The sealing compound shall be capable of expanding to 133% of its original
thickness between parallel faces without separation and contracting to 67% of its original thickness
without extruding.

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Section 12 - Miscellaneous

Expansion joints to be filled with the sealing compound shall first be thoroughly cleaned and dried
before applying an approved primer compatible to the sealing compound to be used. Both primer and
sealing compound shall be applied in accordance with the manufacturer's recommendations for
tropical climates.

12.11

Joint filler

Joint filler for all joints in water retaining structures shall be resin bonded cork filler or similar
approved product and shall be obtained from approved manufacturers.

12.12

Waterstops

Waterstop shall be dense, homogeneous and free of holes or other imperfections. The cross section
shall be uniform along the length and symmetrical transversely so that the thickness at any given
distance from either edge will be uniform. Where not otherwise shown on the Drawings:-

the width of the waterstop shall not be less than 80% of the thickness of the
concrete section and not less than 225mm;
the web thickness shall be not less than 9mm.
all waterstop shall incorporate a solid bulb or major rib at or near each edge;
waterstop at movement joints shall incorporate a central hollow bulb;
waterstop for use at induced contraction joints shall incorporate a crack inducer;
waterstop for use within the concrete thickness shall be of rubber.

Rubber waterstop shall be of natural rubber, suitable synthetic rubber, or a blend of the two and shall
have the following properties when tested at 25C.

Minimum tensile strength (N/mm2)

Minimum elongation at break (%)

450

Hardness (IRHD/Shore A)
Softness (BS 2571)
Specific gravity

60-70
1.05 - 1.15

All intersections and junction in waterstop shall be factory-produced by the manufacturer of the
waterstop, normally as moulded special pieces, so that the only joints remaining to be made at Site
shall be straight butt joints between straight length of waterstop of the same section and material.

12.13

Building Paper

Building paper shall be waterproof Class A complying with BS 1521.

12.14

Interlocking Concrete Pavement Block

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Section 12 - Miscellaneous

General

'UNI-PAVE' interlocking concrete pavement blocks shall be laid to all apron slab areas as indicated in
the Drawings or as directed by the S.O. Concrete pavers shall be 225 x 113 x 60 mm thick laid to
patterns and colours as selected by the S.O.
b)

Workmanship

The sub-base shall be evenly compacted by a vibrating plate compactor. The sub-base construction
should extend beneath any new edge restraints constructed as part of the pavement and be closely
trimmed to the required levels.
Edge restraints in the form of cast in-situ concrete (1:3: 6-1" aggregate) shall be provided along the
edges of "UNI-PAVE' pavements. The restraints shall be cast in such a manner that they are slightly
lower than the adjacent paving units for surface water drainage.
A sand blinding layer, comprising well-graded concreting sand shall be spread and screened and
compacted to consolidated thickness of 30mm to receive the "UNI-PAVE" units.
The laying of "UNI-PAVE" units shall commence from the lowest level edge restraint. The units shall
be laid with 2 to 4mm gap between adjacent units. Immediately after laying, the units shall be
compacted and brought to level with the vibrating plate compactor. Upon completion of compaction,
sand of 2mm size should be broomed over the pavement and into the joints. Excess sand should be
removed as soon as joints are filled.

12.15

Anchor Bars

General

Anchor bars shall consist of untensioned straight or L shaped mild steel or high yield bars, as shown
on the Drawings and/or as directed by the S.O., and which are fully grouted into the foundation in
order to anchor down concrete structure placed onto the foundation. The anchor bars shall be grouted
into holes of nominal diameter which are 25mm larger than the anchor bar diameter and drilled to
such depths, inclinations and orientations as directed by the S.O. The grout shall be a non-shrink
cement grout of Ordinary Portland cement with a water cement ratio of not more than 0.45 with
approved admixtures. The grout strength shall be 30N/mm2 at 28 days. Materials for the grout shall be
as that specified in Section 3.0 Concrete.
b)

Installation Sequence

Anchor bars shall be installed in the following sequence:

drill the hole to the length and diameter required;

ii)

flush out hole with a high pressure air and water jet until return water is clear;

iii)

remove any standing water by means of compressed air;

iv)

fill hole with grout through a plastic tube extending to the base of the drillhole to
ensure that all air and water are displaced by the grout;

install anchor bar centrally in hole by means of approved spacers;

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Section 12 - Miscellaneous

vi)
c)

top up grout level as required.

Pull Out Tests

Prior to the installation of the permanent anchor bars the Contractor shall carry out Pull Out Tests on
trial or working anchor bars selected by the S.O.
The Contractor shall provide all torque wrenches, jacks and other equipment necessary to test the
anchor bars.
Before the test is carried out the Contractor shall submit to the S.O up to date certificate of calibration
for the test equipment to be used for the testing. The Contractor shall submit the proposed testing
procedures to the S.O. for his approval before commencing any test.
Anchor bars for the Pull Out Test shall be tested to 1.5 x working load or to the specified load and the
mode of failure, if any, recorded. The test result shall be accepted if the bar remained in place under
the test load for 5 minutes. Modifications required as a result of the Pull Out Tests shall be approved
by the S.O. before the Contractor commences the drilling for the permanent anchor bars. n no case
shall the drilling for the permanent anchor bars commence until the S.O. has accepted and approved
the results of the Pull Our Tests and confirm whether any modification is required or not.

12.16

Fibreglass Reinforced Plastic (FRP) Fabrications

12.16.1 General
Description

The wok 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

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.

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.

Samples of each type of FRP product proposed shall be submitted for approval.

Quality Assurance

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.

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.

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.

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Section 12 - Miscellaneous

In addition to requirements of these specifications, the Contractor shall comply

with manufacturers instructions and recommendations for work.

Delivery Storage and Handling

All systems, sub-systems and structures shall be shop fabricated and assembled
into the largest practical size suitable for transporting.

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.

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.

All materials, items and fabrications for installation and field assembly shall be
identified and match-marked.

12.16.2

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.

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.

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.

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.

All FRP items shall be corrosion resistant to a 5% concentration of either sulphur

dioxide or hydrogen sulphide.

After fabrication, all cut ends, holes and abrasions of FRP shapes shall be sealed
with a compatible resin coating to prevent intrusion of moisture.

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.

All exposed surfaces shall be smooth and true to form.

Color shall be OSHA safety yellow or gray as gray as instructed by the S.O.

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Section 12 - Miscellaneous

12.17

Fibreglass Reinforced Plastic (FRP) Gratings and Stair

Treads

Compliance

The FRP products shall comply with the ASTM Testing and must be approved by S.O.
Material

FRP gratings shall be manufactured by open molding process. The material shall combine fibreglass
rovings with at least 65% thermosetting resin by weight to form a strong, one-piece molded panel and
provide corrosion resistance characteristic. It shall offer outstanding resistance to a wide range of
highly corrosive situations found in wastewater applications. The quality of product shall be assured
subjecting to extreme tests for chemical resistance, stability under ultraviolet exposure, impact
resistance, load carrying capacity and strength. Unless otherwise stated, the mesh size shall be 25mm,
35mm or 50mm square mesh which is able to provide bi-directional strength.
Design

Molded FRP grating span should be limited to an acceptable deflection. Gratings must be
mechanically fastened in place to prevent sliding. Each grating panel should be fastened to each
supporting structure using a minimum of four M style hold down clips. For larger panels, 6 to 8
hold down clips are recommended. Gratings installed in trenches where they are captive in an
embedment angle do not require hold downs unless bearing surfaces are uneven and the grating panels
would tend to rock. Abutting edges of molded grating panels should be supported by structural
members or fastened together using F style to clips at a minimum spacing of 600mm on centre.
This will prevent differential deflection when one of the abutting gratings is loaded. The top surface
of all panels shall have nonskid grit affixed to the surface by a baked epoxy resin followed by a top
coat of baked epoxy resin.

12.18

Fibreglass Reinforced Plastic (FRP) Handrails

Material

The material shall have a glass reinforcement content of 50 %. The glass fibre E type continuous
strand glass mat or continuous glass strand glass mat or continuous glass strand rovings shall comply
with BS 3749, rails and posts shall be 50x50x4 mm thick fibre glass pultruded square tube, kickplates
shall be 100 x 12.5 (corrugated) x 3 mm thick pultruded fibre glass shape.

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Section 12 - Miscellaneous

Pultruded parts shall meet the following minimum mechanical properties:

Properties

Tensile Stress
Tensile Modulus
Compressive Stress
Compressive Modulus
Flexural Stress
Flexural Modulus
Shear Stress
Density
24 hr. Water Absorption
Coef. Of Thermal Expansion
Flexural Stress
Flexural Modulus

Test Method

ASTM D638
ASTM D638
ASTM D695
ASTM D695
ASTM D790
ASTM D790
ASTM D2344
ASTM D792
ASTM D570
ASTM D696
Full Section
Full Section

Values

207 MPa
17 GPa
207 MPa
17 GPa
207 MPa
11 GPa
31 MPa
1.66 to 1.94 g/cm2
max 0.6%
8 x 10-6 /oC
248 MPa
25 GPa

Design

Design shall conform to loading requirements of OSMA 1910.23, with a minimum factor of safety of
2. Fabrications shall be capable of withstanding a concentrated load of 90 kg applied at any point nonconcurrently, vertically downward or horizontally. Horizontal hand rails shall be 1000mm high with
an intermediate rail at 500mm high.

12.19

Fibre Reinforced Plastic (FRP) Covers

12.19.1 General
a)

Scope

This part of the Specification covers the design, manufacture, supply, installation and testing of glass
fibre reinforced plastic (FRP) covers for tanks, channels and vessels that contain sewage and sludge.
The purpose of the covers is to prevent the emission of gases and offensive odours.
b)

Manufacturer

The manufacturing of the FRP covers shall be undertaken by a specialist firm with at least five years
experience in the design and fabrication of large FRP elements comparable to those required for this
Contract.

12.19.2 Design
a)

Submissions by the Contractor

The detail design of the covering systems, including the structural design, all fixings and support
details, is to be prepared by the Contractor and submitted to the S.O. for approval.
The detail designs submitted by the Contractor shall be undertaken by a Qualified Person experienced
in the design of FRP structures. The Contractor shall submit such calculations in a format required by
the S.O.

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Section 12 - Miscellaneous

Comprehensive calculations shall be prepared for each configuration of cover to accompany the
designs as submitted. These calculations shall be carried out in accordance with established practice
for FRP structures, and reference shall be made to standards such as BS 4994, NF T 57 900 and
DIN 18820 where these are appropriate. The calculations and design drawings shall be in English.
Where reference is made by the Contractor to standards or other documents which are not in the
English language translations shall be provided by the Contractor at the same time that the
calculations and designs are submitted.
The calculations shall determine the following maximum stresses:
-

tension: longitudinal and lateral;

compression: longitudinal and lateral;
shear: in-plane, inter-laminar and punching;
bolt bearing

The corresponding strains shall also be determined.

Calculations shall be carried out to demonstrate that there will be no instability of any kind when the
covers subjected to twice the worst practical combination of factored loads.
The calculations shall include a determination of the maximum loading which will be applied to the
tank structure.
Where computer programs have been used in the design process full listings of input and output data
shall be provided together with a detailed assessment of the salient aspects of the analysis. When
required by the S.O. a copy of the used manual for any computer program shall also be provided.
The covers shall be fabricated in strict accordance with the designs for which the S.O. has granted
final approval.
b)

Design Requirements

The covers and any associated support systems shall be designed to be suitable in all respects for their
proposed use. They shall be capable of withstanding the design loading conditions given below
without exceeding the allowable stresses and strains, while remaining airtight. The maximum
allowable stress shall be related to the measured strength of the proposed laminate as specified below.
The covers shall be designed to withstand the loadings which will result from the impact tests
specified below.
The covers shall be designed to be air-tight with the exception of purpose designed air inlets and
pressure relief devices which form part of the ventilation and odour control system.
c)

Design Loading

The design loading for the covers comprises:

An imposed load of 0.50 kN/m2 or a concentrated load of 0.9 kN, whichever

produces the greatest stress;

ii.

An abnormal loading of 1.00 kN/m2 because of the pressure differential across the
cover which may result from the operation of the ventilation system;

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Section 12 - Miscellaneous

iii.

A wind loading determined in accordance with the requirements of BS 6399: Part

2 using a design wind speed of 32 m/s;

iv.

The self weight of the covers and any additional supports;

Any additional loadings for individual covers;

vi.

Any additional loadings which will be imposed upon the covers by virtue of the
proposed design, the proposed method of lifting cover segments or the proposed
method of installation.

All covers shall be designed to limit state structural design principles. The following load factors
shall be applied to the design loads given above:
Load case
1
2
3
4

Loads
i) + ii) + v) + vi), and
iv)
iii) + iv)
iii) + any other loads
vi)

Load factor
1.6
1.4
1.2
1.2
1.0

An additional unbalanced loading case (load case 5) shall be considered in which the design loads
shall be as for load case 1 except that the imposed loading of 0.50 kN/M2 shall be applied to one half
of the cover only.
d)

Allowable Stresses, Strains and Deflections

Under the worst combination of the above factored loads, and any other effects such as temperature
variations, the stresses in the cover shall everywhere be less than the allowable stresses which shall be
determined by making appropriate reductions to the minimum laminate strengths to allow for the
following factors:
-

long-term loading;
the method of manufacture;
the chemical environment to which the covers are to be exposed;
elevated temperatures;
cyclic loading;
curing procedure

The amount of these reductions shall be determined in accordance with established procedures such as
those set out in Section 9.2 of BS 4994.
An additional reduction to the minimum laminate strength to allow for the effect of long term
exposure to UV radiation shall be made. The amount of this reduction shall be substantiated by the
Contractor with specific reference to the proposed resins, UV absorbers and light stabilisers.
The maximum strain shall not exceed 0.2%, or 10% of the extension to failure (fracture strain) of
unreinforced resin determined in accordance with Appendix B of BS 4994, whichever is the smaller.
Under the worst combination of the above unfactored loads no section of the covers shall deflect by
more than 1/200 of the shortest span of the section.
e)

Supports for Covers

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The covers are to be securely fixed to the tank walls. The fixing arrangements shall be designed in
detail by the Contractor and shall be capable of withstanding all stresses and disturbing forces which
may result from the design loading conditions as well as uplift forces which may occur due to the
flooding of treatment processes. The extent to which uplift forces need to be allowed for shall be
considered for each cover individually. The fixing arrangements shall be capable of accommodating
the maximum relative movement which may occur because of the loading on the covers and variations
in environmental conditions such as temperature and humidity. Where covers are to be installed onto
existing structures the Contractor shall establish, prior to installation of the covers, that those portions
of the existing walls which are to support the covers are adequately level and sound to accept the
Contractors proposed fixing arrangements.
f)

Environmental Conditions

The covers shall be resistant to the environmental conditions which may be encountered and shall
show no deterioration of material or leakage after prolonged exposure to these conditions. The covers
will be placed over tanks, vessels and channels which contain sewage and sludge, and the covers shall
be suitable for continuous exposure to sewage vapours. High humidity levels will occur beneath the
covers and the covers shall be suitable for use in conditions of 100% humidity. The sewage is a
mixture of domestic wastewater and industrial wastewater. Under some conditions sewage will release
hydrogen sulphide, and the covers shall be designed to withstand hydrogen sulphide concentrations of
up to 100 parts per million (by weight). Other chemicals will be present in the sewage and the covers
shall be resistant to a wide range of such substances.
The upper surfaces of the covers may be exposed to the atmosphere and such covers shall therefore be
resistant to the high levels of humidity, rainfall, UV radiation and to the elevated temperatures which
will result from the strong sunlight. The covers shall be suitable in all respects for use in the tropical
climatic conditions which prevail in Malaysia.
g)

Design Features

All cover sections shall include stainless steel lifting eyes which shall allow the sections of cover to be
lifted in a stable and balanced manner. A minimum of three lifting eyes shall be provided in each
section of cover.
The cover shape of the cover shall be proposed by the Contractor for the approval of the S.O. They
shall be generally of low profile to minimise the volume of air contained beneath the cover.
Covers shall generally be designed so that they may be removed, either in single sections, in two or
more sections joined together or in their entirety. The design of covers shall be such that they may be
removed and replaced easily without deformation and without affecting the air tightness of the covers.
The covers shall be designed to avoid the collection of rainwater, and all parts of the cover shall be
curved in cross-section or shall have a slope of at least 1/100. The profile of the covers shall be
designed so that rainwater drains from the covers towards the periphery of the tank. The covers shall
incorporate rainfall collection facilities adequate to accept the flows which will result from the
continuous discharge of the design rainfall rate 215mm/hr. The covers shall be designed so that
rainwater drains to the edge and out of the tank.
Rainwater downpipes shall incorporate a trapped floating ball type of seal, as generally indicated on
the drawings, to prevent the emission of foul air when rainwater is not being discharged.
An alternative mechanism for the prevention of foul air from the rainwater downpipes may be
proposed by the Contractor. Cover designs shall be consistent in appearance with respect to colour;
surface finish and, as far as possible, profile and shall be submitted to the S.O. for approval.
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The covers shall be provided with inspection and access openings generally as indicated on the
drawings. Hatches shall either be of the hinged-type, of the sliding-type, or of the removable-type.
The hatches shall be air-tight when closed, and shall be provided with latches or screw-type fittings to
ensure that they do not rely on self-weight to remain closed. It shall be possible for one person to
remove the hatch easily and without assistance. Hatches of the hinged type shall be hinged to be
opened flat. Detailed proposals for these openings and hatches shall be submitted to the S.O. for
approval.
The cover profile proposed by the Contractor shall allow easy personnel access to these access
openings from adjacent walkways and steps, stairways or ladders shall be provided where necessary.
The covers shall contain various items of equipment and ducting associated with the ventilation and
odour control facilities, including air inlet louvers, air pressure relief devices vacuum relief valves and
foul air ducting, as required for the efficient and safe operation of the covers and ventilation system.
The covers shall be designed to accommodate these items insuch a way that the items may be readily
removed without damaging the covers.
Where mechanical equipment will be enclosed beneath covers, provision shall be made in the design
for the maintenance of this equipment. This will generally be achieved by the use of removable
sections of cover.
Some cover sections shall contain instrumentation equipment such as level sensors and dissolved
oxygen probes. Where these are required the covers shall incorporate flanges for the installation of
these instruments.
Specific requirements for handles, fixings, locks, hinges, returns, moulded architraves, seals, louvers
and screw caps shall be provided where necessary.
The covers shall be securely fixed to the existing tanks. The fixings shall be designed be the
Contractor for the S.O.s approval. Where necessary the design of the fixings shall make allowance
for relative movement between the cover and the fixing which may result from any reason such as
deformation of the covers caused by the loading and by environmental conditions such as temperature
and humidity.
h)

Laminate Design

The laminate shall be designed by the Contractor to be suitable in all respects for the proposed
purpose. It shall have adequate chemical resistance to withstand the environmental conditions to
which it will be exposed, and shall have adequate strength and stiffness to withstand the design
loadings identified above and the impact loadings specified below.
The upper surface of the covers shall have an applied non-slip finish within 1200mm of all access
openings, other fittings such as air inlets, instrumentation fixings and pressure relief valves, and
elsewhere as indicated on the drawings. The non-slip finish shall also be applied in a 1200mm wide
strip between each such access opening or fitting and an adjacent walkway.
The upper layer of laminate shall be a resin-rich layer containing at least 90% resin, into which shall
be incorporated a UV absorber and light stabiliser.
All layers of laminate shall use the same approved isopthalic resin into which shall be incorporated a
light stabiliser.

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Section 12 - Miscellaneous

All laminates shall be of solid construction with void construction with void content not exceeding
3% anywhere except within polyurethane foam inserts.
All laminates shall be at least 5mm thick.
All laminates shall maintain structural continuity through staggered reinforcement overlaps of at least
25mm everywhere.
All exposed internal and external surfaces shall have a resin-rich surface layer consisting of either :
A resin gel coat between 0.75 and 1.25 mm thick applied to the mould surface prior to the main
structural layers; or
A resin flow coat between 0.25 and 0.50 mm thick applied to the free surface of the laminate.
The resin gel coat and the resin flow coat shall contain a continuous layer of surface tissue thoroughly
impregnated with resin.
Laminate properties shall be determined by carrying out mechanical tests on representative samples
using the appropriate test method in BS 2782. Minimum strength values for design process shall be
determined by statistical analysis of test results and calculation of the value which gives 95%
confidence of exceedance.
Test results and the analysis used to determine the design strength of the laminate shall be submitted
to the S.O.
i)

Lightning Protection

Covers at risk of damage by lightning shall be provided with lightning protection facilities, which
shall be designed by the Contractor in such a way that they do not impede access to or the operation
of any of the hatches or items of equipment installed on the covers. Lightning protection facilities
shall be designed and installed in accordance with the requirements of BS EN 62305-1.
The lightning protection system shall be extended to protect the ventilation ductwork, access
platforms and other structures installed and subject to possible damage from lightning.
The electrical resistance of the covers shall be greater than 20 megohms.

12.19.3 Materials
a)

General

All materials used in the fabrication of the covers, supports, fixings, fittings and as sealants shall be
compatible with each other, and shall be suitable for their proposed application. All FRP components
shall be constructed entirely from those materials listed in this section. There shall be no other
materials, such as metal or timber encapsulated within the FRP.

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Section 12 - Miscellaneous

Resins

Covers shall be manufactured using a premium grade, high molecular weight isophthalic polyester
resin in accordance with the requirements of BS 3532. No base acid other than isophthalic acid shall
be present. The proposed resin shall be approved by the S.O.
All resins shall be of the fire resistant type where covers are to be contained within outer structures.
Other covers which are open to the atmosphere shall not be of the fire resistant type. Fire resistant
resins shall achieve a flame spread rating of 25 or less to ASTM E 84, Class 1.
Properties of the liquid resin shall meet the following requirements:
Property
Specific gravity @
25oC
Acid value
Volatile content

Unit
-

Value
1.05 1.15

mgKOH/g
%

15 20
55 60

Test method
BS 2782:19762
BS 2782:1976
BS 2782:1976

Properties of unreinforced resin costings shall meet the following requirements:

Property
Specific gravity
Barcoll hardness
Deflection
temperature
(under load)
Tensile modulus
Elongation at break
c)

Unit
o
C

Value
1.2 1.3
> 45
85

MPa
%

> 3500
> 2.5

Test method
BS 2782:
BS 2782:
BS 2782:

BS 2782:
BS 2782:

Reinforcement

All reinforcement material shall be manufactured from E glass fibres except for surface tissues which
shall be manufactured from C glass fibres or spun bonded polyester.
Reinforcing material shall meet the following requirements:
Type
Chopped strand mat
Continuous strand mat
Woven roving
Unidirectional cloth
Continuous roving
Surface tissue
d)

Maximum weight
600 g/m3
600 g/m3
600 g/m3
800 g/m3
Not applicable
100 g/m3

Specification
BS EN 14118
BS EN 14118
where applicable
BS 3749
BS 3749
BS EN 14020

Additives

Other than reinforcing material, only those materials listed below may be added to the resin. In all
cases they shall be thoroughly mixed in an adequate precautions shall be taken to prevent settling out.
Material

Form

Additive

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Maximum
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Section 12 - Miscellaneous

Pigment
Accelerator

Catalyst

Thixotrope

Release
agent
UV
adsorber
Light
stabiliser
e)

Polyester
paste
Liquid

Liquid

Paste
Powder
Paste

Cobalt naphthanate
Cobalt octoate
t-butyl per 2
ethyl hexanoate
di-methyl aniline
di-ethyl aniline
Methyl ethyl ketone
peroxide )
Acetyl acetone peroxide
t-butyl peris }
enonanoate }
Benzoyl peroxide
Finely divided fumed
silica
}
Fumed silica in
Polyester

}
}
}
}
}
}
}

content
(by weight)
45%

content
(by weight)
8%

0.5% of 1%
0.5% of 1%
2%
0.5%
0.5%
3%

3%
2%

1%
}
}

4% of 50%
4%

15%

Liquid

0.2%

0.5%

Liquid

0.2%

0.5%

Other Materials

All supports for FRP covers shall be of FRP, aluminium Grade 7075-T73 or stainless steel Grade 304
of BS 970: Part 1.
All ferrous fixing bolts, nuts and washers, and all ferrous hinges, handles and latches shall be of
stainless steel Grade 316 of BS 970: Part 1.
Sealing gaskets shall be of neoprene or silicone.
Polyurethane foam may be used as a non-structural former for the construction of box sections.

12.19.4 Workmanship
a)

Premises for Fabrication of Covers

The FRP covers shall be fabricated under cover in premises dedicated to the manufacture of FRP
products. The premises shall have a hard concrete or tiled floor, shall be free of dust and shall be well
illuminated. The covers shall be manufactured under controlled environmental conditions, such as
temperature, humidity and air movement, compatible with the satisfactory productions of FRP
elements.

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Storage of Materials

All materials to be used for the fabrication of covers shall be clearly labelled with the product name,
date of manufacture, use-by date or shelf-life and instructions for use from the material supplier.
Materials shall be stored in a dedicated covered area in accordance with the material suppliers
instructions. Raw materials shall at all times be protected from rain and from direct sunlight. A
detailed record of the date, quantity and type of all deliveries of materials shall be maintained,
together with a record of when materials have been used. All delivery notes for materials shall be
retained and made available for inspection when required by the S.O.
c)

Cover Manufacture

Cover components shall be manufactured by one or more of the following processes:

contact moulding with woven or mat reinforcement;

low pressure press moulding;
resin transfer moulding;
pultrusion;
centrifugal casting.

Cover components shall not be manufactured by the spray-up process.

The cover components shall be manufactured in accordance with the requirements of BS 4994: Clause
26, 27 and 28.
The Contractors proposed laminating procedures and operators shall be approved by the S.O. in
accordance with the requirements of BS 4994: Clause 36.
The manufacture of an individual cover component by contact moulding shall be continuous to ensure
that the laminate has not fully cured before the addition of subsequent layers of laminate.
d)

Curing

After manufacture each component shall be finally cured. This shall be effected by oven curing to
either 60 oC for six hours or 80 oC for five hours. The Contractor may propose an alternative curing
regime, which may be approved by the S.O.
No component shall be removed from its mould until it has achieved a Barcoll hardness of at least 15
(at 20 oC). All components shall achieve a Barcoll hardness of at least 30 within 5 days of removal
from the mould.
e)

Storage of Covers

Once cover segments have been fully cured they shall be stored carefully prior to use to ensure that
they are not damaged. The method and location of the storage shall be approved by the S.O.
f)

Transport of Covers

Cover components shall be transported with care to ensure that they are not damaged in transit.
The Contractor shall be responsible for making whatever arrangements are necessary for the transport
of large or long cover elements.

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Cover Installation

The method of installation of the covers shall be proposed by the Contractor for the S.O.s approval.
Where cover sections or complete covers are to be lifted by crane due allowance shall be made in the
design of the covers, and the Contractor shall, if required by the S.O., submit calculations to
demonstrate that permissible stresses or strains in the covers will not be exceeded. Chain and wire
rope shall not be in direct contact with the FRP when cover sections are being lifted.
Covers shall be securely fixed to the supports generally as indicated on the drawings. The Contractor
shall carry out any necessary work to prepare the supports for the covers prior to installation of the
covers.
All tanks, channels and chambers shall be cleared of any liquid. Sludge, grit, scum or other debris and
the tank walls and floors shall be thoroughly cleaned prior to installation of the covers.
All vertical concrete surfaces shall be painted with a high build pitch/epoxy paint as specified prior to
installation of the covers.
All mechanical equipment shall be inspected repaired and repainted prior to installation of the covers.
h)

Repairs

Where cover elements contain defects which exceed those permitted by the specification or where
cover elements have been damaged during transport, storage or installation the Contractor may
propose to repair the defective or damaged section subject to the approval of the S.O. Such repairs
shall completely reinstate the full structural strength and rigidity, and the full chemical resistance of
the element. Such repairs shall only be undertaken if approved by the S.O., who may require
additional tests to confirm that defects and damage have been adequately repaired.
Repairs shall not detract from the appearance of the covers and where repairs have been permitted by
the S.O. the Contractor shall take precautions to ensure that the appearance of the repaired sections
closely matches that of the other sections of the covers. The S.O. may refuse to accept repairs on the
grounds of appearance, notwithstanding that the full structural integrity and chemical resistance of the
undamaged section of the covers has been reinstated.

12.19.5 Inspection and Testing

General

In general material records, quality control tests and quality control records shall be kept or
undertaken in accordance with the requirements of BS 4994: 1987 where these requirements are
relevant to the manufacture of tank covers.
These tests shall include the following principle stages:
i.

inspection of the workshop conditions where the Contractor proposes to undertake

the workshop;

ii.

inspection of works records relating to the control and issue of materials, resin
mixing, etc, for each cover;

iii.

identification of the materials of construction and their storage conditions;

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Section 12 - Miscellaneous

iv.

approval of laminating procedures and tests for operators and check of validating
documents;

examination of hand lay-up, winding and jointing of resin-glass laminates;

vi.

examination of any repairs carried out during construction;

vii.

verification of the cure of laminates;

viii.

examination on completion of construction as given below for factory testing and

field testing.

When additional inspections by the S.O. are deemed to be necessary because of unsatisfactory results
of the above tests, the costs of these additional inspections shall be borne by the Contractor.
Where material samples are found to have failed any of the specified tests the batch from which the
sample has been taken shall be rejected and shall not be incorporated into the permanent works.
Where cover components are found to have failed any of the specified tests they shall either be
repaired if this is permitted under the specification and subjected to further tests, or shall be rejected.
Rejected components shall not be incorporated into the permanent works. The S.O. may reject other
cover components following the failure of a cover component, or may require additional tests to
establish their acceptability.
b)

Factory Testing

Test certificates shall be provided by the Contractor showing that the Barcoll hardness of the cured
resin used in the manufacture of the covers is greater than or equal to 45.
E glass fibre chopped strand mat shall be subjected to the test requirements of BS EN 14118 Table 1.
Manufacturers test certificates for the mat proposed by the Contractor shall be forwarded to the S.O.
prior to approval of the Contractors laminate design.
Woven roving fabrics of E glass fibre shall be subjected to the test requirements of BS 3749
Appendices A, B and C. Manufacturers test certificates for the fabric proposed by the Contractor
shall be forwarded to the S.O. prior to approval of the Contractors laminate design.
Production samples for mechanical tests on laminates shall be produced and tested in accordance with
the requirements of BS 4994 Clause 37.
The following visual inspections shall be carried out by the Contractor and may be witnessed by the
S.O. The results of the inspections shall be reported to the S.O. in a standard format which has been
approved by the S.O.
i.

Crazing. There shall be no crazing of the gel coats or resin-rich layers.

ii.

Resin-dry areas. On moulded and corrosion resistant surfaces such areas may be
accepted provided they do not exceed 6mm in diameter and are subsequently made
good. Not more than 0.5% of the surface area shall be so affected.

iii.

Other surfaces. All resin-dry areas shall be repaired.

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Section 12 - Miscellaneous

iv.

Mouded and corrosion resistant surfaces. Scratches not exceeding 0.2mm deep
may be accepted without repair provided that no glass fibres are exposed. The
total extent of the scratching shall not exceed 200mm length per square metre or,
where small scratches are grouped together, the affected area shall not exceed 1%
of the surface area. No repairs are acceptable.

Other surfaces. Scratches not exceeding 0.5mm deep may be accepted without
repair provided that no glass fibres are exposed. Scratches more than 0.5mm deep
may be repaired provided that the structural integrity of the laminate is not
impaired.

vi.

Moulded and corrosion resistant surfaces. Voids not exceeding 3mm diameter and
0.5mm deep may be repaired provided that the voids do not occur in discrete
clusters and the sum of the areas of clusters does not exceed 0.5% of the total
moulded area.

vii.

Other surfaces. Voids may be repaired provided that they do not exceed 1.5mm
deep and no more than 3% of the surface area is affected.

viii.

There shall be no apparent cracking of either the moulded and corrosion resistant
surfaces or other surfaces. There shall be no star cracking.

ix.

There shall be no fibres protruding from the surface of the laminates. Wrinkles and
undulations shall be gradual and the surface shall be continuous at such locations.
Such defects shall not appear extensively on a single moulding nor shall they be
repeated throughout a production run.

There shall be no visible extraneous inclusions other than permitted fillers or

aggregates.

xi.

There shall be no visible delamination.

xii.

All surfaces shall have a consistent colour throughout.

xiii.

All drilled and cut edges shall be smooth, even and substantially free from chips,
burrs, sharp corners or exposed fibre strands.

Where repairs are permitted they shall be undertaken using a method which has been approved by the
S.O.
The electrical resistance of the covers shall be tested as follows:
-

cover parallel to the plane of the sheet;

cover normal to the plane of the sheet.

All tests shall be carried out and witnessed by the S.O.

Field Tests

The following tests shall be undertaken on a sample segment of each design of cover;
i.

a soft body impact due to a 50 kg sandbag dropped form a height of 2 metres;

ii.

a hard body impact due to a 1 kg steel ball dropped from a height of 1 metre.

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Section 12 - Miscellaneous

The sample segments shall be selected by the S.O.

The above two tests shall be carried out at intervals of 1 metre along the axis of the greatest span of
each sample.
Failure of the laminate shall be determined by observing star-crazing (if any) on the reverse side or
front face of the laminate and determining the depth of penetration of such a crack. In respect of the
sample laminates, dye shall be impregnated into the cracks and a section shall be cut through the
laminate at the point of fracture to determine the depth of adsorption. Failure under these dynamic
impact tests shall, unless otherwise agreed, be construed if the depth of cracking at the impact points
exceed 25% of the total laminate thickness.
Where failure of the samples has been observed the Contractor shall resubmit the laminate design to
the S.O. and subject it to test again. Where failure of the structural segments has been observed the
Contractor shall rectify the situation by either replacement or an approved repair and subject the
segments to test again.
When required by the S.O. a trial erection of the cover components shall be undertaken to
demonstrate that the cover components fit together accurately without the use of force to align
components. Installation of the covers shall not proceed unless a trial erection has been completed
successfully where one is required by the S.O.
The following visual tests as required for factory testing shall be carried out on site prior to and after
installation of each cover in accordance with the relevant standards:
i)

crazing;

ii)

scratches;

iii)

cracking;

iv)

delamination

drilled and cut edges.

An air-tightness test shall be carried out on completion of the installation of each cover. The air inlets
to the space beneath the cover shall be closed off and a small compressor shall be operated in a
controlled manner to establish a pressure differential across the cover. The cover shall be deemed to
be adequately air-tight if the design operating pressure differential of 0.15 kN/m3 produces an air flow
rate into the covers of less than 10% of the design operating ventilation rate.
A similar test shall be undertaken to determine the adequacy of the structural design of the covers.
Deflections of the covers shall be measured with a pressure differential across the covers of 1.25
kN/m3 and shall be compared with calculated values of deflection used in the design. The covers shall
be deemed to be acceptable if the anticipated deflection is not exceeded during the test. The
Contractor may propose an alternative equivalent method of demonstrating the structural adequacy of
the covers.
The air-tightness test and the structural adequacy test shall generally be undertaken in accordance
with the requirements of BS 4994 Clauses 39.5 and 39.6 using the test pressure given above.

Typical Civil and Structural Engineering Specification for Sewerage Works

Issue 01 / Rev 0
August 2008

12-26

Section 12 - Miscellaneous

Throughout the air-tightness test, and the structural adequacy test, care shall be taken to ensure that
the internal pressure beneath the covers is reduced in a controlled and measured manner and at no
time shall the total maximum loading exceed 1.25 kN/m3. The Contractors proposed procedures for
undertaking these tests shall be submitted in advance to the S.O. The tests shall be carried out in strict
accordance with these procedures once they have been approved. The results of these test shall be
recorded and reported to the S.O. The format of these records and report shall be agreed in advance as
part of the Contractors proposed procedures.

12.19.6 Water Supply System

General

The Contractor shall design the water supply system for the supply of water to the sewage treatment
works for the operation and maintenance of the sewage treatment plant and for the potable and
domestic water supplies which are required for the treatment works including the administration
building and other buildings as specified.
The water supply system shall consist of a high-pressure water supply system and service water
system. The system to be provided shall include filling of chemical preparation tanks, chemical
dosing, high pressure water supply for fire-fighting, motive water supply for chlorination, water for
hosing down tanks, water for odour removal system, water for flushing and cleaning of sludge
pipework, potable water for all water tanks, pump station, lawn water tap and for the laboratory. The
water supply system as envisaged shall be referred to the drawings.
b)

High Pressure Water Supply System

At the branch connection on the treated water delivery main, pipework including a flow meter, a
pressure-reducing valve with a downstream pressure relief valve and pressure gauge shall be installed,
to provide a high-pressure water supply at a controlled pressure.
The high-pressure water supply main shall be laid from pipework to form a ring main around the
treatment works. Interconnections shall be provided along the main to supply high-pressure water to
the various sections of the Works. Branches shall be provided along the main loop to points at the
structures within the sewage treatment works as shown the drawings.
Each branch from the high pressure water supply main shall have an isolating valve and suitable
pressure reducing valve. Branches with isolating valves shall be provided for the supplies for
fire-fighting within buildings and with suitable pressure reducing valves for the domestic water
supplies at the administration building, chemical building, inlet pumping station and other buildings
that require water. Branches shall be provided elsewhere where a supply of high pressure water is
required. Hydrants shall be installed along the route of the high pressure main; the hydrant locations,
capacities and outlets shall conform to the requirements of Jabatan Bomba.
c)

Design Criteria

The operating pressure in the high pressure water supply system shall not be less than 60m head at
any point in the system. Particular attention shall be paid to the end points in the high pressure system
to ensure that the operating head is not less than 60m head. The C-value to be adopted for the design
shall not be more than 100.
The high pressure system pipework shall be laid and tested to 100m head. The diameter of the main
pipe to the ring main shall not be less than 200mm dia. The Sub-Contractor shall design and upgrade
the pipe sizes as required for proper and efficient operation at no additional cost to the Contract.

Typical Civil and Structural Engineering Specification for Sewerage Works

Issue 01 / Rev 0
August 2008

12-27

Section 12 - Miscellaneous

Pipe diameters for outside firefighting system shall not be less than 100mm. The maximum spacing
between fire hydrants and the distance to nearest buildings or structures shall comply with the
requirements of Jabatan Bomba. The quantity of water to be available from three fire hydrants shall be
3m3/min at not less than 40m head; this shall be in addition to the quantity of water required for the
high pressure injector motive water supplies.
Pipe diameters of the main service water supply system from the service water tank shall be amply
sized to permit maximum flows under service conditions, and shall not be less than 100mm diameter
for supplies to the chemical building areas and not less than 25mm diameter for service water supplies
to the chlorine building. The diameter of the branch pipes to the administration building control
buildings shall be not less than 50mm dia.
d)

Pipework

All pipes shall be laid underground generally with 1 m minimum cover. Valves and air valves shall be
provided in drained chambers where required. Any vulnerable pipework shall be suitably protected.
Valved washout branches with effluent drain systems shall be provided at low points in the main
system to permit sections to be emptied.

Typical Civil and Structural Engineering Specification for Sewerage Works

Issue 01 / Rev 0
August 2008

12-28

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