R07 HC3D02 MML SPC Ci 0001

Red Sea Shura Program 7
Hotel Central #3
Civil & Infrastructure Specification
19 September 2022
Mott MacDonald
Unit No 101, 1st floor
Nomura Building
Hiranandani Gardens
Powai
Mumbai
400 076
Maharashtra
India
T +91 22 4908 0100

mottmac.com
Red Sea Shura Program 7

Hotel Central #3
19 September 2022
Mott MacDonald Private Limited.

Registered office: 101, Nomura,
Hiranandani Gardens, Powai, Mumbai 400
076, Maharashtra, India. CIN
U74210MH1970PTC014650
Mott MacDonald | Red Sea Shura Program 7 Hotel Central #3
Issue and Revision Record
Revision Date Originator Checker Approver Description

01 18 Jun 2021 FS FD BS WIP 50% Design Development
02 30 July 2021 FS FD BS 100% Design Development
03 30 Sep 2021 FS FD BS 100% Design Development
Resubmission
04 25 Feb 2022 FS FD BS Updated 100% Design Development
05 19 Sep 2022 FS FD BS Revised 100% Design Development
Document reference: R07-HC3D02-MML-SPC-CI-0001 | | 05
Information class: Standard
This document is issued for the party which commissioned it and for specific purposes connected with the above-
captioned project only. It should not be relied upon by any other party or used for any other purpose.
We accept no responsibility for the consequences of this document being relied upon by any other party, or being
used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied
to us by other parties.
This document contains confidential information and proprietary intellectual property. It should not be shown to other
parties without consent from us and from the party which commissioned it.
R07-HC3D02-MML-SPC-CI-0001 | | 05 | | 19 SEP 2022

Civil & Infrastructure Specifications Divisions
DIVISION TITLE
02 800 Irrigation System
Sewage Network
Storm Water Technical Specifications
Water Network
Telecom ICT Security ELV Ducting Technical

Specifications
Infrastructure Electrical (MV&LV) Technical
Specifications
R07-HC3D02-MML-SPC-CI-0001 | | 05 | | 19 Sep 2022

TABLE OF CONTENTS
SECTION 02800 – IRRIGATION SYSTEMS 3
PART 1 GENERAL 3
1.1 SCOPE 3
1.2 RELATED DOCUMENTS 3
1.3 STANDARDS 3
1.4 DEFINITIONS 4
1.5 QUALITY CONTROL 4
1.6 SUBMITTALS 5
1.7 DELIVERY, STORAGE, AND HANDLING 9
1.8 WARRANTY 9
1.9 COMPLIANCES 9
PART 2 PRODUCTS 9
2.1 GENERAL 9
2.2 PIPES AND FITTINGS 9
2.3 PVC-U CEMENT PRIMER LUBRICANT AND TAPE 11
2.4 UNDERGROUND WARNING TAPE 12
2.5 THRUST BLOCKS 12
2.6 VALVES AND ACCESSORIES 12
2.7 VALVE CHAMBERS AND VALVE BOXES 15
2.8 BUBBLER 16
2.9 EMITTERS 17
2.10 SPRINKLERS 18
2.11 FILTERS 22
2.12 CENTRAL IRRIGATION CONTROL SYSTEM 24
PART 3 EXECUTION 26
3.1 DESIGN CRITERIA 26
3.2 INSTALLATION PROCEDURE 27
3.3 EXCAVATION 28
3.4 BACKFILLING 28
3.5 PVC PIPE INSTALLATIONS 29
3.6 HDPE PIPE INSTALLATION 31
3.7 ANCHOR AND THRUST BLOCKS 33
3.8 VALVES 34
3.9 VALVE BOXES AND CHAMBERS 34
Red Sea Shura Program 7 Hotel Central #3 TABLE OF CONTENTS Page 1

19-Sep-2022
3.10 END FLUSHING POINTS 34
3.11 IRRIGATION EQUIPMENT 34
3.12 ELECTRICAL INSTALLATIONS 34
3.13 CENTRAL CONTROL SYSTEM 37
3.14 FIELD CONTROLLERS INSTALLATIONS 37
3.15 FIELD TESTING 37
3.16 AUTOMATIC SYSTEM COMMISSIONING 39
3.17 IRRIGATION AND CONTROL SYSTEM 39
PART 4 ESTABLISHMENT OPERATIONS AND MAINTENANCE (365 DAYS) 39

4.1 GENERAL 39
4.2 ORGANIZATIONAL STRUCTURE 40
4.3 SYSTEM MONITORING 40
4.4 SYSTEM FLUSHING 41
4.5 SERVICING OF ELECTRIC REMOTE CONTROL SOLENOID VALVES AND
COMPONENTS 41
4.6 ADJUSTMENTS AND CLEANING 41
4.7 EMERGENCY REPAIRS 42

19-Sep-2022
SECTION 02800 – IRRIGATION SYSTEMS
PART 1 GENERAL
1.1 SCOPE
A. This section includes the preparation and installation of automatic irrigation system for
TRSDC including piping, sprinkler heads, emitters, bubblers, valves, controls, control
wiring, fittings and necessary accessories in all respects and in accordance with
the project documentation.
B. This also, includes maintenance for a period of 365 days from the certified substantial
completion date.
1.2 RELATED DOCUMENTS
A. The following sections of the specification shall be read in conjunction with other sections
of the projects.
1.3 STANDARDS
The British Standard (BS) and other International Standards (ISO) and codes of practice
referred to in this specification are listed below and reference shall made to the latest
editions of these, together with all current amendments and additions thereto current at the
time of tender.
Whenever, in respect of any British, a scheme of supervision and control is in operation, all
materials required to comply with that standard shall be marked with BSI certification
trade mark (The Kite mark). Where materials are required to comply with other British
Standards, the contractor shall submit to the Engineer test certificates, furnished by the
supplier or manufacturer of the materials, indicating compliance with the relevant British
Standards.
BS 21 1985 Pipe threads for tubes and fittings where pressure-tight joints are
made on the thread.
BS 543 1966 steel pipes, fittings and specials for water, gas and sewage.
BS 729 Hot dip galvanize
BS 1387 Screwed and socketed steel tubes and tubulars and for plain end steel
tube suitable for welding or for screwing to BS 21 pipe threads.
BS 1452 Grey Iron castings.
BS 1972 Polythene pipe for (Type 32) for above ground use for cold-
water services.
BS 2494 Materials for electrometric joint rings for pipe work and Pipelines.
BS 3416 1975 Black Bitumen coating solutions for cold water applications.
BS 3505 Unplasticised polyvinyl chloride (uPVC) pressure pipe for potable water.
BS 3900 Method of test for paints.
BS 4027 1980 Sulphate resisting Portland cement.
BS 4346 Joints and fittings for use with unplasticised PVC pressure pipes.
Red Sea Shura Program 7 Hotel Central #3 02 800 Page 3

Irrigation Systems 19-Feb-2022
BS 4504 Flanges and bolting for pipes, valves and fittings. Metric series
BS 5152 1974 Cast iron globe and globe stop and check valves for general
purpose.
BS 5153 1974 Cast iron check valves for general purposes.
BS 5155 Butterfly valves.
BS 5163 Cast iron gate valves for waterworks.
BS 5750 Quality systems.
BS 8010 1987 Code of practice for pipelines.
DIN 8061 General quality and testing of PVC-u pipes.
DIN 8062 Dimensions of PVC-u pipes.
ISO 161/1 PVC-u pressure pipe for potable water.
ISO 4427 Polyethylene (PE) pipes for water supply.
ISO 9000 Quality management systems.
1.4 DEFINITIONS
Refer to the definitions in the General Conditions of Contract for Civil Works Contracts.
The definitions apply to this general Specification for Landscape Irrigation Works.
1.5 QUALITY CONTROL
A. Prior to dispatch of any product and/or material from source the Contractor shall notify the
Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect and
test the product and/or material prior to delivery in accordance with relevant sections of
the (GSCW) specification.
B. Products and materials shall be from a manufacturer/supplier who operates a quality

system that is registered to ISO 9000 series or approved equal.
C. To allow the Engineer to inspect the Works the Contractor shall give the Engineer
a minimum of 24 hours notice of carrying out the activities on site.
D. Hold & Witness points:
Do not proceed to complete further works until the following has been inspected and
approved in writing by the Engineers Senior Inspector or approved representative:
1. Submission of works construction program.

2. Monthly progress reports.
3. Approval of all samples and materials
4. Marking out of pipe line route and valve location
5. Trenching and sand bedding.
6. Flushing the main line.
7. Pipe pressure testing.
8. Leak testing of laterals.

9. Flushing the entire section.
10. Installation of electric remote control solenoid valves.
11. Installation of dripper lines.
12. Installation of application devices.
13. Installation of controller.
14. Any soft landscape approvals (See section 02900 & 2950).
15. Detailed Maintenance Manual.
16. As Built drawings prior to PAC
Maintenance work:
1. Endorsed or modified maintenance manuals.

2. Endorsed ‘As Built’ drawings from Construction Contractor.
3. Monthly maintenance schedules.
4. Monthly maintenance records sheets.
5. Weekly maintenance schedules.
6. Weekly maintenance records sheets.
The contractor shall notify the Engineer 48 hours prior to the inspection of the above. Such
notification shall be given by a written inspection request (in a format acceptable to the
Engineer) each and every time various areas of the work are to be carried out or covered
up so as to prevent subsequent inspection.
These activities shall be identified as hold points in the Contractor’s program and inspection
and test plans.
1. If the Contractor does not notify the Engineer in sufficient time to allow for his inspection
prior to covering up or complete installations governed by a hold point, the Contractor shall
remove all such materials / equipment as deemed necessary by the Engineer to verify
compliance of the work.
2. Any delays, additional work or additional costs attributed to the above shall be at the
Contractor’s expense.
1.6 SUBMITTALS
A. The Contractor shall submit to the Engineer the following documentation for review and
approval before commencing work:
1. Existing Irrigation System.

The contractor shall locate and identify the existing irrigation system, electrical control
and monitoring network, pumping stations and reservoirs within and feeding the
project area and shall submit them as ‘Existing Drawings’ for Engineer’s approval in
a suitable scale agreed with the Engineer. These drawings need only to include
down to the solenoid valves. The distribution lines and applicators beyond this are less
important.
The contractor shall then propose the suitable take off points for new irrigation system if
not nominated or shown in the design drawing and the Engineer shall decide as to which
pipe etc. are to be retained, relocated, removed or abandoned.
2. Irrigation Demand

After obtaining the final approved soft landscaping shop drawing and plant list, the
contractor shall re-compute the water requirement for each irrigation circuit valve and
submit to Engineer for approval.
Using updated data gathered the contractor’s irrigation engineer shall prepare water
application schedule co-ordinated with the pump station available irrigation water,
field satellite number, irrigation valve circuit number, cubic meter per hour discharge
per circuit valve, number of hour/minute operation per circuit valve, and proposed time
of operation for each valves. The contractor shall submit the schedules to the Engineer
for approval.
3. Shop Drawings and Verification of Dimensions
The contractor shall carefully check and verify all dimensions on the contract drawings
and shall report all variations to the Engineer. Both Imperial units and Metric units are
used as appropriate, with strong preference for metric.
All shop drawings shall be submitted for approval with supporting calculations prior to
starting the work on site.
Shop drawings shall be prepared to detail any installation not completely detailed in
the contract drawings, or to detail any alterations to the contract drawings and shall
include, but not be limited to:
a) Civil works, mechanical pipe work and electrical control equipment with circuit
diagrams.
b) Details of mainline, lateral pipes and other typical connections.
c) Details of typical connections.
d) Wiring diagrams including conduits, pull boxes, sizing and calculations to verify that
cable sizing is in accordance with valve manufacturer’s printed recommendations
wherever applicable.
e) Electrical power and control wiring diagram system for irrigation controller, field
wiring and grounding.
f) Details for drip line layout in shrub and ground cover beds and showing
interface with planting layout.
The contractor shall remain responsible for maintaining the existing irrigation system in
the contract areas and for any existing plantations until the new automatic system
will be operational.
The approval of shop drawings shall not relieve the Contractor of any of his responsibility
under the contract for a successful and timely completion of the work.
4. Materials and Equipment Schedules
Provide all catalogue cuts, diagrams, drawings, and such other data as may be required to
demonstrate compliance with the specifications.
All materials shall be as described in the specifications. The contractor shall submit
material approvals for all the materials, which are proposed to be used in the system,
sufficiently in advance, to the engineer, prior to their installation. Any material used, which
is not approved, shall be removed from the site and the contractor shall replace them at
his own cost.
5. Installations and Testing.
The contractor shall submit his proposed work method statement for approval prior to
commencing work. The statement shall detail proposed sequence of work, hold points,
testing frequency and document control.

6. Manufacturer’s Certification
a) PVC -u pipe
Certification by a recognized certification mark scheme such as “The

Kitemark”, or by an independent third party testing organisation approved by the
Engineer, that production has been carried out under a system of
supervision, control and testing applied during manufacture in accordance with
BS 5750 / ISO specification or an approved equal procedure.
b) Valves and Special Steel Fittings

Manufacturer's certificate for pressure testing and coating, including holiday
and dry film thickness (DFT) test reports for each valve, fitting, spool, if
applicable.
c) Emitters
Certification of coefficient of Manufacturer’s variation
B. The Contractor shall submit to the Engineer the following documentation for review and
approval before substantial completion handing over.
1. Recommendation of the Manufacturer
The Contractor shall submit manufacturers’ recommendation for each material or

procedure, including recommended spare parts to be utilised, and all relevant
operational data. The Contractor shall have a copy of the manufacturers’
instructions available on-site at all times while work is in progress, and shall follow
these instructions unless otherwise authorise to deviate by the Engineer.
2. Spare Parts
The Contractor shall submit manufacturer’s listing of spare parts for approval prior to
commissioning any piece of equipment. Recommendations shall include stocking
recommendations; exploded assembly diagrams illustrating location and spare parts to be
utilised and all relevant operational data.
3. Manufacturers’ Literature
At such time as the Engineer has approved the list of materials, the Contractor shall
provide four (4) sets of manufacturer’s technical and maintenance literature to the
Engineer. Data sheets shall provide sufficient technical information to identify each
product and shall include the name and the address of the nearest supplier and details
of the local representative. Preformatted Technical Data Sheets for all approved
irrigation items are maintained by the TRSDC and maybe submitted for this purpose.
4. As Built Drawings
The contractor shall maintain one set of “As Built” drawings. All approved changes
and all completed and approved work shall be recorded on these drawings. The
contractor shall maintain these drawings on a daily basis. At Substantial Completion
the contractor shall submit to the Engineer the complete “As Built” set of drawings
for approval and the final approved set shall be submitted within 14 days of Handover.
Once the drawings have been approved the contractor shall prepare and submit 3
nos sets of fully book bound drawings and 1nos. soft PDF copy on CD with scanned
literature as necessary at final completion handing over.
5. Operation and Maintenance Manuals

a) The contractor shall submit to the Engineer two sets of the draft ‘365-days
Establishment Maintenance Manuals’ for approval 14-days prior to substantial
completion.
b) The contractor shall submit to the Engineer for approval two sets of draft ‘Ongoing

Maintenance Manual’ 14-days before final handing over. The Manual shall
have 4 parts:
Part. 1. - Pumping Station and Reservoir Ongoing Maintenance.
Part. 2. - Soft Landscape Ongoing Maintenance.
Part. 3. - Irrigation System Ongoing Operation and Maintenance.
Part. 4. - Hard Landscape Ongoing Maintenance
Note: This may vary depending on the project scope of works
The contractor shall submit to the Engineer two sets of the draft Operation and
Maintenance Manual for approval at Substantial Completion Handing Over. The final
content of the manual shall be agreed with the Engineer but shall include the following:
a) Design basis of irrigation system.

b) A3 copies of As Built drawings.
c) Logic of operation of the systems.
d) Description of equipment:
 Function, normal operating characteristics, and limiting conditions
 Performance curves, data sheets, test reports, relevant catalogues and
warranties
 Complete nomenclature, illustrations, assembly drawings, diagrams required for
maintenance and commercial number of replaceable parts.
e) Operating Procedures:
 Start-up, break-in, routine and normal operating instructions
 Regulation, control, stopping, shut down and emergency instructions
 Summer and winter operating instructions
 Special operating instructions
f) Maintenance Procedures:
 Routine operations
 Guide to trouble shooting

 Disassembly repairs and reassembles
 Alignment, adjusting and checking
g) Valve charts and Irrigation valve operation schedule complete with controller station
No., size, flows sequence of operation and operating time
h) Spare parts.
 List of recommended spare parts
 Names, contact numbers and addresses of spare part suppliers.
i) Bill of Quantities of Material used in the contract.
Depending on the project scope of works this manual should be incorporated with
Landscape soft works and other Landscape hard works maintenance as one complete
volume.
Once approved the Contractor shall prepare and submit three (3) sets of fully book bound
manuals with original manufacturer’s technical catalogues, literature etc and 1nos.

soft PDF copy on CD with scanned literature as necessary at final completion
handing over.
Note: Allow 14-days for Engineer's review of drawings and manuals.
1.7 DELIVERY, STORAGE, AND HANDLING

Delivery, storage and handling of products and materials shall be in accordance with the
manufacturer's recommendations, Section of the (GSCW) specification and the following
provisions.
1. Delivery, storage and handling shall at all times be performed in a manner to avoid
product damage.
2. Only nylon slings shall be allowed for lifting products.
3. Products shall be stored off the ground on timber blocks of sufficient size and spacing to
provide adequate support.
4. Products shall be stored at site in a temperature, humidity etc. environment as
recommended by the manufacturer.
5. Products that are stored outside at site shall be stored under cover to prevent ultra violet
deterioration and as recommended by the manufacturer.
6. The Contractor shall inspect all products upon delivery to site and report any damage to
the Engineer.
7. Any products damaged during delivery, storage and handling shall be marked by the
Contractor and set aside.
8. Proposals for repair of any damaged products shall be submitted in writing to the
Engineer for approval.
9. Any damaged products deemed unsuitable for repair by the Engineer shall be removed
from site and replaced.
1.8 WARRANTY
All work included under this section shall be warranted by the Contractor against all
defects and malfunction of materials and workmanship for a period of one year from the
date of final acceptance of the irrigation system. Should problems arise with the system
during the warranty period the Contractor shall make all necessary repairs and / or
replacements in an expedient manner at no additional cost to the Client.
1.9 COMPLIANCES
Comply with safety standards and governing regulations for cleaning operations. Do
not burn waste materials at site, or bury debris or excess materials on site, or
discharge volatile or other harmful dangerous materials into irrigation or drainage
systems; remove waste materials from site on a day-to-day basis and dispose of in a
lawful manner.
PART 2 PRODUCTS
2.1 GENERAL
All equipments, fittings and accessories shall be suitably rated to comply with the system
design and operating parameters.
2.2 PIPES AND FITTINGS
A. High Density Polyethylene (HDPE) Pipes And Fittings

HDPE pipes shall conform to ISO 4427, pipe grade PE 100 with SDR 17 and rated for PN
10. The normal outside diameter (ND) shall be in accordance to ISOR 161-1.
Characteristics of Resins for Polyethylene Pipes Resin Type - PE100

Melt Flow Rate (g/minute) MFI at 190OC and 5 Kg 0.16 to 0.7
Melt Flow Rate (g/minute) MFI at 190OC and 2.16 Kg < 0.2
Oxidation Induction Time (minutes) OIT in pure oxygen at 200 OC >15
Basic Resin Density (Kg/m3) for compression moulded plaques > 941
Position of Knee in the 80 OC stress rupture curve – black resins > 10,000 hours
50 year strength at the 97.5% Lower Confidence Limit (LCL) MPa >10
Elongation at break - precent >600
Environmental Stress Crack Resistance ESCR - hours >1,000
Percentage of recycled polymer Not Allowed
All jointing shall be fully automatic butt fusion welding with stub flanges drilled to
PN 16 and special restraint transition fittings at PE to metal connections. The
system shall be restrained completely and no thrust blocks are required, except at
locations where HDPE pipes are connected to unrestrained pipe systems.
Fittings and bends shall be fabricated from PE 100 polymer of compatible material to that
of the pipe.
At special locations, but only after approval of the engineer, electro fusion joining will be
allowed.
B. PVC-u Pipes And Fittings.
PVC-u pipe shall conform to ISO 161/1 and shall be class 16/class10 (as per BOQ). Pipes
up to 90 mm nominal diameter shall have solvent welded joints and pipes of 110 mm and
above diameter shall have rubber ring sealing. Rubber sealing pieces shall be fabricated
from EPDM ( Ethylene Propylene Diene Monomer) or an approved equal material, and
shall conform to BS 2494 1976 part 1.
Base PVC-u used for the manufacture of pipes shall be virgin material, purchased
from an internationally recognised manufacturer. Additives stabilisers and agents
used to aid the manufacturing process shall not comprise more than 3.5% of the
pipe material, by weight. Pipes shall be legibly and indelibly marked with the
manufacturing standard, the manufacturer’s name, date of manufacture, nominal bore,
and working pressure/class. Pipe shall be smooth from inside and outside and shall show
no evidence of blisters, grooves or other extrusion marks. The contractor shall
provide three samples of all size pipes of one metre in length for approval prior to
installation of any plastic pipe.
All PVC-u fittings shall be ISO/DIN specification and have a minimum rating of 16 kg/cm²
at 20 degree C. Fittings shall be suitable for use with the above specified pipes. Where
PVC-u flanges are required these shall be drilled to NP16 as detailed in BS 7622 and BS
7772. All fittings above 160 mm shall be fusion bonded epoxy coated ductile iron or cast
iron or flanged GRP. The contractor shall use only fittings that are approved by the
Engineer. All nuts and bolts shall be stainless steel 316 grade.
C. Linear Density Polyethylene (LDPE) Pipe And Fittings.
Polyethylene pipe shall be manufactured from linear

low-density polyethylene incorporating a minimum of 2.8% carbon black, properly
dispersed and antioxidants in an amount not exceeding 0.5%. Working pressure
shall be minimum 4kg/cm² or more.

A random sample of drip pipes shall be subjected to the Teepol crack resistance
test. The sample shall be immersed in a bath containing a solution of 10% Teepol
and 90% water maintained at 50 degree C. The pipe should resist the solution without
showing any fatigue or crack for a period of 150 hours.
Polyethylene pipes shall be legibly and durably marked with letters of minimum
height 3mm. The marking shall be reproduced at intervals of not more than 1m. The
following information shall be marked on the pipe.
a) The manufacturer’s name or registered trademark.

b) The type number and designation ‘PE’ in the form “TYPE 30PE” as appropriate.
c) The class of pipe in the form ‘CLASS IRRIG’.
d) The nominal inside diameter and wall thickness.
e) Identification of place of manufacture. The manufacture’s code is acceptable.
Polyethylene pipes shall be fixed intact to the ground using heat resistant stakes at
every 10 mtrs and an automatic end flush valve shall be installed at the end of the line.
Drip stakes shall be provided at each point of change in direction of drip line.
All fittings for drip lines shall be compression type.
The pipe for sprayers and quick coupling valve connections shall be as per BS 1972-67
class C.
The fittings for the above pipes should be compression quick joint type with minimum 12
bar nominal pressure rating.
D. Steel Pipes and Fittings.
Steel pipes shall be used for all above ground installations and for some selected
underground installations. Pipes shall conform to API-5L (American Petroleum Institute)
schedule 80 or other equal and approved. Welded fittings shall be schedule 80 and
weld neck. Flanges shall be in accordance with BS 4504 PN16.
All bolts, nuts and washers used for flange assemblies, or integral with bolted
couplers shall be of stainless steel A4-70.
Pipes shall be coated by electrostatic fusion bonded epoxy to average DFT 150 microns
or by fusion bonded plastic powder coating to average DFT 500 microns. Pipes and
fittings shall be degreased, blast cleaned to a minimum standard of BS 4232 second
quality (SA 2 ½).
Threaded steel pipe and fittings used for risers less than or equal to 2” shall be in
accordance with BS 1387 designated medium thickness and galvanized in
accordance with BS 729. Any galvanized steel pipe installed in contact with the soil shall
be wrapped with at least two layers of an approved pipe wrapping tape. The wrapping
tape shall extend a minimum of 100mm above soil.
2.3 PVC-U CEMENT PRIMER LUBRICANT AND TAPE
PVC-u cement and thinner shall be of the type approved by the Engineer. The solvent
cement shall have a minimum working pressure of 16 bar and a tensile strength of 112
bar after 72 hours. The cement shall have heavy viscosity, medium cure speed,
and clear color and be suitable for pipe diameters up to 315mm. The cement will
conform to ASTM-D-2564-91 and be NSF/UPC approved.
The primer shall be certified to contain a minimum of 25% THF and must meet ASTM
F656.

The pipe lubricant will be specially formulated to work with rubber ring joints and will be
NSF approved.
All cans of solvent cement primer and lubricant shall have labels intact and shall be
stamped with the date of manufacture and shelf life. No cans with an expired shelf life will
be permitted.
Joints compound for threaded connection shall be PTFE tape or an approved equal
thread sealant.
2.4 UNDERGROUND WARNING TAPE
Marking tape shall be laminated polyethylene and aluminium foil construction capable of
detection by low output generator equipment. Tapes shall remain legible and colour fast in
soil conditions at pH values of 2.5 to 11.0 inclusive. The tapes shall be of the type
specially manufactured for making and locating underground utilities.
The tape shall be not less than 150mm wide and shall have the phrase “CAUTION
– IRRIGATION PIPELINE AND CONTROL CABLES”
In English and Arabic stamped in black letters and repeated at maximum intervals
of two meters. Tape shall be terminated inside valve boxes to allow clipping of detector
equipment to the tape. The tape shall be laid 300mm above pipeline.
2.5 THRUST BLOCKS
Thrust blocks shall be provided to anchor all mechanically jointed pipes. Heavy-duty
polyethylene sheet shall be used to wrap the pipe at the point off contact between pipeline
fittings and thrust block. Concrete shall be Grade Class B in accordance with the concrete
specifications.
Where manifolds and laterals pass under roads or paved areas and through foundations
and walls shall be in ducts.
2.6 VALVES AND ACCESSORIES
A. Isolation Gate Valves.
All isolation gate valve sized 4 inches and above shall be ductile iron (to BS 2789) and
conform to the following features:
1. Construction of valve to BS5163 with flange end connection to PN16 as defined in

BS7772.
2. Internal non-rising stem with clockwise closing rotation.
3. Valve opening and closing shall be with key and not with hand wheel.
4. Stainless steel spindle and resilient seal wedge.
5. Valve body test pressure (open gate) of 2700 kN/sq.meter.
6. Valve seat test pressure of 1600 kN/sq.meter at 60 degree C.
7. Internal and external fusion bonded epoxy finish, minimum thickness 300 micron.
8. Stem cap to main body bolts to be recessed with silicon sealing.
9. Wedge shall be stainless steel with EPDM coating.
10. Sluice gate valves of diameters up to 3” shall be to BS 5157 series B1 class PN20 suitable
for q working pressure of 9 kg/cm² or above. The valves shall have BSP thread inlet and

outlet connections. The body shall be forged brass, cast brass or bronze.
B. Quick Coupling Valve And Fittings.
The valves shall provide plug-in type, underground water outlets for the temporary
connection of hosepipes. Connection and operation shall be by means of special
coupler keys inserted into the valve throat. The valves and key are to be of the same
manufacturer to ensure compatibility of the connection. Valve construction shall be red
brass or bronze with a self-closing protective cover. The valve shall be a single piece
design with single slot and stainless steel spring. The valve should have locking
mechanism to vandal resistance. The valve shall have a maximum of 0.5 bar pressure
loss at the rate of 3.2 lps.
The internal part shall be removable for service. The keys shall be brass with machined
shanks for a positive seal. Valves shall have 25 mm female pipe threaded connection and
keys shall have 25 mm male connection. The valve and key shall be 25 mm bore with no
size reduction.
Swivel hose ELLs shall be of red brass or bronze construction used to connect to
quick coupler keys so that hose can be turned a full 360 degree without breaking hose
near the coupler key. The hose ELLS shall have a female pipe thread of 25 mm and
a male thread of 25 mm.
C. Electric Remote Control Solenoid Valve Complete With Pressure Regulating Module.
The valve body and bonnet shall be constructed of heavy duty glass reinforced
nylon body and internal parts shall be stainless steel diaphragm made of nylon
reinforced nitril rubber and provide for a positive seal between bonnet and body. Solenoid
coils shall be encapsulated in moulded epoxy
Valves shall be normally closed diaphragm type with slow opening and closing
action for protection against surge pressure. Actuation shall be by encapsulated type
solenoids rated at 24 volts, 50 cycles, and 2.0 watts unless otherwise specified. Maximum
pressure rating shall be not less than 200-PSI BSP inlet/outlet, solenoid plunger shall
in co-operate with self-flushing type stainless or internal filter.
There shall be provision for manual open/close and flow control stem with cross
handle for regulating the flow. All valves shall be provided with a pressure
regulator to regulate the pressure between 1 to 5 bar (within an accuracy of ± 0.35
bar regardless of upstream pressure). It shall provide full and accurate pressure
capabilities irrespective of whether it is operated electrically or manually. The
pressure measurement shall be possible via Schrader valve or integral pressure
gauge. The pressure regulator shall be with a calibrated dial for setting the outlet
pressure.
The valve shall be capable for pressure regulating electrical and manual mode
operation using external and internal bleeds. Valve shall be suited for dirty or treated
sewage effluent water.
The valves shall be inline or angle configuration as per the requirements. The valve
construction shall be such as to provide for all internal parts to be removable from
the top of the valve without disturbing the valve installation.
Only moulded PVC-u/Brass fittings shall be used with solenoid valve assemblies.
1. Electrical wire for Solenoid Valves.

All electrical wire for underground use shall be single core solid “underground feeder” type
insulated with a flame retardant thermoplastic compound, rated for 600 volts and direct
burial. The cables shall be suitable for installation in the ground flooded with Treated
Sewage Effluent (TSE) water having corrosive chemicals. Each solenoid valve shall be

connected by a separate control cable from the irrigation Controller Unit (ICU) and a
common cable shall be run connecting all the solenoids for return connection.
The insulation material shall be of low density and high molecular weight. Insulation
shall be suitable for maximum conductor temperature of 60 degree Celsius. Minimum
insulation thickness shall not be less than 1.2 mm.
The cables manufacturer’s name or code, insulation type, gauge of wire and voltage
should be marked at intervals of not more than 1m.
The contractor shall indicate valve number on each cable at both ends as well as at
splices. All the electrical wires should pass through PVC conduit pipes of size as follows:
1 to 6 cables - 32mm
7 to 18 cables - 50 mm
Wire connectors at the solenoid valve shall accomplish with moulded waterproof
PVC plastic connectors. Joints shall be made up using copper crimps and a rapid
hardening. Waterproof sealant, shall be used as recommended by the solenoid valve
manufacturer.
Irrigation control cables shall be colour coded as follows:
Common wire - Black

Drip valve wire - Green
Bubbler valve wire - Blue
Spray valve wire - Red
Sprinkler valve wire - Orange
Spare wire - White
2. Wire Connectors
All wire connections at electric remote valves and all splices of wire in the field shall be
made using wire connectors. The wire connectors shall be specifically designated to
ensure waterproof underground wire connections. The connectors shall be under-
writers laboratories listed water resistant wire connectors, rated 600 volts for PVC-u
insulated copper wire with insulation temperature rating of 105°C.
The connectors shall consist of precision moulded PVC base socket, moulded sealing
plug, wire crimping sleeve and shall be easily installed in the field to give a permanent
waterproof joint by using for joint make-up.
3. Pull boxes
Pull boxes should be provided as detailed in the installation drawing at every 100 mtr and
at each point of change in direction. Each electric remote valve should have a separate
pull box beside the valve box.
D. Flush Valve Assembly
The contractor shall install where required and as shown on the drawings, flushing
points consisting of gate valve, valve box, valve supports, gravel bed, 1.5 meters of
polyethylene pipe coiled inside the valve box.
E. Air Release Valve

Air valve shall be of the double orifice type, rated a minimum working pressure of
16 bar. The air valve shall be for the following functions
a) Large volume of air release on pipeline filling.

b) Vacuum relief in the event of pipe drainage.
c) Air release under pressure when the pipe is operational
Automatic double orifice air valves shall be provided at all high points on the pressure
mains. Automatic air valves shall have non-corrosive floats in chambers with clear
space ensuring blockage free operation. All components for the air valve actuating
mechanism including lever shall be of stainless steel.
The body and cover of the valve shall be of ductile iron, SG-GGG50. Nozzles with seals
and actuating mechanism to be located in the removable upper plate connected to
the valve body using stainless steel (grade 316/A4) bolts. Valves shall be coated with
epoxy internally and externally to average DFT 300 microns for protection against
corrosion of body components. All nuts and bolts shall be of stainless steel grade 316/ A4.
F. Pressure Reducing Valve
Pressure reducing valve shall be hydraulically operated, diaphragm actuated in globe

pattern. The valve shall be designed to automatically reduce a higher upstream pressure
to a constant lower down stream pressure. The valve shall be installed in the
irrigation/supply main line inside chambers where possible pressure reduction is required
as agreed with the Engineer. Pressure settings shall be accurate and repeated through
out the flow range. The regulation action of the valve shall be controlled by and
externally mounted pressure- reducing pilot. The valve shall close drip tight when the down
stream pressure meets the pilot pointing. All sizes shall be equipped with a stabilizing
devise to control smoothly at low flows. The main valve body and cover shall be made
from 300 series stainless steel. The valve shall be with flanged ends. The
diaphragm shall consist of non-fabric reinforced Buna-N rubber and shall not be used as
s seating surface. The pilot shall be adjustable, bronze bodied direct acting, spring
loaded and normally closed. The pilot shall be supplied with a stainless steel seat ring.
Provide adequate clearance for valve servicing and maintenance. Install pressure
gauges to monitor valve inlet and outlet pressure as agreed with the Engineer.
2.7 VALVE CHAMBERS AND VALVE BOXES
A. Valve Chambers
The isolation valve chambers shall be RCC chambers or as specified on the drawings.
Contractor should submit shop drawings as per site conditions for approvals.
The valve chamber covers shall be ductile iron medium duty and epoxy coated. The
word of “IRRIGATION” in English and Arabic should be casted on the covers. Valve
chamber with depth more than 1.5m shall be provided with heavy duty GRP ladder
400mm wide.
B. Valve Boxes
Solenoid valves, isolating valves, flush valves and quick couplers shall be installed
in an access box of sufficient size to permit ready removal of the valve inner
assemblies without removing the box from the ground. Valve numbers and station
numbers must be clearly marked inside and outside of the box with permanent paint or by
using plastic tags.
Valve boxes shall be composite service boxes constructed of high strength cellular
foam ABS or HDPE plastic. The valve boxes should have additional ribbing to strength

the chamber & to counteract the side loading pressures. The valve boxes shall be
green colour and should have Ultra Violet resistance property.
The valve boxes shall conform to the following ASTM standards
Properties ASTM Test Method Value –HDPE Value – ABS
Tensile strength D-638 38 mPa 43 mPa
Plexular Modulus D-790 104 mPa 172 mPa
Notched Izod D-256 0.11 kg-m/cm 0.05 kg-m/cm

Impact strength
Deflection D-648 60 – 76 deg C 98 – 107 deg C

Temperature
The valve box covers shall be labeled in Arabic and English.
The valve box covers shall be lockable or bolt down as directed by the Engineer.
a) Valve boxes shall be with following dimensions (Top External Dimension):

b) Quick coupler 50 mm dia and below – 254 mm dia round green colour box with
minimum depth 254 mm. Weight minimum 1.4 kg
c) Solenoid valves 40 mm dia and below – 305 x 430 x 305 mm deep rectangular
green colour box. Weight minimum 3.5 kg.
d) Solenoid valves 50 and 75 mm dia, Air valve, isolating valve 100 mm dia and below
–381 x 635 x 381 mm deep rectangular green colour box. Weight minimum 11.30
kg
e) For drip solenoid valve assembly with Y strainer – 812.8 x 482.6 x 304.8 mm deep
rectangular green colour box. Weight minimum 14.50 kg.
f) For pull boxes – 254 mm dia round green colour box with minimum depth 254 mm.
Weight minimum 1.4 kg
Valve identification tags shall be made of brass or aluminium and a minimum of 75 mm x

50 mm. They shall be stamped with the valve function number size. The valve shall be
similarly identified on the ‘as installed’ drawings. Valve boxes to have a 2-year warranty
confirmed by the manufacturer.
2.8 BUBBLER
A. Pressure Compensating Bubbler
The bubbler shall be a pressure compensating type capable of providing a

consistent discharge rate of 0.02, 0.03, 0.06 & 0.12 lps at 2 to 5 bar pressure.
Bubblers shall be constructed from UL stabilized engineering grade plastic.
The bubbler assembly shall have a plastic inlet screen to protect the nozzle against
clogging. The bubbler shall have a 15/21 inlet (FNPT) for connection to the piping system
riser.
B. Adjustable Flow Bubbler

The full circle bubbler shall have a discharge rate of 0.09 lps at 2 bar pressure. The
bubbler body and screen shall be constructed of plastic. The adjusting screw shall
be of stainless steel. The bubbler shall have a 15/21 female threaded inlet. All
performance data tests shall be conform to ASAE S 398.1 standard procedures. The
bubbler shall have an inlet screen to protect nozzle against clogging, and adjusting screw,
capable of shutting off the bubbler and regulating the flow.
C. Bubbler Stake
Stakes for bubblers shall be constructed from strong temperature resistant
Polypropylene plastic construction with protective stop collar and length shall be 300-mm.
Double barb inlet shall accept 13mm ID polyethylene tubing and ensure a firm
connection. Outlet for bubbler shall be ½” external male thread.
D. Bubbler Riser
Riser for Bubbler shall be constructed from UV resistant thermoplastic materials for
long life. It shall be one piece, black design with no extra fittings or adapters. It should
be able to withstand pressure up to 5.5 bar and temperature up to 65 deg C.
E. Bubbler Pop-Up Bodies
The body and stem shall be constructed of high impact, corrosion resistant heavy
duty plastic.
The pop-up body shall have co-molded (or) separated wiper seal in the top cover
constructed from EPR rubber in polypropylene base for cleaning debris from pop-up
stem as it retracts into case to prevent from sticking up. Full sealing around the
pop-up stem shall occur at 0.6 bar. The wiper seal form an integral part of the cap and
shall not be detachable.
The riser shall have a strong stainless steel retracts spring for positive pop down.
Pop-up height shall be not less than 10.2 or 30.5 cm as required. The sprinkler shall have
a screen under the nozzle to protect it from clogging and for any removal of cleaning
and flushing system. The sprinkler shall have 15/21 threaded inlet. The sprinkler shall
have a built in check valve to prevent low head drainage. If the elevation is above 3.0 m,
use check valve. The pop- up shall have a ratcheting mechanism and a full flow inlet unit.
2.9 EMITTERS
A. Single Outlet Pressure Compensating Emitter
Emitter shall be the single outlet fully pressure compensating type capable of providing
constant discharge over the pressure range from 0.35 to 4.2 bar. The flow rates
available shall be 4/8/16/24 lph. The emitter shall give a constant flow rate for
temperature up to 60°C.
Each emitter shall have “dual flow regulations” utilizing both turbulent flow labyrinth
and EPDM diaphragm. The complete unit must be resistant to standard agricultural
chemical/fertilizers and withstand UAE environmental conditions. The labyrinth shall
give the emitters large path and works at pressure below 0.35 bar. So no emission
spikes occur at low pressures.
The diaphragm shall free floating and controls the emission flow rate from 4.2 bar. The
emitter shall be continuously self-cleaning. The emitter shall have built in filtration
system in the inlet barb.
The emitter shall have a barbed inlet and nipple outlet to accept 4mm micro tube. The
outlet shall have a baffle to deter insect entry.

The coefficient of manufacturing variable shall be less than 0.05.
All emitters shall be stamped with the manufacturer name, product type and flow rate.
B. Pressure Compensating Dripper Line (In-Line)
The dripper line shall be manufactured from linear low-density polyethylene (LLDPE) with
pressure compensating emitters factory installed to the inside of the tube at selected
intervals. The working pressure shall be minimum 4 kg/cm . The pressure
compensating emitter shall consist of “dual regulation” utilizing both turbulent flow
labyrinth and EPDM diaphragm. The dripper shall be continuously self-cleaning. Pressure
compensation shall be between 0.35 to 4.2 bar and the flow must remain constant at
temperature varying from 0 to 60 deg. C. The coefficient of manufacturing variability must
be less than 0.04 as determined by an independent organization.
The dripper line must be guaranteed against solar damage for 7 years. The dripper line
shall be able to be installed with the dripper in any orientation. Temperature up to 60°C
shall not affect the dripper flow rate. The dripper shall have a large “water path” outlet
that acts as a mechanical barrier to root intrusion.
The drip line shall have an inside diameter of 13.6mm and in dripper flow rates of
2 or 4 lph as agreed with the Engineer. Pressure compensating dripper line
spacing shall be 30, 50, 70 or 100 cm. Minimum 7 years continuous testing in sub-
surface application by an independent organization is required.
Pipes shall be fixed intact to the ground using heat resistant stakes at every 5 mtrs and an
automatic end flush valve shall be installed at the end of the line. Drip stakes shall be
provided at each point of change in direction of drip line.
The maximum length of the pipe to one side shall be based on the manufacturer’s
recommendation.
2.10 SPRINKLERS
A. Spray Head Pop Up Sprinkler
The sprinkler body, stem, nozzle and screen shall be constructed of high impact,
corrosion resistant heavy duty plastic.
The sprinkler shall have co-molded (or) separated wiper seal in the top cover constructed
from EPR rubber in polypropylene base for cleaning debris from pop-up stem as it retracts
into case to prevent sprinkler from sticking up. Full sealing around the pop-up stem shall
occur at 0.6 bar. The wiper seal form an integral part of the cap and shall not be
detachable. The sprinkler shall have a matched precipitation rate (MPR) plastic
adjustable arc nozzle with an adjusting screw capable of regulating the radius and flow.
Nozzles shall be removable to allow for pattern change and easy maintenance.
The sprinkler shall have a strong stainless steel retracts spring for positive pop
down. Pop-up height shall be not less than 10.2 or 30.5 cm as required. The sprinkler
shall have a screen under the nozzle to protect it from clogging and for any removal of
cleaning and flushing system. The sprinkler shall have 15/21 threaded inlet. The sprinkler
shall have a built in check valve to prevent low head drainage. If the elevation is above 3.0
m, use check valve as per specification clause 2.10-E.
The sprinkler shall have a ratcheting mechanism and a full flow inlet unit shall come
complete with a flush plug and nozzle.

The full and part circle pop-up spray type sprinkler shall have the following performance
specifications at 2 bar operating pressure.
Adjustable arc nozzles from 1° to 360° or fixed arc nozzle of full circle, half circle and
quarter circle shall be installed depending on the site condition.
Spray pattern Pressure in Bar And Radius in M Discharge in LPS
Full 2 5.00 0.30
Half 2 5.00 0.18
Third 2 5.00 0.20
Quarter 2 5.00 0.22
Full 2 4.50 0.23
Half 2 4.50 0.12
Third 2 4.50 0.18
Quarter 2 4.50 0.06
Full 2 3.65 0.18
Half 2 3.65 0.09
Third 2 3.65 0.13
Quarter 2 3.65 0.04
Full 2 3.00 0.10
Half 2 3.00 0.50
Quarter 2 3.00 0.02
Strip Nozzle LXW Discharge in LPS
Square 2 7.0 x 7.0 0.23
End strip 2 1.2 x 4.6 0.04
Center strip 2 1.2 x 9.2 0.08
Side strip 2 1.2 x 9.2 0.08
B. Matched Precipitation (MP) Rotator
The pop up rotator shall produce and maintain a matched precipitation not greater than
15mm per hour throughout the arc and radius adjustment range and it shall be of viscous
fluid brake rotary type and produce multiple streams. The full or part circle pop up rotator

shall be capable of covering 2.5 – 9m radius at 2- 3.75 bar with a discharge rate of 0.036-
0.964 m3/hr.
The part circle pop up rotator shall have an infinitely adjustable arc between 900-2100 or
between 2100-2700depending on the model selected. The full circle model shall
irrigate 3600. Full or part circle model shall be capable of up to 25% radius reduction using
a stainless steel radius adjustment screw on the top of the nozzle. The radius
reduction screw shall have a slip clutch mechanism to prevent internal damage if
turned past the minimum or maximum radius settings. The radius reduction screw
shall reduce the pressure and flow upstream of the nozzle there by maintaining the
stream integrity.
Part circle rotator shall have arc adjustment capabilities using a stainless steel ring
at the top edge of the nozzle. The adjustment ring should be effective only while
the sprinkler is popped up and should be ineffective while the sprinkler is popped down.
When turned past the minimum or maximum arc limits the adjustment mechanism shall
have a slip clutch action to prevent internal damage.
The pop up rotator shall have a pop up that occurs approximately 15 psi of water
pressure. Upon cessation of water pressure, the sprinkler shall pop down.
The pop up rotator shall be able to be installed in 5/8-27 male threaded pop up spray
head bodies of nominal pop up height 2”,3”,4”,6” or 12”/ adaptor or having 5/8-28 female
threaded pop up spray head bodies of nominal pop up heights 2”,3”,4”,6” or 12”/
adaptor. The pop up rotator shall be fitted with detachable filter stem and nozzle
orifice shall be manufactured from urethane for durability
C. Pop-Up Sprinkler
The sprinkler shall be of the gear driven rotary type, capable of covering 4.0 to 10.0 foot
spacing at 2 to 3.5 bar. The sprinkler shall include a set of five (5) interchangeable nozzles
and be available interchangeable nozzles discharging from 0.09 to 0.21 lps.
The sprinkler shall be available in an adjustable part circle configuration. The adjustable
part-circle unit shall be minutely adjustable from 40° to 360°. The adjustable unit shall be
adjustable in all phases of installation i.e. before installation, after installation (static),
and after installation while in operation. The pop up versions of the sprinkler shall have a
ratcheting riser assembly for final arc orientation.
The sprinkler shall have a 10.2, 15.2, or 30.5 cm pop-up stroke. The pop-up sprinkler shall
have a built in check valve to prevent low head drainage, and be capable of checking
up to 2 m of elevation change. If the elevation exceeds 2 m, use check valve as per
specification clause 2.10-E
The sprinkler shall have an exposed surface diameter of 5.7 cm after installation. The
sprinkler shall have a 15/21 female threaded inlet. The sprinkler shall be serviceable after
installation by unscrewing the body cap, removing the riser assembly, and extracting the
inlet filter screen.
The body and the riser of the sprinkler shall be constructed of non-corrosive, heavy duty
plastic. The sprinkler shall carry a two-year warranty.
D. Heavy Duty Gear Driven Sprinkler
The sprinklers shall be of the gear driven, rotary type, capable of covering a 6 to 14m
radius at 3.4 bars with a discharge rate of 0.35 lps. The sprinklers shall be available with
eight (8) standard nozzles discharging from 0.06 to 0.52 lps or four (4) low angle
discharging from 0.1 to 0.30 lps. The sprinkler shall have radius adjustment screw. The
sprinkler shall have a provision to enable the user to stop the water flow through an
individual sprinkler head.

The sprinkler shall be available in both full circle and adjustable part circle
configurations. The adjustments part circle unit shall be minutely adjustable from 40° to
360°. The adjustable unit shall be adjustable in all phases of installation. (i.e.
before installation, after installation while static, and after installation while in
operation).
The sprinkler shall have a minimum of 10.2 cm pop-up stroke to bring the rotating
nozzle turret into a clean environment. The sprinkler shall have a rubber firmly
attached to the top of the sprinkler riser. When specified the sprinkler shall have a
cover molded of purple Acryl rubber to indicate the use of reclaimed water.
The sprinklers shall have a built in check valve to prevent low head drainage and be
capable of checking up to 10 feet in elevation change. If the elevation exceeds 10ft, use
check valve as per specification clause 2.10-E.
The sprinklers shall have an exposed surface diameter of 4.4 cm after installation.
The pop-up sprinkler shall have an overall height of 11.4 cm. The unit shall have a 20/27
female bottom threaded inlet. The sprinkler shall be serviceable after installation in the
field by unscrewing the body cap, removing the riser assembly, and extracting the inlet
filter screen.
The body and the riser of the sprinkler shall be constructed of non-corrosive, heavy duty
plastic and nozzle-turret assembly shall be encased in stainless steel. The sprinkler shall
carry a five-year exchange warranty (not prorated).
E. Pop-Up Sprays And Rotor Connection
The flexible connection between the irrigation sprays/rotors and the sub-main shall be via
U.V stabilized class C low-density polyethylene (LDPE) pipe type 32 manufactured to
BS 1972/67 – 3287. All pipes shall have size, class manufacturers name and
standard printed on the product.
Compression fittings shall be used for pipe connection to the sprays/rotor. The
fittings shall have the body, locking ring, thrust collar and internal barb manufactured from
master batch U.V stabilized polyethylene. The locking ring shall be manufactured from
acetylic resin and rubber seal NBR material. The fitting shall have a pressure rating of 16
bar and shall secure the pipe with an external locking ring plus an internal push fit barbed
adaptor. The two locking components shall be compressed onto the pipe to form a secure
seal by the rotation of the locking nut. The final assembly shall have working
pressure rating of 9-bar minimum and test pressure 16 bar pop-up sprays shall use ½”
class C and rotors shall use minimum ¾” class C polyethylene pipe.
F. Check Valve
The check valve shall be a spring-loaded adjustable valve constructed of corrosion

resistant materials. The valve body shall be moulded of heavy-duty, U.V. stable, schedule
80PVC. The internal spring shall be constructed of 300 series stainless steel and the seal
shall be constructed of EPDM material.
The valve shall be available with ½” female inlet with ½” male outlet (or) ¾” female inlet
with ¾” male outlet. The valve shall have an adjustment range of 4 ft to 32 ft (1.2m to
9.8m) of elevation. The adjustment shall be accomplished by turning the adjustment screw
from the discharge side of the valve without taking the unit off the riser.
The valve shall carry a two-year, exchange warranty (not prorated).
G. Big Gun Sprinkler
The big gun sprinkler shall be constructed from non-corrosive materials and easy hand
adjustable stops for precise arc control. The Big Gun sprinkler drive shall

incorporate a pressure and flow compensating drive spoon. A spreader nozzle for
close in watch coverage shall also be incorporated as part of the drive arm unit. All
the ball bearing shall be greased and sealed type.
The Big Gun sprinkler shall be available with a fixed bore nozzle with female threaded
body cap (or) an optional ring nozzle incorporating nozzle body an d seven
interchangeable flow ring discs. The Big Gun sprinkler discharge shall be 24-degree
trajectory.
The Big Gun Sprinkler shall incorporate a key mechanism bolted to the base of the
sprinkler, which shall be compatible for fitment to a mating quick coupling valve
key. There shall be multiple size interchangeable nozzle choices and the nozzles
shall be selected to match the required precipitation rates.
Operating pressure : 3.0 to 7.0 kg/cm²

Discharge : 45.0 to 70.0 m³/hr
Radius of throw ; 28.0 to 58.0 metres
The ‘quick coupling valve’ shall be of heavy-duty cast iron body construction with stainless
steel and brass internal components. The quick coupling valve shall have a 3” female
BSP inlet and spring loaded diaphragm outlet compatible for use with bayonet type
base connection on a mating quick coupling valve key attachment, which shall form
part of the Big Gun sprinkler.
2.11 FILTERS
A. Screen Filter
Automatic self-cleaning screen filter shall be provided at the pump discharge head, which
are specifically designed for use with organic contaminants. Cleaning shall be
effected by hydraulically powered suction scanner automatically activated when the
pressure across the filter reaches 0.35 bar. The capacity of the filter should match with the
system flow.
1. Primary stage filtration shall be performed by a one piece perforated PVC coarse screen
having circular holes of 9mm diameter.
2. Secondary stage filtration shall be provided by a stainless steel grade 316 with 200
mesh size (74 microns). Flushing line to be connected to an existing drainage manhole.
3. Filter shall be equipped with electrical control system contained in a Nema 4X enclosure,
which shall regulate the filter rinse cycles and prevent the filter from engaging in a
continuous rinse. The control system shall be microprocessor based and shall be suitable
for control of up to ten (10) filters. The system shall provide for rinse cycle activation
by one of four options: differential pressure, timer external signal or manually, and shall
include an integral rinse cycle counter which shall record the rinse cycles activated by
each method. The system shall include local alarm and remote contacts to indicate filter
malfunction.
4. Filter shall have flush valve actuator of a heavy duty construction threaded into a brass
valve body.
5. The filter shall clean itself automatically without the need for an external energy
source.
6. The filter shall provide uninterrupted flow and also provide filtration during the flushing
cycle.
7. Fine screen elements shall be easily replaceable without requiring any changes to
be made in the construction of the elements of the cleaning system or the need to
remove the filter from the pipeline.
8. Installation shall be possible in any desired position (horizontal, up-side down, vertical or

inclined).
9. Pressure drop across a clean filter screen shall not exceed 0.21 bar.
10. Filter shall have isolation valves in the suction as well on delivery side for easy
maintenance. The controller for the filters shall be equipped with timer and pressure
differential control unit.
11. Pressure gauges to be connected to suction and delivery side of each filter.
12. All nuts and bolts shall be of stainless steel grade 316 or A4-70.
B. Media Filter
The irrigation filter shall be automatic self-cleaning type, specifically designed for use
with organic contaminants. A hydraulically powered suction scanner, automatically
activated when the differential pressure across the filter reaches an adjustable level,
normally 5 PSI, shall effect cleaning.
The screen shall be stainless steel grade 316 with 200-mesh size (74 micron).
Flushing line is to be connected to the soak pits or nearest storm water drainage manhole.
The control system shall feature a fail-safe timer to prevent continuous flushing due to
malfunction.
The control system for the filters should be such that it will not flush the filters if
the pumps and /or irrigation system is not operating. Filters should flush only during the
operating hours of the irrigation system.
One number in line filter of capacity 9.5 lps shall be installed. The filters shall have less
than 0.18 bar pressure loss.
The screen area shall not be less than 274 sq.inch.
Filter shall have gate valves in the suction as well as on delivery side for easy
maintenance. The controller for the filters shall be equipped with timer and pressure
differential control unit. Pressure gauges are to be connected to suction and delivery side
of each filter.
All nuts and bolts shall be of stainless steel grade 316 or A4-70. The filter body and
internal parts including flanged connection shall be stainless steel.
C. Y – Strainer
Body shall be constructed from high heat and chemical resistant glass reinforced plastic,
wo-piece threaded housing with o-ring seal molded.
Filter screen shall be stainless steel providing 60.8 sq.inch of filtration area.
Outer support shall be woven stainless steel wire and inner screen shall be woven
stainless steel cloth. Inner and outer screens shall be soldered together. Screen
collar molded from vinyl for long life and weather resistant. Screen shall be 150 mesh
sizes.
The pressure rating shall be 10 bar. Working pressure shall be 7-8 bar.
The filter should be available in 25, 40, 50 mm size and flow capacity of each shall
be 1.58,3.15,6.94 lps respectively.
The whole filter unit shall be manufactured from the same manufacturer.

2.12 CENTRAL IRRIGATION CONTROL SYSTEM
The central control station shall be available to satisfy the system requirements and
shall be user friendly. The central computer shall communicate with the field
controller’s directly. Central Control and Monitoring Program shall use a strong protocol to
exchange. This communication shall be direct real time. The control software shall be
year 2000 compliant. The central control software shall allow remote access from
different locations by means of dial-up telephone line for control and monitoring.
Central controller software shall be easy to use and utilizes pointer mouse and
single screen user programming functionality. That is, user definable selections for each
area of operation are performed on a single “at- a-glance” windows screen. For example,
each controller’s watering schedule program i.e. Water days, Start times, Station run
times, Station flow rates, budgets etc. can be viewed and changed by viewing a single
screen.
The software screens mimic the user screens on the touch screen panel of each
controller. Terminology and screen thought layouts in both the software and controllers
make it much easier for an irrigation technician to operate both because of the
consistency of design
The central control system Software shall have the following minimum capabilities:
a) Support more than one project,

b) True windows User Interface
c) Allows printing of any report
d) Allow Uploading of data and programs from Field Units
e) Supports moisture sensor
f) Paging Facility shall be supported and engineered by the system manufacturer,
sending alphanumeric messages.
g) Flow prediction: To analyze the demand on the Hydraulic design.
h) Complete Flow management by enabling flow sensor.
i) Water Network protection
j) Effective Water management using ET sensor
k) Sensor Measurements.
l) Comprehensive and User-friendly irrigation programming screens. (Time based,
quantity based and irrigation depth).
m) Define multiple crop type and adjust water factor for each type.
n) Off-Line programming for Field Units.
A. Surge Protection And Grounding
The central control system shall have a surge protection unit (SPU) to protect
components from electrical surges, to be installed on the external wall of the
computer room and to be grounded as instructed in the technical data sheet.
Approved grounding of the SPU, to be provided for lightning/electrical surges
with 8’ grounding copper rods as per ADEWA regulations.
B. E.T. Sensor
The E.T. Sensor shall be compatible with the Irrigation Central Control System and
automatically provide data to the central computer to analyses the current irrigation
requirements for optimal water management. The E.T. Sensor shall automatically monitor
meteorological conditions that affect water consumption. The central computer calculates

Evapotranspiration (ET) by modified Penman equation from above parameter inputs
(excluding wind direction), and then adjusts the irrigation schedule of each program.
C. Field Controller
The central control system shall be responsible for the monitoring of the
equipment’s under contract scope of work and override local control with manual
commands locally from controller or central. All these controllers shall be field
programmable. The Controllers shall be intelligent device, Modular and Expendable
units and capable of processing local control. It shall control and monitor the pumps,
valves and flow sensors connected to it.
The Controller shall be smart and have the intelligence to accumulate data and make
decision locally. Comprehensive standard application development and diagnostic
program shall be used for programming the controller locally or remotely. The Irrigation
central Control System shall use a solid communication protocol allowing real time,
two-way communication with the central and controller. The communication shall be
direct with central.
Central controllers shall contain full data processing, program intelligence and
communication capability and do not require added hardware or modification to “link”
field controllers to the central base. The basic central system architecture communicates
to and from the base PC via point-to- point, point-to-multipoint, point-to-point repeater
or point-to multipoint repeater with total functionality being available in each standard
controller unit. A multitude of communication options exist that minimize cost yet
increase range potential.
The Controller shall be installed in a weatherproof enclosure equivalent to 1P55

standards. The controller shall have solid-state design utilizing touch screen/ liquid screen
display. The processor module (CPU) shall be real time process controller and shall
support the Data transfer with I/O modules, system memory allocation, and
communication port protocol. The CPU shall have 2 nos. of 9 DB communication port for
allowing LAN capabilities.
The Controller shall be supplied with required number of Input / Output points and shall
include the following minimum configuration:
1. Mother Board
2. Input /Output (I/O) modules or Boards.
3. Power supply
4. Radio Communication Interface.
5. Combination of radio, telephone & hardwire board.
The field controller shall have independent control over each station start time (up to
eight), duration of watering (maximum 99 hours, 59 minutes, 59 seconds), days of
operation and cycle length (I to 30 days), exempt station operation by day of week or
by date. .A “mimic” function shall provide the ability to copy station timing to any other
station. The Controller must operate at ambient temperature range of 30 to 60 deg C with
relative and humidity up to 95 %.
The Controller shall carry irrigation programs with the following minimum capabilities
and requirements per irrigation main line:
a) Control Irrigation system based on time and quantity.

b) Initiate alarms based on high flow, low flow, main line leak.
c) Flexible programming to change valve set combinations.
d) Possibility to create programs based on conditions.

e) Run/Stop main line.
f) Local or host control may be initiated at the keypad along with satellite address.
g) Universal water budget may be modified from 1% to 300% in one percent steps.
h) Individual station programs or all programming may be erased through a two-step
process.
i) A security code can be entered allowing only authorized access to programming
functions.
j) Four windows of irrigation for more flexible operation.
D. Moisture Sensors
Moisture sensors (upto eight) shall be connected to the satellite via a two wire path or use
existing valve wires (one sensor per path) and shall automatically modify or skip any
station. The user shall be able to assign any station to any sensor. The controller shall
have local override capability.
E. Flow Meters
Flow meters (up to two) shall automatically shutdown and bypass any station in the event
of a flow variance (either excess or sub normal as defined by the user). The satellite shall
shutdown the master valve in the event that flow variance cannot be corrected by
an individual station shutdown. Controller shall have local override capability.
F. Other Sensors
Other types of sensing (up to eight) such as rain, wind speed and direction, temperature,
evapotranspiration/humidity, etc. shall be connected to the satellite via a two wire
path (one sensor per path) and shall automatically modify or skip any station. The
user shall be able to assign any station to any sensor. The controller shall have local
override capability.
The controller shall have the ability to automatically calculate and adjust watering
times based on evapotranspiration. The controller shall be able to detect leaks and report
to the main controller and shut the system if the leak is continuous. The central controller
shall display projected flow by program using graphics. The graph will calculate and
display the maximum instantaneous flow as well as the total volume. Maximum flow and
volume will be displayed in user-selected units. Graphs may be displayed for a flow
source, for all selected programs or for an individual field controller.
PART 3 EXECUTION
3.1 DESIGN CRITERIA
A. Watering Requirements
For the purpose of the design the Peak Irrigation Requirement (PIR) of landscape plants
are to be considered as follows:
Plant Type Requirement
l/m2/day or l/day

Plant Type Requirement
l/m2/day or l/day
Groundcover 10
Grass /Lawn 12
* Feature Plants 10 – 20
Shrubs 20
Small Trees 40
Large Trees 80
Other Palms 80
Date Palms 150
* Feature Plants = Depending on the specific needs of the feature plant species
B. Application Devices
It is recommended to use the application devices as follows:
Palms and Trees - Pressure Compensated Bubblers

Shrub - Pressure Compensated In-Line drippers
Ground covers - Pressure Compensated In-Line drippers
Grass - Spray Head or Rotors
3.2 INSTALLATION PROCEDURE
The Contractor shall carry out the works according to the following sequence or as agreed
with the Engineer.
a) Marking out of pipe line route and end valve locations

b) Trenching and sand bedding
c) Installation of mains, sub main and control valve take offs
d) Installation of isolation valves
e) Pipe pressure testing for main and sub main
f) Installation of manifolds and laterals
g) Backfilling
h) Lateral pipes system leak test
i) Installation of electric remote control solenoid valves
j) Flushing of the system
k) Installation of irrigation heads
l) Installation of controllers
m) Final testing and commissioning

3.3 EXCAVATION
Prior to trenching all services crossing or running close to the line of the trench shall be
identified and exposed. In addition the line of the trench shall be swept using an approved
detection device, capable of detecting both “live” and “dead” cables.
Trenches shall be made as narrow as practicable, but not less than the pipe
diameter plus 300mm, and shall provide sufficient room for laying, jointing and
testing. The width of the trench at the crown of the pipe shall not exceed the pipe
diameter plus 600mm.
Sheeting, bracing and shoring shall be used to provide for the safety of all
personnel for all trenches.
The trench bottom shall be composed of stable uniform sand with no

protuberances that might cause point loading of the pipe. The trench formation shall be
trimmed to an even finish, which will provide continuous support for the pipe. Additional
excavation shall be carried out at the position of the pipe socket to ensure proper joint
assembly and pipe support.
If the existing formation is unsuitable for pipe laying, pipes shall be laid on a bed of
imported sand 100mm thick (minimum). This sand may be sourced from sieved
excavated material, but should not contain any particles larger than 5 mm, and should
have good self-compacting properties.
De-watering should be provided (if necessary) to remove any surface or ground water
entering the excavations. Ground water level shall be maintained at least 300mm below
the bottom of each excavation.
The trench should not be excavated more than 3 days prior to pipe laying.
For the main pipe, trench depth shall be 1000mm from crown of the pipe to the finish
grade. For the lateral pipe the depth shall be 600mm.
Mainline and control cables will be allowed to be laid in the same trench with only one
lateral line and to be at different levels.
Pipes shall be centre loaded leaving joints exposed within three days of laying.
3.4 BACKFILLING
Initial backfill shall be by hand in 300 mm lifts and carried in such a manner to ensure
adequate support under the pipe and distributed evenly to ensure there are no voids
under or to the sides of the pipe.
For pipe sizes of 90 mm dia. and below Backfill material shall be clean sand and shall not
contain any particles larger than 5 mm. Backfill shall be placed in 300mm lifts
and consolidated without mechanical compaction by flooding the trench with irrigation
water.
For the pipe sizes 110 mm dia. and above, backfill material shall be deposited in 300mm
lifts in general areas and compacted to 90% (by water tamping or by any other approved
method). In paved areas lifts shall be 150mm and backfill shall be compacted.
Mechanical compactors shall not be used until there is a minimum of 300mm above the
crown of the pipe.
Backfill material shall be sand and shall not contain any particles larger than 25mm
for the first 100mm above the pipe, thereafter backfill material shall contain no particles
larger than 50mm.

Whenever ambient temperatures exceed 35 degree centigrade, centre loading for PVC
pipes greater than 90 mm shall only be carried out in the early morning or shall
alternatively be preceded by cooling of the pipe string by application of water.
3.5 PVC PIPE INSTALLATIONS
PVC pipes shall be stored on site in a covered pipe store. Pipe stacks shall not be greater
than seven layers or two metres high. Pipes shall be shielded from the sun at all times
and shall be placed on a sand bed or on supports at least 75mm wide and placed not
greater than 1.50m apart. Side supports shall be similarly constructed and placed not
greater than 3.00m apart. The pipe store shall allow for circulation of air. Rubber sealing
rings shall be stored inside closed boxes in a shaded place and shall on no account be
exposed to sunlight for more than a few days.
Pipes shall be transported on the site on a flatbed trailer and shall never be
dropped or dragged along the ground.
Spigot ends of all pipes shall be chamfered to a depth of half the wall thickness at an
angle of 15 degree. Pipes cut on site should be cut square to the pipe axis with a fine-
toothed saw. All swarf and burrs should be removed from the pipe prior to
assembly of joints. Pipe cutters may be used for 32 mm pipe and smaller.
Spigot insertion depth shall be measured and marked on all pipes larger than 3” using
indelible ink to allow checking at a later date.
Ring Joints shall be made using an approved non-ionic lubricant compatible with the
sealing ring. Pipes sized up to 225 mm may be jointed using a crowbar and a timber
protection piece. Joints larger than 225 mm shall be assembled using a clamped lever
device. Before backfilling, joints shall be checked to ensure that the spigot is inserted at
least 90% of the socket depth.
Solvent welding shall be carried out by experienced fitters who fully understand the
technique and have successfully made a solvent weld joint in the presence of and to the
approval of the Engineer. Helpers brought up on site may only be allowed to make
solvent joints after inspection of their technique by the Engineer.
Solvent welded joints made on pipe 90 mm and above shall be proceeded by

lightly abrading both surfaces to be jointed using a medium glass paper or clean emery
cloth. Solvent “cleaner” (colour) shall be applied to all mating surfaces using a
dauber or brush (application using rags will not be allowed). After ensuring that
the mating surfaces are clean and dry, solvent cement shall be applied in sufficient
quantities to ensure good bonding but not in excessive quantities that will leave
appreciable residues inside the pipe.
Brush size shall be 3/8” round for 32 mm pipes; 1” flat for 50 mm and 2” flat for larger
pipes.
Solvent cement should be applied by two people simultaneously for pipe 3” and above.
Immediately after application of the solvent cement the pipes shall be pushed
together in a smooth continuous motion that ensures that the spigot is at least 90%
inserted in to the socket. The joint shall be held for a minimum of 20 seconds after
insertion and then surplus cement shall be cleaned from the outside of the pipe using a
rag or paper. Solvent cement and cleaner shall be provided in tins with brush or dauber
fixed to the lid of tin. The lids shall be firmly closed at all times except during application.
Any tins of solvent cement that become viscous or harden shall be discarded.
Brushes on which the solvent cement has hardened must be discarded. All fitters
involved in solvent cement jointing shall be provided with safety gloves that prevent
solvent touching the skin. The gloves shall be kept in good condition and shall be
replaced periodically.

Jointing shall not be carried out in windy conditions (wind speeds greater than
18km/hour).
Where direction of flow is apparent the pipes shall be laid so that the flow is from spigot to
socket.
Because of high coefficient of linear expansion of PVC-u, the pipes shall be allowed
to cool to within 10° C of the ambient temperature at the shaded bottom of the trench
before back filling commences.
Where PVC-u pipes are to be partially encased in concrete, they shall first be
wrapped in compressible material in accordance with the manufacturer’s
instructions.
Where manifolds and laterals pass under roads or paved areas and through
foundations and walls they shall be in ducts.
Junctions shall be formed using 90-degree tees only. Not more than two tees shall be
connected in line barrel to barrel. If third tee is required on the same line it must be
separated from the first two by a pipe not less than 2m long.
When a pipelines is complete or when construction is delayed, the open ends shall
be stopped or sealed off until the pipeline is required to operate or work
recommences. Care shall be taken that the system does not become silted up.
At each point where pipeline is temporarily terminated, temporary end caps shall be used
and a marker shall be attached to the end of the pipeline and fixed at ground level.
A. Pipe laying on a Granular Bed.
Granular material shall be laid to a minimum thickness of 100mm on the trench

floor and shall extend to the full width of the trench.
Pipes shall be laid with the sockets upstream directly on the granular bed, which shall be
adjusted to ensure exact line and level uniform bearing. Pipes shall rest evenly on the
granular bed for the full length of packing such as timber, bricks or stones. Socket
holes, where needed, shall be short as practicable and shall be scraped in the
granular bed deep enough to prevent the socket from bearing on the bottom. Socket holes
shall be repacked after pipe laying.
Adjustments to the level of the pipes shall be by raising or lowering the granular
bedding. The pipes shall rest evenly on the adjusted bedding throughout the length
of their barrels. Adjustments shall never be made by local
B. Pipe laying on Natural Formation
Where shown on the drawings and when in the opinion of the Engineer the ground is such
as to allow the trench formation to be trimmed so as to provide a uniform solid bearing,
pipes shall be laid upon the formation. Socket and joint holes where needed, shall be
as short as practicable and shall be scraped or cut in the foundation, deep enough to
give a minimum clearance of 50mm between the socket and the formation.
If the formations inadvertently low at any point, it shall be brought up to the correct level,
and care shall be taken to ensure uniformity of pipe support. Pipes shall rest evenly
on the formation throughout the length of the barrels. Adjustment shall never be made by
local packing.

3.6 HDPE PIPE INSTALLATION
The pipes shall be bedded on good dry approved bedding material free of lumps or stone
chippings. If the material in the trench bottom is considered unsuitable or unstable, it shall
be removed to a depth of 100 mm and the bottom of the trench shall be filled with a 100
mm layer of suitable approved fill material. All bedding material shall be subject to prior
approval of the Engineer.
Wherever practical, mechanical excavation methods shall be used, except where such
methods may cause damage to existing structures, services, ruins or relics. In such
locations, the contractor shall use hand methods only.
Where shoring is used to stabilize excavations, the shoring shall be removed

progressively to ensure that adequate backfilling is carried out without leaving voids.
All excavated material shall be placed so as to avoid any danger or hindrance to
others.
All pipes, fittings, valves etc. shall be carefully lowered into the trench with suitable
equipment in a manner that will prevent damage. All foreign matter shall be removed from
inside the pipe or fitting before being lowered into position.
The minimum bend radius for the installation of polyethylene pipes shall be 15 times
the outside diameter of the pipe (15 D). It should be noted that this may not be possible for
all sizes and wall thicknesses. The advice of the manufacturer should be sought before
finalising bend radius. When a joint falls within the pipe bend section, then the minimum
radius shall be 25 D.
At the close of a day or whenever pipe laying is not in progress the open ends of the
installed pipe shall be closed by an approved cap or blank to prevent the entrance
of ground water or any other foreign matter. Under no circumstances shall pipes be used
for the storage of tools etc.
It is the Contractor's responsibility to ensure that the pipeline is clear and free of all foreign
matter at all times until taken over by the Employer. Sufficient backfill shall be placed on
the pipe to prevent floatation. Any pipe that has floated shall be removed from the trench
and re-laid in a dry trench. The Engineer's decision is final as regards the suitability of the
weather for pipe laying.
Additional excavations will have to be carried out to provide extra space around couplings.
These shall be large enough to allow unhindered jointing of the pipes.
All pipes shall be laid and maintained to the agreed alignment and grade ensuring that the
pipe is properly bedded along its whole length. Fittings and valves shall be at the
required locations. No deviation shall be made from the agreed alignment or grade
except with the written consent of the Engineer.
The Contractor shall furnish temporary support, adequate protection, and maintenance of
all underground and surface utilities encountered during construction of the Work.
Where the grade or alignment of pipes is obstructed by existing utilities, such as
conduits, ducts, pipes, branch connections etc. the obstruction shall be supported,
relocated, removed, or reconstructed by the Contractor at his own cost unless
otherwise provided to be paid for separately. Whenever it is necessary to determine
the location of existing underground utilities, the Contractor, after an examination of
available records, shall make all explorations and excavations as may be directed by the
Engineer to determine these locations. Only such tools and equipment as have been
approved by the Engineer shall be used by the Contractor to execute the work in a
safe and efficient manner.
Approved backfill material free from clay, rocks and other unacceptable material shall be
compacted by means of hand tools around the pipe up to 30 cm above top of pipe in

layers of not more than 20 cm. If in the opinion of the Engineer the materials excavated
from the trench are not suitable for this purpose, the Contractor shall supply suitable
materials, to be approved by the Engineer.
The materials shall be made damp, if necessary, to attain adequate compaction around
and under the pipes and fittings. The balance of the backfill to the final ground level shall
contain no stones more than 15 cm (6") in their largest dimension, and shall not
contain more than 25 percent of stones. All backfill shall be compacted in a manner
approved by the Engineer. The trenches or any other excavation shall only be backfilled
using approved fill, and shall not be used for dumping unwanted excavated material,
which should be disposed of away from the site as directed by the Engineer. Any
depressions caused by settlements due to trench excavations and backfilling shall be
made good by the Contractor using approved fill material.
A. Butt Fusion Welding Principles and Procedures
a) Machining: Pipe ends shall be machined so that the surfaces to be welded are
totally clean, free from ridges and are square to each other.
b) Bead Up: Pressing pipe against a hot plate which is thermostatically controlled
causes a melt to form and any minor irregularities in surfaces and squareness can
be eliminated by pressing until an even bead of melt forms around the
circumference.
c) ‘Soaking’: Relieving the pressure against the plate stops melt being forced from the
heated zone. (If the pipe is kept just in contact with the plate then a molten region
is formed a short distance along the pipe barrel).
d) Plate removal: 'Snapping' the pipe from the surface of the plate by swift application
of reverse pressure on the hydraulic rams on machine allows the heater plate to be
removed. Reversal of pressure then allows the two surfaces to be brought
into contact and for a weld to form.
e) Fusion: Application of pressure causes the molten surfaces to be forced together.
The melt is pressurised and the surface regions are squeezed out from the
joint region. When it emerges from the interface and melts it has no stiffness and
so folds back on itself to form a bead.
f) Cooling: Following bead formation, the molten interface cools relatively rapidly
and eventually solidifies.It has been the convention to maintain pressure during
cooling and to then wait until the weld has cooled sufficiently to regain sufficient
strength and before allowing the pipe to be removed from the welding machine.
The Specialist Subcontractor shall exercise care and control over the welding
equipment, the cycle itself and the environment in which welding is carried out.
The welders shall be subject to annual welder qualification tests. The acceptance
criteria shall be as in DVS 2203.
B. Welding Equipment
All welding equipment shall be regularly maintained. In particular:
a) The clamps shall be effective in holding the pipe square.

b) The trimmer shall be square and have power in reverse to ensure a clean cut.
c) The heater plate shall have a control system capable of maintaining a uniform
temperature over the area in contact with the pipe.
d) The hydraulic system shall be effective and a gauge must be attached which can
accurately resolve pressures to be used.
e) Pipe shall be supported on well-maintained rollers. This should ensure that the 'drag'
pressure needed to overcome friction is minimised. The drag pressure shall always

be less than the fusion pressure.
(Where circumstances dictate that the drag is unavoidably high, great care shall be taken
with pressure control-especially when using Dual Pressure conditions).
Successful butt fusion welding depends mostly on the degree to which cleanliness is
maintained.
The major factor, which can reduce welding efficiency and cause embitterment of welds, is
the contamination of pipe surfaces by oil, grease and fine dust.
Cleaning equipment to ensure oil and grease do not contact pipe surfaces is
therefore necessary.
Dust is a more difficult factor to control. The major source of dust contamination is from
the heater plate, which attracts dust from the atmosphere by static charge when cold.
The secondary source of contamination can arise after surface trimming. The PE
surface will have a statically charged surface and will attract dust.
To control dust contamination, it is essential to ensure that all welding is carried out in a
simple protective shelter. The floor shall be covered by tarpaulin (or similar) if the
ground is dusty.
To ensure the heater plate is fully clean it is essential to make a dummy weld every time
the plate has been allowed to cool. (See Dummy welding).
To ensure that contamination does not affect welds in installed pipes, it is necessary to
make a dummy weld at the start of any welding session after the plate has been allowed to
cool.
It is only necessary to follow the welding cycle to the point where the pipe is
snapped from the plate. Following cooling, the surfaces may be re-trimmed to allow
production welding to begin. Alternatively a scrap piece of pipe may be used and
then discarded.
For thick walled pipes (wall thickness > 2Omm), it has been found that it is
necessary to make two dummy welds. The surfaces of the heater plate may not be
cleaned sufficiently by the first weld. The weld shall remain clamped until all re-
solidification has taken place. The cooling time shall be such that no significant axial
stress is placed on the weld until it has reached 80 0C. Guidance on cooling time shall be
taken from the pipe manufacturer.
3.7 ANCHOR AND THRUST BLOCKS
Where pipes are laid in common trenches and the thrust block shall not bear onto
undisturbed ground due to other services, the block shall be extended into
undisturbed ground and shall encase these services with a 150mm minimum
surround.
The metal straps and anchor bolts shall be non-corrosive, of adequate strength and
dimension to prevent movement and rubber strips shall be provide under all straps at
contact surfaces.
The contractor shall install thrust blocks at bends, tees, dead ends, and reducers or at
fittings where changes in pipe diameter occur as detailed on the approved shop drawings
and as required by the Engineer. Calculation and design of the thrust blocks shall
be done and to be approved by the Engineer.
Where concrete thrust blocks encase PVC pipe a membrane of polythene film
(1000 gauge) shall be used between the concrete and the PVC pipe.

3.8 VALVES
Valves on horizontal sections of pipe work shall be installed with the spindle
vertical. All valves shall be installed so as to be as accessible as possible.
All open ends of pipe work left during construction shall be covered using purpose made
caps or blind flanges. Such temporary ends must be suitably supported during testing.
Valve identification tags shall be wired to all valves.
Air release valves shall be installed at high points in the system as required by the
Engineer. Gate valves, Air valves and Solenoid valves shall be installed as shown on the
drawings
3.9 VALVE BOXES AND CHAMBERS
Valve boxes shall be bedded in cement sand mortar on a concrete or concrete block
chamber and shall be flush with the surrounding surface.
Block chambers shall have in-situ concrete bases to the Engineer requirements. Blocks
shall be laid in stretcher bond. Beds and vertical joints shall be completely filled with
mortar as the blocks are laid and joints shall be flush cut as the work proceeds.
Valve boxes shall if necessary be re-set to the correct position and level if any settlement
occurs.
3.10 END FLUSHING POINTS
The contractor shall install where required and as shown on the drawings main line end
flushing points consisting of brass valve, PVC riser and adapter, thrust block, valve box
bedded on engineering block and gravel, a flexible 1.5 m length of pipe and a steel
anchor with rubber padding between the PVC-u pipe and anchor.
The contractor shall install where required and as shown on the drawings sub
main and lateral flushing points consisting of a brass valve, PVC riser and adapter,
thrust block, valve box bedded on engineering block and gravel, a flexible 1.5 m length of
pipe and a steel anchor with rubber padding between the PVC-u pipe and anchor.
3.11 IRRIGATION EQUIPMENT
Equipment shall be installed to achieve optimum irrigation efficiency and to

accommodate the requirements of the landscaping. All irrigation equipment such as spray
heads, bubblers and emitters shall be installed only after the laterals and risers are
flushed thoroughly. The installation shall be as per the irrigation detail drawing. The top
of the sprinkler case shall be flush with the final grade level. Riser assemblies shall
be snag free and free of leaks. The spray heads should be installed at least 30cm away
from the kerbstone.
3.12 ELECTRICAL INSTALLATIONS
All electrical equipment under these contract documents shall have passed
adequate routine factory tests. Qualified personnel approved by the Engineer shall
make Field tests. The contractor shall furnish all apparatus, material, labour and facilities
for performing the required tests. Unless otherwise specified the individual electrical
equipment shall undergo the following tests in accordance with the IEC recommendations
or other approved standards.
In the workshop:
a) High Voltage Test

b) Check on mechanical function
c) Pre-test of functional sequences
On site:
a) Visual Inspection
b) Insulation test (megger test)
c) Check of functional sequences
The contractor shall submit to the Engineer acceptance test certificate of all tests carried
out in his workshop including all measuring data and subsequent evaluation.
The following tests are to be carried out for all cables as a minimum:
a) Resistance measurement
b) Insulation test with specified AC power frequency test voltage
c) Insulation resistance measurement of every individual cable length at site
d) Electrical continuity test for all controls.
The following tests shall be carried out upon completion of the earthing system:
a) Measurement of the conductance of the earthing wires

b) Measurement of the intermediate resistance of the earthing electrodes
The contractor shall provide at his expense the necessary qualified personnel and
measuring instruments for the above measurements.
A. Electrical Codes
All the electrical installations shall operate at a system voltage of 380 volts AC three
phase four wire 50 cycles.
B. Insulation Color Code
Insulation colors shall be in accordance with the IEE Regulations.
C. Installation of Cable
Installation of cables shall include the following:
a) Measuring, marking off and cutting of all cables to length before installation or
laying.
b) Temporary sealing, protection and support of cables being installed or laid, and
testing of cables for insulation before jointing or termination
c) Preparation of all necessary materials for the placement, support or carriage or all
cable runs. These shall include earth trenches, sleeve, ducts, cable trays, ladders,
trunking, racks, clamps saddles, etc.
d) If cables pass through foundation walls or other underground structures, the
necessary ducts or openings shall be provided in advance for the same. If it is
necessary to cut holes in existing foundations or structures the electrical contractor
shall determine their location and obtain approval of the Engineer before cutting is
done.
e) Sealing of cables using fire retardant cable sealing material in ducts, sleeves or
trenches to prevent ingress of water.
f) Testing of cable insulation, phasing and continuity.

g) All outdoor terminals shall be shrouded and the termination shall be covered with
heat-shrink shrouds.
h) Cable termination shall be made with proper size cable lugs. Copper strands shall
not be cut to use with under size lugs. Cables in the panels, shall not be connected
directly to the terminals of circuit breaker or isolators, but shall be connected through
terminal block.
i) Terminal board/block shall be leveled and refer to drawings accordingly.
j) Each cable shall be tagged at the termination point, fitted over its over- sheath,
providing cable number and circuit identification.
k) Cores of control wire shall be provided with ferrules or sleeves with markings.
l) Spare cores of control or power cables shall be terminated on the terminal blocks
with identification level and tagged spare.
D. Jointing of Cable
Cable sealing and jointing shall be in accordance with the best current practice.
Cables with metal sheaths or armoring shall be terminated or jointed with metal
sheaths or armoring solidly bonded to the metal joints or terminal boxes to provide a low
resistance path under fault conditions. The cost of material for joints, labor, etc., shall be
included in this work.
Provide joint boxes to extend existing cable to connect to the new panel. Identical
type of cable shall be used for extension. Obtain Engineers prior approval for the job. On
Engineers’ approval, joint on the incoming cable may be allowed. The length of the
additional piece of cable shall not be less than 15 meters.
E. Cable Pulling
When cable is being laid in ground or pulled through trenches, cable pulling shall be by
manual means and sufficient wooden roller supports shall be provided over the
bottom of the trench to prevent damage to cables. Cable guides shall be used for pulling
cables round a bend.
F. Installation of XLPE Cable
A certified cable jointer shall carry out the jointing of XLPE cables. The Contractor
shall provide evidence to the Engineer that the jointer has the relevant experience.
Terminal sealing of cable shall be by compound in cable boxes or by heat shrink kits.
Completed terminations shall be moisture proof. Cable ends shall be flame warmed
thoroughly to ensure all moisture is driven off the dielectric before proceeding to joint or
terminate the cable. In the case of lead sheathed cables cut for installation, the ends
must be sealed immediately by means of a lead cap and wiped to the sheath for air
tightness, if jointing or termination is not carried out immediately.
Bending radii for XLPE cables shall be in accordance with IEC 502.
Cables shall be terminated on cable sockets/lugs of correct size. Cutting of copper strands
of the conductor to suit undersized sockets is not permitted.
Cable entries through sleeves, ducts, floor or wall shall be sealed by tar, epoxy-
resin or other water-repellent compound, suitable for the ambient conditions. Cables
through floors or slabs shall be sleeved through a short section of PVC duct, suitably
bushed to prevent abrasion to the cable.
Cable sheaths shall be bonded by copper earth bonding leads of appropriate size, and
connected to main earth distribution bars at the switchboards or transformers.

G. Cable Trenching
Cable shall be laid along the irrigation pipeline in the same trench, as far as practicable.
The exact location may be adjusted following the approval of the Engineer. Cable routes
shall be as straight as possible and as indicated in the drawing.
Excavation of trenches for the cables shall be as shown in the contract drawing.
The Contractor shall be responsible for the establishment of this level at site and
arrange to excavate and lay the distribution cables at the appropriate time such
that his cables will not be disturbed when installed. Any subsequent damage to
the cable after installation shall be the sole responsibility of the Contractor and he
shall make good the damage at his own cost.
H. Cable Protection
Before the cables are laid, the trench shall be partly filled with soft and pebble-free
sand to a depth of 75 mm. Another 75-mm deep layer of similar sand shall be filled
after laying the cables. At road crossings and other places where cables enter pipe
sleeves, adequate sand bed shall be provided so that the cables do not slack or suffer
damage from pipe ends after back filling.
I. Cable Markers
Cable markers shall be installed over the cable route every 50m and at points of change
of direction, or at the joints, if these exist.
3.13 CENTRAL CONTROL SYSTEM
The central control system shall be installed in a suitable place advised by the Engineer.
The Contractor shall follow the manufacturer’s recommendation for the installation.
Manufacturers’ representative shall supervise all stages of the control system

installations.
3.14 FIELD CONTROLLERS INSTALLATIONS
The field satellite controllers to be installed at the locations shown on the approved
shop drawings.
Controllers shall be installed onto concrete bases, control wire shall be colour coded and
provided with tags.
Control cable shall be bundles and tied with a plastic cable tie at least every 6- metre
interval. Installation of cable bundles in conduits shall be carried out in such a way as
to preclude the possibility of stretching the cable without damaging the insulation.
All the cables splices shall be waterproof and made inside valve or conduit boxes leaving
at least one metre of spare cable neatly coiled and each joint and bend. Controllers shall
be individually earthed by an approved copper clad grounding rod minimum length
15mm x 3 metre driven down into the water table and connected to the controller
by a brass clamp and a 4mm2 grounding wire. Decoders, encoders and terminators
shall be installed in plastic valve boxes and their function and reference number shall be
clearly indicated in indelible ink.
Manufacturers’ representative shall supervise all stages of the control system installations.
3.15 FIELD TESTING
A. Pipeline Pressure Test

All pipelines shall be tested before brought into service. The test shall be a hydraulic test
performed by filling the pipe with water and raising the pressure to test pressure.
The contractor shall give adequate notice to the Engineer of the time and place at
which all tests are to be held. Tests shall be made in the presence of the Engineer. Clean
water shall be used for the hydraulic test and promptly removed upon completion of the
test, as required by the Engineer.
The flushing of each section shall be attended to promptly. Care is to be taken to

drive out all dirt/foreign materials before installing heads.
The length of tests section shall be maximum 500m or as directed by the Irrigation
Engineer. The pipe length to be tested may be blanked off using blank iron or
steel flange previously drilled and tapped for test equipment connection and strutted
as necessary against end thrust. The blank flange may be attached to the pipeline by
a V.J.flange adaptor or similar.
Testing should not be carried out against closed valves. All charging should be carried out
from the lowest point of the under test section and all testing equipment should be located
at this point.
The pressure gauge should also be located at the lowest point or adjustment must be
made for the level of the pressure gauge relative to the pipes location.
Prior to testing care should be taken to ensure that all anchor blocks have attained
adequate maturity and that any solvent welded joints included in the pipe system have
developed full strength. Correct support and anchorage of any above ground sections
of the pipeline is also necessary. Underground pipelines should be back-filled taking
particular care to consolidate around lengths which may have been deflected to
negotiate curves.
All joints should be left exposed until testing is completed. The main pipe should
be charged slowly from the lowest point with any air cock in the open position. Air cocks
should then be closed in sequence from the lowest point, only when water visibly free from
aeration is being discharged through them. Satisfactory charge, the main should be
allowed to stand overnight to allow any residual air to rise out. Re-venting is then
necessary and any water deficiency should be made up.
Pressure testing can then begin by pumping slowly until the pressure reaches 1.5 times
the operational pressure. This pressure shall be kept for maximum 24 hours or otherwise
approved by the Engineer.
A maximum water loss of 3 litres per 1000m lengths per 25mm nominal bore per 24 hours
shall be considered acceptable.
B. Painting
Dry film thickness (DFT) of all painted valves and spool pieces shall be measured
on delivery to site. DFT shall be the average of no less than three measurements with no
one measurement less than 75% of nominal average DFT. Holiday tests shall be carried
out on internal and external surfaces on delivery and also on external surfaces prior to
backfilling.
C. Electrical Tests
Each electrical equipment cable and complete system shall be thoroughly inspected
and tested before finally placing in to service. All tests shall be made in
compliance with respective regulations, recommendations and standards. Any
modifications or repairs deemed necessary upon completion of the tests shall be executed
at the contractor’s expenses. The Employer shall carry out further tests on any modified

or repaired equipment until it is certified trouble free and acceptable for its intended
service. All testing shall be demonstrated to the Engineer.
3.16 AUTOMATIC SYSTEM COMMISSIONING
Commissioning of fieldwork and equipment shall include all works required to bring
the system into service and to make sure that system is operating efficiently and shall
include but not be limited to the following:
1. Flushing all the pipelines.

2. Adjustment of valve outlet pressure +/- 10% of normal.
3. Replacing all clogged or partially clogged emitter lines - delivering less than 50% of normal
flow or any emitter overflowing by more than 50% (squirting).
4. Carrying out emission uniformity, test involving at least 40 emitters on up to 10 valves as
directed by the Engineer
5. Ensure that all valve boxes and sprayers are flush with finish grade
6. Trials shall only be carried out after all valves pressure have been adjusted
7. Adjusting sprayers and sprinklers to ensure spray onto pavement and paths are
minimized.
8. Adjusting spray pattern to ensure optimal coverage.
9. Preparing of irrigation schedules.
10. Adjusting of controllers to give an optimal flow regime generally in accordance with the
drawings and as instructed by the Engineer. Valves sequence may be modified to ensure
that valves operate in a logical sequence to facilitate maintenance operations. Irrigation
cycles for sprinklers and sprayers should be programmed during nighttime and early
morning.
A full cycle shall be run four times and total system flow rates shall be recorded and
stations shall be adjusted in accordance with the instructions of the Engineer based on the
results of these trials. Trials shall only be carried out after all valves pressure has been
adjusted.
3.17 IRRIGATION AND CONTROL SYSTEM
Each particular function of the Irrigation system shall be demonstrated in accordance

with an approved commissioning procedure developed and to the requirements of
the Engineer.
PART 4 ESTABLISHMENT OPERATIONS AND MAINTENANCE (365 DAYS)

4.1 GENERAL
The following relates to maintenance after substantial completion.
The uniformity of water application and efficiency in water delivery of an irrigation system
tends to decrease with each operation because of aging, weathering and corrosion of
different parts. The goal of irrigation system maintenance is to maintain system
performance close to the initial benchmark operating values.

4.2 ORGANIZATIONAL STRUCTURE
The contractor shall ensure that a senior qualified supervisor and planning engineer
are made available for organising and running the maintenance program. The contractor
shall also have available an experienced irrigation technician who can supervise a team of
plumbers and helpers on a day-to-day basis who would be responsible for operation and
maintenance in the downstream side. Pumping station operation and maintenance would
be under the responsibility of a separate team of operatives and maintenance staff
reporting to the pumping station technician.
The maintenance team should carry the essential tools and the spare fittings at all times.
4.3 SYSTEM MONITORING
A. General
1. Repair or replace broken hardware and pipes with materials that match the originals. Test
all repairs.
2. Identify leaks and repair them promptly. Signs of leakage include particularly green spots,
soggy areas around spray heads and above ground hoses, jammed spray heads and torn
hoses.
3. Shut off irrigation systems and adjust whenever irrigation water falls or runs onto hard
surfaces such as sidewalks, streets or driveways.
4. As plants mature, add or relocate system components as needed to maintain uniform
distribution of water. Ensure that system modifications do not exceed the system watering
capacity.
B. System Pressure
The system pressure has to be monitored on the daily basis. The pressure drop is mainly
due to leakage in the system, which has to be attended immediately.
The pressure drop in the filter needs to be checked and if the drop exceeds 0.5 bars the
automatic flushing should start.
C. Irrigation Controller
The following is a checklist for the controller.
1. Check the scheduled functioning of the controller

2. Check for any faulty or tripped stations
3. Reset automatic controllers according to the changing/seasonal needs of the plants.
Irrigation systems should be rescheduled quarterly to correct run times.
4. Program the irrigation controller for multiple start times on watering by sprayers to reduce
runoff and deep percolation below root zone. Drip systems should NOT be cycled in this
manner.
5. Any changes or an alteration in the controller has to be with prior permission of the
Engineer.
D. Solenoid Valves, Quick Coupling Valves and Air Valves
All these valves are to be monitored for efficient working during the operation of the
system.
Inspect the valves to see if they operate without slamming open or closed in order to
prevent damage from surges.

4.4 SYSTEM FLUSHING
Flush valves are provided at the end of the main line if it is not a ring main design and at
the end of each drip laterals. The lines have to be flushed every 3 weeks to maintain the
proper workings of the system.
4.5 SERVICING OF ELECTRIC REMOTE CONTROL SOLENOID VALVES AND

COMPONENTS
The downstream pressure has to be adjusted in the pressure regulator module of the
solenoid valve and set to the design pressure before starting the irrigation system.
With the use of TSE water, the solenoid valves are subjected to clogging and
interrupt in the continuous operation of the system. Hence periodic servicing in every
year is recommended. The contractor should follow the manufacturer’s instruction
for the servicing. Any part, which is faulty, has to be replaced immediately.
The gate valve in the solenoid valve assembly should be closed and opened slowly in
order to avoid surge.
If the valve and or the valve box need to be changed, make sure that the identifying tags
are maintained on the box and the valve.
The y-strainer installed with solenoid valve also needs to be cleaned thoroughly minimum
in every 2 months or more frequently so as to improve the smooth working of the
system.
4.6 ADJUSTMENTS AND CLEANING
A. Drip lines and emitters
With constant movement of people and machinery during maintenance of the landscape
drip lines and emitters are likely to get displaced from its original position causing plants to
yellow. Therefore the position has to be adjusted as and when required.
The chances of salt build up and sand accumulation are high in drip irrigation system and
hence drip tubes are to be flushed and emitters are to be cleaned periodically. A regular
maintenance program of inspection and flushing will prevent emitter clogging.
B. Bubblers
The debris in the water can clog the filters of the bubbler and water emission uniformity
will be substantially reduced, affecting the efficiency of the system. Filter cleaning has to
be performed frequently.
In case the flow of bubbler is still less, check the point of connection for blockage
or bending and rectify.
C. Sprayers
The coverage radius and the flow may have to change depending on water application
rate and can be adjusted by turning the screw on top of the nozzle. The tension
of the spring has to be checked for positive retraction under any conditions. Inspect
alignment of the check valves for eliminating leaks and puddles at the lower heads,
protecting landscape from damage and erosion while reducing wastage of water.
The filter beneath the nozzle gets clogged with debris and needs to be cleaned to
ensure uniform coverage.
D. Rotors

Arc and radius adjustment has to be made from time to time for proper coverage.
The tension of the spring has to be checked for positive retraction under any conditions.
Inspect alignment of the check valves for eliminating leaks and puddles at the lower
heads, protecting landscape from damage and erosion while reducing wastage of water.
The filter at the bottom of the rotors gets clogged and should be cleaned in every year to
ensure uniform coverage.
4.7 EMERGENCY REPAIRS
The maintenance team should be well equipped with tools and fittings to attend to the
repair immediately in coordination with the supervisor and Engineer if required. If
excavation is to be done, following points should be considered.
a) The excavation area should be demarked with warning tape.

b) The area must be isolated using the isolation valve.
c) Care should be taken for not to damage the nearby plants and vegetation.
d) For excavating grass area, lay plastic sheet and put the excavated soil on the
plastic.
e) Care should be taken not to mix the topsoil with soil of lower layer.
f) The replacing materials should be the same as specified and used in the system.
Any materials other than specified require prior permission of the Engineer and ‘As
Built’ drawings updated accordingly.
g) Proper thrust block have to be provided if required.
h) After backfilling, proper levelling has to be done to the satisfaction of the Engineer.
END OF SECTION

TABLE OF CONTENTS
TECHNICAL SPECIFICATION FOR SEWAGE NETWORK 3
PART 1 GENERAL REQUIREMENT 3

1.1 FORMAT AND REFERENCING 3
1.2 ABBREVIATIONS AND DEFINITIONS OF TERMS 3
1.3 SCOPE AND CONTROL OF WORKS 8
1.4 TEMPORARY WORKS 15
1.5 CONTROL OF MATERIALS AND STANDARDS FOR SAMPLING AND TESTING 16
1.6 CONTRACTOR’S PLANT AND EQUIPMENT 19
1.7 MEASUREMENT PROCEDURES 19
1.8 TEMPORARY FACILITIES 21
1.9 SAFETY PRECAUTION MEASURES 24
PART 2 EXCAVATION AND BACKFILLING 24

2.1 SCOPE 24
2.2 SITE CLEARING 24
2.3 EXCAVATION 25
2.4 SOIL FILLING AND BACKFILLING FOR STRUCTURES 37
2.5 SUBGRADE CONSTRUCTION 48
2.6 GABIONS 49
2.7 STONE PITCHING IN CONCRETE 51
2.8 GEOTEXTILES 51
PART 3 PAVEMENT AND ROADS SURFACE FINISHING 52

3.1 SCOPE 52
3.2 GRANULAR SUBBASE AND BASE COURSES 53
3.3 BITUMINOUS LAYERS 55
3.4 PAVEMENT REPAIRS AND TRENCH REINSTATEMENT WORKS 60
3.5 CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS 62
3.6 MAINTENANCE OF TRAFFIC AND DETOURS 67
PART 4 PIPE WORKS AND NETWORK ACCESSORIES 69

4.2 GENERAL REQUIREMENTS 69
4.3 PIPES, FITTINGS AND ACCESSORIES 74
4.4 VALVES, HOUSE CONNECTIONS AND SUNDRY WORKS 104
4.5 BEDDING, SURROUND, HAUNCHING, ENCASEMENT AND THRUST BLOCKS 112
4.6 MANHOLES AND CHAMBERS 113
PART 5 CONCRETE WORKS 118
Red Sea Shura Island Hotel Central 03 TABLE OF CONTENTS Page 1

5.1 CONCRETE AND CONCRETE MIXES AND TESTING 118
5.2 CONCRETE HANDLING, PLACING AND CURING 137
5.3 STEEL REINFORCEMENT AND FIXING 147
5.4 FORMS, FORMWORK AND FALSEWORK 149
5.5 PLAIN AND REINFORCED CONCRETE STRUCTURES 156
5.6 WATERPROOFING FOR STRUCTURES 160
5.7 JOINT SEALING AND JOINT FILLER 166
PART 6 SUMP PUMPS 170

6.1 GENERAL 170
6.2 PRODUCTS 170
6.3 EXECUTION 172
Red Sea Shura Island Hotel Central 03 TABLE OF CONTENTS Page 2

TECHNICAL SPECIFICATION FOR SEWAGE NETWORK
PART 1 GENERAL REQUIREMENT
1.1 FORMAT AND REFERENCING
1.1.1 Format of Specifications
A Part
This Specification is divided into Parts. Each Part is designated by a single- or double-
digit number followed by a title. (Part 1 General Requirements)
B Section
Each Part is divided into Sections. Each Section is designated by the Part number, a
decimal point and a 2-digit sequential number, followed by a title. (Section 1.01 Format and
Referencing)
C Subsection
Each Section is divided into Subsections. Each Subsection is designated by the Part
number, a decimal point and a 2-digit Section number, a decimal point and a single- or
double-digit number followed by a title. (1.01.1 Format of Specifications)
D Clause
Each Subsection may be divided into Clauses. Each Clause is designated by sequential
alphabetic letters and a decimal point. (D.)
E Item
Each Clause may be divided into items. Each Item is designated by the Clause letter, a
decimal point and a single- or double-digit sequential number, followed (if required) by a
title in lower case lettering. The text then normally follows on the same line (E.1).
1.1.2 REFERENCING
A The Specifications for Items in the Bills of Quantities are prescribed in the respective
Section/s corresponding to the type of Works involved.
B All the provisions of these Section/s shall be construed as Specifications for such Items of
Work, except in respect of those provisions clearly inapplicable in the context in which they
appear or unless they are waived or modified in the Contract Documents or by Variation
Orders.
C Specifications and Drawings may contain cross references to other Sections, Clauses,
Items, etc., which shall likewise be construed as Specifications for the Item of Work
involved.
D Any references in the Specification to Work or materials not required will be deemed
inapplicable.
1.2 ABBREVIATIONS AND DEFINITIONS OF TERMS
Red Sea Shura Island Hotel Central 03 Page 3

Sewage Network 19-Sep-22
1.2.1 ABBREVIATIONS
A Interpretation
Wherever the following abbreviations of titles, terms and units of measurement are used in
the Specifications or on the Drawings, the intent and meaning shall be interpreted as
described hereunder.
B Titles and Terms
AASHTO - American Association of State Highway and Transportation Officials:

ABS Acrylonitrile-Butadiene-Styrene
ACI American Concrete Institute
AISC American Institute of Steel Construction
AISI American Iron and Steel Institute
ANSI American National Standards Institute
API American Petroleum Institute
ASTM American Society for Testing and Materials
AV. average
AWG American wire gauge
AWS American Welding Society
AWWA American Water Works Association
Bit. bitumen/bituminous
BS British Standard
BSSC bituminous slurry seal coat
BST bituminous surface treatment
CB circuit breaker
CBR California Bearing Ratio
conc concrete
CIE Commission Internationale de l’Eclairage
DBSC double bituminous seal coat
DIN Deutsches Institute Fur Normalizieung
Equiv equivalent
FSS Federal Standard Specification (USA)
hwy highway
ht height
H:V horizontal: vertical
IEC International Electrical Commission
IEE Institution of Electrical Engineers (UK)
ISO International Organization for Standardization

L.L. liquid limit
L.S. lump sum
max maximum
MCCB molded case circuit breaker
min minimum (or minute)
MUTCD : Manual on Uniform Traffic Control Devices
NEC National Electrical Code (UK)
NEMA National Electrical Manufacturers’ Association (USA)
NJB New Jersey barrier
pav’t pavement
P.C. prime cost
PCC Portland cement concrete
PE polyethylene
P.I. plasticity index
P.L. plastic limit
PTFE Polytetrafluoroethylene
PVC polyvinyl chloride
qty quantity
RC reinforced concrete
RCP reinforced concrete pipe
rdwy roadway
ROW right-of-way
SBSC single bituminous seal coat
S.G. specific gravity
SI Systeme International D’Unites
Sta Station (location along a survey line)
SWG standard wire gauge (UK)
TBSC triple bituminous seal coat
uPVC unplasticized polyvinyl chloride
VDE Verband Deutscher Electrotechniker
wgt weight
GRP Class reinforced plastic
DI Ductile Iron
SASO Saudi Arabia Standards Organization

C Units of Measurement
Throughout the documentation units of measurement are referred to by symbols as

follows:
Nr number
mm millimeter/s
cm centimeter/s
m meter/s
lin.m linear meter/s
km kilometer/s
sq.mm square millimeter/s
sq.cm square centimeter/s
sq.m square meter/s
ha hectare/s
cu.m cubic meter/s
gm gram/s
kg kilogram/s
tonne metric ton (1,000 kg)
ml milliliter/s
ltr liter/s
Pa Pascal/s
N Newton/s
kN kilo Newtons
MN mega Newtons
A amperes
mA milli amperes
V volt/s
W Watt
kW kilowatt
C Celsius (Centigrade)
Hz Hertz (Frequency)
rpm revolutions per minute
km/h kilometers per hour
sec seconds
min minute/s (or minimum)
h hour/s
mS milli Siemens

dB decibel/s
dBA decibels absolute
ppm parts per million
in. inch/inches (1 in. = 25.4 mm)
ft foot/feet (1ft = 0.3048 m)
sq.in square inch/inches
sq.ft square foot/feet
cu.ft cubic foot/feet
lb. pound/s (weight)
psi pounds per square inch
gal gallon/s (U.S.)
gal(Imp) gallon/s (Imperial)
mph miles per hour
HP horsepower
USG American gage
1.2.2 Definitions
A Wherever in the specification or in other Contract Documents any of the following terms is
used, the intent and meaning shall be interpreted as follows:
a) ACCEPTED - Accepted in writing by the Engineer (or by the Employer where

appropriate) as meeting the requirements of the Contract Documents and of any authorized
variations thereto. "Acceptance" means accepted in writing as aforesaid. "Acceptable" means
acceptable to the Engineer as aforesaid.
b) ADDENDUM/NOTICE - Amendment of or revision to any of the Contract Documents
issued to Tenderers, and which is deemed to form part of the Contract Documents.
c) APPROVED - Approved in writing by the Engineer, including subsequent written
approval or confirmation of previous verbal approval by the Engineer. "Approval" means approval
in writing as aforesaid.
d) CERTIFICATE OF GUARANTEE - A signed statement by a person having legal
authority to bind a company or supplier to its product, and which confirms that the materials and
test results conform to the standards of these Specifications.
e) DIRECTED - Directed in writing by the Engineer, including subsequent written
direction or confirmation of previous verbal direction by the Engineer.
f) PRESPLITTING - Establishment of a free surface, or shear plane, in rock cuts, by
controlled use of explosives in specially aligned and closely spaced drill holes along the slope line.
g) SHEATHING - Backfilling to the inside faces of structures such as retaining walls
and abutments, using proprietary filter cloth and porous blocks, or using selected, free-draining
material such as gravel or non-cementitious sand, etc, prior to placing and compacting normal
backfill.
h) SOIL STABILIZATION - Procedure whereby cement, bitumen or lime is added to
soils (subgrade layer) or to granular materials (sub-base course) in order to improve their load
bearing capacity and their resistance to weathering and displacement.
i) SUBGRADE - The top surface of embankment or excavated area on which the
pavement structure and shoulders are constructed. Also referred to as Subgrade Surface or

Subgrade Level.
j) SUBGRADE LAYER - The top layer of material, of at least 200 mm compacted
thickness, immediately below the subgrade surface.
k) SUBSIDIARY WORKS - Works which are subsidiary to or necessary or essential to,
or in support of, or usual to, the execution and completion of other Works.
l) WORKING DRAWINGS - Shop drawings, steel bending schedules, stress sheets,
fabrication and erection drawings, falsework drawings, and any other supplementary drawings or
data which the Contractor is required to submit to the Engineer for approval, generally before such
Works commence.
1.3 SCOPE AND CONTROL OF WORKS
1.3.1 Intent of Contract
A The intent of the Contract is to provide for the construction and completion in every detail
and subsequent maintenance of the Works described. The Contractor shall furnish all
labor, materials, tools, equipment, transportation, supplies and facilities and shall carry out
all Permanent and Temporary Works and all other items necessary for proper completion
of the Works in accordance with all requirements of the Contract Documents.
B Where the Specifications or Drawings describe any portions of the Works in outline only,
and not in complete detail, the best general engineering practice shall prevail and only first
quality materials and workmanship shall be used.
1.3.2 Silence of Specifications
A The apparent silence of the Specifications, Drawings or other Contract Documents as to

any detail or the apparent omission from them of a detailed description concerning any
Works or requirements, shall be regarded as meaning that good engineering practice shall
apply and shall be to the approval of the Engineer.
1.3.3 Contractor's Work Areas
A The Contractor shall make all necessary arrangements, including payment if need be,
regarding any land outside the Site that may be needed as work areas. The Employer will
not acknowledge any liability in respect of such land. The Contractor shall also be
responsible for insuring that all roads and temporary facilities needed are sufficient to
divert traffic adequately.
B The Contractor shall locate and select sites outside the right-of-way for the use of his plant,
equipment, site offices, residences, Temporary Works or any other uses which are
essential during the execution of the Contract. The Contractor shall take the necessary
measures for using these sites and shall be responsible for all expenses that may become
due in return for such use. Prior to using any land owned by public or private owner
outside the Site, the Contractor shall obtain the approval of the concerned Authorities and
the Engineer.
C The Contractor, if so required by the Engineer, whether before or after completion of the
Works, shall remove his constructional plant and duly clean the site and shall, wherever
applicable, remedy all damage and pay all monies due to land owners in return for using
their land.
D It is the Contractor's responsibility to verify the stability of side slopes in cut areas by
specialized staff. The Contractor, at his own expense shall execute any required site
investigation prior to cutting in the relevant areas. The proposal of site investigation
program as well the final recommendation should be approved by the Engineer. No direct

payment shall be made for this work, all expenses should be included in the Contractor's
rates.
E The Contractor shall inspect the location and the surrounding areas and comprehend all
the details related to the type, nature, details, topography and existing services of the
location.
The Contractor shall acquire all the information related to risks, dangers, weather
conditions and any other related factors that may influence his tender, and no later
consideration will be made since these expenses should be added by the Contractor on
the prices of works and other items.
1.3.4 Water Supply
A The Contractor shall be deemed to have executed adequate investigations relating to the
availability of water for the purpose of the Works and to have consulted and arranged with
the appropriate Authorities and taken into consideration all legal aspects. The Contractor
shall be responsible for the supply of sufficient clean, fresh water at all times during
progress of the Works, including making temporary arrangements for storing and
distributing the water on the Site.
1.3.5 Electricity Supply
A The Contractor shall make his own arrangements for the supply of all electrical power and
all lighting and electrical equipment required for execution of the Works, including supplies
for commissioning engineering services and Plant at required voltages. The Contractor
shall also make provisions to store and distribute electrical power and equipment on Site.
B The Contractor shall provide and maintain adequate efficient lighting for all parts of the
Works for safety and security purposes required to facilitate proper execution of work and
to illuminate surfaces during finishing work and inspection. Without prejudice to his liability
under the General Conditions of Contract, the Contractor shall, with respect to the supply
of electricity for power or lighting, take all necessary precautions to ensure the safety of his
workmen and others.
C Permanent electric supply and lighting installations may be used for testing and
commissioning and to illuminate the Works, subject to the following conditions:
a) The Employer does not guarantee that it will be available.

b) The Contractor must take responsibility for the operation, maintenance and
supervision of the system, indemnify the Employer against all damage and pay all costs and renew
all used tubes and lamps.
c) The Contractor must indemnify the Employer against any reduction in the
manufacturer's guarantee periods for equipment etc. due to its use before completion of the
Works.
1.3.6 Existing Utilities and Other Obstructions
A Categories of Obstructions
Obstructions shall be classified as follows:

a) Existing private and public owned utilities, above and below ground, which are
required to be either protected, adjusted, relocated or removed.
b) Obstructions, above and below ground (other than utilities), which are required to be
taken down, dismantled, demolished or excavated, and removed, as appropriate.
B Existing Utilities

1. Utilities shall include, but not be limited to, existing water lines, gas lines, sewer
lines, wire lines, service connections, water and gas meters and valve boxes, light
poles and masts, pylons, cableways, signals, and all utility appurtenances within
the limits of the proposed construction.
a) The Contractor shall submit all plans showing existing utilities under earth and their
relations with pipelines under construction.
b) The Employer/Engineer takes no responsibility as to the correctness, accuracy,
completeness or validity of information obtained from these Drawings and the Contractor shall be
fully responsible for his own interpretation and shall execute whatever additional investigations are
necessary to obtain the needed information at the Contractor's own expense.
c) The costs of all related Works concerning verification and identification of existing
utilities including excavating any trial pits, detection means, mapping detailing of drawings and co-
ordination with respective Authorities shall be fully borne by the Contractor. Should any relocation
of existing utilities, not previously identified by the Contractor, be instructed, or shown on the
Drawings, these shall not constitute a change in the Scope of Work, and shall give no grounds for
extension to the Time for Completion or for other claims. The relocations, however, will be paid for
and valued in accordance with the Contract rates.
2. The necessary utility diversions may be specified or directed to be carried out by
the Contractor. Alternatively, the Employer may make arrangements for such
works to be executed by other parties.
3. The Contractor shall:
a) Take into account that the diversion works shall be carried out to the requirements
and approval of the Utility Owners and/or under their supervision, and also where
required by the Utility Owners, specialist diversion works shall be carried out by
accredited specialist Contractors.
b) Verify and identify the existing utilities by excavating trial pits and other measures
including detection means existing utilities. Coordinate with the relevant Authorities and map these
utilities and prepare detailed and accurate existing utilities drawings identifying the utilities that are
in service and those that are dead or abandoned. Submit these existing utilities Drawings, that are
accurate and detailed giving location of utilities in plan and section with all pertinent data of the
respective utility, to the Engineer and to the Utility Owners.
c) Work out and develop, in coordination with the Utility Owners and the Engineer, the
approved utilities diversion schemes that will be required to enable the execution of the Works and
also maintain continued utilities services in the Area, and to the users.
d) Provide superintendence for the execution of the utility diversions whether they are
carried out by the Contractor directly or by other parties employed by the Contractor.
e) Provide accurate As-Built Drawings of all permanent utility diversions that are
executed under the Contract.
4. The Employer will, in consultation with the Engineer and Contractor, coordinate
with all Utility Owners to ensure prompt adjustment, relocation or removal of all
affected utilities, including any additional utilities that may be encountered during
the Works. The Employer and Engineer will facilitate, to the maximum extent
practicable, the Contractor's Work Program, in this respect.
5. The Contractor shall take into account, in his Program of Work, the time effort
involved in the follow-up and execution of Works pertaining to all utility
adjustments, relocations and removals. The Contractor shall schedule
construction activities so as to avoid or minimize any potential delays,
inconvenience or damage to the Works that may result from utility interference or
the operations of adjustment, relocations and removals.
6. The Contractor shall follow up the execution of the utility diversions whether they
are carried out directly or by other parties employed by the Contractor or directly
by the Employer. The Contractor shall, in good time, inform the Employer and the
Engineer.

7. The Contractor shall be responsible for safeguarding and protecting all utilities and
appurtenances encountered during the Works. The Contractor shall be
responsible for the costs of making good any damage arising out of its own
negligence.
8. The execution of the utility diversions should be done by similar materials of
equivalent grade or strength as minimum to the materials of the existing utilities
and as per the Engineer approval and the utility owners requirements.
9. In case it is required to stop the water in the existing network while execution of
the utilities diversions or replacement of existing water pipeline, the Contractor
should inform the Engineer and coordinate with the water supply authorities in
advance by 48 hours. If the water supply would stop for more than 48 hours, the
Contractor should provide temporary service for water supply on his own
expenses, either using temporary pipelines or by water tanker or any other way
approved by the Engineer. In all cases, the Contractor should get written license
from the water supply authority including the required instructions.
10. Execution of the water networks diversions should be done as per the water
networks specifications stipulated in Section (4) of these specifications. Testing,
cleaning and disinfection of the pipelines should be done according to Section (4-
3-3) of these specifications.
C Obstacles
1. Obstacles shall include, but not limited to existing buildings, walls, fences, gates, wells,
septic tanks, manholes, pits, pipes, culverts, roadways, sidewalks, signs and rubbish
dumps, whether or not shown on the Drawings.
2. At the commencement of the Contract, the Contractor shall examine the Site and
identify/verify all obstacles in the Site above or below ground, and shall record all
such information on suitable Site Drawings which shall be submitted to the
Engineer within one month of commencement date.
3. Existing Septic Tanks:
If the pipelines or the house connections cross any existing septic tanks and it was not
possible to change the pipeline routing to avoid them, the Contractor should proceed to
dry, clean, demolish and backfill those tanks partially or fully.
Wherever possible, only the crossing part of the tank with the water pipeline that will be
demolished and backfilled and the rest of the tank should be separated by building a
suitable wall to make the tank in a good working condition. All precautions should be taken
to keep the existing system working and to pump the sewerage from the tanks and to
dispose of the sewage according to the local authorities instructions. The sewer water
must not be allowed to leak to the water pipelines trenches or the water system.
In case of partial or full demolish, the top slab should be removed either fully or partially
and the walls should be lowered at least by 1m below the ground level. Filling should be
as per the backfilling specifications in this document.
All of the above requirements should be applied to all existing tanks including those
constructed during this pipelines contract and those crossing the pipelines.
Harmful gases concentration should be monitored using special gas monitoring devices
before and during commencing of the work in septic tanks. All laborers entering to the
tanks must be provided with full safety tools and gas masks, etc. and the Contractor must
provide all first aid tools on site.
4. Change of Pipeline Rooting Around Tanks:
When existing tank crosses the proposed pipeline, the pipeline routing should be changed
if possible around the tank leaving a 50 cm clear distance between the tank walls and the
pipeline. Those pipelines should be covered by plain concrete as per the Engineer
recommendations.

THE Contractor should prepare detailed drawings for the tank boundaries that cross the
pipeline, showing all the connection details that are required to relocate the pipe around
the tank. This drawing should be approved by the Engineer prior to construction.
1.3.7 Sign Boards
A Nameboard: The Contractor shall provide suitably sized project nameboards, bearing the
names of the Employer and Engineer together with any corresponding logos, the name of
the project, the name of the Contractor and such other names and information as the
Engineer may request. The design and style of the nameboard shall be submitted to the
Engineer for approval prior to fabrication. Nameboards are to be written in English and the
local language and erected at suitable locations as directed by the Engineer. Refer to
Section 1.08.2 Item “G” for the nameboard details. As detailed in Section 1.08.2, Item E of
the specifications.
B Each sign board shall be erected in a prominent, approved position. Sign boards shall be
maintained in good order at all times and sign boards and supports shall be dismantled
and removed from the site upon completion of the Works.
C All sign boards are to comply with the requirements of concerned authorities (Municipality/
Ministry of Transport/Traffic Directorate).
1.3.8 Surveying Equipment
A The Contractor shall provide sufficient and suitable surveying instruments and other
equipment for his own use in setting out and leveling of the Works, and also to enable the
Engineer to check the setting out. Furthermore, the Contractor shall provide sufficient
chainmen and other assistance as the Engineer may require.
B The accuracy of survey instruments may be verified at any time by the Engineer and any
unsatisfactory instruments shall be promptly calibrated or removed and replaced by the
Contractor at its own expense.
C Upon completion of the Contract, all survey instruments shall remain the property of the
Contractor, unless a Pay Item for such instruments is included in the Bills of Quantities, in
which case the instruments shall become the property of the
1.3.9 Setting Out of Works
A The Contractor shall, prior to any setting out, submit a planned method of operations for
setting out the Works to the Engineer for his approval. The plan shall include the
accuracy, positions of the various types of stakes, method of marking stakes, and methods
to be used for protecting stakes, etc. No survey work shall proceed without to the
Engineer’s approval of the Contractor’s plan.
B The Contractor shall give written notice to the Engineer at least 24 hours before he intends
to survey any portion of the Works. Such notice shall include the time, location and type of
Works to be set out.
C Before commencing Work on Site, the Contractor shall carry out a topographical survey of
the Site, as directed by the Engineer. This survey shall include such parts of the Site as the
Engineer may direct, to record the Site limits, dimensions, ground levels, obstructions and
other features and the survey shall establish base lines and points for future setting out
and also record the basis for re-measurement of excavation and earthwork, where
applicable. The Contractor shall set out the Works, inform the Engineer when setting out is
complete and obtain Engineer’s approval before proceeding with construction. The
Contractor shall provide instruments and assistance for checking the setting out if required
by the Engineer. If, in the opinion of the Engineer, modification of the lines or grade is

required, before or after survey, the Engineer will issue detailed instructions to the
Contractor who shall revise the setting out accordingly.
D Setting Out Utility Works shall be as shown on the Drawings or as instructed on Site.
Stake-out shall be revised if, in the opinion of the Engineer, modifications of line or grade
are required.
E The Contractor shall be responsible for preserving all existing stakes, marks and
monuments and if any construction stakes or marks are destroyed or disturbed, the
Contractor shall replace them at his own expense.
a) Record Drawings: The Contractor shall record details of all grid lines, ex-isting
ground levels, setting-out stations, bench marks and profiles on the site setting-out
drawing. This drawing shall be retained on the Site throughout the duration of the
Contract and handed over to the Engineer upon completion of the Works.
b) All dimensions and levels on the Drawings and the Site, shall be checked
particularly the correlation between components and the work in place. Materials and components
shall not be ordered, or work carried out, until discrepancies have been resolved with the Engineer.
c) Appearance and Fit: The Works shall be constructed to higher levels of accuracy
than those specified where it is necessary to achieve a desired appearance and also to ensure that
materials, elements, and components of the building fit together as designed. Wherever the
accuracy, fit or appearance of the work is likely to be critical, or difficult to achieve, the Contractor
shall obtain the Engineer’s approval of proposals or of the partially finished work as early as
possible.
d) Non-Compliance: Work which fails to meet the specified levels of accuracy must not
be rectified before the Contractor submits and receives approval of proposed rectification works.
All additional costs resulting from these rectification works shall be borne by the Contractor.
1.3.10 Haul Routes for Heavy Vehicles
A The Contractor shall prepare proposals for routes to be used by heavy vehicles particularly
for hauling fill materials. Routes shall where possible, avoid existing roads and built-up
areas. Signs shall be provided and maintained to direct construction traffic to and from
haul routes. Details of haul routes and signing shall be submitted to the concerned in
Traffic Directorate for approval within a period not exceeding one month prior to the
commencement of the Works in the relevant area and the signs shall be erected prior to
actual commencement of the Works.
B If and where it is necessary for Contractor’s plant or vehicles to cross public highways, and
where required by the Engineer, all such crossings shall be equipped with manually
controlled traffic lights.
C Stationary vehicles, equipment, huts, stockpiles of materials, etc., shall be kept well clear
of crossing points so that persons using the highway and the haul road shall have
adequate sight distance at all times.
1.3.11 Scaffolding and Falsework
A The Contractor shall provide scaffolding and falsework to facilitate carrying out
construction of the Works in the required sequence. Scaffolding and falsework shall be
properly designed and constructed specifically for the loads intended. Full details of the
proposed arrangements shall be submitted to the Engineer for his approval. Such
approval, however, shall not relieve the Contractor of his responsibility with regard to the
adequacy of all scaffolding and falsework used in the Works.

1.3.12 Use of Explosives
A Control Measures
1. The Contractor shall not use explosives without the express permission from the
controlling Authority. The Contractor shall abide by all rules and regulations of the
concerned Authorities regarding purchasing, transportation, storing, handling and using the
explosive materials.
2. Explosives and detonators shall be stored in special buildings as approved by the
concerned Authorities. These secured buildings should be located and clearly
marked English and Arabic “DANGER - EXPLOSIVES” as approved by the
concerned authorities. Explosives and detonators shall be stored in separate
buildings.
3. All possible precautions shall be taken against accidental fire or explosion, and to
ensure that the explosives and detonators are kept in proper and safe condition.
4. Explosives and detonators shall always be transported in separate vehicles and
kept apart until the last possible moment. Metallic tools shall not be used to open
boxes of explosives.
B Blasting Procedures
1. Ensure that blasting shall only be carried out by experienced shot firers. Priming,
charging, stemming and shot firing shall be carried out with greatest regard for safety and
in strict accordance with the Rules and Regulations of the concerned Authorities.
Adequate warning of blasting shall always be given and all persons cleared from the area,
before blasting takes place.
2. Ensure that police and other concerned Authorities shall be kept fully informed of
the blasting program so that they may be present when blasting takes place if they
so require.
3. Ensure that explosive charges are not excessive, charged boreholes are properly
protected, and proper precautions are taken for the safety of persons and property.
Only the Contractor shall be responsible of people and premises full protection.
C Explosives Inventory
1. The Contractor shall maintain an up-to-date inventory of all explosives and explosive
devices and shall submit a monthly report to the Engineer, detailing the use of all
explosives by date and location.
1.3.13 Fire Fighting Equipment
A The Contractor shall take all necessary measures to prevent personal injury or death or
damage to the Works or other property and adequate, fully operational fire fighting
equipment shall be furnished and maintained by the Contractor whose workmen shall be
trained in the operation of such equipment.
B Fire fighting arrangements shall be made as required by the local Civil Defense
Department and provision of fire fighting facilities in all vulnerable areas and as instructed
by the Engineer.
C Adequate water for fire fighting shall be available and outlets located so as to be readily
accessible.
D All equipment shall be regularly tested and properly maintained.

1.3.14 Photographic Records of Construction
A The Contractor shall submit each month good quality progress photographs of at least 5
different subjects as agreed by the Engineer. For each subject, the Contractor shall supply
progress photographs taken from approved locations stations but not less than 20 (twenty)
at monthly intervals and submit 3 color prints (gloss finish) not less than size 16cm x 20cm
of each negatives and color transparency.
B Each print and transparency supplied, shall be titled and referenced to a suitable key plan.
Prints and negatives shall also be suitably cross referenced.
1.3.15 Site Cleaning and Final Clean Up
A Site Cleaning During Progress of Works
1. All parts of the Site, and adjacent roads affected by the Works, shall be maintained in a
clean and tidy condition during progress of the Works. All waste and surplus materials and
other rubbish resulting from the Works or otherwise, shall be cleared away to locations
approved by the Municipalities and Directorate at intervals as directed by the Engineer.
2. If the Contractor fails to remove any surplus or waste materials from the Site within
3 days after being instructed to do so by the Engineer, these materials may be
removed by others at the Contractor’s expense.
B Final Clean Up on Completion
1. The entire Site shall be delivered up on completion of the Works, in a clean, neat and
presentable condition, all as specified hereunder and as described in the General
Conditions of Contract.
2. Spoil tips, borrow pits and deposited materials shall be trimmed and regularized to
profiles and levels as directed. Flow of water courses affected by the tips or pits
shall be maintained without interruption and any agreement concerning these
sites, existing between the Employer and the persons or Authorities concerned,
shall be observed.
3. Temporary Markings coverings and protective wrappings shall be removed unless
otherwise instructed by the Engineer.
4. Partial Possession by Employer: Where the Works are to be completed in
sections, and any such section depends for its adequate functioning on work
located elsewhere on the Site, such other work shall be completed in time to
permit sectional completion as required.
1.4 TEMPORARY WORKS
1.4.1 Scope
A The Contractor shall construct, as required, all temporary detour roads, temporary bridges
and culverts, and other facilities for his Works or for maintenance of traffic in locations
affected by his works.
B The Contractor shall construct and maintain all detour routes ensuring at all times that the
detour routes are signed, striped, lighted, maintained and furnished with all traffic control
devices as shown, directed and/or needed. These proposed detours must be submitted to
the Engineer for approval.
C Trench crossings are to be provided for free and safe passage of vehicles and pedestrians
over pipe and other trenches.

1.4.2 Design Requirements
A Designs and detailed working drawings for proposed Temporary Works shall be submitted
for approval, prior to commencing such Works. The Contractor shall be held responsible
for any damage that may result from the Temporary Works.
1.4.3 Agreement of Property Owners
A The Contractor shall obtain the agreement of the affected land owners and approval from
the Engineer prior to commencing Temporary Works. Such approval shall not in any way
relieve the Contractor of his responsibilities expressed in the General Conditions of
Contract.
1.5 CONTROL OF MATERIALS AND STANDARDS FOR SAMPLING AND TESTING
1.5.1 Storage of Materials
A Materials shall be so stored as to assure the preservation of their quality and suitability for
the Works. Stored materials, approved before storage, may again be inspected prior to
their use in the Works. Stored materials shall be located so as to facilitate their prompt
inspection.
B Where materials are stockpiled on Government or private property, such sites shall be
abandoned immediately upon consumption of all stockpiled materials and the natural
surface shall be restored as far as practicable to the original condition by the Contractor
and to the satisfaction of the Engineer.
1.5.2 Handling Materials
A All materials shall be handled in such manner as to preserve their quality and suitability for
the Works. Aggregates shall be transported to the Works in vehicles, which are
constructed to prevent loss or undue segregation of materials after loading and unloading.
1.5.3 Materials Supplied by Employer
A The Contractor shall be responsible for all materials furnished by the Employer and shall
make good any shortages or deficiencies, from any cause whatsoever, or any damage
which may occur, after delivery of such materials.
1.5.4 Local Material Sources
A When material sources are not designated on the Drawings, or in other documents, the
Contractor shall be responsible for locating and providing suitable materials from approved
sources.
B Any information provided in the tender documents about sources of local materials is
considered as a guideline only and does not relieve the Contractor of his responsibility in
respect of investigation and supply of suitable materials as specified.
C Materials, regardless of their source, shall not be incorporated in the Works until approved
by the Engineer.
1.5.5 Sources of Supply and Quality Requirements
A All materials, including manufactured articles, and machinery incorporated in the Works,
shall meet all specified quality requirements and be approved by the Engineer.

B The Contractor shall, before placing any purchase order for any materials intended for
incorporation in the Works, submit for approval a complete description of all such
materials, names of the firms from whom he proposes to purchase them and copies of all
test reports verifying conformity with the provisions of the Specifications. Materials shall
not be ordered without the approval of the Engineer. When directed by the Engineer or
otherwise specified, the Contractor shall submit suitable samples for approval.
C The Engineer shall have the right to retest all materials which have been tested and
accepted at the source of supply after delivery to the Site and prior to incorporation into the
Works and to reject any such materials which are clearly defective or, when retested, do
not conform with the Specifications.
1.5.6 Certificates of Guarantee and Production Plant Inspections
A All shipments of materials shall be accompanied by a Certificate of Origin and a

Manufacturer’s Certificate of Guarantee or Test Certificate from an approved independent
qualified laboratory approved by the Engineer. All certified materials delivered to the Site
shall undergo additional laboratory testing if required by the Engineer.
B Issuance of an invalid or erroneous Certificate of Guarantee shall be just cause for

rejection of the materials without further testing.
1.5.7 Sampling and Testing Procedures
A Sampling
1. Samples of all materials shall be submitted to the Engineer for inspection, testing and
acceptance before incorporation in the Works. All materials being used will be subject to
inspection, testing, or rejection at any time prior to such incorporation.
2. Where untested and unaccepted materials have been used without approval of the
Engineer, such use shall be at the Contractor’s risk.
B Source Tests
1. All source samples shall be taken by the Contractor in the presence of the Engineer, using
approved sampling procedures. All source approval tests shall be performed under the
supervision of the Engineer or, when so specified, by an independent laboratory approved
by the Engineer and engaged by the Contractor.
2. After approval of any source of materials, the Contractor shall produce from such
source only to the extent that materials produced are of substantially the same
quality as the approved samples.
3. The Engineer will periodically order retesting of previously approved sources to
verify that they continue to conform to the Specifications and may order retesting
at the same or at a different laboratory from the one performing the original source
approval tests. If retesting indicates that a previously approved source no longer
conforms with the Specifications, the Contractor shall forthwith cease production
from such source.
C Job Control Tests
1. Job control tests shall be performed by the Contractor prior to submitting any materials to
the Engineer for approval. The Contractor shall submit details to the Engineer of his job
control testing program.
2. The Engineer may declare the Contractor’s job control testing program
unacceptable if frequent rejections of submitted materials occur when subjected to
the Project Control Tests.

D Project Control Tests
1. All Project Control samples shall be taken jointly by the Engineer and the Contractor.
Tests shall be performed in the Site Laboratory, or in situ as appropriate, under the
supervision of the Engineer.
2. The Engineer may order retesting of any material if there has been a significant
delay in the construction operations or if he determines that the material has
deteriorated since its original acceptance. Material which does not conform with
the Specifications will be rejected and shall be removed from the Works and
replaced or corrected by the Contractor. The Engineer may order additional
testing to ascertain the extent of unacceptable material.
E Check Tests
1. The Engineer may periodically order check tests to verify the accuracy of Project Control
testing and equipment. The Engineer may direct that check tests be performed by qualified
persons other than those normally responsible for Project Control testing, or he may direct
that the samples be sent to the Employer’s Central laboratory or to an approved
independent laboratory for testing.
2. The Contractor shall provide the Engineer with all necessary Test Report forms
and expendable materials required to perform all required tests. Copies of all test
results will be issued to the Contractor.
1.5.8 Sampling and Testing Standards
A Standards to be Supplied
1. The Contractor shall, at the commencement of the Contract, furnish for use on site by the
Engineer and the Contractor one complete set of the following standards. The set shall
become the property of the Contractor upon completion of the Works.
a) AASHTO Standard Specifications for Transportation Materials and Methods of
Sampling and Testing (Part I: Specifications, and Part II: Tests).
b) ASTM Standards for Testing and Materials: Section 00 plus all Volumes in Sections
1 to 6 inclusive, plus Specifications, as required, from Sections 7 to 15 inclusive.
c) British Standards referred to in the Specification
d) SASO Standards.
e) DIN
f) ISO
g) All other relevant Standards referred to in the Specifications.
B Precedence of Materials and Testing Specifications
1. All references to methods of testing or specifications of AASHTO, ASTM and others will be
deemed to refer to the latest methods of testing as specified in the Contract Documents.
2. Unless otherwise specified, AASHTO methods of sampling and testing shall be
adopted where available. In the case of absence of an appropriate AASHTO
specification, the ASTM or BS specification shall govern.
1.5.9 Unacceptable Materials
A All materials not conforming to the requirements of the Specifications at the time they are
used will be rejected and shall be removed immediately from the Site unless otherwise
instructed by the Engineer.

B No rejected material, the defects of which have been corrected, shall be used until
approval has been given.
1.6 CONTRACTOR’S PLANT AND EQUIPMENT
1.6.1 General
A Plant and equipment used on the Works shall be of sufficient size and in such mechanical
condition as to meet the requirements of the Specifications and shall be available for use
when required by the Engineer. The Engineer may order removal and replacement of
unsatisfactory plant or equipment.
B Wherever plant or equipment of a particular size or type is specified, the Contractor may
request permission to use an alternative type in place of that specified. In such cases, the
Contractor shall furnish evidence to the Engineer, before approval is given, that the
production of the plant or equipment proposed is at least equal to that of the specified type.
1.6.2 Contractor’s Schedule of Plant and Equipment
A The Contractor shall submit together with his Tender, a detailed schedule of the numbers
and types of plant and equipment which he proposes to utilize on Site to carry out the
Works. The schedule shall contain full details for each item, including type, manufacturer,
model, identification number, year of manufacture, number of years in use, and, for all new
and previously used items, the manufacturer’s brochures, catalogues and specifications.
1.6.3 Provision and Use of Plant and Equipment
A The Contractor shall furnish all plant and equipment listed in his Schedule and necessary
for construction of each phase of the Works. Such plant and equipment shall be delivered
to the Site, inspected, and approved by the Engineer prior to commencement of the
particular phase of the Works for which it is intended. Any plant or equipment, or part
thereof, which becomes excessively worn or defective shall be promptly repaired or
replaced, as required by the Engineer.
B The Contractor shall not remove from the Site any approved plant or equipment without the
permission of the Engineer.
1.7 MEASUREMENT PROCEDURES
1.7.1 General
A All Works shall be measured net and in accordance with of the General Conditions of
Contract. All units of measurement shall be in the Metric System, unless specified
otherwise.
B The method of measurement and computations to be used in determining quantities of

materials furnished and of Works performed shall be as defined in the Method of
Measurement.
C All field measurements of quantities for monthly certificates and for final payment shall be
made by the Contractor in the presence of the Engineer. Original copies of the field
measurement notes, signed by the Contractor, will be retained by the Engineer.
D If the Contractor fails to measure any Pay Items, the Engineer may, at his discretion,
estimate quantities of such items for the monthly Payment Certificate or recommend that
no payment be made for the Items not measured and quantities not computed until it is
measured.

1.7.2 Manufactured Items
A Whenever standard manufactured items are specified, such as fence wire, plates, rolled
shapes, pipe conduit, etc. and these items are identified by gauge, unit weight, section
dimensions, etc., such identifications shall be deemed to be nominal weights or
dimensions. Unless controlled by tolerances in cited specifications, manufacturing
tolerances established by the industries involved may be accepted by the Engineer at the
recommendation of the Concerned Authorities.
1.7.3 Fittings And Accessories
A When any Items are shown on the Drawings or specified as requiring miscellaneous
fittings and accessories for which no separate measurement is provided, the Pay Item will
be deemed to include for all such fittings and accessories.
1.7.4 Weight Measurements
A All materials which are to be measured or proportioned by weight shall be weighed on

accurate and approved scales by competent and qualified personnel, at locations
designated or approved by the Engineer.
1.7.5 Linear And Area Measurements
A All items which are to be measured by linear meter shall be measured parallel to the base
or foundation upon which such items are placed, unless otherwise shown on the Drawings.
B Unless otherwise specified, longitudinal measurements for area computations shall be

made horizontally and no deductions shall be made for fixtures with an area less than one
sq.m. Transverse measurements for area computations shall be the neat dimensions
shown on the Drawings or as ordered by the Engineer.
C No measurements shall be made of rolled down or sloping edges of bituminous courses.
1.7.6 Volume Measurements In Vehicles
A Materials to be measured by volume in the hauling vehicle shall be hauled in approved

type vehicles and measured therein at the point of delivery. Vehicles for this purpose may
be of any size or type approved by the Engineer, provided that the body is of such shape
that the actual contents may be readily and accurately determined. All vehicles shall be
loaded to their level capacity and the Engineer may require loads to be releveled when the
vehicles arrive at the point of delivery.
B When requested by the Contractor and if approved by the Engineer, material specified to
be measured by the cu. m. may be weighed and such weights will be converted to cu. m.
for payment purposes. Factors for conversion from weight measurement to volume
measurement will be determined by mutual agreement between the Engineer and the
Contractor, if no agreement is obtained, the factors will be determined by the Engineer and
shall be accepted by the Contractor.
1.7.7 Earthwork Volume Measurements
A The quantities of excavation paid for under the Contract unit prices shall be limited to the
lines shown on the Drawings and on approved cross sections. Excavation beyond lines
shown on approved cross sections shall not be paid for unless approved by the Engineer.

Excavation in excess of approved cross sections will be measured for payment only in the
case of unstable or unsuitable materials ordered by the Engineer to be removed.
B The Engineer will adjust the angle of slopes for cuts and fills as the Works proceed and
make determinations of the appropriate slope angles following his evaluation of soil
conditions in case there is a change in the type of the soil. The actual slopes of the cuts
as constructed shall be measured and recorded by the Contractor. The Engineer will
check these records and, if satisfactory, will approve the measurements as a basis for
payment.
C Within 60 days of the date of field survey, the Contractor shall submit to the Engineer for
his approval, plots of the original and final earthwork cross sections together with the area
and volumetric earthwork computations. The Contractor’s cross sections shall be on
transparent cross section sheets for print reproductions. All sheets shall have a title block
and be of the size designated by the Engineer. On final approval of the Contractor’s cross
sections, the Contractor shall submit the original transparencies and 3 prints of each such
transparency.
D In case of any variations from the approved Drawings, the Contractor shall submit the
original and 2 copies of the plotted cross sections and profiles and the notes and
computations of his survey. The Contractor shall take cross sections at maximum 25 m
intervals along the centerline and at other locations if directed by the Engineer. Upon
mutual agreement between the Engineer and the Contractor, the Contractor may submit
cross sections intermediate to these locations. The Engineer will indicate, on one copy, his
approval of the proposed lines of the Works or his revisions thereto and return such copy
to the Contractor. The Contractor shall resubmit for approval any cross sections the
Engineer may have revised.
E The Contractor may, as an alternate method of earthwork computation, request approval to

use an electronic computer. Such request shall include details of the computer hardware,
the earthwork software programs, the input and output, and a complete summary of the
methods and procedures to be used. The Contractor may use an electronic computer for
computations, only if approved, and continuance of such approval is contingent upon
satisfactory results being achieved. If results are not as represented or are otherwise
deemed unsatisfactory, the Contractor shall recompute the earthwork quantities by the
cross section method.
1.8 TEMPORARY FACILITIES
1.8.1 General
A LOCATIONS: The Engineer’s approval is to be obtained for the intended locations sitting of
all spoil heaps, Temporary Works and services.
B STANDARDS AND DETAILS: Temporary Works are to be constructed to recognised

standards and codes of practice so that they are fit for their purpose. Drawings and details
of proposed Temporary Works are to be provided by the Contractor if requested by the
Engineer.
C TEMPORARY WORKS and services are to be maintained, altered and adapted and as
necessary and cleared away on completion or when no longer required. Work disturbed is
to be made good.
D GENERAL: The Contractor shall provide all Temporary Works and services and
Contractor’s Equipment and tools required for the efficient and safe execution of the
Works, including but not limited to:
a) Temporary roads, hard standings, sleeper tracks and the like.

b) Temporary fences, gates and barriers.

c) Temporary offices, stores, messrooms, latrines and compounds.
d) Scaffold, ladders, hoists, cranes and the like.
e) Temporary screens, chutes, coverings, roofs and rainwater pipes for protection of
the Works and personnel.
f) Transport and vehicles on and off Site.
g) Fixed and movable mechanical plant and equipment.
h) Small tools.
i) Temporary water and power supplies and site lighting.
j) Temporary drainage.
1.8.2 Temporary Site Facilities
A ROADS: Permanent roads, hard standings and footpaths on the Site may be used
provided they are adequately maintained and thoroughly cleaned and made good after use
and left in unimpaired condition.
B DIVERSIONS: The Contractor shall in accordance with the specification of the Ministry of
Communication and with liaison with the Traffic Department:
a) Provide temporary detour roads, temporary bridges and culverts, and other facilities
to divert traffic through or around any part of the Works or for maintenance of traffic
in locations affected by his works that warrant such Temporary Works. Location,
standard, width, construction and maintenance of detour routes shall be in
accordance with Section 3.06 of the Specification, approved by the Engineer,
ensuring at all times that the routes, are signed, striped, maintained and furnished
with all traffic control devices as shown, directed and/or needed.
b) Submit designs and detailed working Drawings of the proposed Temporary Works
for approval by the Engineer prior to commencement of the works. The design live load for
temporary bridges related to roads exposed to heavy vehicles shall not be less than the design live
load for permanent bridges, or as directed by the Engineer.
c) Where measurements are required for continuously regulating and supervising
traffic, provide temporary roads and bridges for one-way traffic with a minimum width of 3.5m. In all
other cases the minimum width shall be 7m.
d) Phase the execution of temporary and Permanent Works to minimise the disruption
to traffic.
e) Submit a phased programme of Temporary Works one month before
commencement of any part of the works.
C TRAFFIC DIVERSIONS: The Contractor shall provide temporary diversions, detour roads,
temporary bridges, culverts and similar facilities, whenever it is necessary to safely divert
traffic through or around any part of the Works. As per concerned authorities requirements
for locations design widths, construction and maintenance of diversion and detour routes,
including the provision of signs, pavement markings, lighting, traffic control and the like are
to be submitted to and approved by the Engineer prior to execution on Site.
D FRENCH CROSSINGS are to be provided for free and safe passage of vehicles and
pedestrians over pipe and other trenches.
E TEMPORARY SITE FENCE: The Contractor shall provide suitable and secure temporary
site fencing and gates where necessary or as directed by the Engineer. Design of the
fencing and gates, including location, construction details, etc. is to be submitted to the
Engineer for approval prior to fabrication and erection.

F NAMEBOARD: The Contractor shall provide reflecting boards (150 x 150) cm at the start
and end point of the excavations. Those boards should include the project name, project
no., ministry name, Contractor name, and his local address and phone No. in addition to
the supervision Consultants. Boards’ specifications and locations should be approved by
the Client and the Engineer.
General nameboards for the whole project should be fixed at the specified locations by the
Engineer and in each district of the project area. Those boards should include the project
name, Client name, Contractor name, Contact no’s, Consultant name and phone no. for
the supervision staff office. Boards will be of 4 separated slices each of (240 x 240) cm
with spaces of 20 cm between slices that are made of 3 mm thick aluminum and provided
with back grooves for fixing on the columns, so no holes should appear at the face side of
the board. Face slide should be covered with reflective blue layer and text in reflective
white color.
Boards shall be fixed on two columns of hot galvanized (16 or 18) cm I beams and the
clear space from the ground to the bottom of the slices shall be 2.0 m and the columns
should be provided with movable hinge according to the MOT specifications and fixed to
the ground by concrete blocks as per the site conditions. All these details should be
approved by the Engineer prior to installation of boards.
1.8.3 Contractor’s Temporary Buildings
Complete according to Project - Project Specifications. To be completed by the design

consultant and the water authority.
1.8.4 Temporary Services
A WATER: The Contractor shall provide clean, fresh water for the Works and make
temporary arrangements for storing and distributing about the Site.
B ELECTRICITY: The Contractor shall provide electric supply and all equipment for lighting
and power for the Works and make temporary arrangements for distributing about the Site.
C POWER: The Contractor shall provide electric power for the Works, including supplies for
commissioning engineering services and Plant, at the required voltages.
D LIGHTING: The Contractor shall provide lighting for the Site and the Works for safety and
security of the Works and to facilitate proper execution of work and to illuminate internal
surfaces during finishing work and inspection. Spaces designed to be artificially lit during
daylight hours are to have temporary illumination similar to that provided by the permanent
installation.
E PERMANENT ELECTRIC SUPPLY AND LIGHTING INSTALLATION may be used for

testing and commissioning and to illuminate the Works, subject to the following conditions:
a) The Employer does not guarantee that it will be available.

b) The Contractor must take responsibility for the operation, maintenance and
supervision of the system, indemnify the Employer against all damage and pay all costs and renew
all used tubes and lamps.
c) The Contractor must indemnify the Employer against reduction in manufacturer’s
guarantee periods for equipment etc. due to its use before completion of the Works.
F TELEPHONES: The Contractor shall provide joint temporary telephone facilities for his
own and Subcontractors’ use and for the use of those acting on behalf of the Engineer and
shall pay the cost of all calls except international calls made by those acting on behalf of
the Engineer.

1.8.5 Diversion of Public Utility Services
A TEMPORARY DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where execution

of the Works involves the temporary diversion of existing public utility services, the
Contractor shall perform such temporary diversion and shall maintain the flow or service as
directed by the Engineer. Unless otherwise stated, the costs of any such diversions are
deemed to be included in the Contract Price.
B PERMANENT DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where the Works

require the permanent diversion of existing public utility services, either as shown on the
Drawings or directed by the Engineer, the diversion shall be carried out by the Contractor
and shall be paid for at the prices stated for such work in the Bill of Quantities.
1.9 SAFETY PRECAUTION MEASURES
1.9.1 General
A Contractor shall take all necessary measures for public safety for all project components
according to the requirements of municipalities and other concerned authorities.
PART 2 EXCAVATION AND BACKFILLING
2.1 SCOPE
A The Work Covered in this Division Comprises: Clearing of the site, and excavation and
backfilling for roads, structures and trenches and protection work related to gabions, riprap,
stone pitching and geotextiles.
2.2 SITE CLEARING
2.2.1 Clearing and Grubbing
A The Contractor shall remove and dispose of all vegetation, surface debris, stones and
rocks from areas where the Works are to be performed.
B When shown on drawings or directed by the Engineer, the Contractor shall remove and
dispose of pavement layers including asphalt and granular layer to the surface of the
subgrade. Moreover the ground surface under all structures shall be cleared of all existing
concrete foundations (if any) and stumps.
C Trees shall be removed carefully, stored and / or relocated as specified or as instructed by

the concerned Authorities and the Engineer.
2.2.2 Removal or Realignment of Obstruction and Utilities
A The Contractor shall remove wholly or in part and dispose of all obstructions, buildings,
fences, abandoned pipelines and others, as indicated on drawings or as directed by the
Engineer.
B Where indicated on the Drawings, utilities are to be realigned or salvaged as directed by

the Engineer.

2.3 EXCAVATION
2.3.1 General
A Earth: naturally occurring, man made or placed material that can be removed manually or
by mechanical shovel, bulldozer or other mechanical equipment.
B Rock/Hard Materials: naturally occurring, man made or placed material of more than one
cubic meter that cannot be destroyed or removed by methods used for removal of earth
described in Clause A but requires the use of pneumatic tools, impact breakers or, if
allowed, explosives for its removal.
C Materials and conditions: the Contractor shall assess the nature of the work and the
materials to be excavated, and shall take sole responsibility for his assessment of
materials and conditions.
D Ground-water level is to be established at the time the various excavations are carried out.
2.3.2 Top Soil
A Topsoil: before beginning general excavations or filling, the Contractor shall excavate
topsoil from required areas and keep separate from excavated subsoil.
B The Contractor shall stockpile excavated topsoil required to carry out subsequent top-
soiling operations in temporary spoil heaps on the Site as instructed.
C Surplus Topsoil: The Contractor shall remove from the Site to a tip provided by the
Contractor
2.3.3 EXCAVATING
A General
1. All excavation shall be performed to the line, grades, cross section and sizes shown on the
drawings, or/and directed by the Engineer.
2. Methods: The Contractor shall submit with the Tender details of proposed methods
of working which may cause nuisance, damage or danger to people and/or
property.
3. Materials arising from excavations are to remain the property of the Employer
unless instructed to be removed from the Site as per the Engineer or the
authorities instructions.
B Excavations for Adjacent Utilities
1. Underground services must be set out so that their excavations do not encroach below a
line drawn at an angle from the horizontal from the nearest lower edge of building
foundations. The angle shall be 45 degrees for dry stable soil or 30 degrees for wet clays
or soils below water table. If this condition cannot be met obtain instructions before
proceeding.
2. Where an excavation encroaches below a line drawn at an angle from the
horizontal of 45 de-grees for dry stable soil or 30 degrees for wet clays or soils
below water table from the nearest formation level of another higher excavation
then all work within the lower ex-cavation and backfilling thereto must be
completed before the higher excavation is made.
C Excavated formations are to be inspected and approved before new work is laid on them.
The Contractor shall give 24 hours written notice of when excavations will be ready for
inspection. If, after inspection, surfaces become unsuitable due to water, frost or other

causes, excavate further and backfill with ap-proved material all at the Contractor’s
expense. The Contractor shall place concrete or other fill as soon as possible after
inspection.
D The bottom 200 mm thickness of excavation shall be removed by hand just prior to placing
concrete blinding or pipe laying.
E The Contractor shall level or grade and compact bottoms of excavations to Engineer’s
approval.
F Headings: The Contractor shall drive accurately to required line and gradient and provide
adequate support. Construct in ap-proved lengths to size required to contain permanent
work. The Contractor shall obtain approval from the Engineer before commencing
activities.
G Support
1. Sides of Excavations: Responsibility for upholding sides of excavations rests with the
Contractor.
2. Earthwork Support: The Contractor shall use as necessary to support sides of
excavations and remove on completion unless otherwise in-structed. In the event
of any collapse occurring while ex-cavations are open this will be the Contractor’s
full responsibility and he should re-excavate and reinstate such excava-tions and
other work affected at the Contractor’s expense and responsibility.
3. Steel Sheet Piling: The Contractor shall use as necessary to support sides of
excavations and remove on completion unless otherwise in-structed.
4. Special Support: The Contractor shall use as necessary to uphold excavations
against sides of adjoining buildings, public footpaths, roads and the like and
remove on completion unless otherwise instructed.
5. Unstable Ground: The Contractor shall inform the Engineer without delay if any
newly excavated face will not remain unsupported suffi-ciently long to allow the
necessary earthwork support to be inserted. If the instability is likely to affect
adjacent structures or roadways take appropriate emergency action. Responsibility
for preventing instability rests with the Contractor.
H Waterways: Temporary diversion as necessary of ditches, field drains and other waterways
encountered during the excavations is to include reinstatement on completion. If
reinstatement is not possible the Contractor shall obtain instructions.
I Existing watercourses which have been diverted and are to be filled must be cleared of all
vegetable growth and soft deposits before filling.
J Existing Foundations
1. Where old foundations, beds, drains etc. are encountered the Contractor shall obtain
instructions before proceeding.
2. Breaking out old foundations, beds, drains etc. is to include sealing off drain ends,
removing contaminated earth and disinfecting as necessary and according to the
Engineer instructions.
K Backfilling of excavations shall be as specified in other Sections of these specifications.
L Unauthorised Excavations: The Contractor shall backfill and compact as instructed at no

expense to the Employer.

M Water: All excavations shall be kept free from water arising from any source at all times.
The discharge of any water from the excavations must not effect other parts of the works
or adjoining areas.
N Pumping: The Contractor shall not disturb material in and around excava-tions by pumping
operations.
O Sumps: The Contractor shall obtain approval of location of any sumps and fill with
approved material when no longer required.
P Permanent drainage system is not to be used for dis-posal of water from excavations
without approval.
Q The Contractor shall keep all excavations adequately drained at all times. Damage to any
part of the work due to poor drainage facilities shall be repaired at the Contractor’s
expense.
R All excavated slopes shall be cut to the slopes shown on the Drawings.
2.3.4 Disposal of Materials
A No excavated material shall be wasted without written permission from the Engineer.
Suitable material from excavation shall be used for embankment construction or backfill, as
directed by the Engineer.
B Surplus Subsoil: The Contractor shall remove from the Site surplus excavated materials
not specified as to be spread and leveled or stockpiled to a tip provided by the Contractor.
C Tip: The Contractor shall use only public dumpsites assigned by the concerned
authorities for disposal of surplus excavated material removed from the Site and pay all tip
fees.
2.3.5 Rock Excavation
A All blasting shall be carried out in such a manner as will produce the least possible
disturbance of the material left in place.
B All the necessary precautions shall be taken to ensure that the blasting shall not be
dangerous to people or property.
C Where necessary or directed, the Contractor shall provide heavy mesh blasting mats for
protection of persons, properties, and the Works. If, in the opinion of the Authorities and
the Engineer, blasting would be dangerous to persons or adjacent structures, or is being
carried out in an unsafe or unacceptable manner, the Engineer may prohibit blasting and
order the rock to be excavated by other means.
D If the flow of traffic is to be interrupted during blasting operations, the Contractor shall
secure approval of his schedule for such interruptions and his proposed methods for
safeguarding the public and property.
E All drilling and blasting shall be done in such a manner as will most nearly complete the
excavation to the required grade lines, and produce the least practicable disturbance of the
material to be left in place. Blasting by means of drill holes, tunnels, or any other methods
shall be entirely at the Contractor’s risk.
F Unless otherwise approved by the Engineer, rock cuts higher than 3 m shall be formed
using pre-splitting. Prior to starting the pres-splitting operation the Contractor shall submit
a layout plan showing the location of drill-holes, type of explosive to be used and sequence
of firing. This plan does not absolve the Contractor of his responsibilities for the safety of

people and structures, or for producing a satisfactory stable rock face. No extra cost is
charged by the Contractor for using pre-splitting.
G All overbreaks, overhangs loose blocks or unstable parts of the cut face, and benches shall
be cleared and cleaned, to the satisfaction of the Engineer.
H Backfilling of overbreakage shall be carried out as directed, using approved soil or crushed
materials or other special aggregate or cyclopean concrete, as shown on the Drawings or
as directed by the Engineer. Undrained pockets shall not be left in the surface of the rock.
2.3.6 Road Excavation (For Preparation of Service Roads Along Pipelines)
A Scope
1. These Works shall consist of excavating material in cut sections of the road, including
water courses, ditches and wadi relocations (but excluding borrow pits and structural
excavation) all as and where shown on the Drawings, and hauling the excavated material
either to locations for road embankments or to stockpiles or to waste.
2. These Works shall also include any necessary excavations outside the ROW
ordered by the Engineer to safeguard and protect the Works. These may include
diversion of existing water courses, channels; excavation of materials obstructing
or impairing the flow along stream channels; and excavation of unstable materials
which may slide or encroach into ditches or onto the ROW. Disposal of all such
excavated materials shall be as instructed by the Engineer.
B Classification of Road Excavation
1. Any information concerning properties of the soil which may be shown on the plans, in the
Bill of Quantities, in supplementary reports, or as a result of discussion with the Engineer
or others shall be considered as gratis and shall not be a basis for the Contractor’s
determination of his bid prices.
C Utilization of Excavated Materials
1. All materials removed from the excavation shall be used in the formation of the
embankment, subgrade, shoulder, and at such other places as directed, unless it is
declared unsuitable and ordered to be wasted by the Engineer.
2. Unsuitable material shall include:
a) Unstable materials incapable of being compacted to the specified density using
ordinary compaction methods at optimum moisture content for the equipment being
used for compaction.
b) Material too wet to be compacted and circumstance prevent suitable in-place drying
prior to incorporation into the work.
c) Materials which are otherwise unsuitable for use in or under the embankment.
3. No excavation material shall be wasted without written permission from the
Engineer.
4. Excavated rock which is not immediately suitable for incorporation in the works can
either be broken down to acceptable sizes or wasted at Contractor’s expense.
D Drainage of Excavation Areas
1. The Contractor shall schedule road excavation and embankment and drainage Works so
that they complement each other. If the Contractor’s earthwork progress exceeds the
progress of the drainage construction to the point where the road becomes a dam to cross
drainage, the Engineer may order the Contractor to open adequate waterways through the
highway at the locations where drainage structures are to be installed. Any damage to the

highway caused by water passing through these openings shall be repaired at the
2. During construction, surfaces in excavation areas shall be adequately drained at
all times. Side ditches or gutters emptying from cut to embankment shall be so
constructed as to avoid damage to embankments by erosion.
3. Damage to the Works attributable to saturation or erosion through failure to
provide adequate drainage shall be repaired by the Contractor at his expense.
4. Whenever groundwater is encountered which may adversely affect construction,
the Contractor shall advise the Engineer who will evaluate the situation and order
necessary remedial measures to drain or extract water.
E Slopes, Subgrade and Ditches
1. All excavated slopes, subgrade and ditches shall be finished true to lines, grades and
cross sections as shown on the Drawings.
2. Slopes, except in massive rock or other material which require special treatment,
shall be trimmed to slopes not steeper than the specified slope angles and
rounded at top and bottom to a smooth profile to blend in with the adjacent terrain.
Material shall not be loosened beyond the specified slope lines. High cut areas
shall continuously be monitored by an engineering geologist or a geotechnical
Engineer.
3. In cuts where earth overlays a rock formation, slopes shall be benched in an
approved manner.
4. Ditches of all types shall be excavated and trimmed neatly in conformity with the
specified grades and cross sections. All projecting rock, stumps, roots or similar
shall be removed. Ditches include side ditches, furrow ditches, irrigation ditches,
wadi relocations, etc.
5. The Engineer will periodically check all or any part of the Works, to determine
conformance to the correct lines, grades and elevations. Tolerances on finished
subgrade elevations and on elevations of the surface at the underside of the
subgrade layer, shall be as specified in Section 2.05 - “Subgrade Construction”.
F Excavation of Unsuitable Material
1. Where excavation to finished grades and cross sections exposes unsuitable material in the
subgrade, slopes or ditch inverts, etc the Engineer may require the Contractor to remove
the unsuitable material and backfill the excavated areas using approved material. The
Contractor shall conduct his operations in such a way that necessary cross section
measurements are taken before such backfill is placed.
2. Unsuitable material shall be disposed of as directed. Wasted unsuitable material
shall not be deposited on any cropland.
3. When the Contractor is directed to excavate unsuitable material below the surface
of the original ground in fill areas, other than that required for clearing and
grubbing, the depth to which unsuitable material shall be removed will be
determined by the Engineer. The Contractor shall schedule the excavation so that
cross sections are taken before and after material has been removed.
4. Unsuitable materials outside the ROW or ditch slopes which, in the opinion of the
Engineer, are potentially unstable and liable to slide or encroach into the ROW or
into the ditches, shall be excavated and disposed of as specified for unsuitable
material, unless it is approved for use as embankment fill.
5. Unsuitable and surplus materials disposed of elsewhere than within the ROW shall
be spread, leveled and shaped as directed so as to present a neat and tidy
appearance. No materials shall be disposed of in such a way as to adversely
affect natural drainage courses or to cause damage to the highway or adjacent
public or private property.

6. If approved by concerned authorities land can be used for disposal to the
maximum extent practicable. If private land is used for disposal, the Contractor
shall secure the consent of the landowner or tenant and, if necessary, and at his
expense, pay for the use of such land. The use of cropland for disposal purposes
will not be permitted.
2.3.7 Excavation for Structures
A Scope
1. These Works shall consist of all excavation in any material for structures associated with
networks such as water tanks, pump houses, culverts, utility ducts and water underdrains;
for retaining walls of all types; and for other major and minor structures; and including all
necessary clearing and grubbing; bailing; drainage; pumping; sheeting; temporary shoring
and cribbing; construction of temporary cofferdams or cribs; and disposal of all excavated
material and backfilling with suitable approved material; all as and where shown on the
Drawings.
2. These Works shall also include the removal of those portions of existing structures
below ground which would in any way obstruct or interfere with construction of new
structures.
3. The Contractor will be deemed to be fully aware, at the time of tendering, as to the
type and nature of soils and rock that will be encountered in structural excavations.
B Excavation
1. The Contractor shall notify the Engineer a sufficient time in advance of the beginning of
any excavation for structures so that the Engineer may, where necessary, survey and
record the cross sectional elevations and measurements of the existing ground and
existing structures affected by the proposed structure. Any materials removed or
excavated before these measurements have been taken and approved by the Engineer
will not be paid for.
2. The Contractor shall be solely responsible for the safety at all times of all
foundation and trench excavations whether supported or otherwise. Approval of
the Contractor’s support system or omission of a support system for any
excavations shall not absolve the Contractor from his sole responsibility in this
regard.
3. The Contractor shall take all necessary precautions, including shoring or
otherwise, to protect employees in the excavation and on the ground above. The
Engineer will not enter excavated areas to approve the foundation and further
Works until he deems the areas to be safe.
4. In areas where the excavation is adjacent to public roads and walkways, the
Contractor shall erect all necessary barricades, barriers, enclosed walkways, and
warning signs necessary to restrict the exposure of the public to the excavation.
5. The sides of all foundation pits and trenches shallower than 1.5m shall be vertical
and adequately supported at all times unless otherwise shown on the Drawings.
Sides more than 1.5 m in depth shall be sloped at a stable slope or supported in
an approved manner unless the material through which the pit or trench is cut is
deemed to be sufficiently self supporting and not requiring support.
6. Pits and trenches shall be kept free from water until footing concrete has been
placed or pipes have been installed. The Contractor shall minimize, to the
maximum extent practicable, the length of time excavated areas are open. The
Contractor will be held responsible for damage due to weather, equipment, and
other causes during periods when the excavations are left open.
7. The Contractor shall schedule the Works so that no excavation is left in an
exposed condition for a period greater than 20 days unless otherwise approved.

8. In areas where the excavation is adjacent to public highways, roads and
walkways, excavation shall be scheduled such as not to be left in an exposed
condition for more than 7 days unless otherwise approved.
9. For excavation in material sensitive to moisture (stiff clays, marls, etc.) the
excavation shall be cleaned and concrete blinding layer cast immediately on
completion of the excavation.
10. The Contractor must notify the Engineer of any sign of failure or cracks within or
around the excavation immediately when such signs are noticed.
C Temporary Support System
1. When a temporary support system is required to protect adjacent property or to protect the
public during construction, the Contractor’s design for such support system shall be
submitted to the Engineer for approval prior to commencing its construction.
2. All temporary support systems shall be designed with adequate factors of safety to
serve with minimal maintenance, for the duration of its intended use, and shall
include adequate safety provisions to protect the public from construction
activities.
3. Notwithstanding any approval of temporary support systems, the Contractor shall
be solely responsible for the adequacy of their design, construction, maintenance
and all necessary safety precautions associated therewith.
D Excavation for Major Structures
1. The foundations for buildings, water tanks, pump houses and other major structures, shall
be excavated in accordance with the dimensions as shown on the Drawings and shall be
of sufficient size to permit the placing of the full width and lengths of the footings.
2. The excavation shall be carried to the elevations shown on the Drawings or as
established by the Engineer. Borings and soil tests, made during design, and
actual investigation of the completed foundation excavation shall be utilized by the
Engineer to determine final depth. No concrete shall be placed prior to approval of
the excavation pit.
3. Unless shown otherwise on the Drawings, the bottom of all excavations shall be
covered with a 75 mm minimum depth of lean (blinding) concrete Class 110/25 to
serve as a working platform.
4. Foundation pits or trenches shall be of sufficient size and provide minimum
sufficient working space to permit construction of structures or structure footings of
the full width and length shown on the Drawings.
5. Where footings are to be constructed using formwork, the excavations shall
generally not extend more than 500 mm beyond the maximum dimension on each
side of the proposed footing unless additional working space is clearly required
and approved, by the Engineer. Any unauthorised overwidth of excavation beyond
the lateral limits shown on the drawings or approved by the Engineer shall be
backfilled with selected fill or lean concrete as directed by the Engineer.
6. Where footings are to be located, in or adjacent to firm, original ground and where
formwork is not required or ordered, any unauthorized overdepth excavation below
the approved elevation of base of footing shall be backfilled with blinding concrete.
7. Where excavation to rock foundation is required, the excavation shall proceed in
such a manner as to allow the solid rock to be exposed and prepared in horizontal
beds or properly serrated for receiving the concrete. All loose and disintegrated
rock and thin strata shall be removed.
8. All blasting necessary for foundation placement shall be performed prior to placing
any concrete. Blasting will not be permitted in the vicinity of concrete which has
not cured for at least 14 days. Blasting shall not affect concrete properties and
integrity in any way.

9. When unstable material or other unsuitable material is encountered below
foundation elevation like swelling soil or others, the Contractor shall excavate such
material and replace it with suitable backfill material or concrete as directed by the
Engineer.
10. If temporary works are required for maintaining the excavation dry, the Contractor
shall be responsible for the design and execution of the works. The proposed
design shall be submitted to the Engineer for approval, however, such approval
does not relieve the Contractor for his sole responsibility in this regard.
2.3.8 Excavation for Pipe Trenches
A Before excavating trenches for pipes in any road, the contractor shall acquire the
necessary permission from the Engineer and concerned authorities.
B During excavation, material suitable for backfilling (Section 2.04) shall be piled at sufficient
distance from the sides of the trench as to avoid overloading and prevent cave in. All
excavated material not required, or unsuitable for backfilling shall be removed and carted
away to an approved dumping area.
C Trenches shall be excavated to such depths as will permit the pipes to be laid at
elevations, slopes or depths of cover indicated on the drawings, and at uniform slopes
between indicated elevations.
D Where excavation depth exceeds the level indicated on the drawings and is not authorized
in writing by the Engineer, the Contractor shall bear the cost of the excess excavation,
backfill or concrete level make up of any type as instructed by the Engineer.
E Trenches shall be excavated with vertical sides between the level of the bottom of the
trench and an elevation 300 mm above the top of the pipe.
F Unless otherwise indicated on the Drawings, trench widths will be as shown in the
following table:
Trench Width (mm)
Pipe diameter (mm)
Minimum Maximum
< 150 650 950
200 700 1000
250 750 1050
300 850 1150
350 900 1200
400 950 1250
450 1050 1350
500 1100 1400
600 1250 1550
700 1350 1650
800 1500 1800
900 1600 1900
1000 1750 2050

Trench Width (mm)
Pipe diameter (mm)
Minimum Maximum
1100 1900 2200
1200 2000 2300
1300 2150 2450
1400 2250 2550
1500 2400 2700
1600 2550 2850
1700 2650 2950
1800 2800 3100
1900 2900 3200
2000 3050 3350
2100 3200 3500
2200 3300 3600
2300 3450 3750
2400 3550 3850
The lowest trench width will be used for the calculation of quantities and payment for all
types of trenches and excavation in rocks. The contractor should have included in his
prices any extra expenses that will be needed for extra excavation beyond the trench
width, this is applied also for the pavement and road surface finishing works.
G Where the above specified maximum trench widths are exceeded; the Contractor shall
bear the cost of increased pipe strength or additional pipe protection if the Engineer calls
for such measures due to excavations being taken wider than specified.
H Excavation with battered sides shall not intrude into private property and shall respect the
statutory regulations relevant to the R.O.W. and property limits.
I When the pipe, culvert or duct are to be laid in embankments or other fill areas, the
embankment or fill area shall first be filled and compacted as specified to the proposed
finished grade or to a height of at least 300 mm above the crown of pipe whichever is
lower. The trench shall then be excavated as in undisturbed material.
J When pipes, culverts or ducts are to be laid under existing pavements, trenches shall be
excavated carefully and to minimum widths. Methods that will give straight and vertical
face shall be used. The pavement shall be kept at its original level and condition.
K In combined trenches where one pipe is at a lower level than an adjacent pipe the
following shall be applied:
a) The whole trench shall have a depth related to the lower pipe and the thickness of
the bedding shall be increased to the upper pipe as necessary.
b) The lower pipe shall be backfilled with thoroughly compacted granular material up to
a level of 0.30 meters above the higher pipe.
L Excavation for the forming of the trench for beds shall be carried out immediately before
laying beds or pipes. Unstable material, rock projections, boulders and hard spots shall be
removed and replaced with approved well consolidated filling material, that will be

compacted as instructed. Local soft spots shall be hardened by tamping in bedding
material.
M The bottoms of trenches shall be accurately graded to provide uniform bearing and support
for the bottom quadrant of each section of the pipe. Bell holes shall be excavated to the
necessary size at each joint or coupling to eliminate point bearing. Any material or block
that may cause point bearing shall be removed.
N The Contractor shall report to the Engineer any unsuitable or weak ground material that
may found below the indicated excavation levels before executing any trimming of the
excavation, pipe laying, concreting, or other work. Where, in the judgment of the Engineer
the bottom of the trench is found unsuitable, such material shall be removed to the width
and depth ordered by the Engineer. The trench shall then be made up by backfilling with
approved material as specified herein after.
O Where rock excavation is encountered, the trench shall be excavated to min. 200 mm
below pipe invert and replaced with granular material matching the specification in Item
(2.4.5) or concrete class 110/25, as directed by the Engineer. In case of soil, the min.
bedding should be 150 mm.
P Headings, when required, shall be accurately driven to required line and gradient and
adequate support shall be provided. Construction shall be carried out in approved lengths
and to size required to contain permanent work. Approval shall be obtained before starting
pipe laying or other work.
Q Generally, trench excavation, pipe laying, and trench backfilling for any particular project
section shall be completed in twenty (20) days. At any one time, the maximum length of
open trenches in the project shall not exceed 300 meters.
R The Contractor should give special care while excavating in paved areas, so the
excavation width not to exceed the specified width. The Contractor should use the suitable
mechanical machines to cut the pavement in straight lines and the edges should be
vertical. In addition, the Contractor should always use vehicles with suitable tires (Air tire)
that will not damage the road surface pavement.
2.3.9 Technical Specifications of Thrust Boring
A Scope of works
This section covers pipes and fittings installation through Thrust boring. The relevant
sections mentioned in the general specifications for the implementation of the drainage
networks for the Water directorate general in Riyadh shall be considered applicable by the
present agreement unless otherwise stated therein. Furthermore it is a must to comply with
the entire specifications and conditions related to the Ministry of Transport and Saudi
Railway Organization regarding the implementation of such works.
B The general drilling of the ground pits and tunnels
1. The implementation of ground pits and the installation of pipelines should be carried out by
jacking as approved by the engineer.
2. The perforations of the ground pits should be of practical dimensions enabling to
proceed in the structural works properly. The drilling works should be performed
with extreme care preventing earth settlement and sliding and following the design
alignment and levels for the external dimensions of pits not to be anywhere smaller
than the dimensions mentioned in the plans or determined by the engineer. The
Contractor should use specialized manpower in the drilling works of pits.
3. The Contractor should supply and fix all the other temporary supports and other
necessary structures to ensure the safety of works and adjacent structures outside
the permanent work place to the engineer’s approval.

The contractor must provide communication means between the pits and the and the work
areas that should not be of same quality like the telephone communication and that, to the
engineer’s approval.
The contractor should supply and operate and maintain an appropriate lighting and
ventilation network for each pit and the commencement of the drill obtaining the engineer’s
approval. The electricity power supply should be adequate.
All equipment shall be installed and maintained inside and around pits according to the
relevant work regulations and as per the suitable practical application principles to the
engineer’s satisfaction.
4. The pits should have separate openings equipped with stairs in addition to other
required openings during the structural works. Each pit should be surrounded by
closed fence of height not less than 1,80 meter equipped with security red lights
when working in the traffic areas.
When work is suspended for any reason, the sides of pits should be covered and
supported by wooden boards and covered with light mortar for safety reasons, unless the
engineer decides to take other measures.
The contractor should take these temporary works into account while preparing his prices.
All the temporary supports and structure for pits, should be removed when no more
needed unless otherwise directed by the engineer.
5. Before starting to request any trench excavation equipment or starting any work
the contractor should present detailed proposals for making access openings or
the work openings to the engineer.
6. The earth reinforcement must be of sheet steel supports or of similar approved
fixed metal ring supports.
The contractor may use precast concrete pieces for the ground reinforcement above the
permanent work place, if the concrete pieces are used for support, they should be covered
as per the specifications and discarded or broken after the work completion.
Such work shall not be measured nor classified for payment.
C Checking alignment and levels
1. Checking and adjustment of the alignment and levels should be done using laser. The
contractor should prepare and present his proposals for checking and adjustment of the
alignment and levels to the engineer’s representative for approval in an earlier phase in the
Contract.
2. When permanent works are done outside the overstepping boundaries allowed by
the present specifications, the contractor should remedy this situation according to
the engineer’s directives.
D Works for preventing water leakage
All works should not have water leakage upon the completion of works and should remain
free of water leakage until the expiry of the maintenance period.
The contractor should immediately repair the defects at the engineer’s satisfaction.
E Ground treatment
If the contractor considers that special a ground treatment is required and necessary for
preventing settling and sliding during the construction he must request the authorization
from the engineer in this concern. When the contractor is given the authorization, he must
carry out works as mentioned in the specifications. Such authorization (or the refusal the
authorization) does not exempt the contractor from assuming the responsibility of securing
works safety.

The treatment should be implemented in sequences suitable to work requirements and the
contractor should carry out testing according to the engineer’s directives to check their
efficiency during and after the treatment works.
The contractor should keep meticulous and detailed register for all the ground treatment
methods to the engineer’s satisfaction. He must submit everyday copy of such register to
the engineer when the ground treatment is carried out. In the cases where the engineer
considers that such technique is necessary and essential for the appropriate
implementation of works he will give the necessary instructions to the contractor. The
payment for the ground treatment should be included in the prices of the pipeline by thrust
boring. The contractor should assume the responsibility of the damages occurring from the
ground treatment operations.
F Noise restriction means and the electrical machinery.
1. In order to minimize as much as possible the disturbance emanating from the equipment
noise during the night, the contractor should operate the machinery with the electrical
power unless otherwise authorized by the engineer.
2. The operations above ground level during night work should be restricted to the
minimum practicable work and the contractor should take all the precautionary
measures for preventing unnecessary noise.
G Pipe Jacking
Before starting works, the contractor should submit to the engineer full details on his
suggested methods for obtaining the engineer’s approval, such details should include the
following information:
a) Interjacking locations and the reinforcement of the starting points of excavation.
b) Dimensions of the starting points of the tunnel excavation and the supporting
methods of the excavations.
c) Dimensions and details of the retaining wall
d) All the sizes of the operating equipment
e) Locations of the drainage gutter and the methods of preserving works free of water
1. The pipes jacking starts from the reinforced starting point of excavation, which should be
dug in with suitable size to accommodate the reinforcement wall, the jacking equipment
and the appropriate work place.
2. Excavation should be carried out inside the protection installations, which should
be kept in all times close to the work level and must be adjusted for monitoring the
alignment and the level.
3. Reinforcement should be used for the loose non-steady open excavation when
pipe jacking works are suspended.
4. The pipe jacking is done through hydraulic pressure by using appropriate jacket
designed for the higher pressure and using ring supports for distributing the pipe
jacking forces. The pipe jacking system should allow testing from both the surface
location and the surface of excavation starting point.
5. The pipe jacking stations located at the center of the trajectory should properly
serve the jacked pipes joints and the relevant connections. Connections should be
hermetically closed and anti-leakage when in service.
The contractor should take all the necessary steps for securing the safety of pipes and the
tunnel protective coating during jacking of pipes. If damages occur due to the contractor
works, Contractor should carry out the necessary repair to the engineer’s satisfaction and
he should withdraw the damaged pipes and export it out of site if instructed by the
Engineer, without any extra cost.
H Thrust Boring under the railways

The contractor shall assume responsibility of securing the review of the adequate
procedures and the compliance with the specifications of Ministry of Transport regarding
the pipes crossing under the railways.
The attention of the contractor should be drawn particularly to the requirements of the
Railway Saudi Arab Establishment. But all crossings should be placed according to the fifth
and tenth sections of the present guidelines of the Railway Engineering Consultant
Association, a copy of which is enclosed for the proper use of the supervisor and/or
engineer.
2.4 SOIL FILLING AND BACKFILLING FOR STRUCTURES
2.4.1 Scope
A This section covers general soil filling material and source, backfilling for structures,
embankment construction, backfilling for pipe trenches and all particular requirements
related to these works.
2.4.2 Filling Material and Borrow Material
A Filling material shall be approved and capable of being compacted as specified.
B Filling materials for foundations and general filling shall pass a three inch U.S. standard
sieve and the material passing a No. 4 U.S. standard sieve is to have a maximum plasticity
index of 6%. No piece is to have its largest dimension greater than one-third the thickness
of a compacted layer.
C Sampling: The Contractor shall submit 50 kg representative samples to an approved

laboratory for tests as follows and submit results for approval:
a) For Soils with Less than 50% Fines: Sieve analysis and compaction.
b) For Soils with More than 50% Fines: Sieve analysis, Atteberg Limits and
Compaction.
D Approval: Sources and types of materials and moisture contents at which they may be
placed and compacted are to be those approved after receipt of laboratory test results.
E If suitable filling or backfill material is not available from material excavated on the project
site, the Contractor shall be responsible for locating suitable borrow and arranging for the
excavation of suitable material with the land owner.
F Borrow pits are to be excavated in a uniform manner, neatly trimmed and graded and left
in an approved condition.
G The borrow material shall fulfill the requirements specified for the intended use. No borrow
material shall be brought to the site unless it has been approved by the Engineer.
H Testing Fill From Borrow Pits: The Contractor shall sample and test in ac-cordance with
ASTM D1557 to determine the optimum amount of water to be used with fill material to
obtain maximum dry density. Tests are to be conducted for every borrow pit and for every
type of fill material encountered.
I The Engineer will periodically require testing of borrow materials to verify that no change in
quality has occurred since the original approval.
J Field density tests on compacted soils are to be made at an average of one test per 100
m² of area. Minimum density required on soils when made in accordance with ASTM
D2167 ‘Rubber Balloon Method’, ASTM D1556 ‘Sand-Cone Method’ or ASTM D2922
“Nuclear Method” is to be:

a) For Backfill Under Roads, Parking Areas and Paved Areas up to 500 mm: 95% of
maximum dry density
b) For Backfill Deeper than 500 mm Under Same Areas as last Described: 95% of
maximum dry density
c) Elsewhere Such as Landscaped Areas: 90% of maximum dry density.
K Selected Fill: Excavated material conforming to the specification for Filling material and
Borrow material, Clause B above.
2.4.3 Backfilling for Structures
A General Requirements
1. The Contractor shall obtain approval for his proposed method and rate of placing of
backfill, before backfilling commences.
2. Excavated material or material from other sources for use as backfilling shall
conform to the below requirements:
a) The supplied material shall not contain any organic or harmful material e.g: tree,
leaves, roots, and residues.
b) The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4,
according to MRDTM 210 (Directorate of Material and Research at the MOC).
c) The California Bearing Ratio shall not be less than 25% when tested according to
MRDTM 213.
d) The maximum dry density shall not be less than 95% when tested according to
Directorate of Material and Research at the MOC.
e) The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall
contain fine material for proper compaction.
3. Backfill materials shall be uniformly graded granular material, capable of being
compacted to the specified compaction level, and having adequate permeability to
permit free drainage through it. Backfill material shall also conform to the
following:
 Minimum D10 value - 1 mm
 Maximum Plasticity Index - 10 per cent
 Requirement for bridges, culverts etc. specified in subsequent sections.
4. Backfill material shall not be placed against any structure until approval is given.
Unless otherwise shown on the Drawings. Structures shall be backfilled to the
same requirements as specified for the adjacent embankment.
5. Backfill shall be placed in level layers for the full width of the excavated area until
the elevation of the original ground or surrounding embankment is reached.
Backfill next to walls, between columns or in other confined areas, shall be
compacted by approved hand or portable equipment.
6. Each successive layer of backfill shall contain only sufficient material to ensure
proper compaction and in no case shall any layer be greater than 300 mm
thickness (before compaction). The moisture content of the backfill material shall
be uniform and within the moisture range designated.
7. Water shall be drained from the areas to be backfilled wherever practicable. In
cases where, in the opinion of the Engineer, it is not practicable to drain the areas
to be backfilled, the initial backfill material shall consist of crushed, open graded
material conforming to the following gradation:

ASTM Sieve Percentage Passing
Size
3/8" 100
No. 4 < 85
No. 30 < 45
No. 200 <5
Such material may be deposited below the standing water level without compaction. Above
the water level normal laying and compaction will be used.
8. Additional water to be added during placement of backfill material to achieve
required compaction shall be fresh water or brackish water approved by the
Engineer.
9. Minimum tests required during backfilling operations to verify material are:
 One Proctor test for each structure (or for each 100 m2).
 One Gradation of Materials when materials changed.
 One Plasticity Index and field density for 50% of the layers and for each
footing and abutment (or for each 500 m2) as per instruction of the Engineer.
B Workmanship
1. Unsuitable Materials: The Contractor shall remove from the Site imported filling materials
deemed unsuitable by the Engineer.
2. Surplus: The Contractor shall remove surplus imported filling materials from the
Site.
3. The Contractor shall place filling using approved methods to required dimensions,
levels, lines and profiles and to permit water to drain freely.
4. Earthmoving Equipment: The Contractor shall do not use for compaction except
where approved.
5. Heavy Steel or Pneumatic Rollers: Special precautions shall be taken to safeguard
existing structures when steel or pneumatic rollers are used. These shall not be
used when compacting backfill to pipe trenches.
6. Compaction Equipment: Backfilling shall be compacted by approved compaction
equipment suited to the type of material. Compaction around foundation walls,
culverts and small restricted areas shall be carried out by mechanical vibratory
plates, tampers or hydraulic compactors.
7. Moisture Content: Each layer of filling shall be moistened or dried to reach the
correct moisture content for the required dry density. The Contractor shall spread
and compact each layer to at least 95% of maximum dry density, unless otherwise
specified, all as determined by ASTM D1557. Each com-pacted layer shall be
tested and approved prior to placing subsequent layers.
C Placing and Compacting Fill
1. Structures shall not be subject to the pressures of backfilling or to live loads until the 28-
day strength of the concrete has been reached, unless a shorter period is approved in
special circumstances where the load is sufficiently small as not to constitute a risk of any
damage to the structure in the opinion of the Engineer. If approved this period may be
extended if subnormal curing conditions exist.
2. Surfaces to receive filling shall be cleared and all vegetation removed off Site
before filling is placed. Soil surfaces are to be scarified and re-compacted to at
least 95% of maximum dry density as determined by ASTM 1557. Compaction

shall be to a depth of at least 200 mm below ground surface. Hard or smooth
surfaces shall be roughened before filling is placed. Existing road surfaces and
the like shall be broken up and removed or used as part of fill.
3. Soil filling generally shall be selected fill spread and leveled in 300 mm maximum
layers each well consolidated with a suitable mechanical rammer.
4. The Contractor shall deposit soil filling in a manner not to endanger the partly
finished structure or sub-structure either by direct pressure or indirectly by
overloading banks contiguous to the operation or in any other manner.
5. Minor up filling and local adjustment of levels shall be selected fill spread and
leveled in 150 mm maximum layers each well consolidated by suitable mechanical
means.
6. Benching: Where difference in level between adjacent areas of filling exceeds 600
mm the Contractor shall cut into edge of higher filling to form benches having a
minimum width of 600 mm and a height equivalent to the depth of a layer of
compacted filling.
7. Benching: The Contractor shall spread and compact new filling to ensure
maximum continuity with previous filling.
8. Protection of formation:
a) Construction traffic shall not be allowed on completed filling until the level has been
raised not less than 150 mm above formation level by properly compacted
temporary protective filling
b) Temporary protective filling shall be removed from the Site before beginning
permanent construction
c) Stockpiling materials on newly filled areas shall not be done without permission.
D Backfilling for Bridges, Underpasses, Overpasses and Miscellaneous Structures
1. Backfill placed around culverts, abutments and piers, shall be deposited on both sides to
approximately the same elevation at the same time. Special care shall be taken to prevent
any wedging action against the structure and slopes bounding the excavation shall be
stepped, where necessary, to prevent such wedge action occurring.
2. All backfill intended to support falsework loads, including temporary fills and pier
backfill, shall be designed for the minimum support required. As a minimum, such
material shall be AASHTO M 145, Class A-1-a, A-1-b or A-2-4, compacted to 90%
AASHTO T 180 maximum density.
3. Backfill material for bridge abutments and approach embankments within 20 m of
any part of the substructure shall be AASHTO M 145, Class A-1-a, A-1-b or A-2-4
compacted to 95% AASHTO T 180 maximum density up to the underside of the
subgrade layer. The 200 mm minimum thickness of subgrade layer shall consist of
approved subgrade material placed and compacted to 100% maximum density as
specified under Section 2.05 - “Subgrade Construction”. The backfill shall be
completed to the level of the original ground or to the top elevation of any adjacent
embankment.
4. Backfill around retaining walls shall be completed to the level of the original ground
line and to such heights above original ground line or to the levels as shown on the
Drawings. Care shall be exercised to prevent forward movement of the wall.
5. Unless shown otherwise on the Drawings, when special permeable backfill
(sheathing) is to be placed against the back faces of abutments, retaining walls or
wing walls, it shall consist of a continuous covering of approved type proprietary
filter cloth protected by a continuous wall of 200 mm minimum thickness precast,
porous (no-fines) concrete blocks laid in stretcher bond with dry joints. Prior to
construction of the block wall, the proposed underdrain system indicated on the
drawings shall be laid along the base of the wall under the sheathing.

6. The Contractor shall complete the backfill around box culverts to the level of the
original ground line and to the full width of excavation area. If the top of culvert
extends above the original ground line the Contractor shall continue the backfill to
the top of culvert and for a width of 3 m on each side of the culvert for the full width
of highway embankment. If the embankment is in place at the time of backfilling,
the Contractor shall backfill around the culvert to the top of embankment.
7. Miscellaneous structures shall be backfilled in accordance with the methods
specified. Compaction of backfill when structures are outside the roadway right-of-
way or in approach roads, minor roads or similar areas, shall be to 90% of
maximum density as determined by AASHTO T 180 (Method D).
2.4.4 EMBANKMENT CONSTRUCTION
A Scope
1. These Works shall consist of constructing road embankments, including preparation of the
areas upon which they are to be placed; placing and compacting approved material within
areas where unsuitable material has been removed; and placing and compacting approved
embankment material in holes, pits and other depressions within the right-of-way area, all
in accordance with the lines, grades and cross sections shown on the Drawings.
B Materials
1. Material of classes A-1, A-2-4, A-2-5 or A3 “when confined” groups as in AAHSTO M145
and complying with Table 2.1 shall be used when available, except for rock fill
embankments. If material of this character is not available then materials from A-2-6, A-
2-7, A-4, A-5, groups (AASHTO M145) may be used provided it complies with Table 2.1;
however, special attention should be given to the construction.
Table 2.1: Soil Suitable for Embankment
1- Maximum dry density not less than 1.7 (AASHTO T-180D)

2- Organic matter not more than 5% (AASHTO T-267)
3- No use of A-6, A-7 soil (AASHTO M-145)
4- Maximum size not more than 1/2 of the layer thickness
5- Plasticity Index (PI) less than 20%
6- 4 day soaked C.B.R. should not be less than 8% (AASHTO T-193) when compacted at
100% maximum dry density in accordance with AASHTO T-180 Method D
2. The 200 mm depth of embankment subgrade layer immediately below the bottom
of sub base shall consist of selected subgrade material having a 4-day soaked
CBR of at least 20% when tested in accordance with AASHTO T 193 and with a
gradation and P.I. as specified under Section 2.05 - “Subgrade Construction”.
3. The 600 mm depth of embankment immediately below the subgrade layer shall
consist of material having a 4-day soaked C.B.R of at least 15% when compacted
to 95% maximum dry density in accordance with AASHTO T-180D and tested in
accordance with AASHTO T-193 with a P.I. not more than 15%. If rockfill is used
for the bottom 400 mm depth then these requirements shall apply to the top 200
mm below the subgrade layer.
4. In areas subject to flooding and prolonged inundation of the embankment, such as
at bridge and culvert sites, the material used in embankment, unless rock, shall
conform to AASHTO M 145, Class A-1-a, A-1-b, A-2-4.

5. Where embankments are to be constructed using material classified as A3
(AASHTO M 145) or other material subject to side slope erosion or requiring
confinement for stabilization purposes, the embankment plating or confining layer
shall be constructed using AASHTO M 145 Class A-1-a, A-1-b, or A-2-4 materials
or as otherwise approved.
6. The material used in rockfill embankments shall consist predominantly of rock
fragments of such size that the material can be placed in layers of the thickness
prescribed conforming to the requirements stated in Table 2.2.
Table 2.2: Rock Suitable for Embankment
1- Maximum particle size 300 mm or 1/2 or proposed loose layer thickness whichever is
less
2- Passing 0.42mm (Sieve No. 40) 25% maximum
3- Uniformity coefficient, Cu ….. 6 minimum, where Cu = D60/D10

D60 = the Particle size at which 60% passes
7. Rockfill material shall be obtained from roadway or tunnel excavation and shall be
sound, dense, hard and durable rock capable of being spread and compacted as
specified. Individual pieces are to be clean and angular. It shall be the
Contractor’s responsibility to excavate material from rock cuts, whether by blasting
or other manner, so that all excavated materials are of suitable size.
8. When suitable materials of widely divergent characteristics are drawn from
different sources, such materials may, if approved, be mixed to meet the
embankment requirements. Rock and other materials shall be incorporated in such
manner as to avoid segregation and an accumulation of boulders, etc at the toe of
embankment slopes.
9. Logs, trees, stumps, weeds, heavy grass, frozen soil, vegetable matter or other
undesirable and noncompactible materials shall not be placed in embankments.
10. Rocks, broken concrete or other solid materials larger than 100 mm in any
dimension shall not be used as fill material in areas where piling works are to be
carried out.
C Workmanship
1. Prior to placing embankment material on any area, it shall have been cleared and grubbed
as specified in Sub-Section 2.02.1 - “Clearing and Grubbing”, and the foundation prepared
as specified herein.
2. Equipment used for foundation preparation and for placing, spreading and
compacting embankment materials shall be of approved types and furnished in
sufficient numbers for the purposes intended. Provision and use of such
equipment shall conform with the relevant requirements set in these specification
and with the Contractor’s approved Work Program.
3. Draglines shall not be used to construct embankment unless approval is given and
only when special procedures are adopted to keep the layers uniform and the
embankment properly graded and well-drained at all times.
4. Surfaces of embankment layers shall be kept properly shaped and drained at all
times. The Contractor shall utilize a sufficient number of motor graders or tractors
to level and maintain the surface of each layer of embankment during all placing
and compacting operations.

5. Rockfill shall not be used in the top 200 mm of the embankment below the
subgrade. Water must be added as required, and with the approval of the
Engineer, to achieve maximum compaction.
6. Whenever feasible, trucks, scrapers, tractors, loaders and other heavy hauling
equipment shall be routed over the embankment in such a manner as will
contribute effectively to compaction of the fill material.
7. Where an embankment is to be constructed over an area previously occupied by a
building basement, cellar, irrigation canal, well, any previous excavation, or
adjacent to structures, and where the proper use of normal compaction equipment
is not practicable, the embankment shall be constructed and compacted in
accordance with the backfilling requirements of the relevant sub-sections herein
before, until the use of normal compaction equipment is practicable. Layers shall
not exceed 200 mm thickness (after compaction) and shall be compacted to the
degree of compaction specified for the embankment.
8. Each embankment layer shall be tested and approved prior to placing the following
layer in accordance with Subsection D “Testing” here below.
9. The Engineer may at any time order suspension of delivery of materials to the
embankment Sites until previously delivered materials have been properly placed
and preceding layers are leveled and uniformly compacted to the specified density.
10. Unacceptable material placed in any embankment shall be removed and disposed
of by the Contractor at his expense.
11. The Contractor shall be responsible for the stability of all embankments and shall
replace all embankment sections which, in the opinion of the Engineer, have been
damaged or displaced due to carelessness or neglect on the part of the
Contractor, or due to normally occurring natural causes, such as storms, and not
attributable to the unavoidable movement of the natural ground upon which the
embankment is constructed.
12. All embankment side slopes shall be neatly finished true to the lines and not
steeper than the slope angles as shown on the Drawings. The bottom (toe) of side
slopes shall be graded to a well rounded, smooth profile to blend in with the
adjacent terrain.
13. The side slopes of rockfill embankments shall be thoroughly blanketted with A-1,
A-2-4 material, and compacted to the satisfaction of the Engineer.
14. The Engineer may permit the Contractor to utilize suitable surplus material at his
own expense to widen embankments or flatten slopes, etc within the right-of-way.
Surplus material used in such manner shall be compacted to 90 per cent of
maximum density, but this shall not be measured for payment. When widening
embankments, the Contractor shall bear the cost of modifying the culverts and any
protection work necessary.
15. Rockfill shall not be used within 5m of a structural element (next to bridge
abutments footings, etc)
16. Rockfill shall not be used for 600mm on top and bottom of Box and Pipe Culverts.
Subgrade material shall be used in these areas up to width excavated for
structures.
17. If shown on the Drawings, or as required by the Engineer, a trial embankment shall
be constructed. The trial section shall be at least 2 lanes wide by 100 m long at
approved locations at or adjacent to the Site. Compaction and other equipment
used, shall be as specified and listed in the Contractor Equipment Schedule and
approved Programme of work.
18. If the original surface upon which embankment is to be placed is an existing
roadbed, the surface shall be plowed, scarified, or otherwise broken up regardless
of the height of the embankment to be placed thereon.

19. Unacceptable material placed in any embankment shall be removed and disposed
of by the Contractor at his expense.
20. Where embankment is to be placed and compacted on hillsides or where new
embankment is to be compacted against existing embankments or where
embankment is built part width at a time, the slopes steeper than 3:1 (H:V) when
measured at right angles to the highway centerline shall be continuously benched
as the embankment is brought up in layers. Benching shall be of sufficient width to
permit operation of spreading and compaction equipment, and in any case not less
than 2 m wide except where insufficient width is available between existing and
new embankments. Each horizontal cut shall begin at the intersection of the
original ground and the vertical sides of the previous cuts. The vertical face of
each bench shall not be less than 1 m in height and not exceed 2 m. Authorized
benching shall be measured as highway excavation.
21. Where embankment is to be placed and compacted on wadi slopes, the entire
slope area shall be graded and trimmed to remove any vertical faces and
overhangs. The final graded slope shall not be steeper than 1.5:1 (H:V). The
slope shall then be continuously benched as the embankment is brought up in
layers, all as described above for embankment on hillsides.
22. Rockfill shall not be placed on any slopes steeper than 1:1. All slopes steeper
than 1:1 shall therefore be regraded to a slope of 1:1 or shallower and all vertical
faces and overhangs removed.
23. Roadway embankment consisting of soil or granular material shall be placed in
horizontal layers not exceeding 250 mm thickness (before compaction), shall be
compacted as specified and shall be approved prior to placing the next layer. The
thickness of the first layer over areas of Class A-3 dune sand may exceed 250 mm
in order to bridge these areas. Approximately uniform thickness of each layer shall
be achieved prior to compaction. As the compaction of each layer progresses,
continuous leveling and working of the material shall be carried out to ensure
uniform density. The correct moisture content shall be maintained at all times.
24. Where embankments are to be constructed to a height in excess of 1.5 m above
top of original ground level the Engineer may approve layer thickness up to 300
mm (before compaction) if the Contractor’s equipment and the nature of the
material result in the required density throughout the layer thickness.
25. When the moisture content of the embankment material does not fall within the
required moisture range, (optimum moisture ± 2%) water shall be added and
thoroughly mixed into the soil by approved methods or the material shall be
aerated, whichever is necessary to adjust the material to the required moisture
content.
26. When water is added to embankment material, the amount added shall be
sufficient to provide a moisture content within the required range plus a reasonable
additional amount to compensate for evaporation and other unavoidable losses.
Water added in excess of this amount shall be removed by aereation or other
approved means at the Contractor’s expense. Satisfactory methods and sufficient
equipment shall be used for the furnishing and handling of the water in a manner
that will minimize loss due to evaporation or waste.
27. Embankments that consist of rock-soil material with sufficient soil to make rolling
feasible, shall be placed and compacted in an approved manner and to the
required degree of compaction. Water shall be added as and when directed to
assist in the compaction of such materials.
28. In the case of embankments which are to be formed of approved rock-soil material
containing an appreciable quantity (normally not exceeding 30% greater than
80mm) of rock fragments and which cannot be placed in layers of the thickness
prescribed without crushing, pulverizing, or otherwise breaking down the
fragments, the embankment may be constructed in layers not exceeding in
thickness twice the average size of the largest rock fragments and in any case not
exceeding 600 mm (before compaction).

29. Rockfill materials shall be placed in such a manner that the larger rocks are well
distributed and the voids are filled to the maximum practical extent by smaller
particles, each layer shall be bladed into a neat and homogeneous mass prior to
compaction. Any rocks found protruding from the leveled surface shall be
removed and replaced by smaller particles. Initial breakdown compaction shall be
performed with heavy bulldozers. The top level of each layer must be surveyed
before and after compaction and approved by the Engineer before the next layer is
placed. Oversize rock pieces may be used in high rockfill embankments to a level
3 metres below subgrade.
D Testing
1. The Engineer shall test the compaction of embankment materials in accordance with these
Specifications to ensure that adequate compaction or consolidation has been achieved.
All such tests shall be fully documented by the Contractor, in an approved manner.
2. In the case of cohesionless, free draining rock-soil materials, where maximum
density tests fail to produce a well defined moisture - density relationship, the
relative density test shall be used, alternatively an electronic compaction meter or
any other approved test equipment shall be provided by the Contractor and used
to determine the degree of compaction achieved.
3. To determine the degree of compaction for embankment consisting of rock fill,
average differential settlement values shall also be determined from surveys of an
adequate number of grid point elevations as and when directed, at the
commencement of, during and after embankment construction.
4. If it is required to determine the modulus of soil reaction by the Plate Bearing test,
this shall be undertaken using the method given in AASHTO T222-81 (1986).
E Standards of Compaction for Soil and Granular Materials
1. The following compaction standards shall apply to embankment materials other than
predominantly rock materials. The “maximum density” of soil type materials shall be the
modified maximum density determined in accordance with AASHTO T 180 (Method D).
The “relative density” shall be the relative density determined in accordance with ASTM
D4254, which identifies the state of compactness of the material with respect to its loosest
and densest state. The relative density shall be the standard to which the field density is
referred for comparison in the case of cohesionless, free draining granular materials.
2. Soil type materials shall be compacted to at least 90% modified maximum density
for the full depth of embankment. The 600 mm of embankment material
immediately below the subgrade layer shall be compacted to at least 95% modified
maximum density. Moisture content shall be within plus or minus 2% of optimum at
the time of compaction.
3. Cohesionless, free draining granular materials (of 75 mm maximum size and with
not more than 15% passing 0.075 mm (No. 200) sieve) shall be compacted to at
least 70% of relative density for the full depth of embankment. The 600 mm depth
of such material immediately below the subgrade layer shall be compacted to at
least 75% of relative density.
4. Minimum soil tests required during the construction of subgrade and/or
embankment are:
a) One sample for CBR, classification (AASHTO M145), and laboratory (Moisture -
density) or relative density compaction from each source prior to use. Each sample
shall represent not more than 5,000 cu m.
b) One sample for classification representing not more than 3,000 cubic meters of the
material in use.
c) For every completed layer, one field density shall be determined for each 1500 sq.m
or 100 linear meters whichever is less. Testing shall be in accordance with ASTM D1556 or ASTM
D2167.

2.4.5 Pipe Bedding Material and Backfilling for Pipe Trenches
A Granular Bedding and Backfill materials
1. Backfilling above pipe crest shall be with clean granular Class A-3 in layers 30 cm thick
and shall pass sieve No. (4) 4.75 mm and be retained by sieve no. (200) 0.075mm.
2. Granular material for pipe bedding shall be composed of 14 mm maximum size
natural gravel, crushed gravel or crushed rock, free from dirt, clay, roots, organics
and other deleterious material mixed with sufficient sand to fill the voids, about 30
to 35% by volume.
3. Granular bedding shall conform to the following:
4. For GRP pipes bedding shall be of graded crushed stone 2.83-8 mm or as
recommended by Manufacturer.
Standard Sieve size % By Weight Passing
for rigid pipes
(mm) PE pipes
(DI or Concrete etc.)
19.0 (3/4 in) 100
4.76 (No. 4) 25-100 100
1.19 (No. 16) 10-75 25-75
0.300 (No. 50) 5-30 10-30
0.177 (No. 80) 3-10 3-10
0.075 (No. 200) 0-5 0-5
5. Sand bedding and fill up to 300 mm minimum above crown of the pipe shall be
non-plastic, natural well graded sand having hard, strong, durable angular
particles. It shall be clean and free from extraneous materials, clay balls, organic
matter or other detrimental material. The amount of fines passing sieve No. 200
shall not exceed 15% or according to the standard specifications (ASTM C33).
6. Backfill over a pipe shall consist of two different layers: Initial or selected backfill
and main backfill
7. Backfill in contact with the pipes and up to 300 mm minimum above crown of the
pipe shall be selected material
8. Selected fill material shall comply with group type GW, GP, GM, BC, SW, SP, SM,
SL in compliance with ASTM D 2487.
9. Selected fill material shall not contain ashes, cinder, refuse, rubbish, organic
material, or the like. The material shall be capable of being compacted without the
use of heavy rammers.
10. The main backfill (for the remainder of the trench) shall be done with suitable
material either from material removed in the course of excavating the trench or
imported from approved borrow pit. In either case the backfill material shall
conform to paragraph B of section 2.04.2 herein before.
11. Pipelines should be covered by plain concrete if the top cover is less than 1 m or
for deep pipelines as per the manufacturer recommendations.
B Workmanship: Backfilling
1. Trenches shall not be backfilled at joints until after that section of the pipeline has
successfully passed the specified tests required
2. Selected backfill or surround up to a level of 300 mm above top of the pipe, shall
be placed and hand compacted in 150 mm layers. The backfill shall be brought up
evenly on both sides of the pipe for the full length of the pipe. Care shall be taken
to ensure thorough compaction of the fill under the haunches of the pipe.

3. For GRP pipe initial backfill shall be compacted to 95% relative density or as
recommended by manufacturers.
4. Main backfill shall be placed and well compacted in layers not exceeding 300 mm
thick before compaction. Heavy compactors shall not be used until there is 600
mm cover over pipes.
5. Compaction of each layer shall be according to Section 2.04.2 paragraph J herein
before.
6. Heavy steel or pneumatic rollers shall not be used for compacting backfill to pipe
trenches. Special precautions shall be taken to safeguard existing structures when
steel or pneumatic rollers are used.
7. Compaction equipment shall be suited to the type of material and shall be subject
to approval. Compaction around foundation walls, culverts and small restricted
areas shall be carried out by mechanical vibratory plates, tampers or hydraulic
compactors.
8. Backfilling trenches for pipes with concrete beds and or surrounds shall not start
before 24 hours after placing the concrete. Heavy compactors shall not be used
and traffic shall not be allowed before the elapse of 72 hours after placing the
concrete.
9. When the material is too wet from rain or excessive application of water, no
compaction shall be done. In this case the work shall be suspended until the
previously placed and new materials have dried sufficiently to permit proper
compaction. Other measures shall be taken if necessary to obtain proper
compaction.
10. Temporary crossing are to be provided over trenches to prevent construction traffic
damaging pipes after backfilling.
11. The top 500 mm of pipe trenches below road pavement layers shall be filled with
crushed aggregate base course material compacted to 95% of maximum dry
density.
12. If authorized by the Engineer, the main backfill may be consolidated using water-
jetting, puddling, or tamping as directed.
C Restoration of surfaces
1. Restoration of asphalt, concrete, gravel pavements and the likes shall be of materials and
thickness to match the existing pavement. All works, workmanship material shall be in
accordance with concerned authorities specifications (Directorate, Municipality, Ministry of
transport) and Engineer direction.
2. Restoration of pavement shall be done according to the existing pavement quality and
level to ensure that new pavement is matching to provide uniform surface with the existing
profile.
3. Grassed areas shall be restored by spreading, after backfilling, approved fertile soil over
affected area. Seeding, fertilizers and water shall be applied until grass is restored to its
former condition.
4. Surface grading shall be carried out to restore all un-surfaced areas and any adjoining
areas disturbed to provide a level, smooth surface.
5. The Contractor shall proceed with restoration of surfaces as soon after completion of other
work as is practicable, but in no case more than 10 days after backfilling of trenches and
other excavated areas. Restoration shall be completed within 20 days from the start of
restoration or as approved by the concerned authorities.

2.5 SUBGRADE CONSTRUCTION
2.5.1 General
A These Works shall consist of furnishing materials, constructing the sub-grade layer and
preparing the sub-grade surface ready to receive the pavement structure and shoulders, all
as and where shown on the Drawings.
B Sub-grade layer is the 200 mm minimum depth of selected material immediately below the
sub-grade surface, or as defined in the drawings or directed by the Engineer.
2.5.2 Materials
A The supplied material shall not contain any organic or harmful material e.g: tree, leaves,
roots, and residues.
B The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4, according
to MRDTM 210 (Directorate of Material and Research at the MOC).
C Unless otherwise shown on the Drawings, sub-grade material shall consist of selected
material having a 4-day soaked CBR of not less than 25% when tested in accordance with
AASHTO T 193 when compacted at 100% of modified proctor AASHTO (T-180) and
having a maximum P.I. of 12% unless otherwise noted. Sub-grade gradation shall be
reasonably smooth without gap grading. All material shall pass 75 mm sieve and not more
than 18% shall pass 0.075 mm (No. 200) sieve.
D The maximum dry density shall not be less than 95% when tested according to Directorate
of Material and Research at the MOC.
E The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall contain fine
material for proper compaction.
F Minimum tests required on subgrade are indicated in sub-Section 2.04.4 “Embankment

Construction”.
2.5.3 Workmanship
A Subgrade in Cut
1. Where the subgrade is located in rock, the sub-grade, unless shown otherwise on the
Drawings, shall be undercut to a depth of 200 mm by drilling or blasting as directed. No
rock shall project more than 50 mm above the undercut surface elevation. The sub-grade
layer shall then be constructed using approved sub-grade material, as specified for sub-
grade in embankment.
2. Where the subgrade is on in-situ soil that is of a quality and CBR value at least
equal to those specified for sub-grade, the 200 mm depth of such material
immediately below top of sub-grade shall be scarified and all roots, sod, vegetable
and other undesirable matter and stones larger than 75 mm in any dimension shall
be removed. The material shall then be brought to a uniform moisture content
within the specified range and compacted to 100% AASHTO T 180 (Method D)
maximum density.
3. Where the subgrade is on in-situ soil which is unsuitable for retention as the sub-
grade layer, such material immediately below the top of subgrade layer shall be
sub-excavated to a depth of 200 mm, hauled away and disposed off unless
approved for use as embankment fill. The subgrade layer shall then be
constructed using approved subgrade material, as specified for subgrade in
embankment. If the material below subgrade layer does not satisfy the

requirement of top 600 mm, it shall be excavated for further 200 mm and replaced
by suitable material to satisfy the requirements of subgrade.
4. The underlying natural material shall be scarified, leveled and rolled. The surface
of the natural soil shall be approved by the Engineer before placement of suitable
material.
B Subgrade in Embankment
1. The 200 mm minimum depth of embankment immediately below top of subgrade shall
consist of selected, approved sub-grade material. The material shall be spread in one layer
over the full width of the top of embankment, brought to a uniform moisture content within
the specified range and compacted to 100% AASHTO T 180 (Method D) medium density.
C Surface Tolerances
1. All finished elevations, lines and grades shall be in accordance with the details shown on
the Drawings. Each cross section shall be checked at maximum intervals of 25 m, at each
change in cross slope and elsewhere as directed.
2. The tolerances on elevations of finished sub-grade, top of embankment under the sub-
grade layer and sub-excavated (undercut) surface shall be as follows:
Surface Tolerance
Finished Sub-grade:
Soil +10 or -30 mm
Rock (if approved) +50 or -50 mm
Top of Embankment or Sub-excavated Surface: +10 or -30mm
For agricultural roads, tolerances on elevations are allowed to be as follows:
Surface Tolerance
Finished Sub-grade:
Soil +20 or -30 mm
3. When the finished subgrade surface is tested with a 4 m long straightedge placed
parallel to, or at right angles to the centerline, the maximum depression of the
surface from the testing by straight edge shall be 30 mm.
D Maintenance of Finished Subgrade
1. The finished and approved sub-grade shall be continuously maintained in a smooth, well
compacted and properly drained condition until the sub-base (or base) course is
constructed. Reapproval of the subgrade will be required if the overlying course is not
constructed within 14 days of sub-grade completion or if the subgrade layer is damaged by
traffic or any other causes prior to the placement of the sub-base layer.
2.6 GABIONS
2.6.1 General
A The work shall include the supply of all material, preparation of gabions and their
installation as indicated on the Drawings or as instructed by the Engineer. Such works will
be constructed for protection in valleys and flooding areas.

2.6.2 Materials
A Gabions shall consist of approved type galvanized steel wire mesh baskets (or other
approved types such as heavy-duty plastic mesh) filled with selected rocks before
installation.
B Galvanized steel wire mesh shall conform to ASTM A 390 Class 3, or equivalent and with
the requirements shown on the Drawings. The wire mesh shall be twisted to form
hexagonal or rectangular openings of uniform size. The maximum nominal opening size
shall be 100 mm. Mesh shall be constructed so as to resist pulling apart at any of the
twists or connections forming the mesh when a single wire strand in a section is cut.
C Baskets shall be furnished in one or more sizes that can be assembled to provide the
minimum dimensions, stability, and structural integrity of the installation specified. Sizes of
gabion baskets will normally be 2 m long by 1 m wide by 0.5 m to 1 m high. Non-standard
sizes shall be provided to suit the particular installation, as shown on the Drawings.
D Baskets shall be fabricated in such a manner that the sides, ends, lid, and diaphragms can
be assembled on Site into rectangular baskets of the specified sizes. Gabion baskets shall
be of single unit construction. Long gabions assembled with diaphragms between
adjacent baskets, for use as foundation mattresses, etc., may not require lids.
E Base, lid, ends and sides shall be either woven into a single unit or one edge of these
members connected to the base section of the gabion in such a manner that strength and
flexibility at the point of connection is at least equal to that of the mesh.
F All perimeter edges of the mesh forming the basket shall be securely clip bound or
selvedged so that the joints formed by tying the selvedges have at least the same strength
as the body of the mesh.
G Perimeter (edge), tie, and connection wires shall conform to ASTM A 641, Class 3,
Medium Temper, and the minimum diameters shown on the Drawings.
H Riprap material for filling of gabion baskets shall consist of rocks conforming to Riprap
Class A size, clean, strong, durable and highly resistant to weathering. Dimensions shall
range from 250 mm to approximately 125 mm diameters. Not more that 5% shall be
smaller than 100 mm.
2.6.3 Construction
A The surfaces upon which gabions and similar slope protection works are to be placed shall
be excavated and compacted to the required grades and lines and a footing trench where
specified, shall be excavated along the toe of the slopes, all as shown on the Drawings or
as directed. Subgrade or base shall be firm or compacted as directed.
B Each gabion basket shall be assembled by binding together all vertical edges with wire ties
on approximately 150 mm spacing or by use of a continuous piece of connecting wire
stitched around the vertical edges with a coil every 100 mm.
C Empty gabion units shall be installed to line and grade as shown on the Drawings. Wire
ties or connecting wire shall be used to join the units together in the same manner as
described for assembling. Internal tie wires shall be uniformly spaced and securely
fastened in each cell of the structure. A standard fence stretcher, chain fall, or iron rod
may be used to stretch the wire baskets and hold alignment.
D The gabions shall be filled with riprap as specified, placed by hand or machine to assure
alignment and avoid bulges with minimum voids. Alternate placing of rock and connection
wires shall be performed until the gabion is filled. After filling with riprap, the lid shall be

bent over until it meets the sides and edges, and shall be secured to the sides, ends, and
diaphragms with wire ties or connecting wire in the manner described for assembling.
2.7 STONE PITCHING IN CONCRETE
2.7.1 General
A These works will be constructed in valleys and flooding areas.
B Stone pitching shall consist of broken stones, placed as indicated on the Drawings or in
locations as directed by the Engineer.
C Stone pitching shall be constructed to the shape and dimensions shown on the Drawings
in accordance with the provisions of the specification or as directed by the Engineer.
D Stone pitching shall be classified as stone pitching in concrete and shall have a thickness
of 200 mm, unless otherwise indicated on the Drawings.
2.7.2 Materials
A Rock
1. The stones for this work shall be durable, angular field or quarry stones of approved
quality, sound, hard, free from seam and other structural defects and shall have a specific
gravity of not less than 2.40. At least 60% of the stone pitching shall consist of pieces
having a weight of not less than 15 kg and of the remaining 40% no piece shall have a
weight of less than 7 kg. The thickness of each layer shall be achieved by the thickness of
one rock piece. The thickness of the rock piece shall be within 50mm from the specified
layer thickness, measured at the thinnest section of the rock piece.
B Concrete
1. Concrete used for filling shall be of the same class as blinding concrete.
2.7.3 Placing
A Ground surface to be protected by stone pitching shall be thoroughly compacted to the

approval of the Engineer and covered with 50 mm blinding concrete prior to placing of the
rock.
B Rock shall be placed starting with the lowest point of slopes.
C Approval of the Engineer is required for rock laying prior to pouring concrete. The rock
shall then be flushed with water to provide adequate bonding with concrete. Concrete
paring shall start with the lowest point of the area to be protected. Where more than one
layer of stone pitching is specified, or in keys, a layer of 50 mm blinding concrete shall be
placed below the first layer and between consecutive layers.
D The finished surface of the concrete shall be flush with the top of the surrounding stone
pieces.
2.8 GEOTEXTILES
2.8.1 General
A Geotextiles are used for protection and containment of the granular bedding and the first
dump layer around GRP pipes in the presence of water table in the trench.

B The work include the supply and installation of geotextile fabric as indicated on the
Drawings.
2.8.2 Material
A Drainage Fabric
1. Non-woven geotextile, specifically manufactured as a drainage geotextile; made from
polyolefins, polyesters, or polyamides; and with the following minimum properties
determined according to ASTM D 4759 and referenced standard test methods:
 Grab Tensile Strength: 490 N (ASTM D 4632)
 Tear Strength: 178 N (ASTM D 4533)
 Puncture Resistance: 222 N (ASTM D 4833)
 Water Flow Rate: 100 l/sec/m2 (ASTM D 4491)
 Apparent Opening Size: 0.3 mm (ASTM D 4751)
B Separation Fabric
1. Woven geotextile, specifically manufactured for use as a separation geotextile; made from
 Water Flow Rate: 2.7 l/sec/m2 (ASTM D 4491)
2.8.3 Workmanship
A Store and handle geotextiles in accordance with ASTM D 4873. Place and install in
accordance with manufacturer’s written instructions and as follows, to the approval of the
Engineer.
 Overlaps shall not, in any case, be less than 25 mm

 Place bedding layer as soon as possible after placement of the geotextile, in
accordance with approved methods, to thickness shown on Drawings
 Remove and replace any geotextile damaged or punctured either before, during or
after laying.
PART 3 PAVEMENT AND ROADS SURFACE FINISHING
3.1 SCOPE
A These works cover the supply of materials and construction of all components of the
roadwork specified in this Project. The roadwork components include: sub-base and base
courses, bituminous materials, pavement repairs and trench reinstatement and
maintenance of traffic and detours.

3.2 GRANULAR SUBBASE AND BASE COURSES
3.2.1 General
A Contractors Responsibility
1. The Contractor shall locate sources of material, ensure adequate supply and ensure
compliance with the Specifications.
2. The Contractor shall obtain and test, in an approved laboratory, samples from sources and
stockpiles which are in compliance with the Specifications.
3. Samples provided by the Contractor shall satisfy all specified test requirements. The
Contractor shall permit the Engineer to inspect any and all materials used or to be used, at
any time during or after their preparation, or while being used during progress of the
Works. Unsatisfactory materials, whether in place or not, shall be removed promptly from
the Site. The Contractor shall furnish all necessary labor, transport, tools and equipment
required by the Engineer for such inspection.
4. The Contractor shall ensure that screening plants or crushing and screening plants shall
not be put into operation prior to their approval. If, after any plant is put into operation, it
fails to perform as intended, the Contractor shall either rectify the defects in the existing
plant to the satisfaction of the Engineer, or shall provide alternative approved plant.
5. Approval of the crushing and screening plants and other equipment shall in no way relieve
the Contractor of his responsibilities in respect of producing granular materials and
aggregates which conform to the Specifications and in the quantities required for the
completion of the Works on time.
6. The Contractor shall conduct necessary tests in the Field Laboratory in the presence of the
Engineer and the Contractor’s Materials Engineer.
7. Processed materials shall be tested and approved before being stockpiled on Site or
incorporated in the works and may be inspected and tested at any time during their
preparation, storage and use. Questionable materials, awaiting testing and approval, shall
not be unloaded and mixed with materials previously approved. If the grading and quality
of any materials delivered to the Site does not conform to the grading and quality of the
established control samples, the Engineer will reject such materials.
8. Samples shall satisfy all specified test requirements. The Contractor shall permit the
Engineer to inspect any and all materials used or to be used. At any time during or after
their preparation, or while being used during progress of the Works. Unsatisfactory
materials, whether in place or not, shall be removed promptly from the site. The
Contractor shall furnish all necessary labor, transport, tools and equipment required by the
Engineer for such inspections.
9. The contractor shall construct in accordance with the concerned authorities specification.
3.2.2 Materials
A Subbase shall consist of naturally occurring gravel and sand, screened or crushed to
obtain the specified gradation.
B Base course shall consist of crushed gravel, crushed stone or sand with screenings as
required to obtain the specified gradation.
C The supplied material shall not contain any organic or harmful material e.g: tree, leaves,
D Material for subbase and base course shall conform to classification types: A-1-a, A-1-b
according to AASHTO classification system.

E Gravel, crushed gravel and crushed stone shall consist of hard, durable particles, free from
dirt, organic matters, shale and other deleterious materials, and shall not contain more
than 8% of clay lumps and friable particles. The fine material shall pass sieve no. 4 (4.75
mm) and shall consist of natural sand or crushed fine materials.
F Physical and chemical properties of granular materials used for subbase and base courses
shall conform to the requirements specified as follows:
1. Gradation: Subbase and Base shall conform to the following gradation in accordance with
AASHTO T-27.
Sieve Designation Percent by weight passing
Subbase Base
50 mm (2 inch) 100 -
37.5 mm (1 ½ inch) 90-100 100
25 mm (1 inch) 55-85 70 - 95
19 mm (3/4 inch) 50-80 55-85
9.5 mm (3/8 inch) 40-70 -
4.75 mm (No.4) 30-60 30-60
2.00 mm (No.10) 20-50 -
0.425 mm (No.40) 10-20 10-25
0.075 mm (No.200) 0-15 2-10
2. Other Requirements for Subbase and base are indicated in the following table:
3. If it is found necessary to add fine material in order to improve gradation
requirements, this material shall pass sieve 0.425 mm (no. 40) and shall be mixed
with the crushed material in the quarry and not in the project site.
4. The percent passing no. 200 sieve (0.075 mm) shall not be more than half the
percent passing sieve no. 40 (0.025 mm).
3.2.3 CONSTRUCTION
A Mixing and Spreading
1. The Contractor shall thoroughly mix aggregate and water to uniform moisture content.
2. The Contractor shall spread materials on prepared subgrade or subbase in uniform layers
not exceeding the following thickness before compaction:
 For subbase 300 mm
 For base 250 mm
3. All segregated material shall be removed and replaced with well-graded material
4. The Contractor shall compact each layer to the following density requirements:
 Subbase 100% of maximum density AASHTO T.180
 Base 100% of maximum density AASHTO T.180
5. Each layer shall be completely compacted and approved prior to delivery of
materials for the following layer.
B Tolerance
1. The Contractor shall conform to lines, grade and cross sections as shown on the
Drawings.

2. Tolerances on elevations for final layer at 20 m intervals and intermediate points as
follows:
 Subbase: +10 mm to - 20 mm
 Base: +10 mm to - 15 mm.
3. For agricultural roads, tolerances on elevations shall be as follows:
 Base: +15 mm to - 15 mm.
4. The Contractor shall remove defective sections and replace to correct tolerances.
5. The Contractor shall maintain finished course in good condition until succeeding
layer is placed.
C Testing
1. The Contractor shall carry out in-situ testing as directed by concerned authorities
(Municipality/Ministry of Transport) and Engineer or as per the listed-below:
Required Tests Repetition Required for all Tests
1. Proctor Test for every 500 LM for each layer or as per

specifications of the concerned authorities
(Municipality / Governamate / Ministry of Transport)
2. Gradation of Materials When materials changed or whenever instructed by
the Engineer
3. Plasticity Index "
4. C.B. R "
5. Abrasion "
6. Sand equivalent "
7. Clay lumps and friable particles "
8. Field Density "
9. Thickness Test for every 2000 sq.m. and for every layer
D Compaction
1. Compaction shall be tested in accordance with AASHTO T 191 or AASHTO T 205. If there
is a delay between the construction of any layer and the following layer, if necessary and
required by the Engineer the compaction of the lower layer may be re-verified to ensure
that it has not loosened due to traffic, passage of construction equipment, adverse weather
conditions or otherwise.
3.3 BITUMINOUS LAYERS
3.3.1 General
A Responsibility
1. The Contractor shall locate adequate sources and supply of material conforming with the
specifications.
2. The Contractor shall obtain the approval of the Engineer.
3. The Contractor shall sample and test all materials in an approved laboratory for
compliance with the specification.
4. The Contractor shall ensure crushing, screening and sampling materials shall be as
specified in section 3.02.1.

5. The Contractor shall construct as per specification of the concerned authorities
(Municipality / Ministry of Transport).
3.3.2 Materials and Requirements for Bituminous Courses
A Materials
1. The materials specified for use in construction of pavement layers include:

 Coarse and fine mineral aggregate and filler.
 Bitumen products including penetration graded bitumen and cutback bitumen.
2. Physical and chemical properties of all materials used in the bituminous mixes
and/or bituminous layer construction shall conform to the requirements outlined in
sub-sections B, C and D below.
B Aggregates for paving layer
1. Aggregate shall be clean, hard, durable and sound and shall consist of crushed stone, of
uniform quality and free from decomposed rock organic matter or shale. Combined
aggregate grading for bituminous mixes including mineral filler shall conform to the
requirements indicated in the table below:
Binder Course Wearing Course
1" (25.0 mm) 100 ---
¾" (19.0 mm) 75-90 100
½" (12.5 mm) 65-80 90-100
3/8" (9.5 mm) 55-65 78-83
No. 4 (4.75 mm) 35-80 46-60
No. 10 (2.00 mm) 20-35 30-42
No. 40 (0.425 mm) 7-20 14-25
No. 80 (0.180 mm) 5-25 8-16
No. 200 (0.075 mm) 3-7 3-7
2. Other Aggregate Requirements:

 Percentage by weight of friable particles, clay lumps, organic material and shale
shall not exceed 1% as determined by AASHTO T-112.
 Aggregate shall not contain more than 1% gypsum and 5% chert.
 The plasticity index of material passing 0.425mm should not exceed 4%.
 90% of crushed particles retained on No. 4 sieve (4.75 mm) shall have at least 2 or
more fractured faces.
 Flakiness index and elongation index tested in accordance with B.S. 812 shall be
within the following maximum limits:
Wearing Course Binder Course
Flakiness Index 25 30
Elongation Index 25 30
 Added mineral filler shall be fine particles of limestone or cement in accordance
with ASTM D-242. It shall be dry and free from organic material or clay.

 Loss in weight of aggregate after 500 revolutions shall not exceed 35% when
tested in accordance with AASHTO T-96.
 Soundness, when tested in accordance with AASHTO T-104 for aggregate
retained on No 4 sieve (4.75 mm) shall not show signs of disintegration, and the
loss in weight after 5 cycles shall not exceed 10% for the sodium sulphate tests
and 12% for the magnesium sulphate test.
 When tested for resistance to water damage in accordance with ASHTO T. 283,
the retained strength should be greater than 80%.
 Combined mineral aggregate shall have a sand equivalence value not less than 50
when tested in accordance with AASHTO T-176.
 Aggregates shall be washed if directed to remove any clay lumps, adherent dust
and other deleterious materials.
C Bitumen Products
1. Provide adequate transport and storage facilities for bitumen, and protect from temperature
under -5°C or over + 60° C.
2. Sampling of bitumen shall be in accordance with AASHTO T-40.
3. Binder and wearing courses shall be plant mixes in accordance with an
established Job Mix Formula (J.M.F)
4. The J.M.F. shall be established by the Contractor and approved by the Engineer.
The mix design procedures shall be in accordance with the Marshall method
procedure given in the Asphalt Institute Manual, M.S-2.
5. The J.M.F. shall be re-established if the source of aggregate, filler or bitumen is
changed.
6. Unless otherwise specified the bitumen for binder and wearing courses shall be
60/70 penetration graded bitumen and shall conform generally to the requirement
of AASHTO M20.
7. The J.M.F. shall conform to table 3.1
Table 3.1: Job Mix Formula

Number of blows at each end of compacted specimen 75 75

Stability (Marshall) (Kg) 1000 1000
Flow (Marshall) (mm) 2-4 2-4
Percent Air Voids 4-7 4-6
Percent Voids in Mineral Aggregate (V.M.A.) 14 15
Percent Voids filled with bitumen (V.F.B.) 50 - 70 50 - 75
Loss of Marshall Stability (AAHTO T 165) max 25% max 25%
Filler Bitumen Ratio 0.6 - 1.5 0.6 - 1.4
Bitumen content, percent by weight of total mix. * 3.5 - 4.5 3.5 - 4.5
* the optimum bitumen content shall be determined during the design mix procedure. (the
given values
are tentative).
8. The maximum variations of the project mix from the approved J.M.F. are as shown
in table 3.2:

Table 3.2: Surface Tolerances
Sieve Designation (square openings) Specified Tolerances
9.5 mm (3/8 in.) and above + or -5.0%
4.75 mm (No. 4) + or - 4.0%
2.00 mm (No. 10) + or -4.0%
0.425 mm (No. 40) + or -4.0%
0.18 mm (No. 80) + or -4.0%
0.075 mm (No. 200) + or -1.0%
Bitumen Content to be recommended by the Engineer based on
trials conducted by the Contractor.
Temperature of Mix on discharge + or -50°C
Any deviation from these limits shall be made only with the approval of the Engineer.
For agricultural roads the specified gradation tolerances above can be increased by ±±
2%.
D Bituminous Prime and Tack Coats
1. Works shall consist of furnishing and applying MC cutback bitumen prime coat to a
previously constructed subgrade, sub-base, aggregate base course, or road shoulders,
and furnishing and applying RC cutback bitumen as a tack coat to a previously constructed
bituminous binder or wearing surface to provide bond for a superimposed bituminous
course; all as and were shown on the Drawings.
2. Unless otherwise specified MC-70 shall be used for prime coat. Properties to
conform with AASHTO M82.
3. Tack coat shall be RC-70 in accordance with AASHTO M-81.
4. Surface for application to be sufficiently dry for Tack coat, and sufficiently moist for
prime coat. Ambient temperature to be more than 10°C and no rain, dust or strong
wind.
5. Spraying temperature shall be for RC-70 40 - 75°C. and for MC-70: 45 - 60°C.
6. Unless otherwise directed by the Engineer. The following rates of applications
shall be used.
 Prime coat 0.75 - 2.0 liters/ sq.m
 Tack coat 0.3 - 0.6 Kg/ sq.m
7. Prime coat shall be cured for 3 days or as directed by the Engineer.
Tack coat shall be allowed to dry to a suitable tacky condition before succeeding asphalt
layer is placed.
8. Traffic shall not be permitted on surfaces after they have been cleaned and
prepared for prime or tack coat application.
3.3.3 CONSTRUCTION
A Surface Preparation
1. When the bituminous mix is to be placed upon a granular subgrade subbase or base
course, the surface shall have been primed and approved by the Engineer.
2. When the bituminous mix is to be placed upon an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust; to the
approval of the Engineer. If required on the Drawings a tack coat shall be applied
prior to placing the new layer.

B Delivery Spreading and Finishing
1. The maximum temperature of the bituminous mix at the mixing plant shall be 170°C when
60 / 70 penetration bitumen is used. The application temperature shall be between 145°C
and 165°C.
2. The mix shall be laid by means of a paver, and rolled and compacted to not less
than 97% of the average daily Marshall bulk density.
3. Unless otherwise directed, the schedule of testing shall be as shown in table 3.3.
4. The thickness of pavement surface layer equal to the initial pavement layer
thickness with a maximum thickness of 15 cm and with a minimum value of 8 cm
and as per the concerned authorities (Municipality / Government / Ministry of
Transport)
C Tolerances
1. Elevation of finished course at intervals not exceeding 10 m shall be maximum ±± 10mm

(or 15 mm for agricultural roads).
2. When tested with a 3 m long straightedge, parallel to and perpendicular to the
centerline, the maximum deviation between any two contact points shall not
exceed 8 mm for the binder course, and 5 mm for the wearing course (or 10 mm
for binder course and 7 mm for wearing course in case of an agricultural road).
Table 3.3: TESTS FOR BITUMINOUS PAVEMENTS
Minimum Tests required.
(A) Frequency for all (B) Frequency for all
Tests at Source tests mentioned Tests at road tests mentioned
Work item
under (A) under (B)
of material Site
3-1 1. Specific gravity - Test for each
and water source
Materials used
absorption - When materials
in Asphalt mix
2. Abrasion test quality changes
(at Batching
plant) 3. Chert content - As requested,
4. Clay lumps and
Friable materials
5. Flaky and
elongated
Particles.
6. Soundness
3-2 1. Gradation - Test for each
2. Specific gravity and source
Materials used
in Asphalt mix water absorption. - When materials
(from hot bins) 3. Plasticity index quality changes
4. Sand equivalent - As requested,

5. Stripping with
asphalt

(A) Frequency for all (B) Frequency for all
Tests at Source tests mentioned Tests at road tests mentioned
Work item
under (A) under (B)
of material Site
3-3 1. Complete mix - For each job
design in mix
Asphalt mix
accordance with - When materials
design each American Asphalt
layer (At quality
Institute (MS2) changes.
batching plant)
2. Loss of stability - When results
are not
consistent with
the mix design
results.
- As requested,
3-4 At Batching plant - Test each 3 Behind spreader - Test for each
1. Stability working days 1. Stability working day
Asphalt for each
layer 2. Flow - Tests for each 2. Flow - Test for each
batching plant batch
3. Extraction (binder 3. Extraction
content and - As requested, (binder content - As requested,
gradation) & gradation)
4. Air voids 4. Air voids
5. Voids in mineral 5. Voids in
aggregates mineral
6. Daily Marshall aggregates.
density 6. Daily Marshall
7. Loss of Stability density
- Once a week 7. Road density - Test for each
- As requested, and thickness 200 lin.m, per
(after final lane and for
compaction) each layer
- As requested,
3. The combination of permitted tolerances in the levels of the bituminous courses

shall not result in a reduction of thickness of 10 mm from the specified thickness
nor a reduction in the final wearing course by more than 5 mm from that specified.
4. Thickness of each bituminous course shall be determined by taking core samples,
as directed by the Engineer.
3.4 PAVEMENT REPAIRS AND TRENCH REINSTATEMENT WORKS
3.4.1 GENERAL
A Scope
1. Pavement repair and trench reinstatement Works shall consist of removing defective
bituminous pavement, preparing surfaces (after having properly backfilled all trenches and
potholes) to receive repairs, furnishing materials, placing and finishing new pavement, as
and were shown on the Drawings or as directed by the Engineer and the concerned
authorities (Municipality / Governmate / Ministry of Transport).
3.4.2 ASPHALTING
Pavement type “A”

Pavement type “A” shall be considered as asphaltic pavement for main roads with a total
thickness for base and pavement layers exceeding 15 cm in addition to a granular layer
below base with thickness greater than 15 cm.
Pavement type “B”
Pavement type “B” shall be considered as asphaltic pavement for collection roads with a
total thickness for asphalt of 10 to 15 cm in addition to a granular thickness below base
with thickness exceeding 15 cm.
Pavement type “C”
Pavement type “C” shall be considered as asphaltic pavement for roads that are not main
or collection roads and where asphalting is not of type “A” or “B”.
3.4.3 MATERIALS
A General
1. All pavement materials shall conform with the relevant requirements and concerned
authorities mentioned in Section 3.02.2 - “Materials” and Section 3.03.2 - “Materials and
Requirements for Bituminous Layers”.
2. Subgrade materials shall conform with the relevant requirements of Section 2.05 -
“Subgrade Construction” and requirements of concerned authorities.
3.4.4 CONSTRUCTION AND REPAIR WORKS
A Preparation of Pavement
1. Cracks in bituminous pavement that, in the opinion of the Engineer, do not require
reconstruction shall be prepared by wire brushing and blowing out with compressed air.
2. Defective bituminous pavement which, in the opinion of the Engineer, requires
reconstruction shall be cut back to good material using pneumatic cutting tools.
Excavation of pavement layers for trenching shall also be initiated with pneumatic
tools or asphalt saws and later completed with regular excavating equipment. The
cut edges shall be square or rectangular and in line with the direction of traffic.
The depth of cut shall be determined by the Engineer and may include asphaltic
layers, base and sub-base layers and subgrade layers (in the case of failed
pavement, excavation shall include a minimum of 300 mm of subgrade material).
All excavated materials shall be removed and disposed of off-site. When the
bottom of the excavation consists of earth or granular material it shall be
thoroughly compacted using mechanical compactors to the satisfaction of the
Engineer. Excavated bituminous surfaces shall be thoroughly cleaned and wire
brushed prior to receiving repair materials.
3. Utility trench reinstatements in bituminous pavement shall be prepared in the same
way as defective bituminous pavement. Excavation shall include a minimum of
300 mm of subgrade material.
4. If cracks are present in asphalt layer due to trench excavation works for sewage
and water network, the Contractor shall reinstate the defects present as below:
 The crack and longitudinal and transverse joints shall be cleaned by a brush and
by air.
 The cracks shall then be filled with bitumen binder after which crushed sand shall
be spread above this binder.
 If settlement is obtained in the existing asphalt then the Contractor shall identify
these locations which shall be saw-cut in a square or rectangular shape with the
suitable equipment and shall then be reinstated as it was before failure.
B Placing and Finishing Repair Materials

1. Cracks of 3 mm width or wider shall be filled with clean, coarse sand then saturated with
1:1 diluted emulsified bitumen or as directed by the Engineer. Cracks of less than 3 mm
shall be filled with emulsified bitumen or as directed by the Engineer. Cracks shall be filled
to the road surface. Any excess bitumen shall be removed with a squeegee and the
bitumen surface shall be sprinkled liberally with coarse sand.
2. Excavations below subgrade level shall be filled to a level specified by the
Engineer with subgrade material in layers not exceeding 150 mm and compacted
using mechanical compactors to conform with the requirements of Section 2.05 -
“Subgrade Construction” and to the satisfaction of the Engineer.
3. Sub-base and/or base course, if required, shall be placed in layers not exceeding
150 mm and compacted using mechanical compactors. They shall comply with
the relevant requirements of Section 3.02.3 or as directed by the Engineer.
4. Prior to receiving bituminous material the excavations shall be thoroughly cleaned.
Subgrade, sub-base or base course material shall be primed with a light coating of
MC cutback bitumen and existing bituminous surfaces shall be lightly painted with
RC cutback bitumen, all in accordance with the requirements of Section 3.03.3.
5. The excavation shall be filled with bituminous pavement materials placed in layers
not exceeding 70 mm and compacted using vibratory compactors. Unless ordered
to the contrary by the Engineer, the top layer shall be compacted by steel wheeled
roller, first compacting the 150 mm strips adjacent to the traffic edges, then rolling
in the direction of traffic.
6. New utility trenches shall be backfilled according to Section 2.04 and to the details
shown on the Drawings, or ordered, including any surrounds, haunching or
protective materials. Construction of subgrade and pavement shall be as for
pavement repairs.
7. No excavated areas shall remain open overnight.
1. Levels shall be checked by straight edge in relation to the adjacent existing pavement.
2. Surface tolerances for bituminous layers shall conform with the relevant
requirements of Section 3.03.3.
3. Any deficiency in the wearing course surface shall be corrected by cutting out and
replacing.
3.5 CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS
3.5.1 GENERAL
A Scope
1. These Works shall consist of furnishing materials and constructing concrete/limestone

curbs, gutters, curb-and-gutter combinations and concrete/limestone paving to sidewalks
and medians, using in situ concrete construction precast concrete units or limestone units,
as and were shown on the Drawings. The shapes and installation details of curbs and
gutters, sidewalks, and medians shall be coordinated with the concerned Authorities.
Preparation and construction methods shall comply with the requirements of the concerned
authorities (Municipality / Governmate / Ministry of Transport) or as per the Engineers
direction.
3.5.2 MATERIALS AND PRECAST MANUFACTURE
A Concrete
1. Portland cement concrete shall be Class 210/20 for all in situ and precast concrete, except
base course and backing concrete which shall be Class 170/60. All concrete shall conform

with the relevant requirements of Section 5.01 - “Concrete and Concrete Mixes and
Testing” and shall be produced by an approved commercial ready-mix plant.
B Mortar
1. Mortar shall consist of cement and fine aggregate having the same proportions as used in
the concrete construction and shall conform with all relevant requirements of Section 5.01 -
“Concrete and Concrete Mixes and Testing”.
C Reinforcement
1. Reinforcing steel shall conform with the requirements of Section 5.03 - “Steel
Reinforcement and Fixing”.
D Precast Concrete Units

1. All precast units shall be manufactured to the dimensions shown on the Drawings.
Manufacturing tolerances shall be 3 mm in any one dimension. End and edge faces shall
be perpendicular to the base.
2. Each precast curb or gutter unit shall normally be 0.5 m in length and this length
shall be reduced to 0.25 m or as directed, where units are to be installed along
curves of less than 10 m radius.
3. For horizontal curves of radius less than 10 m, curb and gutter units shall be
manufactured to the radius shown and, in such circumstances, where straight
elements or portions of straight elements shall not be used. Bullnoses and curved
faces shall be of constant radius with a smooth change from radius to plain face.
4. Unless shown otherwise on the Drawings, precast concrete tiles (paving slabs)
shall be 400 mm by 400 mm by 40 mm thickness with 5 mm edge bevel. The tile
face shall be grooved in squares of a size agreed by the Engineer as appropriate
to the tile dimensions. Coloring of the top layer, where required, shall be achieved
using mineral oxides.
5. Surfaces of precast units that will be exposed to view after installation, shall be
true and even, with a dense finish of uniform texture and color, free from cracks,
holes, fins, staining or other blemishes or defects. Units failing to meet these
requirements will be rejected. Surfaces that will not be exposed to view after
installation shall have all fins and irregular projections removed and all cavities,
minor honeycombing and other defects made good with mortar after the units have
been saturated with water for at least 3 hours.
6. Precast units shall be cast upside down in approved steel molds under conditions
of controlled temperature and humidity. The units shall be steam cured or any
other method approved by the Engineer until the concrete attains the full specified
28-day strength.
7. The Contractor shall submit for approval, samples of each of the proposed units
together with the manufacturer’s certificates and details of the method of
manufacture and materials to be used. The Engineer’s approval of the samples
will not be considered final and the Engineer may reject any precast units
delivered to the Site which do not meet the required standards or specifications
and requirements of concerned Authorities.
E Limestone
1. Approved best quality limestone shall be obtained from one strata from one quarry,
delivered in one shipment, free from vents, cracks, fissures, discoloration or other defects
which adversely affect strength, durability or ap-pearance, thoroughly seasoned, dressed
and worked before delivery to site, and to the sizes shown on the Drawings, cut square
and true with clean edges.
F Preformed Expansion Joint Filler

1. Preformed expansion joint filler shall conform to AASHTO M 33.
G Epoxy Adhesive
1. Epoxy adhesive (for use in attaching precast units to existing concrete pavement surfaces)
shall be a two-component epoxy of high viscosity and rapid setting characteristics,
conforming to AASHTO M237, Class II.
H Ducts
1. Ducts (if required under sidewalks or medians) shall consist of uPVC plastic pipe
conforming to DIN 8061 and DIN 8062 or SAS 14 or approved equal. If jacking is required,
duct shall be approved galvanized steel tube.
I Bedding
1. Bedding material shall conform to the relevant requirements of Section 3.02 - “Granular
Sub-base and Base Courses” for Class A or Class B granular material.
3.5.3 CONSTRUCTION AND INSTALLATION
A Cast In Situ Curbs and Gutters
1. The subgrade shall be excavated to the grades and sections shown on the Drawings. If
the section is not indicated, the width to be excavated shall be 300 mm each side of the
outside edges of the curb or gutter. The subgrade shall be of approved uniform density.
2. The subgrade foundation shall be excavated to a minimum depth of 150 mm and
the material replaced with bedding material which shall be compacted to at least
95% AASHTO T180 maximum density. All foundations shall be rolled or
compacted to provide a smooth surface and shall be approved before placing
concrete.
3. For stationary side form construction, forms for curb or gutter shall be of approved
steel type. All forms shall be sufficiently strong and rigid and securely staked and
braced to obtain a finished product correct to the dimensions, lines and grades
required. Forms shall be cleaned and oiled before each use. Forms may be
removed as soon as practicable after concreting, provided no damage results to
the curb or gutter and in any case not until 24 hours after completion of concreting.
4. For slip-form construction, curb or gutter may be constructed by use of approved
slip-form or extrusion equipment. The completed curb or gutter shall be true to
shape, grade, and line, and the concrete shall be dense and of the required
surface texture.
5. Concrete shall be placed upon the previously prepared and moistened subgrade
and shall be consolidated with an approved type internal vibrator. The surface
shall be shaped by use of a steel screed to produce the section shown on the
Drawings. The edges shall be rounded with edgers to form the required radius,
which if not shown on the Drawings shall be 5 mm.
6. Contraction and construction joints of the required types shall be constructed at
the intervals and locations shown on the Drawings. Adjacent to flexible base or
surface courses, weaker plane contraction joints in curbs or gutters may be
constructed by sawing through the curb to a depth of not less than 30 mm below
the surface of the gutter, or they may be formed by inserting a suitable removable
metal template in the fresh concrete, or by other approved methods. Sealing of
the joints will not be required unless shown on the Drawings.
7. Exposed surfaces shall be finished full width with a trowel and edger. The top face
of curbs or gutters shall receive a light brush finish. Forms for the roadway face of
curbs and the top surface of gutters shall be removed 24 hours after concrete has
been placed and finishing of the surfaces shall be carried out, provided the
alignment tolerances and other requirements have been met.

8. Tolerances on tangent sections of curb and gutter shall be tested using a 4 m
straightedge. The finished surface of concrete shall not deviate from the
straightedge between any 2 contact points by more than 5 mm. Curved sections
shall be true to the specified radius plus or minus 5 mm and all joints shall be flush
and neat in appearance.
9. All fins and irregular projections shall be removed and cavities produced by form
ties and all other small holes, honeycomb spots, broken corners or edges and
other defects shall be rectified. After saturating with water for a period of not less
than 3 hours, the surfaces shall be carefully pointed and made true with mortar.
All construction and expansion joints shall be left carefully tooled and free of all
mortar and concrete. Joint filler shall be left exposed for its full length with clean
and true edges. The resulting surfaces shall be true and uniform.
10. A rubbed finish shall then be carried out to surfaces that will be exposed to view
after completion of construction. Before rubbing, the concrete shall be kept
saturated with water for at least 3 hours. Sufficient time shall have elapsed before
the wetting down to allow the mortar used in the pointing of holes and defects to
set. Surfaces shall by rubbed with a medium carborundum stone, using mortar on
its face. Rubbing shall remove all remaining form marks, projections and
irregularities, and result in a uniform surface. The final finish shall involve rubbing
with a fine carborundum stone and water until the entire surface is of a smooth
texture and uniform color. After the surface has dried, loose powder shall be
removed and the surface shall be left clean and free from unacceptable flaws or
imperfections.
11. Curbs and gutters shall be moist cured until stripped and finished, and then
membrane cured in accordance with the relevant requirements of Section 5.02 -
“Concrete Handling, Placing and Curing”. Curing compound shall be applied
immediately following completion of rubbed finish.
12. The area adjacent to completed and accepted curbs and gutters shall be backfilled
with approved material to the top edges of the curbs or gutters or to the elevations
shown on the Drawings. Backfill shall be placed and compacted to 95% AASHTO
T180 maximum density.
B Precast Concrete/Limestone Curbs and Gutters
1. Subgrade for the concrete base shall be constructed as for in situ curbs and gutters.
2. Forms for the concrete base shall be approved wood or steel. All forms shall be
sufficiently strong and rigid and securely staked and braced to obtain a finished
product correct to the dimensions, lines and grade required. Forms shall be
cleaned and oiled before each use. If approved, forms for the concrete base may
be omitted and the concrete placed directly against undisturbed excavated faces.
3. Base course concrete shall be placed, compacted and shaped to the sections
shown on the Drawings. Concrete shall be compacted with an approved internal
type vibrator or if approved, by hand spudding and tamping. Edges shall be
rounded if necessary by the use of wood molding or by the use of an edger as
applicable. The concrete base shall be finished to a true and even surface with a
wood float. Concrete shall be membrane or water cured for at least 7 days before
precast units are placed thereon.
4. Precast concrete units shall be soaked in water immediately before installation.
Units shall be set accurately in position in mortar on the concrete base. Joints
between precast units shall not be mortared unless otherwise shown on the
Drawings. Units shall be closely spaced and every 10 m run shall be provided with
an expansion joint.
5. here curbs or gutters are installed on existing concrete pavement using epoxy
resin adhesive, automatic devices for mixing epoxy adhesive shall be equipped so
that the separate components are delivered to the mixing head at the specified
volume. The lines feeding the mixing head shall be equipped with suitable valves
that will allow samples to be taken for checking the ratio of each component. The

machine shall be capable of metering the amount of adhesive required to secure
each curb or gutter.
6. After curbs have been installed, steel forms shall be erected and concrete backing,
if required, shall be placed as shown on the Drawings. Pavement courses shall
not be laid against curbs until the concrete backing has membrane or water cured
for at least 14 days.
7. The tolerances on alignment of completed precast units shall be as specified for in
situ concrete construction.
8. Backfilling shall be carried out as specified for in situ curbs and gutters.
C In Situ Concrete Paving

1. Excavation shall be carried out to the required depth and to a width that will permit the
installation and bracing of the forms. The foundation shall be shaped and compacted to an
even surface conforming to the sections shown on the Drawings. All soft and yielding
material shall be removed and replaced with approved material.
2. Bedding material shall be placed in layers not exceeding 100 mm in depth and
each layer shall be compacted to 95% AASHTO T180 maximum density. The total
bedding course thickness shall be as shown on the Drawings, or if not shown, 100
mm minimum thickness.
3. Forms shall be of steel, wood, or other approved material and shall extend for the
full depth of the concrete. All forms shall be straight, free from warp, and of
sufficient strength to resist the pressure of the concrete without displacement.
Bracing and staking of forms shall be such that the forms remain in both horizontal
and vertical alignment until their removal. All forms shall be cleaned and oiled
before concrete is placed.
4. The foundation shall be thoroughly moistened immediately prior to the placing
concrete. Concrete shall be deposited in one course in such a manner as to
prevent segregation and shall be consolidated by vibrators. The surface shall be
finished with a wooden float and light brooming. No plastering of the surface will
be permitted. All outside edges of the concrete tiles and all joints shall be edged
with a 5 mm radius edging tool.
5. Forms may be removed only when there is no risk of damage to the concrete and
in any case not until at least 24 hours after completion of concreting.
6. The smoothness of paved areas shall be tested using a 4 m straightedge. The
finished surface of concrete shall not deviate from the straightedge between any
two contact points by more than 5 mm. Sections of defective paving shall be
removed and replaced as directed, at the Contractor’s expense.
7. Expansion joints shall be of the dimensions specified and shall be filled with
approved, pre-molded expansion joint filler. The area being paved shall be divided
into sections by weakened plane joints formed by a jointing tool or other
acceptable means as directed. These joints shall extend into the concrete 0.20 to
0.25 times the depth and shall be approximately 3 mm wide. Joints shall match as
nearly as possible adjacent joints in curb or pavements. Weakened plane joints
may be sawn in lieu of forming with a jointing tool.
8. Construction joints shall be formed around all appurtenances such as valve
chambers, utility poles, etc., extending into and through the side-walk or median.
Pre-molded expansion joint filler of 10 mm thickness shall be installed in these
joints. Expansion joint filler of the thickness indicated shall be installed between
concrete construction and any adjacent fixed structures such as buildings or
bridges, etc. The expansion joint material shall extend for the full depth of the
concrete.
9. Concrete shall be cured by membrane curing in accordance with the requirements
of Section 5.02 “Concrete Handling, Placing and Curing”.

D Precast Concrete Tiles (Paving Slabs)
1. Excavation and the placing of bedding material shall be as specified for in situ concrete
paving. The surface of the completed bedding shall be dampened and base course
concrete shall be placed and finished to the thickness as shown on the Drawings or if not
shown, 40 mm minimum thickness.
2. The base course concrete shall be water or membrane cured as specified for in
situ concrete paving, for not less than 7 days before placing precast tiles.
3. Immediately prior to tile laying, the concrete base course shall be dampened and
the concrete tiles shall be immersed in water. Tiles shall then be laid true to line
and grade on a 10 mm to 20 mm thickness of mortar. Joints shall be 3 mm wide.
4. he tolerance on smoothness of precast concrete tiled areas and removal and
replacement of defective tiling, shall be as specified for in situ concrete paving.
5. Tiles shall be cleaned 24 to 36 hours after laying and joints shall be mortared
using, if approved, a plasticizer in the mortar to improve workability and to enable
the mortar to be readily smoothed and finished. As soon as the mortar has
partially set, all mortar material shall be raked from the top 3 mm depth of the joint,
using a grooving tool to produce a smooth circular section.
6. When the mortar is sufficiently set, the surface shall be sprinkled with water and
covered with plastic or nylon sheets during the curing period. The sheets shall be
left in place until final hardening of the mortar, or as directed. All foreign matter,
wood, concrete, mortar lumps, etc., shall then be removed and the surface
cleaned of staining, discoloration and other blemishes.
7. In cases where tiles are required to be cut at the boundaries of tiled areas, or due
to the presence of obstacles, poles, hydrants, etc., or in the construction of the
driveways or side roads, the Contractor shall cut the tiles or substitute in situ
concrete of at least the same quality as the tile concrete. The Engineer will
decide, after trials, on the method to be adopted. Cutting of tiles or substitution of
in situ concrete shall be kept to a minimum. The Contractor shall complete the
areas using uncut precast tiles to the maximum extent practicable.
8. The method of construction and sequence of operations, for areas constructed
using precast tiles, shall be the same as for areas constructed using in situ
concrete. The Contractor shall ensure that the final appearance of such surfaces,
regardless of the method of construction, is substantially the same for both types
of construction.
9. Where a sidewalk crosses the entrance to a shop or a house, etc., which is higher
than the sidewalk, the Contractor shall construct steps, formed by a curb and a
complete or partial tile. Steps shall be backfilled with concrete of the same quality
as specified for concrete base course.
10. Steps shall be constructed wherever the difference in elevation between the
entrance and the sidewalk is more than 250 mm. The Contractor shall submit for
approval, prior to commencing any sidewalk construction, a list of locations where
steps will be required, together with design details for their construction.
3.6 MAINTENANCE OF TRAFFIC AND DETOURS
3.6.1 GENERAL
A Scope
1. These Works shall consist of supplying all materials and equipment, constructing detour
roads, bridges and culverts where necessary; and installing, operating and maintaining all
required temporary lighting, signing, signals, pavement marking, barriers and other safety
measures; all for the proper maintenance of vehicular and pedestrian traffic through and
around the Site of the Works during the Contract Period.

2. Temporary works shall conform with the general requirements of Section 1.04
“Temporary Works” and as specified by the concerned Authorities (Traffic
Directorate /Municipality/Governmate/ Ministry of transport).
3.6.2 MAINTENANCE AND PROTECTION OF TRAFFIC
A General
1. The Contractor shall ensure the free movement of vehicular and pedestrian traffic and shall
maintain all highways including temporary detours and accesses in a clear and safe
condition free from obstructions. Adequate access to the Site shall be maintained at all
times to ensure that traffic on existing roads is not impeded unnecessarily by traffic turning
into the Site.
2. In order to facilitate movement of traffic through or around construction and when
and wherever required by the Engineer, the Contractor shall furnish, erect and
maintain signs, traffic barricades and other facilities necessary for safe and
efficient direction and handling of traffic at specified locations in or around the Site
and as per specification of the concerned authorities and Engineer.
3. The Contractor shall, if required by the Engineer, provide flashing signal lights by
night and provide sturdy barricades for the protection of workmen engaged on
traffic control.
4. The Contractor shall, whenever necessary, provide flagmen at specified locations
with the sole task of directing traffic through or around the Site and shall provide
and erect within or near the Site any “warning” or “directional” signs the Engineer
may require.
5. All barriers, traffic signs, signals and other such devices shall be erected,
maintained and removed when necessary, as directed by the Engineer and
concerned authorities.
6. Whenever it becomes necessary to operate one-way traffic along any stretch of
road in or around the Site, the Contractor shall, for the purpose of maintaining
traffic, provide a single traffic lane not less than 3.5 m wide and shall keep it open
to traffic.
7. Where, in the opinion of the Engineer, construction of a detour is inappropriate,
new construction may be limited to half the road width at a time.
8. The Contractor shall submit for approval, details of the layout, pavement
construction, drainage, lighting, signing and marking of any detours that he
proposes. He shall give the Engineer at least 7 days notice of such proposals.
9. The standard of lighting levels and uniformity for each detour shall be at least
equivalent to that existing on the road that it replaces. In addition to lighting of
detours, the Contractor shall provide and maintain illumination of all temporary
traffic signs during the hours of darkness.
10. Any obstruction associated with detours, including ramps, variations of lane
widths, siting of warning signs, etc., shall be marked by the use of cones, flashing
beacons and warning lamps, appropriate to the location concerned.
11. Detours shall be constructed in advance of the Works which interfere with the
existing highway or access and shall be regularly maintained in a condition
acceptable to the Engineer for as long as required.
12. Before any detour is opened, the Contractor shall obtain approval from the
Engineer. The diversion of traffic on the day on which the detour is initially put into
operation shall be carried out with the assistance and coordination of the Police
Department.
13. All works under this section shall comply with the requirements of the Ministry of
Communication and traffic directorate and the concerned authorities.

14. The Contractor should install sufficient number of metal plates as bridges to cross
the excavations for pipelines according to the Engineer instructions and in
coordination with the citizens as per one bridge for each house. The shopping
stores should be considered. All required roads diversions should be paved.
Enough coordination should be done with the citizens to facilitate their movement during
the construction by printed notification prepared as per the requirements of the water
authority in the project area and sticked on each house.
PART 4 PIPE WORKS AND NETWORK ACCESSORIES
4.1.1 SCOPE
A The works cover the supply of materials, installation, testing and commissioning of all
pipes, fittings, valves, and appurtenances related to wastewater collection works and
sewer force mains.
4.2 GENERAL REQUIREMENTS
4.2.1 GENERAL
A Scope
1. This section outlines the sequence of construction works, aspects related to the right of
way (ROW) and the general requirements for supply and handling of equipments and
materials.
4.2.2 SEQUENCE OF CONSTRUCTION
A The Contractor shall adhere to the sequence of construction as set out below unless a
justified request for modifying this sequence is approved by the Engineer at least two
weeks prior to commencement of work on the affected section of the network:
 Stake out pipe alignments.

 Clear and grade the right of way.
 Conduct field surveys.
 Carry out exploratory trenching across existing roads to verify location, depth, size
and type of existing utilities.
 Prepare and submit for approval composite Shop Drawings for all utilities showing
alignment, ground elevation, trench invert elevation, pipe size, class and length,
station and size of fittings, valves, manholes and inspection chambers, inlets,
appurtenances and structures to be demolished and reinstated (curbstone, rails,
culverts, etc.). Cross sections showing location and inverts of existing pipes and
those proposed shall be prepared. Pipes, structures and other utilities to be
removed or relocated shall be indicated on the Shop Drawings. The Contract
Drawings shall be modified wherever required to produce the detailed Shop
Drawings.
 Relocate, demolish and reinstate existing utilities interfering with pipeline
alignments.
 Remove pavement layers, excavate trenches, place bedding all as required.
 Lay and join pipes, fittings, appurtenances, inspection chambers, manholes, etc…
 Place primary backfill material.
 Perform required air, hydraulic or other required testing.

 Install required house connections and or connections to existing utilities as
required.
 Place final backfill.
 Restore or reinstate surfaces and structures as required.
 Carry out final surface works road surfacing curb stone, backing walls, side walk
tiling, etc…
 Dispose of surplus materials.
4.2.3 RIGHTOF WAY (ROW)
A Extent
1. All utilities services shall be installed in the right-of-way of existing or proposed roads as
shown on the Drawings.
B Clearing and Grading
1. The ROW shall be used for both access to works sites and for service roads for the
pipelines.
2. In case the pipe lines run outside existing roads, the ROW shall be cleared and
graded to the required slopes; road cross-sections and all drains, shall be as
indicated on the Drawings.
3. Road surfacing / resurfacing works shall commence only after completion of pipe
installation and construction of all required works.
4.2.4 MATERIALS, PRODUCTS SUPPLY AND HANDLING
A Structural Materials
1. Concrete shall conform to the requirements specified in Section 5.01 “Concrete and
Concrete Mixes and Testing”.
2. Reinforcement shall conform to the requirements specified in Section 5.03 “Steel
B Products supply requirements
1. Manufacturer’s certificate: Materials shall be supplied with a certificate for each delivery.
The certificate shall clearly state that products comply with the specified Standards and
have been factory tested accordingly.
2. Marking: Unless otherwise specified in the relevant Standard products shall have
legibly cast, stamped or indelibly painted on, the following marks, as appropriate:
 Manufacturer’s name, initials and identification mark.
 Nominal diameter.
 Class designation.
 Initials and number of relevant Standard.
 Length of pipe if shorter than standard length.
 Angle of bends in degrees.
 Date of manufacture.
3. Special tests: Whenever required by the Engineer, the Contractor shall supply and
transport samples of materials selected by the Engineer to a testing laboratory.
The number of samples shall not exceed 0.5% of total supplied. However, at least
one sample from each class, diameter and manufacturer shall be tested. Failure of

any sample shall be followed by a second and if necessary a third test from the
same batch regardless of whether the limits on number of tests has been
exceeded or not. A third test failure shall result in all material from that
manufacturer being rejected and replaced by material from a different
manufacturer, subject to approval and satisfactory tests. Laboratory test report in
an approved form must be provided.
C Products handling
1. General
a) Manufacturer’s recommendations on handling, repairing, laying, jointing, anchoring,
testing and other works for pipes and fittings shall be strictly followed.
b) For loading and unloading, the Contractor shall use cranes, hoists or skidways as
directed by the Engineer. Use of hooks, spreader beams, ropes, band or wire slings etc. shall be
as recommended by the manufacturer of each type of pipe and as approved by the Engineer.
c) Pipes shall be stacked on horizontal surfaces. Pipes shall not be stored on their
sockets or jointing fairlings. End pipes in bottom row shall be secured by chocks. The allowable
height of stacks shall be to the manufacturer’s instructions.
d) Material and equipment shall be handled with care whenever moved by hand,
skidways or hoists and any damage incurred shall result in the material being rejected.
e) The Contractor shall provide safe storage for the material. The interior surfaces of
pipes, fittings etc. shall be kept free from dirt and foreign matter. Shade for materials shall be
provided as required by manufacturer’s instructions and to the Engineer’s approval.
f) Cutting hacksaws, manually operated wheel cutters or pipe cutting machines shall
be used as per manufacturer’s instructions. If, in the opinion of the Engineer, special precautions
are to be taken to eliminate airborne particles, methods and equipment shall be used as directed
by the Engineer. Ends shall be prepared according to type of joint used and as per manufacturer’s
recommendations. Care shall be taken to avoid any damage to the lining. Minor damage may be
repaired on site as directed by the Engineer.
g) The Contractor shall repair damaged coating, sheathing or lining in accordance with
the Specification and manufacturer’s instructions. Material used for repair work shall be compatible
with that originally used. All repair works shall be approved by the Engineer before incorporating
materials into the work.
h) Bricks and cast iron frames and covers of manholes and chambers and all other
construction materials shall be loaded and unloaded by fitting with hoists or skidding so as to avoid
shock or damage. No hooks shall be used inside pipe. Under no circumstances shall such
materials be dropped. Pipe handled on skidways shall not be skidded or rolled against the other
pipe or other materials already on the ground.
i) All materials shall be delivered and distributed at the site by the Contractor. In
distributing the material at the site of the work, each pipe shall be unloaded opposite or at the
nearest possible place where it is to be laid in the trench.
j) A space of suitable width, clear of any spoil materials shall be left all along the
trench so that no pipes shall be placed on excavated material.
2. GRP Pipes and Fittings
For handling GRP pipes, fittings and rubber ring gaskets, instructions of the manufacturer
shall be strictly adhered to GRP pipes and fittings shall be suitably wedged or braced to
prevent damage during shipment and transportation and rubber rings gaskets and
lubricants shall be packed in suitable containers.
The allowable stack height is 2.5 meters. When storing the pipes directly on ground, the
ground shall be free of stones and materials causing any damage.
While lifting, the supports shall be pliable straps or ropes and shall not be steel cables or
chains unless sufficient padding is provided to protect pipes surfaces. Pipes shall never be
dropped.

3. uPVC Pipes and HDPE Pipes and Fittings
Manufacturer’s instructions shall be strictly adhered to while handling uPVC pipes and
fittings. Extreme care shall be taken when handling uPVC pipes and fittings.
The pipes shall be loaded using enough supports to avoid any sort of bending, distortion,
damage, scratches to the barrel or ends or any part of pipes and fittings. When off loading,
pipes shall be lowered taking all precautions to avoid bending, distortion, damage,
scratches and never be dropped to the ground. Pipes shall be given adequate and enough
supports while stacking. Pipes shall never be stacked in large piles or under direct sun light
to avoid ultraviolet degradation and manufacturer’s instructions shall be strictly adhered to.
Any pipe with ends prepared for jointing shall be stacked in layers with sockets placed at
alternate ends of the stack and with the sockets protruding to avoid unstable stacks.
For long term storage, pipes shall be stored in pipe racks providing continuous support
under a shed with insulated roof and shall never be kept under sunlight to avoid ultraviolet
degradation.
Also while loading pipes and fittings, care must be taken to avoid their coming into contact
with any sharp corners such angle irons, sharp steel sheets, loose nail-heads. While in
transit, pipes shall be well secured over their entire length. While off-loading, care shall be
taken that pipes and fittings do not fall one upon another or to any hard or uneven
surfaces. uPVC pipes and fittings shall be transported to the site in special pile rack type
containerized units to facilitate loading, unloading, onsite storage, retrieval and protection
of pipes and fittings from sunlight and ultraviolet radiations.
4. Reinforced Cement Concrete (RCC) Pipe and Vitrified Clay (VC) Pipe
For handling RCC and VC pipes, the instruction of the respective manufacturer shall be
strictly adhered to. RCC and VC pipes shall be handled with great care while transporting
to the site and while installing. Each pipe shall be properly wedged to stop any movement,
which may cause damage to the bell and spigot or tongue and groove ends of the pipes.
Each pipe shall be carefully inspected before being laid and no cracked or defective pipe
shall be used. Chipping of the bell and spigot or tongue and groove pipe ends, which in the
Engineer’s opinion may cause defective joints, shall be avoided. All cracked and defective
pipes shall be rejected.
5. Ductile Iron Pipes and Fittings
All ductile iron pipes and fittings shall be handled and stored strictly according to the
instructions of manufacturer.
Pipes, fittings, valves, hydrants, cast iron frames and covers and all other construction
materials shall be loaded and unloaded by lifting with hoists or skidding so as to avoid
shock or damage. No hooks shall be used inside the pipe. Under no circumstances shall
such materials be dropped. Pipe handled on skidways shall not be skidded or rolled
against pipe or other materials already on the ground.
In distributing the material at the site of the work, each pipe shall be unloaded opposite or
near the place where it is to be laid in the trench.
Pipe shall be so handled that coating and lining will not be damaged. If, however, any part
of the coating or lining is damaged, the repair shall be made by the Contractor at his
expense according to manufacturer’s specifications or in a manner satisfactory to the
Engineer, or be replaced as determined by the Engineer.
6. Rubber Ring Gaskets
All gaskets for vitrified clay (VC), unplasticised polyvinyl chloride (uPVC), Glass fiber
reinforced concrete (RC) pipes and fittings shall be handled and stored strictly according to
their respective manufacturer’s instructions.
For storage of gaskets, the storage temperature is to be between + 5˚C and + 25˚C. If
stored at low temperatures and taken out for immediate use, their temperature must be
brought to approximately 30˚C prior to their use. The gaskets are to be protected from
direct sunlight and a strong artificial light with ultraviolet content. The gaskets must be

protected from the surrounding air either by wrapping them up or storing them in
hermetically sealed boxes.
D Materials and Equipment Furnished by the Contractor
1. The Contractor shall furnish all materials and equipment that will be incorporated in the
works and all other materials and equipment needed during construction. He shall also
furnish such constructional plant and equipment as in the opinion of the Engineer, is
necessary and adequate to perform all work within the scheduled time for completion.
2. The tenderer shall state in the schedule provided in the trade name of materials
and equipment he intends to incorporate in the works as well as the name of the
manufacturer and his full address. The Contractor shall be bound to use the same
manufacturer materials and equipment quoted in his Tender.
3. The Contractor shall, within 60 days after receipt of the order to commence, submit
to the Engineer in triplicate certified copies of the unpriced agreements with the
manufacturers of the materials and equipment to be used in the works. Such
agreements shall embody all the appropriate specification clauses including testing
and inspection and shall state delivery periods.
4. Materials and equipment furnished by the Contractor shall be brand new and of
the type and quality described in the specification. The Contractor shall procure all
materials and equipment, whether specified or substituted, from eligible sources.
Where, because of Employer’s priorities or other causes, materials or equipment
required by the specification become unavailable, substituted materials or
equipment may be used.
5. The Engineer’s decision as to whether substitution shall be permitted and as to
what substitute materials.
E Inspection of Materials and Equipment
1. Materials and equipment furnished by the Contractor which will become a part of the
permanent works shall be subject to inspection at any one or more of the following
locations as determined by the Engineer: at the place of production or manufacture, at the
shipping point, or at the site.
2. The allow sufficient time to provide for inspection, the Contractor shall submit to
the Engineer, at the time of issuance, copies in triplicate of purchase orders,
including drawings and other pertinent information, covering materials and
equipment on which inspection will be made as advised by the Engineer, or shall
submit other evidence in the event such purchase orders are issued verbally or by
letter. The inspection of materials and equipment or the waiving of the inspection
thereof shall in no way relieve the Contractor of the responsibility for furnishing
materials and equipment meeting the requirements of the specification.
F Rejected Materials
Should any materials, equipment or manufactured articles prove to be, in the judgment of
the Engineer or as a result of testing, unsound or of inferior quality or in any way unsuitable
for the works in which it is proposed to employ them, such materials, equipment or
manufactured articles shall not be used in the works but shall be branded, if in the opinion
of the Engineer this is necessary, and shall forthwith be removed from the site and
replaced at the Contractor’s expense and in each case as the Engineer shall direct.
G Approved Manufacturer’s Instructions
1. The Contractor shall supply the equipment, materials or other items from the approved
manufacturers listed or equal and approved.
2. All equipment or materials shall be delivered to the site in the manufacturers’
original unopened containers with the manufacturers’ brand and name clearly
marked on.

3. All equipment or materials shall be assembled, mixed, fixed, applied installed or
otherwise incorporated in the works in accordance with the printed instructions of
the manufacturer of the equipment or materials and/or the relevant standards as
specified.
H Certification and Third-Party Inspection
1. All material provided by Contractor shall be procured from ISO/BS certified manufacturers.
The certificate should cover all the processes associated with the production of the
manufactured item and should be submitted to the Engineer approval with the material
submittals by the Contractor. Upon the request of the Engineer, the Contractor shall
propose an internationally accredited and reputable audit firm to act as a third-party
inspector who shall certify that all material manufactured and shipped for the project have
been manufactured and conforms to the specified international standard governing the
manufacture of the finished item / product as specified in the project Tender Documents.
The scope of the third-party inspection shall cover at least the quality control tests listed in
the fourth coming sections of the Specification. The cost of the third-party inspection shall
be borne by the Contractor
4.3 PIPES, FITTINGS AND ACCESSORIES
4.3.1 MATERIALS
The following table lists the type of pipe material that should be used for sewage network
for different pipe diameters and soil types:
Usage Recommendations
Type of Pipe Dry Areas Dry Areas Wet Areas

(Non-aggressive soil) (Aggressive soil) (Ground water)
(Aggressive soil)
VC For diameters 200 to 600
GRP-GRE
With granular bedding and textile
Stiffness not less than For diameters 700 – 900mm with granular bedding
protection
5000N/m2
For diameters ≥ 1000 mm with
Concrete pipes internally additional external protection
coated with polyethylene For diameters ≥ 1000 mm
(paint with not less than two
with thickness 3mm
layers of bituminous)
HDPE For Diameter 110 to 1000mm For Diameter 110 to 1000mm
The following paragraph describes the specifications of each of these pipes:
A Ductile iron pipe (used for force main)
1. Ductile iron pipe for pressure shall be to BS EN 598 [6] or equivalent SASO Standards.
Unless otherwise indicated in the Bill of Quantities or the Drawings, Class K9 shall be used
for all pipe diameters, and in the case where pressure does not exceed 16 bars for large
diameters, class K8 pipes shall be used.
2. Ductile iron fittings shall be to BS EN545 [1] or ISO 2531or equivalent with socket /
spigot ends. Joint deflection at installation shall not exceed 50% of the maximum
allowed by manufacturer.
3. Spigot and socket ended pipes shall be used for straight runs and adjacent to
elbows or fittings. These joints shall be provided with rubber gaskets, and an
external thrust block is required at elbows or fittings. Anchored or self restrained

joints shall be used for sections adjacent to elbows in areas where space is
restricted or indicated on the Drawings or BOQ. Anchored joints are to be push-in,
self-anchored type able to take up the axial forces thus allowing concrete thrust
blocks to be dispensed with. The Contractor shall submit calculations verifying the
number of restrained joints required noting that pipe pressure testing will be made
when pipes are partially backfilled, and joints are exposed.
4. Rubber gasket to BS/EN 545 or ISO 4633.
5. Flanged pipes wherever specified shall have screwed-on or cast-on flanges to
sustain working pressure of NP 16 minimum.
6. Flanges shall conform to BS 4504 [2].
7. Factory protection for pipes:
 Pipes shall be internally lined with cement and aluminum oxide to ISO 7186 or BS
4027 or equivalent in addition to polyurethane sheets lining with 2 mm thickness
according to the detailed specification in Item (A-8) below. Externally, pipe shall
be coated with metallic zinc to BS EN 545 [1] or ISO 8179 or equivalent and
followed by a bitumen nontoxic coat to BS 3416 [4] or ISO 8179 or equivalent.
8. Additional Site Protection for Metal Pipes (high corrosion areas)
a) Polyurethane Coating
The coating shall be 100% solid polyurethane consists of two components: one
isocyanides-rich solution and one oplyol-rich solution. The coating shall be completely
continuous and free from all holidays, voids, pinholes or other defects. The test certificate
shall state the property of the coating and shall specify the test method used. The
polyurethane coating system shall comply with the data included in the following Tables:
Technical Data of Polyurethane External Coating
Material Polyurethane, 2 Components airless applicator
Color Black
Density 1.6g/mm3
Tensile Strength 25N/ mm3
Adhesion to Steel > 8Mpa (Stee grit blasted SA21/2)
Dielectric Strength 200 Kv/cm
Water Absorption 3.5% at 25C
Impact Resistance > 15Nm
Temperature Resistance 90C continuous
Salt Water Spray No effect after 1000hrs
Elongation > 10%
Chemical Resistance Water solution of salts, acids, and bases of pH 1-14
Thickness 1-1.5mm
b) Polyethylene Sleeves
Protective polyethylene sleeves shall be used with all DI pipes and fittings to be installed in
buried condition and shall be in accordance with ISO 8180.
The minimum nominal thickness of the sleeve shall be 0.010 inch (250 microns) with a
maximum minus tolerance of 10%.
The material shall be made from a polymer with a melt flow index as measured according
to BS 2782, of 10 or less and a density in the range of 0.915 to 925g/ml. The sleeve shall
be free from pinholes, gels, undispresed raw materials and particles of foreign matter. The
film may not contain more than 5% by weight of material other than polyethylene.

Polyethylene sleeving shall be stored in cool dry store away from direct sunlight or
excessive heat, the length of the roll, the pipe size for which it is intended.
c) Repair of Coating and Lining
In case of repairs are needed the Contractor shall take immediate action to correct the
situation.
All the repairs to the coated or lined pipe and fitting shall be at the Contractor own
expense.
The Contractor shall submit the repair procedure to the Employer for approval.
The procedure shall comply with the manufacturer specification.
d) Anti Corrosion Pipe Wrapping Tape
The tape shall be supplied 150 mm or 225 mm wide in 15 m or 25 m rolls, or approved by
Engineer depending upon the requirements.
 Pipe diameters up to 200mm, 150mm width tape shall be used.
 Pipe diameters above 200mm, 225mm width tape shall be used.
The adhesive compound shall be of the pressure sensitive type (that is, not requiring a
primer in order to achieve bond to the substrata) and shall have thickness between 0.75 to
0.90 mm. Flow coefficient of bitumen viscosity at 200˚C and 175˚C shall be 5.5 poise and
7.5 poise respectively.
The tape shall be supplied with a wider high quality silicon release paper covering
complete tape. Both sides of the tape shall have a minimum of 5mm wider silicon release
paper to prevent edge contamination.
During storage at maximum storage temperature of 500 C for six months, the adhesive
material shall not flow out of the release paper and there shall not be any end blocking.
Wrapping tape shall be marked with the following information:
 Manufacturers name & logo
 Date of manufacture
 Width of the tape
 Batch number
e) Wrapping Procedure
To increase the wrapping protection efficiency, pipe diameters up to 300mm must be
wrapped using semi-automatic tape wrapping machine and for pipe diameters above
300mm, fully automatic wrapping machine should be used.
f) Storage
Wrapping tape should be stored in dry, cool, well ventilated condition, out of direct sunlight.
g) Packing
Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator
for safe storage shall separate each layer. The boxes shall be marked at two places given
name and logo of manufacturer, tender no., type, size and quantity of material in black/blue
color letters with a minimum height of 50mm.
The wrapping tape shall also conform to the following specifications given below;
Data Sheet
S. No. Property Test Method Unit Data
1 Color - - -
Blue RAL
1.1 Backing - -
5000/5001/

5005/5010/2017
1.2 Adhesive Compound - - Black
1.3 Release Paper - - White / Cream
3 Backing Thickness Min. - mm 0.75
4 Total Thickness Min. - mm 1.5
5 Elongation BS 2782 % 270
6 Tensile Strength Tape BS 2782 N/mm2 14.8
7 2
Modules BS2782 N/mm 50
8 Tear Strength ASTM D1004 N 50
9 Impact Resistance (Two Layers) DIN 30627 Nm 15
Viscosity at 200˚C Cone & Plate Poise 5.5
11 Adhesion to Steel ASTM D 1000 N/mm 2.75
12 Adhesion to Tape ASTM D 1000 N/mm 2.75
Electrical
13 Dielectric Strength BS 2782 kV 30
14 Insulation Resistance ASTM D 257 Ohm/cm2 1012
15 Cathodic Disbondment ASTM G 8 mm2 NIL
General
16 Water Vapor permeability BS 2782 g/m2/24h 0.4
17 Water Absorption ASTM D 570 % 0.1
18 Bacterial Growth Disbondment - - NIL
Temperature
19 For Wrapping - ˚C 0 to + 50
20 In Service - ˚C 0 to + 50
21 For Storage - ˚C Up to + 50
9. Factory protection for fittings:

Fittings shall be coated internally and externally as per EN 545 Clause 4-5 with minimum
epoxy content 70% and minimum thickness 10 mil. Fittings shall be internally coated with
fusion bonded epoxy.
10. Testing on Ductile Iron Pipes
The following tests shall be carried out on samples from every batch of DI pipes delivered
to site. A report of the third-party inspector shall cover at least these tests all as approved
by the Engineer. All tests shall be carried out according to BS/EN545 or ISO 2531
equivalent:
 Visual inspection
 Microscopic structure
 Tensile strength
 Elongation
 Brinell hardness
 Lining thickness

 Composition and thickness of external coating
 Ring bending and detachment of lining for pipes > 500 mm diameter
 Hydrostatic test
B Vitrified Clay Pipes
1. Use vitrified clay pipes for sewer networks with pipe diameters from 200 to 600 mm.
2. Vitrified clay pipes and fittings shall be to SASO 235/236-1995 or BS EN 295 [18]
and shall be marked accordingly.
3. Pipes and fittings shall be glazed and shall comply with BS 295-1 Clause 2 and in
particular sub-clause 2.2, 2.3, 2.5, 2.9, 2.10 & 2.14.
4. Pipes and fittings shall be Class 160 for pipes ≤ 500mm diameter and Class 120
for pipes ≥ 600mm diameter crusting strength per Class in KN/m2 as given in
Table 5 of BS 295 part 1. Pipe may also be classified as standard strength or extra
strength.
5. Jointing material: sealing elements shall be polyurethane to Clauses 3.12 & 3.13.
6. Joints shall be water tight to Clauses 3.2 & 3.3 of EN 295.
7. Pipes shall be supplied with approved flexible and telescopic rubber ring joints
which shall be capable of withstanding the specified tests pressures applied both
internally and externally
8. Junctions on clay pipe sewers shall be of similar material and suitable for use with
flexibly jointed pipes
9. Before any length of pipe is laid, it shall be inspected and stood or slung vertically
at the side of the trench and “rung” with a wooden mallet. Any damaged or cracked
pipe shall be rejected.
10. Tests on vitrified Clay Pipes
The following tests shall be carried out on vitrified clay pipes and products. The third party
inspection report shall cover the following quality control test all as per SASO 235-1995 or
DIN 1230 or the applicable standard specifications:
 Minimum bore
 Length
 Deviation from straightness
 Crushing strength
 Water tightness
 Polyurethane sealing elements
 Angular deflection
C GRP Pipe
1. Use GRP pipes for sewer networks with minimum stiffness 5000 N/m2 for diameters
700mm to 1000mm.
2. Pipes and fittings shall be to BS 5480, 1990 [11] or AWWA C950-01/ or equivalent.
3. Pipe and fittings shall include a corrosion resistant internal liner, a structural wall
and a resin rich exterior surface.
4. The liner consists of 90% resin and 10% glass reinforcement and shall have a
nominal thickness of 1.0 mm. The liner inner surface in contact with liquid shall be
0.2 mm thick and shall be reinforced with “C” glass. The remainder of the liner

thickness, shall consist of 60% resin and 40% glass reinforcement which shall be
acid resistant chopped “E” glass to BS 3496 or glass fiber rovings to BS 3691.
5. The pipe structural wall shall consist of glass reinforcement, and fine silica sand,
all impregnated with resin. The fine silica sand shall be added to the structural
layer to achieve the design thickness for the required stiffness specified such that
the overall hoop flexural modulus (E) for pipe is not less than 24 GN/m2. Silica
sand and filler content shall not exceed 50%. Continuous glass filament
reinforcement in the structure wall shall be 10% minimum by weight.
6. Pipes shall be provided with a resin rich outer layer reinforced with one layer of “C”
glass veil. The exterior layer shall have a minimum thickness of 0.2 mm. The layer
shall consist of resin rich 90% and reinforced with one layer of C glass 10%.
7. The resin used for the corrosion resistant internal liner of the pipe and fittings shall
be high grade polyester resin (vinyl ester) type. For the structural wall and exterior
layer of the pipe a high grade isophthalic polyester resin shall be used. No dark
pigments shall be used in the pipe or fittings. All resins shall be tested to ASTM C-
581.
8. All glass reinforcements except for the inner and outer surfaces of the pipe and
fittings shall be of the “E” type. Surface reinforcement shall be of the “C” glass
type.
9. Pipes shall be designed for a life of not less than 50 years. Contractor shall submit
calculations for initial and long term deflection with Truck loads, Buckling, Vacuum,
Pressure Class, and Strain corrosion in accordance with Appendix “A” of AWWA,
C-950-01 or equivalent. The maximum calculated long term deflection should not
exceed 3%. Copies of the design calculations shall be submitted to the Engineer
for approval.
 Stiffness: Minimum 5,000 N/m2. Suitability of stiffness shall be verified by
Contractor for the various trench and pipe laying conditions and as recommended
by the manufacturer. Pressure class 6 kg/cm2 minimum or as shown on Drawings.
 Longitudinal Strength: Conform to BS 5480 [11] table 2 or ASTM D3262 table 7.
 Hoop strength shall be according to ASTM D3517 Table 8.
 Strain corrosion resistance tests shall be carried out as per ASTM D 3681 or BS
5480 strain corrosion value at 50 years to equal or exceed 0.7%.
 Markings shall be to BS 5480 [11] clause 11.
 Joints shall be GRP double socket couplings with rubber rings to ISO 4633 or BS
EN 681-2 [10]. The allowable angular deflection shall conform to the requirements
of BS 5480 [11] Table 3.
10. Testing on GRP Pipes: The following tests shall be carried out on manufactured
pipes. Details of testing program shall be submitted to the Engineer for review and
approval prior to commencement of pipe manufacture. The manufacturer quality
control scheme shall be to BS 5750-8 [12] or ISO 9004. Guidance on quality
control and sampling shall be BS 5480 Appendix Q [11]. At least the following tests
shall be carried out and reported for approval.
 Longitudinal Strength: to ASTM D3262
 Hydraulic Test: to ASTM 3517 on every pipe.
 Stiffness: to ASTM D 2412 or BS 5480 [11]
 Wall Thickness: to BS 5480 [11]
 Diameter: to BS 5480 [11]
 Hardness: to ASTM 2583

 Loss of Ignition to ASTM D 2584
 Hoop Tensile: to ASTM 3517
D Concrete pipes for Gravity Networks
1. Use Concrete pipes lined with HDPE for main sewer lines with diameters greater than or
equal 1000 mm.
2. Concrete pipe shall be to BS 5911 or ASTM C14M-99 or DIN 4032 Class KW.
Cement used in manufacture shall be ordinary Portland cement to BS EN 197-1 [3]
3. Joints shall be gasket type with flexible spigots and sockets. The shape of the joint
must be designed to prevent any movement of the gasket during assembly and as
such produce full water-tightness. Rubber gasket shall be to ISO 4633 or BS EN
681-2 [10].
4. Factory Protection for Pipes:
 Internally, pipes smaller than 900 mm diameter shall be coated with coal tar epoxy
with 70% minimum epoxy content. Coat minimum thickness shall be 1000 micron.
Concrete pipes larger than 900 mm diameter shall be internally lined with suitable
HDPE sheeting. The thickness of the lining shall not be less than 3 mm. Pipes
shall be PE lined in the factory, and lining of the joints shall be made on site and
then the spark test and other relevant field tests shall be made. All defective and
damaged surfaces shall be repaired in conformance with the recommendations of
the manufacturer. The lining shall be capable to withstand safely the wastewater
temperatures which could reach 45˚ C and shall form a watertight surface.
 Externally two layers of bitumen to BS 3416 [4] or hot applied coal tar based
material to BS 4164 [5] with 300 micron minimum dry film thickness.
5. Testing for Concrete Pipes
The following tests shall be carried out on samples of concrete pipes delivered to site. The
test report of the third party inspector shall cover at least the following tests all as specified
by adopted international standards.
 Water absorption test
 Hydrostatic
 Crushing test, works proof test load and maximum test load
 Tests for flexible joints
 Deflection, straight draw, shear
E HDPE Pipe
1. Part 1 General
a) Scope
 This specification sets out the general standards and information
requirements for HDPE pipe materials
 All component parts of the Works, including procedures, practices and
services, shall unless otherwise stated in the contract, comply with the
provisions of this section. All work undertaken and equipment supplied
shall comply with all codes, regulations, and specifications referred to
throughout the contract documents.
 Only new materials and equipment shall be used, unless otherwise specified.
 Unless otherwise stated, all minor civil engineering and building works
associated with the installation of pipe and equipment into existing Works shall
be undertaken by the Contractor.

b) Related Documents
The following sections of the specification shall be read in conjunction with this
section.
c) Standards
PE100 pipes and fittings shall comply with the latest revision of the following
standards and other relevant standards noted elsewhere in this specification.
EN 12201-1 Plastics piping systems for water supply, and for drainage and sewerage
under pressure — Polyethylene (PE)-General
under pressure — Polyethylene (PE)-Pipe
under pressure — Polyethylene (PE)-fittings
EN 476 General requirements for components used in drains and sewers
ISO 527 Plastics – Determination of tensile properties
ISO 1083 Spheroidal graphite cast irons - Classification
ISO 1133 Plastic – Determination of melt mass flow rate (MFR) and melt
vacuum flow rate (MVR) of thermoplastics
ISO 1167 Thermoplastic pipes, fittings and assemblies for the conveyance of
fluids – Determination of the resistance to internal pressure
ISO 1183-2 Plastics – Methods for determining the density of non-cellular plastics
– Part 2: Density gradient column method
ISO 2505 Thermoplastics pipes – Longitudinal reversion – Test method and
parameters
ISO 3126 Plastics piping systems – Plastic components – Determination of
dimensions
ISO 4065 Thermoplastic pipes – Universal wall thickness table
ISO 4427 Plastics piping systems - Polyethylene (PE) pipes and fittings for
water supply
ISO 6259 Thermoplastic pipes - Determination of tensile properties
ISO 6964 Polyolefin pipes and fittings – Determination of carbon black content
by calcinations and paralysis – Test method and basic specification
ISO 7005-1 Pipe flanges -- Part 1: Steel flanges for industrial and general service
piping systems
ISO 7005-3 Metallic flanges – Part 3, copper alloy and composite flanges
ISO 9080 Plastic piping and ducting systems – determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
ISO 9624 Thermoplastic pipes for fluids under pressure – mating dimensions of
flange adaptors and loose backing flanges
ISO 11357-6 Plastics – Differential scanning calorimetry (DSC) – Part 6:
Determination of oxidation induction time (OIT)
ISO 11420 Method for the assessment of the degree of carbon black dispersion in
polyolefin pipes, fittings and compounds
ISO 11922-1 Thermoplastic pipes for the conveyance of fluids – Dimensions and
tolerances - Part: 1: Metric series
ISO 12162 Thermoplastic materials for pipes and fittings for pressure

applications - Classification and designation – Overall service
(design) coefficient
ISO 12176 Plastic pipes and fittings –Equipment for fusion jointing polyethylene
systems
ISO 13761 Plastics pipes and fittings – Pressure reduction factors for
polyethylene pipeline systems for use at temperatures above 20ºC
ISO 13479 Polyolefin pipes for conveyance of fluids – Determination
of resistance to crack propagation– Test method for slow crack growth
on notched pipes
ISO 13593 PE pipes and fittings – Determination of tensile strength and failure
mode of test pieces from a butt-fused joint
ISO 14236 Plastics pipes and fittings – Mechanical-joint compression fittings for use
with polyethylene pressure pipes in water supply systems
ISO 14276 Plastics pipes and fittings – Mechanical joint compression fittings for use
with polyethylene pressure pipes in water supply systems
ISO 15512 Plastics – Determination of water content
ISO 16871 Plastics piping and ducting systems – Plastics pipes and fittings –
Method for exposure to direct (natural) weathering
ISO 18553 Method for the assessment of the degree of pigment or carbon black
dispersion in ploy fin pipes, fittings and compounds
ISO 161-1 Thermoplastic pipes for conveyance of fluids – nominal outside diameter
and nominal pressure- part 1: Metric series
ISO 974 Determination of the brittleness temperature by impact
ISO 877 Methods of exposure to direct weathering
BS EN 12099 Plastics piping systems – Polyethylene piping materials and
components – Determination of volatile content
BS 5400-2 Steel, concrete and composite bridges- Specification for loads
ASTM D3550 Standard Practice for Thick Wall, Ring-Lined, Split Barrel, Drive
Sampling of Soils
ASTM F1055 Standard Specification for Electro fusion Type Polyethylene Fittings
for Outside Diameter Controlled Polyethylene and Cross linked
Polyethylene (PEX) Pipe and Tubing
ASTM D638-10 Standard test method for tensile properties of plastics
DIN DVS 2207 EN-Welding of thermoplastics - Heated tool welding of pipes pipeline
components and sheets made of PE-HD
SFS 3115 E- Water tightness test for pressure pipelines
WIS 4-24-01 Specification for mechanical fittings and joints for polyethylene pipes
for nominal sizes 90 to 1000 mm OD
WIS 4-52-01 Specification for polymeric anti-corrosion (barrier) coatings
WIS 4-52-03 Specification for anti-corrosion coatings on threaded fasteners
Guidelines for drinking water quality, Volume 1:
Recommendations, WHO, Geneva
d) Submittals
Products and Materials Approval

 In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the
Contract program allowing for ordering and approval times. Products and
materials approval. Information to be submitted shall comprise but not
necessarily be limited to:
 The Manufacturers design calculations, complete and detailed
specification and test results of the proposed HDPE pipes
and fittings required for the Works including Manufacturer’s
certificates of compliance with this section of the standard
specification. Information on all items listed in Table 25-1
below shall be given for every diameter in each class of pipe.
 Should any details of the pipes and fittings be altered in any way
during manufacture from those proposed and approved by the
Engineer, submit to Engineer for approval the revised details and
test results.
 Submit to the Engineer the results of all quality control tests
carried out on the manufactured pipes and fittings as soon as
practicable after testing as and in any case not later than the time
of delivery of the relevant pipes and fittings to the site.
Product Information for HDPE Pipe and Fittings
Product Information Units
Manufacturing Details
Name of MANUFACTURER -
Manufacturing process for pipes -
Manufacturing process for bends and fittings -
Joint type -
Details of all additives used in the manufacture -
Polymer classification and certificate of origin -
Summary of Design Criteria
Rated working pressure MPa
Design test pressure (165hrs or 100 hrs) MPa
Internal vacuum pressure MPa
Minimum required strength (MRS) MPa
Pipe Details
Nominal external diameter mm
Wall thickness mm
Standard dimension ratio (SDR) -
Standard pipe length m
Method Statements
 The Contractor shall submit method statements (MS) to the Engineer

for approval 4 weeks in advance of commencing the site activity in
accordance to specification. These shall comprise but not necessarily be
limited to:
 Procedures for handling, storage and installation of pipes.

 Procedures for pipes installation into concrete structures.
 Hydrostatic testing procedures for HDPE pressure pipelines.
Drawings
 The Contractor shall submit drawings to the Engineer for approval in advance
of commencing the site activity in accordance with the specification. These
shall comprise but not necessarily be limited to:
 Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.
 Pipe laying diagram and schedule showing location, length, design
designation and designation by number of each pipe section and pipe
special to be furnished and installed.
 All data on curve and bends for both horizontal and vertical alignment.
e) Quality Control
Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery in
accordance with the specification. Manufacturer shall be approved to:
ISO 9001
ISO 14001
OHSAS 18001
To allow the Engineer to inspect the Works the Contractor shall give the
Engineer a minimum of 24 hours notice of carrying out the following activities on
site:
 Installation of pipeline.
 Hydrostatic testing of pipeline.
f) Delivery, Storage, and Handling
 The pipe Manufacturer shall provide packing and shipping procedures to
the Engineer for approval. These shall comply with the following
requirements.
 If used, pallets shall be suitable for transporting the pipes and
fittings from the plant to the designated location without causing
any damage. The pallets shall not contain any broken planks or
extremities that may damage the pipes and fittings.
 Where pipes are transported by vehicles, the vehicle bed shall be
free from sharp edges or projections and the pipes hall be
supported at adequate intervals to prevent movement
between the material and its support. Pipes shall not over-
hang at either end of the trailer.
 Materials shall be stored in accordance with the pipe
Manufacturer’s recommendations and this specification.
 The storage area should have a relatively smooth, level surface
free of sharp stones, debris or other materials that could damage
the pipe or fittings. Where adequate ground conditions do not
exist or when a level gravel bed cannot be prepared, the pipe
shall be placed on timber supports evenly spaced along the pipe
length. The support size and spacing shall be as advised by
the pipe Manufacturer.
 Stacks shall only contain pipes of one size and wall thickness and
shall be constructed in a pyramid, with each successive layer

having one less pipe than the layer below. The bottom layer
should be braced to prevent movement and the stack shall not
exceed a height of 2.0 m.
 Coils should be stored horizontally on pallets. Coils may be
stacked as ‘silos’ but the height of any silo shall not be higher than
2.0 m.
 All coils shall be banded at intermediate stages of coiling and
upon completion of the specified length in order to prevent long
lengths of pipe coming loose during installation. At least 4
intermediate bands shall be provided for each 50 m of the coil
length.
 When pipe material is boxed, the pipe or coil number shall be
clearly marked on the outside edge of the box or silo. Invoices and
packing lists shall include the date of manufacture and
coil/length numbers for all material in the shipment.
 Fittings shall be packaged in bulk or individually protected were
necessary in order to prevent deterioration and contamination.
The package shall have at least one label with
MANUFACTURER name, type and dimension of the fittings
and number of units.
 Tie-downs shall be at least 100 mm wide and be clean and free
from sand, gravel and other such materials. For straight
length pipe (up to 12 m), a minimum of 6 tie-downs are
required.
2. Part 2 Products
a) Materials
 Raw material shall be manufacturer member of the PE100+ Association
and shall comply with applicable part of EN 12201latest revision.
 For design calculation, pressure, reducing coefficients EN 12201, The
thermal stability of polyethylene material shall meet the requirements of
EN 12201.
General Requirements
 Pipes and fittings shall comply with the requirements of EN 12201and

only PE100 pipes shall be used. The pressure rating of the fittings shall be the
same as, or higher than, that of the pipes. The SDR and pressure rating of
the pipes and fittings shall be determined by the designer, based on
the operating conditions.
 Service life of the pipe and fittings shall be minimum 50 years under
normal operating conditions.
 When the annual average operational temperature exceeds 20°C, which
may occur in hot climates, the designer shall apply a pressure reduction
factor to determine the allowable long term operating pressure of the PE100
pipes and fittings. Please note that this will be the steady state
operating pressure i.e. excluding any transient or surge pressures.
 The pipe Manufacturer shall identify the Manufacturer of the resin, the
resin type and classification. In addition, the Manufacturer shall provide
evidence that the resin proposed is suitable for use at the design
temperature and under the design pressures indicated.
 Pipes and fittings shall be homogenous throughout and free from visible
cracks, holes, foreign inclusions, blisters, dents, scoring, cavities and other
efects.

 Material shall be uniform in opacity, density, interior smoothness and
other physical properties. It shall have adequate resistance to weathering and
other ageing from storage for a minimum of two years after manufacture.
 All pipes shall be black in accordance to relevant sections of EN 12201
standard.
 The pipes shall be manufactured from polyethylene containing only those
antioxidants, UV stabilizers and pigments necessary for the manufacture of
pipes conforming to this specification. All material used in the
manufacture of the pipes shall be pre-compounded at the resin
Manufacturer’s facility.
 The carbon black content in the compound shall be 2.25 + 0.25 %
by mass when measured in accordance with ISO 6964. The dispersion of
carbon black when determined in accordance with ISO 11420 shall be equal
to or less than grade 3.
 The pipe Manufacturer shall confirm that all fittings to be provided for the
pipe system meet the same quality requirements as for the pipes to ensure
the same performance over the design life cycle. Fittings shall be
manufactured in accordance with the requirements of EN 12201-3.
 PE100 pipes to be installed in areas having rocky ground conditions and
those to be installed using trenchless technology applications shall be
manufactured from a high stress crack resistant (HSCR) PE100, also referred
to as PE100-RC material. Pipes manufactured from such material shall
have undergone the Notched Pipe Test at an independent 3rd party
laboratory in accordance with ISO 13479 and the time to failure shall have
been a minimum of 8,760 hours (1 year). All other characteristics shall
comply with the requirements of EN 12201 and this specification.
Effects on Water Quality
 The material of the polyethylene pipes and fittings which is in contact with or
likely to come in contact with water shall not constitute a toxic hazard, support
microbial growth or give rise to unpleasant taste or odour, cloudiness
or discoloration of the water.
Materials in contact with water shall be certified by an internationally
recognized authority, such as the WRAS Certification Scheme, as being non-
tainting and suitable for being in permanent contact with potable water in
accordance with BS EN 6920 last revision.
Pipe Dimensions
 Pipe nominal size, ovality, outside diameter and wall thickness shall all
comply with the requirements of the tables given in EN 12201-2 and
measured in accordance with ISO 11922 and ISO 3126.
 All pipes shall comply with the requirements given in Tables 1 and 2
of EN 12201 Part 2. The maximum degree of ovality, where not given in EN
12201, shall be proposed by the pipe Manufacturer and approved by the
Engineer.
 Straight pipes shall be supplied in standard lengths of 12, 18 m or 24 m (-
0 / + 50 mm) as detailed in the specification. In special cases, the
length will be specified by the Engineer.
 Where pipes are to be supplied in coils, the coil lengths shall not exceed
200 m for pipes of up to 50 mm OD, 100 m for pipes of between 63 and 110
mm OD and 50 m for pipes of between 160 and 225 mm OD. Tolerances with
regard to the coil length shall be - 0 / + 50 mm. The internal diameter of pipe
coils shall not be less than 20 x pipe outside diameter and the pipes shall be

coiled so as to prevent any local deformation, buckling or kinking. Other coil
sizes may be used with the Engineer’s approval.
 The Contractor’s method of work shall, where necessary, include for
the uncoiling of the coiled pipes in a controlled manner and the use of re-
rounding equipment to remove ovality in the pipe cross section. .
Polyethylene Fittings
General
 Fittings shall be made of high density polyethylene (HDPE) and shall comply
with the requirements of EN 12201 PE 100. The material shall be produced by
a member of the PE100 + Association.
 Manufacturer shall also supply the gaskets for use in PE100 flange
connections, and provide general recommendations on associated equipment
such as valves, fittings, nuts; bolts and other accessories, .
 PE100 fittings shall comply with the requirements of EN 12201-3 and shall be
injection molded from PE100 material compatible to that of the pipe or
else fabricated from PE100 pipes. The wall thickness of the body of the fitting
at any point shall be equal to or greater than the minimum wall
thickness of the corresponding pipe.
 Only injection molded fittings shall be used for pipe sizes of up to 160 mm
OD.
 Pipes and Fittings shall be from same MANUFACTURER (except echanical
Fittings).
 A protection measures between dissimilar metals like between flanges
and fittings etc. shall be added.
 The straight length of fittings to be butt fusion welded together shall long
enough that the fittings can be held firmly by two clamps on the butt
fusion welding machine.
 The Fittings that made of Ductile Iron (D.I.) shall be fusion bounded
epoxy coating in accordance to Section 02640 DI Pipe and Fitting
Specification.
Butt Fusion Fittings
 Butt fusion fittings shall be in accordance with DVS 2207-1 and shall be
manufactured by injection molding, a combination of extrusion and machining,
or fabricated from PE pipe conforming to this specification.
 Fabricated fittings shall be manufactured using a Data logger to record fusion
pressure and temperature. Butt fusion fittings shall have a pressure rating no
less than that of the pipe. The fittings shall be homogeneous throughout and
free of visible cracks, holes, foreign inclusions, voids and other injurious
defects.
 Fabricated fittings are subject to pressure de-rating factor as in EN12201-3.
 Where PE100 pipes connect to other materials or flanged fittings either
stub flanges with encapsulated backing rings or restrained transition fittings
shall be used. Stub flange backing rings shall be stainless steel 316. Stub
flanges that will be buried shall be encapsulated with fusion bonded epoxy.
They shall be drilled in accordance with ISO 7005-2, PN 16 and have
dimensions in accordance with ISO 9624, PN16 unless otherwise specified.
 Fabricated fittings shall be designed and manufactured in accordance with the

requirements of EN12201, Part 3. The pressure derating factors to be
employed by the fittings fabricator shall be in accordance with annex
sections B3 and B5 unless they can demonstrate that higher factors can be
applied. The use of any higher factors shall be approved by the Engineer prior
to commencement of fitting fabrication considering agreed design
temperature of and selected reduction factor.
 All compression fittings shall be certified by an independent third party as being
fully compliant with the requirements of ISO 14236. They shall be tested and
certified as being class 1 end load bearing fittings i.e. they shall prevent the pull
out of the pipe at their rated operational pressure. Only materials listed in
Tables 1 and 2 of ISO 14236 shall be used in the manufacture of the fitting
body.
 Any bolts, studs, nuts or washers shall be of stainless steel (grade 316).
 Backing rings shall be in accordance with BS EN 1092-1 standards.
 Electro-fusion fittings shall be injection molded fittings made of PE100 but
incorporating integral heating element(s) to enable fusion jointing with PE100
pipes and shall be in accordance with ASTM F1055 and ASTM D3550
standards.
 Materials and constituent elements used in making the fitting (including
elastomers, greases and any metal part) shall be resistant to the internal and
external environment same as the piping system and shall have life expectancy
(during storage, operating conditions, environment etc.) at least equal to pipe
system (i.e. 50 years). The requirements for the level of material performance
for non-polyethylene parts shall be at least as stringent as that of the PE pipe
systems.
 Transition fittings used to join the pipe to flanged fittings and pipes
made of other materials. All fittings shall be certified by an independent third
party as being fully compliant with the class 1 requirement of ISO 14236 or the
Type 2 requirement of WIS 4-24-01 i.e. they shall prevent the pull out of the
pipe at their rated operational pressure.
b) Inspection and Testing
Certification and Documentation
 The raw material and pipe Manufacturer’s shall document and certify all
products and shall undertake all testing required by EN 12201 and this
specification. Prior to delivery of any pipes or fittings the pipe Manufacturer
shall provide the Engineer with a comprehensive Inspection and Testing Plan
(ITP) for their approval. The ITP shall detail all the certificates and documents
that shall be provided by the pipe Manufacturer, together with details of the
testing that they shall undertake, its frequency and associated test reports.
Where the pipe Manufacturer cannot themselves undertake the required
testing they shall employ an independent third party laboratory to undertake
the testing on their behalf.
Testing of Pipes and Fittings and Its Frequency
 The Manufacturer shall establish and maintain a complete record of test results
according to the requirements of the applicable standards, this
specification and the approved ITP.
 Pipe wall thickness shall be measured and controlled on a continuous
basis using and ultrasonic thickness gauge or similar device that shall be
regularly calibrated in accordance with the gauge Manufacturer’s
recommendations.
 The fabricated fitting to be hydrostatically tested shall be a tee or branch
provided the batch in question contains this type of fitting, otherwise a

bend shall be tested.
 In the case of injection molded fittings the Manufacturer shall issue a certificate
confirming compliance with ISO 12201 and providing details of the type testing
they have undertaken.
 In accordance with the recommendations of ASTM D 638, the maximum
thickness of the tensile strength test samples cut from the pipe wall shall be 14
mm. In the event of the pipe wall being thicker than 14 mm the pipe
Manufacturer shall machine the test samples in accordance with the Table 25-
2.
Table 25-2: Preparation of Samples for Tensile Testing
Pipe Wall Thickness Test Sample No of sample to be taken

(WT) Thickness from the pipe wall
(mm) (mm)
≤ 14 WT 1
14 < WT ≤ 28 WT/2 2
28 < WT ≤ 42 WT/3 3
42 < WT ≤ 56 WT/4 4
56 < WT ≤ 72 WT/5 5
 All testing shall be undertaken in accordance with ISO 6259 and all samples
shall achieve a minimum tensile strength at yield of 19MPa in order for the pipe
to successfully pass the test.
Hydrostatic Testing of Pipes
 The Inspecting & Testing Plan (ITP) shall detail the pipe Manufacturer’s
hydrostatic testing regime. As a minimum, the pipe Manufacturer shall have, at
12 monthly intervals, produced and hydrostatically tested pipes manufactured
using the same grade of resin or resins that are to be used to produce the pipes
and fabricated fittings covered by this specification.
Appointment of an Independent Third Party Inspector
 To verify compliance with this specification, the Engineer reserves the right to
appoint an independent Third Party Inspector, at the Client’s cost, to witness
the applicable qualification tests, review production records, and inspect
general handling and shipping procedures.
 The pipe Manufacturer shall ensure that all the applicable codes and standards
are available at their facility for the TPI reference during any visit or inspection.
 The pipe Manufacturer shall provide full assistance and co-operation for
any inspection, when required by the Independent Third Party Inspector.
 When requested, the pipe manufacturer shall provide access to and copies of
all material certificates and inspection and test results obtained in the
course of quality verification.
Acceptance Criteria
 The following criteria requirements shall be fulfilled by the pipe Manufacturer in

order for the pipes and fittings to be approved and accepted by the Engineer.

 Prior to delivery of pipes the pipe Manufacturer shall provide copies of all the
test results and certification required by EN 12201, this specification and the
ITP, but which are not covered by this specification. These documents shall
comprise the Type Test Report.
 The Type Test Report shall include a copy of the raw material Manufacturer's
"Certificate of Quality Control Testing" covering each batch of raw material used
for manufacturing pipes produced under this specification.
 The pipe manufacturer shall provide a copy of the Pipe Run Release Tests i.e.
all those tests listed in this specification, with each pipe run that is delivered to
Site.
 If the Client has appointed an independent third party inspection then
their report shall be submitted to and approved by the Engineer, with a copy to
the pipe Manufacturer, prior to any inspected materials being installed on site.
 The Engineer may reject any item that does not successfully pass the required
tests or fully comply with the requirements of this specification.
 When a pipe or fitting is rejected, the items manufactured immediately before or
after shall be carefully examined. If further defects are found, the entire pipe
batch will be rejected.
4.3.2 Marking
General
 The marking information and sequence shall comply with EN 12201 and
this specification. All pipes and fittings, including test samples shall be clearly
and permanently marked using indent printing in a colour that contrasts
with the pipe.
Marking of Pipes
 All the marking shall be repeated at least every 1.0 m and shall be displayed on
the outside of the pipe length. It shall include the following information.
 International Standard i.e. ISO 12201
 MANUFACTURER /Trademark
 The pipe dimensions (nominal outside diameter x nominal wall
thickness in mm)
 Standard Dimensional Ratio (SDR) value i.e. SDR11 or SDR17
 Material Designation i.e. PE 100- HE3490-LS-H
 Pressure rating in bar i.e PN16
 The raw material MANUFACTURER’s identification
 A Traceability code and date of manufacture e.g. X 29 08 11
where x is the plant
Marking of Fittings
 All injection molded fittings shall be indelibly marked with the following
information:
 International Standard i.e. EN 12201
 MANUFACTURER’s name or trade mark
 Nominal outside diameter and SDR series e.g. 110 / SDR11

 Material designation i.e. the letters "PE" followed by the PE grade
(e.g. PE100)
 Nominal pressure rating in bar e.g. PN16
 Traceability code and date of manufacture, e.g. X 29 08 00, where
X is the plant code
 The marking of fabricated fittings shall be proposed by the pipe Manufacturer
and approved by the Engineer.
Documentation
 The pipe MANUFACTURER shall furnish the following vendor data as a

minimum:
 Catalogues / brochures of the proposed product
 Dimensional details of pipes and fittings
 Detailed material specification
 Complete details of testing facilities at the MANUFACTURER’s
plant
 MANUFACTURER`s drawings showing dimensions
 Quality assurance procedures in use
 Certificate from PE 100 + Association
 Local (UAE) agent name and address
3. Part 3 Execution
a) General
 Trench excavation shall be carried out in accordance with specification and in
accordance to Manufacturer recommendation.
 Install pipe, fittings, and accessories in accordance with Manufacturer's
instructions.
 Provide qualification details of the manufacturer's technical expert to be
assigned to the Contract. The technical expert shall have expertise, experience
and skills necessary for advising and monitoring all aspects of transport,
storage, handling and installation of pipes as appropriate.
 The technical expert shall provide comprehensive technical assistance to
the Contractor throughout the Contract and regularly monitor the
Contractor's activities and report on shortcomings.
 The Contractor shall provide the Engineer copies of all instructions advice or
reports given by the manufacturer's technical expert to him. The technical
expert shall immediately inform the Engineer of any omission, variations
and detractions from the approved handling and installation specification.
 Install bedding, surround and backfill as per specification and as per
Manufacturer’s recommendation.
 Obtain satisfactory initial deflection test results for sections of pipeline
laid between chambers prior to commencement of pipe laying in further
sections.
 When cut pipe is required, ensure that the cutting is done by a machine, leaving
a smooth cut at right angles to the axis of the pipe.
 Ensure that all pipes and fittings are sound and clean before laying. When pipe

laying is not in progress, ensure that the pipe ends are at all times fitted with
watertight plugs or caps. The plugs or caps shall only be removed for
the purposes of making a connection of the pipe end or testing the pipeline.
The plugs or cap shall be replaced immediately on completion of the test.
 Protect bolted connections by an approved heat shrunk PVC sheath.
Wrap the PVC sheath with a protective wrapping tape prior to
backfilling in accordance with the specification.
b) Electro-Fusion Jointing
 Manufacturer recommendations shall be taken in to consideration.
 Only barcode labeled electro-fusion fittings incorporating fusion indicators and
complying with the requirements of EN 12201, Part 3 shall be used.
 The equipment used for electro-fusion jointing of pipes and fittings shall comply
with the requirements of ISO 12176 Part 2. Calibration certificate of the
equipment shall be submitted to Engineer. It shall incorporate an
automatic control unit with data input through the use of a bar code reader pen
and a data retrieval facility to allow historical fusion data to be read on the
unit’s screen and to be exported to an external computer or memory stick.
 The electro-fusion control box shall deliver the correct fusion parameters to the
electro-fusion fitting. The power generator shall provide the power requirements
of the control box, taking into account the electrical characteristics of the control
box.
 Positioning tools including suitable alignment clamps shall at all times be used
to minimize misalignment and prevent movement during the fusion and cooling
cycle of the joint. A suitable shelter shall be used in cold, windy, dusty or wet
weather conditions.
 Prior to commencing the welding process the Contractor shall measure
and ensure that the ovality of the pipe or spigot end is within the limits as per
EN 12201.
 All pipe work shall be cleaned with disposable alcohol impregnated wipes prior
to undertaking the pipe scraping, in order to remove any contamination. Prior to
scraping the Contractor shall measure and mark the area of the pipe or spigot
end to be scraped in order to remove the oxidized surface to a depth between
0.2 and 0.4 mm. The length of the pipe or spigot end to be scraped shall be
equivalent to the insertion depth of the electro-fusion joint plus a
distance of between 10 and 20 mm.
 Only rotating mechanical scrapers or peelers, which are capable of cutting
a continuous strip or ribbon over the insertion length of the coupler or fitting,
shall be used.
 The fitting shall be removed from its packaging and immediately inserted over
the pipe end only after preparation and scraping of the pipe.
 Each pipe or spigot end shall penetrate completely its relevant part of
the electro-fusion socket.
 Alignment clamps shall not be removed before the appropriate cooling time has
elapsed. Abnormal displacement of the electric wire coils shall not occur. This
shall be checked prior to commencement of the fusion process.
 All completed electro-fusion joints shall be inspected in accordance with
the requirements of EN 12007 Part 2. Should the joint contain any of the
faults described in the standard then the electro-fusion fitting shall be cut
out and replaced.
 After completion of the fusion process, all fusion indicators shall be checked to
ensure that they are in the position indicated in the Manufacturer's instructions.
If any fusion indicators are not in the required position the electro-fusion fitting

shall be cut out and replaced.
 The Contractor shall, on a regular basis allow the Engineer to download
the historical data relating to the welds made by the unit through the data
retrieval facility.
c) Butt Fusion Jointing
 The equipment used for butt fusion jointing of pipes and fittings shall comply
with the requirements of ISO 12176 Part 1. It shall incorporate a control unit
that shall comply with the type A requirements of table B.2 of ISO 12176, Part
1 and the following points.
 Automatically preset the fusion jointing parameters based on
the pipe dimensions, material type and fusion jointing procedure
 Automatically control and monitor the fusion jointing process
 Comply with the requirements of Annex A of ISO 12176, Part 1
 Assign a unique joint number to each joint and have a data
retrieval facility to allow historical fusion parameters to be read on
the unit’s screen and to be exported to an external computer or
memory stick
 Calibration certificate of the equipment shall be submitted to Engineer prior to
installation.
 The butt fusion jointing procedures shall comply with the requirements of ISO
21307. The Contractor shall generally follow the single low pressure
fusion jointing procedure described in section 5.1 of ISO 21307.
 Only pipes and fittings of the same size, SDR and material are to be butt fusion
jointed.
 A dummy joint shall be made at the start of each welding session using pipe off
cuts of the same size, material and SDR as the pipe being installed. The normal
trimming, bead up and full heat soak cycles will be adhered to.
 If the pipe size is changed during the day, if the heater plate is allowed to cool
below 180°C or if maintenance of the butt fusion equipment is carried out then a
new dummy weld shall be performed.
 All butt fusion joints shall be inspected in accordance with the requirements of
Appendix B of EN 12007 Part 2. Should the joint contain any of the
faults described in the standard then the joint shall be cut out and
replaced. The inspection shall include the following points:
 The gap between the two single beads shall not be below
the fusion surface.
 The displacement between the fused pipes must not exceed 10%
of the pipe wall thickness.
 The difference between two single bead widths shall not exceed
10% of the double bead width.
 The weld beads shall be free from all contamination and have a
smooth even surface with no evidence of distortion, holes or
bubbles.
 At the direction of the Engineer external beads shall be removed
with an approved tool and inspected for contamination and
defects. They shall also undergo bend back testing. Beads
should be solid and rounded with a broad root as hollow
beads with thin root and curled appearance can be indicative of
excessive pressure or no heat soak.

 Each removed bead shall be numbered with its corresponding
joint number clearly displayed and removed beads shall be
retained for inspection by the Engineer.
 The width of each external bead width shall be measured
using bead gauges and the width of the bead shall be within the
range given by the pipe and / or welding equipment
MANUFACTURER.
 No signs of damage (such as scratches or deep impressions
caused by clamps) shall be visible on either side of the joint.
 Any joints the do not comply with the above requirements shall be
cut out and a new joint made; the failed joint shall be handed over
to the Engineer.
 Records of all tests and inspections shall be maintained by the
Contractor and made available for review and approval by the
Engineer.
d) Testing of Joints
 A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested
under laboratory conditions in accordance with ISO 13953 by an
approved testing organization. The joints to be tested shall be selected by the
Engineer immediately upon completion of the welding process, whereupon
they shall be cut out and delivered for testing.
 A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively
tested under laboratory conditions in accordance with ISO 13954 by an
approved testing organisation. The fittings to be tested shall be selected by the
Engineer immediately upon completion of the welding process, whereupon they
shall be cut out and delivered for testing. They shall comprise at least 1 of each
type of electro-fusion fitting even if this requires more than 1 % of all electro-
fusion fittings to be tested. Please note that the test requirement is for one
fitting of each type i.e. bend, coupling, tapping saddle, tee etc. not one of each
size and type.
 All costs associated with the testing, together with any consequent rectification
of faults and retesting shall be borne by the Contractor.
e) Tying-In
 Where sections of the line are to be tied-in after being laid and filled in
the trench the length of pipeline left un-backfilled shall be kept to a minimum,
but shall be sufficient to allow some flexibility in the uncovered pipe and to
facilitate the tying-in process.
 Tie-in joints in restrained sections of the line shall be made when the ambient
temperature is at the daytime minimum, as far as is practical, to avoid strain in
the pipe. Under no circumstances shall the line be left in tension after
the completion of a tie-in connection.
 Bell holes made in the trench bottom to facilitate electro-fusion or mechanical
jointing shall provide adequate clearance to enable the jointer to undertake their
work without any restrictions.
 Tie-ins after hydro-testing shall be kept to a minimum and will be permitted only
where approved by the Engineer.
 The Contractor shall ensure prior to hydrostatic testing that sufficient length of
pipe (overlap) is available to facilitate tying-in.
f) Hydrostatic Testing
General

 Upon substantial completion of the pipeline or major sections, the line shall be
cleaned and hydrostatically tested to prove integrity of the pipeline section and
to detect any leakage prior to commissioning. Testing shall be performed
in accordance with the Finnish Standard SFS 3115:E and the procedure
described below. The Contractor shall supply all necessary fittings,
equipment and facilities required to undertake the testing.
 The Contractor shall prepare a detailed Method Statement for the pressure test
that shall follow the procedure described below and be subject to the approval
of the Engineer.
Test Procedure
 Seal the pipeline. Fix all blank flanges. Remove all on line equipment that
may be damaged by high pressure.
 Only test against blank flanges, do not attempt to test against closed
valves.
 Cover the pipe with sufficient backfill to protect it from direct sunlight,
leaving joints exposed where practical.
 If backfilling is not practicable schedule the tests for early morning or
evening.
 Fill the pipeline from the lowest point. Bleed the air from all high points
and flange points where it is possible and tighten once water begins to spill.
 When the line is full, close off the filling valve and check all flanges and the
small diameter test pipework for leaks.
Phase 1
Commence raising the pressure at the filling point to the operating pressure or a
pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and add
water whenever the pressure drops by 0.2 bar in order to maintain a steady pressure.
Visually inspect the pipe length for leakage.
Phase 2
After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar,
whichever is higher, as quickly as practical. Again maintain this pressure for two hours by
adding water whenever the pressure drops by 0.2 bar.
Phase 3
At the end of the second two hours release the pressure back down to the phase
I level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes and
as quickly as is practical, in a controlled manner.
Phase 3 – Case 1
If after one hour the pressure in the pipelines remains at or above the operational
pressure, the test is considered to be completed with the pipeline passing the hydrostatic
test.

Graphical Representation of the Hydrostatic Test Process Case 1
Above Figure shows Graphical Representation of the Hydrostatic Test Process Case 1 –
Pipeline passes test without adding any make up water
Phase 3 – Case 2
If after one hour the pressure in the pipeline has fallen below the operational pressure,
water shall be added to raise the pressure back to the operating pressure level,
having first noted the low pressure before adding any water.
Phase 3 – Case 3
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce
pressure to the previously recorded low value and save the water bled off). The measured
quantity is then compared against the allowable quantity to determine if the pipeline
passes the hydrostatic pressure test.

Graphical Representation of the Hydrostatic Test Process Case 2
Above figure shows Graphical Representation of the Hydrostatic Test Process Case
2 – Water to be added to determine if the pipeline passes or fails
 Test Result
If during Phase 3 the pressure within the pipeline remains at or above
the
operational pressure of the pipeline for a period of at least one hour, the
pipeline is considered to have passed the hydrostatic test.
If water needs to be added the pipeline is considered to have passed
the hydrostatic test if the quantity of water added in terms of litres of water per
km of pipeline length per hour of the phase 3 period is less than that given in
the following expression and in Figure 25-3.
Q ≤ Di/50 – 1 (litres / km / hour)
Q = added water in litres.
Di = internal diameter for the pipeline in mm.

Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water
 Notes on Test Equipment

The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It
shall be connected to the feed pipe work.
The small diameter test pipe work shall include a bleed valve at upper end of
the pipeline and at all high points together with feed pipe work and
valve at the lower end of the pipeline. The feed pipe work shall include a
means of draining off the water in to a measuring cylinder that shall have a
capacity of at least 2 litres capacity, graduated to 100 mls.
The Contractor shall also have a thermometer for air and water
temperature measurement.
 Differences in elevation
Care should be taken not to over pressure the lower end of the system during
testing. Gauges should always be placed at the lower end of the length under
test. As far as possible, the difference between the lower and upper end should
be kept to one bar. It is recognized that this may not always be possible when
longer lengths are being tested, or where the slope of the pipeline
makes it impractical.
 Test pressures at elevated temperature
Where the phase II pressure is within the pressure rating of the pipe and test
temperatures are 30 °C or less no adjustment of test pressure is necessary.
When ambient temperatures at the time of test are over 30 °C and test
pressures are over the pressure rating of the pipe then it may be necessary to
modify the test pressure according to the table below or as agreed with the pipe
Manufacturer and Engineer.
Test Temp. (OC) 32 38 43 49 54 60
Multiplier 0.9 0.8 0.75 0.65 0.6 0.5
 Additional Notes
Care should be taken that any mechanical elements on the system are
protected from elevated pressure or completely removed from the pipeline.

Do not subject the line to prolonged over-pressure. Always aim to complete the
procedure within one working day.
During the summer, make sure that the pipe is not subject to direct
sunlight during testing.
During pressure testing pay full attention to the HSE aspects of the procedure.
In particular, keep the public away from high-pressure test areas.
The test equipment must be capable of pressurizing the test length
within a reasonable time. If the procedure becomes protracted (beyond one
working day) the test length may be modified or reviewed. Extremely long test
lengths may be subject to special procedures.
A Pipe Bedding
1. Pipe bedding material shall be as specified in section 2.04.5 of Division 2 herein before
B Pipe Laying and Jointing - Generally
1. The pipe shall be brought to grade and approved prior to the lowering of the pipe into the
trench. Pipes shall be laid to slopes shown on drawings.
2. Lowering of the pipe into the trench shall be carried out using ropes, wire slings,
band slings, and spreader beams etc. as recommended by manufacturer for each
type of pipe and as approved.
3. All material shall be carefully examined for damage and tested in accordance with
manufacturer’s instructions before laying to the satisfaction of Engineer.
4. The Contractor shall examine material to ensure internal coating or lining and
outer coating or sheathing is undamaged. If damaged, make good or dispose of as
directed.
5. Pipe Cleanliness: The Contractor shall remove dirt and other materials before
lowering and clear construction debris from inside of pipe before making joint.
6. Pipe Placement: The Contractor shall lay pipes on even formations true to grade
and line, with sockets (if any) facing up the gradient.
7. Pipe on Solid Ground: The Contractor shall cut holes in bottom of trench to allow
proper jointing and for barrel of pipe to bear evenly on the bedding for its full
length.
8. Pipe on Granular Bedding: The Contractor shall scoop out locally at
sockets/couplings to enable pipe to rest uniformly on barrel and adjust to exact line
and level. After testing the Contractor shall lay and compact further granular
material in 150 mm layers or as approved to levels shown on the Drawings.
9. Pipe on Concrete Bed or Surround: The Contractor shall provide rectangular
blocks of concrete Class 210/25, made in approved moulds at least 14 days before
use, and hardwood folding wedges approved by the Engineer and also provide two
concrete blocks for each pipe, set and bone into correct level on formation bottom
and lay pipe properly centred and socketed. The Contractor shall insert two
hardwood folding wedges of width equal to width of concrete block between body
of pipe and block and drive together until pipe is brought to exact level required
and leave blocks and wedges undisturbed while pipes are being jointed and
concrete bed and haunch or surround are being placed. The Contractor shall
ensure blocks and wedges are of sufficient size and strength to prevent settlement
of pipe and leave sufficient space to enable joints to be made, tested and
inspected.

10. Pipe Plugs: When pipe laying is not in progress, the Contractor shall close open
ends of pipes with properly fitted temporary wooden plugs or standard caps as
directed.
11. Minimum cover over pipes is 1.5 m unless shown on drawings or instructed by the
Engineer.
C Jointing
1. Manufacturer’s instructions shall be followed regard-ing placement of bedding and

backfilling, cleanliness of joint surfaces, lubricant used, correct location of components,
provision of correct gaps between end of spigot and back of socket for flexible joints etc.
2. Deflection of Joint: The Contractor shall not deflect flexible joints beyond 50
percent maximum permissible angles given by manufacturer and/or relevant
Standard.
3. Patent Detachable and Flexible Joints: The Contractor shall strictly comply with
special instructions issued by manufacturers of proprietary joints when laying and
jointing.
4. Differing Pipe and Fitting Material: The Contractor shall joint with adap-tors as
recommended by pipe manufacturer.
D Line and Gradient
1. In Open Excavation: The Contractor shall provide and maintain sight rails and boning rods
properly painted to ensure correct alignment of pipe runs. Sight rails shall be positioned
either ver-tically above the lines of pipes or immediately adjacent thereto. At no time are
there to be less than three sight rails in position on each length of pipeline under
construc-tion to any one gradient.
2. Wherever possible and as per the Engineer instructions, the Contractor should use
the suitable recent surveying devices to adjust the line and gradient of pipelines.
3. In heading the Contractor shall provide and maintain marks to establish line and
level of pipeline. Marks shall be fixed in each working shaft and two further marks
established in each length of heading.
E Floatation
1. Prevention: Whenever water is excluded from interior of pipe the Contractor shall place
sufficient backfill above pipe to prevent floatation.
2. Removal of Pipe: The Contractor shall correct bedding and relay any pipe that has
floated.
F Pipe Built into Structures
1. Treatment of External Surface: The Contractor shall thoroughly clean outside surface of
pipes to be built-in immediately before installa-tion and remove protective coating to metal
pipes, where or-dered. The Contractor shall roughen clay and concrete pipes as directed
and paint plastic pipes with appropriate solvent cement and sprinkle with dry coarse sand
whilst wet. The Contractor shall cut away sheathing from sections to be built-in and after
installation restore protection up to external face of structure with approved bituminous
material.
2. Flexible Joints: The Contractor shall install two flexible joints or flexible patented
joints adjacent to structures and place the first joint not more than one pipe
diameter from face of structure and second not more than the following distances
away from first:
 Pipelines not exceeding 450 mm: 2 pipe diameters
 Pipelines Over 450 mm and Not Exceeding 1000 mm: 1.2 m
 Pipelines Over 1000 mm: 1.8 m.

 In general, the length of the short pieces may be selected as recommended by the
pipe manufacture.
4.3.4 PIPE WORK TESTING
A Field Testing: Generally
1. Provision of Test Equipment: All items for test have to be provided on site before the test
i.e pressure gauges, instruments, water etc...
2. The Contractor shall carry out tests in the presence of the Engineer.
3. Fittings and Joints: The Contractor shall permanently anchor fittings before testing
and leave all joints exposed for checking.
4. Test Sections: The Contractor shall limit test sections to not more than 500 m.
5. Test Sections: The Contractor shall test pressure lines between valve chambers
whenever possible.
6. Test Sections: The Contractor shall test gravity sewers in sections between
manholes.
7. Test Sections: No testing shall be carried out against or through the pressure
reducing valves. The setting of the pressure reducing valves shall not be changed
for testing purposes.
8. Closed Valve: The Contractor shall not test against a closed valve unless there is
no acceptable alternative.
9. The Contractor shall apply pressure by manually operated test pump or, in the
case of large diameter mains, by power driven test pump, if approved.
10. The Contractor shall examine exposed joints and repair visible leaks.
11. Failure: Should a test fail, the Contractor shall locate the leak and replace or make
good defective pipe or replace and make good faulty joint. The Contractor shall
retest main.
12. Records: The Contractor shall keep test records in an approved form and hand
original copy to the Engineer immediately after completion of test.
B Hydrostatic Testing of Pressure Headers (Force Main)
1. Pressure Lines: The Contractor shall carry out hydrostatic test while pipeline is partially
backfilled.
2. The pipeline shall be filled slowly with water from the lowest point. After filling with
water, absorbent pipes shall be allowed to stand for at least 24 hours before
testing to allow for complete absorption.
3. Entrapped air shall be bled and pressurising shall then proceed until the specified
test pressure is reached in the lowest part of the pipeline section under test.
Further quantities of entrapped air shall be bled while the pressure is being raised.
4. Unless otherwise specified, the test pressure shall be equal to 1.5 times the
maximum working pressure of the pipeline as shown on the Drawings or as
determined by the Engineer on Site but shall in no case exceed 75% of the factory
hydrostatic test pressure.
5. The test pressure shall be maintained for one hour by pumping using a separate
test pump. Pumping shall then be stopped for 2 hours; at the end of which time the
line shall be re-pressurized to the original test pressure and the volume of water
pumped into the line recorded.
6. The pipeline shall be deemed to have failed the test if visible leaks are detected
(regardless of leakage being within the allowable specified limit) or if the volume of
water pumped to restore original test pressure after the period when pumping was

stopped exceeds or 0.1 litre/day per km of pipe per mm of pipe diameter for each 3
kg/ cm2 of applied pressure for other pipe material.
C Hydrostatic Testing of Non-Pressure Pipelines
1. Non pressure lines shall be air tested for the whole pipeline after partial backfilling above
the pipeline except the connections then hydrostatic tested for the whole pipeline after
complete backfilling and before surface reinstatement and pavement.
2. Testing procedures should be as per BS 5886 and as per the following steps:
3. Procedure shall be as described for pressure pipelines.
4. Test Pressure: 1.25 m head of water above pipe soffit at highest point and not
greater than 6 m head of water at lowest point of section under test. If maximum
head is exceeded, the Contractor shall test section in stages.
5. Test period shall last 30 minutes.
6. Allowable Leakage: 0.125 litres/linear metre/metre diameter/30 minutes.
D Hydraulic Individual Joint Test for Pipes Exceeding 1000 mm.
1. Procedure: The Contractor shall carry out procedures to BS 5886 [23], Type 2 testing after
partial backfilling, or equivalent. The Contractor shall pressurize joint to 2 bars and wait for
10 minutes at the end of which repressure to 2 bars and again wait for 5 minutes. No
pressure drop should be observed at the end of the latter period.
2. Test Pressure: 2 bars
3. Test Period: 5 minutes.
4. Allowable Leakage or Pressure Drop: None
E Air Testing of Pipelines
1. The Contractor shall carry out tests to BS EN 752-2 [22] and plug length under test.
2. The Contractor shall apply pressure by approved method (ie. hand pump) until a
pressure equivalent to 100 mm head of water is indicated on a U-tube connected
to the system.
3. The Contractor shall allow 5 minutes for stabilisation of air temperature and adjust
pressure to 100 mm
4. Pressure Drop: Pressure shall not be allowed to fall by more than 25 mm in a
period of 5 minutes.
5. Failure to pass the air test is not conclusive and if no leakage can be traced by
external application of soapy water to all sealing areas then an hydrostatic test
shall be carried out before final rejection.
F Visual Inspection Test
1. Timing: The Contractor shall carry out test after total backfilling of length under test.
2. Limit of length to be tested at one time is three full- length pipes unless otherwise
approved.
3. Apparatus: The Contractor shall use rubber tyred bogies that do not damage lining
of pipe and an adequate supply of electric lamps.
4. The Contractor shall check joints by means of feelers to ensure rubber rings are
correctly located.
5. The Contractor shall check pipe barrel for visible cracks.
G Deflection Tests for GRP Pipes

1. The Contractor shall conduct deflection tests for GRP pipes as required by the Engineer at
3 stages. Deflection shall be measured at the spigot end at mid point and at socket
end.
 Stage 1: At completion of primary backfill (deflection at this stage should be below
0.5%).
 Stage 2: At final backfill (Maximum allowable deflection 2.5%).
 Stage 3: Six months after final backfill (maximum allowable deflection 4.0%).
2. Pipes not passing the deflection tests at stage 2 or stage 3 shall be removed and
replaced.
H Testing of Water Retaining Structures
1. All water retaining structures such as reservoirs, tanks, basins ponds, regardless of the
construction material, lining or final surface treatment shall be tested or Water-tightness.
2. Tightness testing shall be carried out according to ACI 350.1-01/350.1R-01.
3. Allowable losses of water, after correction for evaporation, precipitation etc. shall
be as set in the table below:
Type of structure Test and Criteria*
Tanks/Reservoirs/Channels/Conduits for sewer, Concrete HST-VIO & HST-NML
pipes, Open or covered (Stormwater Channels not
included)
Settling tanks/Basins HST-VIO & HST-NML
* For designations refer to ACI 350.1 - 01/350.1 R-01.

4. Notwithstanding satisfactory completion of the water absorption test, any leakage
visible on the outside faces of the structure shall be stopped. Any caulking or
making good of cracks in the wall section shall, where practicable, be carried out
from the inside face, and to the satisfaction of the Engineer.
5. Upon completion of the test, the Contractor shall empty the structure, dispose of
the contents and shall clean the structure and any equipment therein of all
deposits left by the water.
I Field Protection and Coating
1. Iron Pipes: Polyethylene sleeving shall be to ANSI/AWWA C105, Section 4.1 or ISO 8180
or in accordance with the manufacturer’s instructions. Sleeving shall be heavy duty blue
color polyethylene with a minimum thickness of 225 microns.
2. Patented Detachable and Flexible Joints and Flanged Connections: The
Contractor shall protect metal joints with mastic compound and protective tape in
accordance with the manufacturer’s instructions. Minimum overlap shall be 55%
and the Contractor shall press out firmly all folds and irregularities.
J Cleaning and Inspection of Sewers
1. Cleaning: The Contractor shall clean pipeline of silt and debris after back-filling pipe
trenches and completing manholes, hatch boxes etc. but before surfaces are permanently
reinstated and make ready for inspection by the Engineer.
2. Inspection: Pipelines of 700 mm diameter and over are, where practicable, shall be
inspected from the inside and when necessary a suitable trolley is to be provided
for this pur-pose.
3. Inspection: Pipelines less than 700 mm diameter and larger pipelines which cannot
be inspected from the inside, are to be inspected by passing a cylinder of diameter
25 mm less than the internal diameter of the pipe and length not less than the
internal diameter of the pipe through each pipeline.

K Waterproofing of Structures
Waterproofing of water retaining structures shall not be commenced until tested for water-
tightness and found satisfactory.
The waterproofing compound shall penetrate and react with the concrete to form crystals
that seal all capillaries, tracts and shrinkage cracks in the concrete structure. The
compound shall consist of a mixture of chemicals, quartz, sand and cement supplied in
powder form ready to mix with water. Application shall be carried out in accordance with
the manufacturer’s recommendations and as approved by the Engineer.
4.4 VALVES, HOUSE CONNECTIONS AND SUNDRY WORKS
4.4.1 GENERAL
A Scope
1. These works shall consist of furnishing all materials, constructing, installing and completing
in all respects of works described in this Specification and indicated on the Drawings.
4.4.2 VALVES
A Gate Valves
1. Type: Size 50 mm to a diameter less than 300mm and shall be of ductile cast iron (GGG
40) to DIN3202 or equivalent and operation system shall be of non-corrosive cast iron and
shall be non-rising and gate of copper or cast iron covered with rubber.
2. Socket (DIN 8061, DIN 8062, ISO 3606, ISO 4422) or equivalent with flanges to
(DIN 3202, F4 or equivalent).
3. Material of flanged valve and socket:
 Valve body from ductile cast iron to (GGG40) (EN-JS 1030)
 Gate of the type covered with rubber.
 Valve stem of stainless steel and shall be of non-rising type, and valve shall be
operated manually or with a stem.
4. Testing: valves shall be tested to DIN 3230 Part 4 – EN 12266 or equivalent.
5. Operation: Either manually or operation key with a rising stem relative to depth of
installation. It may need an internal disk and shall be as Engineers direction and
manufacturers regulations.
6. Protection: Casting surfaces internally and externally with epoxy at a thickness not
less than 250 microns as per specifications.
B Butterfly Valves
1. Type: To BS EN 593, double flange for NP 10/16 bar or equivalent.

2. Component Parts:
 Butterfly valve with the fixed plate not connection with the stem.
 Valve body and plate of ductile cast iron (GGG 40)
 Valve length as per German Specifications: (DN 3202 F4) series 14 & EN558-1 or
equivalent.
 Valve stem of anti-corrosive cast iron
 Flanges to DIN 2501 or equivalent.
 Opening & closing of valve shall be done by gearbox mounted on valve.

3. Protection: Casting surfaces internally and externally with epoxy at a thickness not
less than 250 microns as per specifications.
C Check Valves for Sewer Lines
1. Check valves shall be to BS EN 12334 [28], swing, straight, for horizontal use and suitable
for working pressure of 16 bars.
2. Material of Component Parts: Ductile iron from basic materials listed in BS EN
12334 [28] Table 5, under ‘copper alloy faced’ column.
3. Special Requirements: Seating or facing rings are to be renewable. An arrow
showing direction of flow is to be visible from outside and cast integral with the
valve housing.
4. End Connections: Either flanged to BS 4504 [2], or screw ended to BS 21 [26] to
suit joints specified for adjoining pipes.
5. Factory Protection: Casting surfaces are to be given an initial coat of protective
paint immediately after shot blasting and a second coat on assembly. Protective
coating is to be hot applied coal tar or bitumen to BS 4164 [5] or BS 3416 [4]
respectively. Minimum thickness of coating shall be 250 microns.
D Flap Valves
1. Type: To be flange mounted, designed for use on end closures to prevent entrance of
backwater. Seating plane is to have 10 deg. inclination.
2. Materials: Cast iron body and cover, bronze seat faces, bronze hinge pins and
spring pins, cast iron follow ring and plated steel ring draw bolts. Materials subject
to de- zincification or de-aluminuzation are not to be used.
3. End Connections: If flange mounted, flanges are to be to DIN 2501 or equivalent.
4. Protection by epoxy with a thickness not less than 250 microns as per
specifications.
E Air Valves for Pressurized Sewage Mains
1. Generally: Valves are to have cast iron body, cover and baffle to BS EN 1561 [29], Grade
14, stainless steel float and float guide, Buna-N seat or needle and Dirlin internal linkages.
Air valves are to have long float stem and body to keep valve operating mechanism free
from contact with sewage by maintaining an air gap between mechanism and waste
media. Float is to hang freely in centre of valve body with 12 mm clearance all around to
prevent large solids getting above the float. Valves are to be fitted with blow off valves,
quick disconnect couplings and minimum 2.0 m of hose to per-mit backflushing without
dismantling valve. Valves are to be factory tested to 1.5 times working pressure and
fac-tory coated with bituminous coating to BS 4164 [5] or BS 3416 [4] respectively.
Thickness of coat shall be 10 mils.
2. Single Air Valves: Type I (or air vacuum valve) for releasing or admitting air during
filling or emptying of pipes. Type II (or air release valve) for automatically
releasing, under pressure, accumulated air at summits of mains. Air valves 50 mm
and smaller are to have screwed in-let to B.S.P. thread with gunmetal male
screwed stop valve. Air valves larger than 50 mm are to be flanged to BS 4504 [2]
or DIN 2501 or equivalent and have nitrite rubber lined butterfly valve with nylon
coated disc on stainless steel shaft operated by lever handle with indicator and
locking thumb screw. Valves are to be suitable for working pressures up to NP16.
3. Double Air Valves (or Combination Air Valves): These are required for relieving air
under pressure and in bulk, are to be an as-sembly of an air vacuum and an air
release valve. Valves shall be suitable for working pressures up to NP16.
 U554 &DAVPSM-PSR&
 INSERT MAXIMUM WORKING PRESSURE.

4.4.3 HOUSE CONNECTIONS FOR SEWER NETWORKS
A Work includes providing and installation of pipes from the manhole or the sewer inlet to the
collector outlet and the property border as shown on drawings. This includes all the
components and requirements.
B Material of sewer house connection pipes shall be vitrified clay as per section 4.3.1 of this
document or uPVC as per section C and of diameters 100 to 200 mm according to
drawings and Bill of Quantities. Piping from inspection chamber to property shall be same
as that used by owner.
C UPVC Pipe for Gravity Flow
1. Pipes shall conform to Saudi Standards SASO 14 or DIN 8061 / 8062 with 10 bars working
pressure or Class (4) as indicated on the Drawings or the Bill of Quantities. Concrete
encasement shall be added to pipes with covers less than 1.0m or more than 5.0m.
2. Fittings and joints shall comply with ISO 4422 or BS EN 1452 [9] Part 3 or DIN
8063 or equivalent and manufactured from same material of pipe.
3. Joints shall be to DIN 8063 part 1, socket spigot with rubber sealing rings shall be
to BS EN 681-2 [10].
4. The following test shall be carried out on samples from every batch of PVC pipes
delivered to site. The report of the third-party inspector shall cover at least the
following tests as requested by DIN 8061/8062:
 Pipe diameter / roundness
 Wall thickness
 Stress resistance tests
 Impact test
 Elevated temperature cycling test
 Resistance to sulfuric acid
5. Pipes and fittings shall be protected from the direct rays of the sun at all times by
means of reflective cover sheets.
D Connection locations shall be as per drawings and as per Engineers and as per Engineers
directions during execution and number and diameters that shall be constructed as per
drawings and Bill of Quantities.
E House connection construction: the Contractor shall clean site and trenches and refill and
lay pipes and put bedding for pipes and paving to specifications as in the main network.
F Records: the Contractor shall keep accurate records for house connections locations
showing diameter length and location. Records shall be in specified formats and shall be
ready for revision. These records shall be submitted to the Client when work finish. The
Contractor shall show this information on graphs in coordination with the Engineer also
securing three copies to be submitted to the Client and as shown in 4-4-7 of this
specifications.
4.4.4 JOINTING MATERIALS AND ADAPTORS
A Generally

1. Gaskets: Elastomeric full face 3 mm thick joint rings to ISO 4633 or BS EN 681-2 [10] with
dimensions to BS 3063 [38].
2. Rings: Elastomeric to ISO 4633 or BS EN 681-2 [10] with dimensions to
manufacturer’s recommendations to suit type of joint required.
3. Bolts and Nuts: ISO metric black hexagon to BS 4190 [39], minimum tensile
strength 433 MN/m2, maximum elongation 17%. After fixing, bolt projection shall to
be maximum 6 mm, minimum 3 mm.
4. Washers: Black steel shall be to BS 4320 [40] or ISO/R 887.
5. Dielectric joints shall have insulating gasket between flanges and Teflon sleeves
and washers between bolts and nuts and flanges. Joints are to be suitable for
operating pressure of system.
6. Saddle connections should meet the following requirements:
 Saddle diameter should be less than sewer line diameter.
 Drilling should be done correctly to avoid any crack / damage to existing line and
to use proper drilling machine/core.
 Concrete surround the branches to protect from impacts
 Branch piece should not project into the main sewer.
B Flexible Couplings
1. Type: Gasket sleeved type, to allow angular deflection and axial movement of two joined
pipe ends and to maintain permanent, leak-tight joint.
2. Components comprise one centre sleeve, two end followers or flanges, two
rubber-compounded wedge-section gas-kets and sufficient draw bolts and nuts to
properly compress gaskets. Tightening of bolts to draw end followers together is
to compress gaskets in recess between centre sleeve and followers onto pipe
ends to effect positive seal.
3. Size: Couplings are to have diameter specifically sup-plied for and to properly fit
type of joined pipe ends. Centre sleeve is to be of adequate thickness and whole
cou-pling suitable for minimum working pressures shown on the Drawings.
4. Centre Sleeve and Followers shall be true circular sections, free from irregularities,
flat spots or surface defects and formed from steel mill sections with space
between sleeve and follower designed to provide confinement of gasket.
5. Bolts shall be special steel having minimum yield strength of 2800 kg/cm2 (40,000
psi) and ultimate strength of 4200 kg/cm2 (60,000 psi). Bolts shall be track-head
design to prevent turning when nut is drawn up and threads are to be rolled with a
nominal diameter larger than diameter of shank. Manufacturer shall supply
information regarding recommended torque to which bolts are to be tightened.
6. Gaskets shall be synthetic rubber-base compound with other products to produce
material which will not deteriorate from age, heat or exposure to air and which is
resilient and able to resist cold flow of material so that joint will remain sealed and
tight indefinitely when sub-jected to shock, vibration, pulsation, temperature and
ad-justment of connected pipes.
7. Factory Protection: Coupling shall be factory painted internally with 10 mils coating
of epoxy and externally with red primer to AWWA 203 Type B chlorinated rubber
solution compatible with bitumen, coal tar and general paints.
8. Installation: Couplings are to be assembled on site in accordance with
manufacturer’s instructions to ensure permanently tight joints under all conditions
of expansion, contraction, shifting and settlement.
C Dismantling Couplings

1. Type: These shall ensure extensible connection between sections of pipework, to be
mounted next to valves to enable easy dismantling from pipework or to permit joining
pipework when butterfly valve is removed for maintenance.
2. Components: Dismantling piece shall be flanged type composed of two parts, one
sliding into the other, and a free flange to compress a trapezoidal section seal to
ensure water tightness. Coupling shall have locking devices to provide elements
of complete rigidity.
3. Construction: All steel with flanges class PN 10, PN 16 or PN 25 depending upon
coupling location on pipework.
4. Size: Couplings shall have diameter specifically supplied for and to properly fit type
of joined ends of pipes and valves. Coupling shall permit tightening of end flanges
without risk of misalignment. Seal shall be locked after end joints are tightened.
D Flanged Adaptor: Ferrous
1. Material: Cast iron to BS EN 545 [1].

2. Length of adaptor shall be 200 mm for diameters up to 150 mm, 250 mm for
diameters between 200 and 300 mm and as approved for diameters larger than
300 mm.
3. Factory Protection: Coated with bitumen or coal tar to BS 3416 [4] or 4164 [5]
respectively.
4.4.5 VALVE ACCESSORIES
1. Hand-wheels shall be to BS 5163 [25], of cast iron to BS EN 1561 [29]. Hand-wheels are to
be marked ‘CLOSE’ with an arrow to indicate clockwise direction of closure. Diameters
and other constructional details shall be to manufacturer’s standards. Hand-wheels are to
be supplied at a rate of 1 in 5 valves.
A Generally
1. Prior to Installation, the Contractor shall inspect for cleanliness of bores, seating surfaces
etc. and for handling damage, cracks, missing parts and tightness of pressure-containing
bolting.
2. The Contractor shall ensure gates and hydrants are in closed posi-tion before
installation.
3. Operate hydrants through one complete opening and closing cycle in the position
in which they are to be installed to ensure proper functioning.
B Installation of Valves
1. Prior to installation, valves shall be inspected for cleanliness of bore, seating surfaces etc.
and for handling damage, cracks, missing parts and tightness of bolting. Valves shall be in
close position before installation.
2. Valves shall be operated through one complete opening and closing cycle in the
position in which they are to be installed to ensure proper functioning.
3. Valves shall be set and jointed to the pipe in the manner specified for laying and
jointing pipe and in accordance with the manufacturer’s recommendations. Each
valve shall be provided with a concrete pad as shown on the Drawings so that the
pipe does not support the weight of the valve. Valves shall not be used to spring
misaligned pipe into alignment during installation.
4. Valves without concrete pads shall be placed on firm footing to prevent settling
and excessive strain on connection to pipe.

5. All stressed bolts (bonnet, seal plate and end connections) shall be inspected for
adequate tightness after installation and prior to field testing.
6. Valves shall be protected against action of external agents by a coat of approved
bituminous compound, applied cold by hand brushing after pressure tests on
pipelines have been completed. Buried bolts etc., shall be protected against
corrosion, with approved paint or polyethylene wrapping.
C Sewer Building Connections
1. Location: The Contractor shall agree location and invert level of connections with the
Engineer before starting construction.
2. The Contractor shall programme connections to follow closely construction of
sewer.
3. Execution: Connection to sewer shall be at manhole, where possible, and add
flexible joint when connecting at manholes without any additional payment
connection can be done by Y junction.
4. Minimum Grade: The Contractor shall lay connections at minimum grade of 20 per
1000 unless otherwise approved.
5. The Contractor shall install, bed and test connections in same manner as main
sewers.
6. For empty lots on those under construction, house connections should be also
added for future connection.
4.4.7 RECORDS
The Contractor shall maintain accurate records details for the whole project components
and show details for the following works, these records should be submitted in both
hardcopy and digital forms, three copies for each form. Digital data and drawings should
be prepared in compliance with geographic information system (GIS) and digital mapping
in the directorate (if any).
A As-built house connection plan:
This record showing the sketch of the particular section indicating the downstream MH &
Upstream MH. Downstream MH usually shown on the lower portion of the record sheet,
thus, a reader is facing Upstream of the section. Listed below is the information required
for this record;
When house connection/s are constructed in a section
 Mainline number
 Mainline section number
 Length of mainline pipe
 Mainline pipe Ө and type of pipe
 Invert level of Upstream MH
 Invert level of Downstream MH
 Connection number & position (numbering will be designated in chronological
order while positioning for left or right derived when facing upstream of the section)
 Type of connection (deep connection; shallow connection; backdrop connection to
MH; shallow connection to MH)
 House connection pipe diameter
 Distance from Downstream MH

 Distance from centerline of sewer to end lateral (end lateral could be a inspection
chamber “I.C.”, a clean-out “C.O” or a end plug “EP” for future connections)
 Invert of street sewer
 Invert of end lateral
 Number of I.C. or C.O.
 A column of remarks must be provided for future up-dating of house connection/s
B As-built House Connection Profile
This record shows the profile information of each house connection/s constructed in a
section installed “Y” junctions on the mainline for future house connection requires no
profile record.
A sketch is to be shown for the particular house connection with complete information as
listed below.
 Mainline number
 Mainline section number
 Mainline Pipe Ө and type of pipe
 House connection number & position
 Distance from Downstream manhole
 Type of connection
 House connection pipe Ө and type of pipe
 House connection slope
Lengths:
 From centerline of mainline to property wall/limit
 From centerline of end lateral to property wall/limit
 Length where pipe slope is derived
Elevations:
 Ground elevation at end lateral
 Ground elevation at mainline
 Invert elevation of mainline
 Outlet Invert elevations
C Mainline Records
There are three (3) important records to be maintained from constructed mainlines, these
are the general lay-out and bench mark, site plan and the line profiles. Description of these
records are as follows.
1. For general lay-out & bench mark
This drawing must be prepared in A-0 size drafting film covering the whole area of work
executed by the contractor with an “appropriate” scale that will accommodate on drawing
sheet. Required informations are as follows:
 Line numbers
 Manhole numbers

 Name of street
 Name of important landmark in the area (i.e mosque, school, garden, hospital,
clinic, shopping mall, government offices, etc…)
 Location of bench marks with there designated numbers and elevations
 A separate table is to be allocated describing the complete bench marks used in
the project.
2. For Site Plans
This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 showing in
segments for the entire area of work executed by the Contractor. Required informations
are as follows;
 Line numbers
 Manhole numbers
 Coordinates for each and every manholes
 Lateral distance location for each and every manhole
 (i.e. distance from center of manhole to property wall or sidewalk curb stone or
street light post or fire hydrant traffic light post or any favorable base of
measurement)
 Properties of sections (pipe diameter & type of pipe, length & slope)
 Elevations:
 Ground level of manholes
 Invert level of manholes
 Invert levels of incoming pipes in the manhole but only if there is drop in invert
from manhole
 Name of street
 Name of important landmark in the area (i.e. mosque, school, garden, hospital,
clinic, shopping mall, government offices, etc…)
3. For Line Profiles
This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 horizontal
and 1:100 vertical for the entire mainlines constructed in the whole area of work by the
Contractor. Required information is as follows:
 Line number
 Surface condition
 Ground level
 Invert level
 Depth-to-invert
 Distance
 Chainage
 Pipe data (pipe diameter & type of pipe, slope and bedding)
 Rock levels
 Underground utilities crossing either below or over the mainline pipes
 Type of utility
 Description

 Top elevation
 Incoming line in the manhole
 Line number
 Pipe invert level
 Pipe diameter & type of pipe
4.5 BEDDING, SURROUND, HAUNCHING, ENCASEMENT AND THRUST BLOCKS
4.5.1 GENERAL
A Scope
1. Pipe bedding, surround and ways of securing pipe installations are specified in this
Section.
4.5.2 MATERIALS
A Pipe bedding and/or surround, and filling materials under and around pipes shall comply
with the appropriate requirements of Section 2.04.
B All concrete work shall comply with the appropriate requirements of Division 5.
C Concrete bedding shall be Class 110/25.
D Concrete for encasements, thrust blocks, arches and haunches shall be Class 250/20.
E Compressible board shall be 20 mm thick fibrous material or similar approved material.
4.5.3 Workmanship
A Placing Concrete
1. After placing pipe the Contractor shall pour concrete in trench and thoroughly work under
pipe to provide solid and uniform bedding.
2. After pipe joint is completed the Contractor shall place the balance of concrete or
haunching and work into place on both sides simultaneously.
3. The Contractor shall form vertical construction joints in concrete beds, surrounds
etc. at the face of pipe joints with compressible board and finish to profile of the
concrete and pipe. The Contractor shall fill any gap between spigot and socket
with approved resilient material.
B Placing Material Other than Concrete
1. The Contractor shall place surround or bedding material in bottom of prepared trench and
carefully hand tamp to minimum thicknesses.
2. After pipe has been laid the Contractor shall place additional material or haunching
in successive layers not exceeding 150 mm thick on both sides simultaneously
and completely fill spaces between pipe and side of trench and carefully hand
tamp without disturbing the pipe.
C Thrust Blocks

1. Thrust blocks shall be provided at bends and other fittings on pressure pipelines.
Additional excavation shall be made as required after pipeline has been jointed. No
pressure is to be applied to the thrust block until concrete has matured for at least 3 days.
4.6 MANHOLES AND CHAMBERS
4.6.1 General
A Scope
1. This section specifies works related to:

 Sewage manholes and Inspection Chambers.
 Valve chambers for sewer force mains.
4.6.2 Materials
A Excavation and backfilling generally shall comply with the appropriate requirements of
Divisions 2 & 3 of the Specification.
B Concrete work generally shall comply with the appropriate requirements of Division 5 of the
Specification.
C Reinforcement shall conform to the requirements as specified in Section 5.03 “Steel

D Precast units to BS 5911 [13] Part 200 or ASTM C478. Except for thickness which shall be
as indicated on the Drawings. Concrete shall be Class 250/20. Cement shall be ordinary
Portland cement to BS EN 197 [3].
E Plain and reinforced concrete for cast In-Situ units shall be Class 210/25 and 250/25
respectively. Cement shall be ordinary Portland cement to BS EN 197 [3].
F Coatings shall be as specified in A5 and A6 of section 3.06.3. Alternative internal coating is

given in Section 3.06.4.
G Covers and frames shall be gray cast-iron non-rocking, locking, as per Ministry of
Transport specification and shall comply with BS EN 124 or ISO 1083 or DIN 1229 or
equivalent. Wording on cover shall indicate nature of network (Sewerage – ‫ )ﺻرف ﺻﺣﻲ‬as
required by Employer. Grades shall be as follows:
 In Roadways: Heavy duty test load 40 tons

 In Sidewalks, Carriage Drive and Cycle Tracks: Medium duty test load 25 tons
 In Footpaths: Light duty, test load 7 tons
H Manhole covers shall be of circular pattern with 600 mm diameter unless otherwise
indicated on Drawings. Frames shall be provided with opening for fixing bolts which ensure
solid frame embedment into manhole concrete neck. Covers and frames shall be coated
with two layers coal tar epoxy (70% epoxy, 30% coal tar) to BS 3416 [4]. Minimum
thickness 250 microns.
I Step irons shall be mild steel to BS 4211 [51], galvanized to BS EN ISO 1461 [52] with 200
grams of zinc per square meter and covered with two layers of polyethylene (PE) or
polypropylene.
J Safety chains shall be 12 mm diameter wrought iron short link chain, galvanized to BS EN
ISO 1461 [52] with 200 grams of zinc per square meter.

K Guardrailing shall be tubular, mild steel, medium grade to BS 1387 [15] with welded joints,
galvanized to BS EN ISO 1461 [52] with 200 grams of zinc per square meter.
L Fixing bolts shall be steel, type suitable for particular purpose and use and to approval.
When used to fix galvanized material, washers are to be galvanized and fixing bolts and
nuts cut to pre-plating limits and electroplated with zinc to BS EN 12329 [53].
M Steel castings shall be mild to medium strength castings and shall conform to AASHTO
M103 (ASTM A27). Unless otherwise shown on the Drawings or instructed by the
Engineer, castings shall be grade 65-35 fully annealed. Steel castings shall conform to the
dimensions shown on the Drawings. Test bars shall be prepared and tested as specified
in AASHTO M103.
N Wrought iron plates and shapes shall conform to the dimensions shown on the Drawings.
Rolled wrought iron bars and shapes shall conform to the requirements of ASTM A207.
Wrought iron plates shall conform to ASTM A42.
O The Contractor shall submit to the Engineer all specified test coupons and Manufacturers’
Certificates of Guarantee for all structural steel, cast iron, cast steel and wrought iron parts
stating that the materials supplied meet the appropriate AASHTO or ASTM specification.
The submission of such test certificates shall not relieve the Contractor of his obligations to
carry out independent tests at an approved laboratory, as directed by the Engineer, at his
own expense.
4.6.3 Construction and Installation
A Manholes and Inspection Chambers
1. Construction: In-situ concrete or precast concrete as indicated on Drawings or as proposed

by Contractor as per the site requirements but the distance between two consecutive
manholes should not exceed 100 m, the minimum distance will be according to site
situation and as directed by the Engineer. In-situ units shall comply with the provisions of
Division 5 for concrete works of this specifications.
2. Precast units shall be cast in steel watertight forms at least 3 weeks before
sections are used. Lowest unit shall be bedded on in situ concrete base and bed
and haunch in cement mortar. Joints of units shall be liberally coated with
approved bituminous material of trowelling grade prior to fixing. Joints shall be
filled solid and neatly striked off surplus compound. Work shall remain
undisturbed for 7 days thereafter. Alternatively joints may be sealed with approved
preformed jointing strip in accordance with manufacturer’s instructions. The
precast concrete cover slab shall be bedded in cement mortar on the top unit.
3. Channels in bottom of manhole shall be smooth, semi-circular and sized equal to
diameter of adjacent sewers. For straight through manholes, channels of half pipe
sections shall be installed. Changes in direction of flow shall be made with smooth
curves as large as manholes permit. Changes in size and grade of channels shall
be gradual and even.
4. Benching shall be formed with sulphate resisting concrete Class 250/20 to rise
vertically from top of channels to a height not less than soffit of outlet pipe, then it
shall be sloped upwards 1 in 10 to walls. Floating shall then be carried out within 3
hours with a coat of sulphate resisting cement-sand mortar 1:2. Smooth finishing
shall then be accomplished with a steel trowel.
5. Manholes and chambers shall be coated externally with three layers of asphaltic
composition that shall be applied by brush in accordance with manufacturer’s
instructions. Minimum thickness shall be 600 microns.
6. Internal faces of chambers shall be coated with four coats of coal tar epoxy paint,
70% epoxy and 30% coal tar. The coating shall be applied by brush in accordance
with manufacturer’s instructions. Minimum thickness shall be 1000 microns.

7. Internal faces of manholes shall be coated with GRP or HDPE and base surfaces
of manholes shall be covered with epoxy mortar.
8. Step irons shall be cast into precast units or grouted into preformed mortices.
Step irons shall not be used as lifting eyes. Devices for lifting and handling are to
be provided on exterior faces.
9. Adjustment of level shall be accomplished with concrete rings after completion of
surrounding levels. Final levels shall be even and accurate.
10. Fames for covers and gratings shall be solidly bedded in mortar and fixed firmly
using fixing bolts. Position centrally over opening and level and square with
surrounding finishes. Set cover in position to prevent twisting.
11. The Contractor shall test manholes as follows:
 Plug manhole inlets and outlets.
 Fill manhole with water and allow to stand for at least 24 hours or such longer
period to allow for complete absorption.
 Re-top with water.
 Allowable leakage over 24 hours shall not to exceed 1% of total volume of
manhole, otherwise necessary repair and re-testing shall be carried to achieve the
required results.
B Drop Manholes
1. For drops greater than 600 mm between the invert of pipe entering the manhole and crown
of pipe exiting the manhole, drop manholes shall be used. Pipes and connections of the
drop structure shall be wrapped with concrete Class “A” as shown in drawings.
C Valve Chambers (on Force Mains)
1. Construction shall be in situ concrete, precast concrete or blockwork as indicated on the

Drawings.
2. When masonry is used in lieu of concrete for square or rectangular structures, the
inside dimensions of the structure shall be of the dimensions shown on the
Drawings unless ordered otherwise by the Engineer. The mortar for masonry shall
be as specified in Section 5.01 “Concrete and Concrete Mixes and Testing “. The
brick or concrete block shall be laid with full mortared joints and with sufficient
header courses to tie the masonry together properly as approved by the Engineer.
3. External coating shall consist of two coats of asphaltic composition applied by
brush in accordance with manufacturer’s instructions. Minimum thickness shall be
400 microns.
4. The covers frame shall be set as per clause B.2 above.
D Inlets and Gullies
1. Construction shall be in situ concrete, precast concrete or blockwork as indicated on the

Drawings
2. When masonry is used in lieu of concrete for square or rectangular structures. This
will be as per clause B.2 above.
3. Castings shall be set in full mortar beds or otherwise secured as shown on the
Drawings and approved by the Engineer. Mortar for setting castings shall be
mixed as specified in Section 5.01 “Concrete and Concrete Mixes and Testing”.
Castings shall be set accurately to correct elevation so that no subsequent
adjustment is necessary
E Cleaning

1. All chambers, catch basins, catch pits, manholes, inlets and outlets shall be thoroughly
cleaned of any accumulations of silt, debris or foreign matter of any kind, and shall be free
from such accumulations at the time of final inspection.
F Coating
1. Structural steel cover plates shall be coated with two coats of coal tar epoxy 250 microns
dry film thickness.
G GRP Lining for Internal Surfaces of Manholes and Chambers:
1. GRP lined manholes and chambers shall be used in case of high aggressive soil and for
high sulphate acids, and shall be constructed in accordance with the Drawings and shall
incorporate a GRP lining at least 7 mm thick to all internal faces.
2. Benchings and channels shall be preformed, inverted and filled with concrete.
Alternatively, the GRP lining may be applied in situ after constructing the benching.
3. GRP lining to walls shall consist of a preformed tube of a white (or near white)
colour, incorporating lugs moulded onto the outside face at 500 mm centres to
allow bonding to the concrete surround. The lining shall have adequate strength to
withstand handing, and shall not buckle or distort during pouring of the concrete
surround. Internal bracing may be used during pouring to maintain circularity and
verticality.
4. Precast cover slabs shall incorporate a preformed flat sheet of white (or near
white) GRP on the soffit, bonded to a circular GRP tube to form the access
opening. Both linings shall incorporate lugs molded onto the surface to allow
bonding to the concrete.
5. The overall size of the lining to the soffit of the slab shall be 150 mm greater than
the internal diameter of the manhole onto which the slab is to be placed.
6. In all cases, the outer surface of the GRP, exposed to sewage/sewer atmosphere,
shall consist of a chemically resistant layer comprising vinyl ester resin suitably
reinforced with a “C” glass or synthetic tissue veil. This layer shall be no less than
2 mm thick, and shall have a resin content by weight of approximately 90% at the
exposed surface, reducing to 65%-75% at the inner surface. The remainder of the
liner shall consist of vinyl ester or isophthalic resins and “E” or “ECR” glass
chopped strand mat.
7. Joints in the lining tubes shall not normally be permitted.
8. Joints between preformed GRP benchings and lining tubes shall be made using an
external sleeve 200 mm long bonded onto both units, and then bandaged using
suitable resin and chopped strand mat. Such bandaging shall extend 75 mm either
side of the edge of the sleeve. On the inside face of the manhole, the joint
between the benching and liner tube shall be filled with vinyl ester paste to
produce a smooth finish.
9. If GRP linings to benching are to be formed in situ, the surface of the wall lining
tube shall be lightly abraded over a height of 150 mm from benching level. A fillet
of 50 mm radius shall than be formed of vinyl ester paste at the junction of
benching and wall. The GRP lining to the channels and benchings shall then be
built up by applying isophthalic or vinyl ester resin to the whole of the benching,
fillet and abraded wall lining. A layer of “E” or “ECR” mat shall then be rolled into
the resin using a suitable steel roller to exclude all air and provide complete
immersion of the glass fibre in the resin.
10. After a period to allow pre-gel to get to a tacky state, a second coat of resin shall
be applied followed by a further layer of glass fibre mat. This process shall be
repeated until the total thickness of lining is approximately 4 mm. Vinyl ester resin
and “C” glass or synthetic tissue veil shall then be used to complete the lining.
11. Top surface of benching shall incorporate silica sand to form a non-slip surface.

12. The precast cover slab shall be seated on the walls using sand/cement mortar.
The joint shall be raked out 15 mm deep on the inside face and pointed with an
approved pitch extended polyurethane sealant.
13. GRP ladders of an approved pattern as specified may be purpose made to suit the
depth of each manhole and chamber. Fixings for ladders shall be approved
stainless steel stud anchors. Fixings holes shall be grouted with epoxy mortar and
sealed as above. Rungs or treads shall be ribbed to provide a non-slip surface.
14. The Contractor shall provide the Engineer with a 7 year unconditional guarantee
against failure of all GRP linings whether caused by defective materials or
workmanship. The guarantee shall be valid from the date of completion of the
installation and must be handed to the Engineer before the issue of the Certificate
of Completion.
15. GRP sealing plates shall be provided to all sewage manhole chambers, sump and
holding tanks access covers. The sealing plates shall be capable of adequately
withstanding 10% sulphuric acid at 50 deg.C (122 deg. F) for a period of 100 days
and shall be a minimum of [] mm thick and shall be designed to withstand a
loading of 7.5 kN/m².
The sealing plates shall be in the form of a plug with a flange to accommodate restraining
bolts and to prevent the plate passing into the manhole. The plates shall incorporate a
synthetic rubber (neoprene or similar approve) sealing ring integrally fixed to the GRP plate
to produce a gas and sand tight joint between it and a specially profiled frame edge without
the use of restraining bolts. Two GRP lifting handles shall be provided securely laminated
to the plate. The underside of the plate shall have a resin rich finish and there shall be no
exposed fibres. Cut and/or drilled faces shall be sealed with resin. The resins and glass
used in the fabrication of the plates shall be generally as specified for GRP pipes.
H HDPE Lining for Manholes
The internal surfaces of manholes shall be properly protected against the corrosive and
aggressive effects of the wastewater on the long term. All concrete surfaces shall be
internally lined with suitable HDPE sheeting structured in the form of T lock, spiked, sure
grip or equivalent as approved and in accordance with the manufacturer
recommendations. Liners should be welded in a circular form and introduced during the
production of pipes. Liner thickness shall be 3 mm.
1. Physical characteristics of HDPE liners
 Density 0.94 g/cm3
 Temperature resistance up to 80˚C
 Friction equivalent to manning 0.013
 Water Absorption DIN 53495 – 0.25%
 Elongation at Yield DIN 53455/6/4 - 17%
 Elongation at Break DIN 53455/6/4 - min 400%
 Tensile Strength at Yield DIN 53455/6/4 - min 15 N/mm2
 Puncture Resistance DIN 16726 - 2000 mm
 Melt Flow rate/ index 190/5 ISO 1133
 Heat reversion 100°C/hr ASTM D1204 ≤ 1%
2. Chemical Properties
Unaffected by continuous exposure to dilute solutions of acids, alkaline chemicals,
corrosive salts, alcohols as they occur in sewage, petroleum products normally occurring in
sewage, vegetable and animal oils and fungus and bacteria.

The Contractor shall submit full details of the materials and their workmanship as per the
manufacturer recommendations and the Engineer’s approval. Special care shall be taken
to protect the surfaces between the manholes and the steps, inlet and outlet sewer pipes.
3. Installation
The seaming of concrete HDPE protective liners is carried out by extrusion welding. The
installation should only be performed by qualified and authorized installers. The following
should also be ensured:
 Stud shear force is over 1800 N/stud in longitudinal and horizontal directions
 High pull-out resistance of up to 42 t/m2, and 1000 N/stud
 High mechanical bond-long lasting sealing.
The lining shall be permanently and physically attached to the concrete with an anchoring
system manufactured from the same material as the lining and shall be suitable for casting
into concrete. The anchoring system shall withstand a pull out test of at least 18kN/m
applied perpendicular to the concrete surface for a period of one minute without rupture of
the anchors or withdrawal from the concrete.
Lining shall have a smooth glossy finish, be impermeable to gases and liquids and non
conducive to bacteria or fungus growth.
Lining shall be capable of being repaired at any time during the life of the structure in
accordance with the lining manufacturer’s instructions.
The lining shall be capable of withstanding a back hydrostatic pressure of 2 bars applied to
the under surface of the lining without losing anchorage and without rupture and leakage.
All lining shall be factory tested for pin holes using an electrical spark tester set at 20,000
volts minimum. Sheets having holes shall be satisfactorily repaired in the factory prior to
delivery.
PART 5 CONCRETE WORKS
5.1 CONCRETE AND CONCRETE MIXES AND TESTING
5.1.1 General
A Scope
1. These Works shall consist of the Specifications for concrete materials including sampling,
testing and storage of such materials, concrete strength requirements, concrete testing
procedures and requirements, and job mixes.
5.1.2 Materials
A Cement
1. Cement shall be Portland Cement, originating from manufacturers approved by the

Engineer and shall comply with ASTMC 150:97a and BS 12 or AASHTO M85 Type I in the
case of Ordinary Portland Cement and with BS 4027 or AASHTO M85 Type II or Type V
as directed by the Engineer in the case of Sulphate Resisting Portland Cement.
2. Only one type or brand of cement shall be used in any one structural member.
Mixing of types or brands will not be permitted.
3. All cement shall be subject to approval and shipments of cement shall be
accompanied by a manufacturer’s Certificate of Guarantee and/or laboratory test
certificate. Approval of any cement sample shall not relieve the Contractor of the
responsibility to fabricate concrete of the specified strength.

4. When tests at the factory or field tests subsequent to the original approval tests
show that the cement does not comply with the specifications, the entire
consignment from which the sample was taken shall be rejected and the
Contractor shall immediately remove the rejected material from the Site and
replace it with cement which meets the required specifications.
5. Whenever low alkali cement is specified the total alkali content estimated as
sodium oxide equivalent, shall not exceed 0.60% by weight. Approval of any
cement sample shall not relieve the Contractor of the responsibility to fabricate
concrete of the specified quality and strength.
6. If no local test certificate is available, the Contractor shall obtain from each
proposed manufacturer a typical sample of cement which shall be fully and
independently tested in accordance with the appropriate standard and the results
submitted for approval. Primary and secondary sources of the required cements
shall be given. All costs associated with the testing shall be allowed for by the
Contractor. All costs associated with the testing shall be allowed for by the
Contractor.
7. Details shall also be submitted of the manufacturer’s name and address of
producing works, manufacturer’s description of cement type and brand name and
standards to which compliance is guaranteed.
8. Average values and corresponding maximum and minimum values in respect of
the following composition and properties shall be submitted, covering a continuous
production period of at least 6 months ending not earlier than 3 months before
submission of the data. The Contractor shall state if any material or production
process changes have been made since the end of the above period; if any are
proposed, brief details shall be given.
Insoluble residue Lime saturation factor (LSF)

Silica (SiO2) Alumina-iron ratio (A/F)
Alumina (Al2O3) Tri-calcium aluminate (Ca3Al)
Total Iron (Fe2O3) Free lime in clinker (as CaO)
Calcium (CaO) Total acid solution alkalis
Magnesium (MgO) Heat of hydration
- at 7 days
- at 28 days
Potassium (K2O)
Sodium (Na2) Fineness (sq.m/kg)
Sulfate (SO3) Setting times
- Initial (min)
- Final (min)
Sulfur (S)
Chloride (Cl) Soundness (mm)
Loss on ignition Compressive strength
- 3 days
- 7 days
- 28 days
- 3 months

9. The requirement of item A.8 may be dispensed with at the discretion of the
Engineer, who shall give such dispensation in writing.
10. The manufacturer’s bulk average test certificate for each consignment of cement
shall be submitted, showing the results for chemical composition and physical
properties determined in accordance with the relevant standard. Samples shall be
taken for each consignment of cement and tested as directed by the Engineer in
an approved independent laboratory, at the cost of the Contractor.
11. Where bulk cement deliveries are proposed, the Contractor shall provide all
information required by the Engineer concerning off-site storage and loading
arrangements and shall provide reasonable facilities for the Engineer to inspect
these arrangements for approval purposes. Consignments shall be used in the
order in which they are delivered.
12. Storage capacity shall be sufficient to meet the schedule of work so that
continuous work is achieved. Cement shall be stored in moisture-proof storage
sheds. Neither stale, caked, nor reclaimed or re-sacked cement shall be used.
The Contractor shall not store cement in areas subject to flooding.
13. Cement remaining in bulk storage at the mill, prior to shipment, for more than 6
months or cement stored in bags in local storage by the Contractor or a vendor for
more than 3 months after shipment from the mill, must not be used for concrete
works.
B Aggregates
1. Potential aggregate sources shall be examined and particular attention shall be paid to the
following aspects of the deposits and the actual or proposed extraction and production
arrangements:
a) Name, location, local national grid reference, type of deposit, potential variability,
methods of extraction.
b) Methods and degree of control exercised over extraction.
c) Processing methods, types of plant, number of processing stages, standards of
maintenance and process control, producer’s laboratory facilities and technical staffing.
d) Stockpiling arrangements, loading and supply arrangements.
e) Potential variations in end-products due to variations inherent in the deposit and in
the existing methods of extraction, processing and stockpiling.
f) Possible modifications to existing extraction, processing, storage and handling
arrangements, and to supervision arrangements to reduce end-product variations.
g) Possible requirements for supplementary processing on site.
h) Photographs shall be provided of each of the proposed new sources and related
production arrangements. The source photographs should preferably include low level (helicopter)
aerial photographs and close-ups of working faces.
2. Aggregate deposits shall be sampled and tested in an appropriate and systematic
manner to assess their potential variability and to assist in determining appropriate
methods of extraction and processing.
3. The deposit investigation and sampling programs shall be relevant to each type of
deposit and shall be devised and supervised by an experienced approved
engineering geologist, after he has made a field reconnaissance of the potential
deposit areas, or the existing workings.
4. Each size of aggregate shall be sampled at the discharge points on the production
plant (i.e. conveyors or hoppers, not stockpiles) at three well spaced intervals
during the course of each of three consecutive production days; these samples
shall be designated “production samples”.

5. In addition, selected samples shall be taken from producer’s stockpiles to
represent any readily visible variations in physical characteristics, or appearance,
or materials ready for loading, these samples shall be designated “stockpile
samples”.
6. All samples shall be taken by arrangement with and in the presence of the
Engineer, or his representative, and shall be tested as required below.
7. Representative portions of the above samples shall be taken for reference
purposes and shall be split and retained on site by the Contractor and by the
Engineer.
C Testing Aggregates
1. Each production sample shall be tested for the following:

 Proportion of natural (uncrushed) material (% by weight) gradings, passing
75mm sieve (U.S. Sieve No.200 to AASHTO M92 or ASTM M81) when tested
in accordance to AASHTO T 11 .
 Total acid soluble chloride content and total acid soluble sulfate content (% by
weight).
 Flakiness and elongation indices.
2. Representative portions of equal weight shall be taken from each of the
production samples of each size of aggregate and then combined to provide
composite production samples for each size of aggregate. The composite
samples shall be tested as for the individual unless otherwise directed by the
Engineer. The tests shall be as follows:
a) Potential Reactivity tests for alkali-silicate and alkali-carbonate reactions:
petrographic examination in accordance with ASTM C295, rapid chemical method in
accordance with ASTM C289 and rock expansion test in accordance with ASTM
C586.
b) If one or more of the tests referred to above are positive then the mortar prism test in
accordance with ASTM C227 shall be carried out.
c) Partial chemical analysis, including insoluble residue (ASTM D3042-84), chloride
content, sulfate content and calculated approximate composition.
d) ASTM Soundness Test C88, using sodium sulfate solution or ASTM Soundness
Test C88, using magnesium sulfate solution.
e) Aggregate Impact Value by the Los Angeles test in accordance with AASHTO T96-
83 ASTM C131-81, ASTM C535-81.
f) 10% Fine Value to BS 812.
g) Aggregate Abrasion Value to BS 812.
h) Specific Gravities and Water Absorption to BS 812 or approved ASTM equivalent.
3. Stockpile samples shall be examined and tested in as many of the above

mentioned respects as are considered relevant by the Engineer.
4. The properties of the aggregates shall be such that the Drying Shrinkage of
concrete prepared and tested in an approved laboratory in accordance with the
United Kingdom Building Research Station Digest No. 35 (Second Series) shall
not exceed 0.045 percent. The Initial Drying Shrinkage of all the proposed
concrete mixes prepared and tested in an approved laboratory in accordance with
BS 1881 shall not exceed 0.06 percent.
5. Aggregate for use in concrete or mortar that will be subject to wetting, extended
exposure to humid atmosphere, or contact with moist ground, shall not contain
material that is deleteriously reactive with the alkalis in the cement, or any which

may be additionally present in the aggregates and mixing water or water in contact
with the concrete or mortar, in amounts sufficient to cause excessive localized or
general expansion of concrete or mortar. The following shall be observed:
a) Under no circumstances shall the Contractor use Dacite, Andesite, Rhyolites, Opal
Cherts and Tuffs.
b) Coarse and fine aggregates shall be tested for reactivity potential in accordance with
the methods listed above and shall satisfy the various criteria given for innocuous aggregates in
the relevant standard.
c) In case the aggregate source has no previous records and no performance history,
potential reactivity should be evaluated using the specified tests. However, if the aggregate has
been used in previous works in adjacent location and performed well without showing signs of
Alkali reaction, the results of these tests should not be used as the only factor deciding the usage
of the aggregate. The Engineer shall then decide on this matter.
d) The period of the tests is minimum 14 weeks to 26 weeks unless the accelerated
test is used instead of the mortar bar test (ASTM C227).
D Fine Aggregates
1. Fine concrete aggregates shall conform to AASHTO M6 and shall consist of natural sand
or crushed rock having hard and durable particles or, if approved by the Engineer, other
inert materials having similar characteristics, 100% passing 9.5 mm sieve and 2% to 10%
passing 0.15 mm sieve. It shall not contain harmful materials such as iron pyrites, coal,
mica, shale or similar laminated materials such as flat and elongated particles or any
materials which may attack the reinforcement in such a form or in sufficient quantity as to
adversely affect the strength, durability and texture of the concrete.
2. The Contractor shall, when directed by the Engineer, wash the fine aggregates to
remove deleterious substances or for consistency of concrete colour. Such
washing shall be carried out using fresh water. The water shall be replaced
regularly as deemed necessary to maintain its chloride and/or sulfate content low.
3. The total acid soluble sulfate content (BS 812: Part 118) of fine aggregate,
expressed as sulphur trioxide (SO3), shall not exceed 0.40% by dry weight
(AASHTO T260-82, BS812: Part 117). The total acid soluble chloride content,
expressed as sodium chloride (NaCl), shall not exceed 0.10% by dry weight of fine
aggregate. The following additional requirements shall apply to the concrete mix:
a) Total sulfate content (as SO3) of any mix, excluding that present in the cement but
including any present in the other materials, shall not exceed 2.5% by weight of
cement in the mix.
b) Total chloride content (as NaCl) of any mix, including any chloride present in the
other materials and in the mix water, shall not exceed 0.35% by weight of cement in the mix.
4. Fine aggregate shall meet the following additional requirements:
a) Fineness modulus, AASHTO M6: +0.20% of approved value which shall be not
greater than 3.1 or less than 2.3. Sieve analysis to AASHTO T27.
b) Sodium or Magnesium Sulfate Soundness AASHTO T104: max 12%, 18% loss
respectively.
c) Content of Clay Lumps and Friable Particles, AASHTO T112-82: 3% max.
d) Sand Equivalent AASHTO T176: min 75%.
e) Coal and Lignite, AASHTO T113-82: 0.5% Max.
f) Organic Impurities AASHTO T21-81: darker than standard colour.
5. The amount of hollow shells likely to form voids and present in material retained on
a 2.36 mm sieve determined by direct visual separation, shall not exceed 3% by
weight of the entire sample.

6. When sampled and tested in accordance with the appropriate sections of BS 812
(using BS 812 test sieves) the grading of fine aggregates shall be within the limits
of the grading zones given in Table 4 of BS 882. The fine aggregate shall be
described as a fine aggregate of the grading zone into which it falls.
7. If the fineness modulus varies by more than 0.2 from the value assumed in the
concrete mix design, the use of such fine aggregate shall be discontinued until
suitable adjustments can be made in the mix proportions to compensate for the
difference in gradation.
E Coarse Aggregates
1. Coarse concrete aggregates shall conform to AASHTO M80 and shall consist of gravel,
crushed gravel, or crushed stone free from coating of clay or other deleterious substances.
It shall not contain harmful or any other materials which may attack the reinforcement in
such a form or in sufficient quantity as to adversely affect the strength and durability of the
concrete. If necessary, coarse aggregate shall be washed to remove deleterious
substances, or for consistency of concrete colour.
2. The total acid soluble sulfate content (BS812: Part 118) of coarse aggregate
expressed as sulphur trioxide (SO3), shall not exceed 0.40% by weight (AASHTO
T260-82, BS812: Part 117). The total acid soluble chloride contents of coarse
aggregates, expressed as sodium chloride (NaCl), shall not exceed 0.05% by
weight. These limits are subject to the following overriding requirements:
a) The total sulfate content (as SO3) of any mix, excluding that present in the cement
but including any present in the other materials, shall not exceed 2.5% by weight of
cement in the mix.
b) The total chloride content (as NaCl) of any mix, including any chloride present in the
other materials and the mix water, shall not exceed 0.35% by weight of cement in the mix.
3. Coarse aggregate shall also meet the following additional requirements:
a) Sodium or Magnesium Sulfate Soundness AASHTO T104: 5 cycles: Max 12%, 18%
loss respectively.
b) Abrasion, in Accordance with AASHTO T96 Max 40% loss.
c) Content of Clay Lumps and Friable Particles AASHTO T112-81: Max 1% by weight.
d) Soft Fragments and Shale AASHTO M80: max 5% by weight.
e) Flakiness Index, BS812: 30% max. Elongation index, BS 812:30% max.
f) Coal and Lignite, AASHTO T113-82: 0.5% max.
4. The grading of coarse aggregate shall comply with AASHTO M43.
5. The coarse concrete aggregate, when tested according to AASHTO T27, shall
meet the following gradation requirements and shall be graded within the limits
stated in Table 5.1.1.
Table 5.1.1: Limits of Gradation for Coarse Aggregates

AASHTO Percent Passing by Weight for
Sieve Grading Grading
mm Grading I Grading II Grading III Grading V
Size IV VI
3' 75 100 - - - - -
2 1/2" 63 - 100 - - - -
2" 50 90-95 95-100 100 - - -
1 1/2" 37.50 - - 95-100 100 - -
1" 25.0 30-65 35-70 - 95-100 100 -

3/4" 19.0 - - 35-70 - 95-100 100
1/2" 12.5 10-30 10-30 - 25-60 - 90-100
3/8" 9.5 - - 10-30 - 20-55 40-70
No. 4 4.75 0-5 0-5 0-5 0-10 0-10 0-15
No. 8 2.36 - - - 0-5 0-5 0-5
No. 200 0.075 0-1 0-1 0-1 0-1 0-1 0-1
6. The type of grading for coarse concrete aggregates shall depend on the maximum
size of aggregate, which shall not be larger than one-fifth (1/5) of the narrowest
dimension between sides of forms, nor larger than two-thirds (2/3) of the minimum
clear spacing between reinforcing bars, whichever is least.
7. Before batching, all types of coarse aggregate shall be separated into fractions
having uniform grading as determined by the Engineer.
8. However, the number of fractions and their gradings shall be fixed on the basis of
the maximum size of the aggregates in the cement concrete as proposed below
 For fractions up to 1-1/4”: between 3/8” and 3/4”
(31.5 mm) (9.5 - 19.0 mm).
 For fractions up 1-1/2” to 3”: between 3/4” and 1-1/4”
(37.5-75 mm) (19.0 - 31.5 mm)
F Combined Aggregates
1. Combined aggregate is composed of a mixture of coarse aggregates and fine aggregates.

They shall be used only in proportions with the prior approval of the Engineer.
2. In no case shall materials passing the No. 200 (0.075 mm) sieve exceed 3% by
weight of the combined aggregate.
3. The combined concrete aggregate gradation used in the work shall be as
specified, except that when approved or directed by the Engineer. Grading 7 of
Table 5.1.2 shall be used for curbs, handrails, parapets, posts and other similar
sections or members with reinforcement spacing too close to permit proper
placement and consolidation of the concrete.
4. Changes from one gradation to another shall not be made during the progress of
work, unless approved by the Engineer.
5. For the proportion of each fraction of coarse aggregate and for the proportion of
fine and coarse aggregate, the combined gradings in Table 5.1.2 shall be utilized
as a guideline for the mix proportion design as to guarantee the maximum
densities of the concrete. Before batching, however, the Engineer or his
representative shall check only the compliance of the grading of the fine and
coarse aggregate with the requirements of the Specifications, since the grading of
each fraction ultimately remains the sole responsibility of the Contractor.
Table 5.1.2: Limits of Gradation for Combined Aggregates

AASHTO Combined Aggregate Percent Passing by Weight for
Sieve
mm Grading 1 Grading 2 Grading 3 Grading 4 Grading 5 Grading 6 Grading 7
Size
3" 75 100 - - - - - -
2 1/2" 63 88-95 100 - - - - -

2" 50 78-90 88-95 100 100 - - -
1 1/2" 37.50 66-81 74-86 80-92 93-98 100 - -
1" 25.0 51-70 56-75 63-80 70-88 87-96 100 -
3/4" 19.0 43-62 47-67 52-72 60-79 73-86 80-96 100
1/2" 12.5 32-53 36-58 41-60 47-66 57-74 61-80 73-86
3/8" 9.5 27-48 30-53 36-54 40-60 48-68 52-72 61-79
No. 4 4.75 19-38 22-42 23-43 28-49 34-55 38-56 43-64
No. 8 2.36 9-27 10-29 12-30 16-36 24-40 25-41 26-46
No. 16 1.18 4-19 5-21 6-22 7-25 9-28 11-29 13-33
No. 30 0.600 3-15 4-17 4-19 5-21 7-23 8-24 10-28
No. 50 0.300 2-11 2-13 2-14 2-15 4-17 5-19 5-21
No.100 0.150 1-7 1-8 1-8 1-9 2-10 2-11 2-12
No.200 0.075 0-3 0-3 0-3 0-3 0-3 0-3 0-3
G On Site Storage of Aggregates
1. Adequate stocks of tested and approved aggregates shall be maintained on site and the
capacity of the storage bins for each type and grading of aggregate shall be sufficient to
hold the respective quantities required for the maximum amount of concrete which the
Contractor is obliged or intends to pour in any continuous operation in one day. Stockpiles
shall be built in layers of 1.50 m maximum height and segregation of the aggregates
prevented. Different grades of aggregates shall be totally separated by concrete block
walls.
2. Dense concrete or bituminous slabs shall be laid with sufficient falls to cover all
aggregate stockpile areas or bins and shall extend to cover all surrounding areas
where aggregates are likely to be discharged or handled. These areas shall be
swept and kept clean at all times to ensure that the aggregates are not
contaminated by the adjacent ground through trafficking or otherwise, and shall be
constructed with adequate drainage for surplus water.
3. Windbreaks shall be provided where aggregates might suffer excessive
contamination by windblown materials. During periods of heavy rain the bins or
compounds shall be covered by tarpaulins or other approved means.
H Rejection of Aggregates
1. The general or localized build up of fines in aggregate stockpiles shall not be allowed and
any material which, in the opinion of the Engineer, is so affected will be rejected after
testing.
2. Aggregates which have suffered segregation or contamination during processing,
handling at source, transportation to the site, stockpiling and handling on site, or
which otherwise do not conform with requirements of the Specifications, either
locally or generally, will be rejected and shall be removed promptly from the site.
3. Aggregates which are found to be contaminated during transportation or during
stockpiling or during handling shall be promptly removed from the site by the
Contractor notwithstanding any prior approval of the source which may have been
given by the Engineer.
I Washing and Processing Aggregate
1. The Contractor may be required to carry out on site supplementary processing or effective
washing of coarse and fine aggregates where the aggregate producer’s methods, in the

opinion of the Engineer, may not result in end products which consistently comply with all
requirements of the Specifications, or where aggregates suffer unacceptable changes
during loading at source or during subsequent transportation to the site, or otherwise.
J Water
1. All sources of water to be used with cement whether for mixing or curing of concrete, or
compaction of backfill around the concrete structures, shall be approved by the Engineer. If
at any time during construction, water from an approved source becomes unsatisfactory,
the Contractor shall provide satisfactory water from other mains sources.
2. Water shall be free from injurious quantities of oil, alkali, vegetable matter and salt
as determined by the Engineer. The water shall be reasonably clear and shall
contain not more than one quarter (0.25) percent solids by weight. Water shall
comply with the requirements of AASHTO T26 and BS 3148. If the specific
conductance is less than 1500 microohms per centimeter the total solids content
requirement may be waived.
3. Non-potable water may be used when potable water is not available provided the
impurities do not exceed the values given in Table 5.1.3.
4. Mortar prepared with water submitted by the Contractor for approval shall show no
marked change in time of set, no indication of unsoundness and a reduction of not
more than ten (10) percent in mortar strength when compared with mortar made
with water of known satisfactory quality.
5. The water used in the mix design shall be the same as the water approved for site
use.
6. Water used for prestressed concrete structures or for concrete containing or in
contact with aluminium fittings or fixtures shall not contain chloride ions.
Table 5.1.3 : Maximum Permitted Impurities in Non-Potable Water

Impurity Max. Concentration Method
(ppm)
Chloride as (Cl-)
a) Prestressed concrete or concrete in bridge decks 500 ASTM D512
b) Other reinforce concrete in moist environment or 1000

containing aluminum embodiments or dissimilar metals or
with stay in place galvanized metals form
Sulfates as SO4 300 ASTM D516
Alkalis as
(Na2O+K2O) 600 AASHTO T-26
Total solid 5000
K Admixtures
1. The quantity and method of using admixtures shall be in accordance with the
manufacturer’s recommendations and in all cases shall be subject to the approval of the
Engineer.
2. In all cases the Contractor shall provide the following information for the
Engineer’s approval:
a) The quantity to be used, in kilograms per kilogram of cement and in kilograms per
cubic meter of concrete.
b) The detrimental effects caused by adding a greater or lesser quantity in kilograms
per cubic meter of concrete.

c) The chemical name(s) of the main active ingredient(s).
d) Whether or not the admixture leads to the entraining of air.
3. The Contractor shall demonstrate the action of an admixture by means of trial
mixes.
4. The use of calcium chloride in any form is prohibited.
5. Reference may be made to ACI Committee 212 report “Guide for Use of
Admixtures in Concrete”.
L Admixture to Produce High Workability
1. Concrete for use in certain construction shall contain an approved superplasticising agent,
when so directed by the Engineer. The superplasticiser shall be stored and used strictly in
accordance with the manufacturer’s instructions and must be fully compatible with all
proposed concrete mix constituents. The optimum dosage of the additive shall be
determined by site and laboratory trials to the Engineer’s approval. The Contractor shall
submit to the Engineer full details of his proposed mix design which must ensure that the
minimum strength requirements as specified for the particular use of the concrete are
achieved. Only when the Engineer has approved the proposed mix design may such a mix
be used in full compliance with the Specifications.
2. The Contractor’s mixing and transporting plant shall be so designed that accurate
metering of the superplasticising agent is possible and so that the additive may be
introduced immediately before placing.
M Admixture to Increase Density
1. Silica Fume: silica fume (SF) may be used as a cement replacement and shall be in
accordance with ASTM C1240-05. There shall be a maximum of 5 percent replacement of
the OPC. The silica fume shall be obtained from an approved supplier.
The approved supplier shall provide documentation to establish the following:
a) that the silica fume complies with ASTM C1240-05.
b) The silica fume results from the production of silicon or ferro-silicon alloys containing
at least 85 percent silicon.
c) That source of supply shall remain the same for the construction period of the
project.
d) That the supply shall be adequate to meet the anticipated peak requirement.
e) Chemical analyses to give the percentages of the following materials:
 Si 02 (Min. 85) C (Percentage 4)
 Ca 0 (Max. 1.0) Mg O (Percentage 5)
 S 03 (Max. 3.0) CL (Max. 0.1)
 Loss on ignition as low as possible.
 Percentage of particles retained on 45 micron sieve (maximum 10).
 Specific surface area and method of test, together with corresponding particle
size (minimum 15m2/g)
Delivery of silica fume to the concrete batching plant shall be in dry powder form, with a
bulk density between 200 and 650 kg/cu.m.
Manufacturer’s test certification shall be supplied for each delivery of silica fume and shall
confirm that the silica fume complies with the above requirements and shall be submitted
by contractor not later than the day of delivery of the silica fume.

Engineer shall have the right to call for tests, the cost of which are to be borne by the
contractor, on each delivery of silica fume, if necessary to establish or confirm that the
silica fume meets the above requirements.
5.1.3 Definitions
A Crushing Strength
1. The crushing strength of a test cylinder prepared in accordance with AASHTO T23 and
AASHTO T126. Alternative standard cubes may be tested in accordance to BS
specifications.
B Average Strength
1. The mean of the crushing strengths of specimens taken from a sample of concrete.
C Characteristic Strength
1. The value of the crushing strength below which 5% of the population of all possible
strength measurements of the specified concrete are expected to fall.
D Fresh Concrete
1. Concrete during the initial period of two hours from the addition of water to the cement.
E Batch
1. The quantity of concrete mixed in one cycle of operations of a batch mixer or the quantity
of concrete conveyed ready-mixed in a vehicle, or the quantity discharged during one
minute from a continuous mixer.
F Sample
1. A quantity of concrete taken from a batch whose properties are to be determined.
G Regular Sampling
1. The sampling of concrete nominally of the same mix received regularly from the same
source.
H Specimen
1. Cylinder or cube taken from a sample for testing.
5.1.4 Concrete Strength Requirements
A Design Mixes
1. Mixes for the classes of concrete shown in Table 5.1.4 shall be designed by the
Contractor, when specified for use in any part of the Works. The quantity of water used
shall not exceed that required to produce a concrete with sufficient workability to be placed
and vibrated in the particular locations required. Unless otherwise approved by the
Engineer, the mix designs shall be on the basis of continuously graded aggregates and all
mix designs shall be submitted to the Engineer for approval.
2. The Cement content in any mix shall not exceed 450 kg/cu.m.
3. The 7-day compressive strengths shall not be less than 75% of the specified 28
day strengths. If the 7 days results are below 75% of the required 28 days
strength, the Contractor may postpone works related to the suspected concrete
until the 28 days results are available and successful, or if the Contractor decides
to continue work, he may do so under his own responsibility and risk.
4. The ultimate cylinder compressive strength of concrete shall be determined on test
specimens obtained and prepared in accordance with AASHTO T23 and AASHTO

T126 except that six inch by twelve inch cylinders shall be used for all compression
tests. Alternatively, the Engineer may require ultimate compressive strength of
concrete to be determined on test specimen obtained by taking and airing cubes in
accordance with BS 1881. The Contractor shall furnish single-use cylinder moulds
conforming to AASHTO M205, or when approved by the Engineer, re-usable
vertical moulds made from heavy gauge metal.
Table 5.1.4: Concrete Class and Design Mixes

Cylinder Works Equivalent Works Cube Maximum Size of
Class of Minimum Cement
Strength @ 28 Days Strength @ 28 Days Aggregate
Concrete Content kg/m3
kg/cm2 kg/cm2 mm
110/25 110 140 25 220
140/25 140 180 25 250
170/60 170 210 60 275
210/50 210 260 50 300
210/25 210 260 25 325
210/20 210 260 20 325
250/20 250 310 20 350
250/30 250 310 30 350
310/20 310 385 20 375
360/20 360 450 20 425
B Nominal Concrete Mix
1. Concrete for use as backfilling for structural excavation shall be either no-fines concrete or
cyclopean concrete as directed by the Engineer. The cement : aggregate ratio of such
nominal mixes shall be not greater than 1:15 and the minimum cylinder strength at 28 days
not less than 50kg/cm2.
2. No-fines concrete shall comply with the grading in Table 5.1.5 and shall be mixed
and laid in general conformity with this Section 5.01.
3. Plums used in cyclopean concrete shall consist of non-reactive broken stone
spalls or boulders ranging in size from 200mm to 300mm. They shall be free from
sharp or angular edges and shall not form more than 30% of the total volume of
concrete. They shall be evenly graded and shall be soaked in water prior to
incorporation in the mix. Plums shall be evenly distributed in the concrete mix with
a minimum cover of 100mm.
Table 5.1.5: Grading For No-Fines Concrete

GRADING OF AGGREGATE % by Dry Weight
Sieve Size Passing
90 mm 100
40 mm 85-100
20 mm 0-20
10 mm 0-5
C Compliance with Strength Requirements
1. Cylinders (or cubes) from concrete as mixed for the Work will be tested in accordance with
AASHTO T22 (BS 1881 for cubes) after seven (7) days and twenty eight (28) days. Test

specimens shall be made and cured in accordance with AASHTO T23. These specimens
will be the basis for acceptance of the concrete in the structure.
2. Prior to the commencement of any concreting work and subsequently, whenever a
change is intended, preliminary tests shall be carried out. From each of three
samples of materials, a trial mix shall be made. For each class of concrete, the trial
mixes shall represent at least two different water cement ratios. From each trial
mix, six cylinders (or cubes) shall be made, three for testing at 7 days, and three
for testing at 28 days. The average strength of the cylinders (or cubes) tested for
each sample shall be taken as the preliminary cylinder (or cube) strength of the
mix.
3. The Engineer will require the preliminary test to be repeated if the difference in
strength between the greatest and the least strength is more than 20 per cent of
the average.
4. The water /cement ratio and slump adopted in the preliminary tests for each class
of concrete shall be used in the works concrete. It shall be such that, if selected for
use at the Site, the concrete can be worked readily into the corners and angles of
the forms and around the reinforcement without permitting the materials to
segregate, or free water to collect on the surface.
5. Preliminary tests shall have these minimum ultimate strengths given in Table 5.1.6.
6. During the first four days of the commencement of concreting with any particular
mix, two sets of six works cylinders (or cubes) in each set shall be made each day.
Three cylinders (or cubes) from each set shall be tested at 7 days, and 3 at 28
days. The above works tests shall be carried out for each class of concrete.
Subsequently, the frequency of making sets of test cylinders (or cubes) and the
number in each shall be as directed by the Engineer.
Table 5.1.6: Preliminary Tests for Strength

Equivalent Cube Strength
Class of Concrete Cylinder Strength (kg/cm2)
(kg/cm2)
110/25 170 210
140/25 210 260
170/60 240 300
210/50 290 360
210/25 290 360
210/20 290 360
250/20 325 400
250/30 325 400
310/20 395 490
360/20 440 550
7. The cylinders (or cubes) shall be cured in the same manner and environment as
the members they represent. The cylinder (or cube) strength shall be accepted as
complying with the specified requirement for work cylinder (or cube) strength if
none of the compressive strengths of the cylinders (or cubes) falls below the
minimum strengths given in Table 5.1.4 or if the average strength is not less than
the specified minimum works cylinder (or cube) strength and the difference
between the greatest and least cylinder (or cube) strength is not more than 20 per
cent of the average.
8. Alternatively, the criterion of acceptable test results shall be that not more than 5
per cent of works cylinders fall below the specified strength. For this to be fulfilled,
the mean strengths of works cylinders (or cubes) less 1.64 times the standard
deviation should not be less than the required strength. This calculation shall be

made for both 7 and 28 day cylinder (or cube) tests as soon as 24 cylinders (or
cubes) have been tested at each age. Thereafter, it shall be repeated as further
test results become available at a frequency determined by the Engineer. The
number of cylinders (or cubes) considered in each calculation shall be the total
number of cylinders (or cubes) of the mix in question tested from the
commencement of the Works.
9. Cores shall be taken in accordance with ACI 318-95, article 5.6.4, and tested in
accordance with AASHTO T24. Load testing shall be carried out in accordance
with ACI 318-89, chapter 20. The Contractor shall hire an authorized independent
laboratory to carry out such tests at no extra cost to the Client.
10. The Engineer may make additional test cylinders to ascertain the effectiveness of
the methods by which the structure is being cured, and also to determine when the
structure may be placed in service. These cylinders shall be cured in the field in
the same manner as the concrete placed in the structure, and the Contractor shall
protect the cylinders from all damage.
11. The Contractor shall take every precaution to prevent injury to the test cylinders
during handling, transporting and sorting. He will be held solely responsible for any
test failure caused by improper handing and transportation, or any other cause
which may be detrimental to the test cylinder.
12. In order that the test cylinders may be transported from field to laboratory
undamaged, the Contractor shall provide a minimum of two (2) approved boxes.
[One (1) for the Contractor’s use and one (1) for the Engineer’s use.] Boxes shall
be of such size to receive a minimum of six (6) test cylinders and leave space for
sawdust packing around all surfaces of the cylinders. Boxes shall be approved by
the Engineer. The Contractor shall, when directed by the Engineer, provide as
many additional boxes as may be required by the remoteness and/or magnitude of
the concrete work.
13. When test cylinders fail to meet minimum strength requirements, the Engineer may
require core samples to be taken to determine the acceptability of such structures.
The Contractor shall, at his own expense, furnish all equipment required for such
core samples.
5.1.5 Composition of Concrete
A Mix Proportions
1. The Contractor shall consult with the Engineer as to mix proportions at least forty-five (45)
days prior to beginning concrete work. The actual mix proportions of cement, aggregates,
and water shall be determined by the Contractor under the supervision of the Engineer.
2. The Contractor shall, in the presence of the Engineer, prepare trial-mixes for each
class of concrete required for the project, made with the approved materials to be
used in the Work. The proportions of the trial-mixes shall be such as to produce a
dense mixture containing the cement content specified and meeting the plasticity
requirements and the preliminary test strength requirements specified for the
designated class of concrete.
3. If the materials supplied by the Contractor are of such a nature or are so graded
that proportions based on minimum cement content cannot be used without
exceeding the maximum allowable water content, the use of admixtures to
maintain the water content within the specified limit shall be permitted. At all times
the concrete mix shall satisfy the durability requirements by satisfying the minimum
and maximum limits specified of cement and water contents respectively. No
additional payment shall be paid due to adding extra amount of cement to the mix.
4. The Engineer will review the Contractor’s trial - mixes and break the test cylinders
at seven (7) and twenty-eight (28) days. The Engineer will then determine which of
the trial-mixes shall be used. If none of the trial-mixes for a class of concrete meets
the specifications, the Engineer will direct the Contractor to prepare additional trial-

mixes. No class of concrete shall be prepared or placed until its job-mix
proportions have been approved by the Engineer.
5. The approval of the job-mix proportions by the Engineer, or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements specified in
these specifications.
6. All costs connected with the preparation of trial-mixes and the design of the job-
mixes shall be borne by the Contractor, except that the Engineer shall not charge
the Contractor for laboratory supervision and the breaking of the test cylinders.
B Design Limits
1. The following will be designated by the Engineer within the limits of the specifications:
a) The minimum cement content in sacks per cubic meter of concrete.
b) The maximum allowable water content in litres per sack of cement, or equivalent
units, including surface moisture, but excluding water absorbed by the aggregates.
c) The ratio of coarse and fine aggregates.
d) Slump or slumps designated at the point of delivery.
C Changes to Mix Design
1. Changes in mix proportions requested by the Contractor to previously approved mix

designs shall only be made after new approval by the Engineer.
2. When, in the opinion of the Engineer, cement is being lost due to windy conditions,
the Contractor shall add additional amounts of cement as directed by the
Engineer. No additional payment will be made for the added cement.
3. As the work progresses, the Engineer reserves the right to require the Contractor
to change the proportions from time to time if conditions warrant such changes to
produce satisfactory results. Any such change may be made within the limits of
the specifications at no additional compensation to the Contractor.
4. When in the opinion of the Engineer, an adjustment for protection against concrete
deterioration due to salty environment is necessary, he may require the cement
content be increased ten (10) per cent over and above that cement content used in
the approved trial-mix design for non-salty environment. Water content shall be
adjusted accordingly to obtain a dense workable mix. All Structure footings and
column lengths to the first construction joint above the ground surface for the
entire project are subject to this increased cement content. No additional payment
will be made for the increase in cement content.
5. Failure of the mix to meet specifications determined by the Engineer under items A
and B in this sub-section will be grounds for the Engineer to reject the concrete.
6. Mortar for laying stone for grouted stone riprap, grouted stone wash checks or
grouted stone ditch lining shall be composed of one (1) part of portland cement
and three (3) parts of fine aggregate by volume with water added to make a
workable mix of such consistency as to perform properly the functions required for
the work being done. Amount of water added shall be approved by the Engineer.
The following criteria shall be observed:
a) Aggregates for masonry mortar shall conform to AASHTO M45.
b) Portland cement shall conform to AASHTO M85, Type I, II or III.
5.1.6 Requirements for Combining Materials
A Measurement for Proportioning Materials

1. The cement shall be measured in bulk or as packed by the manufacturer, a sack of cement
shall weigh 50 kilograms. Measurement shall be accurate to within 3.0 per cent throughout
the range of use.
2. The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within 2.0 percent throughout the range of use.
3. The aggregates shall be measured by weight. The measurement shall be
accurate to within (+ or - 2.0% fine , coarse aggregates) throughout the range of
use.
4. Additives shall be measured by volume if in liquid form and by weights if solid. The
measurement shall be accurate to within 3.0 per cent throughout the range of use.
B Assembly and Handling of Materials
1. Aggregates shall be assembled in such quantities that sufficient material approved by the
Engineer is available to complete any continuous pour necessary for structures. The
batching site shall be of adequate size to permit the stockpiling of sufficient unsegregated
materials having proper and uniform moisture content to ensure continuous and uniform
operation. Aggregates shall enter the mixer in a manner approved by the Engineer and so
as to ensure that no matter foreign to the concrete or matter capable of changing the
desired proportions is included. In the event that 2 or more sizes or types of coarse or fine
aggregates are used on the same project, only 1 size or type of each aggregate may be
used on one continuous pour.
2. All aggregates shall be stockpiled before use in order to prevent segregation of
material, to ensure a uniform moisture content, to provide uniform conditions for
proportioning plant control and to aid in obtaining concrete that is uniform as to
materials and moisture content. The use of equipment or methods of handling
aggregates which results in the degradation of the aggregates is strictly prohibited.
Bulldozers with metal tracks shall not be used on coarse aggregate stockpiles. All
equipment used for handling aggregates shall be approved by the Engineer.
Stockpiling of aggregates shall be in the manner approved by the Engineer, and in
addition, every precaution shall be taken to prevent segregation. Segregation
shall be prevented by making no layer higher than 1.5 meters and if 2 or more
layers are required, each successive layer shall not be allowed to “cone” down
over the next lower layer. Aggregates shall not be stockpiled against the supports
of proportioning hoppers and weighing devices.
3. Segregated aggregates shall not be used until they have been thoroughly remixed
and the resultant pile is of uniform and acceptable gradation at any point from
which a representative sample is taken. The Contractor shall remix aggregate piles
when ordered by the Engineer.
4. If aggregates are to be transported from a central proportioning plant to the mixer
in batch-boxes or dump trucks, such equipment shall be of sufficient capacity to
carry the full volume of materials for each batch of concrete. Partitions separating
batches shall be approved by the Engineer and shall be adequate and effective to
prevent spilling from one compartment to another while in transit or being dumped.
5. Cement may be stored in bulk (unpacked) or in bags in securely locked dry places.
The following shall apply:
a) All cement bags shall be marked with the date of manufacture. Additionally, all bags
shall be marked with the date of storage so that they can be taken out for use in the
same order as they were brought in to storage.
b) Cement bags shall be placed on wooden shelves at least 100 mm above ground
and 150 mm clear of walls.
c) Unpacked cement shall not be used six months after manufacture and bagged
cement three months after manufacture.
d) No cement shall be used which has been affected by humidity, regardless of the
date of manufacture.

e) Cement shall be transported to the mixer in the original sacks. Each batch shall
contain the full amount of cement for the batch. Batches where cement is placed in contact with
the aggregates may be rejected unless mixed within 1.5 hours.
C Mixing
1. Concrete shall be mixed in quantities required for immediate use. Concrete which has
developed initial set shall not be used. Retempering concrete by adding water or by other
means will not be permitted. Concrete that is not within the specified slump limits at the
time of placement shall not be used and shall be disposed of as directed by the Engineer.
a) If washed sand is used while still wet the mixing time starts with the addition of
cement to the aggregate, even if the water required for the mixing has not been
added.
2. The concrete may be mixed at the site of the Works, in a central-mix plant, or in
truck mixers. The mixer shall be of an approved type and capacity. Ready-mixed
concrete shall be mixed and delivered in accordance with the requirements of Sub-
Section 5.01.7 “Ready-Mixed Concrete and Central-Mixed Concrete”.
3. The coarse aggregate shall first be loaded into the mixer followed by the fine
aggregate. Some mix water shall be added to the mix before the cement is loaded
into the mixer. Water shall be continually added throughout the mixing. Additives,
if required and approved by the Engineer, shall be added according to the
manufacturers’ instructions. Retarders shall be added within one minute or 25% of
the total mixing time whichever is the smaller.
4. The manufacturers’ instructions shall be followed in respect of overloading the
mixer and the selections of the rate of revolutions of the mixer.
5. To avoid segregation in the fresh concrete, the free drop height on emptying the
mixer shall be not greater than 1.5 meters.
6. After mixing, the concrete shall be homogeneous and comply with the provisions
of these specifications. The Engineer may, if the mix fails to produce concrete of
the required strength vary the mix time.
D Central Mixing
1. Means provided for storing cement shall be as approved by the Engineer. The Contractor
shall clean all conveyors, bins and hoppers of unapproved cement before starting to
manufacture concrete for the Works.
2. Coarse and fine aggregate to be used in concrete shall be kept in stockpiles and
bins apart from aggregate used in other work. Aggregate shall come from a source
approved by the Engineer. The Contractor shall clean all conveyors, bins and
hoppers of unapproved aggregate before starting to manufacture concrete for the
Works.
3. The Contractor shall be responsible for producing concrete that is homogeneous
and complies with the provisions of these specifications.
4. Mixed concrete from the central-mixing plant shall be transported in truck mixers,
truck agitators, non-agitating trucks having special bodies or other approved
containers.
5. The time elapsing from the time water is added to the mix until the concrete is
deposited in place shall be not greater than:
a) For concrete produced on site and transported by means other than transit mixers or
agitated trucks.
 Thirty minutes when air temperature is 25°C or higher.
 Forty minutes when air temperature is 18°C or below.
 Interpolated time between 18°C and 25°C.

b) For concrete transported by transit mixer or agitators, the time taken for 300
revolutions of the transit mixer or agitator or 20 minutes, whichever is the lesser.
c) The maximum haul time may be reduced at the Engineer’s discretion if the slump
changes or there are signs of the concrete beginning to dry.
6. The Contractor when supplying concrete from a central plant shall have sufficient
plant capacity and transporting equipment to ensure continuous delivery at the rate
required. The rate of delivery of concrete during concreting operations shall be
such as to provide for the proper handling, placing and finishing of the concrete.
The method of delivery and handling the concrete shall be such as will facilitate
placing with a minimum of rehandling and without damage to the structure or the
concrete. Methods of delivery and handling for each site shall be approved, by the
Engineer. The Engineer may delay or suspend the mixing and placing of concrete
at any site, for which he considers the Contractor’s delivery equipment inadequate,
until such time as the Contractor provides additional approved delivery equipment.
5.1.7 Ready-Mixed Concrete and Central Mixed Concrete
A General
1. “Ready-Mixed Concrete” and “Central-Mixed Concrete” shall consist of a mixture of

cement, water and aggregate, without air entraining or water-reducing admixture. When
air-entraining or water-reducing or any other type of admixture is required it shall be at the
Engineer’s discretion. The terms ready-mixed or central-mixed concrete shall include
transit-mixed concrete and will be referred to hereinafter as ready-mixed concrete.
2. Ready-mixed concrete may be used in the construction of all Works, when
3. Approval of any ready mixed concrete plant will be granted only when an
inspection of the plant indicates that the equipment, the method of storing and
handling the materials, the production procedures, the transportation and rate of
delivery of concrete from the plant to the point of use, all meet the requirements
set forth herein.
4. Ready-mixed concrete shall be mixed and delivered to the point of use by means
of one of the following combinations of operations:
a) Mixed completely in a stationary central mixing plant and the mixed concrete
transported to the point of use in a truck mixer or tank agitator operating at agitator
speed, or when approved by the Engineer, in non-agitating equipment (known as
“central-mixed concrete”).
b) Mixed completely in a truck mixer at the batching plant or while in transit (known as
transit-mixed concrete).
c) Mixed completely in a truck mixer at the point of use following the addition of mixing
water (known as truck-mixed concrete).
5. Permission to use ready-mixed concrete from any previously approved plant may
be rescinded at any time upon failure to comply with the requirements of the
Specification.
B Materials
1. All materials used in the manufacture of ready-mixed concrete shall conform to the
requirements of Sub-Section 5.01.2 “Materials”.
C Equipment
Equipment shall be efficient, well maintained, and shall be of the type and number as
outlined in the Contractor’s Program of Work. Transit mixers and agitator trucks shall
comply with the standards specified in ASTM C94. Non-agitating equipment used for
transporting concrete shall be water tight and be equipped with gates that will permit

controlled discharge of concrete and, when required by the Engineer, be fitted with covers
for protection against the weather.
D Supply
1. Where transit mixers are used, the constituent materials shall be mixed dry in the mixer
and water added directly before pour and mixed at the speed and number of turns in
accordance with the manufacturers’ recommendations.
2. Where concrete is mixed at a central plant on or off site, the concrete may be
supplied to the pouring area by agitator trucks or transit mixers which rotate at the
speed specified by the manufacturers. Non-agitating trucks may be used if the
central plant is on site.
3. Time of haul shall not exceed the maximum stated in sub-item D.5 of subsection
5.01.6 of the Specification.
E Uniformity Tests
1. Four samples of fresh concrete shall be taken, two after 15% of discharge from the truck
mixer or agitator truck and two after 85% discharge and within 20 minutes. Slump and
compaction factor tests shall be carried out including any other tests specified or required
by the Engineer.
F Samples
1. Samples for strength test shall be taken as specified in Clause C of subsection 5.01.4 of
the Specification.
2. At least six specimens shall be prepared per sample. Three of these shall be
tested at 7 days and three at 28 days.
G Control of Delivery
1. Driver of delivery trucks shall be provided with trip tickets, which shall be signed by a
responsible member of the central plant staff, for submission to the Engineer. The ticket
shall contain the following information.
 Name and address of the Central Plant.
 Serial number of the ticket and date.
 Truck number.
 Class and/or strength of concrete.
 Cement content of the mix.
 Loading time.
 Slump
 Any other type of relevant information.
2. The Engineer may send his representative to the central plant who may:
 Check the batching and mixing.
 Verify loading time.
 Take a copy of the trip ticket.
3. The Contractor and/or concrete supplier shall afford the Engineer and/or his
representative, without charge, all facilities necessary to take samples, conduct
tests and inspect the central plant to determine whether the concrete is being
furnished in accordance with the Specification.
4. Concrete delivered in outdoor temperatures lower than 5 degrees C, or if the
temperature is expected to drop below 5 degrees C during the curing period, shall

arrive at the Works having a temperature of not less than 10 degrees C nor greater
than 32 degrees C.
5. In supplying ready-mixed concrete, the plant shall have sufficient batching and
transporting capacity to ensure continuous delivery at the rate required. The rate
of delivery of concrete during concreting operations shall provide for the proper
handling, placing and finishing of concrete. If the rate of delivery does not provide
a continuous concrete operation, the Engineer may suspend all or parts of further
concrete work until such time as the Contractor provides sufficient additional
delivery equipment which, in the opinion of the Engineer, will provide for a
continuous concrete operation.
5.2 CONCRETE HANDLING, PLACING AND CURING
5.2.1 General
A Scope
1. These operations shall consist of the placing, compacting and curing of concrete for mass
concrete, reinforced concrete and prestressed concrete structures.
5.2.2 Materials
A General
All concreting materials shall comply with section 5.01 “Concrete and Concrete Mixes and
Testing” of the Specification.
5.2.3 Placing
A General
1. Before preparing and placing any concrete, the Contractor shall submit a work plan to the
Engineer for approval. Besides specifying the characteristics of the concrete to be
employed, this plan shall indicate the time at which placing is to start, the way in which it is
to be performed, and the time at which it is to finish. The Engineer’s approval shall be
sought in writing by the Contractor at least 24 hours in advance.
2. The method and sequence of pour, the equipment to be used, the method of
compaction and curing procedure shall be approved by the Engineer, prior to
concrete pour.
3. In order to allow proper vibration of the concrete, it shall be placed in horizontal
layers which, at no time shall be thicker than fifty centimeters (after vibration).
4. If the concrete is placed in successive phases, there shall be no separations, or
discontinuity, or difference of appearance between two successive placings.
Before each successive placing is made, the surface of the concrete already in
place shall be carefully roughened, cleaned, washed free of loose particles and
dampened.
5. Concrete shall be placed in such a way that it shall be left undisturbed once it is
placed (for example, slabs shall be executed by starting to place the concrete at
the side opposite the one from which the concrete is poured, so that there shall be
no risk of it being disturbed by workers or equipment, or of tools falling in).
6. When concrete is placed for upright reinforced concrete structures, the placing
must be completed (for small structures) or interrupted (for large structures) before
the concrete which has already been placed has started to harden and might,
therefore, be disturbed, if the operation of placing were continued. In such cases
placing shall be started again only after twenty four hours have passed. This
procedure is intended to avoid the risk of the concrete which has already been

placed coming away from the reinforcing bars, because it is moved or disturbed
during setting and the initial phase of hardening.
7. When the concrete is placed, its temperature shall be nearly the same as that of
the reinforcing bars, in order to avoid poor adhesion due to the different
coefficients of thermal expansion of the two materials. The reinforcing bars shall,
therefore, be protected from the sun (or the cold in winter) or cooled by water jets
prior to the placing of the concrete, or the pouring shall start during the cooler
hours of the day and be suspended when the temperature rises above thirty three
degrees C.
8. The free-drop height of concrete shall be not greater than 1.5m and the method of
placing shall be such as to suit the conditions and prevent segregation.
9. Placing of concrete shall be continuous between predetermined points such as
construction joints, contraction joints and expansion joints.
10. Concrete shall be placed so as to avoid segregation of the materials and the
displacement of the reinforcement. Concrete shall not be deposited in large
quantities at any point in the forms and then run or worked along the forms, thus
causing segregation of the materials.
11. The concrete shall be deposited in the forms in horizontal layers and the work shall
be carried on rapidly and continuously between predetermined planes agreed
upon by the Contractor and the Engineer.
12. The slopes of chutes, where used, shall be not greater than 1 vertical to 2
horizontal or smaller than 1 vertical to 3 horizontal. The slope of the chute shall be
constant along its length. The capacity of the chute shall be adequate to deliver
the required volume of concrete at the required rate.
13. Aluminum pipes shall not be used for delivering concrete. The internal diameter of
delivery pipes, if used, shall be not less than 8 times the maximum aggregate size.
At the point of delivery, pipes shall be vertical.
14. Where bucket and hopper are used for delivery of concrete, the discharge opening
shall be not less than 5 times the maximum aggregate size. The sides of hoppers
shall be sloped at not less than 60 degrees to the horizontal.
15. When buggies are used to transport fresh concrete, they shall be run on level
tracks which are securely fixed. The buggies shall be run smoothly without
sudden jerks and the distance shall be not greater than 60 meters.
16. All chutes, buckets and hoppers, buggies and pipes shall be kept clean and free
from coatings of hardened concrete by thorough flushing with water after each run.
The water used for flushing shall be discharged clear of the concrete already in
place.
17. The external surface of all concrete shall be thoroughly worked during the placing
by means of tools of an approved type. The working shall be such as to force all
coarse aggregate from the surface and to bring mortar against the forms to
produce a smooth finish, substantially free from water and air pockets, or
honeycomb.
18. Concrete shall be deposited in water only with the permission of the Engineer and
under his supervision. The minimum cement content of the class of concrete
being deposited in water shall be increased 10 per cent without further
compensation and the slump shall be approximately 15 centimeters.
19. When depositing in water is allowed, the concrete shall be carefully placed in the
space in which it is to remain in a compact mass, by means of a tremie, bottom-
dumping bucket or other approved means that does not permit the concrete to fall
through the water without adequate protection. The concrete shall not be
disturbed after being deposited. No concrete shall be placed in running water, and
forms which are not reasonably watertight shall not be used for holding concrete
deposited under water.

20. When casing is used in drilled shafts, the casing shall be smooth and properly
oiled in accordance with the manufacturers’ manual and shall extend sufficiently
above the grade of the finish shaft to provide excess concrete to be placed for the
anticipated slump due to the casing removal. When the casing is to be pulled, the
concrete placed in the casing shall have such a slump and be of such workability
that vibrating of the concrete will not be required.
21. No concrete work shall be stopped or temporarily discontinued within 45
centimeters of the top of any finished surface unless such work is finished with a
coping having a thickness less than 45 centimeters in which case the joint shall be
made at the under edge of the coping.
22. Concrete in simple slab spans shall be placed in one continuous operation for
each span, unless otherwise directed on the Drawings or directed by the Engineer.
23. Concrete in in-situ beam and slab construction shall be placed in one continuous
operation, or when so shown on the Drawings or approved by the Engineer, may
be placed in two separate operations, each of which shall be continuous; first, to
the top of the girder stems, and second, to completion. Where a construction joint
is permitted between the girder stem and the roadway slab, shop drawings
including complete details of key or other methods of bonding will be prepared by
the Contractor and submitted to the Engineer for approval. When such a joint is
permitted, deck concrete shall not be placed until the concrete in the girder stem
has hardened sufficiently so as not to be damaged by the concreting operations of
the deck pour.
24. Concrete in arch rings shall be placed in such a manner as to load the centering
uniformly. Arch rings shall be divided into section such that each section can be
cast for the full cross-section in one continuous operation. The arrangement of the
section and the sequence of placing shall be as approved by the Engineer, and
shall be such as to avoid the creation of initial stress in the reinforcement. The
section shall be bonded together by suitable keys or dowels. When permitted by
the Engineer, arch rings may be cast in a single continuous operation.
25. The method used for transporting concrete batches, materials, or equipment over
previously placed floor slabs or floor units or over units of structures of continuous
design types shall be subject to approval by the Engineer. Trucks, heavy
equipment and heavy concentrations of materials will be prohibited on floor slabs
until the concrete has attained its design strength.
26. Slump Limits
 Concrete Type Slump Limit * (mm)
 Compacted by vibration 70 - 80
 Compacted by rod 100
*If chemical additives are used to enhance the concrete super plasticization, then above
limits will not be valid.
B Pumping
1. The use of pumps will only be allowed after they have been carefully checked and
approved by the Engineer. Only low pressure piston type pumps, which will work with a
water/cement ratio of not more than sixty five hundredths (0.65), will be allowed. Using
superplastizisers to facilitate pumping for low water/cement ratios is allowed subject to
Engineer’s review and approval.
2. In no case will “bell” or any other type of high pressure pump be allowed, since
they require too high a water/cement ratio and because the concrete segregates
as a result of the high pressure at which it is expelled, even if filled with a suitable
nozzle.
3. The mix design shall be checked for its suitability for pumping and the concrete
shall be tested regularly during pumping for its uniformity and that its properties

have not been altered by pumping. If changes to slump, water-cement ratio,
consistency or any other characteristics occur, corrective measures shall
immediately be taken to ensure that concrete delivered by the pump complies with
the requirements of the Specification. Samples shall be taken at discharge from
the mixer/agitator truck, from the pump and at discharge from the pump.
4. The internal diameter of delivery pipe of the pump shall be not less than 3 times
the maximum aggregate size. The pipes shall not rest on any part of the formwork;
they shall be supported independently and securely and be readily accessible so
that sections can easily be detached to remove any blockage.
5. Before approving the use of a pump, the Engineer shall verify that the Contractor
has sufficiently reinforced the concrete placing team and the equipment for placing
and vibrating the concrete.
6. Pumping will not be permitted from the inside of the foundation forms while
concrete is being placed. If necessary to prevent flooding, a seal of concrete shall
be placed through a closed chute or tremie and allowed to set.
5.2.4 Compacting
A General
1. The vibration of the concrete can be considered completed when a thin layer of cement
grout appears on the surface and when no more air bubbles, indicating the presence of
voids within the concrete, appear on the surface. At the same time, there must not be too
much vibration or this will produce segregation.
2. Vibration may be of three types:
a) Internal
b) External
c) Mixed.
3. Vibration of the concrete and operation shall be undertaken in such a way that the
proper and complete vibrations, but avoiding over vibration, is achieved. The
guidelines as given in Standard Practice for Consolidation of Concrete (ACI 309)
of Part 2 Concrete Practices and Inspection, Pavements, of ACI Manual of
Concrete Practice (latest edition) issued by American Concrete Institute (ACI) shall
be followed, if not otherwise directed by the Engineer.
4. Internal vibration shall be executed in all sections which are sufficiently large to
permit the insertion and manipulation of immersion vibrators, previously approved
by the Engineer, in accordance with the following recommended practices:
a) The concrete shall be placed in horizontal layers not thicker than fifty centimeters.
b) The vibrator shall be inserted vertically into the concrete to its full length such as to
reach the bottom of the freshly placed layer.
c) The distance between two successive insertions shall not exceed five times the
diameter of the vibrator itself.
d) The vibrator shall not rest on or against either the formwork or the main reinforcing
bars.
5. External form vibrators shall be used for external vibration when it is impossible to
use internal vibrators (heavily reinforced thin walls, pipes or other precast, small
cross-section element, etc). The water/cement ratio shall be low (0.4 to 0.45) in
order to avoid the segregation of the concrete and, at the same time, to provide
rapid hardening and, in consequence, the early removal of the formwork and the
finished element.
6. Mixed vibration shall be used in the construction of reinforced or prestressed
concrete beams. External wall vibrators shall also be used. These shall be

mounted on the outside of the formwork after this has been suitably reinforced with
ribs of U-bars. The mounting places of the wall vibrators shall be welded to these
reinforcements. They must be symmetrically positioned on each side of the beam
and produce a rotary movement within the concrete during vibration from the
bottom towards the top and from the part placed first towards the part placed last.
7. Only the vibrators in the zone of the formwork with newly placed concrete will be
used. As the casting of the beam advances, the vibrators shall be dismounted and
remounted as necessary.
8. It is absolutely essential, that elastic supports be provided both under the bottom
of the beam and in correspondence with the braces or tie rods of the formwork
walls.
9. The network of reinforcing bars and tensioning cables should not move as a result
of the vibration. To prevent this from happening, either special ties (passing
through the formwork walls), or spacers shall be used. It is better, if these last are
made of concrete and are of a size and shape that will ensure that the reinforcing
and tensioning cables do not move.
10. Before starting this kind of work the Contractor shall submit to the Engineer for his
approval a work plan giving the following details:
a) The position of the external wall vibrators.
b) Their power, frequency and amplitude.
c) The number of such wall vibrators that will be utilized at the same time.
d) The number and type (frequency and size) of the internal vibrators to be used for the
consolidation of the concrete.
e) The position of the spacers, or the number of ties, to be used to ensure that the
reinforcing bar network and the tensioning cables (if any) do not move during vibration.
f) The way in which the concrete is to be placed and the length of time this operation is
expected to take.
11. When required, vibrating shall be supplemented by hand spading with suitable
tools to assure proper and adequate compaction.
B Poker Vibrators
1. The type and size of poker vibrators shall suit the pour size, density of reinforcement and
member dimensions. Unless otherwise authorized by the Engineer, the vibrator shall be
selected from Table 5.2.1 below:
Table 5.2.1: Selection of Poker Diameter for Size of Pour

Size of Pour Poker Diameter Speed
(m3/h) (mm) (Vibrations/min)
2–4 20 – 45 9000
5 – 10 50 – 65 9000
10 – 20 60 – 75 7000
20 – 30 80 – 115 7000
30 - 40 140 - 170 6000
2. Poker vibrators shall be inserted into the concrete vertically at regular intervals
which shall be no greater than 0.5m. They shall be inserted quickly and withdrawn
slowly. The withdrawal rate shall be not more than 75mm/sec. A cycle of insertion
and withdrawal shall be between 10 and 30 seconds.

3. Poker vibrators shall be kept clear of formwork and concrete previously cast.
4. Vibrators shall be so manipulated as to work the concrete thoroughly around the
reinforcement and embedded fixtures and into corners and angles of the forms.
Vibrators shall not be used as a means to cause concrete to flow or run into
position in lieu of placing.
5. Compaction shall be sufficient to achieve maximum density without segregation in
the fresh concrete.
6. Standby pokers of the same type shall be provided at all times. The standby shall
be not less than half the number of pokers used for compacting the pour.
7. Vibrating shall only be carried out by professional technicians having experience in
this type of work.
C Other Vibrators
1. Form vibrators, vibrating tables and surface vibrators where required shall first be
approved by the Engineer and they shall conform to the requirements of ACI-309.
2. Where form vibrators are used, the form shall be adequately designed so that the
vibration will not cause joints to leak and dimensions and geometry to alter.
3. Unless otherwise permitted by the Engineer, the use of form vibrators shall be
limited to members whose thickness does not exceed 150 mm.
5.2.5 CURING
A Materials
1. Hessian or burlap shall be clean and free from harmful materials. Their unit weight shall
be not less than 230g/sq.m.
2. The following impermeable membranes may, with the Engineer’s approval, be
used:
a) Clear polyethylene film with no holes, tears, scratches and contamination of any
type.
b) Hessian coated with white polyethylene of density not less than 300g/sq.m. The
coating may be on one side only but shall be not less than 0.1mm thick and shall not peel during
and after use.
3. Curing compounds shall conform to AASHTO M148 (ASTM-C309).
4. Sand shall be natural sand, free of silt and clay and contaminants which can be
harmful to the concrete.
5. Water shall satisfy the requirements of Section 5.01 of the Specification.
B Method of Curing
1. The method of curing to be used shall be approved by the Engineer. It shall not cause any
undesirable blemishes such as surface discoloration and surface roughness. Curing
compounds shall not be used on construction joints and surfaces that are to receive
waterproofing, paint or membranes.
2. Curing by ponding may be used for horizontal surfaces such as bases, pile caps
and slabs. Large horizontal surface areas shall be separated into ponds not
exceeding 5 sq.m. The ponds shall first be filled between 12 to 24 hours after pour,
unless otherwise authorised by the Engineer, and shall be replenished from time to
time so as to maintain the ponding for the specified curing period. The concrete
temperature and the temperature of the curing water shall be not greater than
10°C.

3. Unless otherwise approved by Engineer, curing by spraying shall commence
between 12 and 24 hours after the concrete pour. The concrete shall be
maintained damp at all times during the curing period by periodic light sprays.
4. Members to be cured by wet hessian or wet burlap shall be completely wrapped
with the material which shall be kept moist at all times during the curing period by
regular spraying. Unless otherwise approved by the Engineer, the overlap under
normal conditions shall be not less than one-quarter the width of the hessian or
burlap and not less than one-half the width in windy and/or rainy conditions.
Before members are wrapped for curing, they shall first be evenly moistened.
Unless approved by the Engineer, burlaps shall be supplied only in rolls and burlap
bags shall not be used. Secondhand hessian and burlap, if approved for use, shall
be clean without holes and contamination of any kind that can affect the concrete.
5. Waterproof sheets used for curing shall, unless directed by the Engineer, be
spread immediately after the pour. The sheet shall, unless approved by the
Engineer, be clear of the concrete surface but be arranged in such a manner as to
prevent the movement by air over the concrete surface. Waterproof sheets shall
not be used when the air temperature is 25°C or higher.
6. Curing compounds shall be applied in two applications at a coverage rate of not
less than 1 ltr/ 7.4 sq.m. per application or as recommended by manufacturer and
the following criteria shall apply:
a) The first coat shall be applied immediately after the removal of the forms and the
acceptance of the concrete finish and after the disappearance of free water on
unformed surfaces. If the concrete is dry or becomes dry, it shall be thoroughly wet
with water and curing compound applied just as the surface film of water disappears.
The second application shall be applied after the first application has set. During
curing operations, any unsprayed surfaces shall be kept wet with water. The curing
membrane will not be allowed on areas against which further concrete is to be
placed.
b) Hand operated spray equipment shall be capable of supplying a constant and
uniform pressure to provide uniform and adequate distribution of the curing membrane at the rates
required. The curing compound shall be thoroughly mixed at all times during usage.
c) The curing membrane shall be protected against damage for the entire specified
curing period. Any coating damaged or otherwise disturbed shall be given an additional coating.
Should the curing membrane be continuously subjected to injury, the Engineer may require wet
burlap, polyethylene sheeting, or other approved material to be applied at once.
d) No traffic of any kind will be permitted on the curing membrane until the curing
period is completed, unless the Engineer permits the placement of concrete in adjacent sections,
in which case the damaged areas shall be immediately repaired as directed.
7. Steam curing shall be in accordance with ACI 516 and ACI 517.
C Curing Time
1. The minimum curing time shall be the number of days given in Table 5.2.2 unless the
average surface temperature of the concrete during the required number of days falls
below 10°C, in which case the period of curing shall be extended until the maturity of the
concrete reaches the value given in the Table.
2. The minimum curing time given in Table 5.2.2 above shall be compared with the
time required for cylinders (cubes), cured under identical conditions to those which
the concrete is subjected, to attain 70% of the characteristic strength. The greater
shall be taken as the minimum curing time.
D Limitation of Temperature Differentials
1. The Contractor shall limit the development of temperature differentials in concrete after
placing by any means appropriate to the circumstances including the following:
a) Limiting concrete temperatures at placing lower than that set out in clause 5.02.6

b) Use of low-heat cement, subject to the agreement of the Engineer.
c) Insulation of exposed concrete surfaces by insulating blankets. Such blankets shall
have a thermal conductance C value less than 1.0 W/m2oC.
d) Leaving formwork in place during the curing period. Steel forms shall be suitably
insulated on the outside.
e) Preventing rapid dissipation of heat from surfaces by shielding from wind.
f) Shielding concrete surfaces from clear night skies, together with the use of heaters
where appropriate.
2. The Contractor shall ensure that the temperature differentials in a pour do not
exceed 20 oC by appropriate design of mix and use of insulation.
3. The Contractor shall take all necessary steps to limit temperature rise such that the
temperature of the concrete shall not, at any stage, exceed 70 oC.
4. Thermocouples shall be used in large concrete pours where the possibility of
significant thermal gain is, in the opinion of the Engineer considered to be likely.
The disposition of the thermocouples shall be agreed with the Engineer.
5.2.6 Hot Weather Concreting
A Definitions
1. For the purpose of this sub-section of the Specification, Hot Weather is as defined in ACI
305R Chapter 1.
B General
1. The production and delivery of concrete, the placing and curing and the testing and
inspection of concrete shall, in addition to the requirements of the Specification, accord
with the recommendations of ACI 305R.
Table 5.2.2: Normal Curing Periods

Minimum periods of protection for different types of cement
Equivalent Maturity (degree hours) Calculated as
Conditions
Number of Days (where the Average Surface the age of the Concrete in Hours Multiplied by
Under Which
Temperature of the Concrete Exceeds 10˚C the Number of Degrees Celsius by which the
Concrete is
During the Whole Period) Average Surface Temperature of the Concrete
maturing
Exceeds Minus 10˚C
Other * OPC
Other * SRPC
or or
SRPC OPC
RHPC RHPC
1.Hot weather
or drying 7 4 3 3500 2000 1500
winds
2. Conditions
not covered 4 3 2 2000 1500 1000
by (1)
Note. Other* includes all permitted cements except OPC, RHPC and SRPC.
Key OPC = Ordinary Portland cement.
RHPC = Rapid-hardening Portland cement.
SRPC = Sulfate resisting Portland cement.

2. No concreting shall commence when the air temperature is 33°C and rising. The
Contractor shall schedule his operations to place and finish concreting during the
hours that the air temperature will be below 32°C. This should preferably be in the
latter part of the day after the maximum temperature has been reached, and
subject to the approval of the Engineer.
3. If air temperature rises above 33°C in shadow during concrete mixing or pouring,
some or all of the following precautions should be applied and according to the
Engineer recommendations:
a) Covering the storing areas of the gravel. The big size gravel may be cooled using
water spays.
b) If cement is stored in silos, it should be painted by reflective material. If stored in
bags, it should be stored in aired and covered areas.
c) Cooling the water before adding it to the concrete mix.
d) Painting the mixers using reflective paint.
e) Spray water to the forms before pouring the concrete, in case of precast concrete, it
should be poured in shaded areas.
C Control of Temperature
1. Stockpile of aggregates shall be protected from direct sunlight by suitable covering. If

directed by the Engineer, they shall be regularly sprayed with clean water.
2. Water shall be stored in tanks away from sunlight and insulated by suitable means
so as not to be affected by high air temperature. Water tanks liable to be exposed
to sunlight shall be covered with suitable reflective paint such as white gloss paint.
3. If directed by the Engineer or as a condition for concreting in adverse weather
conditions, sufficient ice shall be added to the mix water to ensure that the
temperature of the fresh concrete shall not exceed 32°C.
4. The temperature of the concrete at the time of placing shall not be permitted to
exceed 33 degrees C. Concrete materials shall be stored in a cool shaded
position away from the direct rays of the sun. Aggregates shall be cooled if
necessary prior to mixing and water shall be cooled by means of a proprietary
water chilling plant.
5. Additives as recommended in ACI 305R shall be used to improve workability
and/or delay initial setting.
6. Retarding admixtures to facilitate placing and finishing of the concrete shall
conform to AASHTO M194, Type D and used only if approved by the Engineer.
D Mixing and Placing
1. The time available for handling and placing of concrete during periods of high temperature
may be considerably reduced and the Contractor must take appropriate precautions.
Concrete should be protected during transportation by use of damp hessian or similar
means. No additional water may be added at the time of mixing without the approval of the
Engineer, as this may lead to additional shrinkage of the concrete. On no account shall
water be added during transportation or placing of the concrete.
2. Aggregates and cement shall be thoroughly pre-mixed before adding water.
3. Transit mixers, if used, shall be coated with a reflective paint and while waiting to
be discharged, shall be kept out of direct sunlight.
E Concrete Protection
1. Before the concrete can be de-shuttered, the formwork and shutters shall be cooled by
spraying with water.

2. The concrete and the falsework shall be protected against sunlight, if directed by
the Engineer.
3. If curing is by hessian, it shall be coated with a white polyethylene backing.
4. Members exposed to strong winds shall be provided with windbreakers. The
windbreakers shall, if directed by the Engineer, be kept moist by regular spraying.
5.2.7 Cold Weather Concreting
A Definitions
1. For the purpose of this sub-section of the Specification, Cold Weather is as defined in ACI
306.1, Section 1, Part 1.2.
B General
1. ACI 306.1-90 “Standard Specification for Cold Weather Concreting” applies.

2. The production and delivery of concrete, the placing and curing and the protection
requirement shall be in accordance with the recommendations of ACI 306R-88
“Cold Weather Concreting”.
3. No concreting shall commence when the air temperature is 6°C and falling, unless
authorised by the Engineer.
C Mixing and Placing
1. Aggregates and water, forms, reinforcement etc. shall be free of snow, frost or ice.
2. Aggregates and water may be pre-heated in which case the aggregates and water
shall, if directed by the Engineer, be mixed prior to introducing cement in the mix.
The aggregates shall not be pre-heated to a temperature in excess of 100°C and
the water in excess of 60°C with the additional requirement that the temperature of
the water and aggregate mix, before the introduction of cement, shall not exceed
38°C.
3. Water may be pre-heated by boiling and added to aggregates not pre-heated
provided the temperature of the water and aggregate mix, before the introduction
of cement, does not exceed 38°C.
4. The temperature of concrete at the time of discharge shall be between 10 and 27
°C and for three days after the pour not less than 5°C.
D Protection
1. When directed by the Engineer, members shall be protected against cold winds by suitable
windbreaks.
2. Adequate insulation by way of insulation boards, planks, sheets etc. shall be
provided to maintain the required minimum concrete temperature during the curing
period.
3. Protection measures shall be maintained for a period at which the concrete attains
a strength of at least 65% of the characteristic strength.
5.2.8 Night Concreting
A Night concreting shall not be carried out unless prior approval of the Engineer, in writing, is
obtained.
B Details of the artificial lighting system shall be submitted in advance of the proposed
concreting for the Engineer’s approval. In all cases, at least one stand-by generator shall
be available at all times of the concreting operation.

5.3 STEEL REINFORCEMENT AND FIXING
5.3.1 General
A Scope
1. These works shall consist of the supply and fixing of the unstressed steel bars, wires,
mesh and mats for the reinforcement of concrete in accordance with the Drawings and
Specification.
5.3.2 MATERIALS
A Reinforcing Bars
1. High tensile steel reinforcement bars shall conform to AASHTO M31 (ASTM A615) Grade
60 (with carbon content not exceeding 0.3%) or to BS 4449 with carbon percentage that
dose not exceed 0.3%.
2. Mild steel reinforcing bars shall conform to AASHTO M31 (ASTM A615) Grade 40
or BS 4461.
3. High tensile, low-alloy steel deformed bar shall conform to ASTM A706.
B Welded Fabric Reinforcement
1. Welded steel wire fabric shall conform to AASHTO M55 or BS 4482.

2. Cold drawn steel wire shall conform to the requirements of AASHTO M32 or in the
case of hard drawn steel wire to BS 4482.
C Fabricated Mat Reinforcement
1. Fabricated mat reinforcement shall conform to AASHTO M54 (ASTM A184).
D Certification and Identification
1. Three copies of a mill test report shall be supplied to the Engineer for each lot of billet steel
reinforcement supplied for use on the project. The mill test report shall be sworn to by a
person having legal authority to bind the manufacturer and shall show the following
information:
a) The process or processes used in the manufacture of the steel from which the bars
were rolled.
b) Identification of each heat of open-hearth, basic oxygen, or electric furnace and/or
each lot of acid bessemer steel from which the bars were rolled.
2. The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator
before being offered for inspection. The tag shall show the manufacturer’s test
number and lot number or other designation that will identify the material with the
certificate issued for that lot of steel.
3. The fabricator shall furnish 3 copies of a certificate which shows the heat number
or numbers from which each size of bar in the shipment was fabricated.
E Inspection and Sampling
1. The sampling and testing of reinforcement bars may be made at the source of supply when
the quantity to be shipped or other conditions warrant such procedure. Bars not inspected
and sampled before shipment will be inspected and sampled after arrival at the site.
5.3.3 Construction
A General

1. Reinforcing steel shall be protected at all times from damage. All reinforcement shall be
free from detrimental dirt, loose mill scale, scaly rust, paint, grease, oil or other foreign
substance. There shall be no evidence of pitting or visual flaw in the test specimen or on
the sheared ends of the bars.
2. Rust shall be removed by wire brushing or, if directed by the Engineer, by sand
blasting. Light rust without visible sign of peeling need not be removed.
B Storage
1. Reinforcement shall be stored clear of the ground on platforms, skids or other supports
and be protected against contamination by dirt, grease, oil etc. at all times. If directed by
the Engineer, the Contractor shall provide cover to the reinforcement.
2. Reinforcement of different grades and different diameters shall be stored
separately and marked to facilitate inspection and checking.
C Cutting and Bending
1. Cutting and bending of reinforcement shall be based on an approved bar bending

schedule.
2. Reinforcement shall be cut in specialist cutting machines or cold cut by hand only.
Cutting with oxyacetylene torch is strictly forbidden.
3. Bars shall be bent to the following bend diameters:
Bar Diameter, d. Mild Steel High Yield Steel
Up to 25 mm 4d 6d
25 to 35 mm 6d 8d
35 to 60 mm 10d 10d
4. All reinforcement shall be bent at the temperature range of 5 degrees C and 100
degrees C. Bending by heating, if approved by the Engineer, shall be carried out
in such a manner as not to impair the physical and mechanical characteristics of
the bar.
5. The straight bar length for a hook of 180° shall be not less than 4 times the bar
diameter or 65 mm whichever is the larger.
6. The straight bar length of a hook of 90° shall be not less than 12 times the bar
diameter.
7. The straight bar length after hook in stirrups shall be 6 times the bar diameter or
60mm whichever is the larger.
8. Cold worked bars and hot rolled high yield bars shall not be re-bent or straightened
once having been bent. Where it is necessary to bend mild steel bars projecting
from the concrete, the bend diameter shall comply with the requirements of item
C.3 above.
9. If bending of the bar in accordance with this Specification causes the bar to crack,
the bar shall be rejected, irrespective of any prior approval that may have been
given, and removed from the Site.
10. Bars shall be cut and bent to the following tolerances:
Bar length (mm) Tolerance (mm)
Upto 1000 5
1000 - 2000 +5, -10
above 2000 +5, -25
11. No adjustment to bar length after bending will be permitted.
D Fixing

1. Reinforcement shall be placed and maintained in the position shown on the Drawings.
Unless agreed otherwise by the Engineer, all bar intersections shall be securely tied
together with the ends of the wire turned into the main body of the concrete. 1.2 mm
diameter stainless steel wire shall be used for in situ members having exposed soffits. 1.6
mm diameter soft annealed iron wire shall be used elsewhere.
2. The correct cover to reinforcement on all exposed faces of concrete shall be
maintained by using approved proprietary spacers. Where instructed by the
Engineer the adequacy of such spacers shall be demonstrated by site trials.
3. Concrete cover blocks, where permitted by the Engineer, shall be of approved
dimensions and designed so that they will not overturn when the concrete is
placed. They shall be made with 10 mm maximum size aggregate and the mix
proportion shall be such as to produce the same strength as the adjacent
concrete. Tying wire shall be cast in the blocks for subsequent tying to the
reinforcement.
4. Wherever it is necessary for the Contractor to splice reinforcement at positions
other than those shown on the Drawings, the approval of the Engineer shall be
sought and obtained before the reinforcement is placed. Splices shall be
staggered where possible and shall be designed to develop the strength of the bar
without exceeding the allowable unit bond stress.
5. Proprietary mechanical splicing devices shall be used only with prior approval of
the Engineer in writing. They shall be able to withstand without any slippage a
force of not less than 1.25 times the characteristic yield stress of the smaller bar
spliced multiplied by the cross-sectional area of the smaller bar.
6. Mesh reinforcement shall comply with the sizes of sheets and diameter and
spacing of bars as shown on the Drawings. The sheets of mesh shall be lapped
as shown on the Drawings. The method of placing the mesh and securing it in
position shall be approved by the Engineer.
7. Welding of reinforcement bars, if allowed by the Engineer, shall be carried out in
accordance with the latest publications of the American Welding Society
publication “Structural Welding Code for Reinforcing Steel”, and shall be able to
withstand a force of not less than 1.25 times the characteristic yield stress of the
smaller of the welded bars multiplied by the cross-sectional area of the smaller bar.
8. Cold worked steel bars shall not be welded.
9. Where galvanizing or epoxy coating is required to be applied to the reinforcement,
specific instructions will be given by the Engineer taking into account the particular
design conditions which apply.
10. Dowel Bars: Coat half of each bar with approved proprietary debonding compound
or fit with approved plastics sleeve. Fix bars securely at required level, perfectly
level, at right angles to and centred on the joint. Fit compressible caps to
debonded ends of bars.
5.4 FORMS, FORMWORK AND FALSEWORK
5.4.1 General
A Scope
1. These works shall consist of the design, supply and use of forms, formwork and falsework
for the construction of concrete water tanks.
5.4.2 Definitions
A Forms and Formwork

1. The item of the temporary works used to give the required shape and support to poured
concrete. It consists primarily of sheeting material, such as wood, plywood, metal sheet or
plastic sheet, in direct contact with the concrete and joists or stringers that directly support
the sheeting.
B Falsework
1. Any temporary structure used to support a permanent structure while it is not self-
supporting.
C Scaffold
1. A temporarily provided structure that provides access, or on or from which persons work,
or that is used to support material, plant or equipment.
D Tower
1. A composite structure, usually tall, used principally to carry vertical loading.
5.4.3 Materials
A Wood
1. Soft wood free of faults such as splitting, warping, bending, knots etc.
2. When imported softwood or hardwood is used for falsework, the minimum timber
grade, determined in accordance with BS 4978 shall be SC3.
3. Hardwood used as load-bearing wedges and packing shall be limited to those
listed in Table 5.4.1.
Table 5.4.1: Permitted Hardwoods for Load-Bearing Wedges and Packing

Standard name Botanical species
Ash Fraxinus excelsior
Beech Fagus sylvatica
Greenheart Ocotea rodiaei
Jarrah Eucalyptus marginata
Karri Eucalyptus diversicolor
Keruing Dipterocarpus spp
Oak Quercus spp
B Plywood
1. When plastic coated plywood is used, the Phenol resin on melamine shall be not less than
20% of the total coating weight.
C Steel
1. Except as otherwise specified or shown on the Drawings, the grades and qualities shall
conform to the following applicable standards of AASHTO and ASTM:
a) Structural carbon steel shall conform to AASHTO M183M (ASTM A36M).
b) Structural steel for welding shall conform to AASHTO M183M (ASTM A36M).
c) High-strength low-alloy structural steel shall conform to AASHTO M222 (ASTM
A588).
D Aluminum

1. Aluminum shall conform to the requirements of ASTM B221.
E Other Materials
1. Other materials, with the approval of the Engineer, may be used for falsework. These
include, but not limited to, fibre-glass reinforced plastic, polystyrene, polyethylene, PVC,
rubber, concrete, brick etc.
5.4.4 DESIGN
A General
1. Forms and formwork and falsework shall be designed by the Contractor and submitted to
the Engineer with full design calculations, detailed drawings, material specification and test
certificates for approval. Falsework shall be capable of temperature changes without
causing damage to the concrete.
2. Falsework design shall be in accordance with BS 5972 “Code of Practice for
Falsework”.
3. If the Contractor intends to use ready made proprietary type of falsework, he shall
submit all relevant data, including independent test certificates, which will enable
the Engineer to determine whether or not the Contractor’s proposed falsework are
acceptable.
4. Notwithstanding any approval of falsework design by the Engineer, the Contractor
will not be relieved of his responsibility for the adequacy and correctness of the
design, manufacture and assembly of the falsework.
B Fabrication of Steel
1. Except as otherwise specified or as shown on the Drawings, all details concerning

fabrication shall conform to “AASHTO Standard Specifications for Highway Bridges”.
2. Fabrication of all metal for steel structures and the erection of steel structures shall
be in accordance with shop and erection drawings furnished by the Contractor and
approved by the Engineer before any fabrication is commenced.
3. Fabrication tolerances shall comply with tolerances stated on the Drawings.
4. Compliance with tolerances shall be achieved both during and after fabrication
before any surface preparation. Remedial measures to remove imperfections must
be approved by the Engineer.
5. Approval of Contractor’s drawings shall in no way release the Contractor from his
responsibilities for work under the Contract. Three copies of each shop and
erection drawing prepared by the Contractor shall be submitted to the Engineer for
his approval and further copies of corrected or amended drawings shall be
submitted if required before final approval is given. These drawings shall conform
to the general drawings, stress sheets, design specifications and fabrication
tolerances. Shop drawings shall include a full and clear set of marking drawings.
6. Weld to be visually inspected by the Engineer. If testing is deemed to be required,
the Contractor shall bear all costs.
C Forms and Formwork
1. Formwork shall be sufficiently rigid so as to prevent any grout loss during concreting and
shall not distort due to environmental effects and concreting operations so that member
dimensions, shape, required finish and texture are within the tolerances specified.
2. Forms and formwork shall be designed to be readily assembled, stripped and
transported without distortion to panels and members of the formwork.
3. The method of stripping forms without damaging the concrete or special textured
surface finish, if incorporated, shall be fully considered in the design.

4. If form liners are to be used to achieve the specified surface finish, samples of a
size as directed by the Engineer shall be submitted for approval.
5. Form lining shall not bulge, warp or blister, nor shall it stain the concrete. Form
lining shall be used in the largest practicable panels to minimize joints. Small
panels of the lining material shall not be permitted. The joints in the lining shall be
tight and smoothly cut. Adjacent panels of form lining shall be so placed that the
grain of the wood will be in the same direction (all horizontal or all vertical). Thin
metal form lining will not be permitted. Undressed lumber of uniform thickness may
be used as backing for form lining. Wooden plyform, of adequate thickness which
is properly supported to meet the above requirements, may be used in lieu of the
lined forms specified herein.
6. Metal forms, if used, shall be of such thickness that the forms will remain true to
shape. All bolt and rivet heads shall be countersunk. Clamps, pins or other
connecting devices shall be designed to hold the forms rigidly together and to
allow removal without injury to the concrete. Metal forms which do not present a
smooth surface or do not line up properly shall not be used. Care shall be
exercised to keep metal forms free from rust, grease or other foreign matter.
Under such circumstances the continued use of the metal forms will depend upon
satisfactory performance and their discontinuance may be required at any time by
the Engineer. Steel panels or panels with metal frames and wood or combination
shall be so designed as to leave no lipping or ridges in the finished concrete.
7. The width and thickness of the lumber, the size and spacing of studs and wales
shall be determined with due regard to the nature of the Work and shall be
sufficient to ensure rigidity of the forms and to prevent distortion due to the
pressure of the concrete.
8. Where the bottom of the forms is inaccessible, the lower form boards shall be left
loose or other provisions made so that extraneous material may be removed from
the forms immediately before placing the concrete.
9. Unless otherwise directed by the Engineer, the exterior side of forms shall be
painted with an approved, good quality high gloss white oil base enamel paint prior
to placing concrete. Paint shall be applied to metal forms only. When complete
coverage is not obtained with one coat, the Engineer will order additional coats as
he deems necessary to obtain complete coverage. Forms shall be repainted when
ordered by the Engineer.
10. Unless provided otherwise on the Drawings or directed by the Engineer, all
exposed edges shall be bevelled by using dressed, millcut, triangular molding,
having 20 millimeter sides.
11. Forms shall be maintained after erection to eliminate warping and shrinkage.
D Falsework
1. Falsework and centering shall be designed to provide the necessary rigidity to support all
loads placed upon it without settlement or deformation in excess of the permissible
tolerance for the structure given in the Specifications. Falsework columns shall be
supported on hardwood, concrete pads or metal bases to support all falsework that cannot
be founded on rock, shale or thick deposits of other compact material in their natural beds.
Falsework shall not be supported on any part of the structure, except the footings, without
the written permission of the Engineer. The number and spacing of falsework columns, the
adequacy of sills, caps and stringers and the amount of bracing in the falsework framing
shall be subject to approval of the Engineer.
2. All timber shall be of sound wood, in good condition and free from defects that
might impair its strength. If the vertical members are of insufficient length to cap at
the desired elevation for the horizontal members, they shall preferably be capped
and frames constructed to the proper elevation. Ends of the vertical members
shall be cut square for full bearing to preclude the use of wedges. If vertical
splices are necessary, the abutting members shall be of the same approximate

size, the ends shall be cut square for full bearing, and the splices shall be scabbed
in a manner approved by the Engineer.
3. The Contractor shall compute falsework settlement and deflection for bridges so
that when the final settlement is complete, the structure will conform to the
required camber, section and grade as shown on the Drawings.
4. The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent observer to
observe and correct the settlement.
5. Screw jacks, if used, shall be designed for use with a slenderness ratio not
exceeding 60. The slenderness ratio shall be taken as the ratio of the clear
distance between effective bracing in both horizontal directions to the diameter of
the screw jack measured at the root of the thread. The manufacturers’ certificate
showing the ultimate load capacity of the screw jack shall be submitted with the
design calculations for the falsework. If directed by the Engineer, the Contractor
shall furnish a test certificate carried out at an approved independent laboratory.
6. Props and towers supporting forms or partially completed structures shall be
interconnected in plan orthogonally at levels to be determined in the design. They
shall also be interconnected by diagonal bracings in orthogonal vertical planes.
5.4.5 Finishes
A Types of Finishes
1. Class F1: This class of surface finish denotes a special finish required from aesthetic
considerations. In additions to the requirements of Class F2 finish, the following additional
requirements shall apply.
a) It is of major importance that the special finishes required on F1 surfaces are
uniformly and consistently maintained with no variation in the colour or consistency
of the concrete within the same structure. In order to achieve this, the Contractor
shall make trial panels of the formed finishes specified. These panels shall be not
less than 1.5 m high and 1 m wide and 250 mm thick and shall be cast in the
manner and with materials as proposed for the actual Work. These panels are for
the approval of the liners and are preliminary to the test samples carried out on site.
b) The Contractor shall provide at his own expense as many panels as required by the
Engineer until a satisfactory trial panel has been accepted by the Engineer. The Contractor shall
submit to the Engineer and obtain his approval for all details before commencement of trials.
These samples when approved, will form the standard against which the corresponding finishes on
the actual work will be judged. In all cases of approvals, the decision of the Engineer alone will be
final.
c) Where forms and form-liners to be used for the special finishes specified are
manufactured outside the Country, the forms and form-liners shall not be permitted on Site until the
Engineer has inspected the forms and form-liners and is satisfied that they are suitable for the
Works. Samples and trial panels carried out at the place of manufacture to demonstrate to the
Engineer that the forms and formliners and the methods of assembling and de-shuttering them are
acceptable shall not be paid for and will not relieve the Contractor of the requirement for carrying
out trial panels on site as described above.
d) If the required finish in the opinion of the Engineer, has not been obtained in the
Works, the Contractor shall promptly carry out at his own expense all measures required by the
Engineer to obtain the specified finish. These may include grit blasting followed by the application
of polyester or epoxy paint. Where such remedial action is ordered by the Engineer, the entire
exposed surface shall be so treated irrespective of whether or not the defective areas are localised
or extensive.
2. Class F2: Formwork shall be lined with a material approved by the Engineer to
provide a smooth finish of uniform appearance. This material shall leave no stain
on the concrete and shall be so joined and fixed to its backing so that it imparts no

blemishes. It shall be of the same type and obtained from only one source for any
one structure.
The Contractor shall make good any imperfections in the finish as directed by the
Engineer. Internal ties and embedded metal parts will not be permitted unless otherwise
3. Class F3: Irregularities in the finish shall be no greater than those resulting from
the use of wrought thick square edged boards arranged in a uniform pattern. The
finish is intended to be left as struck. Imperfections such as fins and surface
discoloration shall, however, be made good as and when required by the
Engineer.
4. Class F4: No special requirements.
5. Permanently exposed concrete surfaces to classes F1, F2 and F3 finish shall be
protected from rust marks and stains of all kinds. Internal ties and embedded
metal parts will not be permitted.
6. The Contractor shall submit to the Engineer all details of formwork, liners, joints,
and materials including fabrication drawings and stating procedures involved in the
use of formwork for approval before commencement of any work on fabrication.
No formwork shall be brought to site without the prior approval of the Engineer.
Adequate time shall be allowed by the Contractor in his programme for these
approvals after consultation with the Engineer.
B Unformed Finishes
1. Class U1: The concrete shall be uniformly levelled and screeded to produce a plain or
ridged surface as described in the Contract. No further work shall be applied to the
surface unless is used as the first stage for Class U2 or Class U3 finish.
2. Class U2: After the concrete has hardened sufficiently, the concrete Class U1
surface shall be floated by hand or machine sufficiently to produce a uniform
surface free from screed marks.
3. Class U3: When the moisture film has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a Class
U1 surface shall be steel-trowelled under firm pressure to produce a dense,
smooth uniform surface free from trowel marks.
5.4.6 Tolerances
A The tolerances in the forms and formwork shall be such that members formed shall be
within the tolerances for the size and type of the member specified elsewhere in the
Specification.
B Falsework shall be fixed such that the completed structure shall be within the required
tolerances in plan, elevation and slope for the size and type of structure specified
elsewhere in the Specification.
C Surfaces which are to receive deck waterproofing shall be finished to an accuracy such
that when tested with a three meter long straight edge, the maximum depression shall not
exceed five mm.
5.4.7 Construction Requirements
A The forms and falsework shall be inspected by the Engineer after assembly on the work
area and immediately before concreting. No pour shall commence until the forms and
falsework have been approved by the Engineer.
B The inside surfaces of all forms shall, except for pavement formwork, or unless otherwise
agreed by the Engineer, be coated with a release agent approved by the Engineer.

Release agents shall be applied strictly in accordance with the manufacturer’s instructions
and shall not come into contact with the reinforcement or prestressing tendons and
anchorages. Different release agents shall not be used in formwork which will be visible in
the finished work.
C Immediately before concrete is placed, all forms shall be thoroughly cleaned out.
D Forms that are to be re-used shall be thoroughly cleaned and re-oiled and, if necessary,
shall be reconditioned by revision or reconstruction. Unsatisfactory lumber will be
condemned by the Engineer, and shall be removed from the Site.
E Formwork shall be constructed so that the side forms of members can be removed without
disturbing the soffit forms. If props are to be left in place when the soffit forms are
removed, these props shall not be disturbed during the striking. Top shuttering is to be
provided to concrete if the slope angle exceeds 25 degrees.
F Runways used to move plant, equipment or materials shall be clear of the reinforcement
and shall be robust enough not to deflect excessively or cause movement to the forms due
to dynamic effects.
G During concreting, the forms and their supports shall be constantly monitored for signs of
imminent failure. There shall be skilled operatives in constant attendance during
concreting who are qualified to make immediate adjustments to the forms and falsework so
that concreting can satisfactorily be completed.
H The Engineer may suspend concreting operations if, in his opinion, the forms and
falsework are in danger of failure and that the actions taken by the Contractor are
insufficient or inadequate to guarantee the safe and satisfactory completion of concreting.
In such an event, the Engineer may instruct the Contractor to remove, at his expense, the
concrete already poured.
I If at any period of work, during or after placing of concrete, the forms show signs of
sagging or bulging, the Contractor, at his own expense, shall remove the concrete to the
extent directed by the Engineer, bring the forms to the proper position, and place concrete.
J Immediately after the removal of the forms, all fins caused by form joints and other
projections shall be removed and all pockets cleaned and filled with a cement mortar
composed of 1 part by volume of Portland cement and 2 parts sand. Sufficient white
Portland cement shall be mixed with the cement in the mortar, so that when dry the colour
will match the surrounding concrete. Patches shall be moistened prior to mortaring to
obtain a good bond with the concrete. When directed by the Engineer, the Contractor shall
at his own expense, substitute an approved epoxy grout for the Portland cement mortar or
provide an epoxy bonding agent to be used in conjunction with the Portland cement
mortar. If, in the judgment of the Engineer, pockets are of such extent or character as to
materially affect the strength of the structure or to endanger the life of the steel
reinforcement, he may declare the concrete defective and require the removal and
replacement of that portion of the structure affected. The resulting surfaces shall be true
and uniform. Portions of the structure which cannot be finished or properly repaired to the
satisfaction of the Engineer shall be removed.
5.4.8 Removal of Formwork and Falsework
A To facilitate finishing, forms on handrails, ornamental work, and other vertical surfaces that
require a rubbed finish, shall be removed as soon as the concrete has hardened
sufficiently that it will not be injured, as determined by the Engineer. In determining the
time for the removal of forms, consideration shall be given to the location and character of
the structure, weather and other conditions influencing the setting of the concrete.

B Formwork shall be removed in a manner not to damage the concrete, and at times to suit
the requirements for its curing and to prevent restraint that may arise from elastic
shortening, shrinkage or creep.
C Any remedial treatment to surfaces shall be agreed with the Engineer following inspection
immediately after removing the formwork and shall be carried out without delay. Any
concrete surface which has been treated before being inspected by the Engineer, shall be
liable to rejection.
D Where the concrete compressive strength is confirmed by tests on concrete cylinders

(cubes) stored under conditions approved by the Engineer that simulate the field
conditions, formwork supporting concrete in bending may be struck when the strength is 10
N/sq.mm or three times the stress to which it will be subjected, whichever is the greater.
E For ordinary structural concrete made with ordinary Portland cement only, in the absence
of control cylinders (cubes) the period before striking shall be in accordance with the
minimum periods given in Table 5.4.2 unless otherwise directed by the Engineer.
Table 5.4.2: Minimum Period Before Striking for Ordinary Structural Concrete Made With Ordinary Portland
Cement
Minimum Period Before Striking
Type of Formwork Surface Temperature of Concrete
16˚C 7˚C t˚C
Vertical formwork to columns, walls and large 300

12 hours 18 hours hours
beams
t  10
100
Soffit formwork to slabs 4 days 6 days days
t  10
100
Props to slabs 10 days 5 days days
t  10
230
Soffit to formwork to beams 9 days 14 days days
t  10
360
Props to beams 14 days 21 days days
t  10
5.5 PLAIN AND REINFORCED CONCRETE STRUCTURES
5.5.1 Generally
A Scope
1. This Section of the Specification describes the construction of plain and reinforced
concrete structures.
5.5.2 MATERIALS
A Concrete
1. Concrete shall be produced and supplied in accordance with Section 5.01 “Concrete and
Concrete Mixes and Testing”.
B Reinforcement

1. Reinforcement shall conform to Section 5.03 “Steel Reinforcement and Fixing”.
C Formwork and Falseworks
1. Formwork and Falsework shall be designed and supplied in accordance with Section 5.04
“Forms, Formwork and Falsework”.
D Plant and Equipment
1. Plant and Equipment shall conform with the requirements set in Volume 1 and shall be
according to the type and number outlined in the Contractor’s detailed Program of Work as
5.5.3 Construction
A General
1. The Contractor shall notify the Engineer his intention to concrete at least 24 hours in
advance.
2. The Engineer shall check and certify that:
a) The form and formwork meet the Specification requirements.
b) The falsework and support props are in accordance with the approved Drawings.
c) The reinforcement conforms to the Drawings and that the correct covers have been
provided.
d) The forms are free of dirt and other deleterious matter.
B Concreting
1. Handling, placing and curing shall be in accordance with Section 5.02 “Concrete Handling,
Placing and Curing”.
C Slump
1. Slump shall be within the limits given in Section 5.02 of the Specification.
D Construction and Expansion Joints
1. Whenever the work of placing concrete is delayed until the concrete shall have taken its
initial set, the point of stopping shall be deemed a construction joint. So far as possible the
location of construction joints shall be as shown on the Drawings, but if not shown on the
Drawings, they shall be planned in advance and the placing of concrete carried out
continuously from joint to joint. The joints shall be perpendicular to the principal lines of
stress and in general be located at points of minimum shear.
2. Where dowels, reinforcing bars or other adequate ties are not required by the
Drawings, keys shall be made by embedding water soaked bevelled timbers in soft
concrete. The key shall be sized as shown on the details, or as directed by the
Engineer, which shall be removed when the concrete has set. In resuming work
the surface of the concrete previously placed shall be thoroughly cleaned of dirt,
scum, laitance or other soft material with stiff wire brushes, and if deemed
necessary by the Engineer, shall be roughened with a steel tool. The surface shall
then be thoroughly washed with clean water and pointed with a thick coat of neat
cement mortar, after which the concreting may proceed.
3. Expansion joints shall be constructed at the locations, of the materials and to the
dimensions shown on the Drawings.
E Cold Joints
1. When the continuous placement of concrete in any structural member is interrupted or

delayed, for any reason, for a period long enough for the previously partially placed

concrete to take its initial set, the Engineer shall declare such a joint a cold joint in which
case the Contractor shall immediately remove the previously partially placed concrete from
the forms. No extra payment will be made for the initial placement or the removal of
concrete which is wasted because of a cold joint. The Engineer may suspend all or any
part of the subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.
2. The Engineer may, with due consideration to the location of the cold joint and/or
the importance of the member, allow the Contractor to retain the partially placed
concrete and complete the concreting by a subsequent pour, which for permission,
the Engineer shall instruct the Contractor to carry out at his own expense some or
all of the following measures before completing the pour:
a) Surface leitance shall be removed from the surface of the partially placed concrete
by wire brushing or light tooling or by sand blasting as directed by the Engineer
without damage to reinforcement and formwork.
b) Shear keys shall be cut in the partially placed concrete. The shape, size and
orientation of the shear keys shall be as directed by the Engineer. The reinforcement and
formwork shall not be damaged.
c) The cleaned surface of the partially placed concrete shall be coated with an
approved bonding agent before placing the subsequent pour.
d) Additives to facilitate bonding shall be added to the concrete used for the
subsequent pour.
e) Dowel bars of a type and length to be approved by the Engineer shall be installed in
the partially placed concrete using non-shrink cement grout or resin grout as directed by the
Engineer. The size and spacing of the dowel bars shall be approved by the Engineer. Their
installation shall not damage the reinforcement or formwork.
f) The partially placed concrete and the subsequent concrete shall be stressed by
prestressing bars of a size and type approved by the Engineer to achieve a level of compressive
stress at the interface approved by the Engineer. The method of installing the prestressing bars
and type of anchors used shall be approved by the Engineer. Unless otherwise agreed by the
Engineer, the drill hole shall be grouted with a cement grout containing expanding additive to the
manufacturer’s recommendations.
F Finishing
1. To be as shown on Drawings.
G Concrete Cover to Reinforcement
1. The cover shall be not less than the size of the bar or the maximum aggregate size plus 5
mm or as shown on drawings. In the case of bundled bars, it shall be equal to or greater
than the size of a single bar of equivalent area plus 5 mm.
2. Where surface treatment such as grooved finish or bush hammering cuts in to the
face of the concrete, the expected depth of the treatment shall be added to the
cover.
3. The cover to reinforcement should also be determined by considerations of
durability under the envisaged conditions of exposure. Minimum cover to
reinforcement under particular severe conditions shall be determined by Engineer
on site.
H Tolerances
1. The horizontal and vertical dimensions of in-situ concrete members, but not cross-sections,
shall be within the following tolerances:
Length (mm) Tolerance (mm)
Up to 3000 ±3

3001-4500 ±6
Vertical lines out of plane ± 5 + 1 for every 3000 out of true
line.
2. Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams,
columns, piers etc., shall be within the following tolerances:
Member Dimensions (mm) Tolerance (mm)
Up to 500 6
501 -750 10
Additional for every subsequent 100 mm ±1 mm
3. The horizontal and vertical dimensions of pre-cast members, but not cross-
sections, shall be within the following tolerances:
Up to 3000 ±2
3000 and over ±5
4. Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams,
columns, piers etc., shall be within a tolerances of ± 3 mm.
Up to 500 6
501- 750 9
Additional for every subsequent
250 mm ±3 mm
5. For in-situ and pre-cast construction the tolerance between the short side and the
long side shall be within the following limits:
Member Size (mm) Tolerance (mm)
Up to 3000 ±3
3000 and over ±6
6. For in-situ and precast construction the straightness or bow, defined as deviation
form the intended line, shall be within the following tolerances:
Member Length (mm) Tolerances (mm)
Up to 3000 ±3
3000 and over ±6
7. The alignment of members shall be within the following tolerances:
 Column and Piers: 1:400 of column or pier length.
 Others: 1:600 of length.
8. The flatness of a surface, measured with a straight edge of 1.5 meter, shall be not
greater than 6 mm at any point.
9. Twist, measured as the deviations of any corner from the plane containing the
other three corners, shall be within the following limits.
Member Length (mm) Tolerance (mm)
Up to 6000 6
Above 6000 12

5.6 WATERPROOFING FOR STRUCTURES
5.6.1 General
A Scope
1. These works shall consist of furnishing and placing approved waterproofing membrane
and dampproofing course to external concrete surfaces in contact with earth and furnishing
and placing epoxy coating to internal surfaces of concrete walls, slabs, and beds and
furnishing and installing waterstops to waterproof construction and expansion joints, all as
shown on the Drawings or as directed by the Engineer.
5.6.2 Materials
A Asphalt
1. Waterproofing asphalt shall conform to AASHTO M 115 (ASTM D 449); Type I for use
below ground, and Type II for use above ground.
2. Primer for use with asphalt in waterproofing shall conform to AASHTO M 116
(ASTM D 41).
B Bitumen
1. Waterproofing bitumen shall conform to AASHTO M 118 (ASTM D 450). Type II shall be
furnished unless otherwise specified.
2. Primer for use with coal-tar bitumen in dampproofing and waterproofing shall
conform to AASHTO M 121 (ASTM D 43).
C Waterproofing Fabric
1. Waterproofing fabric shall conform to AASHTO M 117 (ASTM D 173).
D Self-Adhesive Polyethylene Sheet
1. Flexible, preformed waterproof membrane comprising strong, high-density polyethylene

film with self-adhesive rubber/bitumen com-pound, and having the following minimum
properties:
 Total thickness : 1.5 mm
 Weight : 1.6 kg/m2
 Tensile strength : 42 n/mm2
 Elongation: 210% long. ; 160% trans.
 : Tear resistance 340 n/mm long. ; 310 n/mm trans.
 : Puncture resistance : 220 n 65 mm
or other equal and approved.
E Tar for Absorptive Treatment
1. Tar for absorptive treatment shall be a liquid water-gas tar that conforms to the following
requirements:
 Specific gravity, 25/25ºC ............1.030 to 1.100
 Specific viscosity at 40ºC (Engler), not more than ........................3.0
 Total distillate, percent by weight, to 300ºC, not more than .........50.0
 Bitumen (soluble in carbon disulfide) not less than, percent ......98.0
 Water, not more than, percent.......................................................3.0

F Tar Seal Coat
1. Tar seal coat shall conform to AASHTO M 52, Grade RTCB-5 (ASTM D 490).
G Joint Fillers
1. Filler for use in horizontal and vertical joints in waterproofing work shall be a straight
refined oil asphalt conforming to the following requirements:
 Flash point : Not less than 232ºC.
 Softening point : 48.9ºC to 54.4ºC.
 Penetration : At 0ºC, 200 grams, 1 minute, not less than
15.At 25ºC, 100 grams, 5 seconds, 50 to 60.
At 46ºC, 50 grams, 5 seconds, not more than
300.
 Loss on heating : At 163ºC, 50 grams, 5 hours, not more than
0.5 percent.
 Ductility : At 25ºC, 5 centimeters per minute, not less
than 85.
 Total bitumen (soluble in carbon disulfide): not less than 99.5 percent.
H Waterstops
1. Extruded PVC, heavy duty, of the types and sizes shown on the Drawings, and complete
with junction pieces shall be obtained from any of the following manufacturers:
 Expandite Ltd.
 Greenstreak Plastic Products
 Servicised Ltd
2. Copper water stops shall be copper sheets of the thickness shown on the
Drawings and shall conform to the requirements of AASHTO M 138 (ASTM B 152).
3. Plain rubber water stops shall be formed from a stock composed of a high grade
compound made exclusively from new plantation rubber, reinforcing carbon black,
zinc oxide, accelerators, anti-oxidants, and softeners. This compound shall
contain not less than 72 percent by volume of new plantation rubber. The tensile
strength shall be not less than 246 kg per sq.cm, with an elongation at breaking of
550 percent when tested in accordance with ASTM D 412. The unit stresses
producing 300 percent and 500 percent elongation shall be not less than 77 kg.
and 198 kg. per sq.cm, respectively. The Shore Durometer indication (hardness)
shall be between 55 and 65 when tested in accordance with ASTM D 676. After 7
days in air at 126 degrees (plus or minus 1 degree) C or after 48 hours in oxygen
at 126 degrees (plus or minus 1 degree) C both at 21 kg per sq.cm, the tensile
strength and elongation shall not be less than 65 percent of the original when
tested in accordance with ASTM D 572.
4. Synthetic rubber water stops shall be formed from a compound made exclusively
from neoprene, or SBR, reinforcing carbon black, zinc oxide, polymerization
agents, and softeners. This compound shall contain not less than 70 percent by
volume of neoprene or SBR. The tensile strength shall be not less than 175 kg.
per square centimeter with an elongation at breaking of 425 percent when tested
in accordance with ASTM D 412. The Shore Durometer indication (hardness) shall
be between 50 and 70 when tested in accordance with ASTM D 676. After 7 days
in air at 126 degrees (plus or minus 1 degree) C or after 48 hours in oxygen at
126 degrees (plus or minus 1 degree) C, and 21 kg per sq.cm. pressure, the

tensile strength shall be not less than 65 percent of the original when tested in
accordance with ASTM D 572.
I Proprietary Waterproofing Systems
1. Proprietary waterproofing systems shall be bituminous membranes reinforced with layers

of suitable reinforcement, bituminous coated polythene sheet, plasticized polyvinyl chloride
sheet, other approved membranes or applications of resinous reinforced coatings. The
type to be used shall be as indicated on the Drawings and shall be chosen according to its
location and serviceability. The specific system shall be approved after site trials, should
the Engineer decide these to be necessary.
J Epoxy Coating System

1. An approved epoxy coating system shall be furnished and applied to the internal concrete
surfaces of culverts and open channels as shown on the Drawings or as directed by the
Engineer. The thickness of the epoxy coating shall be at least 400 microns in accordance
with the manufacturer’s recommendations.
K Chemical Water Proofing Coating
1. Chemical waterproof coating shall be surface-applied material that causes capillary

waterproofing system to protect concrete in-depth. Manufacturer’s details are as follows:
Man: Xypex Chemical Corporation

Ref.: Xypex
Man: Meynadier
Ref.: Barra Slurry
Vandex International Ltd.

Vandex Super, Vander Premix
Master Builders Technologies

Masterseal 501/502.
5.6.3 Surface Preparation
A Waterproofing
1. All concrete surfaces which shall be waterproofed shall be reasonably smooth and free
from projections or holes which might cause puncture of the membrane. The surface shall
be dry, so as to prevent the formation of steam when the hot asphalt or tar is applied, and,
immediately before the application of the waterproofing, the surface shall be thoroughly
cleaned of dust projecting tying wire and loose material.
2. No waterproofing shall be done in wet weather, nor when the temperature is below
4 degrees C, without special authorization from the Engineer. Should the surface
of the concrete become temporarily damp, it shall be covered with a 50 mm layer
of hot sand, which shall be allowed to remain in place from 1 to 2 hours, or long
enough to produce a warm and surface-dried condition, after which the sand shall

be swept back, uncovering sufficient surface for beginning work, and the operation
repeated as the work progresses.
B Dampproofing
1. The surface to which the dampproofing coating shall be applied shall be cleaned of all
loose and foreign material and dirt and shall be dry. When necessary the Engineer may
require the surface to be scrubbed with water and a stiff brush, after which the surface
shall be allowed to dry before application of the primer.
5.6.4 Inspection, Delivery and Storage
A All waterproofing materials shall be tested before shipment. Unless otherwise ordered by
the Engineer, they shall be tested at the place of manufacture, and, when so tested, a copy
of the test results shall be sent to the Engineer by the chemist or inspection bureau which
has been designated to make the tests, and each package shall have affixed to it a label,
seal, or other mark of identification, showing that it has been tested and found acceptable,
and identifying the package with the laboratory tests.
B Factory inspection is preferred, but in lieu thereof and/or addition thereof, the Engineer
may order that representative samples, properly identified, be sent to him for test prior to
shipment of the materials. After delivery of the materials, representative check samples
shall be taken which shall determine the acceptability of the materials.
C All materials shall be delivered to the work in original containers, plainly marked with the
manufacturer’s brand or label.
D Water proofing and damp proofing material shall be stored in a dry, protected place. Rolls
of waterproofing fabric and membranes shall not be stored on end.
5.6.5 CONSTRUCTION
A Asphalt and Bitumen Waterproofing Fabric
1. Asphalt shall be heated to a temperature between 148.7 degrees C and 176.5 degrees C
and tar for hot application shall be heated to a temperature between 93.3 degrees C and
121 degrees C with frequent stirring to avoid local overheating. The heating kettles shall
be equipped with thermometers.
2. In all cases, the waterproofing shall begin at the low point of the surface to be
waterproofed, so that water will run over and not against or along the laps.
3. The first strip of fabric shall be of half-width; the second shall be full-width, lapped
the full-width of the first sheet; and the third and each succeeding strip shall be full-
width and lapped so that there will be two layers of fabric at all points with laps not
less than 50 mm wide. All end laps shall be at least 300 mm.
4. Beginning at the low point of the surface to be waterproofed, a coating of primer
shall be applied and allowed to dry before the first coat of asphalt is applied. The
waterproofing shall then be applied as follows.
5. Beginning at the low point of the surface to be waterproofed, a section about 500
mm wide and the full length of the surface shall be mopped with the hot asphalt or
tar, and there shall be rolled into it, immediately following the mopping, the first
strip of fabric, or half-width, which shall be carefully pressed into place so as to
eliminate all air bubbles and obtain close conformity with the surface. This strip
and an adjacent section of the surface of a width equal to slightly more than half of
the width of the fabric being used shall then be mopped with hot asphalt or tar, and
a full width of the fabric shall be rolled into this, completely covering the first strip,
and pressed into place as before. This second strip and an adjacent section of the
concrete surface shall then be mopped with hot asphalt or tar and the third strip of
fabric “shingled” on so as to lap the first strip not less than 50 mm. This process

shall be continued until the entire surface is covered, each strip of fabric lapping at
least 50 mm over the last strip. The entire surface shall then be given a final
mopping of hot asphalt or tar.
6. The completed waterproofing shall be a firmly bonded membrane composed of
two layers of fabric and three moppings of asphalt or tar, together with a coating of
primer. Under no circumstances shall one layer of fabric touch another layer at
any point or touch the surface, as there must be at least three complete moppings
of asphalt or tar.
7. In all cases the mopping on concrete shall cover the surface so that no gray spots
appear, and on cloth it shall be sufficiently heavy to completely conceal the weave.
On horizontal surfaces not less than 49 liters of asphalt or tar shall be used for
each 10 sq.m. of finished work, and on vertical surfaces not less than 61 liters
shall be used for each 10 sq.m. The work shall be so regulated that, at the close
of a day’s work, all cloth that is laid shall have received the final mopping of
asphalt or tar. Special care shall be taken at all laps to see that they are
thoroughly sealed down.
8. At the edges of the membrane and at any points where it is punctured by such
appurtenances as drains or pipes, suitable provisions shall be made to prevent
water from getting between the waterproofing and the waterproofed surface.
9. All flashing at curbs and against girders, spandrel walls, etc., shall be done with
separate sheets lapping the main membrane not less than 300 mm. Flashing shall
be closely sealed either with a metal counter-flashing or by embedding the upper
edges of the flashing in a groove poured full of joint filler.
10. Joints which are essentially open joints but which are not designed to provide for
expansion shall first be caulked with oakum and lead wool and then filled with hot
joint filler.
11. Expansion joints, both horizontal and vertical, shall be provided with sheet copper
or lead in “U” or “V” form in accordance with approved details. After the membrane
has been placed, the joint shall be filled with hot joint filler. The membrane shall
be carried continuously across all expansion joints.
12. At the ends of the structure the membrane shall be carried well down on the
abutments and suitable provision made for all movement.
B Proprietary Waterproofing Membranes
1. Proprietary waterproofing membranes shall be installed strictly in accordance with the

manufacturer’s instructions and shall be laid so that no air is trapped between it and the
concrete surface or between successive layers of sheeting.
2. Unless otherwise specified joints between sheets shall be lapped with end laps of
at least 150 mm and side laps of at least 100 mm. The joints shall be arranged so
that at no points are there more than three thicknesses of sheeting and, as far as
possible so that water will drain away from the exposed edge.
C Damage Patching of Waterproofing Fabrics
1. Care shall be taken to prevent injury to the finished fabric membrane by the passage over
it of workmen or wheelbarrows, or by throwing any material on it. Any damage which may
occur shall be repaired by patching. Patches shall extend at least 300 mm beyond the
outermost damaged portion and the second ply shall extend at least 75 mm beyond the
first.
2. Proprietary waterproofing membranes shall be repaired according to the
manufacturer’s specifications and as directed by the Engineer.
D Dampproofing
1. Concrete, brick, or other surfaces that shall be protected by dampproofing shall be

thoroughly cleaned before the primer is applied. They shall then be brush or spray painted

with two or more coats (as indicated on the Drawings) of tar or asphalt for absorptive
treatment. Below ground not less than two coats shall be applied, using 0.56 L/sq.m. of
surface. On the well-primed surface one application of tar or asphalt seal coat shall be
applied by brush, using 0.45 L/sq.m.
2. Care shall be taken to confine all paints to the areas to be waterproofed and to
prevent disfigurement of any other parts of the structure by dripping or spreading
of the tar or asphalt.
E Protection of Waterproofing and Dampproofing
1. Over the waterproofing membrane and dampproofing course, there shall be constructed a
protection course which, unless otherwise specified or shown on the Drawings, shall be a
50 mm course of mortar mixed in the proportion of one part Portland cement and two parts
sand. This mortar course shall be reinforced midway between its top and bottom surfaces
with wire netting of 150 mm mesh and No. 12 gauge, or an approved equivalent. The top
surface shall be troweled to a smooth, hard finish and, where required, true to grade.
2. The construction of the protection course shall follow the waterproofing so closely
that the latter will not be exposed without protection for more than 24 hours.
3. Unless otherwise shown on the Drawings or directed by the Engineer, vertical
faces waterproofed or dampproofed shall be protected by a porous concrete block
wall of not less than 225 mm thickness. If approved by the Engineer, a proprietary
synthetic sheeting may be used as the protective layer in lieu of the porous
concrete block wall.
F Chemical Waterproofing
1. Conditions and rate of application shall be in accordance with manufacturer’s

recommendations.
G Water Stops
1. Copper sheets for water stops shall be of the width and shall be bent to the shapes shown
or ordered. The sheet copper in each joint shall be continuous, separate pieces being
connected by thoroughly workmanlike soldered joints to form a complete watertight unit.
The sheet copper shall be placed in such manner as to ensure its embedment in the
concrete on each side of the joints in the positions shown on the Drawings.
2. Rubber water stops shall be installed in accordance with the details shown on the
Drawings. The water stops shall be formed with an integral cross section which
shall be uniform within 3 mm in width and the web thickness or bulb diameter,
within plus 1.5 mm and minus 0.75 mm. No splices shall be permitted in straight
strips. Strips and special connection pieces shall be well cured in a manner such
that any cross section shall be dense, homogenous, and free from all porosity. All
junctions in the special connection pieces shall be full molded. During the
vulcanizing period the joints shall be securely held by suitable clamps. The
material at the splices shall be dense and homogenous throughout the cross
section. Field splices shall be either vulcanized, mechanical, using stainless steel
parts, or made with a rubber splicing union of the same stock as the water stop, at
the option of the Contractor. All finished splices shall demonstrate a tensile
strength of not less than 50 percent of the unspliced material.
H Testing
1. Unless otherwise agreed by the Engineer in writing, at least one site trial application of the
waterproofing system shall be carried out to determine the suitability of the surface
preparation, method of application and effectiveness of the protective layer. The size of
membrane laid shall be not less than 2.0 meters wide and 5.0 meters long.

5.7 JOINT SEALING AND JOINT FILLER
5.7.1 General
A Scope
1. These works shall consist of furnishing and installing joint sealing and preformed
expansion joint filler materials as and where shown on the Drawings, or as directed by the
Engineer.
5.7.2 Materials: Joint Sealing Compounds
A Hot Type
1. This type shall be a mixture of virgin synthetic rubber or reclaimed rubber, or a combination
of the two, with asphalt plasticisers and tactified. Ground cured rubber scrap shall not be
used.
2. The joint sealing compound, after heating and application, shall form a resilient
and adhesive compound capable of effectively sealing joints in concrete against
the infiltration of moisture and foreign material through repeated cycles of
expansion and contraction. It shall be capable of being brought, by heating, to a
uniform, smooth pouring consistency, free from lumps, and suitable for completely
filling the joints and without damage to the material. It shall not flow from the joints
or be picked-up and tracked by vehicle tyres at summer temperatures.
3. The pour point shall be at least 11 degrees C lower than the safe heating
temperature. The safe heating temperature is defined as the highest temperature
to which the material can be heated and still meet all requirements of this
specification. No sample of the material will be tested until the manufacturer
furnishes his recommended safe-heating and pouring temperatures.
4. After 6 hours of continuous heating, with constant mixing in the laboratory at the
manufacturer’s recommended pour temperature, the joint sealer shall meet all
requirements of this specification.
5. The penetration at 25 degrees C, 150 gm, 5 sec, shall not be less than 50 mm nor
more than 90 mm.
6. The flow at 60 degrees C and at a 75 degree angle shall not exceed 10 mm in 5
hours.
7. Ductility at 25 degrees C shall be not less than 350 mm.
8. The material when tested at minus 17.8 degrees C to 100 percent extension 1270
mm extended to 2540 mm shall, after 5 cycles, show no surface checking,
cracking, separation or other opening in the material or between the material and
the block. At least 2 test specimens in a set of 3 specimens representing a given
sample shall meet this requirement.
9. Recovery shall be not less than 25 percent.
10. Compression recovery of bond specimens shall be not less than 10 mm in 15
minutes.
11. No failure in cohesion or adhesion shall occur.
12. Samples for testing shall consist of not less than a 4.5 kilogram sample from each
batch of the joint sealer. A batch shall be considered as all finished material that
was manufactured simultaneously or continuously as a unit between the time of
compounding and the time of packaging or placing in shipping containers. Each
package or container shall be marked properly to indicate clearly the batch of
which it forms a part. The material shall be sampled in accordance with the
requirements of the “Standard Methods of Sampling Bituminous Materials” (ASTM
D140) for solid materials in cakes.

13. Testing shall be in accordance with AASHTO T 187 except that the tolerances on
dimensions of test specimens, Article 6.3 shall be + 0.13 cm and the temperature
tolerances, Article 6.4 shall be + 2.2 degrees C.
B Cold Type
1. This type shall be homogeneous material of such consistency that it can be applied by
means of high-pressure pump through suitable nozzles to completely fill the joints. The
compound may be blended with a suitable solvent or solvents by the manufacturer to
provide better workability during installation in the joints. The volatility of these solvents
must be such that they will evaporate within a short time after installation leaving a material
that is adhesive and resilient.
2. The flow during a 5 hour period at 60 degrees C shall not exceed 50 mm.
3. After evaporation of the solvent, the penetration at 25 degrees C, 150 gm, 5 sec,
shall not exceed 220 mm.
4. When the compound is tested at minus 17.8 degrees C, the development at any
time during the test procedure of a crack, separation or other opening which is at
any point over 64 mm deep in the material or between the material and the
concrete block, shall constitute failure of the test specimen. The failure of more
than 1 test specimen in a group of 3 specimens, representing a given sample of
joint sealing compound shall be cause for rejection of the sample on the basis of
this requirement.
5. Cold-type joint compound shall be tested in accordance with ASTM D 1851,
except that the material for test specimens Article 7(c) will be stirred manually
rather than mechanically.
6. Preformed Polychloroprene Elastomeric Joint Seals shall comply with the
requirements of AASHTO M 220 (ASTM D 2628).
C Joint Sealant for movement joints in water retaining structures shall be polysulphide based
compound to BS 4254 or as manufactured by:
Man: Expandite Ltd.

Ref: Thioflex 600
Man: Servicised Ltd.

Ref: Paraseal
D Exposed Joint Sealant for movement joints is to be ap-proved polysulphide rubber based
compound unless otherwise specified.
Man: Dunlop Ltd.

Ref: High butyl mastic 421.8
Man: Expandite Ltd.

Ref: Thioflex 600
E Backing strip shall be the type recommended by joint sealant manufacturer.
5.7.3 Preformed Expansion Joint Filler
A Description

1. This type of filler shall be a non-extruding and resilient bituminous type and shall have
relatively little extrusion and a moderate to high amount of recovery after release from
compression.
B Requirement
1. Nonextruding and resilient type of expansion joint filler shall conform to all the
requirements of the Standard Specification for “Preformed Expansion Joint Fillers for
Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous
Types)”, AASHTO M 213 (ASTM D 1751).
C Movement Joint Sheet Material Filler
1. For expansion joints in water retaining structures is to be bonded granular cork to ASTM D
1752 or ASTM D 1751 or as manufactured by:
Man: Expandite Ltd
Ref: Cork filler
Man: Servicised Ltd

Ref: Kork-Pak
5.7.4 Certificate of Guarantee
A The Contractor shall furnish the Engineer with a manufacturer’s certificate of guarantee for
each type of joint material delivered to the Site. The certificate shall note compliance with
the appropriate specifications and shall state the results of the tests performed on the
material, as required by the specifications. The Contractor shall, when so directed by the
Engineer, have the joint material tested for conformance to the applicable specifications at
an approved testing laboratory. All costs connected with certificate of guarantee and any
subsequent quality testing shall be at the Contractor’s expense.
5.7.5 Construction
A Joints shall be:
 Straight, vertical, horizontal or as detailed or ap-proved.

 Formed to accommodate projecting reinforcement.
B Movement joints are defined as:
 Formed expansion joints.

 Formed contraction joints.
 Induced contraction joints.
C Formed Movement Joints: Construct rigid stop ends and formwork at formed movement
joints to permit separate con-struction of structurally separate parts of the work.
D Construction Joints: Where not coincident with movement joints submit proposals for
positions of construction joints and obtain approval.
E Construction Joints: Lightly roughen face to expose coarse aggregate unless otherwise
instructed. Wet and cover with 1:1 cement and sand grout immediately prior to placing
fresh concrete. Stop roughening 25 mm from arrises to sur-faces exposed to view in
finished work. Remove small mortar lips from exposed arrises with carborundum stone.
Face is to be clean and damp before fresh concrete is placed against it.

F Concrete Floors: Side and end forms are to be square edged with steel top surface.
G Waterbars: Nail to forms prior to concreting and butt joint in accordance with the
manufacturer’s instructions.
H Sealing of Movement Joints: Preparation and application is to be strictly as manufacturer’s

recommendations. Joints are to be thoroughly clean and dry, free from oil and loose
material. Vigorously wire brush or grit blast the joint faces and clean out with compressed
air. Prime faces of joint and allow to dry. Where exposed to view mask edges of joint with
tape before priming and remove immediately after sealing. Apply sealant ensuring
maximum adhesion to sides of joint and a neat, smooth and clean finish.

PART 6 SUMP PUMPS
6.1 GENERAL
6.1.1 RELATED DOCUMENTS
I Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.
6.1.2 SUMMARY
J Section Includes:
1. Submersible sump pumps.
K Related Section:
1. Section 221329 "Sanitary Sewerage Pumps" for effluent and sewage pumps.
6.1.3 ACTION SUBMITTALS
L Product Data: For each type of product indicated. Include construction details, material
descriptions, dimensions of individual components and profiles and Include rated
capacities, operating characteristics, electrical characteristics, and furnished specialties
and accessories.
M Wiring Diagrams: For power, signal, and control wiring.
6.1.4 CLOSEOUT SUBMITTALS
N Operation and Maintenance Data: For pumps and controls, to include in operation and
maintenance manuals.
6.1.5 QUALITY ASSURANCE
O Electrical Components, Devices, and Accessories: Listed and labelled as defined in

NFPA 70, by a qualified testing agency, and marked for intended location and application.
P UL Compliance: Comply with UL 778 for motor-operated water pumps.
6.1.6 DELIVERY, STORAGE, AND HANDLING
Q Retain shipping flange protective covers and protective coatings during storage.
R Protect bearings and couplings against damage.
S Comply with pump manufacturer's written rigging instructions for handling.
6.2 PRODUCTS
6.2.1 SUBMERSIBLE SUMP PUMPS
A The unit shall be provided complete with anti-corrosion coated receiver tank with two
submersible sewage pumps, one duty and one standby, all necessary controls including
rotary-contact level switches, control gear with mains operated alarm and volt-free contacts

for remote failure indicators. Control gear shall be arranged for automatic changeover
after each pumping sequence.
B Wastewater and sewage pump with maintenance-free and liquid less cooling system for
permanent operation in dry or submerged installations.
C The pump design must allow an unrestricted free passage of fibres and particles up to 80
mm to pass through the pump.
D A connection between the pump housing and the stator housing must be without the use of
bolts to ensure easy inspection and service of impeller and shaft seal.
E The unit shall be damp and flood-proof suitable for placing in an unventilated area.
F Each pump shall be suitable for pumping surface wastewater containing small solids and
be capable of operation with fluids at temperatures of up to 50 degree C and complete with
an automatic thermal cut-out to protect the pump at higher temperatures.
G Submerged pump installation, pump installed on auto-coupling system. It is required that

the pump installed on auto-coupling system features a guide claw with a leak-proof nitrile
rubber gasket for increased system efficiency
H The pump must have a built-in thermal switch in motor windings along with a moisture
switch.
I Motors shall be protected against damage from dry operation, over frequent starting and
jammed impeller.
1. Insulation class F (155°C)
2. Enclosure class IP68
3. The motor must be cooled without the use of any cooling liquid (liquid-less cooling).
This applies to pumps in both dry and submerged installations.
4. Power cable featuring wires for thermal motor protection in the motor windings.
J Operation and control of duplicate drainage pump installations shall be as follows: -
1. The selected duty pump shall start on the liquid level rising to operate the 'Start Duty
Pump' control and shall stop on a fall in the liquid level operating the 'off' control.
2. The standby pump shall automatically operate in unison with the duty pump if the
liquid level rises to operate the 'Start Standby' control.
3. In the event of failure of the duty pump the standby pump shall operate when the liquid
level rises to operate the 'Start Standby' control.
4. At the end of each pumping cycle, the duty and standby pumps shall automatically
change over, i.e., the standby pump would become the lead duty pump for the
following pumping cycle and vice-versa.
5. The alarm system shall operate if the liquid level rises to operate the 'High Water
Alarm' control.
K The pump set shall be complete with a local wall mounted starter/control/indication panel
comprising: -
i. Main incoming supply electrical isolator interlocked with panel door.

ii. Pilot lamp to indicate panel 'live'.
iii. Starter for each pump with facilities for automatic duty pump selection and
changeover.
iv. Run and tripped pilot lamps for each pump.
v. Pilot lamp to indicate high water level in sump.

vi. Volt-free contacts for the purposes of remote monitoring
L The pumps control system shall incorporate facilities allowing connections by others for
remote monitoring by a BMS as follows: -
i. Duty Pump Failure.

ii. Standby Pump Failure.
iii. High Water Level Alarm.
iv. Recording of hours run for each pump.
M Pump construction
i. Pump housing, motor top and Impeller should be Cast Iron. Impeller to be Vortex or
closed tube type
ii. The Vortex impeller in the pump must be self-cleaning with winglets for improved
hydraulic efficiency.
iii. Double mechanical cartridge shaft seal allowing rotation in either direction.
iv. Stainless steel cable plug filled with cast in sealing barrier to prevent moisture from
penetrating into the motor via the cable core M.M. Motors shall be provided in
accordance with the requirements of the 'Electrical Equipment' Section of this
Specification N.N. Voltage, phases and frequency of the electrical supply to each
pump are stated in the Technical Schedules.
6.3 EXECUTION
6.3.1 EARTHWORK
N Excavation and filling are specified in Section 312000 "Earth Moving."
6.3.2 EXAMINATION
O Examine roughing-in for plumbing piping to verify actual locations of storm drainage piping
connections before sump pump installation.
6.3.3 FIELD QUALITY CONTROL
P Manufacturer's Field Service: Engage a factory-authorized service representative to

inspect, test, and adjust components, assemblies, and equipment installations, including
connections.
Q Perform tests and inspections.
1. Manufacturer's Field Service: Engage a factory-authorized service representative to

inspect components, assemblies, and equipment installations, including
connections, and to assist in testing.
R Tests and Inspections:
1. Perform each visual and mechanical inspection.

2. Leak Test: After installation, charge system and test for leaks. Repair leaks and
retest until no leaks exist.
3. Operational Test: After electrical circuitry has been energized, start units to confirm
proper motor rotation and unit operation.
4. Test and adjust controls and safeties. Replace damaged and malfunctioning
controls and equipment.

S Pumps and controls will be considered defective if they do not pass tests and inspections.
T Prepare test and inspection reports.
6.3.4 STARTUP SERVICE
U Engage a factory-authorized service representative to perform startup service.

1. Complete installation and startup checks according to manufacturer's written
instructions.
6.3.5 ADJUSTING
V Adjust pumps to function smoothly and lubricate as recommended by manufacturer.
W Adjust control set points.
6.3.6 DEMONSTRATION
X Engage a factory-authorized service representative to train Owner's maintenance

personnel to adjust, operate, and maintain controls and pumps.
END OF SECTION

TABLE OF CONTENTS
STORM WATER TECHNICAL SPECIFICATIONS 4
PART 1 SITE CLEARANCE 4

1.1 General 4
1.2 Products 4
1.3 Execution 4
PART 2 SOIL MATERIALS 5

2.1 GENERAL 5
2.2 PRODUCTS 6
2.3 EXECUTION 7
PART 3 AGGREGATE MATERIALS 8

3.1 General 8
3.2 Products 9
3.3 Execution 10
PART 4 ROUGH GRADING 11

4.1 General 11
4.2 Products 11
4.3 Execution 11
PART 5 GROUND DEWATERING 13

5.1 General 13
5.2 Products 13
5.3 Execution 13
PART 6 EXCAVATION 14
6.1 General 14
6.2 Products 15
6.3 Execution 15
PART 7 BACKFILLING 22
7.1 General 22
7.2 Products 23
7.3 Execution 23
PART 8 TRENCHING 26
8.1 General 26
8.2 Products 27
8.3 Execution 28
Red Sea Shura Program 7 Hotel Central 03 TABLE OF CONTENT

Page 1
19-SEP-2022
PART 9 ROCK REMOVAL 32
9.1 General 32
9.2 Products 33
9.3 Execution 33
PART 10 AGGREGATE BASE COURSE 34

10.1 General 34
10.2 Products 35
10.3 Execution 37
PART 11 GLASS REINFORCED PLASTIC PIPES 40

11.1 GENERAL 40
11.2 PRODUCTS 45
11.3 QUALITY CONTROL TESTS 52
11.4 EXECUTION 55
PART 12 UPVC PIPES 60

12.1 GENERAL 60
12.2 PRODUCTS 64
12.3 QUALITY CONTROL TESTS 65
12.4 EXECUTION 67
PART 13 GEOCELLULAR STORAGE STRUCTURE 70

13.1 General 70
13.2 PRODUCTS 72
13.3 EXECUTION 73
PART 14 CONCRETE FORMWORK 75

14.1 General 75
14.2 Products 77
14.3 Execution 78
PART 15 CONCRETE REINFORCEMENT 82

15.1 General 82
15.2 Products 84
15.3 Execution 87
PART 16 CAST-IN-PLACE CONCRETE 90

16.1 General 90
16.2 Products 101
16.3 Execution 108
PART 17 EXPOSED AGGREGATE CONCRETE FINISHES 119

Page 2
19-SEP-2022
17.1 General 119
17.2 Products 120
17.3 Execution 121
PART 18 CONCRETE CURING 122

18.1 18.1 General 122
18.2 Products 123
18.3 Execution 123
PART 19 STRUCTURAL PRECAST CONCRETE 125

19.1 General 125
19.2 PRODUCTS 127
19.3 Execution 129
PART 20 CONCRETE REPAIR 142

20.1 General 142
20.2 Products 147
20.3 Execution 152
PART 21 CONCRETE PROTECTION AND WATER PROOFING 162

21.1 General 162
21.2 Products 166
21.3 Execution 172
PART 22 JOINTS IN CONCRETE 177

22.1 General 177
22.2 Products 179
22.3 Execution 182
PART 23 TESTING OF WATER RETAINING STRUCTURES 183

23.1 General 183
23.2 Products 184
23.3 Execution 184
PART 24 CHAMBERS AND COVERS 187

24.1 General 187
24.2 Product 187
24.3 Execution 191
PART 25 HDPE PIPES 191

25.1 PART 1 GENERAL 191
25.2 PART 2 PRODUCTS 196
25.3 PART 3 EXECUTION 202

Page 3
19-SEP-2022
STORM WATER TECHNICAL SPECIFICATIONS
PART 1 SITE CLEARANCE
1.1 GENERAL
1.1.1 Related Sections
The following sections of the specification shall be read in conjunction with this section.
a) Materials and Equipment
b) Rough Grading.
c) Rock Removal.
1.1.2 Regulatory Requirements
A Conform to applicable code for environmental requirements, disposal of debris, burning

debris on site and use of herbicides.
B Coordinate clearing Work with utility companies.
1.2 PRODUCTS
1.2.1 Materials
A Herbicide: If used, it should be in accordance with the manufacturer's specification and

should be fit for its intended use. Whilst using such material all practicable steps should be
taken in terms of health and safety requirements.
1.3 EXECUTION
1.3.1 Preparation
A Verify that existing plant life designated to remain is tagged or identified.
B Identify a salvage area for placing removed materials.
1.3.2 Protection
1.3.3 Locate, identify, and protect utilities that remain, from damage.
C Protect trees, plant growth, and features designated to remain, as final landscaping.
D Protect bench marks, survey control points and existing structures from damage or
displacement.
1.3.4 Clearing
A In the event that the Contractor is granted permission to remove planted areas, he shall
follow the instruction of the Engineer. Any holes left by removal of trees and shrubs shall
be filled and compacted to the approval of the Engineer. Any debris shall be disposed of to
an approval tip.
Red Sea Shura Program 7 Hotel Central 03 00 Page 4

Storm Water Technical Specification 19-SEP-22
B Clear areas required for access to site and execution of Work.
C Clear undergrowth and deadwood, without disturbing subsoil.
D Apply herbicide to remaining stumps to inhibit growth.
1.3.5 Removal
A Remove debris, rock, and extracted plant life from site.
B Remove paving and curbs.
C Kerbstones together with their concrete haunching and foundation shall be broken out and
disposed off from site.
D Paving slabs and their foundation shall be broken out and disposed off from site.
E Paving slabs such as interlocking blocks bedded in sand shall be carefully removed and
stored, should the Engineer approve their subsequent re-use in the works or elsewhere.
F Existing road signs shall be carefully taken down and handed over to the appropriate
authority.
1.3.6 Topsoil Excavation
A Excavate topsoil from areas to be further excavated, re-landscaped, or re-graded, without

mixing with foreign materials.
B Do not excavate wet topsoil.
C Stockpile in area designated on site to depth not exceeding 2.5 m and protect from
erosion.
D Remove excess topsoil not intended for reuse, from site.
PART 2 SOIL MATERIALS
2.1 GENERAL
2.1.1 Related Section
a) Aggregate Materials
b) Rough Grading
c) Backfilling
d) Trenching
2.1.2 References
AASHTO T180 Moisture-Density Relations of Soils Using a 4.54 kg Rammer and 457 mm Drop
ASTM Test

ASTM D1556 Test Method for Density of Soil in Place by the Sand-Cone Method
ASTM D1557 Test Methods for Moisture-Density Relations of
ASTM D2167 Test Method for Density and Unit Weight of Soil in Place by the Rubber Balloon
Method
ASTM D2487 Classification of Soils for Engineering Purposes
ASTM D2922 Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear
Methods (Shallow Depth).
ASTM D3017 Test Method for Moisture Content of Soil and Soil-Aggregate in Place by
Nuclear Methods (Shallow Depth).
BS1377 Methods of Test for Soils for Civil Engineering Purposes
2.1.3 Submittals For Review
A Submittals:
B Samples: Submit, in air-tight containers, 25 kg sample of each type of fill to testing

laboratory. If CBR test is required, a minimum of 50 kg sample is required.
2.1.4 For Information
A Submittals:
B Materials Source: Submit name of imported materials source.
2.1.5 Quality Assurance
A Perform Work in accordance with TRSDC Standards, unless otherwise specified.
2.2 PRODUCTS
2.2.1 Subsoil Materials
A Subsoil Type: Conforming to Abu Dhabi Standards.
B Subsoil Type S2:
a) Select or local borrow.

b) Graded.
c) Free of lumps larger than 75 mm, rocks larger than 50 mm, and debris.
d) Conforming to ASTM D2487 Group Symbol OL.
2.2.2 Topsoil Materials
A Topsoil Type S3: Conforming to CLIENT standards.
B Topsoil Type S4:

a) Excavated and reused material if suitable, or selected material. Select.
b) Graded.
c) Free of roots, rocks larger than 12 mm, subsoil, debris, large weeds and foreign
matter.
d) Conforming to ASTM D2487 Group Symbol OH.
C Topsoil Type S5:
a) Imported borrow.
b) Friable loam.
c) Reasonably free of roots, rocks larger than 12 mm, subsoil, debris, large weeds, and
foreign matter.
d) Acidity range (pH) of 5.5 to 7.5.
e) Containing a minimum of 4 percent and a maximum of 25 percent inorganic matter.
f) Conforming to ASTM D2487 Group Symbol OH.
2.2.3 Source Quality Control
A Quality Control: Testing Services: Testing and analysis of soil material.
B Testing and Analysis of Subsoil Material: Perform in accordance with ASTM D1557,
AASHTO T180, ASTM D1556 and BS 1337
C Testing and Analysis of Topsoil Material: Perform in accordance with ASTM D1557,
AASHTO T180, ASTM D1556 and ASTM D698
D If tests indicate materials do not meet specified requirements, change material and retest.
E Provide materials of each type from same source throughout the Work.
2.3 EXECUTION
2.3.1 Soil Removal
A Excavate subsoil and topsoil from areas designated.
B Remove lumped soil, boulders, and rock.
C Stockpile excavated material at approved location and remove excess material not being
used, from site.
2.3.2 Stock Piling
A Stockpile materials on site at approved locations.
B Stockpile in sufficient quantities to meet Project schedule and requirements.
C Separate differing materials with dividers or stockpile apart to prevent mixing.
D Prevent intermixing of soil types or contamination.
E Direct surface water away from stockpile site to prevent erosion or deterioration of
materials.

2.3.3 Stock Pile Cleanup
A Remove stockpile, leave area in a clean and neat condition. Grade site surface to prevent
free standing surface water.
PART 3 AGGREGATE MATERIALS
3.1 GENERAL
a) Materials and Equipment
b) Soil Materials
c) Rough Grading
d) Backfilling
e) Trenching
f) Cast-In-Place Concrete
3.1.2 References
AASHTO - M147 Materials for Aggregate and Soil-Aggregate. ASTM C88 - Test Method of
soundness of aggregates
ASTM C136 Sieve Analysis of Fine and course aggregate. ASTM C142 - Clay Lumps
and Friable particles in aggregate
ASTM C294 Constituents of Natural Mineral Aggregate
ASTM C535 Los Angeles abrasion test. ASTM D2419 – Sand Equivalent
ASTM D2487 Standard Practice for Classification of Soil for Engineering Purposes
(Unified Soil Classification Systems).
ASTM D2940 Graded Aggregate for bases or sub bases
ASTM D4318 Test Method for Liquid Limit and Plasticity Index of soil
ASTM D75 Sampling Aggregate
BS 1377 Part 3 Chemical Tests, Sulphates contents
3.1.3 Submittals for Review
A Submittals : as per specifications
B Samples: Submit, in air tight containers, minimum 50 kg sample in accordance with ASTM
D75 of each type of aggregate to testing laboratory.

3.1.4 Submittals for Information
A Submittals: : as per specifications
B Materials Source: Submit name of imported materials crusher and location.
A Perform Work in accordance with CLIENT standards. Maintain one copy on site.
3.2 PRODUCTS
3.2.1 Coarse Aggregate Materials
A Coarse Aggregate Type A1: Conforming to Abu Dhabi standards.
B Coarse Aggregate Type A2 Gravel:AASHTO M147 and ASTM D2940, Grade A; passing
50 mm sieve
C Coarse Aggregate Type A3 Wadi Gravel: Coarse Stone or Crushed Gravel: natural, free of
shale, clay, friable material and debris; graded in accordance with ASTM C136, ASTM
D2487 Group Symbol (GW-GC) within the following limits:
Table 1: Coarse Aggregate Type 3 Limit

Sieve Size Total
Percent Passing (50 mm) 100
(25 mm) 75 to 95
(19 mm) 65 to 90
(9.5 mm) 40 to 75
No. 4 (4.75 mm) 30 to 60
No. 10 (2.0 mm) 20 to 45
No. 40 (425 micro n) 15 to 30
No. 200 (75 micro n) 5 to 12
3.2.2 Fine Aggregate Materials
A Fine Aggregate Type A5: Conforming to CLIENT standards. With a liquid limit of not more
than 25; a plasticity index of not more than 6 in accordance with ASTM D4318.
3.2.3 Aggregate - Granular Bedding
A Concrete, Vitrified Clay and Asbestos Cement Pipes.
a) Granular material for bedding to pipes other than GRP and other plastic materials
shall consist of gravel or broken stone and shall be suitable “all in” ballast or stone.
b) For pipes upto 1200mm nominal internal diameter the material shall be graded
20mm to 5mm all passing 20mm and not more than 20% passing 5mm sieves to
BS410
c) For pipes above 1200mm nominal internal diameter the material shall be graded

37.5mm to 5mm all passing 37.5mm not more than 45% passing 20mm and not
more than 20% passing 5mm sieves to BS410.
d) The minimum thickness of granular material beneath the pipeline shall be to the
following depth below the underside of the socket or coupling:-
e) 150mm for pipes up to and including 600mm nominal internal diameter.
f) 200mm for pipes over 600mm nominal internal diameter and upto 1200mm nominal
internal diameter.
g) 300mm for pipes over 1200mm nominal internal diameter.
h) In exceptional circumstances the Engineer may permit excavated material stated
above. Such permission may at any time to withdrawn and the Contractor shall
provide material to the standards given above at no extra cost to the department.
3.2.4 GRP and other Plastic Pipes.
A Granular material for bedding to GRP and other plastic pipes shall be a single sized
crushed aggregate, nominal size 10mm. The bedding material shall be compacted to
better than 90% Proctor density.
B Prior to placement of the bedding material for the formation and sides of the trench shall be
lined with an approved geotextile filter fabric in accordance with the Specifications. Once
the bedding material is placed around the pipe, the filter fabric shall be folded over the top
of the bedding material and shall have a minimum overlap of 300mm.
C The geotextile filter fabric shall form a continuous barrier to prevent migration of the native
soil into the bedding material and vice versa
A Quality Control: Testing Services: as per specification
B All test results shall comply with CLIENT standards, unless otherwise specified.
C Coarse Aggregate Material - Testing and Analysis: Perform in accordance to related

Section requirements.
D If tests indicate materials do not meet specified requirements, change material or material
source and retest.
E Provide materials of each type from same source throughout the Work.
3.3 EXECUTION
3.3.1 Stockpiling
A Stockpile materials on site at approval locations.
B Stockpile in sufficient quantities to meet Project schedule and requirements.
C Separate differing materials with dividers or stockpile apart to prevent mixing.
D Direct surface water away from stockpile site so as to prevent erosion or deterioration of
materials.

3.3.2 Stockpile Clean-up
A Remove stockpile, leave area in a clean and neat condition. Grade site surface to prevent
free standing surface water
PART 4 ROUGH GRADING
4.1 GENERAL
a) Soil Materials
b) Aggregate Materials
c) Rock Removal.
d) Excavation
e) Backfilling
f) Trenching
A Perform work in accordance with related Section requirements. Maintain one copy of
standards on site.
4.1.3 Project Record Documents
A Submit as per provisions in specification.
B Accurately record actual locations of utilities remaining by horizontal dimensions,

elevations or inverts, and slope gradients.
4.2 PRODUCTS
Not Used.
4.3 EXECUTION
4.3.1 Examination
A Verify site conditions as per specification.
B Verify that survey bench mark and intended elevations for the Work are as indicated.
4.3.2 Preparation
A Identify required lines, levels, contours, and datum.
B Stake and flag locations of known utilities.
C Locate, identify, and protect utilities that remain, from damage.
D Protect above and below grade utilities that remain.

E Protect plant life, lawns, rock outcropping and other features remaining as a portion of final
landscaping.
F Protect bench marks, survey control point, existing structures, fences, sidewalks, paving,
and curbs from excavating equipment and vehicular traffic.
G Comply with the directives set forth in specification for maintaining and supporting services
and structures.
4.3.3 Subsoil Excavation
A Excavate subsoil from areas to be further excavated, re-landscaped, or re-graded.
B Do not excavate wet subsoil.
C When excavating through roots, perform work by hand and cut roots with sharp axe.
D Remove subsoil from site.
E Benching Slopes: Horizontally bench existing slopes greater than 1:4 to key placed fill
material to slope to provide firm bearing.
F Stability: Replace damaged or displaced subsoil to same requirements as for specified fill.
4.3.4 Filling
A Install Work in accordance with standards.
B Fill areas to the required contours and elevations with materials accepted by the Engineer.
C Place fill material on continuous layers and compact in accordance with the schedule at
end of this section.
D Maintain optimum moisture content of fill materials to attain required compaction density.
E Slope grade away from building minimum 50 mm in 3m, unless noted otherwise.
F Make grade changes gradual. Blend slope into level areas.
G Remove surplus fill materials from site.
4.3.5 Tolerances
A Top Surface of Sub grade: Plus or minus 20 mm from required elevation.
4.3.6 Field Quality Control
A Quality Assurance: Field inspection and testing.
B All test results shall comply with TRSDC requirements unless otherwise specified.
C Testing: In accordance with related Section requirements.
D If tests indicate Work does not meet specified requirements, remove Work, replace and
retest.
E Frequency of Tests: One sample every 1,000m2

4.3.7 Schedules
A Structural Fill:
a) Fill Type S2: Maximum 150 mm layers up to the required compacted depth.
b) Compact to minimum 95 percent of maximum density.
B Pervious Structural Fill:
C Subsoil Fill:
D Topsoil Fill:
a) Fill Type S2: 200 mm layers up to the required compacted depth.

PART 5 GROUND DEWATERING
5.1 GENERAL
5.1.1 Related Documents
Materials and Equipment
5.2 PRODUCTS
Not used.
5.3 EXECUTION
5.3.1 Submittals
A In addition to Submittal Section - Procedure for submittals.

a) Submit working drawings and data for review and approval showing the intended
plan for dewatering operations.
b) Submit not less than 30 days prior to start of dewatering operations.
5.3.2 Execution
A Dewatering as required so that all work of the contract is installed in dry areas and
excavations, including without limitations the construction of all structures and underground
piping.
B Dewatering shall be carried out only to a depth sufficient for the required excavation and to
ensure the stability of the excavation and any structures or apparatus in the vicinity. The

Contractor shall demonstrate to the satisfaction of the Engineer that his dewatering
proposals will not adversely affect existing structures, apparatus, roads, paving etc.
C Ensure that, at all times, during construction no ground water shall come into contact with
any concrete surface or reinforcement and that any structure shall be capable of
withstanding any hydrostatic pressure to which it may be subjected during construction
and until completed.
D Any water removed from the excavations shall, wherever practicable, be pumped directly
into the sea or to storm drains, if approved, via an efficient system of discharge lines.
E No water to be discharged into the foul sewer system, the sewage treatment works or onto
open spaces.
F The Contractor shall include for the diversion of all watercourses encountered in the works
until the complete drainage scheme for the site is completed and put into operation.
G Notwithstanding any previous approval, the Contractor shall be fully responsible for and for
the effects of his works for maintaining dry excavations.
H The Contractor shall, where extensive dewatering is required be fully qualified to perform
the dewatering operations or shall furnish the services of an experienced, qualified and
equipped Dewatering Subcontractor to design and operate the dewatering and
groundwater recharging systems required for the works, all subject to the Engineer’s
approval.
I Where required to do so by the Engineer, the Contractor shall establish a specified number
of groundwater level monitoring stations at each site which will be observed during the
work. These shall be located as directed by the Engineer and consist of acceptable open
tube piezometers. Settlement gauges will be provided to the site, times and locations to
monitor settlement of new and existing facilities shall be as directed by the Engineer.
J The release of groundwater to its static level shall be performed so as to maintain the
undisturbed state of natural foundation soils, prevent flotation or movement of structures,
and pipelines.
K No dewatering system shall be removed without the approval of the Engineer. Monitoring
and settlement measurement systems shall be maintained in operation until removal is
approved by the Engineer, to the extent approved by the Engineer, well points and like
items may be abandoned in place.
PART 6 EXCAVATION
6.1 GENERAL
a) Rough Grading
b) Backfilling
c) Trenching
d) Rock removal

6.1.2 Field Measurements
A Verify that survey bench mark and intended elevations for the Work are as indicated.
6.1.3 References
A BS 6031:2009 - Code of Practice for Earthworks DIN 4124 - Building Pits and Trenches
A Where required employ or retain the services of a recognized specialist in groundwater

control system installation and operation, with a minimum of 10 years experience in this
field. The specialist shall be present initially when each new groundwater control system is
installed and operated, and periodically thereafter, to consult on installation and equipment
problems as the need arises, or as requested by the Engineer.
B Adhere to the applicable requirements of all ordinances, codes and regulations of

authorities having jurisdiction over disposal of discharge waters.
C Evaluate collected data relative to groundwater control system performed and modify
systems as necessary to dewater sites in accordance with the Contract requirements.
D If for any reason the groundwater control system is found to be inadequate, make
additions, changes and replacements as necessary to provide a satisfactory system at no
additional cost to the Employer.
6.1.5 Protection of Antiquities
A No requirements of the Specification regarding the disposal of material arising from site
clearance or excavation shall override any provision in the Conditions of Contract as to the
discovery or ownership of fossils, coins, articles of value or antiquity or anything of
geological or archaeological interest found on the Site. The Contractor shall inform the
Engineer within 24 hours of any fossils or antiquities discovered.
6.2 PRODUCTS
Not Used.
6.3 EXECUTION
6.3.1 General
A Make sure the extent of all excavations in open cut is the minimum necessary or
practicable for the construction of the Works.
B Do not make battered excavations in public highways, private gardens or within 30 meters
from any building or structure, unless otherwise approved by the Engineer.
C Provide supports as needed in accordance with Clause 7.3.3 and other requirements of
this Specification.
D Limit amount of excavation to such sizes, depths and inclinations as may be necessary to
construct the Works or as directed by the Engineer.
E Deposit excavated material in approved location as referenced herein for backfilling,

compact in such a manner that will avoid causing any damage or inconvenience. The
stockpiling of excavated material in or adjacent to the work areas will not be permitted.

Unless otherwise approved by the Engineer, the Contractor must allow for immediately
loading and transporting all excavated material to an approved off-site storage area to
avoid any nuisance to persons or property. The Contractor shall transport excavated
material which is suitable for backfill back to the site for backfilling of trenches as soon as
backfilling operations start. The Contractor shall allow for this double handling in his unit
rates.
F Excavated material stockpiled in the approved off-site storage areas shall not obstruct
entrances, sidewalks, driveways, hydrants, manholes, and any other service, and shall not
cause any obstruction to traffic. The Contractor shall ensure that stockpiled excavated
material does not obstruct pedestrian or driver visibility at road crossings or junctions.
G Any damage resulting from Contractor’s failure to comply shall be rectified at the
Contractor’s own expense, all as directed by the Engineer.
H Do not lay pipes or concrete or commence any permanent works until the Engineer has
inspected and accepted the excavation.
I Do not use blasting or explosives during the works.
J The Engineer may stop the works at any time if in his opinion it is considered that methods
of work are not safe.
K Where dewatering is required, provide qualified and experienced crew to perform the
dewatering operation, or furnish the services of a Dewatering Subcontractor approved by
the Engineer to design and operate the dewatering works.
6.3.2 Preparation
A Identify required lines, levels, contours, and datum locations.
B Locate, identify, and protect utilities that remain, from damage in accordance with clause
3.6 of this section.
C Notify all utility authorities weekly or more often as necessary, of the construction
schedule.
D Protect trees, plant, lawns, rock outcroppings and other features remaining as a portion of
final landscaping.
E Protect bench marks, survey control points, existing structures, fences, sidewalks, paving,
and curbs from excavating equipment and vehicular traffic.
F Carefully strip and set aside the surface materials for re-use as directed by the Engineer.
G Break up and dispose of the concrete of concrete roads and foundations as directed by the
Engineer. Cut any existing reinforcement and bend it to the sides of the excavation in order
to lap the new reinforcement to be provided in the reinstatement of the surface with the
existing reinforcement by at least 300 millimetres.
6.3.3 Support of Excavations
A Submit the proposal for the support of excavations in accordance with BS 6031:2009, at
least seven days prior to the commencement of any excavation work.
B In the proposal, take into account the nature of the ground to be excavated, the level of
water table at the site and the proximity of buildings and roads.

C Where the depth of excavation exceeds 1.2 meters, do the following:
a) Batter back the sides of the excavation to soil angle of repose or,
b) Support the sides of the excavation with a system of sheet piling, trench sheeting
and shoring or,
c) Adopt a combination of these.
D Submit to the Engineer detailed calculations and drawings of the measures proposed and
obtain his written acceptance thereof.
E Include in the calculations the slope stability calculations, details of lateral earth pressures,
supporting site investigation results and anticipated surcharge and equipment loads during
installation, removal and backfilling.
F Do not remove temporary works supporting the excavations until in the opinion of the
Engineer the permanent work is sufficiently advanced to permit such removal. Execute
removal of temporary works under the personal supervision of a competent foreman. Any
advice, permission, acceptance or instruction given by the Engineer relative to such
support or its removal will not relieve the Contractor from his responsibilities under the
Contract.
G Unless otherwise directed by the Engineer, all open excavations and other hazardous
areas shall be totally enclosed from all sides by temporary fencing. Damaged sections of
temporary fencing shall be repaired or replaced. Temporary fencing shall not be removed
from any location without the Engineer’s permission which will not be given until the trench
excavation has been refilled and reinstated.
6.3.4 Excavating
A Maintain and support the existing services and structures in accordance with Clause 3.6.
B Excavate subsoil to accommodate building foundations, slabs-on-grade, paving and site

structures.
C Compact disturbed load bearing soil in direct contact with foundations to original bearing
capacity; perform compaction in accordance with specification.
D Slope embankments and stockpiles to angle of repose or less until shored.
E Do not encroach on 45 degree bearing splay of foundations.
F Grade top perimeter of excavation to prevent surface water from draining into excavation.
G Hand trim excavation. Remove loose matter.
H Remove lumped subsoil, boulders, and rock up to 0.25 cu m measured by volume.

Remove larger material as per specification
I Notify Engineer of unexpected subsurface conditions and discontinue affected Work in

area until notified to resume work.
J Correct areas over excavated in accordance with Clause 3.5.
K Stockpile excavated material at approved locations in accordance with specification and in

accordance with Clause 3.1E. Remove excess or unsuitable material from site.
L Remove excavated material from site if site conditions dictate, return if required for backfill.

M Keep all excavations free from water and sewage in accordance with Clause 3.7.
N Remove unsound foundations and soft spots in accordance with Clause 3.8.
O On completion of the permanent works, backfill the excavations in accordance with

specification.
6.3.5 Slips, Falls and Excess Excavation.
A Take every precaution to prevent slips and falls of earth and other materials in the
excavation.
B Fill all voids formed as a result of:
a) Slips or falls occurring or,

b) Excavation being made in excess of the minimum necessary or practicable for the
construction of the Works or,
c) Any over excavation whether or not necessary beneath the formation of a structure
or,
d) Any combination of the above.
C Use concrete Class ‘C’ to fill voids so formed if such voids when backfilled would provide
support for the permanent Works or adjacent structures and services.
D In all other cases, fill voids with coarse aggregate Type 2. Ensure that the material is
thoroughly compacted.
6.3.6 Maintaining and Supporting Services and Structures
A Ascertain the actual locations of all existing services and obstructions by hand excavation
before commencing any part of the Works. The Contractor shall contact all concerned
authorities to secure all information, and shall obtain approvals and any required permits
from all concerned authorities before commencing any part of the work.
B Services shall mean any utilities ranging from the water, gas and oil supply networks,
electrical and telephone networks, poles, pylons, lighting columns and traffic signals, storm
water drainage and sewerage networks as well as roads, gardens, trees, and other public
or private services.
C Some, but not all, of the existing utilities are shown on the Drawings. It should be
emphasized that all the locations of services where shown on the Drawings are for
guidance only and does not necessarily show the exact locations, depths and spacing nor
the smaller branches of services which are not normally indicated on such drawings. After
obtaining approvals from all concerned Authorities, the Contractor shall carefully excavate
at his own expense all necessary trial pits by hand to locate all services and obstructions.
The Contractor shall backfill test pits immediately after their purpose has been satisfied
and restore the surface in a manner satisfactory to the governing authority and to the
Engineer.
D Do not exceed a maximum distance of 25 metres between trial pits. Minimum of three trial
pits between successive manholes.
E Submit to the Engineer detailed drawings showing the services and/or obstructions in
relation to the permanent and temporary works. It should be noted that the Contractor shall
not be allowed to work in any area where services are still not located that are immediately
adjacent to or conflict with the pipeline to be installed. The Engineer shall have the right to
stop work in the area of the Works where the Contractor fails to take the necessary

measures to locate these services and the Contractor shall not be entitled to claim for
compensation in time or money.
F If the proposed method of working will damage, expose or affect these in any way, obtain
written acceptance from the appropriate Authority and the Engineer for this method of
working before commencing work. Such acceptance will in no way relieve the Contractor
from any of his responsibilities under the Contract.
G Call the attention of the Engineer and the appropriate Authority as soon as any existing
service is encountered in the excavation. Take photographs to illustrate the existing
damage or conditions. If the Contractor determines that certain utilities require temporary
relocation in order to permit the Works to be completed, he shall coordinate with the
relevant service authority to carry out, or have carried out, the relocation of the utility in
accordance with their current regulations and specifications.
H The Contractor shall not move any utility or service line, conduit or any structures, above or
below the ground, within the limits of the Works until receiving written permission from the
utility authority, or the permission from the Engineer in writing.
I In the case of temporary relocation, the utility shall be restored to its original location prior
to restoration of the site.
J The Contractor shall perform any protection work for utilities and any temporary relocation
or maintaining services in operation at his own expense.
K The Engineer reserves the right during the progress of the work, upon determination of the
actual position of the existing utilities and utility structures, to request changes in the grade
or alignment of the pipelines, wherever by so doing the necessity for relocation of utility or
structure will be avoided. Such changes will be ordered in writing by the Engineer.
L Authorities shall be notified, weekly or more often as necessary, of the construction

schedule with regard to exposing known services. Services encountered during the
excavation work shall be uncovered and identified and the concerned authority shall be
notified. Where so required by the concerned authority, operations shall not proceed until
the concerned authority is represented on Site. In such cases, the Contractor will not be
entitled to submit any claim for additional money or time. The Contractor shall also submit
every two weeks details of the work contemplated for execution in order to enable the
service authority to inspect and/or to indicate their services on the site and/or to take any
measures deemed necessary.
M The Contractor shall curtail his activities in areas where the services are being relocated by
others until the relocation work is complete.
N The Contractor must ensure that he pays all fees and obtains any work or excavation
permits from the service authorities necessary to allow him to carry out construction works
in the vicinity of existing services.
O Safeguard and maintain all watercourses, sewers, drains, gas pipes, water pipes,
electricity and telecommunication cables and all other services and structures encountered
during the construction of the Works and take any remedial measures necessary to make
good immediately any damage arising out of the construction of the Works.
P Where permanent relocation or support of services is necessary to enable construction of

the Permanent Works to proceed, the Engineer may elect to order its removal and
relocation into its allotted reservation. All work in connection with the removal and
relocation shall be carried out by the Contractor under the supervision of the Engineer
and/or the concerned utility authority. Alternatively, the concerned authority, should it
prefer to, will carry out the work itself, in which case the Contractor shall afford all
reasonable assistance and access during the undertaking of the work.

Q All relocation work shall be designed by the Contractor in conjunction with the utility
authority and shall comply in all respects with their current regulations and specifications.
The Contractor must allow for the preparation of all shop drawings and for obtaining
approvals for the designs from concerned authorities. The cost of permanent relocation of
utilities, if required, will be borne by the relevant Department.
R The Contractor may be required to work in the vicinity of high tension electric cables/lines
in certain locations. These locations are to be ascertained and confirmed on site with the
appropriate Authority. The use of mechanical excavation plant in these areas will not be
permitted.
S Replace all diverted and supported services and structures on completion of the Works.
6.3.7 Keeping the Excavations in Dry Condition and Dewatering
A Keep all excavations free from water and sewage whether affected by tides, floods storms
or otherwise. Ensure that the work is constructed in dry conditions.
B Do not leave in any sub-drainage pipes, unless they are filled with concrete Class ‘C’ or
other accepted material.
C Enwrap any sub-drainage left in below the permanent Works completely in an approved
geotextile membrane material.
D Make sure that the sub grade left in place provides support at least equal to that which
would have been available if the sub-drain was not present.
E Do not discharge water into any watercourse or sewer / drains including those drains laid
under this Contract.
F Obtain written permission of owner for water discharge into an existing facility.
G Perform dewatering as required so that all work of the Contract is installed in dry areas and
excavations.
H Make sure that dewatering is carried out only to a depth sufficient for the required
excavation.
I Make sure that at all times during construction, no groundwater comes into contact with
any concrete surface or reinforcement and that any structure is capable of withstanding
any hydrostatic pressure to which it may be subjected during construction and until
completed.
J Pump water removed from excavations, wherever practicable, directly to the sea or to
storm drains if accepted via an efficient system of discharge lines. Do not discharge any
water into the sewerage system, into the Works or onto open spaces.
K Fully comply with the requirements of CLIENT in regard to the Works for maintaining
excavations, dewatering and the discharge of groundwater arising from dewatering.
L Include for the diversion of all watercourses encountered in the work until the complete
drainage scheme for the Site in completed and put into operation.
M Notwithstanding any previous acceptance, the Contractor will be fully responsible for the
effects of his works for maintaining dry excavations. The methods of controlling
groundwater are to be the option of the Contractor who shall be solely responsible for the
location, arrangement and depth of any system or systems selected to accomplish the
Work. The primary purpose of groundwater control is to preserve the undisturbed bearing
capacity of the subgrade soils.

N Submit working drawings and data for review and acceptance showing the intended plan
for dewatering operations, where deemed necessary by the Engineer.
O Include details of locations and capacities of dewatering wells, well points, pumps, sumps,
collection and discharge lines, standby units, water disposal methods, monitoring and
settlement. Submit all these not more than 30 days prior to start of dewatering operations.
P Draw the static water level down to a minimum of 500mm below the bottom of the
excavation so as to maintain the undisturbed state of the foundation soils and to allow the
placement of any fill or backfill to the required density. Maintain and control the water level
in backfill to prevent flotation of the completed Work, and at a minimum of 500 mm below
the top of backfill during backfill placement and compaction operations.
Q Install and operate the dewatering system so that the groundwater level outside the
excavation is not reduced to the extent that would damage or endanger adjacent roads,
structures or property. Repair damage, disruption or interference resulting directly or
indirectly from groundwater control system operation at no additional cost to the Employer.
R Establish at several site locations, approved by the Engineer groundwater level monitoring
stations, open tube piezometers which can be observed during the work. Also, provide
settlement gauges as directed, accepted and designated by the Engineer at several
locations to monitor settlement of new and existing facilities.
S Perform dewatering so that no flow of water occurs along the pipe zone material. Use
where applicable cut-off walls to reduce the potential groundwater flow along pipe
trenches. Submit to the Engineer for his approval details of the proposed method of
working and temporary works installations to achieve this.
T Perform the restoration of groundwater to its original static level so as to maintain the
undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or
backfill and prevent flotation or movement of structures and pipelines
U Do not remove any dewatering systems without the Engineer’s acceptance. Maintain
monitoring and settlement measurement systems in operation until removal is accepted by
the Engineer. Where necessary, maintain until final compaction is completed.
V At the completion of all excavation and backfilling work, and when approved by the
Engineer, all deep wells, well points, pumps, generators, piezometers, other equipment
and accessories used for the groundwater and surface water control systems shall be
removed from the site. All materials and equipment shall become the property of the
Contractor. All areas disturbed by the installation and removal of groundwater control
systems and piezometers shall be restored to their original condition.
W Where piezometer casings are pulled, holes shall be filled with sand. Where left in place,
piezometer casings should be filled with sand and cut off below ground level as necessary
to restore the ground to its original condition. When directed by the Engineer, piezometers
should be left in place for continued monitoring. When so directed, cut casings flush with
final ground level and provide protective lockable boxes with locking devices. The
protective boxes shall be suitable for the traffic and for any other conditions to which the
piezometers will be exposed.
6.3.8 Removal of Unsound Foundations and Soft Spots
A Excavate further on directions from the Engineer if on reaching the specified levels of
trench or structure, the inspected exposed ground, or part of the ground is considered
naturally unstable by the Engineer or became unacceptable due to exposure to weather
conditions or due to flooding or have become puddled, soft or loose during the progress of
work. Backfill the further excavation with concrete Class ‘C’ or with such materials as the
Engineer may direct.

B Remove the backfill over its full depth and for the full width of the pipe trench shown on the
Drawings, where a pipe is being laid into a port in an existing structure, manhole, chamber
or thrust block, and where the backfill material to the previous excavation beneath the pipe
formation is not concrete. Fill the resulting void with concrete Class ‘C’ to a level approved
by the Engineer.
C The omission by the Engineer to give an instruction under this Clause will not relieve the
Contractor from any responsibility for defects in the Works due to the construction being
placed upon an unsuitable formation if prior to the construction of the work the Contractor
failed to advise the Engineer in writing.
A Quality Control: Field inspection and testing. Provide for visual inspection of bearing
surfaces.
PART 7 BACKFILLING
7.1 GENERAL
a) Soil Materials
b) Aggregate Materials
c) Excavation
d) Trenching
e) Cast-in-Place Concrete
7.1.2 References
AASHTO T180 Moisture-Density Relations of Soils Using a 4.54 kg Rammer and 457
mm Drop
ASTM D1556 Test Method for Density of Soil in Place by the Sand-Cone Method
ASTM D1557 Test Methods for Moisture-Density Relations of Soils and Soil-
Aggregate Mixtures Using 4.54 Kg Rammer and 457 mm Drop
ASTM D1883 CBR Test
ASTM D2487 Classification of Soil
BS 1377 - Part 1 to Part 9 Methods of tests for soils. BS 6031:2009 - Code of Practice for
Earthworks

7.2 PRODUCTS
7.2.1 Fill Materials and Accessories for Backfilling of Excavations other than in Roads
and Paved/Tiled Areas.
A Fill Type S2: As per specification.
B Structural Fill Type S2: As specified in specification.
C Concrete: Class ‘C’ with a compressive strength of 17.5 MPa.
7.2.2 Fill Materials and Accessories for Backfilling of Excavations in roads and
Paved/Tiled Areas.
A Ensure that the specifications of materials for backfilling of excavations in roads and
paved/tiled areas conform with the specifications for Backfilling of Trenches & Excavations
in Asphaltic Roads, Tiled/Paved Parking and Roads’ and in accordance with any other
agency which may have jurisdiction of the roadway area.
7.3 EXECUTION
7.3.1 Examination
A Verify sub-drainage, damp-proofing, or waterproofing installation has been inspected.
B Verify underground tanks are anchored to their own foundations to avoid flotation after
backfilling.
C Verify structural ability of unsupported walls to support imposed loads by the fill.
7.3.2 Preparation
A Compact sub grade to density requirements for subsequent backfill materials.
B Cut out soft areas of sub grade not capable of compaction in place. Backfill with Type A3
fill and compact to density equal to or greater than requirements for subsequent fill
material.
C Scarify and proof roll sub grade surface to a depth of 250mm to identify soft spots; fill and
compact to density equal to or greater than requirements for subsequent fill material.
7.3.3 Backfilling
A This section includes backfilling of structural foundation, building perimeter, and site
structures up to required subgrade elevations, fill under interior and exterior slabs-on-grade
or pavement, and fill under landscaped areas. Backfilling for utility is included in
specifications.
B Commence backfilling of excavations as soon as practicable after the permanent works

have been tested, inspected and accepted by the Engineer.
C Systematically backfill to allow maximum time for natural settlement. Do not backfill over
porous, wet or spongy subgrade surfaces.
D Backfill in layers not exceeding 150mm, the first 500mm over permanent work after its
acceptance by the Engineer in the excavations other than in roads and paved/tiled areas

by hand with lightly compacted selected excavated material. Refill the remaining voids
with selected excavated material in layers not exceeding 300mm in depth to obtain
minimum 90% compaction of the maximum dry density of the material in accordance with
ASTM D1557.
E Backfill all excavations in roads and paved/tiled areas, including areas designated as
future “roads and paved/tiled areas” as directed by the Engineer, in accordance with the
‘Abu Dhabi Municipality Specification for Backfilling of Trenches and Excavations in
Asphaltic roads, Tiled/Paved Parking and Sidewalks’, reproduced in Appendix 2 and in
accordance with any other agency which may have jurisdiction of the roadway area.
F Fill the voids formed as a result of slips or falls or excavation being made in excess of the
minimum necessary or practicable for the construction of the Works or any over excavation
whether or not necessary beneath the formation of a structure with concrete Class ‘C’ in all
cases where support for the permanent works or adjacent structures and services is
required.
G In all other cases fill the voids so formed with selected excavated material thoroughly
compacted.
H Fill all redundant sub-drainage pipes that are left in place with cementitious grout or
material as approved by the Engineer.
I Fill holes made for dewatering pipes with cementitious material as soon as the dewatering
equipment is withdrawn.
J Employ a placement method that does not disturb or damage other work.
K Maintain optimum moisture content of backfill materials to attain required compaction

density.
L Water well to the acceptance of the Engineer all filling materials which are in his opinion of
a non-cohesive nature in the layers specified to obtain the specified compaction.
M Backfill against supported foundation walls. Do not backfill against unsupported foundation
walls.
N Backfill simultaneously on each side of unsupported foundation walls until supports are in
place.
O Slope grade away from building 50mm in 3m, unless noted otherwise.
P Make gradual grade changes. Blend slope into level areas.
Q Remove surplus backfill materials from site.
R Leave fill material stockpile areas free of excess fill materials.
S Remove from the site any excavated material which is in the opinion of the Engineer
unsuitable for backfill.
T Where instructed by the Engineer, arrange for an approved independent testing laboratory
to carry out tests to determine in-situ the density of the backfill material.
7.3.4 Tolerances
A Backfilling Under Paved Areas: Plus or minus 20mm from required elevations for sub
grade, +/-10mm for granular sub-base, in accordance with the ‘Abu Dhabi Municipality

Specification for Backfilling of Trenches & Excavations in Asphaltic Roads, Tiled/Paved
Parking and Roads’.
B Top Surface of General Backfilling: Plus or minus 25mm from required elevations.
A Quality Control: as per specficiation.
B All test results shall comply with specification unless otherwise specified.
C Compaction testing will be performed in accordance with ASTM D1556, ASTM D1557 and
AASHTO T180.
D CBR testing as per ASTM D1883.
E If tests indicate Work does not meet specified requirements, remove Work, replace and
retest.
F Frequency of Tests: Every 1000m2 or any area ready for test, whichever is less.
G Proof roll compacted fill surfaces under slabs-on-grade, pavers, paving, and structures.
7.3.6 Protection of Finished Work
A Reshape and re-compact fills subjected to vehicular traffic.
7.3.7 Schedule
A Interior Crawl Spaces:
a) Fill Type S, 150mm thick layers, compacted to 90 percent,

b) Cover with Fill Type A, 50mm thick, compacted to 95 percent.
B Interior Slab-On-Grade:
a) Fill Type S, 150mm thick layers, compacted to 95 percent,
C Exterior Side of Foundation Walls, Retaining Walls and Over Granular Filter Material and
Foundation Perimeter Drainage:
a) Fill Type S, to subgrade elevation, each lift compacted to 95 percent.
D Underground Tanks:
a) Initial fill of Fill Type S, 250 mm thick, compacted to 95 percent,

b) Remaining fill of Fill Type S, to subgrade elevation, compacted to 95 percent.
E Fill for French Drains:
a) Fill Type A, 250mm below finish grade.

F Fill Under Interlocking Pavers:
a) Embankment Fill: See Specification for Backfilling of Trenches & Excavations in

Asphaltic Roads, Tiled/Paved Parking and Sidewalks’.
b) Sub grade Fill: See Specification for Backfilling of Trenches & Excavations in

c) Filter Fill Material: See Specification for Backfilling of Trenches & Excavations in
d) Geotextile fabric: See Specification for Backfilling of Trenches & Excavations in
e) Granular Sub-base Material: See ‘Specification for Backfilling of Trenches &
Excavations in Asphaltic Roads, Tiled/Paved Parking and Sidewalks’.
G Fill Under Asphalt Concrete Paving: same as Clause 3.7/F of this specification.
H Planter Boxes:
a) Fill Type S, to the required height of lightly tamped.
I Fill to Correct Over-excavation:
a) Concrete Class ‘C’.
J Fill Over Drainage Piping Gravel Cover:
a) Fill Type S, to finish grade, compacted to 90 percent, using 150mm layers
7.3.8 Reinstatement of Surfaces other than Asphalt Paved Roads
A This Section covers reinstatement of all surfaces other than asphalt roads. All non- asphalt
roads and all other surfaces shall be restored to their original condition by the Contractor in
accordance with the requirements of the appropriate authority. This reinstatement is
deemed to be entirely covered by the Contractor’s rates for pipelines. All reinstatement of
cultivated surfaces shall be carried out by the Contractor, at his expense under the
supervision of TRSDC and shall be carried out immediately upon completion of
construction in the affected area.
B All permanent reinstatement shall include the Contractor’s return to Site at regular intervals
during the Period of maintenance to carry out works necessary to ensure that surfaces are
finally left in a condition at least equal to that existing before the contractor first entered
thereon.
PART 8 TRENCHING
8.1 GENERAL
a) Soil Materials Aggregate Materials
b) Rough Grading
c) Excavation
d) Backfilling
e) Rock Removal Subsoil drainage
f) Cast-in-Place Concrete

8.1.2 References
AASHTO T180 Moisture Density Relations of Soils Using 4.54 kg Rammer and 457 mm Drop
ASTM C136 Method for Sieve Analysis of Fine and Coarse Aggregates
ASTM D1556 Test Method for Density of Soil in Place by the Sand Cone Method
ASTM D1557 Test Methods for Moisture Density Relations of Soils and Soil Aggregate Mixtures
Using 4.54 Kg Rammer and 457 mm Drop
ASTM D698 Standard Test Methods for Laboratory. Compaction Characteristics of Soil Using
Standard Effort (12400 ft-lbf/ft3 (600kn-m/m3))
BS 6031:2009 Code of Practice for Earthworks.
8.1.3 Definitions
A Utility: Any buried pipe, duct, conduit, or cable.
8.1.4 Field Measurements
A Verify that survey bench mark, control point, and intended elevations for the Work are as
shown on drawings.
B Take and record levels in the manner specified or agreed with the Engineer before
disturbing any part of the Site or beginning the works thereon. Give the Engineer two
working days’ notice so that the recording of levels can be performed in his presence.
8.1.5 Coordination
A Coordinate work as per specification.
B Verify work associated with lower elevation utilities is complete before placing higher
elevation utilities.
8.2 PRODUCTS
8.2.1 Fill materials and accessories for backfilling of trenches other than in roads or
paved/tiled areas.
A Fill Type S2: As per specification.
B Structural Fill Type S2: As per specification.
C Concrete: Class ‘C’, Lean concrete with a compressive strength of 17.5 (MPa).
D Geotextile Filter Fabric
E Geotextile filter fabric for granular pipe bedding and surround shall comply with the
requirements of Table 2 below and shall be welded or mechanically bonded ultra violet
stabilized polypropylene fibre mats made from continuous / staple fiber/

Table 2: Geotextile Filter Fabric Properties
Property Test Method Required Value
Tensile strength ISO 10319 6kN/m min
Puncture resistance ISO 12236 1000N min
Pore size ISO 12956 120 microns max
Water permeability ISO 11058 50 to 125 l/sec/m2
Weight ISO 9864 130g/m2 min
8.2.2 Fill Materials and Accessories for Backfilling of Trenches in Roads and Paved/Tiled
Areas.
A The specifications of materials for backfilling of excavations in roads and paved/tiled areas
will conform with the specifications defined in the ‘Abu Dhabi Municipality Specification for
Backfilling of Trenches & Excavations in Asphaltic Roads, Tiled/Paved Parking lots and
sidewalks, Clauses 1.1.1, 1.2, 1.3.1 and 1.3.2 and in accordance with any other agency
which may have jurisdiction of the roadway area.
8.3 EXECUTION
8.3.1 General
A Make sure the extent of all trenches in open cut is the minimum necessary or practicable
for the construction of the Works.
B Do not exceed the maximum total length of 500m for open trenches for pipelines.
C Do not make battered trenches in public highways, private gardens or within 30m of any
building or other structure.
D Provide supports in accordance with Clause 3.3 of this Specification, in the event of
adopting the method of trenching with battered sides.
E Form that portion of the trench which extends from the formation to a point 300mm above
the crown of the pipe when laid in its correct position, with vertical sides the minimum
practicable distance apart, unless otherwise specified by the pipe manufacturer and/or
accepted by the Engineer.
F Make the top edge of the trench as straight as practicable.
G Deposit any excavated material stored in approved location for backfilling or any other
purpose compacted in such a manner that will avoid damage or inconvenience. The
stockpiling of excavated material in or adjacent to the work areas will not be permitted.
Unless otherwise approved by the Engineer, the Contractor must allow for immediately
loading and transporting all excavated material to an approved off-site storage area to
avoid any nuisance to persons or property. The Contractor shall transport excavated
material which is suitable for backfill back to the site for backfilling of trenches as soon as
backfilling operations start. The Contractor shall allow for this double handling in his unit
rates.
H Excavated material stockpiled in the approved off-site storage areas shall not obstruct
entrances, sidewalks, driveways, hydrants, manholes, and any other service, and shall not
cause any obstruction to traffic. The Contractor shall ensure that stockpiled excavated
material does not obstruct pedestrian or driver visibility at road crossings or junctions.

I Any damage resulting from Contractor’s failure to comply shall be rectified at the
Contractor’s own expense, all as directed by the Engineer.
J Do not lay pipes or concrete or commence any permanent works until the Engineer has
inspected and accepted the trenching.
K Do not use blasting or explosives during the works.
8.3.2 Preparation
A Identify required lines, levels, contours, and datum locations.
B Protect plant life, lawns, rock outcropping and other features remaining as a portion of final
landscaping.
C Protect bench marks, existing structures, fences, sidewalks, paving, and curbs from
excavating equipment and vehicular traffic.
D Maintain and protect above and below grade utilities which are to remain in accordance
with relevant specification.
E Cut out soft areas of subgrade not capable of compaction in place. Backfill with Fill Type A
and compact to density equal to or greater than requirements for subsequent backfill
material or backfill with concrete class C.
F Carefully strip and set aside the surface materials for re-use as directed by the Engineer.
G Break up and dispose of the concrete of concrete roads and foundations as the Engineer
directs. Cut any existing reinforcement and bend it to the sides of the trench in order to lap
the new reinforcement to be provided in the reinstatement of the surface with the existing
reinforcement by at least 300mm.
8.3.3 Support of Trenches
A Submit the proposals for the support of trenches at least seven days prior to the
commencement of any excavation work.
B In the proposal, take into account the nature of the ground to be excavated, the level of the
water table at the site and proximity of buildings and roads.
C Where the depth of trenches exceeds 1200mm, do the following:
a) Batter back the sides of the trenches to a gradient compatible with the angle of
repose of the soil or,
b) Support the sides of the trenches with a system of sheeting piling, trench sheeting
and shoring or,
c) Adopt a combination of these.
D Submit to the Engineer detailed calculations and drawings of the measures proposed to
adopt and for approval.
E Include in the calculations the slope stability calculations, details of lateral earth pressures,
supporting site investigation results and anticipated surcharge and equipment loads during
installation, removal and backfilling.
F The proposed support for trenching should be approved by the Engineer prior to
installation.

G Do not remove temporary works supporting the trenches until in the opinion of the
Engineer the permanent work is sufficiently advanced to permit such removal. Execute
removal of temporary works under the personal supervision of a competent foreman. Any
advice, permission, acceptance or instruction given by the Engineer relative to such
support or its removal will not relieve the Contractor from his responsibilities under the
contract.
H Fix timbering, steel sheeting, shuttering and sheet piling for the support of trenching where
provided in accordance with BS 6031.
I Unless otherwise directed by the Engineer, all open excavations and other hazardous
areas shall be totally enclosed from all sides by temporary fencing. Damaged sections of
temporary fencing shall be repaired or replaced. Temporary fencing shall not be removed
from any location without the Engineer’s permission which will not be given until the trench
excavation has been refilled and reinstated.
8.3.4 Excavation
A Excavate subsoil required by contract documents.
B Cut trenches sufficiently wide to enable installation and allow inspection. Remove water or
materials that interfere with Work.
C Do not interfere with 45 degree bearing splay of foundations.
D Hand trim excavation. Remove loose matter.
E Remove lumped subsoil, boulders, and rock up to 0.25 cu m, measured by volume. Larger
material will be removed as per specification.
F Correct areas over excavated in accordance with specification.
G Stockpile excavated material at approved locations in accordance with specification, and in

accordance with Clause 3.1G of this section. Remove excess or unsuitable material from
site.
H Take every precaution to prevent slips and falls of earth and other materials in the
trenches.
I Comply with the orders from the Engineer on the restoration of the trench width, or the use
of an alternative bedding material, or taking any other remedial action as in his opinion is
necessary in the event of any trench for pipelines exceeding the maximum allowable
widths as specified or shown on the Drawings.
J Maintain and support the existing services and structures in accordance with specification.
K Keep all trenches free from water and sewage whether affected by tides, floods, and
storms or otherwise so that the Works will be constructed in dry conditions. Perform
dewatering in accordance with specification.
L Remove unsound foundations and soft spots in accordance with specification.
M The Contractor shall ensure that the formation of pipelines / structure are firm, dry, even,
true to grade, free of stones and other protrusions and compacted to a minimum 90
percent proctor dry density before placing pipeline and to satisfy the soil bearing capacity
in case of structures.

8.3.5 Backfilling
A Backfill trenches to contours and elevations with fill materials accepted by the Engineer.
B Pipe with concrete encasement or arches shall not be backfilled before three days after
placing concrete for encasement or arches.
C Where pipe is to be installed in granular bedding, the granular bedding shall be placed and
compacted to the total depth required (rough grade elevation) and then re-shaped for pipe
installation.
D As soon as practicable after the pipe has been laid, jointed, inspected, tested and
approved by the Engineer, backfilling shall begin and thereafter be prosecuted
expeditiously. Granular bedding shall be placed and compacted under and around the pipe
to mid-diameter. Granular bedding shall continue to a depth of 300mm over the top of the
pipe. The granular bedding shall be carried up evenly in maximum 150mm layers
measured prior to compaction and compacted. Compaction of granular bedding shall be
accomplished by a minimum of four passes of a vibratory plate or drum compactor suitable
for trench compaction.
E Where pipes are laid cross country, the remainder of the trench above the granular
bedding or concrete encasement shall be filled with Common Fill in layers not to exceed
200mm prior to compaction and compacted to at least 90 percent of maximum density as
determined by ASTM D698. The backfill shall be mounded 150mm above the existing
grade or as directed. Wherever a loam or gravel surface exists prior to cross country
excavations, it shall be replaced to the full original depth as part of the work under the pipe
items. In some areas it may be necessary to remove excess material during the clean-up
process, so that the ground may be restored to its original level and conditions. If the
Contractor prefers not to store loam or topsoil he shall replace it with loam or topsoil of
equal quality and in equal quantity.
F Where the pipes are laid in existing or future roadways or other paved/tiled areas, the
remainder of the trench above the granular bedding or concrete encasement and up to the
bottom of the sub-grade level shall be backfilled in accordance with the Specification for
Backfilling of Trenches and Excavations in Asphaltic Roads, Tiled/Paved Parking lots and
Sidewalks and in accordance with any other agency which may have jurisdiction of the
roadway area.
G Water well all filling materials which are in the opinion of the Engineer of a non- cohesive
nature to his acceptance in the layers specified to obtain the specified compaction.
H Employ a placement method that does not disturb or damage foundation perimeter
drainage and utilities in trench.
I Maintain optimum moisture content of fill materials to attain required compaction density.
J Remove surplus fill materials from site.
K Leave fill material stockpile areas completely free of excess fill materials.
8.3.6 Tolerances
A Top Surface of Backfilling under Paved Areas: Plus or minus 20mm for subgrade and +/-10
mm for granular sub-base from required elevations.
B Top Surface of General Backfilling: Plus or minus 25mm from required elevations.

a) Quality Control
b) All test results shall comply with the TRSDC standard unless otherwise specified.
c) Compaction testing will be performed in accordance with ASTM D1556, ASTM
D1557, and AASHTO T180.
d) If tests indicate Work does not meet specified requirements, remove Work, replace,
compact, and retest.
e) Frequency of Tests: 1 test every 100 linear metres or for each manhole to manhole,
whichever is less. Compacted test will be performed for each layer of backfilling,
unless otherwise directed by the Engineer.
a) Reshape and re-compact fills subjected to vehicular traffic during construction.
PART 9 ROCK REMOVAL
9.1 GENERAL
a) Rough Grading
b) Excavation
c) Backfilling
d) Trenching
e) Cast-In Place Concrete
9.1.2 Definitions
A Site Rock: Solid mineral material with a volume in excess of 0.25 cu m or solid material
that cannot be removed with a 0.57 cu m capacity power shovel without drilling or blasting.
A Submittals: as per specifications
B Shop Drawings: Indicate the proposed method of rock fracturing and removal.\
Not USed
9.1.5 Regulatory Requirements
A Conform to applicable code for disintegration of rock.
B Obtain permits from authorities having jurisdiction before drilling is started.

C Do not use blasting or explosives for rock fracturing.
9.1.6 Project Conditions
A Conduct survey and document conditions of buildings near locations of rock removal, prior
to the commencement of the works, and photograph existing conditions identifying existing
irregularities.
B Advise owners of adjacent buildings or structures in writing, prior to executing

seismographic survey. Explain planned seismic operations.
C Obtain a seismic survey prior to rock excavation to determine the most appropriate method
of rock fracturing and removal without damaging adjacent properties or other work.
9.1.7 Scheduling
A Schedule work under the provisions of specification.
B Schedule Work to avoid working hours of and disruption to occupants of nearby buildings.
9.2 PRODUCTS
9.2.1 Materials
A Mechanical Disintegration Compound: Grout mix of materials that expand on curing.
9.3 EXECUTION
9.3.1 Examination
A Verify site conditions under provisions of specification.
B Verify site conditions and note subsurface irregularities affecting work of this section.
9.3.2 Preparation
A Identify required lines, levels, contours, and datum.
9.3.3 Rock Removal by a Mechanical Method
A Excavate and remove rock by the mechanical method.
B Drill holes and utilize expansive tools, wedges, mechanical disintegration compound to
fracture rock.
C Cut away rock at bottom of excavation to form level bearing.
D Remove shale layers to provide sound and un-shattered base for footings, foundations.
E In utility trenches, excavate to 150mm below invert elevation of pipe and 600mm wider
than pipe diameter.
F Remove excavated materials from site and reuse for sitelandscaping as approved/directed
by the Engineer.

G Correct unauthorized rock removal in accordance with backfilling and compacting
requirements of specification, with lean concrete fill in accordance with specification, or to
directions of the Engineer.
A Provide for visual inspection of foundation bearing surfaces and cavities formed by
removed rock.
PART 10 AGGREGATE BASE COURSE
10.1 GENERAL
a) Aggregate Materials.
b) Rough Grading
c) Backfilling.
d) Trenching. Riprap
10.1.2 References
AASHTO T-89 Determining the Liquid Limit of Soils.
AASHTO T-90 Determining the Plastic Limit and the Plasticity Index of Soils.
AASHTO T-96 - Resistance to Abrasion of Small Size Coarse
Aggregates.
AASHTO T-180 Moisture-Density Relations of Soils Using a 4.54 kg Rammer 457 mm

Drop.
ASTM C88 Standard Test Method for Soundness of aggregate by use of Sodium
Sulfate or Magnesium Sulfate.
ASTM C131 Los Angeles Abrasion Test.
ASTM C136 Sieve analysis of fine and course aggregate. ASTM C142 – Clay
Lumps and Friable Particles.
ASTM D1556 Density of Soil in Place by Sand Cone method.
ASTM D1557 Test Methods for Moisture-Density Relations of Soils and Soil-
Aggregate Mixtures Using 4.54 Kg Rammer and 457 mm Drop.
ASTM D1883 CBR (California Bearing Ratio) of laboratory Compacted Soil. ASTM
D2419 - Sand Equivalent Value of Materials.
ASTM D2940 Graded Aggregate for bases and sub-bases. ASTM D75 - Sampling

Aggregate.
BS 812 Testing Aggregates.
BS 1377 Part 4 Compaction related tests.
U.A.E. Public Works Department Standard Specifications for Roads.
10.2 PRODUCTS
10.2.1 Material Requirements
A Submit samples of all materials to the Engineer for acceptance prior to furnishing and
placing any materials.
B Provide natural aggregate sub-base and base courses consisting of coarse and fine
mineral aggregates which have been screened and blended to the various gradations
specified herein and constructed to the thickness as indicated on the Drawings.
C Provide crushed aggregate sub-base and base courses consisting of crushed coarse
aggregate and crushed or natural fine aggregate screened and blended in accordance with
the gradation specified herein and constructed to the thicknesses as indicated on the
Drawings.
10.2.2 Fine Aggregates
A Provide fine aggregates (passing the No. 4 sieve) consisting of natural sand and/or
crushed sand. Ensure that the fine material is of such gradation that when combined with
other required aggregate fractions in proper proportions, the resultant mixture will meet the
gradation specified.
B The aggregates shall be clean with a maximum 0.15% content of organic matter, clay and
other extraneous or detrimental materials.
C Ensure that the portion of fine aggregates passing the No. 200 (75 micron) sieve does not
exceed 2/3 of the portion passing the No. 40 (425 micron) sieve.
D Ensure that the materials passing the No. 40 (425 micron) sieve have the maximum liquid
limit of 25, and the plasticity index does not exceed 6.
E When the source of fine aggregates does not meet the above requirements, add with the
Engineer’s approval additional fine aggregate and/or filler to correct the gradation or to
change the characteristics of material passing the No. 40 sieve so as to meet the
Specifications. Add such additional material in a manner, which ensures a completely
homogenous gradation as accepted by the Engineer.
10.2.3 Coarse Aggregates
A Provide coarse aggregate retained on the No. 4 sieve (4.75 mm) consisting of crushed
stone, crushed gravel or natural gravel. Ensure that aggregates are of such gradation that
when combined with other required aggregate fractions in proper proportion, the resultant
mixture will meet the gradation specified.
B When crushed aggregate is required, not less than 50 percent by weight of the particles
retained on the No. 4 sieve shall have at least one fractured face. The Flakiness Index of
the crushed aggregate shall not exceed 35 percent.

C Ensure that the percentage of wear of coarse aggregate does not exceed 40 percent when
tested for resistance to abrasion (AASHTO T-96).
D Provide hard and durable coarse aggregates free from organic matter, clay and other
extraneous or detrimental materials.
E Ensure that the maximum sodium sulphate soundness loss of the coarse aggregate does
not exceed 18 percent in conformance with ASTM C88
10.2.4 Types of Aggregate Sub-Base and Base Courses
A Ensure that the combined gradation including fine and coarse aggregates conform to the
gradation of Type A or B or C as listed below in Table 3.
Table 3: Types of Aggregates
Percent Passing by Weight

No of Sieve Size
Gradation A Gradation B Gradation C
50 mm - - 100
37.5 mm - 100 75-100
25 mm 100 70-100 55-85
19 mm 70-100 60-90 50-80
9.5 mm 50-80 45-75 40-70
No. 4 35-65 30-60 30-60
No. 10 25-50 20-50 20-50
No. 40 15-30 10-30 10-30
No. 200 5-15 5-15 5-15
B The gradation of materials to be used in the aggregate sub-base and base courses as
shown in the above table indicates the limits within which the material could be accepted.
C Keep the continuous smooth gradation of materials used within the specified gradation
limits and avoid gap grading.
D Unless otherwise indicated on the Drawings or in these Specifications, use gradation C

when aggregate base or sub-base is specified.
E The aggregate should have a minimum 80% CBR in accordance with ASTM D1883, 4
days water soaking at 100% of Maximum Dry Density in accordane with ASTM D 1557
F The ‘sand equivalent’ value of materials shall be a minimum 40% in conformance with
ASTM D2419. Loss by abrasion shall be a maximum 40%.
G Acid soluble sulphates (Combined Aggregates) shall not be greater than 0.5% in
conformance with (BS 812:P118). Clay lumps and friable particles shall be a maximum
0.25% in conformance with ASTM C142.
H Acid soluble chlorides (Combined aggregates) shall not be greater than 1% in

conformance with (BS 812:P117).

10.2.5 Spreaders
A Use spreaders with a screen and vibrator that strikes off and distributes the material to the
required width and level for each layer and capable of spreading the sub-base and base
materials in one operation so as to make it ready for compaction with minimum shaping.
B Ensure that the width of each spread is not less than a traffic lane wide. Use a spreader
with a screen that can be adjustable to the required cross-section. Screed action includes
any practical motion that produces a finished surface texture of uniform appearance.
10.2.6 Central Mixers
A Provide central mixing plant of either an approved drum or pugmill type with a moisture
control system so that the material may be spread without further mixing or processing.
B Mixing should be done before spreading (out of site).
10.3 EXECUTION
10.3.1 Examination
A Verify sub grade has been inspected and complies with the Specification, is compacted to
the maximum dry density of 100%, Maximum dry density in conformance with ASTM
D1557 and Field density with ASTM D1556, and its levels and slopes comply with the
longitudinal and cross-section drawings (see Clause 3.2).
B Obtain acceptance of the Engineer before commencing spreading of material for the sub-
base and base courses.
10.3.2 Preparation
A Correct irregularities in substrate/subgrade gradient and elevation by scarifying, reshaping,

and re-compacting, to obtain smooth, hard, uniform surface.
B Do not place fill on soft or muddy surfaces.
10.3.3 Screening and Mixture of the Materials
A Apply screening for the materials used in aggregate sub-base and base courses.
B Use screens of the size and number required to remove oversize aggregate and, if
necessary, to separate the materials into two or more fractions so that they may be
combined to meet the required gradation.
C When conveyor belt samples from the end of the screening and/or crushing-screening
operation yield a product consistently within the specified gradation, no further mixing will
be required at the plant and the material may be loaded and hauled directly to the road.
D Stockpile material, if required, so as to prevent segregation.
E Mix the material through using central mixing plant.
F Where separate size materials are to be blended to meet the gradation, blend them as
directed by the Engineer, prior to delivery to the roadway. Mixing of separate materials on
the roadway by the motor grader will not be permitted.

10.3.4 Aggregate Spreading and Compacting
A Take samples of the screened mixed and approved material in order to determine the
optimum moisture content in accordance to ASTM D1557
B Spread the material on the prepared surface in layers not more than 15 cm compacted
thickness to achieve the total thickness as indicated on the Drawings.
C Ensure that the geotextile fabric is not damaged by spreading and compacting the
aggregate sub-base.
D Determine the natural moisture content of materials constituting the sub-base and base
courses. If it is less than the optimum moisture content, add the necessary amount of
water to obtain the optimum moisture content. Allow for the quantity which may be lost by
evaporation in the process of raking, levelling and compacting, depending on atmospheric
temperature, quantity of material and the equipment and plant to be used in this operation,
provided that the layer is compacted when the moisture content therein is within +1 of the
optimum moisture content in order to obtain maximum dry density, and moisture content is
uniform in all parts of the section where the work is being carried out and in the various
depths of the layer thickness. Any segregated spots to be replaced to fill depth with well
graded material.
E Aerate the material in order to reach the optimum moisture content, if the natural moisture
content in materials exceeds the optimum moisture content.
F Start the compaction immediately thereafter, by means of pneumatic and steel rollers or
vibratory rollers and in accordance with the instructions from the Engineer.
G Start the compaction with rollers from extreme sides proceeding gradually toward the road
axis.
H Continue rolling until an average relative density of not less than 100 percent but no single
value below 98% (for sub-base and for road base layer) of the Maximum Dry Density has
been obtained as determined by the Moisture-Density Relationship Test AASHTO T-180
by test method ASTM D1557. Ensure that the CBR (ASTM D1883) of the sub-base
material and road base is not less than 80% at 100% compaction, 96 hours water soaking.
I Take care during the operations of mixing spreading compacting and levelling of sub- base
and base course materials so that layers already compacted under the layer being
executed are not affected, or that the finished sub-grade or base surface is also not
affected.
J Where equipment makes turns in going back and forth, make good any damage that
results in mixing the various layers constituting the different sub grades and base courses
at your own expense and to the satisfaction of the Engineer.
K Where the finished total compacted thickness exceeds 150 mm, execute each layer in
composite layers not exceeding 150 mm in thickness after compaction unless otherwise
accepted by the Engineer in writing.
10.3.5 Protection of Surface
A Protect the sub-base or base course and maintain it sound during work progress, after its
completion and prior to receiving the bituminous layers or prior to laying the surface
overlay thereon.
B Repair damages caused to the layer to the satisfaction of the Engineer, if exposed to traffic
or natural conditions resulting in damage to the surface.

C Do not roll the sub-base and base courses when the underlying material is soft or yielding
or when the rolling causes a wave-like motion in this course.
D When the rolling develops irregularities.
a) Loose the irregular surface, then refill it with the same kind of material as used in
constructing the course and again roll according to the specifications.
b) Tamp thoroughly the sub-base and base course material with mechanical tampers
along places inaccessible to rollers.
E Do not work on the sub-base and base course during rainy weather.
F Hauling equipment may be routed over completed portions of the sub-base and base
courses provided no damage results and provided that such equipment is routed over the
full width of the course to avoid rutting or uneven compaction.
G The Engineer has the right to stop all hauling over completed or partially completed sub-
base and base courses when in his opinion such hauling is causing damage.
10.3.6 Tolerances
A Flatness: Maximum variation of 10mm measured with 3m straight edge.
B Scheduled Compacted Thickness: Within 8mm.
C Variation from Design Elevation: Within 10mm.
A Quality Control as per specification.
B Compaction testing will be performed in accordance with ASTM D1556, ASTM D1557 and
AASHTO T180.
C Test the aggregate sub-base and/or base courses. Obtain acceptance of the Engineer
prior to the application of any prime coat or any other paving course.
D The minimum requirements for the aggregate sub-base and base courses shall be as
follows:
a) Compaction: Wherever the degree of compaction is found to be less than the

average 100% and for any single value of 98% specified, re-compact and correct the
area of sub-base or road base course involved satisfactorily so that the minimum
specified density is achieved.
b) Gradation: Wherever the gradation is found to be outside the limits specified, scarify,
remove or otherwise rework the area of sub-base and/or base course involved as
directed by the Engineer to provide a material within the specified limits.
c) Thickness: In the event of the constructed thickness of the aggregate sub- base or
base course being 8mm more than the total thickness indicated on the Drawings,
correct the area involved as directed by the Engineer by removing excess material in
an accepted manner.
In the event of the constructed thickness of the aggregate sub-base or base course
being 8 mm less than the total thickness indicated on the drawings, provide
additional material in the next course (base course or wearing course).
Construct the aggregate sub-base or base course to the grade level as indicated on
the Drawings, as specified, and as accepted by the Engineer.

Do not allow the total sum thickness of the sub-base course, base course and
wearing course to be less than the total sum thickness of all courses as indicated on
the Drawings.
d) Evenness of surface and grade level:
 Test the final surfaces of the sub-base or base courses by means of a 3 metre
long straight edge.
 Ensure that no rises or depressions in excess of 10mm appear on the surface.
Otherwise, strip such areas, correct and recompact to comply with all
specification requirements and as accepted by the Engineer.
 Construct the finished surface of the sub-base or base course to within 10mm
of the grade levels indicated on the Drawings.
E Minimum frequency test requirements for road base shall be as follows:
a) One sample every 1,000m3 shall be tested for gradation, P.I., S.E., Soundness,
Maximum Dry Density, CBR and L.A.
b) One in-situ density test for every 300m2 of the laid aggregate road base, base and
sub-base.
PART 11 GLASS REINFORCED PLASTIC PIPES
11.1 GENERAL
This section of the specification gives the requirements for Glass Reinforced Plastic (GRP)
pipeline materials and the installation and testing. The Manufacturer's design shall satisfy
the minimum requirements set herein.
a) Material and equipment
b) Excavation
c) Backfilling
d) Trenching
11.1.2 Standards
All activities relating to this section of the standard specification shall comply with the
following or approved equal standards
ASTM D2584 Standard test method for ignition loss of cured reinforced resins.
ASTM D4161 Standard specification for ''fiberglass" (Glass fibre reinforced thermosetting
resin) pipe joints using flexible elastomeric seals
BS 3532 Aerospace Series. Steel FE- PM2701
BS 4549-1 Guide to quality control requirements for reinforced plastics moldings. Guide to the
preparation of a scheme to control the quality of glass reinforced polyester mouldings

BS EN 681 Elastomeric seals. Material requirements for pipe joint seals used in water and drainage
applications.
BS EN 1394 Plastic piping system Glass reinforced thermosetting plastic (GRP) pipes. Determination
of the apparent initial circumferential tensile strength
BS EN 1092-2 Circular flanges for pipes, valves and fittings (PN designated). Steel, cast iron and
copper alloy flanges. Specification for cast iron flanges.
BS EN 14364 Plastic piping system for drainage and sewerage with or without pressure. Glass
reinforced-thermosetting plastics (GRP) based on unsaturated polyester resin (UP).
Specification for pipes and fittings
BS 5840 Specification for glass fibre reinforced plastic (GRP) pipes and fittings for use for water
supply or sewerage.
ISO 9000 Quality management systems
ISO 10468 Plastic Piping Systems - Glass- Reinforced thermosetting
Plastic (GRP) pipes.
DIN/BS EN 14364 Plastics piping systems for drainage and sewerage with or without pressure - Glass-
reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)
DIN-53769- Part 3 Testing of GRP pipes - Determination of Initial and Long-term Ring stiffness
DIN-53769- Part 6 Testing of GRP pipes under pulsating internal pressure
DIN EN 1120 Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes and
fittings - Determination of the resistance to chemical attack from the inside of a section in
a deflected condition
DIN EN ISO 75 Plastics - Determination of temperature of deflection under load
DINEN1119 Plastics piping systems - Joints for glass-reinforced thermosetting plastics

(GRP) pipes and fittings - Test methods for leak tightness and resistance to
damage of flexible and reduced articulation joints
DIN EN 1447 Plastics piping systems - Glass-reinforced thermosetting plastics (GRP) pipes-
Determination of long-term resistance to internal pressure
ASTM C-581 Standard Practice for Determining Chemical Resistance of Thermosetting Resins Used
in Glass-Fibre-Reinforced Structures Intended for Liquid Service
ASTM D3681 Standard Test Method for Chemical Resistance of "Fiberglass" (Glass-Fibre-Reinforced
Thermosetting-Resin) Pipe in a Deflected Condition
DIN 53769 Testing of glass fibre reinforced plastics pipes; determination of the longitudinal shear
strength of type B pipe fittings

ASTM D2992 Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for
"Fiberglass" (Glass-Fibre-Reinforced Thermosetting-Resin) Pipe and Fittings
11.1.3 Submittals
11.1.3.1 Products and Materials Approval
In order to verify compliance with the specification the Contractor shall submit information
for all products and materials used in the Works to the Engineer for approval sufficiently
in advance of their use in accordance with the Contract programme allowing for ordering
and approval times. Information to be submitted shall comprise but not necessarily be
limited to:
a) The manufacturers design calculations, complete and detailed specification,
standard Quality Control test results including the latest Type Tests (Long Term test)
results not later than three years from the date of approval submission of the
proposed GRP pipes and fittings required for the Works including Manufacturers
Certificates of compliance with this section of the standard specification. Information
on all items listed in Table 1 below shall be given.
b) Should any details, including materials of the pipes and fittings be altered in any way
during manufacture from those proposed and approved by the Engineer, submit
for the Engineer's approval the revised details and test results, including Type Test
results [in case of altering of material (Long Term 10,000hrs tests.)]
c) Submit to the Engineer the results of all standard quality control tests carried out on
the manufactured pipes and fittings as soon as practicable after testing as and in
any case not later than the time of delivery of the relevant pipes and fittings to the
site.
d) Pipe manufacturer's guarantee that the pipe and its materials are suitable for its
intended use and application.
e) Joint materials and gaskets.
f) Where applicable, standard produced pipe lengths shall be 12 meter for Filament
Wound (FW) and 6 meter for Centrifugal Cast (CC). Tolerance shall be governed by
the relevant manufacturing standard.
Table 4: Product Information for GRP Pipe and Fittings

Name of Manufacturer -
Joint type -
Nominal internal / external diameter mm
Pressure class of pipe (PN) kN/m2

Minimum depth of cover m
Maximum depth of cover m
Maximum working pressure kN/m2
Design test pressure kN/m2
Internal vacuum pressure kN/m2
Pipe Wall Structure
Nominal total wall thickness mm
Inner liner Resin** Type %
Glass* Type %
Thickness mm
Structural wall Resin** Type %
Chopped Glass** Type %
Hoop Glass** Type %
Aggregate** Type %
Thickness mm
External layer Resin***Type %
Glass***Type %
Thickness mm
Minimum Initial Pipe Properties
Stiffness (SN) N/m2
Longitudinal tensile strength N/mm
Hoop flexural modulus GN/m2
Hoop tensile strength N/mm2
Last date of publishing the Type Test (Long Term) results
Notes to Table 1
Pipe data to be provided for every diameter in each class of pipe.
* By weight of liner.
** By weight of structural wall.
*** By weight of layer
11.1.3.2 Method Statements
The Contractor shall submit method statements to the Engineer for approval, 4-8 weeks in
advance of commencing the site activity in accordance with relevant section of the
specification. These shall comprise but not necessarily be limited to:-

a) Procedures for handling, storage and installation of pipes.
b) Hydrostatic testing procedures for GRP non-pressure pipelines
c) Hydrostatic testing procedures for GRP pressure pipelines.
d) Deflection measurement procedures for GRP pipelines, where necessary, as per
manufacturing standard.
11.1.4 Drawings
The Contractor shall submit drawings to the Engineer for approval well in advance of
commencing the site activity in accordance with relevant section of the specification.
These shall comprise but not necessarily be limited to:
a) Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.
b) Pipe laying diagram and schedule showing location, length, design designation
and designation by number of each pipe section and pipe special to be
furnished and installed.
c) All data on curve and bends for both horizontal and vertical alignment.
11.1.5 Quality Control
Inspection of the products by the manufacturer shall be in accordance with the definitions
in the product standards and in additional quality specification, as per the selected
technique of the manufacturing.
a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the opportunity
to inspect and test the product and/or material prior to delivery in accordance with
relevant section of the specification.
b) Products and materials shall be from a manufacturer/supplier who operates a quality
control system which is registered to ISO 9000 series or approved equal.
c) To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 48 hours’ notice of carrying out the following activities on site:-
 Installation of pipeline.
 Hydrostatic testing of pipeline.
 Deflection measurement of pipeline.
11.1.6 Delivery, Storage and Handling
manufacturer's recommendations, relevant section of the specification and the following
provisions:-
a) Delivery storage and handling shall at all times be performed in a manner to avoid
product damage.
b) Pipes and fittings shall not come in contact with any sharp projections that may
cause damage to the pipes and fittings during transportation loading and unloading.
Ensure that pipes and fittings are well secured during transit and adequately
supported along their length. Cover pipes and fittings of plastic materials during
transportation. Do not allow pipe to overhang the end of a vehicle during
transportation.
c) Ensure that pipes and fittings are lifted using nylon or large diameter rope slings
positioned at a quarter of the pipe length from each end. Do not allow the use of wire
rope chains or unpadded forks or clamps on forklifts to lift pipes.

d) Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or crated,
remain on the pallets or in their crates until required.
 Stack non-crated pipes to the approval of the Engineer.
 Stack spigot and socket pipes so that successive pipe layers have sockets
protruding at opposite ends of the stack.
 Stack pipes of different sizes and thickness separately.
 Do not allow stacked pipes to exceed 2m in height or as recommended by the
supplier whichever is the lesser.
e) Store GRP pipes and fittings under opaque cover and out of direct sunlight at all
times. Maintain a free flow of air around the pipes at all times.
f) Store rubber joint rings in a well-ventilated place free from exposure to
sunlight and in their original packing until they are needed.
g) The Contractor shall visually inspect all products upon delivery to site and report any
damage to the Engineer.
 Any products damaged during delivery, storage and handling shall be marked
by the Contractor and set aside.
 Proposals for repair of any repairable products shall be submitted in writing to
 Any damaged products deemed unsuitable for repair by the Engineer shall be
removed from the site and replaced, with an equal.
11.2 PRODUCTS
11.2.1 Pipe Design Requirements
The design requirements for GRP pipes shall be, as given below unless otherwise
indicated on the drawings or on recommendations of Manufacturer depending on site
conditions (soil, installation, compaction, loads etc.) in compliance to the Special Warranty
conditions, quoted elsewhere in this document.
Design Requirements of GRP pipes
a) Minimum initial specific stiffness shall be
 For gravity pipelines in buried installation with cover depths less than 6m shall
be 5000 N/m2.
 For gravity pipelines in buried installation with cover depth more than 6m shall
be 10,000 N/m2
 For all pressure main shall be 10,000 N/m2 (SN10000).
 For all exposed pipe line shall be 10,000 N/m2 (SN10000).
b) Any variance due to the site condition such as native soil condition,
installation, burial depths, deflection limits, buckling and vacuum requirements or
others which necessitates increasing the stiffness (SN) value of GRP pipe shall be
governed by the Manufacturer's design.
c) Pressure mains shall be designed as per the requirement of Table 15 of BS/DIN EN
14364.
d) GRP pipe length used in concrete bed and surround shall be 3.0m unless otherwise
specified in the drawings.
e) All GRP pipes installed up to 10.0m cover depth shall be buried in granular bed and

surround or as specified by the Manufacturer according to the ground conditions.
For cover depths exceeding 10m, the pipe shall have concrete surround or
Manufacturer to suggest suitable higher stiffness pipe.
11.2.2 Pipes and Fittings
11.2.2.1 BURIED GRP
General
a) All GRP components shall be designed and fabricated by one manufacturer.
b) GRP pipes and fittings shall be manufactured in compliance with BS/DIN EN14364
and fabricated to meet the minimum strength requirements
c) Manufacture all pipes by an approved process utilizing a rotating mould or mandrel
besides equipment which accurately control the quantities and placement of all
resins, glass and aggregates.
d) Use resins, reinforcements, and aggregates to produce pipes and fittings when
combined as a composite structure to satisfy the performance requirements of this
section of the specification. Pipes and fittings must be designed to achieve a
minimum working life of 60 years under all applicable standard loadings,
environmental and installation conditions.
e) Both internal and external surfaces shall be free from irregularities, which would
impair the ability of the component to conform to the requirements of European
Standard BS/DIN EN 14364.
Materials and pipe wall construction
The pipe or fitting shall be constructed using chopped and/or continuous glass filaments,
strands or roving, mats or fabric, synthetic veils, and polyester/ vinyl ester resin without
fillers and if applicable additives necessary to impart specific properties to the resin. The
pipe as whole and the part of pipe used for fittings may also incorporate aggregates. All the
raw materials used shall be from the approved list of suppliers.
Filament Wound (FW) GRP pipes and fittings:-
a) Resins
Vinyl ester shall be used in the internal resin rich liner of the pipe and fittings. lsophthalic or
vinyl ester shall be used in the structural wall of the pipes and fittings, as per the design
application requirements. All resins shall be tested in accordance with ASTM C-581or
applicable standard. Provide resin systems to the requirements of BS 3532 type-B or to
applicable standard.
Resins shall be cured to achieve 90% of the manufacturer's recommended Barcol
hardness value and may be tested by external laboratories for their authenticity of type by
random sampling, during the project.
b) Additives
The use of additives such as fire retardant, UV inhibitors or coloured pigments or dyes
shall be subject to the approval of the Engineer and will only be approved in exceptional
circumstances.
c) Aggregates and fillers.
Sand aggregates shall be clean, graded silica sand containing no impurities and be in
accordance with BS/DIN EN 14364.
Fillers (other than sand aggregates) shall be permitted in accordance to BS/DIN/ EN
14364, provided the necessity is scientifically tested, justified and approved by the
Engineer on all accounts of performance, including Qualifying Tests using Long Term type
tests, at minimum a of 10,000 hrs.

Note: Filled pipes and fittings shall only be allowed on a project once the satisfactory Long
Term test results are in hand & all conditions as stipulated above are met in advance.
d) Wall construction
Liner layer
a) The inner liner layer shall comprise minimum 1.5 mm thick rich Vinyl ester Resin
suitably reinforced with C glass veil and backed up by remainder of liner in layers of
powder bound acid resistant glass chopped strand mat or roving depending
on the method of manufacture with a glass content of between 25% and 35%
by weight. or the equivalent of chopped strand "E" glass depending on the method
of manufacture. No chopped strands or sand are allowed in the inner face layer of
the resin rich liner.
b) The pure resin used in this inner liner layer must conform to requirements given in
BS/ DIN EN 14364 and to stipulation of section "a" as above.
c) Resins shall be cured to achieve 90% of the manufacturer's recommended Barco!
hardness value.
Structural layer
a) Build up the structural layers by acid resistant glass chop roving or continuous
roving with a glass content of between 25% and 35% by weight.
b) The structural layer shall consist of glass reinforcement and a
thermosetting isopathalic polyester resin with or without sand aggregates.
c) Aggregates can be used as per the manufacturing techniques applied, however
ensure no aggregate becomes embedded in the internal resin rich liner layer.
Outer layer
a) Pipes shall be provided with an external vinyl ester resin rich layer, with C- glass
Veil.
b) The resin used in the outer layer will be Vinyl ester and in accordance to
BS/DIN EN 14364 shall have a Glass Transition temperature of at least 75°C. In
addition, a sample shall be tested for HOT in accordance with Method A of DIN EN
ISO 75- 2.
c) The use of special constructions is permitted when the pipe is expected to be
exposed to extreme climatic, environmental or ground conditions, for example
provision for the inclusion of pigments or inhibitors for extreme climatic conditions or
fire retardation, upon the approval of the Engineer.
Wall thickness
a) The minimum total wall thickness, including the liner shall be declared by the
manufacturer.
b) Use pipes with wall thickness that achieve a minimum hoop flexural modulus of 15.0
GN/m2 over the whole pipe wall thickness for pipes of 350mm diameter and above,
and 12.0 GN/m 2 for pipes of less than 350mm diameter. This shall be
demonstrated by the application of the equation S = (EI)/03 to show that the hoop
flexural modulus of a pipe is not less than the required minimum figure where S is
the stiffness of the manufactured pipe, D is the mean diameter of the manufactured
pipe, E the required hoop flexural modulus and "I "being given by t3/12 where t is
the whole wall thickness of the manufactured pipe.
Fittings
Fittings shall be manufactured similar to the pipe construction or better thereof as per the
existing worldwide standard manufacturing techniques, complying with applicable
standards on performance and testing.
Centrifugally cast (CC) GRP pipes and fittings:
a) Resin

 Vinyl ester shall be used in the internal resin rich liner of the pipe and fittings.
lsophthalic or vinyl ester shall be used in the structural wall of the pipes and
fittings, as per the design application requirements. All resins shall be tested
in accordance with ASTM C-581 or applicable standard. Provide resin
systems to the requirements of BS 3532 type-S or to applicable standard.
 The resin used in the liner layer will be Vinyl ester and in accordance to
BS/DIN/EN 14364 shall have a Glass Transition temperature of at least 75°c.
In addition, a sample shall be tested for HOT in accordance with Method A of
DIN EN ISO 75 - 2.
 Resins shall be cured to achieve 90% of the manufacturer's recommended
Barco! hardness value and may be tested by external laboratories for their
authenticity of type by random sampling, during the project.
b) Additives.
 The use of additives such as fire retardant, UV inhibitors or coloured pigments
or dyes shall be subject to the approval of the Engineer and will only be
approved in exceptional circumstances.
c) Aggregates and fillers.
 Sand aggregates shall be clean, graded silica sand containing no impurities
and be in accordance with BS/DIN EN 14364.
 Fillers (other than sand aggregates) shall be permitted in accordance to
BS/01N/ EN 14364, provided the necessity is scientifically tested, justified and
approved by the Consultant and the Client on all accounts of performance,
including Qualifying Tests using Long Term type tests, at minimum a of
10,000 hrs.
 Note: Filled pipes and fittings shall only be allowed on a project once the
satisfactory Long-term test results are in hand & all conditions as stipulated
above are met in advance.
d) Wall construction
Liner layer
 The inner liner layer shall comprise minimum 1.5 mm thick pure Vinyl ester
Resin without Glass reinforcement and sand aggregates.
 The pure resin used in this inner liner layer must conform to requirements
given in BS/DIN EN 14364 and to stipulation of section "a" as above.
 Resins shall be cured to achieve 90% of the manufacturer's
recommended Barcol hardness value.
Structural layer
 The structural layer shall consist of glass reinforcement and a thermosetting
isopathalic polyester resin with sand aggregates.
 Aggregates can be used as per the manufacturing techniques applied,
however ensure no aggregate becomes embedded in the internal resin rich
liner.
Outer layer
 This layer shall be formed of mortar in vinyl ester resin with sand aggregates
and without reinforcement of glass or synthetic filaments.
 The resin used in the outer layer will be Vinyl ester and in accordance to
BS/DIN EN 14364 shall have a Glass Transition temperature of at least 75 °C.
In addition a sample shall be tested for HOT in accordance with Method A of
DIN EN ISO 75- 2.
 The outer protective layer shall have a sand content with a minimum

percentage of 65 % of sand for corrosion protection.
 The use of special constructions is permitted when the pipe is expected to
be exposed to extreme climatic, environmental or ground conditions, for
example provision for the inclusion of pigments or inhibitors for
extreme climatic conditions or fire retardation, upon the approval of the
Engineer.
e) Wall thickness
 The minimum total wall thickness, including the liner and outer protective layer
shall be declared by the manufacturer, which shall be complying to the
standard performance criteria.
 Use pipes with wall thickness that achieve a mm1mum hoop flexural modulus
of 15.0 GN/m2 over the reinforced wall thickness for pipes of 350mm diameter
and above, and 12.0 GN/m2 for pipes of less than 350mm diameter. This
shall be demonstrated by the application of the equation S = (EI)/D3 to show
that the hoop flexural modulus of a pipe is not less than the required
minimum figure where S is the stiffness of the manufactured pipe, 0 is the
mean diameter of the manufactured pipe, E the required hoop flexural
modulus and I being given by t3/12 where t is the reinforced wall thickness of
the manufactured pipe.
f) Fittings
 Fittings shall be manufactured similar to the pipe construction or better thereof
as per the existing standard manufacturing techniques, complying with
applicable standards on performance and testing.
Mechanical and other characteristics
The pipe class for a specific application shall depend on the required diameter (DN), the
pressure rating (PN) necessary for the application, and the pipe stiffness (SN) derived from
the structural analysis depending on site conditions (soil, installation, compaction, loads
etc.)
a) Minimum initial specific stiffness.
 As detailed in section 2.1 as above.
 For other nominal stiffness class in certain areas in accordance to defined
parameters of BS/01N EN 14364.
b) Minimum initial specific longitudinal tensile strength shall be in accordance to
BS/DIN EN 14364.
c) Fabricate pipes and fittings capable of withstanding the working pressures, test
pressures and loadings specified.
d) Pipes and fittings shall be suitable for carrying domestic sewage at temperatures up
to 50°C and having a maximum sulphide concentration of 50 mg/litre.
e) Pipes and fittings to be designed to withstand up to 5% long term deflection in their
installed conditions.
f) Conform to BS/DIN EN 14364 for pipe dimensions and tolerances. Deviations in
diameters and wall thicknesses of pipe ends and coupling shall be such that the seal
at the joints is not affected.
g) Ensure that the internal surfaces of the pipes and fittings are smooth, and that the
internal and external surfaces are clean and free from defects such as protruding
fibres, pits, cracks, blisters tackiness and embedded foreign matter. The core of the
pipe wall shall be free of bubbles, voids, cracks and de-bonding.
h) All bends shall be long radius bends unless otherwise approved by the Engineer.
i) Latest Type Tests (Long Term test) results not later than three years from the date
of submission of the proposed GRP pipes and fittings required for the Works

including Manufacturers Certificates of compliance with this section of the standard
specification, to be provided.
JOINTS
General
a) Joint performance shall be according to section 07 of BS/DIN EN 14364; in general.
All buried joints shall be Non-end-load-bearing flexible joints of spigot and socket
type (including double socket designs) with EPDM rubber in full faced elements or
rings in accordance with BS/DIN EN 681; manufactured according to the individual
manufacturing technique and supplied as integral part of the pipe or separately. The
sealing rings shall be supplied by the pipe manufacturer.
b) Non-end-load-bearing flexible joints with elastomeric seals shall be tested using test
pieces conforming to BS/DIN EN 14364, for conformance to the test performance
requirements under hydrostatic pressure.
c) For pipes up to and including 600mm nominal internal diameter joints shall be
capable of withstanding a deflection of not less than one and a half degrees in any
direction and remaining watertight. For pipes over 600mm nominal internal diameter
joints shall be capable of withstanding a deflection of half degree in any direction
and remaining watertight.
d) Joints shall be capable of withstanding a draw of 13mm over and above the initial
jointing allowance and remaining watertight. The initial jointing allowance is the
GRP between the spigot and the shoulder of the socket measured parallel to the
centre line of the pipeline and must not be less than 6mm or greater than 13mm or
as recommended by the pipe manufacturer.
e) Additionally, the pipe joints shall be capable of withstanding an external pressure
equivalent to 10m head of water without leakage in both the straight and deflected
positions.
f) Joint couplers may be used adjacent to structures or special fittings.
g) When a pipe is cut or turned down in order to form a joint fully seal the exposed
surfaces with a continuous coating of vinyl ester resin.
h) Do not use butt/wrap joints without obtaining the approval of the Engineer. Approval
will only be given if the Contractor can demonstrate that this type of joint is the most
suitable method of forming the joint. Such joints will be formed by specialist
operatives under the supervision of the pipe manufacturer and fully in accordance
with his recommendations. Use materials to be compatible with the pipes to be
joined. Obtain the Engineer's approval for the material along with the method, before
work commences.
Table 5: Summary of test requirements for non-end-load-bearing flexible joints
Property to be tested Tests to be performed Test pressure in Bars Duration
Initial Leakage Initial Pressure 1.5 X PN 15 min
External
pressure - 0.8 bar (- 0.08
Negative pressure a 1h
differential MPa)
Misalignment and Draw Positive static pressure 2.0 x PN 24 h
Angular deflection and

draw Initial pressure 1.5 X PN 15 min

Property to be tested Tests to be performed Test pressure in Bars Duration
Positive static pressure 2.0 X PN 24 h
i) Relative to atmospheric, i.e. approximately 0.2 bar (0.02 MPa) absolute.

Marking
Ensure that all pipes including cut lengths and all fittings before dispatch from the pipe
manufacturer's works are indelibly marked as follows:
a) The manufacturer's name, initials, or identification mark.
b) The nominal internal diameter in mm.
c) The length in m.
d) Mark the classification i.e. pressure rating, stiffness.
e) The date of manufacture and batch number.
f) A stamp to show that they meet the required inspection requirements and hydraulic
tests (where applicable) at the point of manufacturer.
g) Stencil in legible letters the pipe identification number on the inside and outside at
each end. Ensure that the same number appears on all record sheets and
documents relating to the manufacture delivery and testing of that pipe.
h) The manufacturing standard.
i) The project or contract number.
11.2.2.2 Exposed GRP
GRP pipes and fittings utilized for exposed service inside pumping stations, and valve
chambers shall be designed to resist all bending stresses, thrust forces, surge pressures,
negative pressures and vibratory forces.
Exposed pipe and fittings shall be manufactured in the same manner and with the same
materials as buried pipe, along with the following requirements unless otherwise approved
by the Engineer.
a) Resin in the structural wall shall be lsophthalic or Vinyl ester.
b) Additional exterior stiffeners may be required to maintain circularity on large
diameter pipes and shall be installed to the manufacturer's requirements.
c) Design of the outer layer of the pipes shall be formed of an vinyl ester resin with or
without sand aggregates and with or without reinforcement of glass. The outer
protective layer shall have a minimum thickness of 1 mm and protect the structural
layer against extraneous causes (atmospheric conditions, mechanical damage, UV
and chemical stress). For Centrifugally Cast GRP Pipe the outer protective layer
shall have a sand content with a minimum percentage of 65 % of sand against ultra-
violet influences.
d) Use flanged joints for all exposed pipes and fittings inside treatment plants, process
structures, pumping stations, and valve chambers.
e) Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed
with epoxy or vinyl ester resins only.
f) All bolts shall be stainless steel grade 316.
g) Flanged pipe joints must incorporate an annular gasket at the joints and these
gaskets must cover the full face of the flange with holes cut in the corresponding to

the bolt holes in the flanges. Drill flanges to BS EN 1092 (metric units) type PN16. If
approved by the Engineer, use a plain ring covering the flange between the bolt
circle and the bore of the pipe. Use 3mm thick gaskets incorporating two layers of
cotton fabric insertions evenly spaced in the gasket. When flanged joints are to be
made, secure the bolts and the nuts initially to finger tightness. Thereafter the final
tightening of the nuts shall be effected by torque spanners in such sequence that
diametrically opposite nuts are tightened together to achieve the
manufacturers recommended torque.
h) All joints shall be in accordance with the manufacturer's instructions.
11.3 QUALITY CONTROL TESTS
11.3.1 GRP Pipes and Fittings
a) Routine Factory Quality Control Tests.

 Carry out the quality control tests listed below at the frequency stated.
 Ensure that records of all tests and inspections are maintained by the
manufacturer.
 Provide the Engineer with two copies of all test certificates and reports.
b) Raw Material Inspection.
 Inspect all raw materials to ensure that they comply with the relevant
standard.
 Check all deliveries of resin for consistency by viscosity and reactivity. Do not
use any resins deviating from the manufacturer's published figures.
 Check all deliveries of sand and aggregates for grading, moisture content
and purity.
 All resin type may be tested for quality and authenticity in external laboratories
as and when deemed fit by the Engineer.
c) Hydraulic Test as per relevant manufacturing & testing standard
For Filament wound GRP pipes.
a) Perform an internal hydraulic pressure test for every pipe at the
manufacturer's works prior to delivery.
b) Apply 1.5 times the pipe design pressure or surge pressure, whichever is greater for
all pressure pipes. Apply the test pressure for a minimum period of 5 minutes
without signs of leakage.
c) In addition to the above:-
 Maintain at test pressure the first pipe and thereafter every 360 meter of
pressure pipe of each diameter produced for a minimum of 4 hours without
signs of leakage.
 Perform an internal low pressure air test for every pipe fitting at the
manufacturer's works prior to delivery. Apply a test pressure of 0.1 bars for a
minimum period of 5 minutes without signs of leakage or distress.
Manufacture fittings which are of mitred construction from pipe which has
successfully passed the tests defined above.
 Follow section (k), given below for Rejections
For Centrifugally cast GRP pipes
a) Perform an internal hydraulic burst pressure test for minimum 1 pipe specimen
or 360 meters, whichever comes first of pressure pipes produced.

b) Burst pressure shall be more than 4 times the pressure rating of the Pipe. Testing is
to be carried out as per relevant standard.
c) In addition to the above.
 Maintain at test pressure the first pipe and thereafter every 360 meter of
pressure pipe of each diameter produced for a minimum of 4 hours without
signs of leakage.
 Perform an internal low pressure air test for every pipe fitting at the
manufacturer's works prior to delivery. Apply a test pressure of 0.1 bars for a
minimum period of 5 minutes without signs of leakage or distress.
Manufacture fittings which are of mitred construction from pipe which has
successfully passed the tests defined above.
 For all gravity pipes apply a test pressure of 15m water head (1.5 bars) for
pressure pipes apply 1.5 times the design pressure or working pressure plus
surge pressure whichever is greater for a minimum period of 5 minutes
without a sign of leakage.
d) Wall Thickness.
 Measure the wall thickness for each pipe and fitting. Maintain the total
thickness of nowhere less than the minimum or greater than the maximum
quoted by the manufacturer's specification relating to initial stiffness.
However, minimum is governed by section 5.1.2 of BS/EN/14364.
e) Stiffness.
 Test a minimum of one pipe, for every 360m pipe length manufactured or any
pipe length supplied for a project, whichever comes first to determine the
initial specific stiffness in accordance with the test method detailed in BS/DIN
EN 14364.
 Test a minimum of one pipe of each class and diameter of pipe.
 Ensure that no test specimen has an initial specific stiffness of less than as
defined in section 2.1.
 In addition.
Deflect each of the stiffness test specimens to the amounts indicated in Table
3 below according to its nominal stiffness. Ensure that at the lower deflection
there is no visible damage as evidenced by surface cracks, and at the higher
deflection there is no indication of structural damage as evidenced by inter
laminar separation, separation of the liner or coating (if incorporated) from the
structural wall, tensile failure of the glass fibre reinforcement, fracture or
buckling of the pipe wall as per standard for inspection available.
Table 6: GRP Quality Control Tests

Nominal Stiffness 10,000N/m2
No visible damage in liner layer as evidenced by surface cracks at a deflection of: 9%
No structural damage at a deflection of: 15%
f) Longitudinal Tensile Strength.

Measure in accordance with BS/DIN EN 14364 the tensile strength of a minimum of
one pipe, for every 360 m pipe length manufactured or any pipe length supplied for a
project, whichever comes first for each class and diameter, as per applied standard.

g) Cure.
Perform in accordance with BS 4549 Part 1 Barcol hardness test on a minimum of
one in every 30 pipes manufactured.
h) Loss on Ignition.
Test in accordance with ASTM D2584 a minimum of one pipe, for every 360 m pipe
length manufactured or any pipe length supplied for a project, whichever comes first
for each class and diameter, as per applied standard.
i) Joint Tests.
Test in accordance with the requirements of ASTM D4161 or, DIN EN 1119 a
minimum of two jointed pipes in every 1200 meter of pipes manufactured with the
following additions.
 Conduct the positive test pressure.
 Conduct the negative pressure test to determine the adequacy of the joint
design against infiltration. Apply an external test pressure of 2.0 bar (gauge)
to two sections of pipe assembled with a deflected joint for non- pressure pipe
system and twice the rating pressure for pressure pipe system in accordance
with ASTM D1161.96 Article 7 Laboratory Performance Requirement Item
7.1.1
j) Initial Circumferential Tensile strength.
Determine the initial circumferential tensile strength of pressure pipes in accordance
with BS/DIN EN 1394.
k) Rejection
 Proceed as stipulated below if any pipe or fitting which fails any one of the
 quality control tests as per the section 2.3.
 In the event of a pipe failing any of the tests outlined, carry out the relevant
test on a further 120 meters of pipes of that class and diameter as follows:
 Carry out the relevant test on 60 meters of these pipes produced
sequentially and immediately prior to the failed pipe and 60 meters
immediately following.
 If any one of these tests on 120 meters of length fails, cease the
manufacturing of pipes of that class and diameter. Discussions will be
held between the Contractor and the Engineer to establish the
significance of the failures. The suitability of manufactured pipes for the
proposed installation conditions will be determined in the light of the
test failures and the Engineer reserves the right to reject all the pipes of
that class and diameter.
Use the results of appropriate type tests to the proposed pipes and fittings to determine the
properties of pipes. Carry out each type test on representative samples of the pipes. If the
manufacturer does not have results of these tests available or if alterations are proposed to
the method of manufacture, pipe design or laminate structure, carry out all the type tests
required by the Engineer to prove the adequacy of the proposed pipes.
Conduct the type tests as stipulated in Table 4 in accordance with the requirements of the
mentioned standards and that the tests will be conducted at 23 +/-2°C ambient
temperature except for strain corrosion & long term failure pressure which will be tested at
40°C +/- 2°C.Table 7- GRP Type Tests (Long Term Tests for a minimum of 10,000 hrs)

Table 7: GRP Type of Tests (Long Term Tests for a minimum of 10,000 hrs)
Property Test method to BS/EN/14364
Long term specific stiffness and ISO 10468, ISO 14828, ISO 10471, DIN 53769 the test results shall be
creep factor under wet and deflected extrapolated to 60 years. Section 5.2.2 of BS/EN/DIN 14364 shall be
condition (min 18 samples)
governing.
ASTM D3681, DIN 53769, DIN EN 1120, the test results to be

Long term resistance to strain extrapolated to 60 years. Section 5.2.8 of BS/EN/DIN 14364 shall be
Corrosion. (min 18 samples)
governing. However, the 95% lower confidence limit failure strain must
not be less than 0.85%,
ASTM D2992, DIN EN 1447, DIN 53769-2 the test results shall be
Long term failure pressure. (min.18
samples) extrapolated to 60 years Section 5.2.7 of BS/EN/DIN 14364 shall be
governing.
11.3.2 Product Warranty
A corporate product warranty shall be provided by the Manufacturer for intended

use/application of the product for a period of 60 years from the date of the Final
Acceptance Certificate of the project issued by the Client.
11.4 EXECUTION
11.4.1 Pipe Installation
a) Trench excavation shall be carried out in accordance with relevant section of the
specification.
b) Install pipe, fittings, and accessories in accordance with BS 8010, EN 1610 and
manufacturer's instructions.
assigned to the Contract. The technical expert shall have expertise,
experience and skills necessary for advising and monitoring all aspects of
transport, storage, handling and installation of pipes as appropriate.
 The technical expert shall provide comprehensive technical assistance to the
Contractor throughout the Contract and regularly monitor the
Contractor's activities and report on shortcomings.
 The Contractor shall provide the Engineer copies of all instructions advice
or reports given by the manufacturer's technical expert to him. The technical
expert shall immediately inform the Engineer of any omission, variations and
detractions from the approved handling and installation specification.
c) Install bedding, surround and backfill as specified in the relevant section of the
specification and shown on the drawings.
d) Lay pipes from downstream to upstream with the socket end at the upstream end of
each pipe.
e) The pipeline shall be within 20mm of the specified line and the invert level shall be
within 6mm of the specified value and shall be such that there is no back fall at any
point on a gravity pipeline.
f) Obtain satisfactory initial deflection test results for sections of pipeline laid between

consecutive manholes or chambers prior to commencement of pipe laying in further
sections.
g) When cut pipe is required, ensure that the cutting is done by a machine, leaving a
smooth cut at right angles to the axis of the pipe.
h) When installing pipes, ensure the joint is cleaned and lubricated and that the rubber
gasket is inserted in the groove of the socket end of the pipe. Align the spigot and
insert home in the socket end. Use a metal feeler to check that the rubber gasket is
correctly located. Spigot and socket flexible joints shall have the annular space
between the pipe and socket sealed with an approved joint sealant to prevent the
ingress of loose material or concrete. This sealing shall be carried out immediately
on completion of a satisfactory initial hydraulic test prior to concreting or backfilling.
i) Ensure that all pipes and fittings are sound and clean before laying. When pipe
watertight plugs or caps. The plugs or caps shall only be removed for the purposes
of making a connection of the pipe end or testing the pipeline. The plugs or cap
shall be replaced immediately on completion of the test.
j) Protect bolted connections by an approved heat shrunk PVC sheath. Wrap the PVC
sheath with a protective wrapping tape prior to backfilling in accordance with the
specification.
k) Excavation for or laying of GRP shall not proceed until an approved device for
gauging pipe deflections is on site.
Use a suitable mechanised device to the approval of the Engineer for gauging pipe
deflections. Maintain devices for gauging pipe deflections in good working order.
Submit calibration certificates before every period of use.
 For pipes of less than 600mm diameter: Diametric dimensional measurement
of the pipe, both vertically and horizontally shall be made and recorded. Each
deflection measurement taken along the length of the pipeline shall be
identified and recorded. Provide a continuous print out or a visual display of
the measurements on a remote monitor. The device shall be calibrated
before each pipe length is tested.
 For pipes of 600mm diameter and greater. Measure deflection by physical
entry into the pipes. Use a regularly calibrated telescopic spring loaded
graduated rod to measure percentage deflections in each diameter. Provide a
suitable trolley to facilitate access into the pipe. Record all measurements.
l) Form cut-off walls or barriers in granular bedding and/or surround to pipes to prevent
the bedding acting as subsoil drainage. Provide barriers at suitable locations along
the length of the pipeline and at manholes or chambers. Ensure that the maximum
spacing is 50m. Use concrete barriers of Class C concrete installed across the full
cross section of the granular bedding. Provide concrete barrier of at least 300mm in
length along the axis of the pipelines. Pipe wrap placed around pipe at stanks shall
be self-advisable water proof membrane or other self-adhesive tape as approved by
the Engineer.
11.4.2 Mandatory Installation Monitoring
It shall be absolutely mandatory for the manufacturer to give proper training with
certification to educate contractor's representative (name of the person and copy of the
certificate to be provided) for installation procedures for their products and depute qualified
personnel to monitor the installations intermittently throughout the course of the project
execution and till the final commissioning test approvals from the designated authority. Any
discrepancies or non-compliance thereof, if observed, shall be promptly reported to
Engineer or Client for remedial measures. NOTE: In case of non-compliance to the
installation procedures set forth by the Manufacturer, further installation shall be stopped
with immediate effect, by the Engineer without placing any project time lapse liability on the
Engineer or Client, by the main Contractor of award until it is otherwise advised. However,

a project delay penalty clause may be applied on the main Contractor as per the rules and
regulations set by Client.
11.4.3 Field Hydrostatic Testing of Pipelines
11.4.3.1 General
a) Submit for the Engineer's approval details of the proposed methods and program for
testing, including details of test equipment. Arrange for all tests to be witnessed by
the Engineer or other person appointed by the Engineer. Provide everything
necessary for carrying out testing and cleaning including water, pumps, gauges,
piped connections, stop ends and all other temporary works. Ensure that pipelines
are properly completed and supported before being put under test except as
hereinafter detailed.
 No testing will be permitted until seven days after thrust blocks and other
holding down works have been completed.
 In addition to any tests of individual joints or other interim tests, which may be
specified elsewhere, submit all parts of the pipelines to a final test.
 Notwithstanding the foregoing, carry out at any stage of construction other
tests that the Engineer considers desirable to check materials and
workmanship on the pipeline. Ensure that the obligations to perform
successful tests under the Contract are achieved.
b) Use potable water for hydrostatic testing and pipeline cleaning
c) Test the pipeline in lengths between valve pits or such shorter lengths as the
Engineer may direct or permit.
d) Use properly designed fittings for the purpose of temporarily closing the openings in
pipelines to be tested. Use fittings adequately strutted to withstand the pressure
specified.
e) Ensure that the arrangement for testing a pipeline includes provision for the purging
of air from the pipeline prior to a water test.
f) Where multiple pipelines are laid in common trench, test only one line at any one
time.
g) Ensure that gauges used for testing pipelines have a dial diameter of not less than
100mm and a full scale reading not greater than twice the specified test pressure.
Before any gauge is used, arrange for independent laboratory to check the accuracy
of the gauge. Provide a dated certificate of its accuracy/calibration to the Engineer.
h) The Contractor must make his own arrangement for the supply and disposal of
water used for testing which must be obtained from a source accepted by the
Engineer.
i) The Contractor must complete the pipelines between the ends of laid and tested
lengths of pipeline by tie-in sections of the shortest practical length.
j) Any other testing method if intended to be used shall be according to the adequate
and satisfactory reference provided along with Engineer & Client approval.
k) Field testing of GRP pipes shall be in accordance with the relevant sections of the
specification.
11.4.3.2 Field Hydrostatic Testing of Pressure Pipelines
a) Divide pressure pipelines into sections not exceeding 500m in length or as directed
by Engineer. Test each section separately.
b) Before pressure testing is started, re-check the pipes and the valves for cleanliness,
and re-check the operation of all valves. Cap off the open ends of the pipeline (or

sections thereof) with blank flanges or cap ends additionally secured where
necessary with temporary struts and wedges. Complete all anchor and thrust blocks
and fasten securely all pipe straps and other devices intended to prevent the
movement of pipes.
c) Apply test pressure to the entire pipeline or section being tested to 1.5 times working
pressure or 1.5 times the surge pressure whichever is greater. Immediately prior to
commissioning, complete the pipeline and test the entire pipeline.
 Fill each pipeline or section with water and displace all free air from the
pipeline.
 Raise the pressure in the pipeline by pumping water until the highest of the
working pressure/surge pressure is attained in the lowest part of the section.
 Maintain at this level by further pumping until it is steady for a period of not
less than 24 hours.
 Monitor the pipeline over a period of 24 hours without further pressurisation.
 At the end of this period, measure the reduced pressure in the pipeline, the
original test pressure restored by pumping and the loss measured by drawing
off water or air from the pipeline until the pressure has fallen to match the
reduced pressure previously noted.
 Ensure that the loss does not exceed 0.02 litre per millimeter of pipe diameter
per kilometre of pipe per day for each bar of head applied.
 If the pipeline fails the test, locate the faults, repair the repairable or replace
with equivalent and retest the pipeline until it passes.
 Visually inspect all exposed pipe, fittings, valves and joints during the tests.
 After satisfactory completion of the 24 hour period test, bring the pipeline to
test pressure and maintain it at this pressure, by pumping if necessary, for
one hour. Disconnect the pumping and no water is allowed to enter the
pipeline for a further period of two hours.
 At the end of the two hours period, restore the original test pressure by
pumping water into the pipeline. Determine the volume of makeup water
required to achieve the test pressure specified and deemed to represent the
cumulative loss during the two hour period of test.
 Ensure the loss does not exceed the limit stated in 'vi' above. If the pipeline
fails the test, locate and repair the faults and repeat the test.
d) Ensure that all valves in the pipeline are satisfactorily operating under working
pressure and that the pipelines have been finally cleaned out as specified hereafter.
e) Do not test pipes against closed valves.
11.4.4 Hydrostatic Testing of Non-Pressure Pipelines
a) Test all non-pressure pipelines up to 1000mm diameter after completion of concrete

or granular bedding up to the soffit of the pipeline. Clear the bedding around pipe
joints to allow for visual inspection for leaks. Ensure that the trench is kept dry. Apply
water head for testing of either depth to invert plus 1.0m, or 5.0m, whichever is the
greater. Measure the head at the lower end of the pipeline.
b) Maintain the water head over a period of 30 minutes and if necessary, add water
from a measuring vessel at 10minute intervals. Record the quantity of water added
from the measuring vessel.
 The leakage in (liters) out of quantity of water added, shall not exceed 0.5 X
pipe diameter (m) X length of pipe under test (m).
c) For non-pressure pipes greater than 1000mm diameter, inspection for water

tightness, workmanship and compliance to this specification shall be carried out by
man entry.
d) Not more than 7 days prior to handover all pipelines shall be subject to an infiltration
test as follows:
 Test the pipeline in lengths between manholes or such shorter lengths as the
Engineer may direct or permit. Maximum length to be tested shall be 1
kilometre.
 Dewatering shall have been discontinued for at least 3 days prior to test.
 Maximum infiltration shall not exceed 1 liter per millimetre of pipe diameter per
kilometre of pipe per day.
e) Keep a record of all tests and make them available for inspection. Hand over test
records to the Engineer for approval.
f) Pipes or joints shall not be accepted if any leakage or damage is visible during an
internal inspection.
g) If the result of any test or inspection does not comply with the requirements of the
specification, the Contractor shall investigate the reason and carry out remedial work
to the approval of the Engineer at no cost to CLIENT. The pipeline shall then be re-
tested. This process shall be repeated until the requirements of the specification are
satisfied.
h) The Contractor may be required to incorporate a 300mm tee on property connection
laterals near the junction of the main drain and this tee may be used to insert an
expanding stopper in the lateral for testing purposes. On the satisfactory completion
of such tests, remove all temporary fittings from the lateral. Provide the tee with a
watertight or plug.
11.4.5 Field Deflection Measurement of Pipelines
a) For pipeline length greater than 6.0m measure the horizontal and vertical deflections
for all GRP pipes at each end at points 100mm away from the joint, 1.5m away from
the joint and at 3.0m intervals hereafter. For pipeline lengths of equal to and less
than 6.0m, measure the mentioned deflections at each end at a point 100mm away
from the joint, and at the mid-point. For GRP pipes installed with granular bed and
surround, take measurements on at least three separate occasions as follows.
 After the pipe surround material has been placed and compacted to 150mm
above the pipe crown. Do not proceed with further pipe laying until this test
has been satisfactorily completed.
 On completion of all backfill material up to ground level but before the
dewatering is removed. Take this measurement within one day of the
completion of backfilling.
 Immediately prior to the issue of a Provisional Acceptance Certificate.
b) For GRP pipes with concrete surround, carry out the deflection testing as in stages
(i) and (ii) above. For proving the pipes immediately prior to the issue of the
Provisional Acceptance Certificate, draw a pig or ball through the pipeline, sized so
that it will not pass any point in the pipeline which has been deflected to a greater
degree than that permitted in the long term.
c) For pipes exhibiting any negative deflection in the vertical in excess of 2% in (i)
above and pipes exhibiting any deflection in excess of 4% in (ii) above, expose the
pipe and replace and re-compact the surrounding bedding material. Replace the
pipe should the deflection exceed 5% in (iii) above. Any pipe to be replaced must be
taken away from site and not be incorporated into the permanent works.
d) Subject pipes exposed for re-compaction and pipes replaced for other reasons, to
the three deflection checks listed in clause 3.4.a above. Carry out deflection checks

on adjacent pipes for 50m either side of the re-compacted or replacement pipes.
e) Tabulate the results of the deflection measurements. Submit copies of the results to
the Engineer immediately after each set of measurements has been taken.
PART 12 UPVC PIPES
12.1 GENERAL
12.1.1 Scope
This section of the specification gives the requirements for unplasticised Polyvinyl Chloride
(uPVC) pipeline materials and the installation and testing thereof for storm water systems.
a) Material and equipment
b) Excavation
c) Backfilling
d) Trenching
12.1.3 Standards
All activities relating to this section of the standard specification shall comply with the
following or approved equal standards.
BS EN 1452 Plastic piping systems for water supply and for buried and above-ground
drainage and sewerage under pressure Unplasticised polyvinylchloride.
ASTM D2564 Standard Specification for Solvent Cements for Poly Vinyl Chloride (PVC) Plastic
Piping Systems.
ASTM F 656 Specification for Primers for Use in Solvent Cement Joints of Poly Vinyl Chloride
(PVC) Plastic Pipe and Fittings.
BS EN 681 Elastomeric seals. Material requirements for pipe joint seals used in water and
drainage applications.
BS EN 1092--2 Circular flanges for pipes, valves and fittings (PN designated). Steel, cast iron
and copper alloy flanges. Specification for cast iron flanges.
ISO 161--1 Thermoplastics pipes for the conveyance of fluids -- Nominal outside diameters
and nominal pressures
ISO 1167 Thermoplastic pipes for the transport of fluids. Resistance to internal pressure.
Test method.
ISO 2045 Single sockets for unplasticised polyvinyl chloride (PVC-u) and chlorinated
polyvinyl chloride (PVC-c) pressure pipes with elastic sealing ring type joints.
Minimum depths of engagement.

ISO 2048 Double socket fittings for unplasticised polyvinyl chloride (PVC- u) pressure pipes
with elastic sealing ring type joints. Minimum depths of engagement.
ISO 2505--1 Thermoplastic pipes. Longitudinal reversion. Determination methods.
ISO 2505-2 Thermoplastic pipes. Longitudinal reversion. Determination parameters.
ISO 2507 Unplasticised polyvinyl chloride (PVC-u) pipes and fittings. Vicat softening
temperature. Test methods and specification.
ISO 3126 Plastic pipes. Measurement of dimensions.
ISO 3127 Thermoplastic pipes. Determination of resistance to external blows. Round the
clock method.
ISO 4065 Thermoplastic pipes. Universal wall thickness table.
ISO 11922-1 Thermoplastic pipes for the conveyance of fluids. Dimensions and tolerances.
12.1.4 Submittals
In order to verify compliance with the specification the Contractor shall submit information
for all products and materials used in the Works to the Engineer for approval sufficiently in
advance of their use in accordance with the Contract programme allowing for ordering and
approval times. Information to be submitted shall comprise but not necessarily be limited
to:-
a) The manufacturer's complete and detailed specification and test results of the
proposed uPVC pipes and fittings required for the Works including Manufacturer's
Certifications of compliance with this section of the standard specification.
Information on all items listed in Table 8 shall be given.
b) Should any details of the pipes and fittings be altered in any way during manufacture
from those proposed and approved by the Engineer, submit for the Engineer's
approval the revised details and test results.
c) Submit to the Engineer the results of all quality control tests carried out on the
manufactured pipes and fittings as soon as practicable after testing and in any case
not later than the time of delivery of the relevant pipes and fittings to the site.
Table 8: Product Information For uPVC Pipe and Fittings
Name of manufacturer
Manufacturing process for pipes

Manufacturing process for bends and fittings
Joint type
Details of all additives used in the manufacture
Minimum depth of cover m

Maximum depth of cover m
Maximum working pressure KN/m2
Design test pressure KN/m2

Internal vacuum pressure KN/m2
Pipe Details
Class of pipe --
Wall thickness mm
Notes to Table 8
1) Pipe data to be provided for every diameter in each class of pipe.
The Contractor shall submit method statements to the Engineer for approval 4 weeks in
advance of commencing the site activity in accordance with the relevant section of the
specification. These shall comprise but not necessarily be limited to.
b) Hydrostatic testing procedures for uPVC non-pressure pipelines.
c) Deflection measurement procedures for uPVC pipelines.
12.1.4.3 Drawings
The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the relevant section of the specification.
These shall comprise but not necessarily be limited to:-
a) Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.
b) Pipe laying diagram and schedule showing location, length, design designation and
designation by number of each pipe section and pipe special to be furnished and
installed.
c) All data on curve and bends for both horizontal and vertical alignment.
a) Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the opportunity

to inspect and test the product and/or material prior to delivery in accordance with
the relevant section of the specification.
b) Products and materials shall be from a manufacturer/supplier who operates a quality
control system which is registered to ISO 9000 series or approved equal.
c) To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours’ notice of carrying out the following activities on site:
 Installation of pipeline.
 Hydrostatic testing of pipeline.
 Deflection measurement of pipeline.
12.1.6 Delivery, Storage and Handling
manufacturer's recommendations and relevant section of the specification and the
following provisions:-
a) Delivery storage and handling shall at all times be performed in a manner to avoid
product damage.
b) Pipes and fittings shall not come in contact with any sharp projections that may
cause damage to the pipes and fittings during transportation loading and unloading.
Ensure that pipes and fittings are well secured during transit and adequately
supported along their length. Cover pipes and fittings of plastic materials during
transportation. Do not allow pipe to overhang the end of a vehicle during
transportation.
c) Ensure that pipes and fittings are lifted using nylon or large diameter rope slings
positioned at a quarter of the pipe length from each end. Do not allow the use of wire
rope chains or unpadded forks or clamps on forklifts to lift pipes.
d) Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or crated,
remain on the pallets or in their crates until required.
e) Stack non-crated pipes to the approval of the Engineer.
 Stack spigot and socket pipes so that successive pipe layers have sockets
protruding at opposite ends of the stack.
 Stack pipes of different sizes and thickness separately.
 Do not allow stacked pipes to exceed 2m in height or as recommended by the
supplier whichever is the lesser.
 Store uPVC pipes and fittings under opaque cover and out of direct sunlight at
all times. Maintain a free flow of air around the pipes at all times.
 Store rubber joint rings in a well-ventilated place free from exposure to
sunlight and in their original packing’s until they are needed.
 The Contractor shall visually inspect all products upon delivery to site and
report any damage to the Engineer.
 Any products damaged during delivery, storage and handling shall be marked
by the Contractor and set aside.
 Proposals for repair of any damaged products shall be submitted in writing to
 Any damaged products deemed unsuitable for repair by the Engineer shall be
removed from site and replaced.

12.2 PRODUCTS
12.2.1 Pipe Design Requirements
a) uPVC pipe shall conform to BS EN ISO 1452 and shall be PN16 I PN10.
 For gravity pipelines with cover depths less than 6 m, pipes class 10 will be
used.
 For gravity pipelines with cover depths more than 6 m, pipes class 16 will be
used.
b) Pipes up to 90 mm nominal diameter shall have solvent welded joints and pipes of
110 mm and above diameter shall have rubber ring sealing.
c) All uPVC fittings shall be ISO/DIN specification and have a minimum rating of 16
kg/cm2 at 20 oc.
d) Fittings shall be suitable for use with the above specified pipes. Where uPVC
flanges are required these shall be drilled to PN16 as detailed in BS EN 1092.
12.2.2 Pipes and Fittings
a) All uPVC components shall be designed and fabricated by one manufacturer.

b) Use polyvinyl chloride, together with those additives that are needed for the
manufacture and performance of pipe to this section of the standard specification.
Pigments may be added to achieve the manufacturer's nominal pipe color.
c) Provide uPVC pipes and fittings capable of withstanding the working pressure, test
pressure, and the loading specified.
d) Recycled material shall not be used.
e) Supply pipes in straight lengths of not greater than 6 meters excluding the depth of
any socket.
f) Determine the nominal pipe wall thicknesses from the table in ISO 4065.
g) Comply with the limits specified in ISO 11922 when measuring the nominal outside
diameters and wall thicknesses in accordance with ISO 3126.
h) All bends shall be long radius bends unless otherwise approved by the Engineer.
i) uPVC-u cement and thinner shall be of the type approved by the Engineer.
 The solvent cement shall have a minimum working pressure of 16 bar and a
tensile strength of 112 bar after 72 hours.
 The cement shall have heavy viscosity, medium cure speed, and clear colour
and be suitable for pipe diameters up to 315 mm.
 The cement will conform to ASTM-D-2564 and be NSF/UPC approved.
 The primer shall be certified to contain a minimum of 25% THF and must
meet ASTM F656.
 All cans of solvent cement primer and lubricant shall have labels intact and
shall be stamped with the date of manufacture and shelf life. No cans with an
expired shelf life will be permitted.
j) EPDM rubber sealing rings shall be in accordance with BS EN 681. The sealing
rings shall be supplied by the pipe manufacturer.
 Joints shall be capable of withstanding a "draw" of 13mm over and above the
initial jointing allowance and remaining watertight. The initial jointing
allowance is the GRP between the spigot and the shoulder of the socket
measured parallel to the center line of the pipeline and must not be less than
6mm or greater than 13mm or as recommended by the pipe manufacturer.

 Joints shall be capable of withstanding a deflection of not less than one and a
half degrees in any direction and remaining watertight.
 The pipe joints shall be capable of withstanding an external pressure
equivalent to 10m head of water without leakage in both the straight and
deflected positions.
 Single sockets shall be in accordance with ISO 2045.
 Double sockets shall be in accordance with ISO 2048 may be used adjacent
to structures or special fittings.
 The ends of cut pipes shall be suitably chamfered prior to making the joint.
k) Joints compound for threaded connection shall be PTFE tape or an approved equal
thread sealant.
l) Ensure that all pipes including cut lengths and all fittings before dispatch from the
pipe manufacturer's works are indelibly marked as follows:
 The letters uPVC.
 The manufacturer's name initials or identification mark.
 The nominal external diameter in millimeters.
 The pressure classification in MPa.
 The date of manufacture and batch number.
 A stamp to show that they meet the required inspection requirements and
hydraulic tests at the point of manufacture.
 Stencil on each end of the pipe in legible letters the pipe identification number.
Ensure that the same number appears on all record sheets and documents
relating to the manufacture delivery and testing of that pipe.
 The manufacturing standard.
 The project or contract number.
12.3 QUALITY CONTROL TESTS
12.3.1 uPVC Pipes and Fittings
Use the results of appropriate type tests for the proposed pipes and fittings to determine
the properties of the pipes. Carry out each type test on representative samples of the pipes
and fittings to be used. If the manufacturer does not have appropriate results of these tests
available or if alterations are proposed to the method of manufacture, pipe design or pipe
composition, carry out all the type tests required by the Engineer to prove the adequacy of
the proposed pipes.
12.3.2 Type Tests
a) Vicat Softening Point. Ensure that the deformation temperature of each tested
sample is not lower than 79°C, when two random samples taken from the pipe are
tested in accordance with ISO 2507.
b) Impact Resistance. Ensure that the pipe sample when tested to ISO 3127, have a
true impact rate (TIR) below 10 % at a confidence level of 90 %.
c) Heat Reversion. Ensure that at no position around the pipe the length changes by
more than 5 % when three samples of each pipe size are tested to ISO 2505.
Samples shall not show faults such as cracks, cavities or blisters during or after the
tests.
d) Hydraulic Test. Test specimens of pipe of each pipe size in accordance with ISO

1167, three specimens at 20°C and a further three specimens at 60°C. Ensure that
samples of pipe will sustain the stresses without failure for the times and
temperatures given in the Table 9 below.
Table 9 - uPVC Hydraulic Test
Test Temperature °C Minimum Time to Failure (Hrs) Induced Stress N/mm2
20 1 42
60 1000 10
e) Joint Tests. Two jointed pipes of each pipe size to be tested in accordance with the
requirements of BS EN 1452.
 No leakage at any point of the jointing area during the test.
 Negative Pressure change shall be < 0.5bar.
 Maintain 2° deflection during the deflected joint tests.
 The Engineer may require fittings to undergo similar type tests to those
specified above. Carry out such tests in accordance with the appropriate ISO
standard. Use fittings of similar quality to those of the pipes being tested.
 Quality Control Tests. Carry out the quality control tests listed below at the
frequency stated. Records of all tests and inspections to be maintained by the
manufacturer. Forward two copies of all test certificates and reports to the
Engineer. Ensure that the raw materials are checked for compliance with the
relevant standard.
 Superficial appearance. Ensure that the internal and external surfaces
of every pipe are visually inspected both before shipment and after off-
loading at site and that they are free from defects.
 Impact Resistance. Perform a program of testing to ensure that the pipe
complies with the type tests.
 Heat Reversion. Test at least one specimen during every 8 hours
production run from each machine. Test in accordance with ISO 2505.
Ensure that the length does not change by more than 5 % at any point
around the sample. The tested samples should not show faults, such as
cracks, cavities or blisters.
 Hydraulic Test. Test at least one specimen during every 8hour
production run from each machine to comply with the requirements of
the type test at 20°C.
 Joint Test. Perform a program of testing to demonstrate that the pipe
joints continue to comply with the type tests.
 Reject any pipe or fitting which fails any of the quality control tests stipulated
in this specification. In the event that the pipe fails any of the tests outlined
above, repeat the relevant test on a further ten pipes of that class and
diameter as follows.
 Carry out the relevant test on five of these pipes produced immediately
and sequentially prior to and five immediately following the failed pipe.
If any of the ten pipes fail, cease the fabrication of pipes of that class
and diameter. Discussions will be held between the Contractor and the
Engineer to establish the significance of the failures. The suitability of
manufactured pipes for the proposed installation will be determined and

the Engineer reserves the right to reject all the pipes of that class and
diameter.
12.4 EXECUTION
12.4.1 Pipe Installation
a) Trench excavation shall be carried out in accordance with the relevant sections of
the specification.
b) Install pipe, fittings, and accessories in accordance with BS 8010 and
assigned to the Contract. The technical expert shall have expertise,
experience and skills necessary for advising and monitoring all aspects of
transport, storage, handling and installation of pipes as appropriate.
 The technical expert shall provide comprehensive technical assistance to the
Contractor throughout the Contract and regularly monitor the Contractor's
activities and report on shortcomings.
 The Contractor shall provide the Engineer and CLIENT copies of all
instructions advice or reports given by the manufacturer's technical expert to
him. The technical expert shall immediately inform the Engineer and CLIENT
of any omission, variations and detractions from the approved handling and
installation specification.
c) Install bedding, surround and backfill as specified in the relevant sections of the
specification and shown on the drawings.
d) Lay pipes from downstream to upstream with the socket end at the upstream end of
each pipe.
e) The pipeline shall be within 20mm of the specified line and the invert level shall be
within 6mm of the specified value and shall be such that there is no backfill at any
point on a gravity pipeline.
f) Obtain satisfactory initial deflection test results for sections of pipeline laid between
consecutive manholes or chambers prior to commencement of pipe laying in further
sections.
g) When cut pipe is required, ensure that the cutting is done by a machine, leaving a
smooth cut at right angles to the axis of the pipe.
h) When installing pipes, ensure the joint is cleaned and lubricated and that the rubber
gasket is inserted in the groove of the socket end of the pipe. Align the spigot and
insert home in the socket end. Use a metal feeler to check that the rubber gasket is
correctly located. Spigot and socket flexible joints shall have the annular space
between the pipe and socket sealed with an approved joint sealant to prevent the
ingress of loose material or concrete. This sealing shall be carried out immediately
on completion of a satisfactory initial hydraulic test prior to concreting or backfilling
but not prior to the test.
i) Ensure that all pipes and fittings are sound and clean before laying. When pipe
watertight plugs or caps. The plugs or caps shall only be removed for the purposes
of making a connection of the pipe end or testing the pipeline. The plugs or cap shall
be replaced immediately on completion of the test.
j) Excavation for or laying of uPVC pipes shall not proceed until an approved device
for gauging pipe deflections is on site.
k) Use a suitable mechanized device to the approval of the Engineer for gauging pipe
deflections. Maintain devices for gauging pipe deflections in good working order.

Submit calibration certificates before every period of use. Diametric dimensional
measurement of the pipe, both vertically and horizontally shall be made and
recorded. Each deflection measurement taken along the length of the pipeline shall
be identified and recorded. Provide a continuous print out or a visual display of the
measurements on a remote monitor. The device shall be calibrated before each pipe
length is tested.
12.4.2 Hydrostatic Testing of Pipelines
a) Field test of completed uPVC pipelines shall be in accordance with relevant

specification
b) Proposed methods and program for testing, including details of test equipment,
shall be submitted to the Engineer for approval. All tests shall be witnessed by the
Engineer or other person appointed by the Owner. All equipment necessary for
carrying out testing and cleaning including water, pumps, gauges and calibration
certificates, piped connections, stop ends and all other temporary works shall be
provided prior to commencement of testing.
c) Use potable water for hydrostatic testing and pipeline cleaning. The Contractor must
make his own arrangement for the supply and disposal of water used for testing
which must be obtained from a source accepted by the Engineer.
d) The pipeline shall be tested in sections as the Engineer may direct or permit. Each
section shall be tested separately. Testing shall not be carried out against closed
valves.
e) Use properly designed fittings for the purpose of temporarily closing the openings in
pipelines to be tested. Use fittings adequately strutted to withstand the pressure
specified.
f) Where multiple pipelines are laid in common trench, test only one line at any one
time.
g) The pipeline shall be thoroughly cleaned prior to testing.
h) Ensure that gauges used for testing pipelines have a dial diameter of not less than
100mm and a full scale reading not greater than twice the specified test pressure.
Before any gauge is used, arrange for independent laboratory to check the accuracy
of the gauge. Provide a dated certificate of its accuracy to the Engineer.
i) Before pressure testing commences pipes and valves shall be rechecked for
cleanliness and the operation of all valves shall be rechecked. The open ends of the
pipeline, or sections thereof, shall be blanked off and additionally secured where
necessary by temporary struts and wedges. All anchor and thrust blocks shall be
completed and all pipe straps and other devices intended to prevent the movement
of pipes shall be in place.
j) During summer months all pressure testing shall be carried out when ambient
temperatures are at their lowest in order to avoid excessive stresses on the pipe
during testing. Exposed areas of pipe in trenches, such as at joint locations, shall be
shaded during hydraulic testing at all times throughout the year.
k) The fill and test position shall be located at the lowest point of the pipeline profile to
encourage the expulsion of air as the pipe is being filled. Adequate air release
mechanisms shall be sited at all high points. An air bleed shall be incorporated as
close to the crown of the pipe at the highest point and at each end of the test
section.
l) The pipeline shall be filled taking all appropriate precautions to avoid air entrapment
as the presence of air could invalidate the test. The pipeline shall then be left to
stabilize for a minimum of 3 hours and air released as necessary by opening the
bleed valves.
m) Visually inspect all exposed pipe, fittings, valves and joints during the tests

n) Ensure that all valves in the pipeline are satisfactorily operating under working
pressure.
o) Pressure testing shall begin by pumping slowly until the pressure reaches 1.5 times
the rated pressure of the lowest rated component in the section of pipeline under
test. This pressure shall be kept for maximum 24 hours or otherwise approved by
the Engineer.
p) A maximum water loss of 3 liters per 1000m lengths per 25mm nominal bore per 24
hours shall be considered acceptable. For UPVC pressure pipeline ensure that the
loss do not exceed 0.02 liter per mm diameter per kilometre per 24 hours for each
bar of head applied. For UPVC non-pressure. Pipe, do not accept pipeline if the total
infiltration exceed 1 liter per day per millimetre of nominal internal diameter per
kilometre of pipeline.
q) Keep a record of all tests and make them available for inspection. Hand over test
records to the Engineer for approval.
r) Pipes or joints shall not be accepted if any leakage or damage is visible during an
internal inspection.
s) If the result of any test or inspection does not comply with the requirements of the
specification, the Contractor shall investigate the reason and carry out remedial work
to the approval of the Engineer at no cost to CLIENT. The pipeline shall then be re-
tested. This process shall be repeated until the requirements of the specification are
satisfied.
12.4.3 Deflection Measurement of Pipelines
a) Deflection measurement of pipelines shall be carried out at the discretion of the

Engineer, but the Contractor shall be deemed to have included for deflection
testing in his rates.
b) Excavation for or laying of uPVC pipelines shall not proceed until an approved
device for gauging pipe deflections is on site.
 Use a suitable mechanized device to the approval of the Engineer for gauging
pipe deflections. Maintain devices for gauging pipe deflections in good
working order. Submit calibration certificates before every period of use. Use
a regularly calibrated telescopic spring loaded graduated rod to measure
percentage deflections in each diameter. Provide a suitable trolley to
facilitate access into the pipe. Record all measurements.
c) The pipeline shall be inspected for deflection and ovality immediately after 600 mm
of the soil envelope has been placed to obtain a reference status. The final
deflection shall be taken 30 days after the backfill has been built up to final ground
level. The Contractor is advised to check for deflection at all times so that he may
make corrections during the backfill construction phase.
d) When fully installed and completely backfilled to ground level the deflection inclusive
of any initial ovality shall not be more than 5.0 % based on the base outside
diameter and measured 30 days after installation.
e) If the visual inspection or the deflection test indicates excess deflection, the
Contractor shall determine the exact cause of the deflection before proposing a
remedy.
 Isolated areas of severe deflection may be the result of construction loads
being on the pipe before adequate cover has been placed. These areas may
be able to be re-rounded with special equipment without any excavation.
Long lengths of pipe with high deflection levels may be indicative of overall
installation deficiencies. The Contractor shall submit proposals for corrective
action in the event of unacceptable deflection or upon indications of poor
installation likely to cause future distress to the pipeline.

 Depending on the severity, the material around the pipe may have to be
excavated and replaced with the recommended backfill and compacted.
Provided the pipe has not deflected to the point of reverse curvature, it may
be allowed to be returned to its original round shape before acceptance.
PART 13 GEOCELLULAR STORAGE STRUCTURE

The following Specification is to be read in conjunction with the local authority guidelines
for Storm Water Works. All construction works and supply of material shall be performed
by contractors/sub-contractors and suppliers approved by CLIENT for storm water works
and shall be in accordance with standard specifications.
13.1 GENERAL
This specification covers the design, manufacturer, testing, inspection and documentation
of geocellular storage structures and accessories for surface water drainage systems.
13.1.1 Scope of Works
The scope of work for storm water network include the following:
13.1.2 Submittal
The contractor shall obtain the Engineer’s approval before placing orders for materials,
allowing for the limits of the construction program. The following documents shall be
submitted to the Engineer:
a) Product technical data.
b) Geotechnical design report. .
c) Originals of catalogues and engineering data sheets for manufactured items.
d) Each item and option to be provided shall be clearly marked and each item not to be
provided shall be deleted.
e) Documentation to show that products provided meet the requirements for material,
construction, operation and tests.
f) Manufacturer’s installation instructions for all items.
g) Certified reports for all tests and inspections designated herein, signed and sealed,
showing full compliance with referenced standards and Specifications.
h) Maintenance requirements and procedures.
i) Period of guarantee for materials / products.
13.1.3 Codes and Standards
Code of practice for strengthened / reinforced soils and other fills

BS 8006-1:2010; Annex A
(Structural design guidance
The design of buried concrete box and portal frame structures.

BD 31/01
(Structural design guidance and loading cases)
Guidelines for the determination of the long-term strength of

PD ISO/TR 20432:2007
geosynthetics for soil reinforcement

CIRIA C680 (2008) Structural design of modular geocellular drainage tanks
CIRIA 697 (2007) The SUDS manual
Plastics pipework (thermoplastics materials).Code of practice for the

installation of unplasticized PVC pipework for gravity drains and
BS 5955-6:1980
sewers
(Withdrawn 01 January 2009) Replaced By: DD ENV 1401-3:2001
Plastics piping systems for non-pressure underground drainage and

DD ENV 1401-3:2001 sewerage. Unplasticized poly(vinylchloride) (PVC-U) Guidance for
installation
Building and civil engineering - Vocabulary - Part 2: Spaces,

BS 6100-2:2007
building types, environment and physical planning
Manual of Contract Documents Series 600 Earthworks

for Highway Works Volume 1
Specification for Highway Works
Methods of test for geotextiles. Determination of the tensile

properties using a wide width strip Status: Superseded, Withdrawn
BS 6906-1:1987
Published: December 1987 Replaced By: BS EN ISO 10319:1996,
ISO 10319:1993
BS EN ISO 10319:2008 Geosynthetics - Wide-width tensile test.
Methods of test for geotextiles. Determination of the apparent pore

BS 6906-2:1989 size distribution by dry sieving Status: Superseded, Withdrawn
Published: January 1989 Replaced By: BS EN ISO 12956:2010
Geotextiles and geotextile-related products. Determination of the

BS EN ISO 12956:2010
characteristic opening size
Methods of test for geotextiles. Determination of water flow normal

to the plane of the geotextile under a constant head Status:
BS 6906-3:1989
Superseded, Withdrawn Published: November 1989 Replaced By:
BS EN ISO 12958:1999
Geotextiles and geotextile-related products. Determination of water

BS EN ISO 12958:2010
flow capacity in their plane
BS EN 1997-1:2004 Eurocode 7: Geotechnical design Part 1 - General Rules
BS EN 752:2008 Drain and sewer systems outside buildings
Barriers, Liners and cover systems for containment of land

CIRIA Special publication 124
contamination

13.2 PRODUCTS
13.2.1 Manufactures
Selection of manufacturer and products should be approved by the Engineer based on

compliance with requirements stipulated in this specification, local specification documents
and the design documents.
13.2.2 GEOCELLULAR UNITS
Geocellular box units shall be manufactured from one of the following virgin materials:
a) Polypropylene.
b) High Density Polyethylene.
c) Polyvinyl Chloride.
The manufacturer shall supply the following test results to the Engineer:
a) Stress / Strain curves for vertical and lateral compression tests to be carried out in
accordance with CIRIA Report C680 at temperatures of 23°C and 40°C.
b) The maximum deflection of a geocellular unit shall be: 1mm per every: 60N/m2 of
applied pressure at 23°C ± 2°C
c) 30 KN/m2 of applied pressure at 40°C ± 5°C
d) Creep test under sustained long term loading to be carried out in accordance with
CIRIA Report C680 at temperatures of 23°C and 40°C.
e) The manufacturer shall carry out short term load tests at different temperatures
(23°C, 30°C, 35°C and 40°C) and produce a graph for correction factors for 50
years.
f) The static proof shall be based on the individual correction factor for 40°C.
g) Confirmation of 50-year design life, to be validated by a minimum 300-day creep
test, extrapolated by two orders of magnitude.
All material shall be marked by stamp or other marking, before dispatch from the
manufacturer, displaying the following information as a minimum (where applicable):
a) The manufacturer’s name, initials, or identification mark.
b) The dimensions in millimetres.
c) The classification of material.
d) The date of manufacture and batch number.
e) A stamp, or other marking, to show that the material meets the inspection
requirements at the point of manufacture.
f) Identification number - the same number shall appear on all record sheets and
documents relating to the manufacture, delivery and testing of that particular
material.
g) The manufacturing standard.
13.2.3 Geotextiles and Geomembranes
Geotextiles shall:
a) Have a minimum puncture resistance of 1.200N when determined in accordance
with BS EN ISO 12236.
b) In both machine and cross-machine directions, sustain loads of not less than 5kN/m
at break and have minimum failure strain of 10% when determined in accordance

with BS EN ISO 10319:1996.
c) Have a minimum tear resistance of 200N when determined in accordance with
ASTM standard D4533-91 (1996).
13.3 EXECUTION
13.3.1 Delivery, Storage, and Handling
Each geocellular unit shall be marked with the manufacturer’s identification.

The transport, handling and storage of materials shall be carried out in accordance with the
manufacturer’s recommendations, subject to the approval of the Engineer.
Effective precautions shall be taken to prevent damage to the geocellular units and other
materials.
During transport:
a) Material shall be well secured and adequately supported.
b) Bolsters and binding of appropriate type shall be used.
c) No material shall overhang the end of a vehicle.
d) Parts made of plastic material shall be covered.
All material shall be subject to inspection by the Engineer on deliver to site and before
storage and installation.
Handling of material shall be in accordance with the manufacturer’s recommendations and
the following:
a) Handling shall be by use of a fork lift truck or slings (webbing or fabric) not less than
250mm wide.
b) The use of wire rope and chains shall for handling shall not be permitted.
c) Material shall not be dropped or bumped.
d) Material shall not be dragged along the ground.
Materials shall be stored in accordance with the manufacturer's recommendations and the
following:
a) Material must be stored on a flat, level surface, free from small or sharp objects.
b) Material susceptible to ultra violet degradation shall be stored under an opaque and
well ventilated cover.
c) Material shall not be stacked higher than two rows (one above the other) and shall
be provided with sufficient temporary anchorage to prevent any movement of units.
Material damaged during transportation shall not be accepted and shall be returned to the
supplier.
Material damaged during storage or handling on site shall not be used for installation and
shall be removed from site and replaced by the Contractor at his own expense.
13.3.2 INSTALLATION
Excavation:
a) Shall be undertaken in accordance with local specifications and requirements or as
Foundation:
a) For shallow single-layered installations, the base of the excavation shall have a sand
or gravel sub-grade layer. The depth and compaction shall be based on the in situ

ground conditions.
b) The sub-base (formation level) of the excavation shall provide a minimum 3 - 5%
minimum CBR.
c) For deeper or multi-layered installations, the base shall be designed by a suitably
qualified person to provide sufficient structural support to the installation. For
attenuation tanks, this shall include the provision of a concrete blinding layer in
accordance with the requirements of the design drawings.
Backfilling:
a) The method for installation (backfilling) depends on the ground conditions, water
table and whether subject to heavy loads (i.e. traffic).
b) Backfilling around structures shall be undertaken in such manner as to avoid uneven
loading or damage.
c) A coarse sand protection layer, minimum 100mm thick shall be placed over the top
of the units.
d) For attenuation structures, the backfill material shall consist of natural or recycled
coarse aggregate complying with BS EN 13242, maximum size 40mm.
e) For infiltration structures, the backfill material shall consist of a single size aggregate
in accordance with local specifications.
f) Backfill to be compacted in layers, maximum 150mm thick in accordance with the
specialist tank manufacturer's recommendations. Backfill shall be compacted to 95%
of maximum dry density.
g) A geogrid suitable for biaxial loading shall be placed in the backfill above the top of
the structure. The geogrid shall be specified by the designer and shall be located at
a minimum distance of 250mm above the top of the tank.
Geotextiles shall be installed in accordance with the manufacturer’s recommendations and
the following requirements:
a) Joining of geotextile shall be by overlapping only and all overlaps shall be a
minimum of 500mm.
b) Any punctures or damage to geotextile shall be made good by overlapping with
geotextile of at least 500mm from the edge of the damaged area.
Impermeable geomembrane shall be installed in accordance with the manufacturer’s
recommendations and the following requirements:
a) Joints between adjacent sheets of impermeable geomembrane shall be sealed
using appropriate welding techniques, in accordance with the recommendations of
CIRIA SP 124:1996.
b) Joints shall be tested by non-destructive test methods in accordance with the
recommendations of CIRIA SP 124:1996.
c) Geomembrane will be protected with inner and outer protection fleece with a
minimum weight of 300gm/m.
13.3.3 Inspection & Testing
Testing of materials shall be in accordance with local specifications.

All materials to be used in contact with sewerage or its atmosphere must be shown to
withstand corrosion.
The manufacturer shall carry out testing of materials in accordance with an approved
inspection and test plan. The results of these tests shall be made available to the Engineer
who shall also be permitted to witness some or all of these tests.
Test certificates shall be provided to the Engineer.

In addition to those test specifically required, the Engineer may request additional samples
of any material for testing by the Engineer. All expenses incurred in obtaining samples for
testing shall be borne by the contractor at no additional cost to the contract.
After successful completion of the testing of the equipment the contractor must clean all
equipment and ensure that it is free of debris.
PART 14 CONCRETE FORMWORK
14.1 GENERAL
The following sections of the specification shall be read in conjunction with this section
a) Materials and equipment
b) Concrete Reinforcement
c) Cast in-Place Concrete
d) Joints in Concrete
14.1.2 References
ACI 117-06 Specifications for tolerances for concrete construction and materials and
commentary.
ACI 347-04 Guide to formwork for concrete.
BS 5975 Code of practice for false work.
CIRIA C511 Controlled permeability formwork.
Design Formwork, taking into account the following:

a) Vertical load (Dead load and Live load).
b) Lateral pressure of concrete.
c) Unit stress.
d) Safety factors for accessories.
e) Height and rate of pour.
f) Thickness of member.
g) Placing temperature.
h) Concrete slump and density.
i) Wind load
j) Impact load

14.1.4 Performance Requirement
Sufficiently rigid and must be designed so that concrete slab, walls, and other members
will be of correct dimensions, shape, alignment, elevation, and position and within
tolerances as specified. Design Formwork to safely support all vertical and lateral loads
that might be applied until such load can be supported by the concrete structure.
A Submit to the requirements of as per specifications.
B Shop Drawings: Submit design calculations sheet and detailed working drawings of the
proposed formwork for review as follow.
Design calculations sheet includes:

a) All major design values and loading conditions, include assumed value of live and
dead loads; the compressive strength of the concrete for formwork removal and for
application of construction loads; wind load; impact load; rate of placement,
temperature, height and drop of concrete; weight of moving equipment operated on
formwork; camber diagrams.
Working drawings include:
a) Details of the individual panel.
b) Anchors, form ties, shores, lateral bracing, and horizontal lacing.
c) Field adjustment of forms and tolerance.
d) Water stops, keyways, and inserts.
e) Working scaffolds and runways.
f) Weep holes, cleaning holes and vibratory holes when required.
g) Detailed size, location, and dimension of tendon conduit in post tensioned concrete
structures.
h) Construction joints, contraction joints, and expansion joints to conform to design
drawings.
i) Sequence of concrete placement and minimum elapsed time between adjacent
placements.
j) Notes to formwork erector showing size and location of conduits and pipes
embedded in concrete.
k) Special provisions such as safety, fire, drainage, and protection from debris at water
crossing.
l) Procedures, sequence, and criteria for removal of forms, shores, and reshores.
A The design and the erection of the formwork is the responsibility of the contractor.
B Design formwork to the correct dimensions, shape, alignment, elevation, and position.
14.1.7 Job Mock-Up
A Provide Mock-ups to the requirements of as per specifications.
B Construct a job mock-up of formwork to a reasonable size include items such as

reinforcement, accessories, expansion and control joints, stiffeners, bracings, penetrations

through concrete, and obtain Engineer’s approval prior to commencement of related work;
columns, slabs, girders and beams, walls, and staircases.
C Upon approval by the Engineer, the job mock-up may remain as part of the finished work.
14.1.8 Delivery, Storage, and Protection
A Transport, handle, store, and protect products to the requirements of he specification.
B Store off ground in ventilated and protected manner to prevent deterioration from moisture.
14.2 PRODUCTS
14.2.1 Fabricated Metal from Materials
A In accordance to manufacturer’s design and instructions and Engineer’s approval.
14.2.2 Formwork Accessories
A Form Ties: Removable or snap-off type, galvanized metal or plastic, fix or adjustable
length, factory -fabricated, cone ends if required by the drawings.
B Form Release Agent: Colourless mineral oil, which will not stain concrete, or absorb
moisture, or impair natural bonding or colour characteristics of coating.
C Corners: Filleted chamfered, rigid plastic or wood strip type; (20x20) mm size on all
exposed corners of finished concrete of columns, walls, and beams unless otherwise
stated in the contract specification.
D Dovetail Anchor Slot: Galvanized steel, foam filled or non-filled, release tape sealed slots.
E Nails, Spikes, Lag Bolts, Through Bolts, and Anchorages: Sized as required, of sufficient
strength and character to maintain formwork in place while placing concrete.
F Water stops: Polyvinyl chloride (PVC).
a) All construction joints and movement joints in water retaining structure must
incorporate water stops.
b) PVC Water stop:
 Minimum tensile strength 13.7N/mm2
 Minimum web thickness without provision for wiring to reinforcement 10mm.
 Average web thickness with provision for wiring to reinforcement 4 mm.
Provision for wiring to reinforcement shall be with use of brass eyelets.
 Site jointing heat welding using apparatus as provided by the water stop
manufacturer.
 Elongation at break: Minimum 300%.
c) Minimum width of water stop is 230 mm.
d) Minimum width for surface type water stop is 230 mm with a minimum of two flange
integral ribs to the approval of the engineer.
e) All water stop intersections and joints must be factory made.
G Form Anchors: Factory-fabricated metal. Select form anchors in accordance with the
manufacturers publish design data and test information.

H Form Hanger: Factory-fabricated metal
I Side form Spacer: Factory-fabricated or job-site fabricated, equivalent to main body

concrete with non-smooth surfaces.
14.2.3 Fabrication
A Fabricate movement joints water stop into the longest practical units at the supplier’s
works. Ensure that the fabricated water stop is continuous throughout the structure below
highest water level.
14.3 EXECUTION
14.3.1 Examination
A Verify lines, levels and centres before proceeding with formwork. Ensure that dimensions
agree with drawings.
14.3.2 Earth Forms
A Earth forms are not permitted.
14.3.3 Erection - Formwork
A Erect formwork, shoring and bracing to achieve design requirements.
B Provide bracing to ensure stability of formwork. Shore or strengthen formwork subject to

overstressing by construction loads.
C Arrange and assemble formwork to permit dismantling and stripping. Do not damage
concrete during stripping. Permit removal of remaining principal shores.
D Align joints and make watertight. Keep form joints to a minimum.
E Obtain approval before framing openings in structural members, which are not indicated on
Drawings.
F Provide fillet and chamfer strips on external exposed corners of beams, joists columns and
slabs.
G Coordinate this section with other sections of work, which require attachment of
components to formwork.
H Formwork placed after reinforcement shall have sufficient concrete cover over
reinforcement before proceeding.
I Maintain safe working condition for workmen and public during erection.
J Provide top formwork to concrete faces where the slope exceeds 1 in 2.5.
K Provide a uniform pattern of joint lines to face of concrete when erecting forms.
L Provide a uniform joint with a batter of approved dimension for non-vertical joints to give a
straight and neat joint line.

M Do not use form supports, which result in holes or tie-wires extended through the full width
of a member.
N Where part of a metal tie remains embedded in concrete, it shall not have less cover than
reinforcement. Fill holes with concrete or mortar.
O Position chamfer-moulding strips on exposed corners.
P Do not apply form release agent where concrete surfaces receive special finishes or
coating, which may be affected by agent.
14.3.4 Construction Joints
A Form construction joints as required in slabs and beams at the quarter point of the span
and at right angles to the member except where otherwise approved by the Engineer.
Where slabs are supported by beams, construct both beams and slabs in one operation.
B In all cases, provide vertical stop boards at the end of each section of work, which is to be
concreted in one operation. Thoroughly compact concrete against these stop boards.
C Construct construction joint panels consecutively where slabs, beams and walls
incorporate. Where this is not possible, form a gap not exceeding 1 meter between
adjacent panels. Do not concrete the gap until a minimum interval of 7 days has expired
since the casting of the most recent adjacent panel.
D The size of bays for reinforced floors walls and roofs shall not exceed 7.5 meters in either
direction or 6 meters when unreinforced or with nominal reinforcement.
E Provide construction joints of plain butt type or rebated type as directed or approved by the
Engineer.
F Expose the aggregates at the construction joint of the freshly poured concrete over the full
section to provide have a sound irregular surface by means of water spray and light
brushing or other means approved by the Engineer prior to placing new concrete against it.
G Thoroughly clean away all foreign matter, moisten the surface immediately before placing
the new concrete.
H Provide water stops to construction joints in water retaining structures.
I Ensure that all such construction joints are watertight and any joints, which may leak or
weep to be rectified to the Engineer's satisfaction.
J If during the course of the Contract it should become apparent that the Contractor's
methods of forming construction joints are not proving effective the Engineer may order the
Contractor to execute at the Contractor's expense such preventative measures, as the
Engineer may consider necessary to ensure the water tightness of construction joints in
further work.
14.3.5 Movement Joints
A Construct movement joints for expansion and contraction in accordance with the details
and to the dimensions shown on the drawings or where otherwise ordered by the
Engineer.
B Pay particular attention to the effect of climatic extremes on any material used in any
movement joint. Submit for the approval of the Engineer your proposals for the proper

handling and use of the said materials having due regard for any recommendations made
by manufacturers.
C Incorporate water stops into all expansion and contraction joints of structures, which retain
liquid, or any structures below water level.
a) Do not use different types of water stop material together in any complete
installation.
b) For horizontally placed surface type water stop, use water stop of an interposing
sliding plate.
c) Maintain water stops carefully in the position shown on the drawings. Support the
water stop on accurately profiled stop boards to create rigid conditions.
D Fix the joint filler to the required dimensions of the joint cross section. Provide a firm base
for the joint sealer. Where the depth of joint between the concrete surface and the water
stop does not exceed 500mm place filler in a single piece.
E Carry out the sealing of movement joints only when adjacent concrete surfaces are
perfectly dry.
F Clean the joint grooves, insert a bond breaker, and adequately prime and fill the groove
with approved sealer strictly in accordance with the manufacturer’s instructions.
G Store the sealer in accordance with the manufacturer's instructions. Do not use sealer after
its shelf life has elapsed.
14.3.6 Application - Form Release Agent
A Apply form release agent on formwork in accordance with manufacturer's

recommendations.
B Apply prior to placement of reinforcing steel, anchoring devices, and embedded items.
C Do not apply form release agent where concrete surfaces will receive special finishes or
applied coatings, which are affected by agent. Soak inside surfaces of untreated forms
with clean water. Keep surfaces coated prior to placement of concrete.
14.3.7 Inserts, Embedded Parts, And Openings
A Provide formed openings where required for items to be embedded or pass through
concrete work.
B Locate and set in place items, which will be cast directly into concrete.
C Coordinate with work of other sections in forming and placing openings, slots, reglets,
recesses, sleeves, bolts, anchors, other inserts, and components of other Work.
D Install accessories in accordance with manufacturer's instructions, straight, level, and

plumb. Ensure items are not disturbed during concrete placement.
E Install water stops in accordance with manufacturer's instructions continuous without

displacing reinforcement.
F Provide temporary ports or openings in formwork where required to facilitate cleaning and
inspection. Locate openings at bottom of forms to allow flushing water to drain.
G Close temporary openings with tight fitting panels, flush with inside face of forms, and
neatly fitted so joints will not be apparent in exposed concrete surfaces.

H Do not allow form support ties, bolts and other devices to be embedded in the concrete
without prior approval from the Engineer.
a) Ensure that the embedded portions of the ties in concrete have a minimum cover of
that to the reinforcement.
14.3.8 Form Cleaning
A Clean forms as erection proceeds, to remove foreign matter within forms.
B Clean formed cavities of debris prior to placing concrete.
C Flush with water or use compressed air to remove remaining foreign matter. Ensure that
water and debris drain to exterior through clean-out ports.
14.3.9 Formwork Tolerances
A Formwork shall be fixed in perfect alignment and to the true shape and dimension for the
permanent work shown on the Drawings.
A Field inspection and testing to the requirements of Quality Control.
B Inspect erected formwork, shoring, and bracing to ensure that work is in accordance with
formwork design, and that supports, fastenings, wedges, ties, and items are secure.
C Do not reuse damaged wood formwork for concrete surfaces exposed to view. Do not
patch formwork.
14.3.11 Form Removal
A Do not remove forms or bracing until concrete has gained sufficient strength to carry its
own weight and imposed loads.
B Loosen forms carefully. Do not wedge pry bars, hammers, or tools against finish concrete
surfaces scheduled for exposure to view.
C Store removed forms in manner that surfaces to be in contact with fresh concrete will not
be damaged. Discard damaged forms.
D Do not remove formwork without the approval of the engineer.
E No claim for delay of work will be considered if the Engineer requires to delay the removal
of the formwork for a period of time not exceeding 28 day on account of the weather or
other reasons such as a transference of loading on the newly completed work that might
occur on the removal of any timbers or supports struts waling or soldiers.
14.3.12 Removal of Formwork
(Average air temperature approximately 250 C)

Table 10: Minimum Period Prior to Removal of Formwork
Removal of formwork to: Minimum period prior to Removal
Slab and beam sides walls and unloaded columns 1 Day
Slab and beam soffits props left in position 7 Days
Removal of props to slab and beam soffits 14 Days
PART 15 CONCRETE REINFORCEMENT
15.1 GENERAL
15.1.1 Scope
A This section of the specification gives the requirements for concrete reinforcement,
fabrication and placing
15.1.3 Standards
All activities relating to this section of the specification shall comply with the following or
approved equal standard
ASTM A615 Standard Specification for Deformed and Plain Billet-Steel Bars for
Concrete Reinforcement.
BS 4449 Specification for carbon steel bars for the reinforcement of concrete.
BS 4483 Steel fabric for the reinforcement of concrete.
BS 8666 Specification for scheduling, dimensioning, bending and
cutting of steel reinforcement for concrete.
BS 7123 Metal arc welding of steel for concrete reinforcement.
BS 7973 Spacers and chairs for steel reinforcement.
BS 5135 Arc welding of carbon and manganese steel.
BS EN 1992 Design of Concrete Structures.
ISO 9000 Quality management system
15.1.4 15.1.4 Submittals
A Method statements.
The Contractor shall submit method statements to the Engineer for approval four weeks in
advance of commencing the site activity in accordance with specification. These shall
comprise but not necessarily be limited to:
a) Proposals for cleaning reinforcement from any deleterious material before
fabrication commences.
b) Proposals for welding connections between reinforcing bars including epoxy coated
bars where specified. Certificates for welders shall be provided and verified by a

recognized authority.
B Drawings
The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the specification. These shall comprise
but not necessarily be limited to:
a) Detailed fabrication and placement drawings for all reinforcement indicating:
 Layout of the individual panels.
 Plans and sections showing bar sizes, spacing, splicing locations, position of
construction joints and control joints.
 Quantities of reinforcing steel and wire fabric, bending and cutting schedules
in accordance with BS 8666.
 Supporting and spacing devices and notes to reinforcement erector showing
size and location of embedded conduits, pipes and sleeves.
C Samples
Representative samples, as agreed with the Engineer, must be submitted for all
reinforcement that the Contractor proposes to use in the Works, at the same time as the
particulars are submitted.
A Prior to dispatch of any product and/or material from source the Contractor shall notify the
test the product and / or material prior to delivery in accordance with the specification.
B Products and materials shall be from a manufacturer/supplier that operates a quality

system, which is registered to ISO 9000 series, or approved equal.
C To allow the Engineer to inspect the Works, the Contractor shall give the Engineer. A
minimum 24-hour notice to carrying out the following activities on site:
a) Commencement of fixing of steel reinforcement to allow inspection of formwork.

b) Completion of fixing of steel reinforcement for final approval by the Engineer prior to
concreting
D The Engineer shall have access to the fabrication plant for inspection and verification of
length, size and bending of steel reinforcement as indicated in the bending schedules.
Advance notice of the date of commencement and duration of shop fabrication shall be
provided by the Contractor.
E The Engineer reserves the right to sample and test each batch of reinforcement upon its
arrival at the work site.
a) The following tests shall be carried out for each delivery of reinforcement, to the
procedures and frequencies given in BS 4449 unless otherwise directed by the
Engineer.
 Mass per unit length.
 Ultimate tensile strength.
 Yield stress.
 Elongation.
 Bend and rebend test.

b) Test results for each bar diameter shall be submitted to the Engineer three weeks
before concrete works commences on site. Reinforcement not meeting the required
standards shall be removed from site at the Contractor’s expense.
c) Further tests may be called for, at the Contractor’s expense, if the source of
supply of reinforcement changes.
manufacturer’s recommendations, and as per specification and the following provisions:
a) Every delivery of steel reinforcement shall be legibly tagged by the manufacturer.
 The tag shall show the manufacturers test number, batch number and other
applicable data that will identify the material with the corresponding certificate
issued for that batch of steel.
 Steel reinforcement shall be delivered clean and free of rust.
b) Store steel reinforcement at all stages on suitable supports a minimum of 200mm
above the ground surface or as directed by the Engineer and in such a manner that
permits easy access for inspection and identification.
c) All steel reinforcement shall be covered with suitable canvas tarpaulins. Plastic
sheeting is not allowed.
d) Steel reinforcement shall not be rough handled, dropped from a height or subject to
shock loading or mechanical damage.
e) Equipment handling for epoxy coated reinforcement if specified shall be adequately
padded to prevent damage to coating and the reinforcement shall be adequately
supported to prevent bar to bar abrasion from sags in the bundle when lifting.
f) Provide tags for all bundles of reinforcement and include bar schedule and bar mark
reference after bending. The bundle tag shall be traceable back to the
manufacturer’s consignment.
15.2 PRODUCTS
15.2.1 Reinforcement Bars
A All steel reinforcement shall conform to the requirements of the specifications for type
500B to BS 4449, unless otherwise shown on the drawings or specified by the engineer.
B Deformed high yield bars shall have yield strength of 460N/mm2 and shall be classified as
Type 2 unless otherwise specified.
C The mill test report for three different samples shall be furnished to the Engineer for each
consignment of steel reinforcement bars proposed for use on the project.
D The bars in each consignment shall be legibly tagged in accordance with CARES
requirements (or similar international certification organisation) by the manufacturer and/or
fabricator before being offered for inspection. The tag shall show the manufacturer's test
number and consignment number and other applicable data that will identify the material
with the certificate issued for that consignment of steel.
E The fabricator shall furnish copies of a certification which shows the heat number or
numbers from which each size of bar in the shipment was fabricated.
F The Contractor shall provide certificates confirming that samples taken from the bars
delivered to the Works pass all the tests required in BS 4449. The frequency of sampling
and the method of quality control shall be in accordance with BS 4449. The Engineer

reserves the right to inspect, sample and instruct testing of the reinforcement steel upon its
arrival at the work site, in accordance with clause B of BS 4449. All such sampling and
associated testing costs shall be borne by the Contractor.
G All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust, paint,
grease, oil or other foreign substance, fins, or tears. There shall be no evidence of visual
flaws in the bars, test specimens or on the sheared ends of the bars.
H All reinforcement shall be cleaned before use to remove rust, oil, grease, salt and other
deleterious materials. Where pitting has occurred, the bars shall be rejected. Blasting may
be required when the reinforcement is in position, or partially cast in. Partially set concrete
adhering to exposed bars during concreting operations shall be removed.
I Water cleaning of reinforcement to remove chloride contamination shall be carried out prior
to pouring of concrete. Cleaning water shall be the same quality as mixing water for
concrete.
J Where specified by drawings/Engineer, epoxy coating to steel reinforcement shall be in

accordance with ASTM A775.
a) The coating shall be applied by the electrostatic spray method at a factory

b) The film thickness of the coating after curing shall be at least 0.15mm and shall not
exceed 0.25mm over the complete periphery including deformations and ribs. The
bond classification of coated bars to concrete determined in bond performance tests
shall not be less than that of uncoated bars.
K The minimum thickness of concrete cover to reinforcement shall be as shown on the

drawings. Only approved spacers shall be used.
15.2.2 Welded Wire Fabric
A Welded wire fabric to be used for the reinforcement of concrete shall conform to the
following requirements.
B Welded steel wire fabric reinforcement shall have yield strength of 460N/mm2 and shall be
classified as Type 2 unless otherwise specified.
C Dimensions: Welded steel wire fabric shall conform to the size and dimensions shown on
the Drawings.
D Properties: Wire fabric furnished under this Specification shall conform to both BS 4483
and BS 4449.
15.2.3 Spacer Blocks
A Spacers as approved by the Engineer shall be of such material and design as will be
durable, not lead to corrosion of the reinforcement and not cause spilling of the concrete
cover.
B Spacer blocks made from cement, sand and small aggregate shall match the mix
proportions of the surrounding concrete so far as is practicable be comparable in strength,
durability and appearance. Their surface shall be roughened to ensure satisfactory bond
with the surrounding concrete.

15.2.4 Mechanical Couplers for Reinforcement
A Couplers are only to be supplied from a manufacturer with a QA/QC system accredited by
an internationally recognized accreditation agency.
B The contractor is to furnish three (3) copies of all test certificates for each size and type of
coupler proposed, demonstrating their compliance with the requirements of relevant
British Standards, and the particular performance requirements of this specification.
C The performance criteria for couplers for each representative gauge length assembly
comprising of reinforcement the size, grade and profile to be used and a couple of the
precise type to be used the following minimum criteria must be attained.
D The strength of the coupled bar in both tension and compression must exceed 125 percent
of the yield strength of the bar (1.15fy) for grade 250 and 500A and 500B reinforcement or
95 percent of the ultimate actual tensile strength of the reinforcement bars.
E The couplers in each consignment shall be legibly tagged by the manufacturer and/or
fabricator before being offered for inspection. The tag shall show the manufacturer's test
number and consignment number and other applicable data that will identify each coupler
with the certificate issued for that consignment.
F The Contractor shall provide certificates confirming that samples taken from the couplers
delivered to the Works pass all the tests required by this specification. The frequency of
sampling and the method of quality control shall be in accordance with British Standards
and agreed with the Engineer prior to commencing.
G The minimum on site testing requirements are as follows:
a) Prior to installation in the permanent works, 3 tests of each coupler size and type to
be used are to be completed by an approved independent testing laboratory with
results submitted for review and approval by the Engineer. Failure of any one of
these tests will result in the immediate testing of no less than 25 couplers from the
failed batch to determine if manufacturing defects exist.
b) Once initial testing is successfully completed and couplers are approved for use in
the permanent works 1 sample for every 200 couplers of each coupler type. If one
coupler test fails 25 from the failed batch must be tested immediately to determine if
a manufacturing defect exists in the current delivery. The subsequent rate of testing
will then be reassessed.
H The Engineer reserves the right to inspect, sample and instruct testing of the coupler
assemblies upon its arrival at the work site. All such sampling and associated testing costs
shall be borne by the Contractor.
15.2.5 Accessories
A Tie wires shall be 1.6mm diameter soft annealed steel wires. For epoxy-coated
reinforcement, this shall be PVC coated.
B Steel chairs, bolsters and bar supports shall be of sufficient size, shape and strength to
provide adequate support to steel reinforcement during placement of concrete.
C Spacers shall be made of concrete, plastic or other material as approved by the Engineer.
Concrete spacers shall have the same or greater strength as the surrounding concrete and
have an embedded plastic coated tie wire.

15.3 EXECUTION
15.3.1 Reinforcement
A Bar Schedules and Shop Drawings
a) The contractor shall schedule the reinforcement in accordance with BS 8110 and BS
8666 and the information on the drawings, this specification and subsequent
instructions.
b) The contractor shall include for all necessary supports, chairs and spacers, and his
price and rates for reinforcement thus shown shall include for these.
c) The contractor shall prepare reinforcement detail drawings and other relevant shop
drawings to the following scales:
 Walls and slabs 1:50
 Beams and column elevations 1:20
 Beam and column sections 1:20 or 1:10
d) hop drawings shall show all openings for services, up stands or plinths for
equipment and cast-in items and be fully coordinated with relevant trades.
e) Reinforcement details drawings shall be in accordance with the Standard Method of
Detailing Structural Concrete published by the Institution of Structural
Engineers/Concrete Society. Sketches will not be acceptable.
f) Bar bending schedules and coordinated shop drawings shall be submitted for the
Engineer's approval. An average of 21 days shall be allowed for the Engineer’s
review of this documentation.
g) The Contractor shall correct these schedules incorporating the Engineer’s
comments and resubmit as reasonably required to ensure a high standard of work.
He shall programme his work and submit schedules for approval allowing time for
such verification, rectification and resubmission as necessary. Such approval shall
not relieve the Contractor of his contractual responsibility.
h) No concreting shall be allowed to proceed until such a time that the shop drawings
and bending schedules for that particular section of works are approved.
15.3.2 Bar Cutting and Bending
a) Reinforcement shall be cut and bent in accordance with BS 8666. Cutting or bending
by the application of heat is not permitted. Welding of reinforcement shall only be
permitted when approved in writing by the Engineer. If such approval is given then
the workmanship shall be in accordance with BS 5135. The Contractor shall submit
full technical details of his proposed procedures prior to seeking approval
b) Hot rolled high yield bars shall not be straightened or bent again, having once been
bent. If the Engineer gives approval to bend mild steel reinforcement projecting from
the concrete, the internal radius of bend shall not be less than four times the nominal
size of the bar.
A Placing and Fixing Reinforcement
Reinforcement shall be placed and maintained in the position shown in the Contract
Drawings. Unless otherwise permitted by the Engineer, all bar intersections shall be tied
together using 1.2mm diameter steel wire and the ends of the tying wire s
a) hall be turned into the main body of the concrete
b) Spacer blocks or other supports approved by the Engineer, shall be provided and
used to retain the reinforcement at proper distances from the forms. The contractor
shall secure the cage/reinforcement by providing adequate supports. All

reinforcement shall be so rigidly supported and fastened that displacement will not
occur during construction. Reinforcing steel shall be inspected in place and must be
approved by the Engineer before any concrete is deposited.
c) No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.
d) Reinforcement temporarily left projecting from the concrete at construction or other
joints shall not be bent out of position during the periods in which concreting is
suspended, except with the approval of the Engineer.
e) Minimum lap lengths are as follows unless otherwise noted in the contract drawings.
Table 11: Minimum Lap Lengths
Diameter (mm) Lap Length (mm) Diameter (mm) Lap Length (mm)
8 400 20 1000
10 500 25 1250
12 600 32 1600
16 800 40 2000
f) The minimum lap length for deformed high yield bars and welded steel wire fabric
reinforcement shall comply with BS EN 1992 C.3.12.8.
B Electrical Continuity of Reinforcement
a) The Contractor shall provide and ensure the electrical continuity of all reinforcing
steel.
15.3.3 15.3.3 Placement
A All steel reinforcement shall be securely and accurately fixed in position as shown on the
drawings and supported to ensure that the reinforcement cage as a whole shall retain its
shape and correct position in the forms during the process of depositing and compacting
the concrete.
B Maintain concrete cover around reinforcement to within + or - 5mm of the values given in
Table 12 below.
Table 12: - Concrete cover to reinforcement

Concrete cover to Reinforcement Minimum cover
External work, work against earth faces and in liquid retaining

structures. 75mm
External work in a tidal environment and concrete placed in or

under water. 75mm
Internal work in non-liquid retaining structures.
Walls, beams and columns. 50mm to the nearest bar including links

Concrete cover to Reinforcement Minimum cover
Slab reinforcement. 30mm to all bars or diameter of the largest

bar whichever is the greater.
Distance between parallel bars. 25mm or the diameter of the largest bar
whichever is the greater.
C Turn ends of tie wires into the main body of the concrete. Do not allow tie wire to project
towards the surface.
D Place chairs, bolsters, or bar supports between parallel layers of steel reinforcement in
slabs.
E Place spacers against steel reinforcement to separate layers of reinforcement from

concrete blinding and formwork.
F Do not use shapes of steel reinforcement not shown on the drawings.
G Where epoxy coated reinforcement is specified provide adequate scaffolding system to

ensure that the coating is not damaged during fixing and concreting.
H Welding of steel reinforcement shall not be carried out unless authorized by the Engineer.
I Mechanical splices shall only be used as indicated on the drawings or as authorized by the
Engineer.
J Steel reinforcement shall be fixed so that it does not come into contact with other non-
ferrous or dissimilar metals.
K Do not damage forms or linings when fixing steel reinforcement.
L Do not fix reinforcement above membranes applied to blinding and other horizontal
surfaces until cement mortar screed protection has been applied.
M Protect exposed steel reinforcement from all aggressive elements.
15.3.4 Cleaning and Adjustment of Reinforcement
A At the time of concreting, all steel reinforcement shall be thoroughly cleaned and freed
from all loose rust, loose mill scale, oil, grease, mud, paint and other deleterious material to
the satisfaction of the Engineer including partially set concrete, which may have been
deposited during the placing of a previous lift of concrete.
B Immediately prior to concrete placing, all reinforcing steel shall be thoroughly washed with
high-pressure potable water jets and shall be free off and corrosion product.
C Check position of steel reinforcement during concreting operations and if movement is

observed adjust to the satisfaction of the Engineer or stop concreting.

PART 16 CAST-IN-PLACE CONCRETE
16.1 GENERAL
a) Materials and equipment Section
b) Contract Close out
c) Concrete Formwork
d) Concrete Reinforcement
e) Joints in Concrete
16.1.2 References
ACI 318 Building Code Requirements for Structural Concrete.
ASTM C920 Specification for Elastomeric Joint Sealants.
ASTM D994 Preformed Expansion Joint Filler for Concrete. (Bituminous Type)
ASTM D1751 Preformed Expansion Joint Fillers for Concrete Paving and Structural
Construction. (Non-extruding and Resilient Bituminous Types)
ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete
Paving and Structural Construction.
BS 4254 Specification for two-part polysulphide-base sealants.
BS 5215 Specification for one-part gun grade polysulphide-base sealants.
BS EN 1992 Design of Concrete Structures. Cement
ASTM C150 Specification for Portland cement.
BS EN 197-1 Cement. Composition, specifications and conformity criteria for common

cements.
BS 410 Specification for Test Sieves.
BS 4027 Specification for sulfate-resisting Portland cement.
BS 4550-0 Methods of testing cement. General introduction.
BS 4550-3.1 Methods of testing cement. Physical tests. Introduction.
BS 4550-3.4 Methods of testing cement. Physical tests. Strength tests.
BS 4550-3.8 Methods of testing cement. Physical tests. Test for heat of hydration.

BS 4550-6 Methods of testing cement. Standard sand for mortar cubes. Ground
Granulated Blast Furnace Slag (GGBS)
BS EN 15167-1 &15167 Specification for ground granulated blast furnace slag for use with Portland
cement. Pulverized Fuel Ash (PFA)
BS EN 450-1 Pulverized-fuel ash. Specification for pulverized- fuel ash for use with
Portland cement.
BS EN 450 Fly ash for concrete. Definition, requirements and quality control.
Silica Fume ASTM C1240 Standard Specification for Silica Fume Used in Cementitious Mixtures.
Aggregates ASTM C88 Standard test method for soundness of aggregates by use of sodium sulfate
or magnesium sulfate.
ASTM C123 Standard test method for lightweight particles in aggregate.
ASTM C127 Standard test method for density, relative density (specific gravity) and
absorption of coarse aggregate.
ASTM C128 Standard test method for density, relative density (specific gravity) and
absorption of fine aggregate.
ASTM C131 Standard test method for resistance to degradation of small size coarse
aggregate by abrasion and impact in the Los Angeles machine.
ASTM C142 Standard test method for clay lumps and friable particles in aggregates.
ASTM C227 Standard test method for Test for potential alkali reactivity of cement-
aggregate combinations. (mortar bar method)
ASTM C289 Standard test method for potential alkali-silica reactivity of aggregates.
(Chemical method)
ASTM C535 Standard test method for Resistance to Degradation of Large size Coarse
Aggregate by Abrasion and impact in the Los Angeles Machine.
ASTM C1260 Standard test method for potential alkali reactivity of aggregates. (Mortar-bar
method)
BS 812-105.1 Testing aggregates. Methods for determination of particle shape. Flakiness

index
BS 812-109 Testing aggregates. Methods for determination of moisture content.
BS 812-112 Testing aggregates. Method for determination of aggregate impact value.
BS 882 Specification for Aggregates from Natural Sources for Concrete.
BS EN 933-1 Tests for geometrical properties of aggregates. Determination of particle size

distribution. Sieving method.
BS EN 933-2 Tests for geometrical properties of aggregates. Determination of particle size

distribution. Test sieves, nominal size of apertures.
BS EN 933-7 Tests for geometrical properties of aggregates. Determination of shell

content. Percentage of shells in coarse aggregates.
BS EN 1367-4 Tests for thermal and weathering properties of aggregates.

Determination of drying shrinkage.
BS EN 1744-1 Tests for chemical properties of aggregates. Chemical analysis.
BS 1305 Specifications for batch type concrete mixers. Concrete admixtures
ASTM C494 Chemical Admixtures for Concrete.
BS EN 480-1 Admixtures for concrete, mortar and grout. Test methods.

Reference concrete and reference mortar for testing.
BS EN 480-2 Admixtures for concrete mortar and grout. Test methods.

Determination of setting time.
Determination of bleeding of concrete.
Determination of capillary absorption.
Infrared analysis.
Determination of the conventional dry material content.
Determination of water soluble chloride content.
BS EN 480 11 Admixtures for concrete, mortar and grout. Test methods. Determination of
air void characteristics in hardened concrete.

Determination of the alkali content of admixtures.
BS 5075 Concrete admixture Water
ASTM D512 Standard test methods for chloride ion in water.
ASTM D513 Standard test methods for total and dissolved carbon dioxide in water.
ASTM D516 Standard test method for sulfate in water.
BS 3148 Methods of test for water for making concrete.
DIN 1048-5 Testing Concrete – Water Permeability Concrete

ACI 301 Structural Concrete for Buildings
ACI 304 Recommended Practices for Measuring, Mixing, Transporting and Placing
Concrete.
ACI 305R Hot Weather Concreting.
ACI 308 Standard Practices for Curing Concrete.
ASTM C33 Specifications for Concrete Aggregate.
ASTM C94 Ready-Mixed Concrete.
ASTM C138 Standard test method for density (unit weight), yield and air content
(gravimetric) of concrete.
ASTM C143 Standard Test Method for Slump of Hydraulic Cement Concrete.
ASTM C173 Standard test method for air content of freshly mixed concrete by the
volumetric method.
ASTM C231 Standard test method for air content of freshly mixed concrete by the
pressure method.
ASTM C232 Standard test methods for bleeding of concrete.
ASTM C497M Standard test methods for concrete pipe, manhole sections, or tile. (Metric
version)
ASTM C1064 Standard test method for temperature of freshly mixed hydraulic-cement
concrete.
ASTM C1202 Standard test method for electrical indication of concrete’s ability to resist
chloride ion penetration.
BS 1704 Specification for Solid-stem general purpose thermometers
BS 1881 Testing Concrete
BS 6089 Assessment of in-situ compressive strength in structures and precast

concrete components
Part 101 Method of sampling fresh concrete on site.
Part 102 Method for determination of slump.
Part 103 - Method for determination of compacting factor.
Part 114 – Method for determination of density of hardened concrete.
Part 115 – Specification for Compression testing machines for concrete.

Part 116 – Method of determination of compressive strength of concrete cubes.
BS 8500 Concrete.
BS EN 206 Concrete. Specification, performance, production and conformity.
BS EN 12350-2 Testing fresh concrete. Slump test.
BS EN 12350-6 Testing fresh concrete. Density.
BSEN12390-2 Testing hardened concrete. Making and curing specimens for strength tests.
BS EN 12390-3 Testing hardened concrete. Compressive strength of test specimens.
BS EN 12309-7 Testing hardened concrete. Density of hardened concrete.
BS EN 12390-8 Testing hardened concrete. Depth of penetration of water under pressure.
BS EN 12504-1 Testing concrete in structures. Cored specimens. Taking, examining and

testing in compression.
BS EN 1997 Foundation
DIN 4235 Compacting Concrete by Vibrating. Curing compounds
ASTM C309 Standard specification for liquid membraneforming compounds for curing
concrete.
General
ISO 9000 Quality management systems
A Design a mix for each grade of concrete as indicated in Table 13 to be used throughout the
course of work.
B Use concrete class A, or B, or C for different type of concrete works as indicated in Table
3-3 unless otherwise noted elsewhere. All structural elements shall comply with the
requirements of durable concrete utilizing supplemental mineral additive such as GGBS,
fly ash, and/or silica fume, as necessary
C Maintain and control the water content in the concrete mix to the minimum required to
obtain a workable concrete suitable for the nature of the work to be executed. Ensure that
the free water cement ratio does not exceed 0.45 for Class A concrete and B concrete and
0.5 for Class C concrete.
D Ensure that the addition of proprietary admixtures intended to change the flow
characteristics cohesion or rate of setting of the concrete should not be made without the
approval of the Engineer. Ensure that the chloride content is NIL to BS 5075.
E Ensure that the concrete mixes are to produce concrete cube strength at 28 days of not
less than 40 MPa for grade C40 concrete and 20 Mpa for grade C20 concrete together
with all other property requirement.

F Produce a workable non-segregated concrete when handled, transported and compacted.
A Submittals: Procedures for submittals.
B Submit concrete mix design on S.S.D. (Saturated Surface Dry) basis for each class of
concrete to be used for the specific project. Include:
a) Name and qualification of the supplier.

b) Location of the supplier plant.
c) Certification of quality assurance.
d) Quality control facility.
e) Mix design ingredients and its proportion.
f) Certificate and test reports on concrete ingredient.
g) Sources of concrete ingredients.
h) Production capacity.
i) C.V. of the quality control personnel.
Product Data: Provide data on concrete ingredient, attachment accessories, and
admixtures
C Method of statement: Submit method statement during the mobilization period, detailing
the proposals for the organization of concrete activities on site.
a) Plant proposed.
b) Layout of concrete production facility.
c) Proposed method of organization of the concrete production facility.
d) Quality control procedures for concrete and concrete materials.
e) Transport and placing of concrete.
f) Details of formwork and procedure of temporary support for beams and slabs.
Submit quality assurance and quality control plan and procedures for the ready mix plant
proposed to use for the specific job.
Submittals: Procedures for submittals.

Manufacturer’s Casting Instructions: Indicate installation procedures and interface required
with adjacent Work.
Manufacturer’s Certification: Submit manufacturer’s certification of compliance for each
consignment of cement certifying compliance with the relative standard.
16.1.6 Submittals at Project Closeout
A Contract Closeout.
B Submit accurate record and as-built drawings of embedded utilities and components,
which are concealed from view.

A Perform Work in accordance with ACI 301.
B Maintain one copy of each document on site.
C Acquire cement and aggregate from same source for all work.
D Conform to ACI 305R when concreting during hot weather.
E Develop and observe strict quality control procedures.
16.1.8 Qualifications of Off-Site Ready-Mix Plant
A All ready-mix plant must be off-site commercial plant unless otherwise approved by the
Engineer or allowed in the contract document.
B Aggregate bins compartments must adequately separate the different type of aggregates.
C Ready-mix plant must contain a mechanical batching mixer approved by the Engineer.
D Ready-mix plant must have cement and aggregates weight batchers.
a) Submit recent certified calibrations for weight batching systems.

b) Perform calibration tests for the weight batching systems as requested by the
engineer.
E Ready-mix plant must have a computerized batching system with print out as per the latest
requirements of TRSDC and a delivery ticket, which must print out the minimum following
information:
a) Name of batching plant

b) Serial number of the ticket
c) Date
d) Name of purchaser
e) Project designation
f) Class or designation of concrete
g) Weights and quantities of each concrete ingredient
h) Time of loading
i) Time of departure
j) Amount of concrete batched
k) Type and amount of admixture
l) Slump at plant and site
m) Proposed concrete strength
n) Vehicle number
o) Driver’s name
p) Concrete Temperature at plant and site
q) Time of adding water for the first time in the mix.

F The Ready-mix plant must be equipped with separate automatic dosing dispensers for
each type of admixture, and feeds a fixed quantity of additive into the mixing water before
the water is discharged into the mix
G The batching plant shall comply with the following tolerance limits for ready-mixed concrete
ingredients:
Table 13: Tolerance limits for ready-mix concrete ingredients
No Ingredients Individual Batch (%) Load Cumulative (%)
1 Coarse aggregate (20mm) ±2 ±1
2 Coarse aggregate (10mm) ±2 ±1
3 Fine aggregate (5mm) ±2 ±1

4 Dune Sand ±2 ±1
5 Cement ±2 ±1
6 Water ±1 ±1
7 Ice ±1 ±1
8 Liquid Admixture(s) ±3 ±3
H Plant must be equipped with a sufficient capacity water chillier capable of maintaining the
water temperature in the water storage tank to 5°C during the hot weather. There shall be
facilities to monitor the temperature of cement in the silos and water.
I Plant must have an automatic computer controlled flaked ice supply.
J Qualified personnel at the ready-mix plant.
K Sufficient number of concrete mixing trucks and concrete pumps capable to maintain the
smooth flow of the concrete to the job site during the concrete pours.
L A fully equipped testing laboratory.
M Back up facilities.
16.1.9 Mock-Up
A Quality Control: Requirements for mock-up.
B Construct and erect a field sample for architectural concrete surfaces receiving special
treatment or special formwork finish.
C Sample Panel: Sufficient size to indicate special treatment or finish required. Include all
items such as stiffeners, sheet, ties, etc.
D If requested by Engineer, cast concrete against sample panel. Obtain acceptance of

resultant surface finish prior to erecting formwork.

E Accepted sample panel is considered basis of quality for the finished work. Keep sample
panel exposed to view for duration of concrete work.
F Mock-up may remain as part of the work with the approval of the Engineer.
16.1.10 Delivery and Storage
A Material and Equipment: Transport, handle, store, and protect products to the
requirements of spepcifcation.
B Storage of cement, aggregates, and admixtures.
a) Cement:
 Store and protect cement from deterioration and contamination.
 Store above the ground in filtered or an approved ventilation dust control dry
waterproofed silos.
 Provide separate cement silos for each consignment of cement. Do not mix
cement consignments.
 Maintain the temperature of cement in the silo at less than 45 degrees
 This can be accomplished be shading the silos and painting white to reflect
sunrays.
 Store bagged cement above ground on wooden slats or duckboards to allow
the efficient circulation of air around the bags in a dry waterproofed storage
facility.
b) Aggregates:
 Store in a special bin or on a specially prepared shaded and covered concrete
platform. The heap of the aggregate must be capable of draining freely.
 Maintain a separate storage facility for different type or grade of aggregates.
Prevent contamination of aggregates.
c) Admixtures: Store in waterproofed shaded closed container fitted with a circulation
pump.
16.1.11 16.1.11 Concrete Mix Design
A The Contractor shall provide concrete that is described by the Engineer by reference to a
combination of characteristic properties.
B Mixes for structural concrete shall be designed by the Contractor to meet the performance
requirements specified in clause 1.11.A above.
C The Contractor is responsible to the Engineer for demonstrating that the proposed mix
meets with the performance requirements.
D Concrete shall comply with BS EN 1992-3. Sampling for test purposes shall comply with
BS 1881 Part 101 (on site) & Part 125 (in laboratory).
E If air-entrainment is specified, the average air content at the time of placing measured in
accordance with either Method A or Method B of BS 1881 Part 106 shall be 5% ± 1% for
concrete containing 20mm maximum size aggregate.
F Concrete for water-retaining elements shall be watertight and shall comply with the
recommendations of BS EN 1992-3.

G Concrete for paving or precast units shall be tested to BS 1881 Part 118.
H If concrete specimens are cured at higher temperatures or for longer periods than BS 1881
Part 111 requires, the adjusted Characteristic Compressive Strength (CCS) shall be
calculated as follows:
100f'/f = A + B log {24D (T+12)/1000} where
f' = adjusted CCS
f = specified CCS
T = curing temperature in ºC
D = age at testing in days
A&B = are coefficients given in the following table
The equation applies only to OPC, MSRPC and SRPC.
Table 14: Coefficients for adjusted CCS Calculations

Recorded Cube Strength (MPa) A B
Less than 15 10.0 67.5
15 to 35 20.0 60.0
Greater than 35 30.0 52.5
This calculation may be applied for curing at temperatures up to 27oC.
I I.Before placing concrete, the Contractor shall obtain approval of the mixes proposed for
each class of concrete and the average target strengths. The mixes shall be designed to
achieve the minimum workability for the Contractor to place and compact the concrete with
the equipment proposed for use.
J J.The design mean strength shall exceed the minimum CCS specified in the performance
requirements by a margin of 1.64 times the standard deviation expected from the
concreting plant, except that no standard deviation less than 3.5 MPa shall be used as a
basis for designing a mix.
16.1.12 Preliminary Mix Tests
A Perform preliminary mix tests before commencement of the main concreting operation.
B Determine for each class of concrete, minimum water-cement ratio, and the actual mix
proportions of the fine and coarse aggregates required.
C Determine accurately the weight of materials in the preliminary mix test; allowances must
be made for the moisture content of the aggregates.
D Test the preliminary mix design for strength and workability.
E Repeat and adjust proportions of the preliminary mixes as necessary until concrete mixes
meet the relevant requirements.

16.1.13 Concrete Trial Mixes
A Preliminary laboratory tests shall be carried out to determine if the mixes satisfy the
Specification with the approved materials.
B Trial mixes shall be tested to determine the following properties of mixes proposed for
initial field tests:
a) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed 0.5%.
b) Drying shrinkage in accordance with BS 812 Part 120.
c) Air content if applicable BS 1881 Part 106.
d) Free water/cement ratio.
e) Workability tests BS 1881 Part 102, 103, 104 and 105.
f) Fresh and hardened concrete densities BS 1881 Parts 107 and 114 respectively.
g) Compressive strength BS 1881 Part 116. The CCS of the concrete shall be
determined on test specimens obtained and prepared in accordance with BS 1881
Part 108.
h) Tensile strength BS 1881 Part 118.
i) Water Permeability DIN 1048.
j) Water absorption BS 1881 Part 122.
k) Initial surface absorption BS 1881 Part 5.
l) Chloride Permeability to AASHTO T277.
m) Chloride and sulphate levels to BS 1881 Part 124.
n) Coefficient of linear expansion to US Army Corps of Engineers CRD-C 39- 81.
o) Heat of hydration BS 8110-97 Part 1 clause 6.2.4.2 – Point (d).
p) Other tests as dictated by concrete performance requirements or directed by the
Engineer.
C If the values obtained do not comply with the Specification or are not to the full satisfaction
of the Engineer then the mixes shall be re-designed.
D Before commencement of concreting approved trial mixes shall be prepared under full-
scale site conditions and tested in accordance with the relevant standards.
E Three trial batches of each mix shall be made and from each batch, a minimum of 6 cubes
shall be tested for strength. Three cubes shall be tested at 7 days and three cubes at 28
days by a laboratory approved by the Engineer. The results shall be submitted to the
Engineer within 24 hours of testing. Additional cubes shall be required as instructed by the
Engineer for durability testing.
F Further trial mixes shall be made if the range (the maximum minus the minimum of the
three cube results in any batch) exceeds 15% of the average of that batch, or if the range
of the three batch averages exceeds 20% of the overall average of the batches.
G Actual Characteristic Strength
a) The average 28 day cube strength achieved in the trials shall be designated as the
Target Mean Strength and from this the Actual Characteristic Strength shall be
calculated for each mix.
b) The Actual Characteristic Strength equals the Target Mean Strength minus a margin
of 1.64 times the standard deviation, except that the margin shall not be less than
4MPa.

c) In no case shall the Actual Characteristic Strength be less than the minimum CCS
specified in the performance requirements.
d) The Actual Characteristic Strength so determined shall be used throughout the
duration of the project as the primary indicator of control of mix proportions and
water/cement ratio.
H The Engineer will review the Contractor's trial-mixes and all test results. The Engineer will
then determine which of the trial mixes shall be used. If none of the trial mixes for a class
of concrete meets the Specifications, the Engineer will direct the Contractor to prepare
additional trial-mixes. No class of concrete shall be prepared or placed until its job-mix
proportions have been approved by the Engineer.
I The approval of the job-mix proportions by the Engineer in establishing those proportions,
in no way relieves the Contractor of the responsibility of producing concrete which meets
the requirements of these Specifications.
J The Engineer may also require practical tests to be made on the site by filling trial moulds
incorporating the reinforcing details to confirm the suitability of the mix for the Works. In
these tests, the type of plant used for mixing, the method of placing and compaction used
and the type of formwork intended for use in the Works shall be used.
K All costs connected with the preparations of trial-mixes and the design of the job- mixes
shall be borne by the Contractor.
L When the mix has been approved, no variations shall be made in the proportions, the
source of the cement and aggregates, or in the type, size and grading zone of the latter
without the consent of the Engineer who prior to giving such consent may require further
tests to be made.
M The heat of hydration test sample shall comprise a 1m x 1m x 1m test cube, insulated with
polystyrene. Temperature measurements shall be carried out in accordance with the
Specification clauses for controlling heat and shall determine the peak temperature
generated within the test sample.
16.1.14 Concrete Under Water
A Ensure that the actual mix proportions and selection of aggregates for concrete to be
placed in or under water will result in a concrete with a good flow and cohesion
characteristics.
B Provide the concrete for under water including piles with cement content of 10% greater
than for a comparable mix for use in dry conditions. Use a mix designs capable of
producing minimum works cube strength for all concrete as given in Table 3-3 for the
comparable mixes for use in dry conditions.
C The slump of the concrete must not be less than 125 mm when tested in the dry condition
in accordance with BS 1881.
16.2 PRODUCTS
16.2.1 Concrete Materials
A Cement: Comply with ASTM C150 Type I & Type II – Ordinary Portland Cement and
Moderate Sulphate Resisting Cement, respectively.
a) Use Type I Ordinary Portland cement throughout the works except for the
substructures, piling and sanitary related structure where moderate sulphate-
resisting cement type II shall be used unless otherwise stated on the contract

documents or drawings or dependent on soil conditions as determined by the
Engineer.
B Fine and Coarse Aggregates: Shall be examined for classification by petro graphic
examination and shall comply with the requirements of Section 02207 and the following:
a) Hard strong and durable. Contain no harmful material in sufficient quantity to affect
adversely the strength or the durability of the concrete or in the case of reinforced
concrete to attack the reinforcement.
b) Clay, silt and dust shall be to the minimum level acceptable in accordance with BS
882.
c) Coarse aggregates: Crushed quarried gabbro type, or limestone that meets the
physical requirements and chemical properties specified hereinafter.
d) Fine aggregates: Natural gabbro sand or Crushed quarried gabbro or lime stone
types that meet the physical requirements and physical properties specified
hereinafter.
e) Physical requirement:
 Weight of voided shells in fine aggregates not to exceed 3 percent.
 Clay, silts, and dust content not to exceed the following limits:
 Coarse aggregates 1 percent by weight.
 Crushed stone sands 5 percent by weight.
 Natural sands 3 percent by weight.
 Combined Flakiness index of coarse aggregates not to exceed 35 percent as
determined in accordance with BS 812
 Combined Elongation index of coarse aggregates not to exceed 35 percent as
determined in accordance with BS 812.
 Absorption of fine and coarse aggregates not to exceed 2.5 percent as
determined in accordance with BS 812.
 10% fines value of coarse aggregates shall not be less than 75KN as
determined in accordance with BS 812-111.
 Los Angeles abrasion value shall not exceed 30% as determined to ASTM
C131 or C535.
 Nominal size of coarse aggregates except otherwise stated in the contract
document to be as follow:
 Concrete class 'A' 10 mm.
 Concrete class 'B' 20 mm.
 Concrete class 'C' (unreinforced) 20 mm.
f) Except as may be modified hereunder, the aggregate (fine and coarse) for all types
of concrete shall comply in all respects with BS 882 "Concrete aggregates from
natural sources" and shall also comply with local regulations.
g) The aggregates used in the permanent works shall be naturally occurring crushed
materials obtained only from approved sources. Aggregates subject to high drying
shrinkage such as quartz shall not be used. Aggregates shall be clean, hard, and
durable and shall not contain iron pyrites, iron oxides, mica, shale, coal or other
laminar, soft or porous materials or hollow shells.
h) Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the necessary
tests and analyses to show that the samples comply with the Specification. During
the progress of the Works, the grading and chemical characteristics shall be

checked at frequent intervals.
i) The results of these tests shall be submitted to the Engineer and his approval shall
be obtained before any of the material is used in the Works. Part of each sample will
be required for concrete trial mixes and part shall be retained for comparison with
subsequent deliveries.
j) Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102.
k) The maximum size of the aggregate shall not be larger than:
 20% of the narrowest dimension between sides of the member for which the
concrete is to be used.
 75% of the maximum clear distance between reinforcing bars or the side form.
 The nominal aggregate size specified for the mix.
l) Fine Aggregate shall be clean sharp natural and/or crushed sand and shall be within
BS882 Table 4 zones C and M only.
m) Beach sand shall not be used in concrete mixes.
n) Coarse aggregate shall be crushed aggregate obtained from a quarry approved by
the Engineer.
o) Unless otherwise authorised by the Engineer coarse aggregate shall be delivered to
the batching plant in separate sizes according to the maximum specified aggregate
size for each grade of concrete.
p) Coarse aggregate shall be prepared as single sized aggregate and blended to
produce normal size grading. The combined grading shall be within the appropriate
grading limits given in BS 882.
q) The Contractor may mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
r) No part of the aggregates shall contain any mineral known to have a potential to
cause alkali silica, alkali silicate, alkali carbonate, or any other damaging chemical
reaction between alkalis and aggregates. The Contractor shall demonstrate to the
Engineer's satisfaction that the cement-aggregate combination will be stable and not
liable to excessive internal expansion due to alkali-aggregate reaction. The
Contractor's proposals for demonstrating this shall be submitted and shall take
account of the time necessary for any testing. Under exceptional circumstances, the
demonstration may be based on previous long-term experience of the materials.
Otherwise, the Contractor shall undertake a programme of tests using an
independent testing laboratory in accordance with the following requirements:
 Aggregates shall comply with the requirements of Table 3-3.
 Aggregates shall be initially assessed for reactivity in accordance with ASTM
C289 and C1260 and if potential reactivity is indicated, then tests in
accordance with ASTM C227 and C586 shall be carried out.
s) The Contractor shall carry out routine testing of aggregates for compliance with the
Specification during the period in which concrete is being produced for the
Permanent Works. The tests set out below shall be performed on aggregates from
each separate source.
C Water: Comply with the requirement of BS 3148.
a) Potable, clean, fresh, and free from sand grit and all mater, this is detrimental to
concrete.
b) PH of water in concrete work not be less than 5 and no more than 9.
c) The maximum content of acid soluble chlorides (as NaCl) in any concrete mix not to
exceed 0.4 % by weight of cement.

Table 15: concrete classification, mix design, and material specification
No Item Class of concrete
A B C
1 Typical applications Reinforced Unreinforced
Anchor blocks
Slabs 250mm thick.
Precast Work Slabs
<200mm thick
Shall be used in Columns and
Infilling soft areas and
congested areas at the beams. Circular
over break. Blinding &
discretion of the shafts
Chambers, pipe surround.
Engineer.
manholes, inlet,
catch basins,
outfalls, pump
stations and all RC
members.
2 Grade C40 C20
3 Minimum Cube Strength N/mm2
7 Days 30 min 15
28 Days 40 min 20
4 Cement
Type Above GL OPC
Below GL MSRC MSRC
Content Minimum 390 250
Kg/m3 Maximum 450 325
Age |>3 months
5 Aggregate
Nominal Size(mm) 10 20
% Fine 30-45 45-55
Combined Flakiness
|>35%
Index
Combined Elongation
|>35%
Index
10% fines value ≥75kN

>
Los Angeles abrasion

|>30%
value

A B C
Grading Fine | 10% > 5mm

>
|>5%>10mm
Coarse |>10%< |>5% > 20mm | 10% < 5mm

>
5mm
Clay Lumps (by weight) Fine >

| 3% Coarse >
| 1% by Weight
Absorption | 2.5%
>
Voided Shells | 3.0%

>
Chlorides Fine >

| 0.06% Coarse >
| 0.03%
Sulphates />0.4%
Soundness Loss of Na3SO4 >

| 10% & MgSO4 >
| 15%
Alkali Reaction None
Thermal Expansion |>Low
Friable Particles (by

Fine >
| 1% Course >
| 0.5% by Weight
weight)
6 Water
Free Water/Cement
| 0.40
> |>0.5
Ratio
Ph 7 < pH < 9
Chlorides | 0.025%
>
Sulphates | 0.035%
>
Alkali Carbonates &

| 0.05%
>
Bicarbonates
TDS | 0.2%
>
7 Density
Minimum Kg/m3 2400 2300
To be determined during design mix tests but normal range

8 Slump
75-125mm
Strictly in accordance with manufacturer’s instructions with CaCl2

9 Admixtures N/A
content zero
10 Temperature
Cement |>45oc when entering mixers
Concrete | 32oc
At Placement >

A B C
Shade |>40oc & Rising or < 43oc & Falling
11 Quality Control on fresh and hardened concrete in accordance with clause 3.10 of this section
16.2.2 Admixtures
A Chemical: ASTM C494 and BS 5075.
a) Do not use admixtures containing chlorides.

b) Use water-reducing admixture, retarding admixture, and accelerating admixture in
accordance with the manufacturer's recommendation.
c) Conduct trial mixes in the presence of the Engineer and the manufacturer
representative.
d) Do not use admixture together with other admixture in the same mix.
e) Do not use admixture intended to change the flow characteristics, cohesion or rate
of setting of the concrete without the approval of the Engineer.
16.2.3 Accessories
A Bonding Agent: Polymer resin emulsion, Polyvinyl Acetate, Latex emulsion, two
component modified epoxy resin, Non-solvent two-component polysulfide epoxy, Mineral
filled polysulfide polymer epoxy, Mineral filled polysulfide polymer epoxy resin, cured
epoxy.
B Vapour Retarder: 0.25 mm or 0.5 mm thick clear polyethylene film type, for below grade
application.
C Non-Shrink Grout: Premixed compound consisting of non-metallic aggregate, cement,

water reducing and plasticizing agents; capable of developing minimum compressive
strength of 17 MPa in 48 hours and 48 MPa in 28 days;
D Curing Compounds: High efficiency curing compound to ASTM C309, or Water base
concrete curing compound ASTM C309.
a) Store, handle, and apply curing compound in accordance with the manufacture's
specification and instructions.
b) Must be capable of retaining moisture and water in the fresh concrete and provide
an effective barrier to acidic atmospheric gases and water borne salts responsible
for the corrosion mechanism of concrete.
16.2.4 Joint Devices and Filler Materials
A Joint Filler: ASTM D 1751; ASTM D 994; Bitumen impregnated fibreboard, for use in dry
structures.
B Joint Filler: ASTM D 1752; High performance cross-linked, closed cell, non- absorbent,
polyethylene for use in liquid bearing structures.
C Joint Sealant: Non-degradable for its particular application, suitable for use in hot climates,
elastoplastic, with a movement accommodation factor of at least + 12 percent.

a) Joint sealer suitable for sealing movement, control, or construction joints in liquid
bearing structures. Resistant to aerobic and anaerobic bacteriological attack, acids,
alkalis and UV to ASTM C 920, Type S, Grade NS, class 25.
b) Joint sealer suitable for sealing movement, control, or construction joints in dry
structures:
 Polyurethane to ASTM C 920, Grade NS, Class 25, type M.
 Polysulphide- to ASTM C 920, Grade NS, Class 25, Type M, and BS 4254
gun grade.
16.2.5 Batching and Mixing of Concrete
A Cast-in-place concrete shall be ready mixed concrete, batched off the site, generally as
defined in BS EN 206 and BS 8500 but as amended in these Specifications.
B The weighing and water-dispensing mechanisms shall be maintained in good order. Their
accuracy shall be maintained within the tolerances described in BS 1305 and checked
against accurate weights and volumes when required by the Engineer.
C The mass of cement and of aggregate indicated by the mechanism employed shall be
within a tolerance of 2% of the respective mass per batch agreed by the Engineer. The
mass of the fine and coarse aggregates shall be adjusted to allow for the free water
contained in them. The water to be added to the mix shall be reduced by the quantity of
free water contained in the fine and coarse aggregates, which shall be determined by the
Contractor by a method approved by the Engineer immediately before mixing begins and
further as the Engineer requires.
D Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch type mixer
manufactured in accordance with BS 1305. The mixing blades of pan mixers shall be
maintained within the tolerances specified by the manufacturer of the mixer and the blades
shall be replaced when it is no longer possible to maintain the tolerance by adjustment.
The period of mixing, judged from the time that all the ingredients including water are in the
mixing drum shall be as ordered by the Engineer's representative and shall be in
accordance with the mixer manufacturer’s recommendations.
E Mixers that have been out of use for more than 30 minutes shall be thoroughly cleaned
before any fresh concrete is mixed.
F The method of discharge from the mixer shall be such as to cause no segregation whether
partial or otherwise of the concrete materials.
G The Contractor shall ensure that the constituent materials of the concrete are sufficiently
cool to prevent the concrete from stiffening in the interval between its discharge from the
mixer and compaction in its final position. Precautions shall include the shading of
aggregate stockpiles and the use of chilled water.
H The Concrete shall be carried in purpose-made agitators, operating continuously, or truck

mixers. The concrete shall be compacted and in its final position within 1 hour of the
introduction of cement to the aggregates, unless a longer time is agreed by the Engineer.
The time of such introduction shall be recorded on the delivery note together with the
weight of the constituents of each mix.
I Concrete shall only be mixed at a batching plant approved by the Engineer.
J Unless specially authorised by the Engineer, the concrete shall be mixed and the water
added to the mixer at the batching plant. No additional water shall be added at any stage
from batching to placing. When the Engineer is asked to authorise dry batching, he will
require to be satisfied that appropriate steps will be taken to ensure the quality,

consistency and strength of the concrete as placed and that the water will be added to the
dry ingredients under properly controlled conditions.
K Truck mixer units and their mixing and discharge performance shall be to the satisfaction
of the Engineer. Mixing shall continue for the number and rate of revolutions
recommended in the manufacturer's instructions, in the absence of which mixing shall
continue for not less than 100 revolutions at a rate of not less than 7 revolutions per
minute.
L Pumping concrete through delivery pipes may be permitted but only with the prior approval
of the Engineer.
M Re-mixing of concrete that has commenced to set shall not be allowed and in no case shall
such concrete be used in the Works.
16.3 EXECUTION
16.3.1 Examination
A Verify site conditions as per specification.
B Verify requirements for concrete cover over reinforcement.
C Verify that anchors, seats, plates, reinforcement and other items to be cast into concrete
are accurately placed, positioned securely, and will not cause hardship in placing concrete.
16.3.2 Preparation
A Prior to the commencement of concrete works, the Contractor shall provide the Engineer
with fully detailed proposals of the method of placing, compacting, finishing and curing the
concrete. The method statements, which shall be subject to the approval of the Engineer,
shall cover all principle types of concrete elements, e.g. foundations, walls, columns,
beams, slabs etc.
B As a minimum requirement, preparations for concreting shall follow the guidelines given in
ACI 305R-91 Section 4.
C The concrete-mixing plant, mixers, pipelines, pumps chutes and transport equipment shall
be shaded and/or painted white. Pump lines and other surfaces shall be kept cool by
insulating them or by covering them with hessian kept damp by spraying with water.
D Surfaces on which concrete is to be placed shall be moist but free of standing water at the
time of concreting. This shall be achieved by spraying the forms and reinforcement prior to
placing concrete. Shading shall be provided to prevent solar heat gain of forms and
reinforcement and to prevent evaporation / drying.
E When daytime temperature and drying conditions are critical the concreting shall be
scheduled to begin during the late afternoon to prevent the occurrence of severe thermal
effects. Consideration should also be given to nighttime concreting.
F The Contractor shall give the Engineer at least 24 hours written notice before concreting to
allow time for final inspection and approval.

16.3.3 Concrete Transport and Placing
A The method of transport and placing concrete shall be to the approval of the Engineer.
Concrete shall be so transported and placed that contamination, segregation or loss of the
constituent materials does not occur.
B All formwork and reinforcement shall be clean and free from standing water immediately
before placing concrete.
C Prior to placing any concrete on natural surfaces, a blinding layer of concrete shall be laid
to a minimum of 75 mm thickness unless otherwise specified on the drawings. This
blinding shall be suitably cured prior to subsequent concrete placement. The blinding shall
be clean and free from any dust or impurities prior to subsequent concrete placement.
D No concrete shall be placed in a foundation until the extent of excavation and the character
of bearing material have been approved and no concrete shall be placed in any structure
until the placement of reinforcing steel and the adequacy of the forms and false work have
been approved.
E Concrete shall not be placed in any part of the Works until the Engineer's approval has
been given. If concrete has not started within 24 hours of such approval being given,
approval shall again be requested. Concreting shall then proceed continuously over the
area between construction joints. Fresh concrete shall not be placed against in-situ
concrete that has been in position for more than 30 minutes unless a construction joint is
formed in accordance with the Specification. When the concrete has been in place for 4
hours, or less as directed by the Engineer, further concrete shall not be placed against it
for at least a further 20 hours.
F Concreting in Hot Weather
a) Hot weather is defined as any combination of the following conditions that tend to
impair the quality of the freshly mixed or hardened concrete:
 High ambient temperature.
 High concrete temperature.
 Low relative humidity.
 Wind velocity.
 Solar radiation.
b) When the rate of evaporation of surface moisture from concrete is expected to
approach 1 kg/m²/hr (using Fig. 2.1.5 in ACI 305R-91) or when the shade air
temperature is 35ºC and rising, precautions shall be taken, including the following:
 Dampening the forms.
 Reducing the concrete temperature to the lowest practical level by procedures
such as: shading the aggregate; cooling the mixing water before use and
screening the mixing plant and transporting vehicles from wind, rain and sun.
 Erecting wind breaks and sunshades at the concrete placing location.
 Reducing the time between the placing of the concrete and the start of curing
to the minimum possible.
 Minimising evaporation (particularly during the first few hours subsequent to
placing the concrete) by suitable means such as applying moisture by fog
spraying or use of evaporation retarders.
c) All precautions to be taken shall be subject to the Engineer's approval and the
Contractor shall demonstrate that all approved precautions are available for use
prior to the Engineer granting approval to any concreting operations.

d) In the event that conditions become such that these requirements cannot be met,
concreting shall be suspended immediately and not resumed until the requirements
can be met again. Under such circumstances, additional precautions shall be taken
to avoid the hot weather concreting conditions being exceeded on future pours.
G Control of Temperature
a) The temperature of the concrete when placed shall not exceed 32ºC nor shall
concrete be mixed or placed when the shade air temperature is 40ºC or above, or is
expected to reach such a level during concreting and 3 hours after placing, without
special permission from the Engineer.
b) For all concrete sections the Contractor shall take precautions to limit the effects of
heat of hydration.
c) The Contractor shall determine the expected heat of hydration for the concrete batch
by testing at least 1m3 insulated concrete cubes, in accordance with the
Specification clauses for the trial mixes.
d) For concrete sections greater than 1000 mm thick, the Contractor shall submit to the
Engineer for approval detailed proposals of the measures to be taken. These
measures shall include but are not limited to: building mock- ups; control of concrete
mix constituents; curing water; formwork type; surface insulation; and, cooling by
embedded pipes. All submissions shall be based on measured values of heat of
hydration generated by the proposed mix to meet the criteria set out below:
 Maximum temperature difference between the core and the surface of any
pour. Design target 15ºC. Field maximum 20ºC.
 Maximum temperature difference between a new pour and a previous pour.
Design target 12ºC. Field maximum 15ºC.
 Absolute maximum temperature anywhere in a pour. Design target 60ºC.
Field maximum 70ºC.
 The Contractor shall install instrumentation in the Works to verify compliance
with the above criteria. Temperature measurements shall be made by means
of thermocouples positioned in a line perpendicular to the concrete faces. The
thermocouples shall be fixed: at the concrete faces; at the centre of the
section; and at equal intervals of approximately 300mm.
 Temperatures shall be measured and logged continuously from the start of
the pour until instructed to stop by the Engineer. The Contractor shall submit
to the Engineer for approval details of the proposed methods and equipment
for the measuring and logging of temperatures. An automatic data logger or
other suitable device shall log data. The equipment shall be capable of
reading all thermocouples in less than one minute and results shall be
submitted to the Engineer on a daily basis.
H If temperature measurements exceed any of the criteria above then action shall be taken
in accordance with the clauses on defective concrete.
I Concrete shall be compacted in its final position within 30 minutes of discharge from the
mixer unless carried in purpose made agitators operating continuously, when the time shall
be within 1 hour of the introduction of cement to the mix and within 30 minutes of
discharge from the agitator.
J Precautions shall be taken to ensure that the loss of slump due to temperature rise during
transport, pumping and placing does not exceed 25mm.
K Except where otherwise agreed by the Engineer, concrete shall be deposited in horizontal
layers to a compacted depth not exceeding 400mm where internal vibrators are used or
300mm in all other cases.

L Unless otherwise agreed by the Engineer, concrete shall not be dropped into place from a
height exceeding 2m. When trunking or chutes are used, they shall be kept clean and used
in such a way as to avoid segregation. Where steep slopes are required for placing
concrete with chutes, the chutes shall be equipped with baffle boards or be in short lengths
that reverse the direction of the movement. Chutes and the use of chutes must be
approved by the Engineer. All chutes shall be kept clean and free from coating of
hardened concrete by thoroughly flushing with water after each run. The water used for
flushing shall be discharged clear of the concrete already in place.
M Concrete shall not be pumped through aluminium alloy conduits.
N No concrete shall be placed in flowing water. Underwater concrete shall be placed in

position by tremie or by pipeline from the mixer.
O Full details of the method proposed shall be submitted in advance to the Engineer and his
approval obtained before placing begins. Where the concrete is placed by the tremie, its
size and method of operation shall be in accordance with BS EN 1997. During and after
concreting under water, pumping or dewatering operations in the immediate vicinity shall
be suspended until the Engineer permits them to be continued.
P Approved measures shall be taken to avoid premature stiffening of concrete placed in

contact with hot, dry surfaces. Surfaces including reinforcement against which concrete is
to be placed shall be shielded against the direct rays of the sun and shall be sprayed with
water to prevent excessive absorption by the surfaces of water from the fresh concrete.
Q A complete pour record shall be kept of the date, time, temperature and conditions of
placing, the concrete in each portion of the work and shall be available for inspection by
the Engineer at any time.
R No concrete shall be mixed or placed when the light is insufficient, unless an adequate and
approved artificial lighting system is operated and such night work is approved by the
Engineer.
16.3.4 Extent of Pours
A The limit of individual pours and the height of lifts shall be as approved by the Engineer.
The sequence of pours shall be arranged to minimise thermal and shrinkage strains.
B The Concrete Works have been designed as continuous construction in accordance with
BS EN 1992-3. Therefore, consideration should be given to maximising the size of pours
and minimising the number of construction joints.
16.3.5 Compaction of Concrete
A All concrete shall be compacted to produce a dense homogeneous mass. Unless

otherwise agreed by the Engineer, it shall be compacted with the assistance of vibrators.
Sufficient vibrators in serviceable condition shall be on site so that spare equipment is
available in the event of breakdown. A 50mm diameter internal vibrator shall be deemed
capable of compacting 20 m3/hr. Internal vibrators shall be capable of producing not less
than 10,000 cycles per minute.
B Vibration shall not be applied by way of the reinforcement. Where immersion vibrators are
used, contact with reinforcement and all inserts shall be avoided.
C Vibrators shall be so manipulated as to work the concrete thoroughly around the

reinforcement and embedded fixtures and into corners and angles of the forms. Vibrators
shall not be used as a means to cause concrete to flow to its position in lieu of placing. The
vibration at any point shall be of sufficient duration to accomplish compaction. After initial

set of the concrete, the forms shall not be jarred and no strain shall be placed on the ends
of projecting reinforcement.
D External vibration shall not be used unless permitted by the Engineer for special
circumstances.
16.3.6 Concrete Blinding Layer
A Place a concrete blinding layer immediately upon completion of the excavation and where
shown on the drawings or ordered by the engineer, to prevent deterioration of the
formation and to form a clean working surface for the structure.
B Place a concrete Class C blinding layer of a minimum thickness of 100 mm or to the depth
shown on the contract drawing
16.3.7 Separate Floor Toppings
A Prior to placing floor topping, roughen substrate concrete surface and remove deleterious
material. Broom and vacuum clean.
B Place required dividers, edge strips, reinforcing and other items to be cast in as shown in
the drawings.
C Apply sand and cement slurry coat on base course, immediately prior to placing toppings.
D Place concrete floor toppings to required lines and levels.
E Screed toppings level, maintaining surface flatness of maximum 1:1000.
16.3.8 Concrete Finishing
A As per the relevant specifications.
16.3.9 Curing and Protection
A Immediately after compaction and for 14 days thereafter, concrete shall be protected from
the harmful effects of weather, including rain and rapid temperature changes, and from
drying out. The methods of protection shall be subject to the Engineer’s approval. The
Engineer's approval will be conditional upon the proposed curing method proving to be
satisfactory on site.
B The method of curing used shall minimise the loss of moisture from the concrete. On
concrete surfaces that are to be waterproofed or coated, curing membranes shall not be
used unless agreed by the Engineer. Details of all curing methods to be used shall be
subject to the approval of the Engineer.
C Concrete surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimise evaporation. The
hessian sheeting shall be maintained continuously damp for a minimum period of 14 days
after casting, using water of the same quality as that allowed in mixing the concrete. Water
used for curing purposes shall be within 5ºC of the placed concrete temperature.
D Subject to the approval of the Engineer, curing with an approved proprietary product may
be used as an alternative to curing with water except that the curing product shall not be
applied to surfaces of concrete from which the shuttering has been struck, until the
concrete has been inspected and approved by the Engineer's representative. The curing
material shall not be detrimental to concrete.

E The concrete curing compound shall be of an approved type, which shall be readily
distinguishable upon the concrete surface for at least four hours after application. The
curing compound shall be compatible with concrete admixtures and with subsequent
surface finishes. The curing compound shall be removed using a method approved by the
Engineer prior to application of the finishes. The colour, if any, shall become inconspicuous
within seven days after application.
A Independent Testing Laboratory
a) Comply with pertinent provisions of specification of Quality Control.

b) Comply with pertinent requirements of the authorities having jurisdiction. Obtain
approvals from these authorities.
c) The Contractor shall provide a qualified independent testing laboratory, experienced
with local construction conditions and materials, to conduct tests and submit reports
for the concrete mixes to ensure compliance with the Specification. The use of the
proposed laboratory is subject to the approval of the Engineer.
d) Constituent materials shall be obtained from suppliers operating quality systems in
accordance with relevant specification.
B Transporting and Curing of Samples
a) Samples shall be taken on site at the point of delivery. Test cubes shall be made,
cured, stored, transported and tested to BS 1881 Parts 108, 111 and 116.
b) The Contractor shall establish a site curing facility. Test cubes shall not to be de-
moulded at periods of less than 24 hours and shall not be transported before 48
hours have elapsed.
C Sampling Cubes
a) A sample of concrete shall be taken at random on eight separate occasions during

the first five days of using a mix, at least one sample being taken each day.
b) Thereafter one sample shall be taken at random for each class of concrete in
accordance with Table 3-7 of the Specification.
c) In addition to the above requirements, at least one sample shall be taken from each
individual structural unit, or part of a unit, when the latter is the product of a single
pour.
d) From each sample, three cubes shall be made for testing at 28 days and one for
testing at 7 days for control purposes.
e) The frequency of sampling may be required to be varied if directed by the Engineer.
f) The procedures shall be repeated when materials or design mixes are changed.
D Cube Strength Results
a) The results will be acceptable only if both of the conditions below are met:
 The mean field cube strength at age of 28 days shall exceed the Actual
Characteristic Strength given in par. 3.1.3.7 by a margin of 1.64 times the
Standard Deviation, except that no Standard Deviation lass than 4Mpa shall
be used in calculation.
 If the above criteria are not satisfied, the unit represented by the sample is
questionable and any or all of the following actions may be instructed by the
Engineer at the Contractor’s expense:
 Changing the mix.

 Improving quality control.
 Cutting and testing cores from placed concrete.
 Non-destructive testing of placed concrete.
 Cutting-out and replacing defective concrete.
b) If any individual 28 day cube strength from a sample exceeds the Target Mean
Strength achieved in the trial mixes by more than 10 MPa then any or all of the
actions listed above may be instructed by the Engineer at the Contractor’s expense.
c) In the event cutting and testing of cores are required, the Contractor shall cut cores
from approved locations, and test them to BS1881 as modified by BS 6089.
E Flexural Tensile Strength Tests
a) Samples shall be taken and two beams cast to determine the tensile strength of the
concrete at 7 days and 28 days, as specified in BS 1881 Part 118.
b) The samples shall be taken in accordance with the minimum test requirements for
concrete in the Specification and shall coincide with samples taken for test cubes.
F Durability Tests
a) Samples shall be taken in accordance with the minimum test requirements for
concrete in the following section and shall coincide with samples taken for test
cubes. The concrete shall be tested for durability properties as directed in the
following table.
Table 16: Durability Properties for Concrete Tests

Silica Fume Concrete (SF)
Waterproof Concrete
TYPE OF CONCRETE
GGBS Concrete
OPC Concrete
PFA Concrete
DESCRIPTION OF TEST (WPC)
Rapid Chloride Permeability (RCP) to AASHTO T277 Max 3,800 1,000 1,200 1,200 800
Charge Pass (Coulombs) at 28 days
Water Permeability (SWP) to DIN 1048 Max Penetration 20 10 10 10 8

(mm) at 28 days
Initial Surface Absorption Test (ISAT) to BS 1881 Part 0.3 0.15 0.15 0.15 0.02
208: Maximum ISAT at 28 days: 10 minute test (ml/m²/s)
30 Minute Absorption (WA) to BS 1881 Part 122: 30 2.0% 1.5% 1.5% 1.5% 1.0%
minute test (at 7 days unless noted otherwise)
b) The durability test results will be deemed to be acceptable only if both of the

following conditions are met:
 The average value of all of the results for each test on each type of concrete
is less than or equal to the pertinent value in the above table.
 Each test shall be given a weighting of unity and the overall score of the four
durability test results on each set of samples shall be evaluated in accordance
with the following formula:
Score = (RCP/800)+(DIN/8)+(ISAT/0.02)+(WA/1.0)
Where
RCP = measured value from the Rapid Chloride Permeability test to AASHTO T277 in
Coulombs
DIN = measured value from the Water Permeability test to DIN 1048 in mm
WA = measured value from the Water Absorption test to BS1881 Part 122 expressed as
a percentage
ISAT = measured value from the Initial Surface Water Absorption test to BS1881 Part 208
expressed in ml/ (mm².s)
The score for each set of samples shall comply with the following values:
Table 17: Set of Samples Values

Type of Concrete Score to be less than or equal to
OPC 20
SF 10
GGBS 12
PFA 12
WPC 4
c) For blended mixes, such as OPC/SF/GGBS or OPC/SF/PFA, the most onerous test
conditions shall apply.
d) The chloride and sulphate levels in the concrete mix to BS 1881 Part 124 shall be in
accordance with the table below:
Table 18: Chloride & Sulphate levels

Type of Concrete Chlorides as Cl (a) Sulphates SO3 (a)
For reinforced concrete
- made with OPC/MSRPC 0.10 3.70

- made with SRPC 0.06 3.70
Prestressed concrete & heat-cured 0.06 3.70
reinforced concrete.
For mass concrete(b) 0.10 3.70

e) When silica fume is used it shall not be included as cement binder for the purpose of
chloride and sulphate limitations.
f) The OPC and MSRPC cements can also contain chlorides, the relevant standard BS
12 allows up to 0.1% Cl. Therefore, any chloride content present in the cement has
to be taken into account while computing total Cl in the mix.
G Other Tests
a) The Contractor shall submit to the Engineer for approval his proposed methods for
complying with the creep strain criteria of the performance requirements of the
Specification. These shall include, but are not limited to:
 a. Tests to establish the strength of the concrete and the static modulus of
elasticity of the concrete to BS 1881: Part 121 at 7 days, 28 days, 3 months
and 6 months.
 b. Sufficient tests shall be undertaken to allow an accurate assessment of
the creep strain to be made prior to, and during, the concreting operations.
These tests shall only cease when directed by the Engineer.
b) When instructed by the Engineer concrete shall be tested for drying shrinkage and
wetting expansion, for which 75x75mm prisms shall be prepared and tested in
accordance with BS 812 Part 120. The maximum acceptable limits shall be:
 a. Drying Shrinkage: 0.04%.
 b. Wetting Expansion: 0.03%.
c) Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.
d) The air content of air-entrained concrete shall be determined in accordance with
ASTM C231 for each batch produced until consistency has been achieved, when
one in five batches may be tested. The maximum value shall not exceed 2%.
e) Compaction factor, slump, Vebe or other workability tests shall be carried out as
required during concreting of permanent Works to control workability at the batching
plant and at the site of the pour. For each sample the temperature of the concrete
shall be measured and recorded with the time the test was performed. The degree
of workability shall be as for the trial mixes; permitted tolerances shall be in
accordance with BS 5328.
H Minimum Test Requirements for Concrete
a) Samples shall be taken and 4 (four) cubes made for strength testing for each class
of concrete and for each particular application at a frequency shown in Table 19:
Table 19: Rate of Sampling Concrete
Sampling to Represent a
Type of Structure Element Volume of Concrete (m3)
Cube Strength Tests Durability Tests

Critical elements Columns, piles 10 50
Normal structural elements General 50 250
Heavy concrete construction Raft 100 500
b) The point of sampling of fresh concrete shall be at delivery into the Works unless
otherwise directed by the Engineer.

c) Cement: One 2 kg sample for quality testing to ensure compliance with Part 2 of the
Specification shall be taken from each 1,500 bags or equivalent weight or one day’s
output of the cement plant for each class of cement, whichever is the lesser.
d) Water: One 5 litre sample shall be obtained prior to use from each source for quality
testing in accordance with the “Water For Concrete” section of the Specification.
e) Samples of concrete, cement and water shall be taken and tested as described in
the above sub-section at least once a week during concreting operations.
f) In addition to the cubes made for strength testing, samples shall be taken and
specimens made for durability testing.
I Testing frequencies and reference standards for Fresh Concrete.
Table 20: Testing Frequencies & Reference Standards for Fresh Concrete
No. Test Frequency Standard
Every load for structural & every alternative load for

1 Temperature ASTM C1064 or BS 1704
non-structural concrete
Every load for structural & every alternative load for ASTM C143 or BS EN
2 Slump
non-structural concrete 12350-2
During trial mixes and further up to ASTM C138 or BS

3 Unit Weight
the engineer EN 12350-6
During trial mixes for structural concrete and further up

4 Air Content ASTM C231 or ASTM C173
to the Engineer
5 Identification of
Every load for all grades None/ by washing
aggregates
During trial mixes for structural concrete and once

6 Bleed ASTM C232
every month
J Testing frequencies and reference standards for Hardened Concrete
Table 21: Testing Frequencies & Reference Standards for Hardened Concrete
ASTM or BS1881 Pt.

1 Density All cylinders and cubes required for compressive strength
114
Min. one set per casting per day and every 50m3 for
ASTM or BS 1881Pt.
2 Compressive strength structural concrete. Min.one set every 100m3 cumulative
116
for non-structural concrete
Concrete coring from

3 As directed by the Engineer ASTM or BS
structure
4 Non-destructive Up to the engineer As per contract

(NDT) requirements
BS EN 12390-8
5 Water permeability One set for every 100m3 cumulative for structural concrete
or DIN 1048
ASTM C497M
6 Water absorption As directed by the Engineer
test Method B
Rapid Chloride ASTM C1202 or

7 Up to the engineer
Test AASHTO T277
16.3.11 Early Loading
A During the first 28 days after compaction, the concrete shall at no time be subject to
loading, including its own weight, which will induce a compressive stress in it exceeding
0.25 of its compressive strength at the time of loading or of the specified 28 day strength
whichever is lower. The strength of the concrete and the stresses produced by the loads
shall be subject to the agreement of the Engineer.
B No load shall be placed until the Engineer so permits, but in no case shall any load of any
kind be placed until the curing has been completed. The Contractor shall not place any
temporary loads or open any section of the Works to traffic or construction equipment until
permitted by the Engineer.
C In addition to the above, the Contractor is responsible for conforming to the performance
requirements for concrete in general and for the creep requirements in particular.
16.3.12 Patching
A Allow the Engineer to inspect concrete surfaces immediately upon removal of forms.
B Excessive honeycomb or embedded debris in concrete is not acceptable. Notify the

Engineer upon discovery.
C Patch imperfections as directed in accordance with ACI 301.
D Do not treat concrete surfaces until the Engineer's inspection is completed.
16.3.13 Defective Concrete
A The action to be taken in the event of non-compliance of test results with the Specification,
including but not limited to cube results, shall be determined by the Engineer and may
range from qualified acceptance to rejection and removal of all or part of the affected works
as described in the “Field Quality Control” section of the specification.
B The Contractor shall provide at his own expense all tests and rectification works including
records, samples, including core samples, and their results as may be required by the
Engineer, whether the concrete be finally accepted or not.
16.3.14 Schedule - Concrete Types and Finishes
A See Table 15 for concrete type.

B Provide qualities of finish as indicated in the description of the works. Ensure that the
quality of finish is not inferior to those described below. Any defective concrete finish will
be rejected and the Engineer may, at his discretion, order the defects to be cut out and
made good to his satisfaction. Do not allow fins and featheredges in the concrete surfaces.
C Apply the following requirements for the finish of concrete surfaces as appropriate:
a) Exposed surfaces and surfaces in contact with liquid other than upper surfaces:
Surface texture to be obtained from the use of formwork of a smooth impervious
face of metal or the like.
b) Concealed surfaces: Surface texture required to be obtained from the use of
formwork of sawn close jointed timber or the like.
c) Exposed upper surfaces and upper surface in contact with liquid: Surface to be
floated with a steel trowel to a smooth finish.
d) Other exposed upper surfaces to have a smooth finish with a wood trowel. The
troweling shall be executed so that an excessive amount of fine material is not
brought to the surface.
e) Tanked surfaces: Surface texture required to be obtained from the use of formwork
of the "mechanical face" of hardboard or the like.
f) Road and hard standing surfaces: Surface finish to be obtained by the conventional
use of a hand tamper or vibrating beam.
g) Rendered or surfaces areas: Areas to be subsequently rendered or to receive a
surfacing other than as (3) must be adequately scored to provide an effective key.
h) Surfaces adjacent to block work: All necessary wall ties to be cast in to concrete
faces against which block work is to be subsequently built. Space the ties 400 mm
vertically and 800 mm horizontally.
i) Non-slip surfaces: Surface texture to be obtained by the use of a wood float. Stipple
the concrete whilst wet to roughen it.
j) Exposed arises: To be formed with a 20mm by 20mm chamfer.
Plastering of defective concrete as a means of making good will not be permitted, except in
the case of minor surface porosity when the Engineer may approve a surface treatment by
running in cement and sand mortar of the same richness as the concrete. Perform this
treatment immediately after removing the formwork.
16.3.15 Testing for Water tightness Of Water-Retaining Structures
A This shall be done in accordance with relevant specification of ‘Testing of Water Retaining
Structures.
PART 17 EXPOSED AGGREGATE CONCRETE FINISHES
17.1 GENERAL
b) Contract Close out

c) Cast-In Place Concrete Section
d) Concrete Curing
17.1.2 References
ACI 303R - Guide to Cast-in-Place Architectural Concrete.
17.1.3 17.1.3 Submittals for Review
A Submittals as per specification.
B Samples: Submit two number 5 kg plastic buckets of each aggregate specified, illustrating
size, colour and the extremes of colour range.
A Perform Work in accordance with specification and ACI 303R.
B Maintain one copy of the document on site.
17.1.5 17.1.5 Mock-Up
A Quality Control as per specification
B Construct one horizontal field sample panel, 2m by 3m, with full aggregate colour range
represented.
C Locate as directed by the Engineer.
D Mock-up may not remain as part of the permanent Work.
17.1.6 Pre-Installation Meeting
A Coordination and Meetings.
B Convene one week prior to commencing work of this section.
A Materials and Equipment.
B Provide all product information in manufacturer's packaging, including use instructions to

the Engineer or as directed.
17.2 PRODUCTS
17.2.1 Concrete Materials
A Cement, Water, Admixtures: as per relevant specifications.
17.2.2 Accessory Materials
17.2.2.1 Surface Retarder as approved by the Engineer
A Acid Etch Solution as approved by the Engineer.

17.2.3 Concrete Mix
A Utilize concrete mix design as per relevant specification.
A Provide testing and analysis of concrete mix design.
B Test samples in accordance relevant specification.
17.3 EXECUTION
17.3.1 17.2.5 Examination
A Verification of existing conditions and readiness of formwork and reinforcement prior to

beginning work.
B Verify that items to be cast into concrete are placed securely and will not impede placing
concrete.
C Notify the Engineer minimum 24 hours prior to commencement of concreting operations.
17.3.2 17.2.6 Preparation
A Clean formwork surfaces.
B Apply surface retarder to formwork in accordance with manufacturer's instructions.
C Clean previously placed concrete with steel brush and apply bonding agent in accordance
with manufacturer's instructions.
17.3.3 17.2.7 Placing Concrete
A Place concrete in accordance with specification.
B Place concrete continuously between predetermined construction and contraction joints.

Do not interrupt successive placement such that cold joints occur.
C Cast test panels, size approved by Engineer, simultaneously with approved cu m of

concrete placed. Use test panels to determine when each section of work is ready for
exposed aggregate treatment.
17.3.4 Aggregate Exposure
A Remove forms after seven days
B After removal of formwork, wet concrete surfaces with water and scrub with acid etch
solution exposing aggregate to match accepted sample panel
C Do not expose more than 40% of aggregate surface.
17.3.5 Curing
A Cure concrete floor surfaces in accordance with Concrete Curing,

B Spraying: Spray water over floor slab areas and maintain wet for seven days.
C Maintain concrete with minimal moisture loss at relatively constant temperature for a period
necessary for hydration of cement and concrete hardening.
17.3.6 Cleaning
A Cleaning installed work.
B When desired finish is achieved, wash and rinse exposed aggregate surfaces.
17.3.7 Defective concrete
A Remove and replace any exposed concrete, which displays surface defects unless the
Engineer approves patching or other remedial measures.
B Defects include colour and texture irregularities, cracks, spalls, air bubbles, honeycombs,
fins and other projections on the surface, stains and discolorations that cannot be removed
by cleaning and other defects which in the opinion of the Engineer adversely affects the
finish appearance.
C Permission for patching or other remedial measures is not a waiver of the Engineer’s right
to require complete removal of the defective work in his opinion such measure does not
satisfactorily restore the quality and appearance of the surface.
17.3.8 Protection of finished work
A Protecting installed work.
B Protect concrete from premature drying or staining, excessively hot or cold temperatures,
or mechanical injury
Schedules
A A.Exterior Main Entry: Light brown aggregate, 6mm minimum and 9mm maximum size,
25% exposure.
B B.Exterior Spandrels: Medium brown aggregate, 12mm minimum and 20mm maximum
size, 35% exposure.
PART 18 CONCRETE CURING
18.1 18.1 GENERAL
18.1.1 18.1.1 Related Documents
b) Cast-In Place Concrete

18.1.2 18.1.2 References
ACI 308 Standard Practice for Curing Concrete.
ASTM C171 Sheet Materials for Curing Concrete.
ASTM C309 Liquid Membrane-Forming Compounds for Curing Concrete.
ASTM D2103 Polyethylene Film and Sheeting.
BS 8110 Structural Use of Concrete: Code of practice for design and construction.
18.1.3 Submittals
A Submit as per specification.
B Product Data: Provide data on equipment, materials, organization, management and

names of concreting crew, names of compacting crew, their skills and training received to
perform the tasks on specified in the works.
A Perform Work in accordance with the specification.
A Deliver, store, protect, and handle products as per specifications.
18.2 PRODUCTS
18.2.1 Materials
A Hessian shall be close-knit hessian. Hessian shall be new. Hessian used previously for
packaging shall not be used.
B Water: Potable, not detrimental to concrete.
18.3 EXECUTION
18.3.1 Examination
A Verify substrate conditions as per specification.
B Curing shall be applied immediately after compaction and finishing and shall not be
delayed.
18.3.2 Execution
A Immediately after finishing, the concrete shall be protected by placing overlapped

polyethylene sheets of 500 gauge for the first 24 hours. Overlapping shall be at least
150mm.
B The polyethylene sheet shall be kept in contact or near contact with the surface of the
concrete and prevented from displacement by wind, foot traffic or other disturbances.

C After the first 24 hours, remove the polyethylene sheet. Overlapped hessian that has been
pre-wetted shall be placed in direct contact with the surface of the concrete. The hessian
shall be overlapped by at least 150mm.
D Cover the wet hessian immediately with polyethylene sheet overlapped by at least 150mm.
The overlapped edges of the polyethylene shall not be coincident with the overlapped
edges of the hessian underneath it.
E Secure the polyethylene and wet hessian against displacement by wind, foot traffic or other
disturbances.
F The concrete surface shall be kept wet or at 100% relative humidity continuously for a
period of at least 5 days.
G A system of wet drip plumbing akin to that used in the agricultural industry shall be
installed to keep the concrete wet.
H The system shall be monitored and managed. Corrections and adjustments shall be made
if necessary by a nominated staff and approved by the Engineer.
I For free standing vertical columns the polyethylene for the first 24 hours and the
polyethylene and wet hessian subsequently shall be wrapped helically and secured by
tying tightly against the column.
J Exposed free ends containing protecting reinforcements shall be protected and kept wet by
stuffing with crumpled strips of wet hessian and polyethylene into the spaces in between
the protruding reinforcements.
K Ponding shall not be allowed.
L Where pipes and cavities enter the structure the open areas of the pipes shall be stopped
with loose stuffing and the free openings taped up with polyethylene to prevent moisture
loss from the concrete surface into such cavities.
M In manholes or completely enclosed spaces it may only be necessary to keep the cavity
completely isolated and closed with a 10 litre bucket of water contained within. The
Engineer’s prior approval shall be sought before implementing this form of curing.
N Chemical curing membranes shall not be used unless the geometry is of such a nature that
there is no alternative upon which it shall be used with the prior approval of the Engineer. If
curing membranes are used, at least three of four coats shall be applied depending on the
nature and characteristics of the proprietary material.
18.3.3 Execution - Vertical Surfaces
A Refer to relevant Sections
A Protect finished Work as per specification.
B Do not permit traffic over unprotected floor surface.

PART 19 STRUCTURAL PRECAST CONCRETE
19.1 GENERAL
19.1.1 Summary
A This section specifies plant cast, architecturally finished glass fiber reinforced concrete and
includes, but is not limited to, the following:
a) Wall panels
b) Anchors and supports
c) Attachments
a) Cast-in-Place Concrete
b) Structural Precast Concrete
c) Unit Masonry System
d) Structural Steel Work
e) Metal Fabrications
19.1.3 References
Product manufacture, testing and installation shall comply with the following references,
unless otherwise stated in the specifications or unless otherwise approved by the
Engineer.
ASTM C494 Concrete Materials (Chemicals).
ASTM C979 Pigments for Integrally Colored Concrete.
PCI Recommended Practice for Glass Fiber Reinforced Concrete Panels.
PCI MNL-117 Manual for Quality Control for Plants and Production of Architectural
Precast Concrete Products.
BS 1014 Pigments for Portland cement and Portland Cement Products.
BS 6432 Method for determining properties of glass fiber reinforced cement material.
ACI 301 Structural Concrete for Buildings.
ACI 318 Building Code Requirements for Structural Concrete.
PCI MNL-116 Manual for Quality Control for Plants and Production of Pre- cast and Pre-
stressed Concrete Products.
PCI MNL-120 Design Handbook Pre-cast and Pre-stressed Concrete.
BS 5911 Concrete Pipes and Ancillary Concrete Products. Specification for
unreinforced and reinforced concrete products
BS 8110-1 Structural Use of Concrete: Code of practice for design and construction
BS EN 13369 Common rules for pre-cast concrete products

A Design unit to withstand all loading such as service, wind, suction, deflection, and thermal
movement loads and restraint conditions from initial fabrication to the completion of the
structure, including form removal, storage, transportation, and erection.
B Design system to accommodate construction tolerances, deflection of other building

structural members and clearances of intended openings.
C Design anchor bolts, inserts, plates, angles and other cast in items with sufficient
anchorage and embedment to support applicable loads.
B Submit Shop Drawings which will indicate layout, unit locations, configuration, unit
identification marks, reinforcement, connection and joints details, support items, bearing
seats, inserts, anchors, concrete cover, location of lifting devices, dimensions, openings,
embedded items and relationship to adjacent materials.
C Submit design calculations for the reinforcing, hoisting and connection and anchorage
devices.
D Do not proceed with the fabrication until the design calculation and the shop drawing are
E Submit a method statement for lifting, transporting, and erection of the recast units.
F Product Data: Indicate standard component configurations, design loads, deflections,

cambers, bearing requirements, and special design condition.
B Submit design data reports indicating calculations for loadings and stresses of fabricated,
designed framing.
C Submit quality assurance and quality control procedures for the fabrication of the pre-cast
units.
A Perform work as per specification and in accordance with the requirements of PCI MNL-
116, and PCI MNL-120.
B Design precast concrete members under direct supervision of a Professional licensed

Structural Engineer experienced in design of this work.
C Maintain plant records on production runs and make records available to the engineer
upon request.
19.1.8 Samples
A Representative samples, as agreed with the Engineer, must be submitted for at least the
following items at the same time as the particulars are submitted. Sample of pre-cast panel

as agreed with the Engineer to be representative of the Works to be constructed to
demonstrate adequacy of pre-casting operations.
19.1.9 Drawings
A The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the specification. These shall comprise but
not necessarily be limited to:
B Layout plans and detailed fabrication and placement drawings for each structural pre-cast
unit which shall include:
a) Reinforcement details.
b) Connection and anchorage details.
c) Lifting devices, locations and handling limitations.
d) Openings, sleeves, inserts and embedded items.
e) Precast concrete unit location.
f) Relationship to adjacent units and/or structures.
g) Pre-cast concrete unit identification number.
A Transport, handle, store, and protect products as per specfication:
B Handle pre cast members in position consistent with their shape and design. Lift and
support only from support points.
C Lifting or Handling Devices: Capable of supporting member in positions anticipated during

manufacture, storage, transportation, and erection.
D Protect members to prevent staining, chipping, or spilling of concrete.
E Mark each member with date of production and final position in structure.
19.2 PRODUCTS
19.2.1 Precast Concrete Yard Requirements
A Commercial and Site Pre-cast Concrete yards shall meet the requirements stipulated in the
checklists given in Appendix
19.2.2 Materials
A Cement: Cement is covered as per relevant specification.
B Aggregate materials covered as per relevant specification
C Water and admixtures are as per relevant specification.
A Reinforcing Steel: as per relevant specification.

19.2.4 19.2.4. Accessories
Not used
19.2.5 19.2.5. Mix
A Concrete: Class B as per relevant specification.
19.2.6 19.2.6. Fabrication
A Fabrication procedure to conform to PCI MNL-116.
B Maintain plant records and quality control program during production of recast members
and make these available to the Engineer upon request.
C Ensure that reinforcing steel, anchors, inserts, plates, angles, and other cast-in items are
embedded and located as indicated on Contract drawings.
D Place and vibrate concrete to ensure proper consolidation, elimination of cold joints, and
minimise entrapped air on vertical surfaces.
E Locate lifting devices to permit removal after erection.
F Observe the formwork while the concrete is being placed.
G Provide an individual number or letter for identification purposes for each mould and
ensure that the number or letter is either embossed on or recessed in to the mould so that
each unit cast in a particular mould will bear the identification of that mould.
H Provide date of casting the product, either scratched or painted on the unit.
I Test concrete for pre-cast units as per relevant specification.
J Place and compact concrete for pre-cast concrete units by means approved by the
Engineer.
K Ensure finish surfaces of pre-cast concrete units are uniform.
L Do not move or transport pre-cast concrete from the place of casting until an approved
curing period elapsed and the design strength has been attained.
19.2.7 Finishes
A Ensure exposed-to-view finish surfaces of pre-cast concrete members are uniform in

colour and appearance.
B Cure members under identical conditions to develop required concrete quality, and
minimise appearance blemishes such as non-uniformity, staining, or surface cracking.
C Architectural Finish (Finish C): Surface holes or bubbles over 1/4 inch (6 mm) filled with
matching cementitious paste, and fins or protrusions removed and the surface ground
smooth.
19.2.8 Fabrication Tolerance
A Fabrication tolerances on pre-cast units shall be as noted below:
a) Maximum Variation from Nominal Dimension: 25 mm.

b) Maximum Out of Square: 10-mm/3 m, non-cumulative.
c) N/A
19.2.9 Source Quality Control and Test
A Quality control and concrete testing will be carried out as per specification.
19.3 EXECUTION
19.3.1 Examination
A Verify that site conditions are ready to receive work and field measurements are as shown
on shop drawings or as instructed by the fabricator.
19.3.2 19.3.2. Preparation
A Prepare support equipment for the erection procedure.
19.3.3 19.3.3. Erection
A Erect members without damage to structural integrity, shape, or finish and replace or repair
damaged members.
B Maintain temporary bracing in place until final support is provided. Protect members from
staining.
C Level differential elevation of adjoining horizontal members with grout to maximum slope of
1:12.
D Grout between underside of unit and bearing surface.
E Lift pre-cast unit from the design lifting hooks.
F Secure units in place.
19.3.4 Erection Tolerance
A Tolerances: These shall be as per relevant specification.
B Erect members’ level and plumb within allowable tolerances.
19.3.5 Protection
A Protect members from damage caused by erection operations.

Table 22: Commercial precast concrete yard check list
1-TRSDC Form NO.
Precast concrete yard name: Location: Inspection date:
Compliance Comments
SN. Requirement
Yes No N/A (Obtain details where applicable)
A GENERAL
1. General Layout of Pre-Cast Area to Scale
The area of the yard shall be of sufficient size to accommodate the following
facilities,
● Rebar fabrication
2. ● Casting area
● Curing area
● Storage area
● Coating area
● Laboratory area
● Office for the Engineer’s representative
The yard boundary wall shall be min. 2.5m high for protection from wind-blown
3.
sand.
4. Contract specifications shall be available for casting units and shall comply with.
5. Approved shop-drawings of related ADSS Contract’s shall be available.
6. Form-works shall be clean, stable, water-tight and true to required dimension
7. Access gates shall be facilitated at suitable locations
The yard shall have concrete or asphalt paved flooring and be provided with
8.
elevated platforms
Red Sea Shura Program 7 Hotel Central #2 00 Page 130

Storm Water Technical Specification 30-Sept- 2021
1-TRSDC Form NO.
Compliance Comments
SN. Requirement
9. Covered roofing area shall be provided for green concrete sampling zones.
10. Water points shall be provided at convenient locations with easy regulating
valves and flexible hoses.
11. The yard shall be adequately illuminated and provided with overhead floodlights.
12. Adequate lifting and transportation equipment shall be facilitated.
13. Suitable pumps, conveyer buckets, chutes, hoppers and platforms shall be
properly prepared to the satisfactory in-time and easy casting of concrete.
The yard shall be equipped with sufficient number of poker vibrators, mould
14. mounted vibrators, vibrating table and sufficient additional working pokers as
spare.
Water used for curing and cleaning shall be in- compliance with the relevant
15.
standards. Provide details.
B Casting Area
1. Cast units identification numbering system shall be maintained
Handling, placing and stacking of post-cured units shall be in accordance with

2.
the int. code of practice. (Please Specify)

1-TRSDC Form NO.
Compliance Comments
SN. Requirement
3. Office facilities shall be provided for Engineer’s representatives.
4. Safety regulatory sign boards shall be available
5. Yard shall be clean from debris and dust
C Curing Area
The area shall be facilitated with effective water sprinklers and covering
1.
hessians, polythene sheets etc.
2. Water curing method shall be satisfactory to the int. code of practice. (please
specify)
3. Water supply shall be facilitated with proper storage capacity and as,
● Ground level tank capacity: minimum 4000 USG
● Over head tank capacity: minimum 2000 USG
● Overhead tank height: minimum 6m.
D Bar bending, Caging Area

1-TRSDC Form NO.
Compliance Comments
SN. Requirement
The area shall be provided with a suitable roof designed so as to accommodate

1.
the lifting and the transportation equipment.
2. The area shall have a raised floor for storage of rebars.
3. Bar bending, cutting machines and all relevant tools shall be available.
For Fusion Bond Epoxy coated (FBEC) rebars,

● Teflon mandrels shall be used of sufficient diameters as per relevant
4. standard.
● Approved touch-up epoxy material shall be available.
● Plastic coated tie-wire shall be used.
E Coating Area
1. The yard shall be fully covered, enclosed and properly ventilated.
The yard shall be equipped with the suitable equipment for surface preparation,
2. mixing and application in accordance with the coating manufacturer
recommendations.
Calibrated testing equipment shall be made available for the following,
● Humidity and ambient temperature measurement
3. ● Surface moisture and contact temperature measurement
● Coating thickness (WFT and DFT) measurement
● Pull – off test
● Holiday test
4. Applicators shall be trained and certified at least by the approved coating

1-TRSDC Form NO.
Compliance Comments
SN. Requirement
manufacturer. Provide certificates.
5. QC - Records shall be maintained. Provide details.
F Laboratory
1. Relevant International Standards for sampling and testing shall be available.
2. Curing water temperature shall be maintained at 22 +/- 2oC.
3. Relevant sampling and testing facilities shall be provided.
4. Placement of cubes in the curing tanks shall be as per the International Code of
practice. Provide details.
5. Qualified QC-technician shall be available for sampling and testing.
6. All measuring and testing instruments shall be calibrated.
7. Written sampling and testing procedures shall be available.
G Storage Area

1-TRSDC Form NO.
Compliance Comments
SN. Requirement
1. Storage areas shall be clean, well drained and stabilized.
2. Storage for paints, chemicals, rubber, sealants, etc. shall be air-conditioned, and
stored as per manufacturer recommendations.
UV sensitive products such as PVC-U, GRP shall be stored under shaded and
3.
ventilated area.
H Quality Control
1. QC Manual shall be available
2. Organization chart and responsibility matrix shall be available
3. Qualified QC Engineers & Inspectors shall be available at all

time.
4. Pre-cast units shall have unique identification serial numbers and casting dates.
5. Training plan and records for all activities shall be maintained.
Method statements and procedures for the following shall be available at the
yard.
6. ● Mould preparation
● Casting
● Demoulding

1-TRSDC Form NO.
Compliance Comments
SN. Requirement
● Handling
● Curing
● Repairing
● Coating
● Storage of materials and UV sensitive products
● Transportation
QC Records of following shall be available.

● Casting and sampling records.
7. ● Curing of concrete units.
● Repairs
● Testing of cubes.
● Coating
Current international standards and technical leaf-lets of chemicals, sealants,
8.
membranes, etc., shall be made available and accessible.
9. Operation and maintenance plan and records for plant and all equipment shall be
available.
10. NCR and CAR shall be maintained.

Table 23: Site Precast Concrete Yard Check List
2. TRSDC Form No.: Site Precast Concrete Yard Check List:
Contractor: Contract No. Location: Inspection Date:

Compliance Comments
SN. Requirement
Yes NO N/A (Obtain details where applicable)
A General
1. General Layout of Pre-Cast Area To Scale
2. Approved shop-drawings shall be available
The yard boundary wall shall be having protection from wind-

3.
blown sand.
The area of the yard shall be of sufficient size to accommodate
the following facilities,
4. ● Rebar fabrication
● Casting area
● Curing area
● Storage area
● Coating area
5. Access gates shall be facilitated at suitable locations
6. The yard shall have elevated concrete or asphalt paved flooring.
7. Covered roofing area shall be provided for green concrete

sampling zones.
Water points shall be provided at convenient locations with easy
8.
regulating valves and flexible hosepipes.
The yard shall be adequately illuminated and provided with
9.
overhead floodlights.
10. Adequate lifting and transportation equipment shall be facilitated.


Compliance Comments
SN. Requirement
Suitable pumps, conveyer buckets, chutes, hoppers and

11. platforms shall be properly prepared to the satisfactory in-time
and easy casting of concrete.
The yard shall be equipped with sufficient number of poker
12. vibrators, mould mounted vibrators, vibrating table and sufficient
additional working pokers as spare.
B Casting Area
1. Cast units identification numbering system shall be maintained
2. Handling, placing and stacking post-cured units shall be in

adequate with the methods approved.
3. Safety regulatory sign boards shall be available
4. Yard should be clean from debris and dust
C Curing Area
1. Sweet water (e.g. ADWEA) shall be adequately supplied for

curing, cleaning and cooling reinforcement.
2 The Area shall be facilitated with effective covering hessians,

polythene sheets etc.
3. Water supply shall be facilitated with proper storage capacity.
D Bar bending, caging Area
1. The area shall be provided with a suitable roof designed so as to

accommodate the lifting and the transportation equipment.


Compliance Comments
SN. Requirement
2. The area of the yard should be of sufficient size
The reinforcement shall be stored at elevated platform and shall

3.
be completely wrapped.
Bar bending, cutting machines and all relevant tools shall be
4.
available.
5. The area shall have a raised floor for storage of rebar.
E Coating Area
The yard shall be of sufficient area and shall have sufficient

1.
protection against wind-blown sand, dust.
The yard shall be equipped with coating manufacture’s
recommended equipment. And shall be provided with facilities of
2.
wire brush, stone abrasion tools, compressed air, pressure water
jetting, etc.
Calibrated testing equipment shall be made available for the
following,
3. ● Hygrometer
● Surface moisture and contact temperature meters
● Coating thickness (DFT and WFT) measuring tools
● Pull – off Tester
4. Applicators shall be trained and certified at least by the approved

coating manufacturer. Provide certificates.
Experienced and qualified personnel shall supervise the coating
5.
work.


Compliance Comments
SN. Requirement
6. QC - Records shall be maintained. Provide details.

F Laboratory
Curing water temperature shall be maintained at 22

1.
+/- 2oC.
Minimum sampling facilities like green concrete sampling cube
2. preparation slump and temp. Check and wet density checks, etc.,
shall be provided.
3. All measuring and testing instruments shall be calibrated.
Qualified QC-technician shall be available for sampling and

4.
testing.
5. Written sampling and testing procedures shall be available.
G Storage Area
1. Are storage areas shall be clean and well drained.
Storage for paints, chemicals, rubber, sealants, etc. shall be air-

2.
conditioned, and stored as per manufacturer recommendations.
UV sensitive products such as PVC-U, GRP shall be stored
3.
under shaded and ventilated area.
H Quality Control
1. Qualified QC inspector shall be available
2. Control and testing methods shall be defined


Compliance Comments
SN. Requirement
In-house and routine test results shall be properly filed and up to

3.
date.
Method statements and procedures for the following shall be
available at the yard.
● Mould preparation
● Casting
4. ● De-moulding
● Handling
● Curing
● Repairing
● Coating
● Storage of materials and UV sensitive products
● Transportation
QC Records of following shall be available.
● Casting and sampling records.
5. ● Repairs
● Curing of concrete units.
● Testing of cubes.
● Coating
Current international standards shall be made available and
6.
accessible.
Daily mould and cast repair and delivery check sheets shall be
7.
available.
8. NCR and CAR shall be accessible

PART 20 CONCRETE REPAIR
20.1 GENERAL
20.1.1 Scope and General Requirements
A This section of the specification gives the requirements for concrete repair.
B The repair system to be utilized for a particular area or member will be subject to a trial
demonstration as designated by the Engineer and will generally be as follows:
C Epoxy fillers shall be utilized to fill small cavities and pinholes on all concrete surfaces to
receive epoxy coating.
D Epoxy and cementitious repair mortars shall be utilized for small surface repairs.
E Shotcrete, concrete and micro concrete shall be used for large, deep repairs.
F Cracks up to 0.3mm wide shall be filled with an epoxy filler or epoxy crack injection resin.
G Cracks or joints which are leaking shall be injected with a polyester resin.
A The following sections of the specification shall be read in conjunction with this section.
a) Concrete formwork
b) Concrete reinforcement.
c) Cast in place concrete.
d) Concrete protection and waterproofing systems.
20.1.3 Standards
A All activities relating to this section of the specification shall comply with the following or
approved equal standards.
ACI 506 Guide to shotcrete.
ACI 506.2 Specification for shotcrete.
ACI 506.3 Guide to certification of shotcrete nozzlemen.
ACI 506.4 Guide for the evaluation of shotcrete.
ACI 548.1 Guide for the use of polymers in concrete.
ASTM C157 Standard test method for length change of hardened hydraulic- cement, mortar
and concrete.
ASTM C881 Standard specification for epoxy resin base bonding systems for concrete.
ASTM C1202 Standard test method for electrical indication of concrete’s ability to resist
chloride penetration.

BS 1881 Testing Concrete
BS 4449 Steel for the reinforcement of concrete. Weldable reinforcing steel. Bar, coil and
decoiled product. Specification
BS 4551 Mortar. Methods of test for mortar. Chemical analysis and physical testing.
BS 4652 Specification for zinc rich priming paint (organic media).
BS 6319-2 Testing of resin and polymer/cement compositions for use in construction.

Method for measurement of compressive strength.

Methods for measurement of modulus of elasticity in flexure and flexural
strength.

Method for measurement of tensile strength.
BS 6744 Stainless steel bars for the reinforcement of and use in concrete. Requirements
and test methods.
ISO 17660-1 & 2 Specification for metal arc welding of steel for concrete reinforcement.
BS EN 1542 Products and systems for the protection and repair of concrete structures. Test
methods. Measurement of bond strength by pull off.
BS EN 12390-3 Testing hardened concrete. Compressive strength of test specimen
CIRIA R092M Reinforcement connector and anchorage methods.
20.1.4 Submittals
A In order to verify compliance with the specification the Contractor shall submit information
approval times. Reference shall also be made to relevant specification on products and
materials approval. Information to be submitted shall comprise but not necessarily be
limited to:
Repair materials.
a) Manufacturers name.
b) Suppliers name.
c) Product name (if applicable).
d) Product description.
e) Manufacturer’s technical data.
f) Manufacturers guarantee
g) Manufacturer’s statement that the material is suitable for the intended purpose.
h) Mix design.
i) Test results or certificates.

j) Storage instructions.
k) Application instructions.
l) Product health and safety requirements.
m) Endorsements of previous long term successful usage.
Once materials have been approved, substitution will not be permitted unless otherwise
agreed by the Engineer.
A The Contractor shall submit method statements to the Engineer for approval 4 weeks in
advance of commencing the trial and demonstration repairs in accordance with the
specification. These shall comprise but not necessarily be limited to:
B Procedures for surface preparation and application of repair materials for all concrete
repair methods including reinforcement cleaning and coating.
C Procedures for mixing and application of shotcrete.
D Procedures for crack injection.
E Procedures for coating application.
F Statements shall, if relevant, address at least the following points.
a) Description of problem.
b) Description of how the proposed materials will prevent a recurrence of the problem.
c) The projected life of the repair.
d) Identification of the expertise and skills required to perform the repair.
e) Identification of the workforce with the required expertise and skills.
f) Pre works precautions and planning.
g) Safety arrangements.
h) Substrate preparation.
i) Work schedules.
j) Materials application plan with descriptions and methods.
k) Equipment and tools.
l) Finishing operations.
m) Removal of debris and cleaning.
n) Quality control forms and schedules.
o) Inspection and approval forms.
p) Measurements techniques and methods.
q) Records and forms list and samples.
r) Acceptance by material manufacturers.
s) CV’s of qualified supervision staff.
t) Material, location and sample labeling system.
u) Scheduling and project management report format.
G The Contractor shall follow the approved method statements. No change to the method
statements shall be allowed unless otherwise approved by the Engineer. Proposals for

revisions to the method statements shall be submitted for the Engineer’s approval. The
Engineer may require to alter the work sequence and method statement if he deems it
necessary or if the Contractor has made omissions, deviated from the proposed plan or
caused damage deliberately or accidentally to sound structures.
H The Contractor shall bear all costs in the latter event.
20.1.4.3 Drawings
A The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with Section 01300 of the specification. These
B Drawings of repair areas showing the location, size, depth and proposed repair method.
20.1.4.4 Mock Up
A Provide a mockup of each type of proposed concrete repair method as directed by the
Engineer for the Engineers approval.
B Mock up shall be of sufficient size to illustrate repair method, colour and texture of repair
surface.
20.1.4.5 Progress Reporting
A The Contractor shall submit a detailed and summary work schedule showing all activities
to be carried out for the Engineers approval.
B The Contractor shall submit to the Engineer daily progress reports. The progress report
shall include a description of activities carried out, materials delivered and used on site,
test results, safety records, problems encountered and the approved solutions.
C Weekly reports shall be submitted to include but not be limited to an updated work
schedule reflecting the actual progress of the works, a summary statement of the salient
points in the daily progress reports and dated photographs comprising a set of negatives
and 150mm X 100mm prints
20.1.4.6 Quality Control
test the product and/or material prior to delivery in accordance with the specification.

system, which is registered to ISO 9000 series or approved equal.
C To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours notice of carrying out the following activities on site:
a) Removal of areas of defective concrete.

b) Commencement of surface preparation.
c) Repair of reinforcement.
d) d.Application of repair method.
e) Application of final protective coating.
D Only specialist contractors thoroughly familiar with concrete repair techniques shall carry
out the work.

E The Contractor shall appoint a QA/QC Engineer approved by the Engineer. The QA/QC
Engineer shall be conversant with the aims of quality control, the materials being used in
the contract and the levels of workmanship required.
F The Contractor shall be responsible for all testing as specified and shall supply the
Engineer with the test results immediately after completion of the tests. Cost of all testing
including those for trial purposes shall be borne by the Contractor.
G The level of quality and workmanship required and that will be imposed on the work is
high. The Contractor shall ensure that materials, systems and skilled personnel are
sourced with the level of quality and workmanship required of the works.
H Cost of testing carried out which is not in accordance with the specification or of
unapproved items shall be borne by the Contractor.
I Samples shall be taken, and testing shall be conducted, in locations and at intervals
stipulated by the Engineer. The Engineer shall witness all sampling and testing unless he
decides otherwise.
J All samples shall be properly labelled and secured at site and accompanied by the
Engineer during transportation to the testing laboratory.
K All repair works shall be carried out in the presence of the Engineer unless prior
agreement otherwise is obtained from the Engineer.
L The Contractor shall keep a daily record of the maximum and minimum ambient
temperature and relative humidity in the application areas.
M The number, frequency and selection of tests prescribed in the documents and the
Engineer’s study is a reflection of the depth of inquiry and the quality expected of the
respective works and shall be binding on the Contractor. Depending on circumstances, the
Engineer may require additional tests to be conducted to satisfy himself on material,
workmanship or adequacy of the repair.
N Existing structures, machinery or devices associated with the repair areas such as
pipelines, pumps, chambers shall not be damaged during the repair period. The Contractor
shall take all precautions to safeguard these. Any damage shall be made good to its
original condition at the Contractors own cost.
O All damage caused by in-situ destructive testing shall be repaired using the approved
materials and to the Engineer’s satisfaction.
20.1.5 Delivery, Storage and Protection
A Delivery, storage and handling of products and materials shall be in accordance with the
manufacturers recommendations, as per the specification and the following provisions:
B Delivery, storage and handling shall at all times be performed in a manner to avoid product
damage.
C Store materials on a flat level area and raised above the ground on timber bearers.
D Where product manufacturer recommends storage under controlled temperatures, the

Contractor shall provide an enclosed, insulated cool store maintained at the proper
temperature at all times.
E If stored outside, store materials under opaque cover and out of direct sunlight at all times.
Maintain a free flow of air around the materials at all times.

F Bulk mixed shotcrete shall be suitably stored on polythene sheets and kept covered with
additional sheets to provide complete protection as directed by the Engineer and be used
within 3 days unless otherwise agreed by the Engineer.
G The Contractor shall visually inspect all products upon delivery to site and report any
a) Any products damaged during delivery, storage and handling shall be marked by the
b) Proposals for repair of any damaged products shall be submitted in writing to the
Engineer for approval.
c) Any damaged products deemed unsuitable for repair by the Engineer shall be
removed from site and replaced.
d) All products shall be clearly labeled with date of manufacture and shelf life or date of
expiry. Any expired products shall be removed from site.
20.1.6 Warranty
A The manufacturer and the Contractor shall jointly guarantee the completed repairs to be
free from defects in materials and workmanship for a period of 10 years from the date of
completion of the Works.
B The Contractor shall furnish the Engineer with the manufacturer’s guarantee and warranty
certificates for all materials and components used.
C If the concrete repairs are found to be defective during the warranty period, the
manufacturer and Contractor shall replace and/or repair the concrete to the satisfaction of
the Engineer.
20.2 PRODUCTS
20.2.1 Epoxy Fillers
A Epoxy fillers shall be two component solvent free epoxy resin compounds, suitable for
repair of small activities, pinholes, offsets or imperfections.
B All fillers shall be special purpose products manufactured in premeasured quantities for
easy site mixing.
C Bonding agents and ancillary products shall be as recommended by the manufacturer,

unless otherwise directed by the Engineer.
D Epoxy fillers shall meet the requirements of ASTM C881, Type 1, Grade 3, classes B and
C.
20.2.2 Epoxy Repair Mortar
A Epoxy repair mortar shall be a two-part epoxy resin mortar suitable for use in the climatic
conditions prevailing in Fujairah with regard to pot life, useable life of freshly mixed
components and curing.
B Mortar shall be packaged in pre-measured quantities for easy site mixing.
C Bonding agents and ancillary materials shall be as recommended by the manufacturer.

D Mortar shall have a minimum compressive strength of 50N/mm2 at 7 days when tested in
accordance with BS 6319-2.
E Mortar shall have a minimum tensile strength of 10N/mm2 at 7 days when tested in
F Mortar shall have a rapid chloride penetration of 1000 coulombs maximum when tested in
accordance with ASTM C1202.
20.2.3 Cementitious Repair Mortar
A Cementitious repair mortar shall be a single component general purpose concrete

reinstatement mortar exhibiting the following characteristics.
B Low permeability to provide good protection against carbon dioxide and chloride
penetration.
C Excellent bond to the concrete substrate.
D Shrinkage compensated.
E Pre bagged to overcome site batched variations requiring only the site addition of potable
water.
F Contains no chloride admixtures.
G Bonding agents and ancillary materials shall be as recommended by the manufacturer.
H Minimum compressive strength of 28N/mm2 at 28 days when tested in accordance with

BS 6319-2.
I Rapid chloride penetration of 1000 coulombs maximum when tested in accordance with
ASTM C1202.
20.2.4 Polymer Modified Cementitious Repair Mortar
A Polymer modified cementitious repair mortar shall be a single component lightweight

polymer modified concrete reinstatement mortar exhibiting the following characteristics.
B Lightweight formulation to allow high build.
C Low permeability to provide good protection against carbon dioxide and chloride
penetration.
D Excellent bond to the concrete substrate.
E Shrinkage compensated.
F Pre bagged to overcome site batched variations requiring only the site addition of potable
water.
G Bonding agents and ancillary materials shall be as recommended by the manufacturer.
H Contains no chloride admixtures.
I Minimum compressive strength of 40N/mm2 at 28 days when tested in accordance with

BS 6319-2.

J Rapid chloride penetration of 1000 coulombs maximum when tested in accordance with
ASTM C1202.
20.2.5 Shotcrete
A Pre-bagged shotcrete shall be a single component cementitious material suitable for dry or
wet mix applications with the properties given in Table 24 below.
B A suitable approved fibre shall be added to the shotcrete to reduce crack propagation.
a) The use of fibre shall be strictly in accordance with the manufacturer’s instructions
and as approved by the Engineer.
b) Prior to the approval of shotcrete the Contractor shall carry out trials mixes in the
presence of the Engineer.
Table 24: Shotcrete Properties

Property Test Method Value
Max aggregate size - 12.5mm
Min compressive strength BS 4551-1 40 N/mm2 at 28 days
Min flexural strength BS 6319-3 10 N/mm2 at 28 days
Min tensile strength BS 6319-7 5 N/mm2 at 28 days
Water absorption BS 1881 < 2%
< 300 microstrain at 7 days

Drying shrinkage ASTM C157
< 500 microstrain at 28 days
Rapid chloride penetration ASTM C1202 1000 coulombs max
C Bulk mixed shotcrete compliant with the recommendations of ACI 506.2 may be utilized in
lieu of pre-bagged shotcrete, if approved by the Engineer.
D Aggregates shall meet the requirements in relevant specification except as modified

hereunder.
E The combined grading shall be within the limits given in Table 25 below unless otherwise
agreed by the Engineer.
Table 25:Shotcrete Aggregate Grading

Sieve Size (mm) Percent Passing
12.5 100
9.5 90-100
4.75 70-85
2.36 50-70
1.18 35-55

Sieve Size (mm) Percent Passing
0.6 20-35
0.3 8-20
0.15 2-10
F Suitable approved fibre shall be added to the shotcrete to reduce crack propagation.
a) The use of fibre shall be strictly in accordance with the manufacturer’s instructions
and as approved by the Engineer.
b) Prior to the approval of shotcrete the Contractor shall carry out trials mixes in the
presence of the Engineer.
G Minimum cement content shall be 415 kg/m3.
a) Type of cement shall be ASTM Type I, unless otherwise approved by the Engineer.
b) Shotcrete shall have the properties given in Table 9-1 above.
c) The temperature of the mix shall not be more than 32ºC.
d) Where applicable shotcrete shall comply with the ACI 506, ACI 506.2, ACI 506.3,
ACI 506.4 and ACI 548.1.
e) Prior to the start of the work each nozzle man will be subject to certification by the
Engineer in accordance with ACI 506.3
f) The Contractor has to spray shotcrete in to the approved moulds for cutting cores.
Cores shall be taken as directed by the Engineer for the specified tests.
g) The Contractor shall be allowed to start the works only after the Engineer has
approved the materials mix design, nozzlemen and the site procedure including
mixing procedure.
h) The finished surface shall be smooth, free from voids, cracks, honeycombing, and
suitable for the application of surface coatings or other finishes as applicable.
20.2.6 Concrete
A Requirements for C40/10 concrete shall be in accordance with specification.
20.2.7 Micro-Concrete
A Shall be supplied as a pre-bagged special purpose product requiring only the addition of a
pre-determined volume of water at site to produce a mix of predictable performance.
B Micro-concrete shall be a single component, shrinkage controlled, free flowing concrete

without segregation of the materials with the properties given in Table 26 below.
Table 26: Micro-Concrete Properties

Min compressive strength BS 4551 60 N/mm2 at 28 days
Min flexural strength BS 6319-3 9 N/mm2 at 28 days
Min tensile strength BS 6319-7 5 N/mm2 at 28 days

Water absorption BS 1881 < 2%
< 300 micro strain at 7 days

Drying shrinkage ASTM C157
< 500 micro strain at 28 days
Rapid chloride penetration ASTM C1202 1000 coulombs max
C Bonding agents and ancillary material shall be as recommended by the repair material
manufacturer, unless otherwise directed by the Engineer.
20.2.8 Epoxy Lining Mortar
A Epoxy lining mortar shall be a heavy duty, high strength, durable, chemical and abrasion
resistant trowel-applied epoxy resin lining mortar with the physical properties given in
Table 27 below.
Table 27:- Epoxy Lining Mortar Properties

Compressive strength BS 6319-2 70 N/mm2
Flexural strength BS 6319-3 28 N/mm2
Tensile strength BS 6319-7 12 N/mm2
Density - 1750 kg/m3
20.2.9 Concrete Coating Systems
A Coating systems for concrete shall comply with the specification.
A Reinforcement shall comply with the requirements the specification.
20.2.11 19.1.16 Coating to Reinforcement
A Coating to reinforcement shall be a single component zinc epoxy primer meeting the
requirements of BS 4652 Type 2 with a minimum zinc content of 85% dry film.
20.2.12 Epoxy Crack Injection Resins
A Epoxy crack injection resins shall be two part epoxy resins suitable for use in the climatic
conditions prevailing in Abu Dhabi with regard to pot life and curing and shall be generally
used for structural repairs
B The resin and hardener shall be pre-packaged.
C Resins shall have a minimum compressive strength of 70 N/mm2 at 7 days when tested in

20.2.13 Polyester Crack Injection Resins
A Polyester crack injection resins shall be two part polyester resins suitable for use in the
climatic conditions prevailing in Abu Dhabi with regard to pot life and curing and shall
generally be used for stopping water leakage.
B The resin and catalyst shall be pre-packaged.
C The end product shall be a foam, gel or solid according to the specific repair requirement
as agreed by the Engineer.
20.3 EXECUTION
20.3.1 Condition Survey
A A detailed study of the condition of the structures shall be carried out by the Contractor
under the direction and supervision of the Engineer. The detailed condition survey shall be
carried out to the satisfaction of the Engineer.
B The condition survey shall include testing to assess the quality and mechanical properties
of the concrete and reinforcing steel in a structure.
C Test samples shall be obtained by core sampling using diamond studded bits and by
random sampling of broken concrete.
a) The number, size and location of core samples shall be selected to permit all
necessary laboratory tests and be agreed with the Engineer.
b) The core diameter for strength properties shall have a minimum diameter of three
times the maximum aggregate size, or 50mm, whichever is the greater.
c) The core length for testing of strength property shall be a minimum of twice the
diameter. Allowance shall be made for possible break off damage at the base of the
core where the core does not completely penetrate the structure. Reinforcement
shall not be included in a core that is to be tested for strength. A minimum of three
cores shall be removed at each location to determine strength. The average value
shall be used.
d) Small bore core samples may be used for chemical sampling.
e) Samples of broken concrete shall not be used to determine the strength of the
concrete. Random samples of broken concrete shall only be used to determine the
chemical properties of the deteriorated concrete.
D The following properties of aggregates shall be determined by petrographic evaluation of

concrete samples as agreed with the Engineer.
a) Particle shape, size distribution and composition.

b) The extent to which particles are coated, and the nature of the coating substance.
c) The potential for deleterious reactions between the aggregate and cement alkalis,
sulphates and sulphides.
d) Presence of unsound aggregate (fractured, porous and degree of weathering).
E The following properties of the concrete shall be determined by petrographic analysis as

agreed with the Engineer.
a) The density of the paste and colour of the cement.

b) Homogeneity of the concrete.
c) Occurrence and distribution of cracking.

d) Characteristic and distribution of voids.
e) Presence of contaminating substances.
f) Proportion of un-hydrated cement.
g) Presence of mineral admixtures.
h) Volumetric proportion of aggregates, cement paste and air voids.
i) Air content and various dimensional characteristics of the air void system.
j) Weathering pattern from surface to bottom.
k) Presence of deterioration due to abrasion, chemical or fire exposure.
F The following chemical properties of the concrete shall be determined by chemical tests as
a) Chloride ion content.

b) Sulphate content.
G Where destructive testing of specimens of reinforcement steel is required, the samples
should be removed as follows:
a) At location of minimum stress in the reinforcement.

b) No two samples shall be removed from the same cross section of a structural
member.
c) Samples shall be a minimum of 400mm long.
H Non-destructive testing of concrete surface shall consist of:
a) Delamination tests to determine and map areas of delamination.

b) Cover meter reading and recording of the results to determine the depth of
reinforcement. This shall be undertaken in 1m2 panels.
I A condition survey report shall be prepared for submission to the Engineer. The report
shall include the results of the testing with laboratory report, photographs, drawings and
recommended repairs in accordance with this section of the specification. Two copies of
the condition survey report are to be submitted to the Engineer.
20.3.2 Repair Strategy
A Upon receipt of the condition survey report the Engineer shall study the same and give his
written instructions backed up by marked up copies of plans showing the repairs to be
carried out.
B Depending on the nature, location and extent of defects the Engineer will need time to
construct the appropriate instructions for the repairs. The Engineer may need to carry out
further selected investigations, calculation, and analysis, hold meetings and seek
approvals through the various bodies. The Contractor shall therefore in his programme,
allow the Engineer a reasonable period of time of not less than 14 days to carry out his
study, analysis and repair strategies and to formulate the necessary instructions. For this
reason the Contractor must notify the Engineer immediately of any unreasonable delay or
disruption that the Contractor may envisage due to late instructions by the Engineer. Any
claim citing late instructions by the Engineer as a cause will not be considered unless
written notifications with satisfactory proofs have been forwarded to the Engineer
immediately after the cause has occurred. The Contractor shall not claim ignorance of the
event as a justification for his delayed or late submission of claims.
C The repair strategy shall be determined by the Engineer. This shall include but not be
limited to the following:

a) Concrete to be repaired and methods proposed based on the approved system.
b) Basis for concrete removal and replacement. This shall extend to areas of concrete
contaminated with aggressive agents such as chlorides, sulphates, physical defects
such as spalling, cracking and rust staining; chemical deterioration such as alkali-
silicate reaction, carbonation, magnesium and sulphate attack; or any other form of
attack.
c) Extent and limitations and pre-repair preparations.
d) Repair systems and materials to be used.
e) Management and supervision.
f) Quality control.
D On receipt of the repair strategy from the Engineer, the Contractor shall prepare detailed
methodologies for undertaking the repair. These shall include, if appropriate, safeguards,
including structural support system, before staged removal of the defective areas of
concrete.
20.3.3 Trial and Demonstration Repairs
A In order to ensure that materials, equipment and methods of application proposed by the
Contractor are suitable for the intended purpose, trial and demonstration repairs shall be
carried for each and every application and scenario prior to commencement of the actual
work. Tests shall be carried out regarding materials. Testing programmes shall be
dependent on the material, application and exposure. Methods are therefore subject to
modification and change depending on the trial results.
B No work shall start until successful trials have been carried out and the test reports have
been studied, analyzed and approved by the Engineer.
C Sample trial repairs for approval shall be undertaken for each type of designated repair or
system not less than six weeks before the relevant work is scheduled to begin. Trial
repairs shall be carried out using the same materials intended to be used in the works. If
any of the materials, system or formulas are changed during the course of the works new
trials shall be carried out.
D The Contractor shall ensure that the operators he selects have the necessary skills to
complete the application in a professional manner. In the event the Contractor is unable to
recruit skilled staff, he shall propose a professional subcontractor.
E Trial repairs shall be assessed by the Engineer to ensure that the required standards will
be achieved with the materials, methods and workmanship proposed and demonstrated by
the Contractor. Trial repair areas shall be used as a standard against which subsequent
work shall be compared and judged.
F Sample repairs shall be chosen, as far as it is reasonably possible to emulate the

geometry, complexity and orientation of the structure to be repaired.
G The Contractor shall prepare a complete record of the trials, to include but not be limited to
the following:
a) Date, time, location of trials and ambient conditions.

b) Method of substrate preparation and standard.
c) Materials used together with the mix proportions.
d) Equipment and tools used.
e) Material handling, mixing and application methods and records.

f) Man hours expended.
g) Location and name of laboratory and results.
h) Expert interpretation, analysis, conclusions and informed opinion and knowledge.
i) Record omission, difficulties, failures and defects.
H On submission of the trial report, the Engineer shall review the report and add his
comments and instructions accordingly.
I Until the Contractor proves that the trials have been carried out to the requirements of the
specification and to the Engineer’s satisfaction, no permanent repair works will be allowed
to begin.
20.3.4 Removal of Areas of Defective Concrete
A Areas to be repaired shall be surveyed, inspected and marked out by the Contractor in
accordance with the preliminary repair maps accompanying the Engineer’s instructions.
B Prior to commencement of concrete removal the Engineer shall inspect the area marked,
verify and issue instructions accordingly.
C The Contractor shall map the depth of the reinforcement using an electronic cover meter
over the area to be repaired before cutting the concrete. Each repair area shall be cut in a
series of straight lines on the surface to a depth of approximately 25mm, 10mm for repairs
using epoxy mortar, using a disc cutter or similar. The concrete shall be chipped out to the
depths required. The exposed concrete surfaces shall be roughened and cleaned by sand
blasting followed by high pressure water wash at the same time as cleaning the
reinforcement.
D No cutting out of either reinforcement or concrete shall be carried out without the
Engineer’s approval. Before cutting out an area the Engineer shall check that the structure
is safe or made safe by propping or other suitable means.
E Where the cover is low, disc cutting shall be omitted or limited in order to avoid damage to
the reinforcement. Care shall be exercised when roughening the disc-cut surfaces to
prevent damage to the surrounding sound concrete.
F The power, size and suitability of the equipment used for concrete removal shall be
relevant to the demands of the individual repair and shall be subject to the approval of the
Engineer. Where percussive equipment is used particular care shall be taken to ensure
that damage is not caused to adjoining sound concrete substrate and reinforcement.
G Where there are environmental constraints, it may be necessary to use environmentally

friendly methods.
H Where concrete is to be replaced by shotcrete the slope of the cut out shall be
approximately 60o to the surface of the sound concrete.
I Loose aggregate and concrete pieces shall be removed by light chipping hammers, stone
chisels and bolsters.
J Concrete in repair areas shall not be removed to expose the main reinforcement unless it
is required and instructed by the Engineer.
K The repair area shall be initially cleaned by oil free compressed air. The area shall be
inspected by the Engineer and the Engineers instructions shall be followed.
L Additional concrete removal shall be carried out in any of the following circumstances:

a) Remove concrete to assess condition deeper inside the concrete.
b) When the reinforcement is badly corroded and requires full exposure to allow
replacement if necessary.
c) If it is found that the carbonated depth has not been fully cleaned out.
d) Where reinforcement has corroded and adjacent continuous length of 50mm of
corrosion free reinforcement needs to be exposed. The boundaries of active
corrosion areas shall be assessed by the Engineer.
e) An additional length of un-corroded bar, up to 200mm, shall be broken out if
couplers are to be used for replacement reinforcement.
f) If concrete surrounding the exposed area is not sound or is contaminated.
g) When chloride initiated corrosion is evident and not completely cut out.
h) When insufficient cover to the reinforcement is noted and that reinforcement is of
small diameter to allow the reinforcement to be pushed back to provide enough
cover.
i) When the reinforcement has become loose as a result of cover removal operations
and the concrete needs to be cut back to areas of sound embedment.
M When instructions are given to cut concrete behind the embedded reinforcement a
minimum gap of 20mm shall be created behind the reinforcement to allow the full
circumference of the reinforcement to be sand blasted as specified. Removal shall not be
more than 50mm measured from the back of the reinforcement.
N The extent of concrete removal shall be agreed by the Engineer before any reinforcement
preparation and repair commences.
O All necessary precautions shall be taken to ensure that dust or falling debris does not
constitute a hazard to personnel, equipment, the structure and the general public. Effective
means of clearing dust and debris away from the working area shall be continuously
implemented. Repair work shall not be allowed amidst debris, dust, waste and rubbish.
P The extent and depth of concrete removal required shall be measured and recorded on
drawings by the Contractor and verified by the Engineer as the work proceeds.
20.3.5 Repair of Reinforcement
A The Contractor and Engineer shall assess the extent and type of deterioration in the
affected area. If the structural appraisal indicates that the area requires to be strengthened,
the Engineer shall so instruct.
B Additional reinforcement shall generally be of the same size and type as the reinforcement
to be replaced and shall be in accordance with the specification.
20.3.5.1 Provision for Extra Reinforcement Using Straight Laps
A Where existing concrete remains bonded to the main bars, no breaking out shall take place
to provide lap lengths for supplementary reinforcement unless applied loads are relieved
by temporary propping. If propping is not feasible then other methods of strengthening the
member should be considered. Lap lengths should be a minimum of 40 times the
reinforcement bar diameter and be greater if the repair material does not provide a bond
strength equivalent to that of the substrate concrete.
20.3.5.2 Provision for extra reinforcement which is anchored
A Extra reinforcement may be installed with reduced lap lengths by anchoring the ends at
90o to the concrete face. The ends shall be grouted into holes drilled into the concrete
using resin or cementitious mortars. Care must be taken to avoid damaging adjacent areas

where the existing reinforcement to concrete bond remains intact, unless the structure or
member can be temporarily propped or as agreed by the Engineer. Bond and bearing
stresses of the anchors shall be adequate.
20.3.5.3 Provision for Extra Reinforcement Using Connectors
A This method of supplementing reinforcement may require greater access around the
reinforcement in order to make the connection. The finished connections will in some
cases significantly reduce the cover to the reinforcement.
B The connector shall be capable of transferring all the forces in the reinforcement and the
properties of the connected reinforcement shall correspond as closely as possible to those
of the original reinforcement.
20.3.5.4 Provision for Extra Reinforcement Using Welding
A Site welding of reinforcement shall be avoided if alternative methods of repair are

available.
B If site welding is to be carried out the following essential features shall be included in the
programme of work:
a) The relevant standard shall be applied.

b) A written procedure shall be agreed before work commences, covering method, type
of welding, competencies, sampling and testing.
c) Qualification tests to certify all welders shall be carried out both before the beginning
of the work and at intervals during the course of work.
d) A quality control program shall be instituted which shall include visual assessment,
tensile testing, radiographic inspection and other non-destructive testing.
e) Reference shall be made to EN ISO 17660 and CIRIA report 92.
f) In some cases it may be necessary to dowel in additional small diameter
reinforcement to anchor back repairs to corners and arises. If adequate cover
cannot be obtained reinforcement shall be of stainless steel to BS 6744. The method
of doweling in reinforcement shall be approved by the Engineer.
g) All stainless steel reinforcement shall be pickled and passivated to approved
methods before installation.
C When instructed by the Engineer, all tie rod inserts, tie wires, chairs, steel spacers and
other accessories shall have a concrete cover of 40mm.
D Rust, scale, corrosion products and other deposits shall be removed from exposed
reinforcement in the area of repair by grit blasting to achieve SA 2½.
E Consideration shall be given to the protection of the general public and the immediate
environs from grit and dust nuisance, noise pollution, undue disturbances and
considerations of respect for quiet periods.
F Grit blasting shall be carried out in such a way as to enable the shadow faces at the backs
of bars and at intersections of bars to be cleaned to the same standard.
G Grit blasting abrasives shall be new, clean, dry and of a grade suitable for the preparation
of steel to the standard indicated above. Abrasives shall be of a type approved by the
Engineer. Exhausted abrasive shall be bagged up and removed from site.
H Equipment shall be capable of delivering abrasives at a nozzle pressure sufficient to

achieve the standard of cleaning specified above and the air supply shall be free of
entrained oil and water.

I All reinforcement shall be adequately fixed and tied in position such that it will not be
displaced during the repair process. The clear distance between newly placed
reinforcement and existing reinforcement shall be 35mm for shotcrete applications.
J All sand blasted areas shall be washed with high pressure washing and dried prior to
coating of reinforcement.
K Reinforcement in the repair area shall be primed using a single component zinc rich epoxy
resin, which shall be an active type capable of avoiding the generation of incipient anodes
and shall be fully compatible with the repair material. The reinforcement shall be in surface
condition SA2½ at the time of application of the primer. Any reinforcement not meeting this
standard shall be reblasted before the protective system is applied.
L The number of coats, time between coats, mixing and application of the reinforcement
protective system shall all be in accordance with the manufacturer’s instructions.
M Damaged epoxy coated reinforcement shall be repaired in accordance with the epoxy
coating manufacturers recommendations.
N Concrete repair shall not proceed until 7 days have elapsed after the application of the zinc
rich primer or epoxy coating repair.
20.3.6 Concrete Repair General Requirements
A The Contractor shall ensure that the ambient conditions are suitable for the application of
the repair materials. The suitability of ambient conditions during application are either
stipulated for the generic class of materials or is dependent on the manufacturer’s
statements. The Contractor shall submit the relevant information in each case. Bonding
polymers shall be used in bonding new cementitious products to old matured concrete.
Bonding polymers must be suitable for external environments. The polymer must be un-
saponifiable if embedded or laid on concrete surfaces.
B Where breaking out of concrete is not required the surface to be repaired shall be
roughened and any laitance removed by sand blasting.
C All surfaces to receive repair material shall be clean and free from dust, unsound or
contaminated material, oil, paint, grease, corrosion deposits and algae.
D The substrate should be primed and the agreed material to be used for the repair mixed,
applied and cured all in accordance with the manufacturers recommendations.
E Surface finishes and tolerances for all repair areas shall comply with the specification,
unless approved otherwise by the Engineer.
F Contractor shall conduct pull-off tests on all concrete repair applications as directed by the
Engineer in accordance with the requirements of BS EN 1542. All failures shall either be in
the substrate or if the failure occurs at the interface between repair material and substrate
or within the repair material the minimum pull off value shall be 1.5N/mm2. One pull off test
shall be conducted for every 50m2 of each type of repair.
G Frequency of sampling and test requirements for concrete repair systems shall be as
follows:
a) Cementitious mortars. 6 cubes shall be taken for every 400 bags utilized with 3
cubes being tested for compressive strength and 3 cubes for rapid chloride
penetration at 28 days.
b) Shotcrete. Two number 800mm X 800mm X 200mm samples shall be taken from
shotcrete applications on a daily basis. 3 cores shall be taken at 7 days and 3 cores
at 28 days and tested for compressive strength. For every 15th sample 1 core shall

be taken at 28 days and tested for rapid chloride penetration.
c) Concrete shall be sampled and tested for compressive strength and rapid chloride
penetration in accordance with the requirements of Section 03300 of the
specification.
d) Micro-concrete. 6 cubes shall be taken for every 100 bags utilized with 3 cubes
being tested for compressive strength and 3 cubes for rapid chloride penetration at
28 days.
H In the event of the test results not achieving the specified requirements the Contractor shall
remove the defective work and reinstate the repaired area to the satisfaction of the
Engineer.
20.3.7 Repair Using Epoxy Resin Mortars
A Primer shall be applied to the substrate ensuring that it is well brushed into the prepared
surface taking care to avoid uneven film thicknesses. Only one coat of primer shall be
allowed.
B The epoxy resin mortar shall be applied after 24 hours has elapsed after the application of
the primer.
C The mixed epoxy resin mortar material shall be applied to the primed surface in layers not
exceeding the manufacturer’s recommended maximum thickness per layer.
D Subsequent layers shall be applied within the open time of the mortar or if the previous
layer has stage cured before the next layer is applied, the surface shall be roughened by
abrading to provide a key.
E Intermediate stages and the completed repair shall be protected from rain until at least 24
hours after the application. The repair shall be shaded from direct sunlight for at least 24
hours after application.
20.3.8 Repair Using Cementitious Mortars
A The repair mortar shall be non-shrink and shall be applied in layers not exceeding the
thickness specified by the manufacturer of the mortar.
B Each layer shall be thoroughly worked and compacted into the repair zone and around or
between reinforcement ensuring that the substrate and reinforcement are thoroughly
wetted. The technique employed shall ensure that air is not entrapped within and in the
boundary of the reinforcement/mortar or mortar/substrate.
C Successive layers shall be applied as soon as the preceding layer has become sufficiently
stiff but still open to ensure bonding to the subsequent layer. The time between layers shall
be in accordance with the manufacturer’s recommendations. If sagging occurs the material
shall be completely removed and reapplied at a reduced thickness.
D If the previous layer has dried out and loses its open time before the next layer is applied
the surface shall be prepared according to the manufacturer’s recommendations before
the subsequent layer is applied.
E The final layer within a repair shall be leveled off or profiled using trowelling techniques to
produce an acceptable and matching finish.
F Curing to retain moisture shall be implemented immediately on completion of each layer of

application. The surface of the mortar shall be protected from sunlight and drying winds.

G The repair shall be cured by the method and for the period recommended by the
manufacturer of the repair system. During this period the repair shall be shaded from direct
sunlight. Curing membranes shall not be permitted unless otherwise agreed by the
Engineer in exceptional situations where the geometry is complex.
20.3.9 Repair Using Shotcrete
A Spraying equipment, nozzles, assemblies, equipment, tools and accessories shall be

regularly checked for working efficiency, freedom from leaks and that worn parts are
regularly replaced. The air supply shall be adequate in volume and pressure and be dry
and free from pressure fluctuations.
B The Contractor or his sub-contractor shall demonstrate his ability to satisfactorily spray
cementitious mortars and concrete. He should also be fully conversant with the relevant
codes of practice relating to the spraying of mortars and concrete.
C The Contractor shall employ operatives who are competent and experienced in spraying.
Nozzle men shall have at least 3 years of experience in spraying concrete. Moreover, they
will be subject to qualifying tests as directed by the Engineer.
D Profile guides shall be used to ensure that concrete is placed to the required thickness,
uniformity and texture with minimum surface trimming or finishing work.
E Interfaces shall be dampened for at least 12 hours, with no excess free water, prior to
commencement of spraying. During spraying operations, interfaces, joints and subsequent
layers of sprayed concrete shall be subject to continuous removal of trapped rebound,
overshoot and laitance.
F Spraying shall commence at the bottom of vertical panels and progress upwards. The
position and type of construction joints shall be approved by the Engineer.
G For each particular area, the maximum thickness of each layer shall be determined
beforehand to avoid slumping. The surface of each layer shall be dampened again upon
initial set before the application of the next layer.
H Sand pockets and laminations are not acceptable. The finished surface shall not deviate
from the required plane by more than 3mm per metre in any direction when measured with
a straight edge 1m long.
I Uninterrupted wet curing for at least 10 days shall be ensured. Means of curing shall vary
depending on condition on site, size, shape and position of the concrete in question. Wet
hessian with polyethylene cover as a minimum shall be used throughout the curing period.
J Cracks appearing in the new works are not acceptable and shall be repaired at the
Contractor’s own cost and to the Engineer’s satisfaction.
20.3.10 Repair Using In-Situ Concrete
A When it is possible to pour in-situ concrete using conventional methods such as repair to
slabs, walls etc. the requirements for cast in place concrete as given in the specification
shall apply.
B Aggregate sizes may have to be changed in view of the repair geometry. The Contractor
shall submit proposals for approval by the Engineer.
C Cracks appearing in the new works are not acceptable and shall be repaired at the
Contractor’s own cost and to the Engineer’s satisfaction.

20.3.11 Repair Using Free Flowing Cementitious Micro-Concrete
A A.Adequate formwork shall be provided in accordance with the relevant codes of practice.
This shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete
repair material without distortion or movement during placement.
B B.The formwork shall be sealed and made watertight at all joints between panels and
between the formwork and the existing concrete surface so as to prevent grout loss.
C C.The formwork shall be constructed from appropriate materials as agreed with the
Engineer to achieve the required finish as specified in specifcation.
D D.Formwork surfaces that are to be in contact with the micro-concrete shall be treated with
a suitable mould release agent. This shall be used in accordance with the manufacturer’s
recommendations.
E E.The entry point of the feed pipe into the form shall be at the lowest point of the void.
F F.Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the
void is filled completely and air is not entrapped.
G G.Where necessary, provision shall be made for controlled bleed points to prevent air
entrapment and enable the extent of flow of the repair material to be assessed.
H H.The micro-concrete shall be mixed and placed in accordance with the manufacturer’s
recommendations, particularly with regard to water content, mixing equipment and placing
time.
I I.The placing of the micro-concrete shall be, as far as possible, continuous. The mixing
operation shall be timed so that there is minimal interruption in the material flow. If
however, placing is interrupted, the operation shall recommence as soon as possible while
the repair material retains its flow characteristics.
J J.The formwork shall not be removed until the area repaired with micro concrete has
achieved a compressive strength of at least 10 N/mm2 or as directed by the Engineer.
K K.Immediately after the removal of the formwork the area shall be cured in accordance
with the manufacturer’s recommendations. Details of method of curing shall be submitted
to the Engineer for approval.
20.3.12 Repair of Surface Cracks
A Surface cracks less than or equal to 0.3mm in width shall be chased out by an approved
mechanical means to the depth of the crack or where no further cracking to the substrate is
visible. The chase shall be profiled to a ‘V’ section of equal depth to width.
B The mixed epoxy filler shall be applied using a trowel, scraper or filling knife ensuring that
full compaction is achieved into the chased section and providing a flush finish with the
host concrete.
C Allow to cure for up to 24 hours before applying subsequent protective coating systems.
20.3.13 Crack Injection
A Crack injection shall be performed as directed by the Engineer with epoxy resins generally
being used for structural repairs and polyester resins used to stop water leakage.

B All injection shall be carried out by drilling holes at approximately 45o to the surface in
order to intersect the crack at the centre of the member.
C Crack injection shall typically start at the bottom of vertical surfaces and shall continue
upwards as resin is seen to exit the crack.
20.3.14 Application of Epoxy Lining Mortar
A All surface laitance, traces of curing membrane and other forms of contamination shall be
entirely removed by high pressure water jetting or light abrasive blasting followed by
rinsing with water and complete surface drying. Priming of the prepared substrate shall be
carried out if so recommended by the manufacturer.
B The minimum application thickness shall be 3 mm or as recommended by the

manufacturer.
C All surface preparation, priming, mixing and application of the epoxy resin lining mortar
shall be carried out in strict accordance with the manufacturer’s instructions.
20.3.15 Final Protective Coating
A At the discretion of the Engineer, where it is required to provide a uniform texture to the
overall exposed concrete surface, an epoxy filler and protective coating shall be applied,
strictly in accordance with the manufacturer’s instructions.
B In preparation for the protective coating all existing surfaces shall be free from oil, grease,
loose particles, decayed matter, moss or algae growth and general curing compounds. All
surface contamination and surface laitance must be removed through the use of high
pressure water jetting or sand blasting.
C Blowholes and areas of substantial pitting shall then be filled with epoxy filler. The mixing
and application of this must be in strict accordance with the manufacturer’s
recommendations.
D Coating materials are required to provide in-depth protection against chlorides and
carbonation whilst providing excellent abrasion resistance.
E The Contractor is required to adhere strictly to the manufacturer’s specifications regarding

the use, storage, application and safety rules in respect of the approved materials.
F The exposed concrete surfaces as agreed with the Engineer shall be coated with 2 coats
of a high build solvent free epoxy resin coating in accordance with the manufacturer’s
instructions and relevant specification. The finished coating shall be pinhole free and have
a total minimum dry film thickness of 400 microns.
PART 21 CONCRETE PROTECTION AND WATER PROOFING
21.1 GENERAL
21.1.1 Scope and General Requirements
A This section of the specification gives the requirements for the manufacture and application
of protection and waterproofing systems to concrete surfaces and includes coatings,
membranes, linings and waterproof membranes.

B The internal surfaces of surface water drainage pumping station wet sumps, culverts,
chambers, tanks, manholes, and other concrete structures shall be protected by epoxy
coating unless specified otherwise.
C The internal faces of pumping station wet sumps, culverts, chambers, tanks, manholes,
and other concrete structures in contact with sewage or sewage gas shall be protected
with a preformed glass reinforced plastic (GRP) lining. Where it is impracticable to
construct a preformed GRP lining such faces shall be protected by means of an in situ
GRP lamination unless specified otherwise.
D Waterproofing systems shall be applied to upper faces of concrete blinding layers and
below ground horizontal and vertical faces of substructures unless specified otherwise.
The following sections of the specification shall be read in conjunction with this section:
b) Concrete repair
21.1.3 Standards
ASTM D36 Standard test method for softening point of bitumen (ring-and- ball
apparatus).
ASTM D146 Standard test methods for sampling and testing bitumen- saturated felts
and woven fabrics for roofing and waterproofing.
ASTM D570 Standard test method for water absorption of plastics.
ASTM D638 Standard test method for tensile properties of plastics.
ASTM D2240 Standard test method for rubber property – Durometer hardness.
ASTM D2583 Standard test method for indentation hardness of rigid plastics by means
of a barcol impressor.
ASTM D4073 Standard test method for tensile-tear strength of bituminous roofing
membranes.
BS 3396 Woven glass fabrics for plastics reinforcement.
BS 3532 Method of specifying unsaturated polyester resin systems.
BS EN 14020-1 Reinforcements. Specification for textile glassrovings. Designation.
BS EN 14020-2 Reinforcements. Specification for textile glass rovings.ethods of test and
general requirements.
BS EN 14020-3 Reinforcements. Specification for textile glass rovings. Specific
requirements.
BS EN 14118-1 Reinforcement. Specifications for textile glass mats (chopped strand and
continuous filament mats). Designation.
continuous filament mats). Methods of test and general requirements.
continuous filament mats). Specific requirements.
BS EN 14364 Plastic piping system for drainage and sewerage with or without
pressure. Glass reinforced-thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Specification for pipes and fittings.

ISO 527-2 Plastics - Determination of tensile properties – Part 2: Test conditions for
moulding and extrusion plastics
ISO 527-5 Plastics - Determination of tensile properties – Part 5: Test conditions for
unidirectional fibre-reinforced plastic composites
21.1.4 Submittals
approval times. Reference shall also be made to the specification on products and
materials approval. Information to be submitted shall comprise but not necessarily be
limited to:
a) For each proposed product.

b) Manufacturers name.
c) Suppliers name.
d) Product name (if applicable).
e) Product description.
f) Manufacturer’s technical data.
g) Test results or certificates.
h) Storage instructions.
i) Application instructions.
21.1.4.2 20.1.4.2 Method Statement
advance of commencing the site activity in accordance with the specification. These shall
a) Procedures for surface preparation, application and testing of coatings.

b) Procedures for surface preparation, application and testing of membranes.
c) Procedures for installation, welding and testing of PVC-u and GRP linings.
d) Procedures for installation and testing of GRP linings.
e) Procedures for application of in-situ GRP lamination.
f) Procedures for installation of waterproof membranes.
21.1.4.3 Drawings
A A.The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance the specification. These shall comprise but not
necessarily be limited to:
a) Preformed GRP lining layout including details of anchorage and sealing around
pipes and openings.
b) PVC and HDPE lining layout including details of anchorage and sealing around
pipes and openings.

c) Waterproof membrane details including details of sealing to concrete surfaces above
ground level, sealing at intersection of horizontal and vertical membranes and
sealing at openings and projections.
21.1.4.4 Samples
following items at the same time as the particulars are submitted.
a) Samples of primers and coatings.

b) Samples of PVC and HDPE linings.
c) Samples of GRP lining.
d) Samples of waterproof membrane sheet.
21.1.4.5 Mock Up
A Provide a 2m by 2m mock-up of each type of coating, membrane, lining and waterproof

membrane system as directed by the Engineer for the Engineers approval.
21.1.4.6 Quality Control
B Products and materials shall be from a manufacturer/supplier who operates a quality

system, which is registered to ISO 9000 or approved equal.
minimum of 24 hours’ notice of carrying out the following activities on site.
a) Application of coatings after surface preparation.

b) Casting of concrete for embedded lining.
c) Application of in-situ GRP lamination.
d) Application of waterproof membrane and protection system.
D Only specialty trained personnel thoroughly familiar with the application of protection and
waterproofing systems shall carry out the work.
E The Contractor shall provide to the Engineer before the work begins, instruments for
measuring the substrate and coating properties as listed below:
a) Surface moisture determining instruments.

b) Wet and dry film thickness instruments.
c) Holiday tester.
d) Adhesion testers.
21.1.4.7 Delivery, Storage and Protection
manufacturer’s recommendations, specification and the following provisions.
a) Delivery, storage and handling shall at all times be performed in a manner to avoid
product damage.

b) Store materials on a flat level area and raised above the ground on timber bearers.
c) Where product manufacturer recommends storage under controlled temperatures,
the Contractor shall provide an enclosed, insulated cool store maintained at the
proper temperature at all times.
d) If stored outside, store materials under opaque cover and out of direct sunlight at all
times. Maintain a free flow of air around the materials at all times.
e) The Contractor shall visually inspect all products upon delivery to site and report any
B Any products damaged during delivery, storage and handling shall be marked by the
C Proposals for repair of any damaged products shall be submitted in writing to the Engineer
for approval.
D Any damaged products deemed unsuitable for repair by the Engineer shall be removed
from site and replaced.
E All products shall be clearly labelled with date of manufacture and shelf life or date of
expiry. Any expired products shall be removed from site.
21.1.4.8 Warranty
A The manufacturer and the Contractor shall jointly guarantee the completed concrete
protective coating, membrane, lining and waterproof membrane systems to be free from
defects in materials and workmanship for a period of 10 years from the date of completion
of the Works.
certificates for all materials and components used.
C If the concrete protective coating, membrane, lining and waterproof membrane systems
are found to be defective during the warranty period, the Contractor shall replace and/or
repair the concrete protective coating, membrane, lining and waterproof membrane
systems to the satisfaction of the Engineer.
21.2 PRODUCTS
21.2.1 General
A Each type of coating, membrane, lining and waterproof membrane system including
primers and accessories as necessary shall be compatible and supplied by the same
manufacturer unless otherwise approved by the Engineer.
21.2.2 Epoxy Coating
A Epoxy coatings shall be solvent free, two component high build epoxies meeting the
requirements of Table 28 below.
Table 28:– Epoxy Coating Requirements

Property Requirement
Volume of solids 100%

Number of coats Minimum of 2
Dry film thickness Minimum of 250 microns per coat
Adhesion to concrete Minimum of 1.0N/mm2
Colour (Inside manholes and chambers) Light grey or off white
B Coal tar epoxies shall not be used.
C Coating system shall have a proven track record of not less than 5 years in Abu Dhabi or
in similar environmental conditions. Coating system shall be suitable for use in the climatic
conditions prevailing in Abu Dhabi with regard to pot life, useable life of freshly mixed
components and curing.
D Intermediate coats shall be tinted to facilitate inspection of coverage for each coat.
E UV resistant over coating for external applications shall be as recommended by the

manufacturer.
21.2.3 Polyurethane Elastomeric Membrane
A The polymer shall be two part solvent free polyurethane with the properties given in Table
29 below, unless otherwise approved by the Engineer.
Table 29: Polyurethane Elastomeric Membrane Requirements

Elongation at Break Minimum of 250%
Tensile strength Minimum of 8N/mm2
Nominal hardness Minimum of 80 (Shore A)
Nominal thickness 3mm
Average adhesion Minimum of 1.0N/mm2
B Application shall be made with specialised spray equipment to produce a fast curing,
seamless membrane in a single coat.
C A penetrating primer must be utilised to assure permanent bond with substrate.
D Abrasive for non-slip wearing surface shall be as recommended by the manufacturer.
E UV resistant over coating for external applications shall be as recommended by the

manufacturer.
21.2.4 PVC and HDPE Lining
A Lining shall be manufactured from PVC or HDPE specially compounded to retain flexibility
in manufacturing the lining. All joint, corner and welding strips shall be made from similar
materials.

B The actual resin used in the manufacture must constitute not less than 99% of the resin
used in the formulation. Copolymer resins will not be permitted.
C The lining shall be permanently and physically attached to the concrete with an anchoring
system manufactured from the same material as the lining and shall be suitable for casting
into concrete. The anchoring system shall withstand a pull out test of at least 18kN/m
applied perpendicular to the concrete surface for a period of one minute without rupture of
the anchors or withdrawal from the concrete.
D All joints in the lining shall be sealed using appropriate welding techniques.
E Lining shall have a smooth glossy finish, be impermeable to gases and liquids and non-
conducive to bacteria or fungus growth.
F Lining shall have good impact resistance, be flexible and have an elongation sufficient to
bridge up to 6mm wide settling cracks, which may occur after installation without breaking
the lining.
G Lining shall be capable of being repaired at any time during the life of the structure in
accordance with the lining manufacturer’s instructions.
H The lining shall be capable of withstanding a back hydrostatic pressure of 2 bars applied to
the under surface of the lining without losing anchorage and without rupture and leakage.
I All linings shall be factory tested for pin holes using an electrical spark tester set at 20,000
volts minimum. Sheets having holes shall be satisfactorily repaired in the factory prior to
delivery.
J All lining sheets, joints, corner and welding strips shall meet the requirements of Table 30
below when tested at a temperature of 43ºC.
Table 30:– Physical Properties PVC and HDPE Linings

Tensile strength at break ASTM D638 Min 15 N/mm2
Elongation at break ASTM D638 Min 200%
Weld strength at break
Shear - Min 60 kg/25mm weld

Peel - Min 35 kg/25mm weld
Hardness, Shore D ASTM D2240 50
Thickness - Min 1.65 mm
Distance between anchors - Max 65 mm
21.2.5 GRP Lining
21.2.5.1 Raw Materials
A Materials used in the manufacture of the lining shall be new stock and of the best quality.
B Materials shall be free from all defects and imperfections that might affect the performance
of the finished product.

C Resins shall comply with the relevant provisions of BS 3532 Type B, unless otherwise
approved by the Engineer. Vinylester resins shall have an elongation at break of 3 to 6%.
D Glass shall comply with the relevant provisions of the following standards unless otherwise
approved by the Engineer. Surface tissues shall also comply with one of the following
standards.
a) BS EN 14020-1, BS EN 14020-2 and BS EN 14020-3 for roving.

b) BS 3396 for woven fabric.
c) BS EN 14118-1, BS EN 14118-2 and BS EN 14118-3 for chopped strand mat.
E All glass shall be corrosion resistant glass, unless otherwise approved by the Engineer.
F Roving size shall not exceed 2400 Tex.
G Chopped strand mat shall not exceed 450g/m2.
H Sand aggregate used for non-slip surfaces on benching shall be clean graded silica sand,
nominal size 2mm.
21.2.5.2 Preformed GRP lining.
A All linings shall be designed to protect the concrete for a period of at least 60 years. They
shall be keyed and bonded into the concrete at the time of concrete casting. They shall be
designed to withstand a backpressure of 2 bars without deflection.
B Lining shall be composed of a minimum 1.5 mm thick inner layer (layer in contact with
liquid) and a minimum 5.5 mm structural layer as follows:
a) The inner layer shall comprise one layer of glass surface veil 30g/m2 and two layers
of chopped strand mat 300 g/m2, “Advantex” powder bound corrosion resistance or
equivalent approved, impregnated with vinylester resin of approved type. Resin to
glass ratio shall be 70% to 30% by weight with a tolerance of ± 5%. Fillers and
aggregates shall not be used.
b) The structural layer shall comprise six layers of chopped strand mat 450 g/m2,
“Advantex” powder bound corrosion resistance or equivalent approved, impregnated
with isophthalic resin of approved type and 0.5 mm flow coat on the external surface
with vinylester resin of approved type. Resin to glass ratio shall be 70% to 30% by
weight with a tolerance of ± 5%. Fillers and aggregates shall not be used.
c) Overall properties of the lining shall be as given in Table 31 below.
Table 31:- GRP Lining Properties

Axial tensile strength ISO 527-2 100 N/mm2
Water absorption maximum ASTM D570 0.15% not short term boiling method
Barcol hardness ASTM D2583 Min 35 prior to dispatch
d) Lining shall have bonding lugs consisting of 100mm long GRP strips or GRP round
studs bonded to the concrete, adjacent to the face of each GRP panel. Lugs shall be
spaced in a grid pattern not exceeding 500 mm x 500 mm approximately.
e) The shape of each bonding lug shall be such that it produces a secure bond in the

cast-in-situ concrete such that the lining is held firmly in place and in contact with the
concrete surface, alleviating any tendency of the lining to become debonded from
the concrete.
f) All bonding lugs shall be orientated in the vertical direction to allow the concrete to
easily flow around or through the anchors.
21.2.5.3 In-situ GRP lamination.
A Field joints shall be at least 150 mm wide by 7 mm thick and shall be constructed with
similar materials and in a similar fashion to the preformed GRP lining, except that all resin
used at site shall be vinylester.
B In-situ GRP lamination shall be constructed with similar materials and in a similar fashion
to the preformed GRP lining, except that all resin used at site shall be vinylester.
21.2.5.4 Pipe connections.
A GRP benching shall be fitted with pipe sockets or spigots suitable for connection to the
designated pipes.
B GRP benching for connection to PVC-u pipes shall utilize PVC-u sockets, couplers or
spigots manufactured by the same PVC-u manufacturer as the pipes to which they will
connect.
C GRP benching for connection to GRP pipes shall utilize GRP sockets, couplers or spigots
manufactured by the same GRP manufacturer as the pipes to which they will connect.
D Backdrops for connection to PVC-u pipes shall be made with long radius non- pressure
PVC-u fittings manufactured by the same PVC-u manufacturer as the pipes to which they
will connect.
E Backdrops for connection to GRP pipes shall be made with long radius non pressure GRP
fittings manufactured by the same GRP manufacturer as the pipes to which they will
connect.
F Any GRP lamination to PVC-u sockets, couplers or spigots shall comply with the following:
a) The surface of the PVC-u fitting shall be roughened to accept a 100mm wide GRP
lamination on the inside of the fitting and a 25 mm wide GRP lamination on the
inside of the fitting.
b) Isopthalic resin shall then be applied to the roughened areas and one layer of
chopped strand mat 300 g/m2 applied and wetted out with the resin.
c) The PVC-u fitting shall be inspected by the Engineer prior to placing in the benching.
21.2.5.5 GRP Formwork
A GRP formwork, which remains in place, shall be fabricated as follows unless otherwise
a) The outer layer shall comprise one layer of glass surface veil 30 g/m2 of approved
type impregnated with corrosion resistant vinylester resin of approved type.
b) The structural layer shall comprise one layer of chopped strand mat 450 g/m2, two
layers of 800 g/m2 woven roving and one layer of chopped strand mat 450 g/m2 of
approved type impregnated with corrosion resistant isophthalic resin of approved
type.
c) The inner layer shall comprise one layer of glass surface veil 30 g/m2 of approved

type impregnated with corrosion resistant vinylester resin of approved type.
d) Resin to glass ratio shall be 70% to 30% by weight with a tolerance of ± 5%.
e) Total minimum thickness shall be 4 mm.
B Suitable straps or anchors shall be fitted to the formwork to prevent handling damage and
hold the formwork in place during concreting.
C Any exposed surfaces shall be given a 100 micron thick gel coat with ultra violet inhibitor.
21.2.6 Waterproof Membrane
A The waterproof membrane system shall have a proven track record of not less than 5
years in Abu Dhabi or in similar environmental conditions.
B The waterproof membrane shall be an impervious torch applied purpose formulated

modified bituminous membrane consisting of an atactic polypropylene (APP) bitumen
compound reinforced with a polyester fabric core
C Self-adhesive tanking membranes shall not be used.
D Waterproof membrane shall meet or exceed the properties given in Table 32 below.
Table 32:– Waterproof Membrane Requirements

4 mm (for single layer) 6mm (for

Nominal thickness -
double layer)
Weight of reinforcing fabric - 200 g/m2
Tensile strength ASTM D146 500 N/50mm in either direction
Elongation at break ASTM D146 40% in either direction
440 N in transverse direction

Tear resistance ASTM D4073
550 N in longitudinal direction
Softening point ASTM D36 110°C
A Accessories
a. Waterproof membrane primer shall be:
A Compatible with the waterproof membrane.
B Recommended by the membrane manufacturer.
C Formulated for use in hot climates.
a) Bituminous mastic for moulding into 40 mm by 40 mm fillets for use at

b) 90 degree internal junctions and sealing around pipes and penetrations through
walls shall be a cold applied gun grade rubber/bitumen compound as recommended
by the membrane manufacturer and be formulated for use in hot climates.
c) 40 mm x 40 mm triangular fillets shall be hollow triangular PVC extrusions, fixed to
the concrete or other surfaces using adhesives as recommended by the

manufacturer.
d) Protection board shall be minimum 6mm thick plywood or blockboard as approved
by the Engineer.
e) Cement sand screed shall comprise 1 part cement to 3 parts sand (5mm maximum
aggregate size) or as approved by the Engineer.
f) Flashing shall be 1 mm thick aluminum.
21.3 EXECUTION
21.3.1 General
A Prior to the application of coatings, membranes, insitu lamination or waterproofing and

periodically as work progresses the services of the manufacturer’s technical representative
must be provided at the work site as often as deemed necessary by the Engineer to advise
on all phases of the work.
B The Contractor shall follow the manufacturer’s recommendations for specific procedures
and details not specified herein.
C The following conditions shall apply wherever coatings, membranes, in-situ GRP
lamination or waterproofing work is being carried out.
a) Work shall only be undertaken when the ambient temperature is within the ranges
recommended by the manufacturer.
b) Sufficient lighting to the approval of the Engineer shall be provided and used
whenever work is in progress.
c) Forced draught ventilation to the approval of the Engineer shall be provided and
used whenever work is in progress.
d) When the humidity rises above 85% where there is a danger of condensation on the
surface affecting operations, works shall cease and re-start only with the approval of
the Engineer.
e) No work shall be carried out during a sand storm as determined by the Engineer.
f) Primers to concrete shall not be applied until the moisture content of the
cementitious surface is less than 5% when measured by an electronic moisture
meter or other instrument approved by the Engineer.
g) Where appropriate adjacent surfaces shall be protected by the use of drop cloths or
other approved precautionary measures.
h) The manufacturer's recommendations concerning health and safety shall be
followed.
i) Operatives shall work not less than two in number.
j) Procedures and treatment plans shall be in force in the event of any accidents
occurring.
D The Contractor shall take all necessary measures to prevent damage to installed
coating/membrane/lining/waterproofing from equipment, materials and personnel until
completion of the Works. Any damage resulting from the Contractor’s operations shall be
repaired to the satisfaction of the Engineer at the Contractor’s expense.
21.3.2 Preparation of Concrete Surfaces
A Concrete surfaces to be protected with coatings, membranes in-situ GRP lamination or

waterproof membrane shall be a minimum 30 days old and be prepared as follows.

a) Concrete surfaces to receive coating/membrane/lining /waterproofing shall be
prepared by sand blasting or as otherwise recommended by the product
manufacturer with the surface being uniformly roughened but not damaged by
excessive sand blasting.
b) In locations where the Engineer determines that sand blasting is not practical the
surface shall be etched with a solution of muriatic acid and the surface subsequently
cleaned to the approval of the Engineer.
c) Prepared surfaces shall be dry, clean and free of oil, grease and loose materials.
Surface protrusions and offsets shall be removed.
d) Any previously applied coatings or surface treatments must be removed.
e) Surface repairs shall be carried out with the appropriate repair system prior to the
application of coating/membrane/lining /waterproofing as specified in the
specification.
21.3.3 Application of Epoxy Coatings
A Coatings shall be mixed and applied in strict accordance with the manufacturer’s
recommendations.
B Special attention shall be given to ensure that edges, corners, crevices and other areas
receive a film thickness at least equivalent to that of adjacent coated surfaces.
C The penetrating solvent containing two component epoxy amine primer shall be applied
over the whole area to be coated by suitable nylon bristle brush or spray. The primer shall
soak into the concrete and shall not leave a resin rich layer on the surface. Primers
containing fillers or pigments shall not be used. A minimum of 24 hours shall lapse before
filling the surface.
D The surface of the primed concrete shall be scraped with approved two component solvent
free epoxy filler supplied by the coating manufacturer. The filler shall be squeezed into
blowholes. The filler shall have the property of being resin rich such that the finished
surface shall look semi glossed when finished.
E There shall be strict control of surface cleanliness between coats. Dust and sand shall be
used by vacuuming and any dust embedded in the coated surface shall be removed with
abrasive paper.
F Two coats of a solvent free coating system as specified above shall be used. Any thick
runs or collections of coating shall be removed before they harden. Any blowholes visible
after each topcoat shall be filled and sealed.
G Wet film thickness shall be continually checked by the coating operators to verify that
sufficient coating is being applied to achieve the required dry film thickness.
H Dry film thickness shall be checked for every 100 m2 of coated surface.
I Coated surfaces shall be visually inspected to ensure proper and complete coverage has
been obtained.
J At least one adhesion test shall be conducted for every 100m2 of coated surface. The
resulting test specimens shall show no evidence of poor adhesion to the substrate,
residual laitance or intercoat adhesion weakness.
21.3.4 Application of Polyurethane Elastomeric Membranes
A Coatings shall be mixed and applied in strict accordance with the manufacturer’s
recommendations.

B Application shall be made using specialized spray equipment to produce a fast curing
(within seconds) seamless, flexible membrane in one coat.
C The membrane shall be applied in sufficient thickness to cover all air holes, pinholes and
irregularities without the application of a second coat.
D Coated surfaces shall be visually inspected to ensure proper and complete coverage has
been obtained.
E At least one adhesion test shall be conducted for every 100m2 of coated surface. The
resulting test specimens shall show no evidence of poor adhesion to the substrate,
residual laitance or intercoat adhesion weakness.
21.3.5 Installation of PVC and HDPE Lining
A All work for and in connection with the installation of the lining including any accessories
and welding of joints shall be carried out in strict conformity with the manufacturer’s
recommendations.
B On completion the lining shall be continuous and free of holes in the lining itself and in the
joints.
C The lining shall be in sheets made or cut to fit the forms to which it is to be closely fitted
and properly secured, using a minimum number of separate pieces. Care shall be taken
not to puncture the lining in anyway.
D Joints between adjacent sheets shall not be more than 3 mm wide and shall be sealed on
the concrete side to prevent loss of grout during concreting.
E Concrete poured against the lining shall be compacted by suitable methods in a careful
manner so as not to damage the lining and produce a dense, homogenous concrete
securely anchoring the ribs or anchors into the concrete. The Engineer shall reject any
work if he considers that any part of that work contains defective concrete and the work
shall be removed and reinstated at no cost to the ADM.
F After pouring, the concrete shall be left to cure for a minimum of 48 hours prior to striking
the formwork. When removing formwork care shall be taken to protect the lining from
damage.
a) Sharp instruments or tools shall not be used to pry formwork from the lining.
b) Any formwork materials that remain in the lining shall be removed and the resulting
holes clearly marked.
c) Formwork tie holes shall be marked before ties are broken off and all areas of
abrasion or damage shall be marked.
G All abraded areas in the lining shall be patched. Any one patched area shall not exceed
0.25 m2 or as directed by the Engineer.
a) Patch shall be made of the same material as the parent lining.

b) All surfaces shall be prepared and all patching work shall be carried out in
accordance with the manufacturer’s recommendations.
H Unless otherwise shown on the drawings the lining shall be returned at least 100 mm onto
built in items such as manhole frames, gate guides and pipes or to where the type of lining
is changed or new work is built against existing unlined concrete. At each return, the lining
shall be sealed to the adjacent material with an approved adhesive system or if this is not
acceptable an alternative proposal shall be submitted to the Engineer for approval.

I The lining at joints shall be free of all foreign matter and shall be clean and dry before the
joints are welded.
J All jointing materials shall be similar to that of the parent lining for thickness, corrosion
resistance and impermeability unless otherwise approved by the Engineer.
K Welded joints shall show no cracks or separations.
L Welding strips which extend beyond the edge of the lining shall be tested as follows:
a) Welding strips shall extend 50mm beyond the edge of the lining to provide a tab to
which a 5kg pull will be applied.
b) Force shall be applied normal to the face of the structure by means of a spring
balance.
c) Lining adjacent to the welding strip shall be held against the concrete during
application of the force.
d) The 5kg force shall be maintained if a weld failure develops until no further
separation occurs.
e) Defective welds shall be retested after repairs have been made and following
successful testing the tabs shall be neatly trimmed away.
M Hot joint compounds such as coal tar shall not come into contact with the lining.
21.3.6 Installation of Preformed GRP Lining
A The GRP lining shall be prefabricated and shaped to match the required dimensions and
configurations, as shown on the drawings.
B Installation shall be in sections as part of the concrete works and as required for proper
concrete placement and GRP field jointing techniques.
C The prefabricated GRP lining shall be adequately braced and carefully handled so that
excessive damaging deflections or cracking of the lining do not occur during handling and
installation.
D The sheet lining shall be keyed and bonded into the concrete at the time of concrete
casting. It shall be closely fixed to the formwork before erection and shall be cut and
shaped to fit curved or complex profiles in a manner to minimize the number of joints. Care
shall be taken not to puncture the lining in any way.
E Any holes formed by nails for fixing the sheet lining to the formwork shall be in the zone
that is to be covered by the subsequently applied sealing strips on the external face. All
nails shall be of the headless type.
F Joints between the sheets of lining shall be sealed on the concrete side to prevent loss of
grout during concreting. After casting the concrete shall be left to cure for a minimum of 48
hours prior to striking the formwork. Shutters shall then be carefully removed allowing any
nails to pull through the liner. Joints between the sheets of lining shall then be sealed.
G Where pipes enter or leave lined structures the joints between the ends of the pipes and
the lining shall be sealed as specified or shown on the drawings with sealants approved by
the Engineer.
H Where penstocks or the like are to be fitted to concrete walls protected with linings, the
linings shall be constructed behind the penstock frame with a minimum gap of 50 mm.
Subsequent to the grouting in of the frame the joint between the lining and the frame shall
be satisfactorily sealed with materials approved by the Engineer.

I Joints between sheets shall be laminated over with a 100mm wide resin rich glass tape of
minimum thickness 4mm to provide a gas and watertight seal. The strip shall be formed
using the same resin and glass used for the lining. The joint shall be finished with a resin
rich layer to give a surface to match the lining.
J Joints in the lining at internal corners shall have a GRP covering bonded with adhesive to
the lining and laminated over as described above.
K Where non-slip surfaces to GRP linings are specified or shown on the drawings the
surface shall be ground to receive a coat of catalyzed vinylester resin. The resin shall be
dusted with an approved silica sand to produce the non-slip finish and surplus sand shall
be brushed off no less than 24 hours after application.
21.3.7 Application of In-Situ GRP Lamination
A Contractor shall demonstrate all his methods, equipment and materials for the Engineers
approval before any work commences.
B GRP lamination shall only be carried out by experienced, trained personnel, familiar with
GRP lamination techniques.
C Contractor shall ensure that working areas are well ventilated when insitu GRP lamination
is being carried out.
D Prime surfaces with catalysed isopthalic resin primer to a maximum 0.125 mm thickness
by rolling, brushing or spraying.
E Once the primer coat has set, fill up voids in concrete surface with a resin paste.
F Lamination is to be applied as agreed with the Engineer and shall comprise:
a) In situ lamination shall be a total of 7 mm minimum thickness.

b) The first six layers applied to the concrete surface shall consist of chopped strand
mat 450 g/m2, “Advantex” powder bound corrosion resistance or equivalent
approved, impregnated with isophtalic resin of approved type. Resin to glass ratio
shall be 70% to 30% by weight with a tolerance of ± 5% to provide a lining of 5.5 mm
thickness
c) The next two layers shall consist of chopped strand mat 300 g/m2, “Advantex”
powder bound corrosion resistance or equivalent approved, impregnated with vinyl
ester resin of approved type. Resin to glass ratio shall be 70% to 30% with a
tolerance of ± 5%.
d) The final layer shall consist of glass surface veil 30 g/m2 of approved type
impregnated with corrosion resistant vinylester resin of approved type.
G When laminating vertical and overhead surfaces, add 2% Thixotrope agent to the resin to
prevent slumping of the coating.
21.3.8 Installation of Waterproof Sheet Membrane
A Membranes applied to vertical and inclined surfaces shall be protected below finished
ground level by means of an approved plywood or blockboard not less than 4mm thick.
a) Membranes applied to upper faces of concrete blinding layers and upper horizontal
faces of the substructures below finished ground level shall be protected by a 50mm
thick cement sand mortar screed.
b) The protection material shall be placed against the membrane and be firmly held in
position by temporary struts or other means while backfill is being placed. Struts that

apply point loading shall not be used.
c) Damage to the membrane during protection and backfilling shall not be accepted.
Damaged membranes shall be repaired by means of a method approved by the
Engineer.
PART 22 JOINTS IN CONCRETE
22.1 GENERAL
22.1.1 Scope
This section of the specification gives the requirements for joints in concrete, including
joints in water retaining structures and water tight structures.
22.1.3 Standards
ASTM D624 Standard test method for tear strength of conventional vulcanized rubber and
thermoplastic elastomers.
ASTM D638 Standard test method for tensile properties of plastics.
ASTM D747 Standard test method for apparent bending modulus of plastics by means of a
cantilever beam.
ASTM D1751 Standard specification for preformed expansion joint filler for concrete paving and
structural construction.
ASTM D2240 Standard test method for rubber property – Durometer hardness.
ISO 11600 Building Construction. Jointing Products. Classification and requirements for
sealants
22.1.4 Submittals
approval times. Reference shall also be made to specification on products and materials
approval. Information to be submitted shall comprise but not necessarily be limited to:
B Manufacturer’s literature for waterstops and waterbars, including details of intersections,

reducers and junctions and a certificate showing the manufacturer’s name and that the
waterstops and waterbars comply with the requirements of the specification and include
results of tests for:
a) Tensile strength.

b) Elongation at break point.
c) Tear strength.
d) Stiffness in flexure.
e) Hardness.
C Manufacturer’s literature and a certificate for joint fillers showing the manufacturer’s name
and that the joint fillers comply with the requirements of the specification and including
results of tests for:
a) Disintegration and shrinkage.

b) Recovery value and reduction in mass.
c) Extrusion.
D Manufacturer’s literature for joint sealants, including details of the method and time
required for mixing the different components, and a certificate showing the manufacturer’s
name, and that the joint sealants comply with the requirements of the specification and
including results of tests as appropriate for:
a) Rheological properties.
b) Plastic deformation.
c) Adhesion and tensile modulus.
d) Application life.
e) Adhesion in peel.
f) Loss of mass after heat ageing.
g) Staining.
h) Movement range.
i) Extension.
j) Flow.
k) Penetration.
l) Degradation.
E Particulars of joint sealant primers, backing rods and bond breaker tape.
F Confirmation that all materials in the joint system are compatible with each other.
G Complete instructions for handling and storage of all materials and mixing, priming,
installation and curing of each type of sealant.
advance of commencing the site activity in accordance with the specification. These shall
B Installation procedures for water stops, water bars, joint fillers and sealants.
22.1.4.3 Samples
following items at the same time as the particulars are submitted:

B Water stops and water bars including intersections, reducers and junctions.
C Joint fillers.
D Fully cured sealant samples 300 mm long installed between the materials to be sealed.

system which is registered to ISO 9000 series or approved equal.
minimum of 24 hours’ notice of carrying out the following activities on site.
D Installation of water stops, water bars, joint fillers and joint sealants.
manufacturer’s recommendations, specification and the following provisions.
B Store all materials in a dry, temperature controlled if required, weatherproof store with a
raised floor in such a manner as to prevent damage or intrusion of foreign matter.
C All materials shall be fully identified with brand, type, grade, class and all other qualifying
information.
D Any damaged materials shall be clearly marked “rejected” and removed from site.
22.1.7 Warranty
A The manufacturer and the Contractor shall jointly guarantee the joint system to be
watertight and free from defects in materials and workmanship for a period of 10 years
from the date of completion of the works.
certificates for all materials used.
C If the joint system is found to be defective during the warranty period, the manufacturer
and the Contractor shall replace and/or repair the joint system to the satisfaction of the
Engineer.
22.2 PRODUCTS
22.2.1 General
A Materials for joints in water retaining structures and water tight structures for sewage shall
be resistant to aerobic and anaerobic bacteriological attack and to attack by petrol, diesel
oil, mineral acids, alkalis, sabkha soils and be suitable for long term immersion in
seawater.

22.2.2 21.2.2 Water stops
A Materials shall be a proprietary type and be sourced and supplied by a single

manufacturer.
B Type and configuration shall be as shown on drawings and as specified below.
C Water stops shall be extruded from a high grade elastomeric polyvinyl chloride compound
and manufactured from virgin materials necessary to meet the performance requirements
below:
a) Suitable for storage, handling, installation and service within a range of 15oC to
50oC.
b) All water stop intersections and joints shall be factory made.
c) Site jointing shall be limited to butt joints, heat sealed using equipment and
instructions as provided by the manufacturer.
d) All water stops shall have reinforced fixing eyes or clips for fixing in place.
e) Water stops shall be fabricated into the longest practical units at the manufacturers
works.
f) Water stops shall have the physical properties given inTable 33 below.
Table 33: Water stops Physical Properties

Property Test Method Minimum Requirements
Tensile strength ASTM D638 12N/mm2
Ultimate elongation ASTM D638 250%
Tear resistance ASTM D624 50KN/m
Stiffness in flexure ASTM D747 4N/mm2
Hardness, shore A/15 ASTM D2240 70 to 80
D Base slab expansion/movement joints shall incorporate external waterstops at least

230mm wide with a 25mm wide centre bulb which shall be flat to accept joint filler.
E Base slab construction and contraction joints shall incorporate external waterstops at least
230 mm wide.
F Wall and roof expansion/movement joints shall incorporate internal waterstops at least
230mm wide with four ribs, a centre bulb to accommodate movement with a web thickness
of 10mm.
G Wall and roof construction and contraction joints shall incorporate internal waterstops at
least 230mm wide.
22.2.3 Injection Hose Water stop System
A Injection hose shall be a flexible polyvinyl chloride compound with at least 3 continuous
rows of release holes suitable for resin injection.
B Resin used for injection shall be a water swelling vinylester suitable for use in saline
ground water conditions.

22.2.4 Self Swelling Water bars
A 1.Self-swelling water bars shall be polymer based, be reactive with saline ground water (for
which a typical analysis for Abu Dhabi is given in Division 1) and non-saline ground water
and have the physical properties given in Table 34 below.
Table 34: Self Swelling Water bars Physical Properties

Property Test Method Minimum Requirements
Elongation ASTM D638 200%
Water migration at or through joint - None
Expansion in saline and non- saline ground water - 20%
22.2.5 Joint Filler
A Unless otherwise shown on the drawings joint filler shall be a proprietary type and shall be
a firm, preformed compressible cellular, single thickness, non-rotting filler to ASTM D1751.
For joints in water retaining structures and watertight structures the filler shall be non-
absorbent.
B The filler shall be able to recover more than 98% after 50% compression and shall have a
compressive strength of at least 0.15 N/mm2.
22.2.6 Joint Sealant
A Joint sealant shall be non-degradable for its particular application and be suitable for use in
the climatic conditions of Abu Dhabi with a minimum life expectancy of 15 years and shall
have a proven track record of no less than 10 years under similar climatic conditions. In the
event that any defects occur within 10 years of completion of the works, the Contractor
shall arrange all repairs necessary to remedy the defects.
B Joint sealant for exposed joints shall be grey unless otherwise specified.
C Joint sealants for use in all types of joints in water retaining structures and water tight
structures subjected to a sewage environment shall be polyurethane based. The
polyurethane based sealant shall be a cold applied two part sealant.
D Polysulphide based sealant shall be a cold applied two part sealant. Polysulphide based
sealant for use in expansion joints in water retaining structures and water tight structures
shall have a movement accommodation factor of at least 20%.
E The appropriate hardness of elastomeric sealants shall be determined in consultation with

the manufacturer, considering joint movement and exposure conditions for the size of joint
to be sealed. Any sealant exposed to traffic shall have adequate strength and modulus of
elasticity to resist damage by traffic.
F Backing rod shall be a proprietary type recommended by the sealant manufacturer and
have a diameter 25% greater than the joint width.
G Bond breaker tape shall be a proprietary type recommended by the sealant manufacturer
and shall be the full width of the joint.

22.3 EXECUTION
22.3.1 Construction Joints
A Watertight construction joints shall be provided in water retaining structures and structures
below ground water table. Construction joints should preferably be provided by exposing
the aggregate and cement matrix of the set surface and casting the new concrete against
this. This method may avoid the need for waterstops. However, it is essential that such
joints are watertight and it may be necessary to provide waterstops depending on
conditions and the contractor’s methodology.
B Injection hose systems may be used in construction joints and shall be installed in
accordance with the manufacturer’s instructions with resin being injected according to
manufacturer’s recommendations until resin is seen to exit the joint face.
C Self-swelling waterbars may be used in construction joints in lieu of conventional

waterstops at the discretion of the Engineer.
D If during the course of the Contract it should become apparent that the Contractor’s
methods of forming construction joints are not proving effective the Engineer may order the
Contractor to execute at the contractor’s expense such preventative measures as the
Engineer may consider necessary to ensure the water tightness of construction joints in
further work.
22.3.2 Movement Joints
A Incorporate water stops into all expansion and contraction joints of structures, which retain
liquid, or any structures below ground water table.
B Do not use different types of water stop material in any single complete installation.
C Maintain water stops carefully in the position shown on the drawings. Support the water
stop on accurately profiled stop boards to create rigid conditions.
D Install water stops in accordance with manufacturer's instructions without displacing

reinforcement.
E Water stop splicing defects which shall be considered unacceptable shall include but not
be limited to:
F Tensile strength less than 80% of parent section.
G Misalignment of centre bulb, ribs and fins by an amount greater than 1.5mm.
H Bond failure at joint deeper than 1.5 mm or 15% of material thickness whichever is greater.
I Visible porosity in the welded joint.
J Charred or burnt material.
K Visible signs of splice separation when cooled splices are bent by hand to a sharp angle.
22.3.3 Joint Sealant
A The manufacturer’s technical representative shall be present when commencing the

installation of each type of sealant.

B Sealants shall not be installed when extreme temperatures or heavy winds are forecast
during the curing period.
C All joints to be sealed shall be formed and the joint mechanically abraded to remove all
traces of deleterious materials such as form oil or curing compounds and also to remove
any surface laitance from the sides of the joint.
D Fix the joint filler to the required dimensions of the joint cross section to provide a firm base
for the joint sealant. Where the depth of joint between the concrete surface and the
waterstop does not exceed 500mm place filler in a single piece.
E The base of the joint shall receive a backing rod or bond breaker tape in order to provide
the correct depth to width ratio and prevent 3 sided adhesion.
F Carry out the sealing of movement joints only when adjacent concrete surfaces are
perfectly dry.
G The areas adjacent to the joint shall be protected using masking tape before the primer is
applied and until the joint sealing is complete.
H The sides of the joint shall be primed with the relevant primer and the joint filled with
sealant after the primed surface has become tacky all in accordance with the
manufacturers recommendations particularly with regard to temperature during application
of sealant and subsequent curing.
I Tool exposed surfaces so as to compress sealants to the appropriate profile for the joint.
Remove excess sealant promptly as the work progresses and clean the adjoining surfaces
as necessary.
J The sealants shall be cured in accordance with the manufacturer’s instructions to obtain
maximum bond to surfaces and durability at the earliest possible date.
K The sealants shall be adequately protected during the remainder of the construction period
so that they will be without damage or deterioration upon completion of the works.
PART 23 TESTING OF WATER RETAINING STRUCTURES
23.1 GENERAL
23.1.1 Scope
A This section of the specification gives the requirements for the methods and evaluation
criteria for testing water retaining/excluding concrete structures.
B The Contractor shall test all concrete structures that are intended to be water
retaining/excluding which shall include but not be limited to the following:
a) Concrete tanks and reservoirs.

b) Concrete channels.
c) Concrete sumps.
d) Concrete underground chambers or structures subject to groundwater infiltration.

C For water retaining structures, testing shall be carried out after application of any interior
protective coatings but prior to application of any exterior coatings or membranes.
D The cost of obtaining and the subsequent disposal of the test water shall be at the
A The following sections of the specification shall be read in conjunction with this section.
a) Submittals.
b) Concrete Protection and waterproofing systems.
23.1.3 Standards
A All activities relating to this section of the specification shall comply with the following or
BS EN 1992 Design of Concrete Structures.
23.1.4 Submittals
A Method Statements
a) The Contractor shall submit method statements to the Engineer for approval 4
weeks in advance of commencing the site activity in accordance with specification.
These shall comprise but not necessarily be limited to:
b) Proposals for filling, testing and emptying of water retaining/ excluding concrete
structures.
c) Proposals for repairing any leakage in accordance with the requirements of the
specification.
23.1.5 Water
A Water used for testing shall be potable or irrigation water as agreed with the Engineer.
23.1.6 Repair Materials
A Materials for repairing any leaks or damp areas shall be in accordance with the
requirements of the specification.
23.2 PRODUCTS
Not Applicable
23.3 EXECUTION
23.3.1 General
A Testing shall be in accordance with the requirements of BS EN 1992 and this section of the
specification.

23.3.2 Cleaning
A All water retaining/excluding structures shall on completion, be carefully cleaned to the

complete satisfaction of the Engineer.
B All structures shall first be pumped dry and cleaned of all debris. The structure shall then
be brushed down on all internal faces with a stiff broom while still dry and swept clean.
C All associated pipe work shall be cleaned in accordance with the relevant specification
requirements.
23.3.3 Test Preparation
A General
a) Testing shall not be undertaken until written approval has been obtained from the
Engineer.
b) Filling shall not take place earlier than 28 days after the casting of the final sections
of the structure, unless otherwise agreed by the Engineer.
c) In the case of structures which are sub-divided into individual tanks, each individual
tank shall be tested separately, provided that the design of structure will sustain all
imposed loads.
d) All temporary bulkheads, cofferdams, pipe blank flanges and closed valves shall be
checked to see that they form a complete seal and if possible, they should be
observed during the actual test.
e) Backfilling against exterior walls shall not take place until the Engineer has given his
written approval.
23.3.4 Test Procedure
A After completion and cleaning of the structure and all associated pipework, if any, the
Contractor shall fill the structure with potable water or irrigation water as approved by the
Engineer, at a rate of not more than 2m in 24 hours or as agreed with the Engineer. The
structure shall then be left filled for a stabilizing period of 7 days or as directed by the
Engineer.
a) The water level shall be filled up to the maximum operational level.

b) Water shall be added during the stabilizing period to maintain the maximum
operational level.
c) The final water level for the test shall be the top water level or the operational water
level or as shown on the drawings.
d) Should any dampness or visible leakage occur at any stage the Contractor shall
immediately stop filling and investigate and repair the problem to the satisfaction of
the Engineer prior to continuation of the test.
e) If emptied for repairs, the structure shall be refilled, as described above.
f) Before and during testing, flows in the structure underdrainage, if any, shall be
monitored, measured and recorded. Each underdrain shall be numbered and
observations reported by underdrain number to facilitate analysis of the data.
g) After stabilization, two shallow watertight evaporation trays 200 x 200 x 150 mm
deep shall be filled with 75mm of water and placed to float in the structure.
h) The containers shall be positioned away from the sides of the structure and any
overhead members that may shield or shade the container.
i) The level of the water surface in the structure shall be measured at a minimum of

two locations to be agreed with the Engineer at the start of the test. Commence the
test and continue for a period of seven days, unless otherwise agreed by the
Engineer.
j) Readings of water levels in the structure and trays shall be made and recorded
every 24 hours over this period.
k) At the end of the test period the leakage rate from the tank shall be computed and
corrected for evaporation.
l) The acceptance criteria shall be as follows:
 If the average per day for the fall of water level in the structure over a test
period of 7 days minus the fall accounted for by evaporation does not exceed
3mm the structure shall be deemed watertight.
 The roofs of water retaining structures shall be watertight and shall be tested
on completion by flooding with 25mm minimum depth of water for a period of
24 hours.
m) The roof shall be considered satisfactory if no leaks or damp patches show on the
soffit.
n) Where it is not practicable to flood the roof an alternative form of testing shall be
23.3.5 Remedial Work
A Notwithstanding the satisfactory completion of the 7 day test, any leakage, wet/damp
patches or sweating visible on the outside faces of the structure shall be repaired in
accordance with the requirements of the specification. Surface repairs will not be accepted.
B Should the structure under test fail the above tests in any respect, the Contractor shall:
a) Immediately take such steps as may be necessary to ascertain the nature and
positions of any defects or leakage.
b) Empty the structure and drain the roof surface.
c) Remedy the defects in a manner approved by the Engineer, employing staff or a firm
that are specialists in this type of work.
C When the remedial work has been completed in the manner approved by the Engineer, the
testing shall be repeated until a satisfactory test result is achieved.
D If water leakage is severe, the Engineer may reject the entire structure.
E Any costs incurred by the Contractor in remedial or replacement work necessary to

achieve a satisfactory test shall be entirely at the expense of the Contractor.
23.3.6 Disposal of Water Used For Testing
The Contractor shall provide suitable means for disposal of water used for testing at his
expense, such that no damage results to facilities, structures or property. These means of
disposal of water shall be subject to the approval of the Engineer and the local authorities.

PART 24 CHAMBERS AND COVERS
24.1 GENERAL
Cast-In-Place Concrete
24.1.2 References
BS 970 Part 4 - Specification for wrought steels for mechanical and allied engineering
purposes. Valve steels.
BS 1387 - Specification for screwed and socketed steel tubes and tubulars and for plastic
and steel tubes suitable for welding or for screwing to BS 21 pipe threads.
BS 2789 - Specification for spheroidal graphite or modular graphite cast iron: Ductile iron.
BS EN 124 – Gully tops and manhole tops for vehicular and pedestrian areas
BS 5911-3 Concrete pipes and ancillary concrete products – Part 3
BS EN 1990 – Specification for Steel bridges, concrete and composite bridges. Specification
loads
BS 7874 Specification for elastomeric for joints in pipework and pipelines
BS 1247 – Foundry Machinery. Safety requirements for ladles, pouring equipment,

centrifugal casting machines, continuous and semi continuous casting
machines
A Shop Drawings: Shop Drawings shall indicate details of chamber locations, elevations,
dimensions, sizes, configuration, lifting eyes and penetrations.
B Product Data: Products data shall be submitted for covers, component construction,
features, configuration and dimensions.
C Samples: Samples of material shall be submitted for testing and for approval by the
Engineer.
24.1.4 Qualifications
A Manufacturer: The Company shall be specialized in manufacturing products specified in

this section with documented experience.
24.2 PRODUCT
24.2.1 Materials
A Precast Concrete Manhole Chambers: As BS 5911 Part 3 to the sizes given on the
Standard Drawings

B Non-recessed Covers and frames:
a) Covers and frames for access to pumping station sumps and valve chambers shall
comply with BS EN 124. A GRP sealing plate and heavy grease seal, to be formed
between the cover and frame, shall be provided to prevent the ingress of sand.
b) Covers and frames shall be unvented and made of spheroidal graphite cast iron
(ductile iron). They shall be supplied to suit the clear openings shown in the
Drawings.
c) Unless otherwise shown on the drawings or instructed by the Engineer or specified
in this Section the class of covers and frames shall be Class D400 in carriageways
and parking area subject to full vehicular loading, C250 in block paved areas outside
the carriageway and parking areas and Class B125 in locations not subject to
vehicular traffic.
d) All covers to storm water drain manholes in trafficked areas shall be classified as
non-rocking and single piece. The contact surfaces shall be machined on two faces
or shall incorporate on EPDM seal on the frame set into a reversed taper. Clear
opening for covers to inlets, catch basins and chambers shall be as shown on the
drawings.
e) Unless otherwise indicated on Drawings cover sizes are as stipulated on the
following for respective sizes of Manholes:
 750mm dia: for pipe dia up to 800mm
 900mm dia: for pipe dia greater than 800mm
f) Covers and frames shall be coated with minimum 50 microns of metallic zinc primer
plus minimum 500 microns (applied in two coats) of abrasion resistant solvent free
epoxy. Minimum adhesion of the coating system to the substrate shall be 2.0 MPa
g) Provide the following cover face badging in Arabic and English:-
 STORMWATER
TRSDC
 STORMWATER
for 150x150m surface boxes
h) Multiple ducts covers and frames shall be cast iron, water proof and non- rocking.
They shall be of the type incorporating integral removable intermediate beams to
give the required clear pit opening shown in the Drawings. All covers frames and
supporting metal work shall be designed for loading to BS EN 1990.
i) Covers and frames and multiple ducts covers and frames shall be coated in
accordance with relevant specification exposure class C2. Coated covers and
frames shall not be handled and transported until full cure has been achieved. An
original of the approved coating specialist's quality control report for each itemised
component shall be provided with each delivery. The report shall bear an original
company stamp and signature.
j) Covers and frames to be provided with proper key holes for easy lifting, heavy
covers to be provided with special lifting hooks.
k) Surface boxes shall include a cast iron heavy duty cover and frame and be suitable
for wheel loads of 11.43 tones. Ductile iron surface boxes may be used if requested
by the Engineer. They shall be coated in accordance with relevant specification,
exposure class C2. Surface boxes shall have a 150mm diameter clear opening and
the cover shall be attached to the frame by a hinge.
l) Cover badging shall include: Cast iron/ductile iron, size (clear opening), foundry logs
and name, foundry batching number to covers and frames and class.
m) Cover slabs of the manhole and inlets falling in asphalt should be terminated
minimum below the wearing course or lower to ensure no concrete part will be

exposed to the traffic.
C Recessed Covers and Frames
a) In areas of high amenity or prestigious value the Engineer may instruct the use of
recessed covers, these being covers to which a decorative surface finish can be
inserted to match the surrounding area, such as paviors or setts. The relevant parts
of Section B1 above shall apply in addition to the sub-sections below.
b) Face badging shall not be provided.
c) The Covers and frames shall be coated with minimum 50 microns of metallic zinc
primer plus minimum 500 microns (applied in two coats) of abrasion resistant
solvent free epoxy. Minimum adhesion of the coating system to the substrate shall
be 2.0 MPa
d) Recessed covers may be designed by the manufacturer as required structural infill,
such as reinforced concrete, or with non-structural infill such as paviors or setts.
e) Where the manufacturer produces covers which are designed to have a structural
infill applied on site, the manufacturer shall state the relevant physical properties of
the infill required to achieve the desired load capacity. The Contractor shall ensure
that the applied structural infill meets these requirements and that it cannot detach,
degrade or crack during normal use and maintenance.
f) Where the manufacturer produces covers which are designed to have non-
structural infill they shall be designed to have adequate load capacity without the
infill.
g) The Contractor shall ensure that all in fills match the immediately surrounding area
in terms of material, colour and surface finish.
h) Covers shall be of sufficient depth to receive infill items such as paviors or sets of
the same thickness as the adjoining area and be laid on a suitable bedding. Paviors
and sets shall not have their thickness cut down when used as cover infill without
the approval of the engineer.
D Grab Handles:
a) Provide an internal grab handle in all cover slabs above circular access shafts to
chambers in open areas where the cover is raised above the natural ground level.
Form the grab handle from a 20mm stainless steel bar Grade 316S16 to BS970:Part
4 or mild steel bar shot blasted and resin sealed, coated with vinyl ester resin rich
GRP laminate.
E Sealing Plates:
a) Sealing plates shall be provided to chambers and sump access covers where there
is risk of ingress of surface water.
b) The sealing plate thickness shall be a minimum 5mm and the minimum design load
is 7.5 kN/sq.m.
c) The sealing plate shall be in the form of a plug with a flange to prevent the plate
dropping into the manhole.
d) The sealing plate shall incorporate a peripheral retained rubber ring such that when
the cover is closes a gas tight seal formed.
e) The plate shall be designed such that a watertight seal is obtained without the use of
bolts.
f) The rubber rings shall be made from nitrile rubber, SBR or EPDM formulations, in
compliance of BS7874 and BS EN 681.
g) The sealing plates shall have two securely laminated GRP lifting handles.
h) The underside of the plate shall be protected with a resin only liner 1.5 millimeters

thick. Fibers shall not protrude into the resin layer or form bridges to the free
surface.
i) Cuts and/or drilled faces shall be sealed with resin only.
j) Pigments shall not be added to the GRP formulations.
k) GRP sealing plates shall be seated on the lips of the frames without causing any
reduction to the dimensions of the specified openings.
F Ladders:
The ladders shall be made of GRP as detailed on the Drawings.
G Step Irons:
a) Step Irons shall be plastic encapsulated and shall comply with BS1247: part 2 and
be of the general purpose or precast concrete manhole pattern as applicable.
H Tanking:
All manholes and chambers shall be protected externally with tanking.
I Safety Chains:
Safety Chains shall be high density polyethylene or stainless steel of accepted size and
strength with suitable hooks at one end to permit access.
J Hand railing:
a) Hand railing shall be moulded GRP as detailed in the drawings.
K Aluminium Covers:
a) Aluminium covers are to be obtained from an approved experienced manufacturer.

b) The covers shall be capable to withstand 750kg/m2 without deflecting more than 1%
and without damage or permanent deflection.
c) Dissimilar materials to be separated by gaskets.
d) Sealing to be provided around entire frame by 33kg density polyethylene sealing
strip 25mm wide.
e) Surface boxes to be provided at appropriate locations for access to valves extension
spindles (grade OPC 25 for superstructure) if required.
f) Faces of the frame which comes into contact with cement mortar or concrete to be
painted with 2 coats of bituminous paint before installation of the frame.
g) Housing box shall be continuously aluminium welded.
h) Locking bars to be provided with stainless steel pad locks and master key.
A Shop testing and inspection of covers shall be provided as per specification.
B Sample covers shall be tested by an approved laboratory.
C Testing frequency per batch delivery shall be as follows:
1 - 50 units One unit for each size and class

Up to 250 units Two units for each size and class
Up to 500 units Three units for each size and class
Over 500 units Four units for each size and class

24.3 EXECUTION
24.3.1 General
A In the carriageway and parking areas, the cover frame shall be set on a 15mm thick bed of
cement mortar No.2. which shall sit on a minimum of four 75mm thick fibre concrete
bedding rings. Concrete surround Class ‘B’ shall be applied to the bedding rings and frame
as shown on the Drawings. The minimum distance from the top of the road surfacing to the
manhole cover slab shall be 450mm.
B In paved areas the chamber cover shall be set accurately to the level and slopes of the
surrounding surface. In unpaved areas the top of the cover shall sit 100mm above the
surrounding surface.
C Where the height of the curb stone is 100mm, part of the asphalt area (equal to length of
grating) should have slope towards the curb inlet grating to get the minimum height
required for the curb inlet grating to insure proper road drainage
D Immediately prior to the inspection of the works all covers and frames shall be cleaned
thoroughly by accepted means to the satisfaction of the Engineer.
E Holes will not be allowed to be made through the shaft rings and liners.
F Unless otherwise directed, cut-off walls shall be constructed to prevent the formation of
drainage paths within the pipe bedding. They shall be extended from the base to both
sides of the excavation and keyed into the native soil to a depth of 150mm. They shall be
constructed 300mm above the top of the pipe bedding as detailed on the Drawings.
24.3.2 Examination
A A.Items provided by other sections of Work shall be verified for proper size and location.
B Built-in items shall be verified for proper location, and for being ready for roughing into
Work.
24.3.3 Preparation
A A.Placement of inlet and outlet pipe or duct sleeves required by other sections shall be
coordinate.
PART 25 HDPE PIPES
25.1 PART 1 GENERAL
25.1.1 Scope
B This specification sets out the general standards and information requirements for HDPE
pipe materials
C All component parts of the Works, including procedures, practices and services, shall
unless otherwise stated in the contract, comply with the provisions of this section. All
work undertaken and equipment supplied shall comply with all codes, regulations,
and specifications referred to throughout the contract documents.

D Only new materials and equipment shall be used, unless otherwise specified.
E Unless otherwise stated, all minor civil engineering and building works associated with
the installation of pipe and equipment into existing Works shall be undertaken by the
Contractor.
25.1.3 Standards
PE100 pipes and fittings shall comply with the latest revision of the following standards and
other relevant standards noted elsewhere in this specification.
under pressure — Polyethylene (PE)-General
under pressure — Polyethylene (PE)-Pipe
under pressure — Polyethylene (PE)-fittings
EN 476 General requirements for components used in drains and sewers
ISO 527 Plastics – Determination of tensile properties
ISO 1083 Spheroidal graphite cast irons - Classification
ISO 1133 Plastic – Determination of melt mass flow rate (MFR) and melt
vacuum flow rate (MVR) of thermoplastics
ISO 1167 Thermoplastic pipes, fittings and assemblies for the conveyance of
fluids – Determination of the resistance to internal pressure
ISO 1183-2 Plastics – Methods for determining the density of non-cellular plastics
– Part 2: Density gradient column method
ISO 2505 Thermoplastics pipes – Longitudinal reversion – Test method and
parameters
ISO 3126 Plastics piping systems – Plastic components – Determination of
dimensions
ISO 4065 Thermoplastic pipes – Universal wall thickness table
ISO 4427 Plastics piping systems - Polyethylene (PE) pipes and fittings for
water supply
ISO 6259 Thermoplastic pipes - Determination of tensile properties
ISO 6964 Polyolefin pipes and fittings – Determination of carbon black content
by calcinations and paralysis – Test method and basic specification
ISO 7005-1 Pipe flanges -- Part 1: Steel flanges for industrial and general service
piping systems
ISO 7005-3 Metallic flanges – Part 3, copper alloy and composite flanges
ISO 9080 Plastic piping and ducting systems – determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
ISO 9624 Thermoplastic pipes for fluids under pressure – mating dimensions of
flange adaptors and loose backing flanges
ISO 11357-6 Plastics – Differential scanning calorimetry (DSC) – Part 6:

Determination of oxidation induction time (OIT)
ISO 11420 Method for the assessment of the degree of carbon black dispersion in
polyolefin pipes, fittings and compounds
ISO 11922-1 Thermoplastic pipes for the conveyance of fluids – Dimensions and
tolerances - Part: 1: Metric series
ISO 12162 Thermoplastic materials for pipes and fittings for pressure
applications - Classification and designation – Overall
service (design) coefficient
ISO 12176 Plastic pipes and fittings –Equipment for fusion jointing polyethylene
systems
ISO 13761 Plastics pipes and fittings – Pressure reduction factors for
polyethylene pipeline systems for use at temperatures above 20ºC
ISO 13479 Polyolefin pipes for conveyance of fluids – Determination
of resistance to crack propagation– Test method for slow crack growth
on notched pipes
ISO 13593 PE pipes and fittings – Determination of tensile strength and failure
mode of test pieces from a butt-fused joint
ISO 14236 Plastics pipes and fittings – Mechanical-joint compression fittings for
use with polyethylene pressure pipes in water supply systems
ISO 14276 Plastics pipes and fittings – Mechanical joint compression fittings for
use with polyethylene pressure pipes in water supply systems
ISO 15512 Plastics – Determination of water content
ISO 16871 Plastics piping and ducting systems – Plastics pipes and fittings –
Method for exposure to direct (natural) weathering
ISO 18553 Method for the assessment of the degree of pigment or carbon black
dispersion in ploy fin pipes, fittings and compounds
ISO 161-1 Thermoplastic pipes for conveyance of fluids – nominal outside
diameter and nominal pressure- part 1: Metric series
ISO 974 Determination of the brittleness temperature by impact
ISO 877 Methods of exposure to direct weathering
BS EN 12099 Plastics piping systems – Polyethylene piping materials and
components – Determination of volatile content
BS 5400-2 Steel, concrete and composite bridges- Specification for loads
ASTM D3550 Standard Practice for Thick Wall, Ring-Lined, Split Barrel, Drive
Sampling of Soils
ASTM F1055 Standard Specification for Electro fusion Type Polyethylene Fittings
for Outside Diameter Controlled Polyethylene and Cross linked
Polyethylene (PEX) Pipe and Tubing
ASTM D638-10 Standard test method for tensile properties of plastics
DIN DVS 2207 EN-Welding of thermoplastics - Heated tool welding of pipes pipeline
components and sheets made of PE-HD
SFS 3115 E- Water tightness test for pressure pipelines
WIS 4-24-01 Specification for mechanical fittings and joints for polyethylene pipes
for nominal sizes 90 to 1000 mm OD
WIS 4-52-01 Specification for polymeric anti-corrosion (barrier) coatings
WIS 4-52-03 Specification for anti-corrosion coatings on threaded fasteners

Guidelines for drinking water quality, Volume 1:
Recommendations, WHO, Geneva
25.1.4 Submittals
F In order to verify compliance with the specification the Contractor shall submit information
for all products and materials used in the Works to the Engineer for approval sufficiently
in advance of their use in accordance with the Contract program allowing for
ordering and approval times. Products and materials approval. Information to be
submitted shall comprise but not necessarily be limited to:
a) The Manufacturers design calculations, complete and detailed specification and

test results of the proposed HDPE pipes and fittings required for the Works
including Manufacturer’s certificates of compliance with this section of the
standard specification. Information on all items listed in Table 25-1 below shall
be given for every diameter in each class of pipe.
b) Should any details of the pipes and fittings be altered in any way during manufacture
from those proposed and approved by the Engineer, submit to Engineer for
approval the revised details and test results.
c) Submit to the Engineer the results of all quality control tests carried out on the
manufactured pipes and fittings as soon as practicable after testing as and in any
case not later than the time of delivery of the relevant pipes and fittings to the site.
Table-25-1: Product Information for HDPE Pipe and Fittings

Name of MANUFACTURER -
Joint type -
Details of all additives used in the manufacture -
Polymer classification and certificate of origin -
Rated working pressure MPa
Design test pressure (165hrs or 100 hrs) MPa
Internal vacuum pressure MPa
Minimum required strength (MRS) MPa
Pipe Details
Wall thickness mm
Standard dimension ratio (SDR) -

G The Contractor shall submit method statements (MS) to the Engineer for approval 4
weeks in advance of commencing the site activity in accordance to specification. These

b) Procedures for pipes installation into concrete structures.
c) Hydrostatic testing procedures for HDPE pressure pipelines.
25.1.4.3 Drawings
H The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity in accordance with the specification. These shall comprise
but not necessarily be limited to:
I Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.
J Pipe laying diagram and schedule showing location, length, design designation and
designation by number of each pipe section and pipe special to be furnished and
installed.
K All data on curve and bends for both horizontal and vertical alignment.
Prior to dispatch of any product and/or material from source the Contractor shall notify the
Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect
and test the product and/or material prior to delivery in accordance with the specification.
Manufacturer shall be approved to:
ISO 9001
ISO 14001
OHSAS 18001
To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours notice of carrying out the following activities on site:
a) Installation of pipeline.
b) Hydrostatic testing of pipeline.
L The pipe Manufacturer shall provide packing and shipping procedures to the
Engineer for approval. These shall comply with the following requirements.
a) If used, pallets shall be suitable for transporting the pipes and fittings from the plant
to the designated location without causing any damage. The pallets shall not
contain any broken planks or extremities that may damage the pipes and fittings.
b) Where pipes are transported by vehicles, the vehicle bed shall be free from sharp
edges or projections and the pipes hall be supported at adequate intervals to
prevent movement between the material and its support. Pipes shall not over-
hang at either end of the trailer.
c) Materials shall be stored in accordance with the pipe Manufacturer’s
recommendations and this specification.
d) The storage area should have a relatively smooth, level surface free of sharp
stones, debris or other materials that could damage the pipe or fittings. Where
adequate ground conditions do not exist or when a level gravel bed cannot be

prepared, the pipe shall be placed on timber supports evenly spaced along the pipe
length. The support size and spacing shall be as advised by the pipe
Manufacturer.
e) Stacks shall only contain pipes of one size and wall thickness and shall be
constructed in a pyramid, with each successive layer having one less pipe
than the layer below. The bottom layer should be braced to prevent movement and
the stack shall not exceed a height of 2.0 m.
f) Coils should be stored horizontally on pallets. Coils may be stacked as ‘silos’ but the
height of any silo shall not be higher than 2.0 m.
g) All coils shall be banded at intermediate stages of coiling and upon completion of the
specified length in order to prevent long lengths of pipe coming loose during
installation. At least 4 intermediate bands shall be provided for each 50 m of the coil
length.
h) When pipe material is boxed, the pipe or coil number shall be clearly marked on the
outside edge of the box or silo. Invoices and packing lists shall include the date of
manufacture and coil/length numbers for all material in the shipment.
i) Fittings shall be packaged in bulk or individually protected were necessary in order
to prevent deterioration and contamination. The package shall have at least one
label with MANUFACTURER name, type and dimension of the fittings and
number of units.
j) Tie-downs shall be at least 100 mm wide and be clean and free from sand, gravel
and other such materials. For straight length pipe (up to 12 m), a minimum
of 6 tie-downs are required.
25.2 PART 2 PRODUCTS
25.2.1 Materials
M Raw material shall be manufacturer member of the PE100+ Association and shall
comply with applicable part of EN 12201latest revision.
N For design calculation, pressure, reducing coefficients EN 12201, The thermal

stability of polyethylene material shall meet the requirements of EN 12201.
25.2.1.1 General Requirements
O Pipes and fittings shall comply with the requirements of EN 12201and only PE100
pipes shall be used. The pressure rating of the fittings shall be the same as, or higher
than, that of the pipes. The SDR and pressure rating of the pipes and fittings shall be
determined by the designer, based on the operating conditions.
P Service life of the pipe and fittings shall be minimum 50 years under normal
operating conditions.
Q When the annual average operational temperature exceeds 20°C, which may occur in hot
climates, the designer shall apply a pressure reduction factor to determine the
allowable long term operating pressure of the PE100 pipes and fittings. Please note that
this will be the steady state operating pressure i.e. excluding any transient or surge
pressures.
R The pipe Manufacturer shall identify the Manufacturer of the resin, the resin type and
classification. In addition, the Manufacturer shall provide evidence that the resin proposed
is suitable for use at the design temperature and under the design pressures
indicated.

S Pipes and fittings shall be homogenous throughout and free from visible cracks, holes,
foreign inclusions, blisters, dents, scoring, cavities and other efects.
T Material shall be uniform in opacity, density, interior smoothness and other physical
properties. It shall have adequate resistance to weathering and other ageing from storage
for a minimum of two years after manufacture.
U All pipes shall be black in accordance to relevant sections of EN 12201 standard.
V The pipes shall be manufactured from polyethylene containing only those antioxidants,
UV stabilizers and pigments necessary for the manufacture of pipes conforming to this
specification. All material used in the manufacture of the pipes shall be pre-
compounded at the resin Manufacturer’s facility.
W The carbon black content in the compound shall be 2.25 + 0.25 % by mass when
measured in accordance with ISO 6964. The dispersion of carbon black when determined
in accordance with ISO 11420 shall be equal to or less than grade 3.
X The pipe Manufacturer shall confirm that all fittings to be provided for the pipe system meet
the same quality requirements as for the pipes to ensure the same performance over the
design life cycle. Fittings shall be manufactured in accordance with the requirements
of EN 12201-3.
Y PE100 pipes to be installed in areas having rocky ground conditions and those to be
installed using trenchless technology applications shall be manufactured from a high
stress crack resistant (HSCR) PE100, also referred to as PE100-RC material. Pipes
manufactured from such material shall have undergone the Notched Pipe Test at an
independent 3rd party laboratory in accordance with ISO 13479 and the time to failure
shall have been a minimum of 8,760 hours (1 year). All other characteristics shall comply
with the requirements of EN 12201 and this specification.
25.2.1.2 Effects on Water Quality
Z The material of the polyethylene pipes and fittings which is in contact with or likely to come
in contact with water shall not constitute a toxic hazard, support microbial growth or give
rise to unpleasant taste or odour, cloudiness or discoloration of the water.
Materials in contact with water shall be certified by an internationally recognized authority,

such as the WRAS Certification Scheme, as being non-tainting and suitable for being in
permanent contact with potable water in accordance with BS EN 6920 last revision.
25.2.1.3 Pipe Dimensions
AA Pipe nominal size, ovality, outside diameter and wall thickness shall all comply with the
requirements of the tables given in EN 12201-2 and measured in accordance with
ISO 11922 and ISO 3126.
BB All pipes shall comply with the requirements given in Tables 1 and 2 of EN 12201
Part 2. The maximum degree of ovality, where not given in EN 12201, shall be proposed
by the pipe Manufacturer and approved by the Engineer.
CC Straight pipes shall be supplied in standard lengths of 12, 18 m or 24 m (- 0 / + 50 mm) as

detailed in the specification. In special cases, the length will be specified by the
Engineer.
DD Where pipes are to be supplied in coils, the coil lengths shall not exceed 200 m for pipes of
up to 50 mm OD, 100 m for pipes of between 63 and 110 mm OD and 50 m for pipes of
between 160 and 225 mm OD. Tolerances with regard to the coil length shall be - 0 / + 50

mm. The internal diameter of pipe coils shall not be less than 20 x pipe outside diameter
and the pipes shall be coiled so as to prevent any local deformation, buckling or kinking.
Other coil sizes may be used with the Engineer’s approval.
EE The Contractor’s method of work shall, where necessary, include for the uncoiling of
the coiled pipes in a controlled manner and the use of re-rounding equipment to remove
ovality in the pipe cross section. .
25.2.1.4 Polyethylene Fittings
General
A Fittings shall be made of high density polyethylene (HDPE) and shall comply with the
requirements of EN 12201 PE 100. The material shall be produced by a member of the
PE100 + Association.
B Manufacturer shall also supply the gaskets for use in PE100 flange connections, and
provide general recommendations on associated equipment such as valves, fittings, nuts;
bolts and other accessories, .
C PE100 fittings shall comply with the requirements of EN 12201-3 and shall be injection
molded from PE100 material compatible to that of the pipe or else fabricated from
PE100 pipes. The wall thickness of the body of the fitting at any point shall be equal to
or greater than the minimum wall thickness of the corresponding pipe.
D Only injection molded fittings shall be used for pipe sizes of up to 160 mm OD.
E Pipes and Fittings shall be from same MANUFACTURER (except echanical Fittings).
F A protection measures between dissimilar metals like between flanges and fittings
etc. shall be added.
G The straight length of fittings to be butt fusion welded together shall long enough that the
fittings can be held firmly by two clamps on the butt fusion welding machine.
H The Fittings that made of Ductile Iron (D.I.) shall be fusion bounded epoxy coating
in accordance to Section 02640 DI Pipe and Fitting Specification.
25.2.1.4.5 Butt Fusion Fittings
A Butt fusion fittings shall be in accordance with DVS 2207-1 and shall be
manufactured by injection molding, a combination of extrusion and machining, or
fabricated from PE pipe conforming to this specification.
B Fabricated fittings shall be manufactured using a Data logger to record fusion pressure and
temperature. Butt fusion fittings shall have a pressure rating no less than that of the pipe.
The fittings shall be homogeneous throughout and free of visible cracks, holes, foreign
inclusions, voids and other injurious defects.
C Fabricated fittings are subject to pressure de-rating factor as in EN12201-3.
D Where PE100 pipes connect to other materials or flanged fittings either stub flanges
with encapsulated backing rings or restrained transition fittings shall be used. Stub flange
backing rings shall be stainless steel 316. Stub flanges that will be buried shall be
encapsulated with fusion bonded epoxy. They shall be drilled in accordance with ISO

7005-2, PN 16 and have dimensions in accordance with ISO 9624, PN16 unless
otherwise specified.
E Fabricated fittings shall be designed and manufactured in accordance with the

requirements of EN12201, Part 3. The pressure derating factors to be employed by the
fittings fabricator shall be in accordance with annex sections B3 and B5 unless they
can demonstrate that higher factors can be applied. The use of any higher factors shall be
approved by the Engineer prior to commencement of fitting fabrication considering
agreed design temperature of and selected reduction factor.
F All compression fittings shall be certified by an independent third party as being fully
compliant with the requirements of ISO 14236. They shall be tested and certified as being
class 1 end load bearing fittings i.e. they shall prevent the pull out of the pipe at their rated
operational pressure. Only materials listed in Tables 1 and 2 of ISO 14236 shall be used
in the manufacture of the fitting body.
G Any bolts, studs, nuts or washers shall be of stainless steel (grade 316).
H Backing rings shall be in accordance with BS EN 1092-1 standards.
I Electro-fusion fittings shall be injection molded fittings made of PE100 but

incorporating integral heating element(s) to enable fusion jointing with PE100 pipes and
shall be in accordance with ASTM F1055 and ASTM D3550 standards.
J Materials and constituent elements used in making the fitting (including elastomers,
greases and any metal part) shall be resistant to the internal and external environment
same as the piping system and shall have life expectancy (during storage, operating
conditions, environment etc.) at least equal to pipe system (i.e. 50 years). The
requirements for the level of material performance for non-polyethylene parts shall be at
least as stringent as that of the PE pipe systems.
K Transition fittings used to join the pipe to flanged fittings and pipes made of other
materials. All fittings shall be certified by an independent third party as being fully
compliant with the class 1 requirement of ISO 14236 or the Type 2 requirement of WIS 4-
24-01 i.e. they shall prevent the pull out of the pipe at their rated operational pressure.
25.2.2 Inspection and Testing
25.2.2.1 Certification and Documentation
A The raw material and pipe Manufacturer’s shall document and certify all products
and shall undertake all testing required by EN 12201 and this specification. Prior to
delivery of any pipes or fittings the pipe Manufacturer shall provide the Engineer with a
comprehensive Inspection and Testing Plan (ITP) for their approval. The ITP shall detail
all the certificates and documents that shall be provided by the pipe Manufacturer,
together with details of the testing that they shall undertake, its frequency and associated
test reports. Where the pipe Manufacturer cannot themselves undertake the required
testing they shall employ an independent third party laboratory to undertake the testing on
their behalf.
25.2.2.2 Testing of Pipes and Fittings and Its Frequency
A The Manufacturer shall establish and maintain a complete record of test results according
to the requirements of the applicable standards, this specification and the approved
ITP.

B Pipe wall thickness shall be measured and controlled on a continuous basis using
and ultrasonic thickness gauge or similar device that shall be regularly calibrated in
accordance with the gauge Manufacturer’s recommendations.
C The fabricated fitting to be hydrostatically tested shall be a tee or branch provided

the batch in question contains this type of fitting, otherwise a bend shall be tested.
D In the case of injection molded fittings the Manufacturer shall issue a certificate confirming
compliance with ISO 12201 and providing details of the type testing they have undertaken.
E In accordance with the recommendations of ASTM D 638, the maximum thickness of

the tensile strength test samples cut from the pipe wall shall be 14 mm. In the event of
the pipe wall being thicker than 14 mm the pipe Manufacturer shall machine the test
samples in accordance with the Table 25-2.
Table 25-2: Preparation of Samples for Tensile Testing
Pipe Wall Thickness Test Sample No of sample to be taken

(WT) Thickness from the pipe wall
(mm) (mm)
≤ 14 WT 1
14 < WT ≤ 28 WT/2 2
28 < WT ≤ 42 WT/3 3
42 < WT ≤ 56 WT/4 4
56 < WT ≤ 72 WT/5 5
F All testing shall be undertaken in accordance with ISO 6259 and all samples shall
achieve a minimum tensile strength at yield of 19MPa in order for the pipe to successfully
pass the test.
25.2.2.3 Hydrostatic Testing of Pipes
A The Inspecting & Testing Plan (ITP) shall detail the pipe Manufacturer’s hydrostatic
testing regime. As a minimum, the pipe Manufacturer shall have, at 12 monthly intervals,
produced and hydrostatically tested pipes manufactured using the same grade of resin or
resins that are to be used to produce the pipes and fabricated fittings covered by this
specification.
25.2.2.4 Appointment of an Independent Third Party Inspector
A To verify compliance with this specification, the Engineer reserves the right to appoint an
independent Third Party Inspector, at the Client’s cost, to witness the applicable
qualification tests, review production records, and inspect general handling and
shipping procedures.
B The pipe Manufacturer shall ensure that all the applicable codes and standards are
available at their facility for the TPI reference during any visit or inspection.
C The pipe Manufacturer shall provide full assistance and co-operation for any
inspection, when required by the Independent Third Party Inspector.

D When requested, the pipe manufacturer shall provide access to and copies of all material
certificates and inspection and test results obtained in the course of quality
verification.
25.2.2.5 Acceptance Criteria
A The following criteria requirements shall be fulfilled by the pipe Manufacturer in order for
the pipes and fittings to be approved and accepted by the Engineer.
B Prior to delivery of pipes the pipe Manufacturer shall provide copies of all the test results
and certification required by EN 12201, this specification and the ITP, but which are not
covered by this specification. These documents shall comprise the Type Test Report.
C The Type Test Report shall include a copy of the raw material Manufacturer's "Certificate
of Quality Control Testing" covering each batch of raw material used for manufacturing
pipes produced under this specification.
D The pipe manufacturer shall provide a copy of the Pipe Run Release Tests i.e. all those
tests listed in this specification, with each pipe run that is delivered to Site.
E If the Client has appointed an independent third party inspection then their report
shall be submitted to and approved by the Engineer, with a copy to the pipe Manufacturer,
prior to any inspected materials being installed on site.
F The Engineer may reject any item that does not successfully pass the required tests or
fully comply with the requirements of this specification.
G When a pipe or fitting is rejected, the items manufactured immediately before or after shall
be carefully examined. If further defects are found, the entire pipe batch will be rejected.
25.2.3 Marking
25.2.3.1 General
A The marking information and sequence shall comply with EN 12201 and this
specification. All pipes and fittings, including test samples shall be clearly and permanently
marked using indent printing in a colour that contrasts with the pipe.
25.2.3.2 Marking of Pipes
A All the marking shall be repeated at least every 1.0 m and shall be displayed on the
outside of the pipe length. It shall include the following information.
a) International Standard i.e. ISO 12201

b) MANUFACTURER /Trademark
c) The pipe dimensions (nominal outside diameter x nominal wall thickness in mm)
d) Standard Dimensional Ratio (SDR) value i.e. SDR11 or SDR17
e) Material Designation i.e. PE 100- HE3490-LS-H
f) Pressure rating in bar i.e PN16
g) The raw material MANUFACTURER’s identification
h) A Traceability code and date of manufacture e.g. X 29 08 11 where x is the plant
25.2.3.3 Marking of Fittings

A All injection molded fittings shall be indelibly marked with the following information:
a) International Standard i.e. EN 12201

b) MANUFACTURER’s name or trade mark
c) Nominal outside diameter and SDR series e.g. 110 / SDR11
d) Material designation i.e. the letters "PE" followed by the PE grade (e.g. PE100)
e) Nominal pressure rating in bar e.g. PN16
f) Traceability code and date of manufacture, e.g. X 29 08 00, where X is the plant
code
B The marking of fabricated fittings shall be proposed by the pipe Manufacturer and
25.2.3.4 Documentation
A The pipe MANUFACTURER shall furnish the following vendor data as a minimum:
a) Catalogues / brochures of the proposed product

b) Dimensional details of pipes and fittings
c) Detailed material specification
d) Complete details of testing facilities at the MANUFACTURER’s plant
e) MANUFACTURER`s drawings showing dimensions
f) Quality assurance procedures in use
g) Certificate from PE 100 + Association
h) Local (UAE) agent name and address
25.3 PART 3 EXECUTION
25.3.1 General
A Trench excavation shall be carried out in accordance with specification and in accordance
to Manufacturer recommendation.
B Install pipe, fittings, and accessories in accordance with Manufacturer's instructions.
C Provide qualification details of the manufacturer's technical expert to be assigned to

the Contract. The technical expert shall have expertise, experience and skills necessary
for advising and monitoring all aspects of transport, storage, handling and installation
of pipes as appropriate.
D The technical expert shall provide comprehensive technical assistance to the

Contractor throughout the Contract and regularly monitor the Contractor's activities
and report on shortcomings.
E The Contractor shall provide the Engineer copies of all instructions advice or reports
given by the manufacturer's technical expert to him. The technical expert shall
immediately inform the Engineer of any omission, variations and detractions from the
approved handling and installation specification.
F Install bedding, surround and backfill as per specification and as per Manufacturer’s
recommendation.

G Obtain satisfactory initial deflection test results for sections of pipeline laid between
chambers prior to commencement of pipe laying in further sections.
H When cut pipe is required, ensure that the cutting is done by a machine, leaving a smooth
cut at right angles to the axis of the pipe.
I Ensure that all pipes and fittings are sound and clean before laying. When pipe laying is
not in progress, ensure that the pipe ends are at all times fitted with watertight plugs or
caps. The plugs or caps shall only be removed for the purposes of making a
connection of the pipe end or testing the pipeline. The plugs or cap shall be replaced
immediately on completion of the test.
J Protect bolted connections by an approved heat shrunk PVC sheath. Wrap the PVC
sheath with a protective wrapping tape prior to backfilling in accordance with the
specification.
25.3.2 Electro-Fusion Jointing
A Manufacturer recommendations shall be taken in to consideration.
B Only barcode labeled electro-fusion fittings incorporating fusion indicators and complying
with the requirements of EN 12201, Part 3 shall be used.
C The equipment used for electro-fusion jointing of pipes and fittings shall comply with the
requirements of ISO 12176 Part 2. Calibration certificate of the equipment shall be
submitted to Engineer. It shall incorporate an automatic control unit with data input
through the use of a bar code reader pen and a data retrieval facility to allow historical
fusion data to be read on the unit’s screen and to be exported to an external computer or
memory stick.
D The electro-fusion control box shall deliver the correct fusion parameters to the electro-
fusion fitting. The power generator shall provide the power requirements of the control
box, taking into account the electrical characteristics of the control box.
E Positioning tools including suitable alignment clamps shall at all times be used to minimize
misalignment and prevent movement during the fusion and cooling cycle of the joint. A
suitable shelter shall be used in cold, windy, dusty or wet weather conditions.
F F. Prior to commencing the welding process the Contractor shall measure and
ensure that the ovality of the pipe or spigot end is within the limits as per EN 12201.
G All pipe work shall be cleaned with disposable alcohol impregnated wipes prior to
undertaking the pipe scraping, in order to remove any contamination. Prior to scraping the
Contractor shall measure and mark the area of the pipe or spigot end to be scraped in
order to remove the oxidized surface to a depth between 0.2 and 0.4 mm. The length of
the pipe or spigot end to be scraped shall be equivalent to the insertion depth of the
electro-fusion joint plus a distance of between 10 and 20 mm.
H Only rotating mechanical scrapers or peelers, which are capable of cutting a

continuous strip or ribbon over the insertion length of the coupler or fitting, shall be used.
I The fitting shall be removed from its packaging and immediately inserted over the pipe end
only after preparation and scraping of the pipe.
J Each pipe or spigot end shall penetrate completely its relevant part of the electro-
fusion socket.

K Alignment clamps shall not be removed before the appropriate cooling time has elapsed.
Abnormal displacement of the electric wire coils shall not occur. This shall be checked
prior to commencement of the fusion process.
L All completed electro-fusion joints shall be inspected in accordance with the

requirements of EN 12007 Part 2. Should the joint contain any of the faults
described in the standard then the electro-fusion fitting shall be cut out and
replaced.
M After completion of the fusion process, all fusion indicators shall be checked to ensure that
they are in the position indicated in the Manufacturer's instructions. If any fusion indicators
are not in the required position the electro-fusion fitting shall be cut out and replaced.
N The Contractor shall, on a regular basis allow the Engineer to download the
historical data relating to the welds made by the unit through the data retrieval facility.
25.3.3 Butt Fusion Jointing
A The equipment used for butt fusion jointing of pipes and fittings shall comply with the
requirements of ISO 12176 Part 1. It shall incorporate a control unit that shall comply with
the type A requirements of table B.2 of ISO 12176, Part 1 and the following points.
a) Automatically preset the fusion jointing parameters based on the pipe

dimensions, material type and fusion jointing procedure
b) Automatically control and monitor the fusion jointing process
c) Comply with the requirements of Annex A of ISO 12176, Part 1
d) Assign a unique joint number to each joint and have a data retrieval facility to allow
historical fusion parameters to be read on the unit’s screen and to be exported to an
external computer or memory stick
B Calibration certificate of the equipment shall be submitted to Engineer prior to installation.
C The butt fusion jointing procedures shall comply with the requirements of ISO 21307. The
Contractor shall generally follow the single low pressure fusion jointing procedure
described in section 5.1 of ISO 21307.
D Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.
E A dummy joint shall be made at the start of each welding session using pipe off cuts of the
same size, material and SDR as the pipe being installed. The normal trimming, bead up
and full heat soak cycles will be adhered to.
F If the pipe size is changed during the day, if the heater plate is allowed to cool below
180°C or if maintenance of the butt fusion equipment is carried out then a new dummy
weld shall be performed.
G All butt fusion joints shall be inspected in accordance with the requirements of Appendix B
of EN 12007 Part 2. Should the joint contain any of the faults described in the
standard then the joint shall be cut out and replaced. The inspection shall include
the following points:
a) The gap between the two single beads shall not be below the fusion surface.
b) The displacement between the fused pipes must not exceed 10% of the pipe wall
thickness.
c) The difference between two single bead widths shall not exceed 10% of the double
bead width.

d) The weld beads shall be free from all contamination and have a smooth even
surface with no evidence of distortion, holes or bubbles.
e) At the direction of the Engineer external beads shall be removed with an approved
tool and inspected for contamination and defects. They shall also undergo bend
back testing. Beads should be solid and rounded with a broad root as hollow
beads with thin root and curled appearance can be indicative of excessive pressure
or no heat soak.
f) Each removed bead shall be numbered with its corresponding joint number clearly
displayed and removed beads shall be retained for inspection by the Engineer.
g) The width of each external bead width shall be measured using bead gauges
and the width of the bead shall be within the range given by the pipe and / or
welding equipment MANUFACTURER.
h) No signs of damage (such as scratches or deep impressions caused by clamps)
shall be visible on either side of the joint.
i) Any joints the do not comply with the above requirements shall be cut out and a new
joint made; the failed joint shall be handed over to the Engineer.
j) Records of all tests and inspections shall be maintained by the Contractor and made
available for review and approval by the Engineer.
25.3.4 Testing of Joints
A A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under
laboratory conditions in accordance with ISO 13953 by an approved testing
organization. The joints to be tested shall be selected by the Engineer immediately upon
completion of the welding process, whereupon they shall be cut out and delivered for
testing.
B A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested
under laboratory conditions in accordance with ISO 13954 by an approved testing
organisation. The fittings to be tested shall be selected by the Engineer immediately upon
completion of the welding process, whereupon they shall be cut out and delivered for
testing. They shall comprise at least 1 of each type of electro-fusion fitting even if this
requires more than 1 % of all electro- fusion fittings to be tested. Please note that the test
requirement is for one fitting of each type i.e. bend, coupling, tapping saddle, tee etc. not
one of each size and type.
C All costs associated with the testing, together with any consequent rectification of faults
and retesting shall be borne by the Contractor.
25.3.5 Tying-In
A Where sections of the line are to be tied-in after being laid and filled in the trench
the length of pipeline left un-backfilled shall be kept to a minimum, but shall be sufficient to
allow some flexibility in the uncovered pipe and to facilitate the tying-in process.
B Tie-in joints in restrained sections of the line shall be made when the ambient temperature
is at the daytime minimum, as far as is practical, to avoid strain in the pipe. Under no
circumstances shall the line be left in tension after the completion of a tie-in
connection.
C Bell holes made in the trench bottom to facilitate electro-fusion or mechanical jointing shall
provide adequate clearance to enable the jointer to undertake their work without any
restrictions.

D Tie-ins after hydro-testing shall be kept to a minimum and will be permitted only where
E The Contractor shall ensure prior to hydrostatic testing that sufficient length of pipe
(overlap) is available to facilitate tying-in.
25.3.6 Hydrostatic Testing
General
A A. Upon substantial completion of the pipeline or major sections, the line shall be cleaned
and hydrostatically tested to prove integrity of the pipeline section and to detect any
leakage prior to commissioning. Testing shall be performed in accordance with the
Finnish Standard SFS 3115:E and the procedure described below. The Contractor shall
supply all necessary fittings, equipment and facilities required to undertake the testing.
B The Contractor shall prepare a detailed Method Statement for the pressure test that shall
follow the procedure described below and be subject to the approval of the Engineer.
Test Procedure
A Seal the pipeline. Fix all blank flanges. Remove all on line equipment that may be
damaged by high pressure.
B Only test against blank flanges, do not attempt to test against closed valves.
C Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints
exposed where practical.
D If backfilling is not practicable schedule the tests for early morning or evening.
E Fill the pipeline from the lowest point. Bleed the air from all high points and flange
points where it is possible and tighten once water begins to spill.
F When the line is full, close off the filling valve and check all flanges and the small diameter
test pipework for leaks.
Phase 1
Commence raising the pressure at the filling point to the operating pressure or a
pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and add
water whenever the pressure drops by 0.2 bar in order to maintain a steady pressure.
Phase 2
After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar,
whichever is higher, as quickly as practical. Again maintain this pressure for two hours by
adding water whenever the pressure drops by 0.2 bar.
Phase 3
At the end of the second two hours release the pressure back down to the phase
I level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes and
as quickly as is practical, in a controlled manner.

Phase 3 – Case 1
If after one hour the pressure in the pipelines remains at or above the operational
pressure, the test is considered to be completed with the pipeline passing the hydrostatic
test.
Figure 25-1: Graphical Representation of the Hydrostatic Test Process Case 1
Above Figure shows Graphical Representation of the Hydrostatic Test Process Case 1 –
Pipeline passes test without adding any make up water
Phase 3 – Case 2
If after one hour the pressure in the pipeline has fallen below the operational pressure,
water shall be added to raise the pressure back to the operating pressure level,
having first noted the low pressure before adding any water.
Phase 3 – Case 3
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce
pressure to the previously recorded low value and save the water bled off). The measured
quantity is then compared against the allowable quantity to determine if the pipeline
passes the hydrostatic pressure test.

Figure 25-2: Graphical Representation of the Hydrostatic Test Process Case 2
Above figure shows Graphical Representation of the Hydrostatic Test Process Case
2 – Water to be added to determine if the pipeline passes or fails
G Test Result
If during Phase 3 the pressure within the pipeline remains at or above the
operational pressure of the pipeline for a period of at least one hour, the pipeline is
considered to have passed the hydrostatic test.
If water needs to be added the pipeline is considered to have passed the
hydrostatic test if the quantity of water added in terms of litres of water per km of pipeline
length per hour of the phase 3 period is less than that given in the following expression
and in Figure 25-3.
Q ≤ Di/50 – 1 (litres / km / hour)
Q = added water in litres.
Di = internal diameter for the pipeline in mm.

Figure 25-3: Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water
H Notes on Test Equipment
The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be
connected to the feed pipe work.
The small diameter test pipe work shall include a bleed valve at upper end of the pipeline
and at all high points together with feed pipe work and valve at the lower end of
the pipeline. The feed pipe work shall include a means of draining off the water in to a
measuring cylinder that shall have a capacity of at least 2 litres capacity, graduated to 100
mls.
The Contractor shall also have a thermometer for air and water temperature
measurement.
I Differences in elevation
Care should be taken not to over pressure the lower end of the system during
testing. Gauges should always be placed at the lower end of the length under test. As far
as possible, the difference between the lower and upper end should be kept to one bar. It
is recognized that this may not always be possible when longer lengths are being
tested, or where the slope of the pipeline makes it impractical.
J Test pressures at elevated temperature
Where the phase II pressure is within the pressure rating of the pipe and test
temperatures are 30 °C or less no adjustment of test pressure is necessary.
When ambient temperatures at the time of test are over 30 °C and test pressures
are over the pressure rating of the pipe then it may be necessary to modify the test
pressure according to the table below or as agreed with the pipe Manufacturer and
Engineer.
Test Temp. (OC) 32 38 43 49 54 60
Multiplier 0.9 0.8 0.75 0.65 0.6 0.5
K Additional Notes
Care should be taken that any mechanical elements on the system are protected
from elevated pressure or completely removed from the pipeline.

Do not subject the line to prolonged over-pressure. Always aim to complete the procedure
within one working day.
During the summer, make sure that the pipe is not subject to direct sunlight during
testing.
During pressure testing pay full attention to the HSE aspects of the procedure. In
particular, keep the public away from high-pressure test areas.
The test equipment must be capable of pressurizing the test length within a
reasonable time. If the procedure becomes protracted (beyond one working day) the test
length may be modified or reviewed. Extremely long test lengths may be subject to special
procedures.
END OF SECTION

TABLE OF CONTENTS
TECHNICAL SPECIFICATION FOR WATER NETWORK 3
PART 1 GENERAL REQUIREMENT 3

1.1 FORMAT AND REFERENCING 3
1.2 ABBREVIATIONS AND DEFINITIONS OF TERMS 4
1.3 SCOPE AND CONTROL OF WORKS 9
1.4 TEMPORARY WORKS 17
1.5 CONTROL OF MATERIALS AND STANDARDS FOR SAMPLING AND TESTING 17
1.6 CONTRACTOR'S PLANT AND EQUIPMENT 20
1.7 MEASUREMENT PROCEDURES 21
1.8 TEMPORARY FACILITIES 23
1.9 SAFETY PRECAUTION MEASURES 26
PART 2 EXCAVATION AND BACKFILLING 26

2.1 SCOPE 26
2.2 SITE CLEARING 26
2.3 EXCAVATION 26
2.4 FILLING AND BACKFILLING FOR STRUCTURES 38
2.5 SUBGRADE CONSTRUCTION 49
2.6 GABIONS 51
2.7 STONE PITCHING IN CONCRETE 52
2.8 GEOTEXTILES 53
PART 3 PAVEMENT AND ROADS SURFACE FINISHING 54

3.1 SCOPE 54
3.2 GRANULAR SUBBASE AND BASE COURSES 54
3.3 BITUMINOUS LAYERS 57
3.4 PAVEMENT REPAIRS AND TRENCH REINSTATEMENT WORKS 62
3.5 CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS 64
3.6 MAINTENANCE OF TRAFFIC AND DETOURS 69
PART 4 PIPE WORKS AND NETWORK ACCESSORIES 70

4.1 SCOPE 70
4.2 GENERAL REQUIREMENTS 70
4.3 PIPES, FITTINGS AND ACCESSORIES 75
4.4 VALVES, GATES, STOPS, WATER CONECTION S FIRE HYDRANTS AND SUNDRY
WORKS 93
4.5 BEDDING, SURROUND, HAUNCHING, ENCASEMENT AND THRUST BLOCKS 106

19-Sep-2022
4.6 CHAMBERS AND INLETS 107
4.7 RECORDS 108
PART 5 CONCRETE WORKS 110

5.1 CONCRETE AND CONCRETE MIXES AND TESTING 110
5.2 CONCRETE HANDLING, PLACING AND CURING 128
5.3 STEEL REINFORCEMENT AND FIXING 138
5.4 FORMS, FORMWORK AND FALSEWORK 141
5.5 PLAIN AND REINFORCED CONCRETE STRUCTURES 148
5.6 WATERPROOFING FOR STRUCTURES 151
5.7 JOINT SEALING AND JOINT FILLER 157

19-SEP-2022
TECHNICAL SPECIFICATION FOR WATER NETWORK
PART 1 GENERAL REQUIREMENT
1.1 FORMAT AND REFERENCING
1.1.1 FORMAT OF SPEICIFICATIONS
A Part
1. This Specification is divided into Parts. Each Part is designated by a single- or double-
digit number followed by a title. (Part 1 General Requirements)
B Section
1. Each Part is divided into Sections. Each Section is designated by the Part number, a
decimal point and a 2-digit sequential number, followed by a title. (Section 1.01 Format
and Referencing)
C Subsection
1. Each Section is divided into Subsections. Each Subsection is designated by the Part
number, a decimal point and a 2-digit Section number, a decimal point and a single- or
double-digit number followed by a title. (1.01.1 Format of Specifications)
D Clause
1. Each Subsection may be divided into Clauses. Each Clause is designated by sequential
alphabetic letters and a decimal point. (D.)
E Item
1. Each Clause may be divided into items. Each Item is designated by the Clause letter, a
decimal point and a single- or double-digit sequential number, followed (if required) by a
title in lower case lettering. The text then normally follows on the same line (E.1).
1.1.2 REFERENCING
A The Specifications for Items in the Bills of Quantities are prescribed in the respective
Section/s corresponding to the type of Works involved.
B All the provisions of these Section/s shall be construed as Specifications for such Items of
Work, except in respect of those provisions clearly inapplicable in the context in which they
appear or unless they are waived or modified in the Contract Documents or by Variation
Orders.
C Specifications and Drawings may contain cross references to other Sections, Clauses,
Items, etc., which shall likewise be construed as Specifications for the Item of Work
involved.
D Any references in the Specification to Work or materials not required will be deemed
inapplicable.

Water Network Specifications 19-Sep-2022
1.2 ABBREVIATIONS AND DEFINITIONS OF TERMS
1.2.1 ABBREVIATIONS
A Interpretation
A Wherever the following abbreviations of titles, terms and units of measurement are used in
the Specifications or on the Drawings, the intent and meaning shall be interpreted as
described hereunder.
B Titles and Terms
 AASHTO - American Association of State Highway and Transportation Officials:
 ABS : Acrylonitrile-Butadiene-Styrene
 ACI : American Concrete Institute
 AISC : American Institute of Steel Construction
 AISI : American Iron and Steel Institute
 ANSI : American National Standards Institute
 API : American Petroleum Institute
 ASTM : American Society for Testing and Materials
 AV. : average
 AWG : American wire gauge
 AWS : American Welding Society
 AWWA : American Water Works Assoication
 bit. : bitumen/bituminous
 BS : British Standard
 BSSC : bituminous slurry seal coat
 BST : bituminous surface treatment
 CB : circuit breaker
 CBR : California Bearing Ratio
 conc : concrete
 CIE : Commission Internationale de l'Eclairage
 DBSC : double bituminous seal coat

 DIN : Deutsches Institute Fur Normalizieung
 Equiv : equivalent
 FSS : Federal Standard Specification (USA)
 hwy : highway
 ht : height
 H:V : horizontal:vertical
 IEC : International Electrical Commission
 IEE : Institution of Electrical Engineers (UK)
 ISO : International Organization for Standardization
 L.L. : liquid limit
 L.S. : lump sum
 max : maximum
 MCCB : molded case circuit breaker
 min : minimum (or minute)
 MUTCD : Manual on Uniform Traffic Control Devices
 NEC : National Electrical Code (UK)
 NEMA : National Electrical Manufacturers' Association (USA)
 NJB : New Jersey barrier
 pav't : pavement
 P.C. : prime cost
 PCC : Portland cement concrete
 PE : polyethylene
 P.I. : plasticity index
 P.L. : plastic limit
 PTFE : Polytetrafluoroethylene
 qty : quantity
 RC : reinforced concrete

 RCP : reinforced concrete pipe
 rdwy : roadway
 ROW : right-of-way
 SBSC : single bituminous seal coat
 S.G. : specific gravity
 SI : Systeme International D'Unites
 Sta : Station (location along a survey line)
 SWG : standard wire gauge (UK)
 TBSC : triple bituminous seal coat
 VDE : Verband Deutscher Electrotechniker
 wgt : weight
 GRP : Class reinforced plastic
 DI : Ductile Iron
 SASO : Saudi Arabia Standards Organization
C Units of Measurement
1. Throughout the documentation units of measurement are referred to by symbols as

follows:
 Nr : number
 mm : millimeter/s
 cm : centimeter/s
 m : meter/s
 lin.m : linear meter/s
 km : kilometer/s
 sq.mm : square millimeter/s
 sq.cm : square centimeter/s
 sq.m : square meter/s
 ha : hectare/s
 cu.m : cubic meter/s

 gm : gram/s
 kg : kilogram/s
 tonne : metric ton (1,000 kg)
 ml : milliliter/s
 ltr : liter/s
 Pa : Pascal/s
 N : Newton/s
 kN : kilo Newtons
 MN : mega Newtons
 A : amperes
 mA : milli amperes
 V : volt/s
 W : Watt
 kW : kilowatt
 C : Celsius (Centigrade)
 Hz : Hertz (Frequency)
 rpm : revolutions per minute
 km/h : kilometers per hour
 sec : seconds
 min : minute/s (or minimum)
 h : hour/s
 mS : milli Siemens
 dB : decibel/s
 dBA : decibels absolute
 ppm : parts per million
 in. : inch/inches (1 in. = 25.4 mm)
 ft : foot/feet (1ft = 0.3048 m)

 sq.in : square inch/inches
 sq.ft : square foot/feet
 cu.ft : cubic foot/feet
 lb. : pound/s (weight)
 psi : pounds per square inch
 gal : gallon/s (U.S.)
 gal(Imp) : gallon/s (Imperial)
 mph : miles per hour
 HP : horsepower
 USG : American gage
1.2.2 DEFINITIONS
A Wherever in the specification or in other Contract Documents any of the following terms is
used, the intent and meaning shall be interpreted as follows:
 ACCEPTED - Accepted in writing by the Engineer (or by the Employer where appropriate) as
meeting the requirements of the Contract Documents and of any authorized variations thereto.
"Acceptance" means accepted in writing as aforesaid. "Acceptable" means acceptable to the
Engineer as aforesaid.
 ADDENDUM/NOTICE - Amendment of or revision to any of the Contract Documents issued to

Tenderers, and which is deemed to form part of the Contract Documents.
 APPROVED - Approved in writing by the Engineer, including subsequent written approval or

confirmation of previous verbal approval by the Engineer. "Approval" means approval in writing as
aforesaid.
 CERTIFICATE OF GUARANTEE - A signed statement by a person having legal authority to bind a

company or supplier to its product, and which confirms that the materials and test results conform
to the standards of these Specifications.
 DIRECTED - Directed in writing by the Engineer, including subsequent written direction or

confirmation of previous verbal direction by the Engineer.
 PRESPLITTING - Establishment of a free surface, or shear plane, in rock cuts, by controlled use of
explosives in specially aligned and closely spaced drill holes along the slope line.
 SHEATHING - Backfilling to the inside faces of structures such as retaining walls and abutments,
using proprietary filter cloth and porous blocks, or using selected, free-draining material such as
gravel or non-cementitious sand, etc, prior to placing and compacting normal backfill.

 SOIL STABILIZATION - Procedure whereby cement, bitumen or lime is added to soils (subgrade
layer) or to granular materials (sub-base course) in order to improve their load bearing capacity
and their resistance to weathering and displacement.
 SUBGRADE - The top surface of embankment or excavated area on which the pavement structure
and shoulders are constructed. Also referred to as Subgrade Surface or Subgrade Level.
 SUBGRADE LAYER - The top layer of material, of at least 200 mm compacted thickness,
immediately below the subgrade surface.
 SUBSIDIARY WORKS - Works which are subsidiary to or necessary or essential to, or in support
of, or usual to, the execution and completion of other Works.
 WORKING DRAWINGS - Shop drawings, steel bending schedules, stress sheets, fabrication and
erection drawings, falsework drawings, and any other supplementary drawings or data which the
Contractor is required to submit to the Engineer for approval, generally before such Works
commence.
1.3 SCOPE AND CONTROL OF WORKS
1.3.1 INTENT OF CONTRACT
A The intent of the Contract is to provide for the construction and completion in every detail
and subsequent maintenance of the Works described. The Contractor shall furnish all
labour, materials, tools, equipment, transportation, supplies and facilities and shall carry
out all Permanent and Temporary Works and all other items necessary for proper
completion of the Works in accordance with all requirements of the Contract Documents.
B Where the Specifications or Drawings describe any portions of the Works in outline only,
and not in complete detail, the best general engineering practice shall prevail and only first
quality materials and workmanship shall be used.
1.3.2 SILENCE OF SPECIFICATIONS
A The apparent silence of the Specifications, Drawings or other Contract Documents as to

any detail or the apparent omission from them of a detailed description concerning any
Works or requirements, shall be regarded as meaning that good engineering practice shall
apply and shall be to the approval of the Engineer.
1.3.3 CONTRACTOR'S WORK AREAS
A The Contractor shall make all necessary arrangements, including payment if need be,
regarding any land outside the Site that may be needed as work areas. The Employer will
not acknowledge any liability in respect of such land. The Contractor shall also be
responsible for insuring that all roads and temporary facilities needed are sufficient to
divert traffic adequately.
B The Contractor shall locate and select sites outside the right-of-way for the use of his plant,
equipment, site offices, residences, Temporary Works or any other uses which are
essential during the execution of the Contract. The Contractor shall take the necessary
measures for using these sites and shall be responsible for all expenses that may become
due in return for such use. Prior to using any land owned by public or private owner
outside the Site, the Contractor shall obtain the approval of the concerned Authorities and
the Engineer.

C C.The Contractor, if so required by the Engineer, whether before or after completion of the
Works, shall remove his constructional plant and duly clean the site and shall, wherever
applicable, remedy all damage and pay all monies due to land owners in return for using
their land.
D D.It is the Contractor's responsibility to verify the stability of side slopes in cut areas by
specialized staff. The Contractor, at his own expense shall execute any required site
investigation prior to cutting in the relevant areas. The proposal of site investigation
program as well the final recommendation should be approved by the Engineer. No direct
payment shall be made for this work, all expenses should be included in the Contractor's
rates.
E E.The Contractor shall inspect the location and the surrounding areas and comprehend all
the details related to the type, nature, details, topography and existing services of the
location.
F The Contractor shall acquire all the information related to risks, dangers, weather
conditions and any other related factors that may influence his tender, and no later
consideration will be made since these expenses should be added by the Contractor on
the prices of works and other items.
1.3.4 WATER SUPPLY
A The Contractor shall be deemed to have executed adequate investigations relating to the
availability of water for the purpose of the Works and to have consulted and arranged with
the appropriate Authorities and taken into consideration all legal aspects. The Contractor
shall be responsible for the supply of sufficient clean, fresh water at all times during
progress of the Works, including making temporary arrangements for storing and
distributing the water on the Site.
1.3.5 ELECTRICITY SUPPLY
A The Contractor shall make his own arrangements for the supply of all electrical power and
all lighting and electrical equipment required for execution of the Works, including supplies
for commissioning engineering services and Plant at required voltages. The Contractor
shall also make provisions to store and distribute electrical power and equipment on Site.
B The Contractor shall provide and maintain adequate efficient lighting for all parts of the
Works for safety and security purposes required to facilitate proper execution of work and
to illuminate surfaces during finishing work and inspection. Without prejudice to his liability
under the General Conditions of Contract, the Contractor shall, with respect to the supply
of electricity for power or lighting, take all necessary precautions to ensure the safety of his
workmen and others.
C Permanent electric supply and lighting installations may be used for testing and
commissioning and to illuminate the Works, subject to the following conditions:
 The Employer does not guarantee that it will be available.
 The Contractor must take responsibility for the operation, maintenance and supervision of the
system, indemnify the Employer against all damage and pay all costs and renew all used tubes
and lamps.
 The Contractor must indemnify the Employer against any reduction in the manufacturer's
guarantee periods for equipment etc. due to its use before completion of the Works.

1.3.6 EXISTING UTILITIES AND OTHER OBSTRUCTIONS
A Categories of Obstructions
1. Obstructions shall be classified as follows:
 Existing private and public owned utilities, above and below ground, which are required to be either
protected, adjusted, relocated or removed.
 Obstructions, above and below ground (other than utilities), which are required to be taken down,
dismantled, demolished or excavated, and removed, as appropriate.
B Existing Utilities
1. Utilities shall include, but not be limited to, existing water lines, gas lines, sewer lines, wire
lines, service connections, water and gas meters and valve boxes, light poles and masts,
pylons, cableways, signals, and all utility appurtenances within the limits of the proposed
construction.
2. The Contractor shall submit all plans showing existing utilities under earth and their
relations with pipelines under construction.
3. The Employer/Engineer takes no responsibility as to the correctness, accuracy,
completeness or validity of information obtained from these Drawings and the Contractor
shall be fully responsible for his own interpretation and shall execute whatever additional
investigations are necessary to obtain the needed information at the Contractor's own
expense.
4. The costs of all related Works concerning verification and identification of existing utilities
including excavating any trial pits, detection means, mapping detailing of drawings and co-
ordination with respective Authorities shall be fully borne by the Contractor. Should any
relocation of existing utilities, not previously identified by the Contractor, be instructed, or
shown on the Drawings, these shall not constitute a change in the Scope of Work and
shall give no grounds for extension to the Time for Completion or for other claims. The
relocations, however, will be paid for and valued in accordance with the Contract rates.
5. The necessary utility diversions may be specified or directed to be carried out by the
Contractor. Alternatively, the Employer may make arrangements for such works to be
executed by other parties.
6. The Contractor shall:
 Take into account that the diversion works shall be carried out to the requirements and approval of
the Utility Owners and/or under their supervision, and also where required by the Utility Owners,
specialist diversion works shall be carried out by accredited specialist Contractors.
 Verify and identify the existing utilities by excavating trial pits and other measures including
detection means existing utilities. Coordinate with the relevant Authorities and map these utilities
and prepare detailed and accurate existing utilities drawings identifying the utilities that are in
service and those that are dead or abandoned. Submit these existing utilities Drawings, that are
accurate and detailed giving location of utilities in plan and section with all pertinent data of the
respective utility, to the Engineer and to the Utility Owners.
 Work out and develop, in coordination with the Utility Owners and the Engineer, the approved
utilities diversion schemes that will be required to enable the execution of the Works and also
maintain continued utilities services in the Area, and to the users.
 Provide superintendence for the execution of the utility diversions whether they are carried out by
the Contractor directly or by other parties employed by the Contractor.

 Provide accurate As-Built Drawings of all permanent utility diversions that are executed under the
Contract.
2. The Employer will, in consultation with the Engineer and Contractor, coordinate with all
Utility Owners to ensure prompt adjustment, relocation or removal of all affected utilities,
including any additional utilities that may be encountered during the Works. The Employer
and Engineer will facilitate, to the maximum extent practicable, the Contractor's Work
Program, in this respect.
3. The Contractor shall take into account, in his Program of Work, the time effort involved in
the follow-up and execution of Works pertaining to all utility adjustments, relocations and
removals. The Contractor shall schedule construction activities so as to avoid or minimize
any potential delays, inconvenience or damage to the Works that may result from utility
interference or the operations of adjustment, relocations and removals.
4. The Contractor shall follow up the execution of the utility diversions whether they are
carried out directly or by other parties employed by the Contractor or directly by the
Employer. The Contractor shall, in good time, inform the Employer and the Engineer.
5. The Contractor shall be responsible for safeguarding and protecting all utilities and
appurtenances encountered during the Works. The Contractor shall be responsible for the
costs of making good any damage arising out of its own negligence.
6. The execution of the utility diversions should be done by similar materials of equivalent
grade or strength as minimum to the materials of the existing utilities and as per the
Engineer approval and the utility owners requirements.
7. In case it is required to stop the water in the existing network while execution of the utilities
diversions or replacement of existing water pipeline, the Contractor should inform the
Engineer and coordinate with the water supply authorities in advance by 48 hours. If the
water supply would stop for more than 48 hours, the Contractor should provide temporary
service for water supply on his own expenses, either using temporary pipelines or by water
tanker or any other way approved by the Engineer. In all cases, the Contractor should get
written license from the water supply authority including the required instructions.
8. Execution of the water networks diversions should be done as per the water networks
specifications stipulated in Section (4) of these specifications. Testing, cleaning and
disinfection of the pipelines should be done according to Section (4-3-3) of these
specifications.
C Obstacles
1. Obstacles shall include, but not limited to existing buildings, walls, fences, gates, wells,
septic tanks, manholes, pits, pipes, culverts, roadways, sidewalks, signs and rubbish
dumps, whether or not shown on the Drawings.
2. At the commencement of the Contract, the Contractor shall examine the Site and
identify/verify all obstacles in the Site above or below ground, and shall record all such
information on suitable Site Drawings which shall be submitted to the Engineer within one
month of commencement date.
3. Existing Septic Tanks:
If the pipelines or the house connections cross any existing septic tanks and it was not possible to change
the pipeline routing to avoid them, the Contractor should proceed to dry, clean, demolish and backfill those
tanks partially or fully.
Wherever possible, only the crossing part of the tank with the water pipeline that will be demolished and
backfilled and the rest of the tank should be separated by building a suitable wall to make the tank in a
good working condition. All precautions should be taken to keep the existing system working and to pump
the sewerage from the tanks and to dispose of the sewage according to the local authorities instructions.
The sewer water must not be allowed to leak to the water pipelines trenches or the water system.

In case of partial or full demolish, the top slab should be removed either fully or partially and the walls
should be lowered at least by 1m below the ground level. Filling should be as per the backfilling
specifications in this document.
All of the above requirements should be applied to all existing tanks including those constructed during this
pipelines contract and those crossing the pipelines.
Harmful gases concentration should be monitored using special gas monitoring devices before and during
commencing of the work in septic tanks. All laborers entering to the tanks must be provided with full safety
tools and gas masks, etc. and the Contractor must provide all first aid tools on site.
9. Change of Pipeline Rooting Around Tanks:
When existing tank crosses the proposed pipeline, the pipeline routing should be changed if possible,
around the tank leaving a 50 cm clear distance between the tank walls and the pipeline. Those pipelines
should be covered by plain concrete as per the Engineer recommendations.
The Contractor should prepare detailed drawings for the tank boundaries that cross the pipeline, showing
all the connection details that are required to relocate the pipe around the tank. This drawing should be
approved by the Engineer prior to construction.
1.3.7 SIGN BOARDS
A Nameboard: The Contractor shall provide suitably sized project nameboards, bearing the
names of the Employer and Engineer together with any corresponding logos, the name of
the project, the name of the Contractor and such other names and information as the
Engineer may request. The design and style of the nameboard shall be submitted to the
Engineer for approval prior to fabrication. Nameboards are to be written in English and the
local language and erected at suitable locations as directed by the Engineer. Refer to
Section 1.08.2 Item “G” for the nameboard details. As detailed in Section 1.08.2, Item E of
the specifications.
B Each sign board shall be erected in a prominent, approved position. Sign boards shall be
maintained in good order at all times and sign boards and supports shall be dismantled
and removed from the site upon completion of the Works.
C All sign boards are to comply with the requirements of concerned authorities (Municipality/
Ministry of Transport/Traffic Directorate).
1.3.8 SURVEYING EQUIPMENT
A The Contractor shall provide sufficient and suitable surveying instruments and other
equipment for his own use in setting out and leveling of the Works, and also to enable the
Engineer to check the setting out. Furthermore, the Contractor shall provide sufficient
chainmen and other assistance as the Engineer may require.
B The accuracy of survey instruments may be verified at any time by the Engineer and any
unsatisfactory instruments shall be promptly calibrated or removed and replaced by the
Contractor at its own expense.
C Upon completion of the Contract, all survey instruments shall remain the property of the
Contractor, unless a Pay Item for such instruments is included in the Bills of Quantities, in
which case the instruments shall become the property of the Employer.

1.3.9 SETTING OUT OF WORKS
A The Contractor shall, prior to any setting out, submit a planned method of operations for
setting out the Works to the Engineer for his approval. The plan shall include the
accuracy, positions of the various types of stakes, method of marking stakes, and methods
to be used for protecting stakes, etc. No survey work shall proceed without to the
Engineer's approval of the Contractor's plan.
B The Contractor shall give written notice to the Engineer at least 24 hours before he intends
to survey any portion of the Works. Such notice shall include the time, location and type of
Works to be set out.
C Before commencing Work on Site, the Contractor shall carry out a topographical survey of
the Site, as directed by the Engineer. This survey shall include such parts of the Site as the
Engineer may direct, to record the Site limits, dimensions, ground levels, obstructions and
other features and the survey shall establish base lines and points for future setting out
and also record the basis for re-measurement of excavation and earthwork, where
applicable. The Contractor shall set out the Works, inform the Engineer when setting out is
complete and obtain Engineer's approval before proceeding with construction. The
Contractor shall provide instruments and assistance for checking the setting out if required
by the Engineer. If, in the opinion of the Engineer, modification of the lines or grade is
required, before or after survey, the Engineer will issue detailed instructions to the
Contractor who shall revise the setting out accordingly.
D Setting Out Utility Works shall be as shown on the Drawings or as instructed on Site.
Stake-out shall be revised if, in the opinion of the Engineer, modifications of line or grade
are required.
E The Contractor shall be responsible for preserving all existing stakes, marks and
monuments and if any construction stakes or marks are destroyed or disturbed, the
Contractor shall replace them at his own expense.
1. Record Drawings: The Contractor shall record details of all grid lines, ex¬isting ground
levels, setting-out stations, benchmarks and profiles on the site setting-out drawing. This
drawing shall be retained on the Site throughout the duration of the Contract and handed
over to the Engineer upon completion of the Works.
2. All dimensions and levels on the Drawings and the Site, shall be checked particularly the
correlation between components and the work in place. Materials and components shall
not be ordered, or work carried out, until discrepancies have been resolved with the
Engineer.
3. Appearance and Fit: The Works shall be constructed to higher levels of accuracy than
those specified where it is necessary to achieve a desired appearance and also to ensure
that materials, elements, and components of the building fit together as designed.
Wherever the accuracy, fit or appearance of the work is likely to be critical, or difficult to
achieve, the Contractor shall obtain the Engineer's approval of proposals or of the partially
finished work as early as possible.
4. Non-Compliance: Work which fails to meet the specified levels of accuracy must not be
rectified before the Contractor submits and receives approval of proposed rectification
works. All additional costs resulting from these rectification works shall be borne by the
Contractor.
1.3.10 HAUL ROUTES FOR HEAVY VEHICLES
A The Contractor shall prepare proposals for routes to be used by heavy vehicles particularly
for hauling fill materials. Routes shall where possible, avoid existing roads and built-up
areas. Signs shall be provided and maintained to direct construction traffic to and from
haul routes. Details of haul routes and signing shall be submitted to the concerned in
Traffic Directorate for approval within a period not exceeding one month prior to the

commencement of the Works in the relevant area and the signs shall be erected prior to
actual commencement of the Works.
B If and where it is necessary for Contractor's plant or vehicles to cross public highways, and
where required by the Engineer, all such crossings shall be equipped with manually
controlled traffic lights.
C Stationary vehicles, equipment, huts, stockpiles of materials, etc., shall be kept well clear
of crossing points so that persons using the highway and the haul road shall have
adequate sight distance at all times.
1.3.11 SCAFFOLDING AND FALSEWORK
A The Contractor shall provide scaffolding and falsework to facilitate carrying out
construction of the Works in the required sequence. Scaffolding and falsework shall be
properly designed and constructed specifically for the loads intended. Full details of the
proposed arrangements shall be submitted to the Engineer for his approval. Such
approval, however, shall not relieve the Contractor of his responsibility with regard to the
adequacy of all scaffolding and falsework used in the Works.
1.3.12 USE OF EXPLOSIVES
A Control Measures
1. The Contractor shall not use explosives without the express permission from the
controlling Authority. The Contractor shall abide by all rules and regulations of the
concerned Authorities regarding purchasing, transportation, storing, handling and using
the explosive materials.
2. Explosives and detonators shall be stored in special buildings as approved by the
concerned Authorities. These secured buildings should be located and clearly marked
English and Arabic "DANGER - EXPLOSIVES" as approved by the concerned authorities.
Explosives and detonators shall be stored in separate buildings.
3. All possible precautions shall be taken against accidental fire or explosion, and to ensure
that the explosives and detonators are kept in proper and safe condition.
4. Explosives and detonators shall always be transported in separate vehicles and kept apart
until the last possible moment. Metallic tools shall not be used to open boxes of
explosives.
B Blasting Procedures
1. Ensure that blasting shall only be carried out by experienced shot firers. Priming,
charging, stemming and shot firing shall be carried out with greatest regard for safety and
in strict accordance with the Rules and Regulations of the concerned Authorities.
Adequate warning of blasting shall always be given and all persons cleared from the area,
before blasting takes place.
2. Ensure that police and other concerned Authorities shall be kept fully informed of the
blasting program so that they may be present when blasting takes place if they so require.
3. Ensure that explosive charges are not excessive, charged boreholes are properly
protected, and proper precautions are taken for the safety of persons and property. Only
the Contractor shall be responsible of people and premises full protection.
C. Explosives Inventory
1. The Contractor shall maintain an up-to-date inventory of all explosives and explosive
devices and shall submit a monthly report to the Engineer, detailing the use of all
explosives by date and location.

1.3.13 FIRE FIGHTING EQUIPMENT
A The Contractor shall take all necessary measures to prevent personal injury or death or
damage to the Works or other property and adequate, fully operational fire fighting
equipment shall be furnished and maintained by the Contractor whose workmen shall be
trained in the operation of such equipment.
B Fire fighting arrangements shall be made as required by the local Civil Defence
Department and provision of fire fighting facilities in all vulnerable areas and as instructed
by the Engineer.
C Adequate water for fire fighting shall be available and outlets located so as to be readily
accessible.
D All equipment shall be regularly tested and properly maintained.
1.3.14 PHOTOGRAPHIC RECORDS OF CONSTRUCTION
A The Contractor shall submit each month good quality progress photographs of at least 5
different subjects as agreed by the Engineer. For each subject, the Contractor shall supply
progress photographs taken from approved locations stations but not less than 20 (twenty)
at monthly intervals and submit 3 color prints (gloss finish) not less than size 16 cm x 20
cm of each negatives and color transparency.
B Each print and transparency supplied, shall be titled and referenced to a suitable key plan.
Prints and negatives shall also be suitably cross referenced.
1.3.15 SITE CLEANING AND FINAL CLEAN UP
A Site Cleaning During Progress of Works
1. All parts of the Site, and adjacent roads affected by the Works, shall be maintained in a
clean and tidy condition during progress of the Works. All waste and surplus materials and
other rubbish resulting from the Works or otherwise, shall be cleared away to locations
approved by the Municipalities and Directorate at intervals as directed by the Engineer.
10. If the Contractor fails to remove any surplus or waste materials from the Site within 3 days
after being instructed to do so by the Engineer, these materials may be removed by others
at the Contractor's expense.
B Final Clean Up on Completion
1. The entire Site shall be delivered up on completion of the Works, in a clean, neat and
presentable condition, all as specified hereunder and as described in the General
Conditions of Contract.
2. Spoil tips, borrow pits and deposited materials shall be trimmed and regularized to profiles
and levels as directed. Flow of water courses affected by the tips or pits shall be
maintained without interruption and any agreement concerning these sites, existing
between the Employer and the persons or Authorities concerned, shall be observed.
3. Temporary Markings coverings and protective wrappings shall be removed unless
otherwise instructed by the Engineer.
4. Partial Possession by Employer: Where the Works are to be completed in sections, and
any such section depends for its adequate functioning on work located elsewhere on the
Site, such other work shall be completed in time to permit sectional completion as
required.

1.4 TEMPORARY WORKS
1.4.1 SCOPE
A The Contractor shall construct, as required, all temporary detour roads, temporary bridges
and culverts, and other facilities for his Works or for maintenance of traffic in locations
affected by his works.
B The Contractor shall construct and maintain all detour routes ensuring at all times that the
detour routes are signed, striped, lighted, maintained and furnished with all traffic control
devices as shown, directed and/or needed. These proposed detours must be submitted to
C Trench crossings are to be provided for free and safe passage of vehicles and pedestrians
over pipe and other trenches.
1.4.2 DESIGN REQUIREMENTS
A Designs and detailed working drawings for proposed Temporary Works shall be submitted
for approval, prior to commencing such Works. The Contractor shall be held responsible
for any damage that may result from the Temporary Works.
1.4.3 AGREEMENT OF PROPERTY OWNERS
A The Contractor shall obtain the agreement of the affected land owners and approval from
the Engineer prior to commencing Temporary Works. Such approval shall not in any way
relieve the Contractor of his responsibilities expressed in the General Conditions of
Contract.
1.5 CONTROL OF MATERIALS AND STANDARDS FOR SAMPLING AND TESTING
1.5.1 STORAGE OF MATERIALS
A Materials shall be so stored as to assure the preservation of their quality and suitability for
the Works. Stored materials, approved before storage, may again be inspected prior to
their use in the Works. Stored materials shall be located so as to facilitate their prompt
inspection.
B Where materials are stockpiled on Government or private property, such sites shall be
abandoned immediately upon consumption of all stockpiled materials and the natural
surface shall be restored as far as practicable to the original condition by the Contractor
1.5.2 HANDLING MATERIALS
A All materials shall be handled in such manner as to preserve their quality and suitability for
the Works. Aggregates shall be transported to the Works in vehicles, which are
constructed to prevent loss or undue segregation of materials after loading and unloading.
1.5.3 MATERIALS SUPPLIED BY EMPLOYER
A The Contractor shall be responsible for all materials furnished by the Employer and shall
make good any shortages or deficiencies, from any cause whatsoever, or any damage
which may occur, after delivery of such materials.

1.5.4 LOCAL MATERIAL SOURCES
A When material sources are not designated on the Drawings, or in other documents, the
Contractor shall be responsible for locating and providing suitable materials from approved
sources.
B Any information provided in the tender documents about sources of local materials is
considered as a guideline only and does not relieve the Contractor of his responsibility in
respect of investigation and supply of suitable materials as specified.
C Materials, regardless of their source, shall not be incorporated in the Works until approved
by the Engineer.
1.5.5 SOURCES OF SUPPLY AND QUALITY REQUIREMENTS
A All materials, including manufactured articles, and machinery incorporated in the Works,
shall meet all specified quality requirements and be approved by the Engineer.
B The Contractor shall, before placing any purchase order for any materials intended for
incorporation in the Works, submit for approval a complete description of all such
materials, names of the firms from whom he proposes to purchase them and copies of all
test reports verifying conformity with the provisions of the Specifications. Materials shall
not be ordered without the approval of the Engineer. When directed by the Engineer or
otherwise specified, the Contractor shall submit suitable samples for approval.
C The Engineer shall have the right to retest all materials which have been tested and
accepted at the source of supply after delivery to the Site and prior to incorporation into the
Works and to reject any such materials which are clearly defective or, when retested, do
not conform with the Specifications.
1.5.6 CERTIFICATES OF GUARANTEE AND PRODUCTION PLANT INSPECTIONS
A All shipments of materials shall be accompanied by a Certificate of Origin and a

Manufacturer's Certificate of Guarantee or Test Certificate from an approved independent
qualified laboratory approved by the Engineer. All certified materials delivered to the Site
shall undergo additional laboratory testing if required by the Engineer.
B Issuance of an invalid or erroneous Certificate of Guarantee shall be just cause for

rejection of the materials without further testing.
1.5.7 SAMPLING AND TESTING PROCEDURES
A Sampling
1. Samples of all materials shall be submitted to the Engineer for inspection, testing and
acceptance before incorporation in the Works. All materials being used will be subject to
inspection, testing, or rejection at any time prior to such incorporation.
11. Where untested and unaccepted materials have been used without approval of the
Engineer, such use shall be at the Contractor's risk.
B Source Tests
1. All source samples shall be taken by the Contractor in the presence of the Engineer, using
approved sampling procedures. All source approval tests shall be performed under the
supervision of the Engineer or, when so specified, by an independent laboratory approved
by the Engineer and engaged by the Contractor.
12. After approval of any source of materials, the Contractor shall produce from such source

only to the extent that materials produced are of substantially the same quality as the
approved samples.
13. The Engineer will periodically order retesting of previously approved sources to verify that
they continue to conform to the Specifications and may order retesting at the same or at a
different laboratory from the one performing the original source approval tests. If retesting
indicates that a previously approved source no longer conforms with the Specifications,
the Contractor shall forthwith cease production from such source.
C Job Control Tests
1. Job control tests shall be performed by the Contractor prior to submitting any materials to
the Engineer for approval. The Contractor shall submit details to the Engineer of his job
control testing program.
2. The Engineer may declare the Contractor's job control testing program unacceptable if
frequent rejections of submitted materials occur when subjected to the Project Control
Tests.
D Project Control Tests
1. All Project Control samples shall be taken jointly by the Engineer and the Contractor.
Tests shall be performed in the Site Laboratory, or in situ as appropriate, under the
supervision of the Engineer.
2. The Engineer may order retesting of any material if there has been a significant delay in
the construction operations or if he determines that the material has deteriorated since its
original acceptance. Material which does not conform with the Specifications will be
rejected and shall be removed from the Works and replaced or corrected by the
Contractor. The Engineer may order additional testing to ascertain the extent of
unacceptable material.
E Check Tests
1. The Engineer may periodically order check tests to verify the accuracy of Project Control
testing and equipment. The Engineer may direct that check tests be performed by
qualified persons other than those normally responsible for Project Control testing, or he
may direct that the samples be sent to the Employer's Central laboratory or to an approved
independent laboratory for testing.
2. The Contractor shall provide the Engineer with all necessary Test Report forms and
expendable materials required to perform all required tests. Copies of all test results will
be issued to the Contractor.
1.5.8 SAMPLING AND TESTING STANDARDS
A Standards to be Supplied
1. The Contractor shall, at the commencement of the Contract, furnish for use on site by the
Engineer and the Contractor one complete set of the following standards. The set shall
become the property of the Contractor upon completion of the Works.
a) AASHTO Standard Specifications for Transportation Materials and Methods of
Sampling and Testing (Part I: Specifications, and Part II: Tests).
b) ASTM Standards for Testing and Materials: Section 00 plus all Volumes in Sections
1 to 6 inclusive, plus Specifications, as required, from Sections 7 to 15 inclusive.
c) British Standards referred to in the Specification
d) SASO Standards.
e) DIN
f) ISO

g) All other relevant Standards referred to in the Specifications.
B Precedence of Materials and Testing Specifications
1. All references to methods of testing or specifications of AASHTO, ASTM and others will be
deemed to refer to the latest methods of testing as specified in the Contract Documents.
2. Unless otherwise specified, AASHTO methods of sampling and testing shall be adopted
where available. In the case of absence of an appropriate AASHTO specification, the
ASTM or BS specification shall govern.
1.5.9 UNACCEPTABLE MATERIALS
A All materials not conforming to the requirements of the Specifications at the time they are
used will be rejected and shall be removed immediately from the Site unless otherwise
instructed by the Engineer.
B No rejected material, the defects of which have been corrected, shall be used until
approval has been given.
1.6 CONTRACTOR'S PLANT AND EQUIPMENT
1.6.1 GENERAL
A Plant and equipment used on the Works shall be of sufficient size and in such mechanical
condition as to meet the requirements of the Specifications and shall be available for use
when required by the Engineer. The Engineer may order removal and replacement of
unsatisfactory plant or equipment.
B Wherever plant or equipment of a particular size or type is specified, the Contractor may
request permission to use an alternative type in place of that specified. In such cases, the
Contractor shall furnish evidence to the Engineer, before approval is given, that the
production of the plant or equipment proposed is at least equal to that of the specified type.
1.6.2 CONTRACTOR'S SCHEDULE OF PLANT AND EQUIPMENT
A The Contractor shall submit together with his Tender, a detailed schedule of the numbers
and types of plant and equipment which he proposes to utilize on Site to carry out the
Works. The schedule shall contain full details for each item, including type, manufacturer,
model, identification number, year of manufacture, number of years in use, and, for all new
and previously used items, the manufacturer's brochures, catalogues and specifications.
1.6.3 PROVISION AND USE OF PLANT AND EQUIPMENT
A The Contractor shall furnish all plant and equipment listed in his Schedule and necessary
for construction of each phase of the Works. Such plant and equipment shall be delivered
to the Site, inspected, and approved by the Engineer prior to commencement of the
particular phase of the Works for which it is intended. Any plant or equipment, or part
thereof, which becomes excessively worn or defective shall be promptly repaired or
replaced, as required by the Engineer.
B The Contractor shall not remove from the Site any approved plant or equipment without the
permission of the Engineer.

1.7 MEASUREMENT PROCEDURES
1.7.1 GENERAL
A All Works shall be measured net and in accordance with of the General Conditions of
Contract. All units of measurement shall be in the Metric System, unless specified
otherwise.
B The method of measurement and computations to be used in determining quantities of

materials furnished and of Works performed shall be as defined in the Method of
Measurement.
C All field measurements of quantities for monthly certificates and for final payment shall be
made by the Contractor in the presence of the Engineer. Original copies of the field
measurement notes, signed by the Contractor, will be retained by the Engineer.
D If the Contractor fails to measure any Pay Items, the Engineer may, at his discretion,
estimate quantities of such items for the monthly Payment Certificate or recommend that
no payment be made for the Items not measured and quantities not computed until it is
measured.
1.7.2 MANUFACTURED ITEMS
A Whenever standard manufactured items are specified, such as fence wire, plates, rolled
shapes, pipe conduit, etc. and these items are identified by gauge, unit weight, section
dimensions, etc., such identifications shall be deemed to be nominal weights or
dimensions. Unless controlled by tolerances in cited specifications, manufacturing
tolerances established by the industries involved may be accepted by the Engineer at the
recommendation of the Concerned Authorities.
1.7.3 FITTINGS AND ACCESSORIES
A When any Items are shown on the Drawings or specified as requiring miscellaneous
fittings and accessories for which no separate measurement is provided, the Pay Item will
be deemed to include for all such fittings and accessories.
1.7.4 WEIGHT MEASUREMENTS
A All materials which are to be measured or proportioned by weight shall be weighed on

accurate and approved scales by competent and qualified personnel, at locations
designated or approved by the Engineer.
1.7.5 LINEAR AND AREA MEASUREMENTS
A All items which are to be measured by linear meter shall be measured parallel to the base
or foundation upon which such items are placed, unless otherwise shown on the Drawings.
B Unless otherwise specified, longitudinal measurements for area computations shall be

made horizontally and no deductions shall be made for fixtures with an area less than one
sq.m. Transverse measurements for area computations shall be the neat dimensions
shown on the Drawings or as ordered by the Engineer.
C No measurements shall be made of rolled down or sloping edges of bituminous courses.

1.7.6 VOLUME MEASUREMENTS IN VEHICLES
A Materials to be measured by volume in the hauling vehicle shall be hauled in approved

type vehicles and measured therein at the point of delivery. Vehicles for this purpose may
be of any size or type approved by the Engineer, provided that the body is of such shape
that the actual contents may be readily and accurately determined. All vehicles shall be
loaded to their level capacity and the Engineer may require loads to be releveled when the
vehicles arrive at the point of delivery.
B When requested by the Contractor and if approved by the Engineer, material specified to
be measured by the cu. m. may be weighed and such weights will be converted to cu. m.
for payment purposes. Factors for conversion from weight measurement to volume
measurement will be determined by mutual agreement between the Engineer and the
Contractor, if no agreement is obtained, the factors will be determined by the Engineer and
shall be accepted by the Contractor.
1.7.7 EARTHWORK VOLUME MEASUREMENTS
A The quantities of excavation paid for under the Contract unit prices shall be limited to the
lines shown on the Drawings and on approved cross sections. Excavation beyond lines
shown on approved cross sections shall not be paid for unless approved by the Engineer.
Excavation in excess of approved cross sections will be measured for payment only in the
case of unstable or unsuitable materials ordered by the Engineer to be removed.
B The Engineer will adjust the angle of slopes for cuts and fills as the Works proceed and
make determinations of the appropriate slope angles following his evaluation of soil
conditions in case there is a change in the type of the soil. The actual slopes of the cuts
as constructed shall be measured and recorded by the Contractor. The Engineer will
check these records and, if satisfactory, will approve the measurements as a basis for
payment.
C Within 60 days of the date of field survey, the Contractor shall submit to the Engineer for
his approval, plots of the original and final earthwork cross sections together with the area
and volumetric earthwork computations. The Contractor's cross sections shall be on
transparent cross section sheets for print reproductions. All sheets shall have a title block
and be of the size designated by the Engineer. On final approval of the Contractor's cross
sections, the Contractor shall submit the original transparencies and 3 prints of each such
transparency.
D In case of any variations from the approved Drawings, the Contractor shall submit the
original and 2 copies of the plotted cross sections and profiles and the notes and
computations of his survey. The Contractor shall take cross sections at maximum 25 m
intervals along the centerline and at other locations if directed by the Engineer. Upon
mutual agreement between the Engineer and the Contractor, the Contractor may submit
cross sections intermediate to these locations. The Engineer will indicate, on one copy, his
approval of the proposed lines of the Works or his revisions thereto and return such copy
to the Contractor. The Contractor shall resubmit for approval any cross sections the
Engineer may have revised.
E The Contractor may, as an alternate method of earthwork computation, request approval to

use an electronic computer. Such request shall include details of the computer hardware,
the earthwork software programs, the input and output, and a complete summary of the
methods and procedures to be used. The Contractor may use an electronic computer for
computations, only if approved, and continuance of such approval is contingent upon
satisfactory results being achieved. If results are not as represented or are otherwise
deemed unsatisfactory, the Contractor shall recompute the earthwork quantities by the
cross section method.

1.8 TEMPORARY FACILITIES
1.8.1 GENERAL
A LOCATIONS: The Engineer's approval is to be obtained for the intended locations sitting of
all spoil heaps, Temporary Works and services.
B STANDARDS AND DETAILS: Temporary Works are to be constructed to recognised

standards and codes of practice so that they are fit for their purpose. Drawings and details
of proposed Temporary Works are to be provided by the Contractor if requested by the
Engineer.
C TEMPORARY WORKS and services are to be maintained, altered and adapted and as
necessary and cleared away on completion or when no longer required. Work disturbed is
to be made good.
D GENERAL: The Contractor shall provide all Temporary Works and services and
Contractor's Equipment and tools required for the efficient and safe execution of the
Works, including but not limited to:
- Temporary roads, hard standings, sleeper tracks and the like.
- Temporary fences, gates and barriers.
- Temporary offices, stores, messrooms, latrines and compounds.
- Scaffold, ladders, hoists, cranes and the like.
- Temporary screens, chutes, coverings, roofs and rainwater pipes for protection of the Works and
personnel.
- Transport and vehicles on and off Site.
- Fixed and movable mechanical plant and equipment.
- Small tools.
- Temporary water and power supplies and site lighting.
- Temporary drainage.
1.8.2 TEMPORARY SITE FACILITIES
A ROADS: Permanent roads, hard standings and footpaths on the Site may be used
provided they are adequately maintained and thoroughly cleaned and made good after use
and left in unimpaired condition.
B DIVERSIONS: The Contractor shall in accordance with the specification of the Ministry of
Communication and with liaison with the Traffic Department:

 Provide temporary detour roads, temporary bridges and culverts, and other facilities to divert traffic
through or around any part of the Works or for maintenance of traffic in locations affected by his
works that warrant such Temporary Works. Location, standard, width, construction and
maintenance of detour routes shall be in accordance with Section 3.06 of the Specification,
approved by the Engineer, ensuring at all times that the routes, are signed, striped, maintained and
furnished with all traffic control devices as shown, directed and/or needed.
 Submit designs and detailed working Drawings of the proposed Temporary Works for approval by
the Engineer prior to commencement of the works. The design live load for temporary bridges
related to roads exposed to heavy vehicles shall not be less than the design live load for
permanent bridges, or as directed by the Engineer.
 Where measurements are required for continuously regulating and supervising traffic, provide
temporary roads and bridges for one-way traffic with a minimum width of 3.5m. In all other cases
the minimum width shall be 7m.
 Phase the execution of temporary and Permanent Works to minimise the disruption to traffic.
 Submit a phased programme of Temporary Works one month before commencement of any part
of the works.
C TRAFFIC DIVERSIONS: The Contractor shall provide temporary diversions, detour roads,
temporary bridges, culverts and similar facilities, whenever it is necessary to safely divert
traffic through or around any part of the Works. As per concerned authorities requirements
for locations design widths, construction and maintenance of diversion and detour routes,
including the provision of signs, pavement markings, lighting, traffic control and the like are
to be submitted to and approved by the Engineer prior to execution on Site.
D FRENCH CROSSINGS are to be provided for free and safe passage of vehicles and
pedestrians over pipe and other trenches.
E TEMPORARY SITE FENCE: The Contractor shall provide suitable and secure temporary
site fencing and gates where necessary or as directed by the Engineer. Design of the
fencing and gates, including location, construction details, etc. is to be submitted to the
Engineer for approval prior to fabrication and erection.
F NAMEBOARD: The Contractor shall provide reflecting boards (150 x 150) cm at the start
and end point of the excavations. Those boards should include the project name, project
no., ministry name, Contractor name, and his local address and phone No. in addition to
the supervision Consultants. Boards’ specifications and locations should be approved by
the Client and the Engineer.
G General nameboards for the whole project should be fixed at the specified locations by the
Engineer and in each district of the project area. Those boards should include the project
name, Client name, Contractor name, Contact no’s, Consultant name and phone no. for
the supervision staff office. Boards will be of 4 separated slices each of (240 x 240) cm
with spaces of 20 cm between slices that are made of 3 mm thick aluminium and provided
with back grooves for fixing on the columns, so no holes should appear at the face side of
the board. Face slide should be covered with reflective blue layer and text in reflective
white color.
H Boards shall be fixed on two columns of hot galvanized (16 or 18) cm I beams and the
clear space from the ground to the bottom of the slices shall be 2.0 m and the columns
should be provided with movable hinge according to the MOT specifications and fixed to
the ground by concrete blocks as per the site conditions. All these details should be
approved by the Engineer prior to installation of boards.

1.8.3 CONTRACTOR'S TEMPORARY BUILDINGS
A Complete according to Project - Project Specifications. To be completed by the design

consultant and the water authority.
1.8.4 TEMPORARY SERVICES
A WATER: The Contractor shall provide clean, fresh water for the Works and make
temporary arrangements for storing and distributing about the Site.
B ELECTRICITY: The Contractor shall provide electric supply and all equipment for lighting
and power for the Works and make temporary arrangements for distributing about the Site.
C POWER: The Contractor shall provide electric power for the Works, including supplies for
commissioning engineering services and Plant, at the required voltages.
D LIGHTING: The Contractor shall provide lighting for the Site and the Works for safety and
security of the Works and to facilitate proper execution of work and to illuminate internal
surfaces during finishing work and inspection. Spaces designed to be artificially lit during
daylight hours are to have temporary illumination similar to that provided by the permanent
installation.
E PERMANENT ELECTRIC SUPPLY AND LIGHTING INSTALLATION may be used for

testing and commissioning and to illuminate the Works, subject to the following conditions:
 The Employer does not guarantee that it will be available.
 The Contractor must take responsibility for the operation, maintenance and supervision of the
system, indemnify the Employer against all damage and pay all costs and renew all used tubes
and lamps.
 The Contractor must indemnify the Employer against reduction in manufacturer's guarantee
periods for equipment etc. due to its use before completion of the Works.
F TELEPHONES: The Contractor shall provide joint temporary telephone facilities for his
own and Subcontractors' use and for the use of those acting on behalf of the Engineer and
shall pay the cost of all calls except international calls made by those acting on behalf of
the Engineer.
1.8.5 DIVERSION OF PUBLIC UTILITY SERVICES
A TEMPORARY DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where execution

of the Works involves the temporary diversion of existing public utility services, the
Contractor shall perform such temporary diversion and shall maintain the flow or service as
directed by the Engineer. Unless otherwise stated, the costs of any such diversions are
deemed to be included in the Contract Price.
B PERMANENT DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where the Works

require the permanent diversion of existing public utility services, either as shown on the
Drawings or directed by the Engineer, the diversion shall be carried out by the Contractor
and shall be paid for at the prices stated for such work in the Bill of Quantities.

1.9 SAFETY PRECAUTION MEASURES
1.9.1 GENERAL
A Contractor shall take all necessary measures for public safety for all project components
according to the requirements of municipalities and other concerned authorities.
PART 2 EXCAVATION AND BACKFILLING
2.1 SCOPE
A The Work Covered in this Division Comprises: Clearing of the site, and excavation and
backfilling for roads, structures and trenches and protection work related to gabions, riprap,
stone pitching and geotextiles.
2.2 SITE CLEARING
2.2.1 CLEARING AND GRUBBING
A The Contractor shall remove and dispose of all vegetation, surface debris, stones and
rocks from areas where the Works are to be performed.
B When shown on drawings or directed by the Engineer, the Contractor shall remove and
dispose of pavement layers including asphalt and granular layer to the surface of the
subgrade. Moreover the ground surface under all structures shall be cleared of all existing
concrete foundations (if any) and stumps.
C Trees shall be removed carefully, stored and / or relocated as specified or as instructed by

the concerned Authorities and the Engineer.
2.2.2 REMOVAL OR REALIGNMENT OF OBSTRUCTION AND UTILITIES
A The Contractor shall remove wholly or in part and dispose of all obstructions, buildings,
fences, abandoned pipelines and others, as indicated on drawings or as directed by the
Engineer.
B Where indicated on the Drawings, utilities are to be realigned or salvaged as directed by

the Engineer.
2.3 EXCAVATION
2.3.1 GENERAL
A Earth: naturally occurring, manmade or placed material that can be removed manually or
by mechanical shovel, bulldozer or other mechanical equipment.
B Rock/Hard Materials: naturally occurring, manmade or placed material of more than one
cubic meter that cannot be destroyed or removed by methods used for removal of earth
described in Clause A but requires the use of pneumatic tools, impact breakers or, if
allowed, explosives for its removal.
C Materials and conditions: the Contractor shall assess the nature of the work and the
materials to be excavated, and shall take sole responsibility for his assessment of
materials and conditions.

D Ground-water level is to be established at the time the various excavations are carried out.
2.3.2 TOP SOIL
A Topsoil: before beginning general excavations or filling, the Contractor shall excavate
topsoil from required areas and keep separate from excavated subsoil.
B The Contractor shall stockpile excavated topsoil required to carry out subsequent top-
soiling operations in temporary spoil heaps on the Site as instructed.
C Surplus Topsoil: The Contractor shall remove from the Site to a tip provided by the
Contractor
2.3.3 EXCAVATING
A General
1. All excavation shall be performed to the line, grades, cross section and sizes shown on the
drawings, or/and directed by the Engineer.
2. Methods: The Contractor shall submit with the Tender details of proposed methods of
working which may cause nuisance, damage or danger to people and/or property.
3. Materials arising from excavations are to remain the property of the Employer unless
instructed to be removed from the Site as per the Engineer or the authorities instructions.
B Excavations for Adjacent Utilities
1. Underground services must be set out so that their excavations do not encroach below a
line drawn at an angle from the horizontal from the nearest lower edge of building
foundations. The angle shall be 45 degrees for dry stable soil or 30 degrees for wet clays
or soils below water table. If this condition cannot be met obtain instructions before
proceeding.
2. Where an excavation encroaches below a line drawn at an angle from the horizontal of 45
de¬grees for dry stable soil or 30 degrees for wet clays or soils below water table from the
nearest formation level of another higher excavation then all work within the lower ex-
cavation and backfilling thereto must be completed before the higher excavation is made.
C Excavated formations are to be inspected and approved before new work is laid on them.
The Contractor shall give 24 hours written notice of when excavations will be ready for
inspection. If, after inspection, surfaces become unsuitable due to water, frost or other
causes, excavate further and backfill with ap¬proved material all at the Contractor's
expense. The Contractor shall place concrete or other fill as soon as possible after
inspection.
D The bottom 200 mm thickness of excavation shall be removed by hand just prior to placing
concrete blinding or pipe laying.
E The Contractor shall level or grade and compact bottoms of excavations to Engineer's
approval.
F Headings: The Contractor shall drive accurately to required line and gradient and provide
adequate support. Construct in approved lengths to size required to contain permanent
work. The Contractor shall obtain approval from the Engineer before commencing
activities.
G Support
1. Sides of Excavations: Responsibility for upholding sides of excavations rests with the
Contractor.

2. Earthwork Support: The Contractor shall use as necessary to support sides of excavations
and remove on completion unless otherwise instructed. In the event of any collapse
occurring while excavations are open this will be the Contractor’s full responsibility and he
should re-excavate and reinstate such excavations and other work affected at the
Contractor's expense and responsibility.
3. Steel Sheet Piling: The Contractor shall use as necessary to support sides of excavations
and remove on completion unless otherwise instructed.
4. Special Support: The Contractor shall use as necessary to uphold excavations against
sides of adjoining buildings, public footpaths, roads and the like and remove on completion
unless otherwise instructed.
5. Unstable Ground: The Contractor shall inform the Engineer without delay if any newly
excavated face will not remain unsupported sufficiently long to allow the necessary
earthwork support to be inserted. If the instability is likely to affect adjacent structures or
roadways take appropriate emergency action. Responsibility for preventing instability rests
with the Contractor.
H Waterways: Temporary diversion as necessary of ditches, field drains and other waterways
encountered during the excavations is to include reinstatement on completion. If
reinstatement is not possible the Contractor shall obtain instructions.
I Existing watercourses which have been diverted and are to be filled must be cleared of all
vegetable growth and soft deposits before filling.
J Existing Foundations
1. Where old foundations, beds, drains etc. are encountered the Contractor shall obtain
instructions before proceeding.
2. Breaking out old foundations, beds, drains etc. is to include sealing off drain ends,
removing contaminated earth and disinfecting as necessary and according to the Engineer
instructions.
K Backfilling of excavations shall be as specified in other Sections of these specifications.
L Unauthorised Excavations: The Contractor shall backfill and compact as instructed at no

expense to the Employer.
M Water: All excavations shall be kept free from water arising from any source at all times.
The discharge of any water from the excavations must not effect other parts of the works
or adjoining areas.
N Pumping: The Contractor shall not disturb material in and around excavations by pumping
operations.
O Sumps: The Contractor shall obtain approval of location of any sumps and fill with
approved material when no longer required.
P Permanent drainage system is not to be used for disposal of water from excavations
without approval.
Q The Contractor shall keep all excavations adequately drained at all times. Damage to any
part of the work due to poor drainage facilities shall be repaired at the Contractor's
expense.
R All excavated slopes shall be cut to the slopes shown on the Drawings.

2.3.4 DISPOSAL OF MATERIALS
A No excavated material shall be wasted without written permission from the Engineer.
Suitable material from excavation shall be used for embankment construction or backfill, as
B Surplus Subsoil: The Contractor shall remove from the Site surplus excavated materials
not specified as to be spread and leveled or stockpiled to a tip provided by the Contractor.
C Tip: The Contractor shall use only public dumpsites assigned by the concerned authorities
for disposal of surplus excavated material removed from the Site and pay all tip fees.
2.3.5 ROCK EXCAVATION
A All blasting shall be carried out in such a manner as will produce the least possible
disturbance of the material left in place.
B All the necessary precautions shall be taken to ensure that the blasting shall not be
dangerous to people or property.
C Where necessary or directed, the Contractor shall provide heavy mesh blasting mats for
protection of persons, properties, and the Works. If, in the opinion of the Authorities and
the Engineer, blasting would be dangerous to persons or adjacent structures, or is being
carried out in an unsafe or unacceptable manner, the Engineer may prohibit blasting and
order the rock to be excavated by other means.
D If the flow of traffic is to be interrupted during blasting operations, the Contractor shall
secure approval of his schedule for such interruptions and his proposed methods for
safeguarding the public and property.
E All drilling and blasting shall be done in such a manner as will most nearly complete the
excavation to the required grade lines and produce the least practicable disturbance of the
material to be left in place. Blasting by means of drill holes, tunnels, or any other methods
shall be entirely at the Contractor's risk.
F Unless otherwise approved by the Engineer, rock cuts higher than 3 m shall be formed
using pre-splitting. Prior to starting the pres-splitting operation the Contractor shall submit a
layout plan showing the location of drill-holes, type of explosive to be used and sequence
of firing. This plan does not absolve the Contractor of his responsibilities for the safety of
people and structures, or for producing a satisfactory stable rock face. No extra cost is
charged by the Contractor for using pre-splitting.
G All overbreaks, overhangs loose blocks or unstable parts of the cut face, and benches shall
be cleared and cleaned, to the satisfaction of the Engineer.
H Backfilling of over breakage shall be carried out as directed, using approved soil or
crushed materials or other special aggregate or cyclopean concrete, as shown on the
Drawings or as directed by the Engineer. Undrained pockets shall not be left in the surface
of the rock.
2.3.6 ROAD EXCAVATION (FOR PREPARATION OF SERVICE ROADS ALONG PIPELINES)
A Scope
1. These Works shall consist of excavating material in cut sections of the road, including
water courses, ditches and wadi relocations (but excluding borrow pits and structural
excavation) all as and where shown on the Drawings, and hauling the excavated material
either to locations for road embankments or to stockpiles or to waste.

2. These Works shall also include any necessary excavations outside the ROW ordered by
the Engineer to safeguard and protect the Works. These may include diversion of existing
water courses, channels; excavation of materials obstructing or impairing the flow along
stream channels; and excavation of unstable materials which may slide or encroach into
ditches or onto the ROW. Disposal of all such excavated materials shall be as instructed
by the Engineer.
B Classification of Road Excavation
1. Any information concerning properties of the soil which may be shown on the plans, in the
Bill of Quantities, in supplementary reports, or as a result of discussion with the Engineer
or others shall be considered as gratis and shall not be a basis for the Contractor's
determination of his bid prices.
C Utilization of Excavated Materials

1. All materials removed from the excavation shall be used in the formation of the
embankment, subgrade, shoulder, and at such other places as directed, unless it is
declared unsuitable and ordered to be wasted by the Engineer.
14. Unsuitable material shall include:
 Unstable materials incapable of being compacted to the specified density using ordinary
compaction methods at optimum moisture content for the equipment being used for compaction.
 Material too wet to be compacted and circumstance prevent suitable in-place drying prior to
incorporation into the work.
 Materials which are otherwise unsuitable for use in or under the embankment.
15. No excavation material shall be wasted without written permission from the Engineer.
16. Excavated rock which is not immediately suitable for incorporation in the works can either
be broken down to acceptable sizes or wasted at Contractor's expense.
D Drainage of Excavation Areas
1. The Contractor shall schedule road excavation and embankment and drainage Works so
that they complement each other. If the Contractor's earthwork progress exceeds the
progress of the drainage construction to the point where the road becomes a dam to cross
drainage, the Engineer may order the Contractor to open adequate waterways through the
highway at the locations where drainage structures are to be installed. Any damage to the
highway caused by water passing through these openings shall be repaired at the
Contractor's expense.
2. During construction, surfaces in excavation areas shall be adequately drained at all times.
Side ditches or gutters emptying from cut to embankment shall be so constructed as to
avoid damage to embankments by erosion.
3. Damage to the Works attributable to saturation or erosion through failure to provide
adequate drainage shall be repaired by the Contractor at his expense.
4. Whenever groundwater is encountered which may adversely affect construction, the
Contractor shall advise the Engineer who will evaluate the situation and order necessary
remedial measures to drain or extract water.
E Slopes, Subgrade and Ditches
1. All excavated slopes, subgrade and ditches shall be finished true to lines, grades and
cross sections as shown on the Drawings.
2. Slopes, except in massive rock or other material which require special treatment, shall be
trimmed to slopes not steeper than the specified slope angles and rounded at top and
bottom to a smooth profile to blend in with the adjacent terrain. Material shall not be

loosened beyond the specified slope lines. High cut areas shall continuously be monitored
by an engineering geologist or a geotechnical Engineer.
3. In cuts where earth overlays a rock formation, slopes shall be benched in an approved
manner.
4. Ditches of all types shall be excavated and trimmed neatly in conformity with the specified
grades and cross sections. All projecting rock, stumps, roots or similar shall be removed.
Ditches include side ditches, furrow ditches, irrigation ditches, wadi relocations, etc.
5. The Engineer will periodically check all or any part of the Works, to determine
conformance to the correct lines, grades and elevations. Tolerances on finished subgrade
elevations and on elevations of the surface at the underside of the subgrade layer, shall be
as specified in Section 2.05 - "Subgrade Construction".
F Excavation of Unsuitable Material

1. Where excavation to finished grades and cross sections exposes unsuitable material in the
subgrade, slopes or ditch inverts, etc the Engineer may require the Contractor to remove
the unsuitable material and backfill the excavated areas using approved material. The
Contractor shall conduct his operations in such a way that necessary cross section
measurements are taken before such backfill is placed.
2. Unsuitable material shall be disposed of as directed. Wasted unsuitable material shall not
be deposited on any cropland.
3. When the Contractor is directed to excavate unsuitable material below the surface of the
original ground in fill areas, other than that required for clearing and grubbing, the depth to
which unsuitable material shall be removed will be determined by the Engineer. The
Contractor shall schedule the excavation so that cross sections are taken before and after
material has been removed.
4. Unsuitable materials outside the ROW or ditch slopes which, in the opinion of the
Engineer, are potentially unstable and liable to slide or encroach into the ROW or into the
ditches, shall be excavated and disposed of as specified for unsuitable material, unless it
is approved for use as embankment fill.
5. Unsuitable and surplus materials disposed of elsewhere than within the ROW shall be
spread, leveled and shaped as directed so as to present a neat and tidy appearance. No
materials shall be disposed of in such a way as to adversely affect natural drainage
courses or to cause damage to the highway or adjacent public or private property
6. If approved by concerned authorities land can be used for disposal to the maximum extent
practicable. If private land is used for disposal, the Contractor shall secure the consent of
the landowner or tenant and, if necessary, and at his expense, pay for the use of such
land. The use of cropland for disposal purposes will not be permitted.
2.3.7 EXCAVATION FOR STRUCTURES
A Scope
1. These Works shall consist of all excavation in any material for structures associated with
networks such as water tanks, pump houses, culverts, utility ducts and water underdrains;
for retaining walls of all types; and for other major and minor structures; and including all
necessary clearing and grubbing; bailing; drainage; pumping; sheeting; temporary shoring
and cribbing; construction of temporary cofferdams or cribs; and disposal of all excavated
material and backfilling with suitable approved material; all as and where shown on the
Drawings.
2. These Works shall also include the removal of those portions of existing structures below
ground which would in any way obstruct or interfere with construction of new structures.
3. The Contractor will be deemed to be fully aware, at the time of tendering, as to the type
and nature of soils and rock that will be encountered in structural excavations.

B Excavation
1. The Contractor shall notify the Engineer a sufficient time in advance of the beginning of
any excavation for structures so that the Engineer may, where necessary, survey and
record the cross-sectional elevations and measurements of the existing ground and
existing structures affected by the proposed structure. Any materials removed or
excavated before these measurements have been taken and approved by the Engineer
will not be paid for.
2. The Contractor shall be solely responsible for the safety at all times of all foundation and
trench excavations whether supported or otherwise. Approval of the Contractor's support
system or omission of a support system for any excavations shall not absolve the
Contractor from his sole responsibility in this regard.
3. The Contractor shall take all necessary precautions, including shoring or otherwise, to
protect employees in the excavation and on the ground above. The Engineer will not enter
excavated areas to approve the foundation and further Works until he deems the areas to
be safe.
4. In areas where the excavation is adjacent to public roads and walkways, the Contractor
shall erect all necessary barricades, barriers, enclosed walkways, and warning signs
necessary to restrict the exposure of the public to the excavation.
5. The sides of all foundation pits and trenches shallower than 1.5m shall be vertical and
adequately supported at all times unless otherwise shown on the Drawings. Sides more
than 1.5 m in depth shall be sloped at a stable slope or supported in an approved manner
unless the material through which the pit or trench is cut is deemed to be sufficiently self-
supporting and not requiring support.
6. Pits and trenches shall be kept free from water until footing concrete has been placed or
pipes have been installed. The Contractor shall minimize, to the maximum extent
practicable, the length of time excavated areas are open. The Contractor will be held
responsible for damage due to weather, equipment, and other causes during periods when
the excavations are left open.
7. The Contractor shall schedule the Works so that no excavation is left in an exposed
condition for a period greater than 20 days unless otherwise approved.
8. In areas where the excavation is adjacent to public highways, roads and walkways,
excavation shall be scheduled such as not to be left in an exposed condition for more than
7 days unless otherwise approved.
9. For excavation in material sensitive to moisture (stiff clays, marls, etc.) the excavation shall
be cleaned and concrete blinding layer cast immediately on completion of the excavation.
10. The Contractor must notify the Engineer of any sign of failure or cracks within or around
the excavation immediately when such signs are noticed.
C Temporary Support System
1. When a temporary support system is required to protect adjacent property or to protect the
public during construction, the Contractor's design for such support system shall be
submitted to the Engineer for approval prior to commencing its construction.
2. All temporary support systems shall be designed with adequate factors of safety to serve
with minimal maintenance, for the duration of its intended use, and shall include adequate
safety provisions to protect the public from construction activities.
3. Notwithstanding any approval of temporary support systems, the Contractor shall be solely
responsible for the adequacy of their design, construction, maintenance and all necessary
safety precautions associated therewith.
D Excavation for Major Structures
1. The foundations for buildings, water tanks, pump houses and other major structures, shall
be excavated in accordance with the dimensions as shown on the Drawings and shall be

of sufficient size to permit the placing of the full width and lengths of the footings.
2. The excavation shall be carried to the elevations shown on the Drawings or as established
by the Engineer. Borings and soil tests made during design, and actual investigation of
the completed foundation excavation shall be utilized by the Engineer to determine final
depth. No concrete shall be placed prior to approval of the excavation pit.
3. Unless shown otherwise on the Drawings, the bottom of all excavations shall be covered
with a 75 mm minimum depth of lean (blinding) concrete Class 110/25 to serve as a
working platform.
4. Foundation pits or trenches shall be of sufficient size and provide minimum sufficient
working space to permit construction of structures or structure footings of the full width and
length shown on the Drawings.
5. Where footings are to be constructed using formwork, the excavations shall generally not
extend more than 500 mm beyond the maximum dimension on each side of the proposed
footing unless additional working space is clearly required and approved, by the Engineer.
Any unauthorised overwidth of excavation beyond the lateral limits shown on the drawings
or approved by the Engineer shall be backfilled with selected fill or lean concrete as
6. Where footings are to be located, in or adjacent to firm, original ground and where
formwork is not required or ordered, any unauthorized over depth excavation below the
approved elevation of base of footing shall be backfilled with blinding concrete.
7. Where excavation to rock foundation is required, the excavation shall proceed in such a
manner as to allow the solid rock to be exposed and prepared in horizontal beds or
properly serrated for receiving the concrete. All loose and disintegrated rock and thin
strata shall be removed.
8. All blasting necessary for foundation placement shall be performed prior to placing any
concrete. Blasting will not be permitted in the vicinity of concrete which has not cured for
at least 14 days. Blasting shall not affect concrete properties and integrity in any way.
9. When unstable material or other unsuitable material is encountered below foundation
elevation like swelling soil or others, the Contractor shall excavate such material and
replace it with suitable backfill material or concrete as directed by the Engineer.
10. If temporary works are required for maintaining the excavation dry, the Contractor shall be
responsible for the design and execution of the works. The proposed design shall be
submitted to the Engineer for approval, however, such approval does not relieve the
Contractor for his sole responsibility in this regard.
2.3.8 EXCAVATION FOR PIPE TRENCHES
A Before excavating trenches for pipes in any road, the contractor shall acquire the
necessary permission from the Engineer and concerned authorities.
B During excavation, material suitable for backfilling (Section 2.04) shall be piled at sufficient
distance from the sides of the trench as to avoid overloading and prevent cave in. All
excavated material not required, or unsuitable for backfilling shall be removed and carted
away to an approved dumping area.
C Trenches shall be excavated to such depths as will permit the pipes to be laid at
elevations, slopes or depths of cover indicated on the drawings, and at uniform slopes
between indicated elevations.
D Where excavation depth exceeds the level indicated on the drawings and is not authorized
in writing by the Engineer, the Contractor shall bear the cost of the excess excavation,
backfill or concrete level make up of any type as instructed by the Engineer.
E Trenches shall be excavated with vertical sides between the elevation of the bottom of the
trench and an elevation 300 mm above the top of the pipe.

F Unless otherwise indicated on the Drawings, trench widths will be as shown in the
following table:
Pipe diameter (mm) Trench Width (mm)
Minimum Maximum
< 150 650 950
200 700 1000
250 750 1050
300 850 1150
350 900 1200
400 950 1250
450 1050 1350
500 1100 1400
600 1250 1550
700 1350 1650
800 1500 1800
900 1600 1900
1000 1750 2050
1100 1900 2200
1200 2000 2300
1300 2150 2450
1400 2250 2550
1500 2400 2700
1600 2550 2850
1700 2650 2950
1800 2800 3100
1900 2900 3200
2000 3050 3350
2100 3200 3500
2200 3300 3600
2300 3450 3750
2400 3550 3850
The lowest trench width will be used for the calculation of quantities and payment for all types of trenches
and excavation in rocks. The contractor should have included in his prices any extra expenses that will be
needed for extra excavation beyond the trench width, this is applied also for the pavement and road
surface finishing works.
G Where the above specified trench maximum widths are exceeded; the Contractor shall
bear the cost of increased pipe strength or additional pipe protection if the Engineer calls
for such measures due to excavations being taken wider than specified.

H Excavation with battered sides shall not intrude into private property and shall respect the
statutory regulations relevant to the R.O.W. and property limits.
I When the pipe, culvert or duct are to be laid in embankments or other fill areas, the
embankment or fill area shall first be filled and compacted as specified to the proposed
finished grade or to a height of at least 300 mm above the crown of pipe whichever is
lower. The trench shall then be excavated as in undisturbed material.
J When pipes, culverts or ducts are to be laid under existing pavements, trenches shall be
excavated carefully and to minimum widths. Methods that will give straight and vertical
face shall be used. The pavement shall be kept at its original level and condition.
K In combined trenches where one pipe is at a lower level than an adjacent pipe the
following shall be applied:
 The whole trench shall have a depth related to the lower pipe and the thickness of the bedding
shall be increased to the upper pipe as necessary.
 The lower pipe shall be backfilled with thoroughly compacted granular material up to a level of 0.30
meters above the higher pipe.
L Excavation for the forming of the trench for beds shall be carried out immediately before
laying beds or pipes. Unstable material, rock projections, boulders and hard spots shall be
removed and replaced with approved well consolidated filling material, that will be
compacted as instructed. Local soft spots shall be hardened by tamping in bedding
material.
M The bottoms of trenches shall be accurately graded to provide uniform bearing and support
for the bottom quadrant of each section of the pipe. Bell holes shall be excavated to the
necessary size at each joint or coupling to eliminate point bearing. Any material or block
that may cause point bearing shall be removed.
N The Contractor shall report to the Engineer any unsuitable or weak ground material that
may found below the indicated excavation levels before executing any trimming of the
excavation, pipe laying, concreting, or other work. Where, in the judgment of the Engineer
the bottom of the trench is found unsuitable, such material shall be removed to the width
and depth ordered by the Engineer. The trench shall then be made up by backfilling with
approved material as specified herein after.
O Where rock excavation is encountered, the trench shall be excavated to min. 200 mm
below pipe invert and replaced with granular material matching the specification in Item
(2.4.5) or concrete class 110/25, as directed by the Engineer.
P Headings, when required, shall be accurately driven to required line and gradient and
adequate support shall be provided. Construction shall be carried out in approved lengths
and to size required to contain permanent work. Approval shall be obtained before starting
pipe laying or other work. In case of soil, the min. bedding should be 150 mm.
Q Generally, trench excavation, pipe laying, and trench backfilling for any particular project
section shall be completed in twenty (20) days. At any one time, the maximum length of
open trenches in the project shall not exceed 300 meters.
R The Contractor should give special care while excavating in paved areas, so the
excavation width not to exceed the specified width. The Contractor should use the suitable
mechanical machines to cut the pavement in straight lines and the edges should be
vertical. In addition, the Contractor should always use vehicles with suitable tires (Air tire)
that will not damage the road surface pavement.

2.3.9 Technical Specifications of Thrust Boring
A Scope of works
1. This section covers pipes and fittings installation through Thrust boring. The relevant
sections mentioned in the general specifications for the implementation of the drainage
networks for the Water directorate general in Riyadh shall be considered applicable by the
present agreement unless otherwise stated therein. Furthermore, it is a must to comply
with the entire specifications and conditions related to the Ministry of Transport and Saudi
Railway Organization regarding the implementation of such works.
B The general drilling of the ground pits and tunnels
1. The implementation of ground pits and the installation of pipelines should be carried out by
jacking as approved by the engineer.
2. The perforations of the ground pits should be of practical dimensions enabling to proceed
in the structural works properly. The drilling works should be performed with extreme care
preventing earth settlement and sliding and following the design alignment and levels for
the external dimensions of pits not to be anywhere smaller than the dimensions mentioned
in the plans or determined by the engineer. The Contractor should use specialized
manpower in the drilling works of pits.
3. The Contractor should supply and fix all the other temporary supports and other necessary
structures to ensure the safety of works and adjacent structures outside the permanent
work place to the engineer’s approval.
17. The contractor must provide communication means between the pits and the and the work
areas that should not be of same quality like the telephone communication and that, to the
engineer’s approval.
18. The contractor should supply and operate and maintain an appropriate lighting and
ventilation network for each pit and the commencement of the drill obtaining the engineer’s
approval. The electricity power supply should be adequate.
19. All equipment shall be installed and maintained inside and around pits according to the
relevant work regulations and as per the suitable practical application principles to the
engineer’s satisfaction.
4. The pits should have separate openings equipped with stairs in addition to other required
openings during the structural works. Each pit should be surrounded by closed fence of
height not less than 1,80 meter equipped with security red lights when working in the traffic
areas.
20. When work is suspended for any reason, the sides of pits should be covered and
supported by wooden boards and covered with light mortar for safety reasons, unless the
engineer decides to take other measures.
21. The contractor should take these temporary works into account while preparing his prices.
All the temporary supports and structure for pits, should be removed when no more
needed unless otherwise directed by the engineer.
5. Before starting to request any trench excavation equipment or starting any work the
contractor should present detailed proposals for making access openings or the work
openings to the engineer.
6. The earth reinforcement must be of sheet steel supports or of similar approved fixed metal
ring supports.
7. The contractor may use precast concrete pieces for the ground reinforcement above the
permanent work place, if the concrete pieces are used for support, they should be covered
as per the specifications and discarded or broken after the work completion.
22. Such work shall not be measured nor classified for payment.
C Checking alignment and levels

1. Checking and adjustment of the alignment and levels should be done using laser. The
contractor should prepare and present his proposals for checking and adjustment of the
alignment and levels to the engineer’s representative for approval in an earlier phase in
the Contract.
2. When permanent works are done outside the overstepping boundaries allowed by the
present specifications, the contractor should remedy this situation according to the
engineer’s directives.
D Works for preventing water leakage
All works should not have water leakage upon the completion of works and should remain
free of water leakage until the expiry of the maintenance period.
The contractor should immediately repair the defects at the engineer’s satisfaction.
E Ground treatment
If the contractor considers that special a ground treatment is required and necessary for
preventing settling and sliding during the construction he must request the authorization
from the engineer in this concern. When the contractor is given the authorization, he must
carry out works as mentioned in the specifications. Such authorization (or the refusal the
authorization) does not exempt the contractor from assuming the responsibility of securing
works safety.
The treatment should be implemented in sequences suitable to work requirements and the
contractor should carry out testing according to the engineer’s directives to check their
efficiency during and after the treatment works.
The contractor should keep meticulous and detailed register for all the ground treatment
methods to the engineer’s satisfaction. He must submit everyday copy of such register to
the engineer when the ground treatment is carried out. In the cases where the engineer
considers that such technique is necessary and essential for the appropriate
implementation of works he will give the necessary instructions to the contractor. The
payment for the ground treatment should be included in the prices of the pipeline by thrust
boring. The contractor should assume the responsibility of the damages occurring from the
ground treatment operations.
F Noise restriction means and the electrical machinery.
1. In order to minimize as much as possible the disturbance emanating from the equipment
noise during the night, the contractor should operate the machinery with the electrical
power unless otherwise authorized by the engineer.
2. The operations above ground level during night work should be restricted to the minimum
practicable work and the contractor should take all the precautionary measures for
preventing unnecessary noise.
G Pipe Jacking
Before starting works, the contractor should submit to the engineer full details on his
suggested methods for obtaining the engineer’s approval, such details should include the
following information:
a) Interacting locations and the reinforcement of the starting points of excavation.

b) b) Dimensions of the starting points of the tunnel excavation and the
supporting methods of the excavations.
c) Dimensions and details of the retaining wall
d) All the sizes of the operating equipment
e) Locations of the drainage gutter and the methods of preserving works free of water
23. The pipes jacking starts from the reinforced starting point of excavation, which should be
dug in with suitable size to accommodate the reinforcement wall, the jacking equipment
and the appropriate workplace.
24. Excavation should be carried out inside the protection installations, which should be kept
in all times close to the work level and must be adjusted for monitoring the alignment and
the level.
25. Reinforcement should be used for the loose non-steady open excavation when pipe
jacking works are suspended.
26. The pipe jacking is done through hydraulic pressure by using appropriate jacket designed
for the higher pressure and using ring supports for distributing the pipe jacking forces. The
pipe jacking system should allow testing from both the surface location and the surface of
excavation starting point.
27. The pipe jacking stations located at the center of the trajectory should properly serve the
jacked pipes joints and the relevant connections. Connections should be hermetically
closed and anti-leakage when in service.
The contractor should take all the necessary steps for securing the safety of pipes and the
tunnel protective coating during jacking of pipes. If damages occur due to the contractor
works, Contractor should carry out the necessary repair to the engineer’s satisfaction and
he should withdraw the damaged pipes and export it out of site if instructed by the
Engineer, without any extra cost.
H Thrust Boring under the railways
The contractor shall assume responsibility of securing the review of the adequate
procedures and the compliance with the specifications of Ministry of Transport regarding
the pipes crossing under the railways.
The attention of the contractor should be drawn particularly to the requirements of the
Railway Saudi Arab Establishment. But all crossings should be placed according to the
fifth and tenth sections of the present guidelines of the Railway Engineering Consultant
Association, a copy of which is enclosed for the proper use of the supervisor and/or
engineer.
2.4 FILLING AND BACKFILLING FOR STRUCTURES
2.4.1 SCOPE
A This section covers general soil filling material and source, backfilling for structures,
embankment construction, backfilling for pipe trenches and all particular requirements
related to these works.
2.4.2 FILLING MATERIAL AND BORROW MATERIAL
A Filling material shall be approved and capable of being compacted as specified.
B Filling materials for foundations and general filling shall pass a three-inch U.S. standard
sieve and the material passing a No. 4 U.S. standard sieve is to have a maximum plasticity

index of 6%. No piece is to have its largest dimension greater than one-third the thickness
of a compacted layer.
C Sampling: The Contractor shall submit 50 kg representative samples to an approved

laboratory for tests as follows and submit results for approval:
 For Soils with Less than 50% Fines: Sieve analysis and compaction.
 For Soils with More than 50% Fines: Sieve analysis, Atterberg Limits and Compaction.
D Approval: Sources and types of materials and moisture contents at which they may be
placed and compacted are to be those approved after receipt of laboratory test results.
E If suitable filling or backfill material is not available from material excavated on the project
site, the Contractor shall be responsible for locating suitable borrow and arranging for the
excavation of suitable material with the land owner.
F Borrow pits are to be excavated in a uniform manner, neatly trimmed and graded and left
in an approved condition.
G The borrow material shall fulfill the requirements specified for the intended use. No borrow
material shall be brought to the site unless it has been approved by the Engineer.
H Testing Fill from Borrow Pits: The Contractor shall sample and test in accordance with
ASTM D1557 to determine the optimum amount of water to be used with fill material to
obtain maximum dry density. Tests are to be conducted for every borrow pit and for every
type of fill material encountered.
I The Engineer will periodically require testing of borrow materials to verify that no change in
quality has occurred since the original approval.
J Field density tests on compacted soils are to be made at an average of one test per 100
m² of area. Minimum density required on soils when made in accordance with ASTM
D2167 'Rubber Balloon Method', ASTM D1556 'Sand-Cone Method' or ASTM D2922
"Nuclear Method" is to be:
 For Backfill Under Roads, Parking Areas and Paved Areas up to 500 mm: 95% of maximum dry
density
 For Backfill Deeper than 500 mm Under Same Areas as last Described: 95% of maximum dry
density
 Elsewhere Such as Landscaped Areas: 90% of maximum dry density.
K Selected Fill: Excavated material conforming to the specification for Filling material and
Borrow material, Clause B above.
2.4.3 BACKFILLING FOR STRUCTURES
A General Requirements
1. The Contractor shall obtain approval for his proposed method and rate of placing of
backfill, before backfilling commences.
2. Excavated material or material from other sources for use as backfilling shall conform to
the below requirements:

 The supplied material shall not contain any organic or harmful material e.g: tree, leaves, roots,
and residues.
 The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4, according to
MRDTM 210 (Directorate of Material and Research at the MOC).
 The California Bearing Ratio shall not be less than 25% when tested according to MRDTM
213.
 The maximum dry density shall not be less than 95% when tested according to Directorate of
Material and Research at the MOC.
 The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall contain fine
28. Backfill materials shall be uniformly graded granular material, capable of being compacted
to the specified compaction level, and having adequate permeability to permit free
drainage through it. Backfill material shall also conform to the following:
 Minimum D10 value 1 mm
 Maximum Plasticity Index 10 per cent
 Requirement for bridges, culverts etc. specified in subsequent sections.
29. Backfill material shall not be placed against any structure until approval is given. Unless
otherwise shown on the Drawings. Structures shall be backfilled to the same requirements
as specified for the adjacent embankment.
30. Backfill shall be placed in level layers for the full width of the excavated area until the
elevation of the original ground or surrounding embankment is reached. Backfill next to
walls, between columns or in other confined areas, shall be compacted by approved hand
or portable equipment.
31. Each successive layer of backfill shall contain only sufficient material to ensure proper
compaction and in no case shall any layer be greater than 300 mm thickness (before
compaction). The moisture content of the backfill material shall be uniform and within the
moisture range designated.
32. Water shall be drained from the areas to be backfilled wherever practicable. In cases
where, in the opinion of the Engineer, it is not practicable to drain the areas to be
backfilled, the initial backfill material shall consist of crushed, open graded material
conforming to the following gradation:
ASTM Sieve Percentage Passing
Size
3/8" 100
No. 4 < 85
No. 30 < 45
No. 200 <5
Such material may be deposited below the standing water level without compaction. Above the water level
normal laying and compaction will be used.
33. Additional water to be added during placement of backfill material to achieve required
compaction shall be fresh water or brackish water approved by the Engineer.
34. Minimum tests required during backfilling operations to verify material are:
 One Proctor test for each structure (or for each 100 m2).

 One Gradation of Materials when materials changed.
 One Plasticity Index and field density for 50% of the layers and for each footing and abutment (or
for each 500 m2) as per instruction of the Engineer.
B Workmanship
1. Unsuitable Materials: The Contractor shall remove from the Site imported filling materials
deemed unsuitable by the Engineer.
2. Surplus: The Contractor shall remove surplus imported filling materials from the Site.
3. The Contractor shall place filling using approved methods to required dimensions, levels,
lines and profiles and to permit water to drain freely.
4. B.4 Earthmoving Equipment: The Contractor shall do not use for compaction except
where approved.
5. Heavy Steel or Pneumatic Rollers: Special precautions shall be taken to safeguard
existing structures when steel or pneumatic rollers are used. These shall not be used
when compacting backfill to pipe trenches.
6. Compaction Equipment: Backfilling shall be compacted by approved compaction
equipment suited to the type of material. Compaction around foundation walls, culverts
and small restricted areas shall be carried out by mechanical vibratory plates, tampers or
hydraulic compactors.
7. Moisture Content: Each layer of filling shall be moistened or dried to reach the correct
moisture content for the required dry density. The Contractor shall spread and compact
each layer to at least 95% of maximum dry density, unless otherwise specified, all as
determined by ASTM D1557. Each com¬pacted layer shall be tested and approved prior to
placing subsequent layers.
C Placing and Compacting Fill
1. Structures shall not be subject to the pressures of backfilling or to live loads until the 28-
day strength of the concrete has been reached, unless a shorter period is approved in
special circumstances where the load is sufficiently small as not to constitute a risk of any
damage to the structure in the opinion of the Engineer. If approved this period may be
extended if subnormal curing conditions exist.
35. Surfaces to receive filling shall be cleared and all vegetation removed off Site before filling
is placed. Soil surfaces are to be scarified and re-compacted to at least 95% of maximum
dry density as determined by ASTM 1557. Compaction shall be to a depth of at least 200
mm below ground surface. Hard or smooth surfaces shall be roughened before filling is
placed. Existing road surfaces and the like shall be broken up and removed or used as
part of fill.
36. Soil filling generally shall be selected fill spread and leveled in 300 mm maximum layers
each well consolidated with a suitable mechanical rammer.
37. The Contractor shall deposit soil filling in a manner not to endanger the partly finished
structure or sub-structure either by direct pressure or indirectly by overloading banks
contiguous to the operation or in any other manner.
38. Minor up filling and local adjustment of levels shall be selected fill spread and leveled in
150 mm maximum layers each well consolidated by suitable mechanical means.
2. Benching: Where difference in level between adjacent areas of filling exceeds 600 mm the
Contractor shall cut into edge of higher filling to form benches having a minimum width of
600 mm and a height equivalent to the depth of a layer of compacted filling.
3. Benching: The Contractor shall spread and compact new filling to ensure maximum
continuity with previous filling.
4. Protection of formation:

 Construction traffic shall not be allowed on completed filling until the level has been raised not less
than 150 mm above formation level by properly compacted temporary protective filling
 Temporary protective filling shall be removed from the Site before beginning permanent
construction
 Stockpiling materials on newly filled areas shall not be done without permission.
D Backfilling for Bridges, Underpasses, Overpasses and Miscellaneous Structures
1. Backfill placed around culverts, abutments and piers, shall be deposited on both sides to
approximately the same elevation at the same time. Special care shall be taken to prevent
any wedging action against the structure and slopes bounding the excavation shall be
stepped, where necessary, to prevent such wedge action occurring.
2. All backfill intended to support falsework loads, including temporary fills and pier backfill,
shall be designed for the minimum support required. As a minimum, such material shall
be AASHTO M 145, Class A-1-a, A-1-b or A-2-4, compacted to 90% AASHTO T 180
maximum density.
3. Backfill material for bridge abutments and approach embankments within 20 m of any part
of the substructure shall be AASHTO M 145, Class A-1-a, A-1-b or A-2-4 compacted to
95% AASHTO T 180 maximum density up to the underside of the subgrade layer. The
200 mm minimum thickness of subgrade layer shall consist of approved subgrade material
placed and compacted to 100% maximum density as specified under Section 2.05 -
"Subgrade Construction". The backfill shall be completed to the level of the original
ground or to the top elevation of any adjacent embankment.
4. Backfill around retaining walls shall be completed to the level of the original ground line
and to such heights above original ground line or to the levels as shown on the Drawings.
Care shall be exercised to prevent forward movement of the wall.
5. Unless shown otherwise on the Drawings, when special permeable backfill (sheathing) is
to be placed against the back faces of abutments, retaining walls or wing walls, it shall
consist of a continuous covering of approved type proprietary filter cloth protected by a
continuous wall of 200 mm minimum thickness precast, porous (no-fines) concrete blocks
laid in stretcher bond with dry joints. Prior to construction of the block wall, the proposed
underdrain system indicated on the drawings shall be laid along the base of the wall under
the sheathing.
6. The Contractor shall complete the backfill around box culverts to the level of the original
ground line and to the full width of excavation area. If the top of culvert extends above the
original ground line the Contractor shall continue the backfill to the top of culvert and for a
width of 3 m on each side of the culvert for the full width of highway embankment. If the
embankment is in place at the time of backfilling, the Contractor shall backfill around the
culvert to the top of embankment.
7. D.7 Miscellaneous structures shall be backfilled in accordance with the methods
specified. Compaction of backfill when structures are outside the roadway right-of-way or
in approach roads, minor roads or similar areas, shall be to 90% of maximum density as
determined by AASHTO T 180 (Method D).
2.4.4 EMBANKMENT CONSTRUCTION
A Scope
1. These Works shall consist of constructing road embankments, including preparation of the
areas upon which they are to be placed; placing and compacting approved material within
areas where unsuitable material has been removed; and placing and compacting
approved embankment material in holes, pits and other depressions within the right-of-way
area, all in accordance with the lines, grades and cross sections shown on the Drawings.

B Materials
1. Material of classes A-1, A-2-4, A-2-5 or A3 "when confined" groups as in AAHSTO M145
and complying with Table 2.1 shall be used when available, except for rock fill
embankments. If material of this character is not available then materials from A-2-6, A-
2-7, A-4, A-5, groups (AASHTO M145) may be used provided it complies with Table 2.1;
however, special attention should be given to the construction.
Table 2.1: Soil Suitable for Embankment
1- Maximum dry density not less than 1.7 (AASHTO T-180D)
2- Organic matter not more than 5% (AASHTO T-267)
3- No use of A-6, A-7 soil (AASHTO M-145)
4- Maximum size not more than 1/2 of the layer thickness
5- Plasticity Index (PI) less than 20%
6- 4 day soaked C.B.R. should not be less than 8% (AASHTO T-193) when compacted at 100%
maximum dry density in accordance with AASHTO T-180 Method D
39. The 200 mm depth of embankment subgrade layer immediately below the bottom of sub
base shall consist of selected subgrade material having a 4-day soaked CBR of at least
20% when tested in accordance with AASHTO T 193 and with a gradation and P.I. as
specified under Section 2.05 - "Subgrade Construction".
40. The 600 mm depth of embankment immediately below the subgrade layer shall consist of
material having a 4-daysoaked C.B.R of at least 15% when compacted to 95% maximum
dry density in accordance with AASHTO T-180D and tested in accordance with AASHTO
T-193 with a P.I. not more than 15%. If rockfill is used for the bottom 400 mm depth then
these requirements shall apply to the top 200 mm below the subgrade layer.
41. In areas subject to flooding and prolonged inundation of the embankment, such as at
bridge and culvert sites, the material used in embankment, unless rock, shall conform to
AASHTO M 145, Class A-1-a, A-1-b, A-2-4.
42. Where embankments are to be constructed using material classified as A3 (AASHTO M
145) or other material subject to side slope erosion or requiring confinement for
stabilization purposes, the embankment plating or confining layer shall be constructed
using AASHTO M 145 Class A-1-a, A-1-b, or A-2-4 materials or as otherwise approved.
43. The material used in rockfill embankments shall consist predominantly of rock fragments of
such size that the material can be placed in layers of the thickness prescribed conforming
to the requirements stated in Table 2.2.
Table 2.2: Rock Suitable for Embankment
1- Maximum particle size 300 mm or 1/2 or proposed loose layer thickness whichever
is less
2- Passing 0.42mm (Sieve No. 40) 25% maximum
3- Uniformity coefficient, Cu …. 6 minimum, where Cu = D60/D10

44. Rockfill material shall be obtained from roadway or tunnel excavation and shall be sound,
dense, hard and durable rock capable of being spread and compacted as specified.
Individual pieces are to be clean and angular. It shall be the Contractor's responsibility to
excavate material from rock cuts, whether by blasting or other manner, so that all
excavated materials are of suitable size.
45. When suitable materials of widely divergent characteristics are drawn from different
sources, such materials may, if approved, be mixed to meet the embankment
requirements. Rock and other materials shall be incorporated in such manner as to avoid
segregation and an accumulation of boulders, etc at the toe of embankment slopes.
46. Logs, trees, stumps, weeds, heavy grass, frozen soil, vegetable matter or other
undesirable and noncompatible materials shall not be placed in embankments.
47. Rocks, broken concrete or other solid materials larger than 100 mm in any dimension shall
not be used as fill material in areas where piling works are to be carried out.
C Workmanship
1. Prior to placing embankment material on any area, it shall have been cleared and grubbed
as specified in Sub-Section 2.02.1 - "Clearing and Grubbing", and the foundation prepared
as specified herein.
48. Equipment used for foundation preparation and for placing, spreading and compacting
embankment materials shall be of approved types and furnished in sufficient numbers for
the purposes intended. Provision and use of such equipment shall conform with the
relevant requirements set in these specifications and with the Contractor's approved Work
Program.
49. Draglines shall not be used to construct embankment unless approval is given and only
when special procedures are adopted to keep the layers uniform and the embankment
properly graded and well-drained at all times.
50. Surfaces of embankment layers shall be kept properly shaped and drained at all times.
The Contractor shall utilize a sufficient number of motor graders or tractors to level and
maintain the surface of each layer of embankment during all placing and compacting
operations.
51. Rockfill shall not be used in the top 200 mm of the embankment below the subgrade.
Water must be added as required, and with the approval of the Engineer, to achieve
maximum compaction.
52. Whenever feasible, trucks, scrapers, tractors, loaders and other heavy hauling equipment
shall be routed over the embankment in such a manner as will contribute effectively to
compaction of the fill material.
53. Where an embankment is to be constructed over an area previously occupied by a
building basement, cellar, irrigation canal, well, any previous excavation, or adjacent to
structures, and where the proper use of normal compaction equipment is not practicable,
the embankment shall be constructed and compacted in accordance with the backfilling
requirements of the relevant sub-sections herein before, until the use of normal
compaction equipment is practicable. Layers shall not exceed 200 mm thickness (after
compaction) and shall be compacted to the degree of compaction specified for the
embankment.
54. Each embankment layer shall be tested and approved prior to placing the following layer in
accordance with Subsection D "Testing" here below.
55. The Engineer may at any time order suspension of delivery of materials to the
embankment Sites until previously delivered materials have been properly placed and
preceding layers are leveled and uniformly compacted to the specified density.
56. Unacceptable material placed in any embankment shall be removed and disposed of by
the Contractor at his expense.
57. The Contractor shall be responsible for the stability of all embankments and shall replace
all embankment sections which, in the opinion of the Engineer, have been damaged or
displaced due to carelessness or neglect on the part of the Contractor, or due to normally
occurring natural causes, such as storms, and not attributable to the unavoidable
movement of the natural ground upon which the embankment is constructed.
58. All embankment side slopes shall be neatly finished true to the lines and not steeper than
the slope angles as shown on the Drawings. The bottom (toe) of side slopes shall be
graded to a well-rounded, smooth profile to blend in with the adjacent terrain.
59. The side slopes of rockfill embankments shall be thoroughly blanketted with A-1, A-2-4
material, and compacted to the satisfaction of the Engineer.
60. The Engineer may permit the Contractor to utilize suitable surplus material at his own
expense to widen embankments or flatten slopes, etc within the right-of-way. Surplus
material used in such manner shall be compacted to 90 per cent of maximum density, but
this shall not be measured for payment. When widening embankments, the Contractor
shall bear the cost of modifying the culverts and any protection work necessary.
61. Rockfill shall not be used within 5m of a structural element (next to bridge abutments
footings, etc)
62. Rockfill shall not be used for 600mm on top and bottom of Box and Pipe Culverts.
Subgrade material shall be used in these areas up to width excavated for structures.
63. If shown on the Drawings, or as required by the Engineer, a trial embankment shall be
constructed. The trial section shall be at least 2 lanes wide by 100 m long at approved
locations at or adjacent to the Site. Compaction and other equipment used, shall be as
specified and listed in the Contractor Equipment Schedule and approved Programme of
work.
64. If the original surface upon which embankment is to be placed is an existing roadbed, the
surface shall be plowed, scarified, or otherwise broken up regardless of the height of the
embankment to be placed thereon.
65. Unacceptable material placed in any embankment shall be removed and disposed of by
the Contractor at his expense.
66. Where embankment is to be placed and compacted on hillsides or where new
embankment is to be compacted against existing embankments or where embankment is
built part width at a time, the slopes steeper than 3:1 (H:V) when measured at right angles
to the highway centerline shall be continuously benched as the embankment is brought up
in layers. Benching shall be of sufficient width to permit operation of spreading and
compaction equipment, and in any case not less than 2 m wide except where insufficient
width is available between existing and new embankments. Each horizontal cut shall
begin at the intersection of the original ground and the vertical sides of the previous cuts.
The vertical face of each bench shall not be less than 1 m in height and not exceed 2 m.
Authorized benching shall be measured as highway excavation.
67. Where embankment is to be placed and compacted on wadi slopes, the entire slope area
shall be graded and trimmed to remove any vertical faces and overhangs. The final
graded slope shall not be steeper than 1.5:1 (H: V). The slope shall then be continuously
benched as the embankment is brought up in layers, all as described above for
embankment on hillsides.
68. Rockfill shall not be placed on any slopes steeper than 1:1. All slopes steeper than 1:1
shall therefore be regraded to a slope of 1:1 or shallower and all vertical faces and
overhangs removed.
69. Roadway embankment consisting of soil or granular material shall be placed in horizontal
layers not exceeding 250 mm thickness (before compaction), shall be compacted as
specified and shall be approved prior to placing the next layer. The thickness of the first
layer over areas of Class A-3 dune sand may exceed 250 mm in order to bridge these
areas. Approximately uniform thickness of each layer shall be achieved prior to
compaction. As the compaction of each layer progresses, continuous levelling and
working of the material shall be carried out to ensure uniform density. The correct

moisture content shall be maintained at all times.
70. Where embankments are to be constructed to a height in excess of 1.5 m above top of
original ground level the Engineer may approve layer thickness up to 300 mm (before
compaction) if the Contractor's equipment and the nature of the material result in the
required density throughout the layer thickness.
71. When the moisture content of the embankment material does not fall within the required
moisture range, (optimum moisture ± 2%) water shall be added and thoroughly mixed into
the soil by approved methods or the material shall be aerated, whichever is necessary to
adjust the material to the required moisture content.
72. When water is added to embankment material, the amount added shall be sufficient to
provide a moisture content within the required range plus a reasonable additional amount
to compensate for evaporation and other unavoidable losses. Water added in excess of
this amount shall be removed by aeration or other approved means at the Contractor's
expense. Satisfactory methods and sufficient equipment shall be used for the furnishing
and handling of the water in a manner that will minimize loss due to evaporation or waste.
73. Embankments that consist of rock-soil material with sufficient soil to make rolling feasible,
shall be placed and compacted in an approved manner and to the required degree of
compaction. Water shall be added as and when directed to assist in the compaction of
such materials.
74. In the case of embankments which are to be formed of approved rock-soil material
containing an appreciable quantity (normally not exceeding 30% greater than 80mm) of
rock fragments and which cannot be placed in layers of the thickness prescribed without
crushing, pulverizing, or otherwise breaking down the fragments, the embankment may be
constructed in layers not exceeding in thickness twice the average size of the largest rock
fragments and in any case not exceeding 600 mm (before compaction).
75. Rockfill materials shall be placed in such a manner that the larger rocks are well
distributed, and the voids are filled to the maximum practical extent by smaller particles,
each layer shall be bladed into a neat and homogeneous mass prior to compaction. Any
rocks found protruding from the levelled surface shall be removed and replaced by smaller
particles. Initial breakdown compaction shall be performed with heavy bulldozers. The top
level of each layer must be surveyed before and after compaction and approved by the
Engineer before the next layer is placed. Oversize rock pieces may be used in high rockfill
embankments to a level 3 metres below subgrade.
D Testing
1. The Engineer shall test the compaction of embankment materials in accordance with these
Specifications to ensure that adequate compaction or consolidation has been achieved.
All such tests shall be fully documented by the Contractor, in an approved manner.
2. In the case of cohesionless, free draining rock-soil materials, where maximum density
tests fail to produce a well-defined moisture - density relationship, the relative density test
shall be used, alternatively an electronic compaction meter or any other approved test
equipment shall be provided by the Contractor and used to determine the degree of
compaction achieved.
3. To determine the degree of compaction for embankment consisting of rock fill, average
differential settlement values shall also be determined from surveys of an adequate
number of grid point elevations as and when directed, at the commencement of, during
and after embankment construction.
4. If it is required to determine the modulus of soil reaction by the Plate Bearing test, this
shall be undertaken using the method given in AASHTO T222-81 (1986).
E Standards of Compaction for Soil and Granular Materials
1. The following compaction standards shall apply to embankment materials other than
predominantly rock materials. The "maximum density" of soil type materials shall be the
modified maximum density determined in accordance with AASHTO T 180 (Method D).

The "relative density" shall be the relative density determined in accordance with ASTM
D4254, which identifies the state of compactness of the material with respect to its loosest
and densest state. The relative density shall be the standard to which the field density is
referred for comparison in the case of cohesionless, free draining granular materials.
2. Soil type materials shall be compacted to at least 90% modified maximum density for the
full depth of embankment. The 600 mm of embankment material immediately below the
subgrade layer shall be compacted to at least 95% modified maximum density. Moisture
content shall be within plus or minus 2% of optimum at the time of compaction.
3. Cohesionless, free draining granular materials (of 75 mm maximum size and with not more
than 15% passing 0.075 mm (No. 200) sieve) shall be compacted to at least 70% of
relative density for the full depth of embankment. The 600 mm depth of such material
immediately below the subgrade layer shall be compacted to at least 75% of relative
density.
4. Minimum soil tests required during the construction of subgrade and/or embankment are:
 One sample for CBR, classification (AASHTO M145), and laboratory (Moisture - density) or relative
density compaction from each source prior to use. Each sample shall represent not more than
5,000 cu m.
 One sample for classification representing not more than 3,000 cubic meters of the material in use.
 For every completed layer, one field density shall be determined for each 1500 sq.m or 100 linear
meters whichever is less. Testing shall be in accordance with ASTM D1556 or ASTM D2167.
2.4.5 PIPE BEDDING MATERIAL AND BACKFILLING FOR PIPE TRENCHES
A Granular Bedding and Backfill materials
1. Backfilling above pipe crest shall be with clean granular Class A-3 in layers 30 cm thick
and shall pass sieve No. (4) 4.75 mm, and be retained by sieve No. (200) 0.075 mm.
76. Granular material for pipe bedding shall be composed of 14 mm maximum size natural
gravel, crushed gravel or crushed rock, free from dirt, clay, roots, organics and other
deleterious material mixed with sufficient sand to fill the voids, about 30 to 35% by volume.
77. Granular bedding shall conform to the following:
Standard Sieve size % By Weight Passing
(mm) for rigid pipes (DI or AC etc.) PE pipes
19.0 (3/4 in) 100
4.76 (No. 4) 25-100 100
1.19 (No. 16) 10-75 25-75
0.300 (No. 50) 5-30 10-30
0.177 (No. 80) 3-10 3-10
0.075 (No. 200) 0-5 0-5
78. For GRP pipes bedding shall be of graded crushed stone 2.83-8 mm or as recommended
by Manufacturer.

79. Sand bedding and fill up to 300 mm minimum above crown of the pipe shall be non-plastic,
natural well graded sand having hard, strong, durable angular particles. It shall be clean
and free from extraneous materials, clay balls, organic matter or other detrimental
material. The amount of fines passing sieve No. 200 shall not exceed 15% or according to
the standard specifications (ASTM C33).
80. Backfill over a pipe shall consist of two different layers: Initial or selected backfill and main
backfill
81. Backfill in contact with the pipes and up to 300 mm minimum above crown of the pipe shall
be selected material
82. Selected fill material shall comply with group type GW, GP, GM, BC, SW, SP, SM, SL in
compliance with ASTM D 2487.
83. Selected fill material shall not contain ashes, cinder, refuse, rubbish, organic material, or
the like. The material shall be capable of being compacted without the use of heavy
rammers.
84. The main backfill (for the remainder of the trench) shall be done with suitable material
either from material removed in the course of excavating the trench or imported from
approved borrow pit. In either case the backfill material shall conform to paragraph B of
section 2.04.2 herein before.
85. Pipelines should be covered by plain concrete if the top cover is less than 1 m or for deep
pipelines as per the manufacturer recommendations.
B Workmanship: Backfilling
1. Trenches shall not be backfilled at joints until after that section of the pipeline has
successfully passed the specified tests required
2. Selected backfill or surround up to a level of 300 mm above top of the pipe, shall be placed
and hand compacted in 150 mm layers. The backfill shall be brought up evenly on both
sides of the pipe for the full length of the pipe. Care shall be taken to ensure thorough
compaction of the fill under the haunches of the pipe.
3. For GRP pipe initial backfill shall be compacted to 95% relative density or as
recommended by manufacturers.
4. Main backfill shall be placed and well compacted in layers not exceeding 300 mm thick
before compaction. Heavy compactors shall not be used until there is 600 mm cover over
pipes.
5. Compaction of each layer shall be according to Section 2.04.2 paragraph J herein before.
6. Heavy steel or pneumatic rollers shall not be used for compacting backfill to pipe trenches.
Special precautions shall be taken to safeguard existing structures when steel or
pneumatic rollers are used.
7. Compaction equipment shall be suited to the type of material and shall be subject to
approval. Compaction around foundation walls, culverts and small restricted areas shall be
carried out by mechanical vibratory plates, tampers or hydraulic compactors.
8. Backfilling trenches for pipes with concrete beds and or surrounds shall not start before 24
hours after placing the concrete. Heavy compactors shall not be used, and traffic shall not
be allowed before the elapse of 72 hours after placing the concrete.
9. When the material is too wet from rain or excessive application of water, no compaction
shall be done. In this case the work shall be suspended until the previously placed and
new materials have dried sufficiently to permit proper compaction. Other measures shall
be taken if necessary, to obtain proper compaction.
10. Temporary crossing are to be provided over trenches to prevent construction traffic
damaging pipes after backfilling.
11. The top 500 mm of pipe trenches below road pavement layers shall be filled with crushed
aggregate base course material compacted to 95% of maximum dry density.

12. If authorized by the Engineer, the main backfill may be consolidated using water-jetting,
puddling, or tamping as directed.
C Restoration of surfaces
1. Restoration of asphalt, concrete, gravel pavements and the likes shall be of materials and
thickness to match the existing pavement. All works, workmanship material shall be in
accordance with concerned authorities specifications (Directorate, Municipality, Ministry of
transport) and Engineer direction.
2. Restoration of pavement shall be done according to the existing pavement quality and
level to ensure that new pavement is matching to provide uniform surface with the existing
profile.
3. Grassed areas shall be restored by spreading, after backfilling, approved fertile soil over
affected area. Seeding, fertilizers and water shall be applied until grass is restored to its
former condition.
4. Surface grading shall be carried out to restore all un-surfaced areas and any adjoining
areas disturbed to provide a level, smooth surface.
5. The Contractor shall proceed with restoration of surfaces as soon after completion of other
work as is practicable, but in no case more than 10 days after backfilling of trenches and
other excavated areas. Restoration shall be completed within 20 days from the start of
restoration or as approved by the concerned authorities.
2.5 SUBGRADE CONSTRUCTION
2.5.1 GENERAL
A These Works shall consist of furnishing materials, constructing the sub-grade layer and
preparing the sub-grade surface ready to receive the pavement structure and shoulders, all
as and where shown on the Drawings.
B Sub-grade layer is the 200 mm minimum depth of selected material immediately below the
sub-grade surface, or as defined in the drawings or directed by the Engineer.
2.5.2 MATERIALS
A The supplied material shall not contain any organic or harmful material e.g: tree, leaves,
B The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4, according
to MRDTM 210 (Directorate of Material and Research at the MOC).
C Unless otherwise shown on the Drawings, sub-grade material shall consist of selected
material having a 4-day soaked CBR of not less than 25% when tested in accordance with
AASHTO T 193 when compacted at 100% of modified proctor AASHTO (T-180) and
having a maximum P.I. of 12% unless otherwise noted. Sub-grade gradation shall be
reasonably smooth without gap grading. All material shall pass 75 mm sieve and not more
than 18% shall pass 0.075 mm (No. 200) sieve.
D The maximum dry density shall not be less than 95% when tested according to Directorate
of Material and Research at the MOC.
E The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall contain fine
F Minimum tests required on subgrade are indicated in sub-Section 2.04.4 "Embankment

Construction".

2.5.3 WORKMANSHIP
A Subgrade in Cut
1. Where the subgrade is located in rock, the sub-grade, unless shown otherwise on the
Drawings, shall be undercut to a depth of 200 mm by drilling or blasting as directed. No
rock shall project more than 50 mm above the undercut surface elevation. The sub-grade
layer shall then be constructed using approved sub-grade material, as specified for sub-
grade in embankment.
2. Where the subgrade is on in-situ soil that is of a quality and CBR value at least equal to
those specified for sub-grade, the 200 mm depth of such material immediately below top of
sub-grade shall be scarified and all roots, sod, vegetable and other undesirable matter and
stones larger than 75 mm in any dimension shall be removed. The material shall then be
brought to a uniform moisture content within the specified range and compacted to 100%
AASHTO T 180 (Method D) maximum density.
3. Where the subgrade is on in-situ soil which is unsuitable for retention as the sub-grade
layer, such material immediately below the top of subgrade layer shall be sub-excavated to
a depth of 200 mm, hauled away and disposed off unless approved for use as
embankment fill. The subgrade layer shall then be constructed using approved subgrade
material, as specified for subgrade in embankment. If the material below subgrade layer
does not satisfy the requirement of top 600 mm, it shall be excavated for further 200 mm
and replaced by suitable material to satisfy the requirements of subgrade.
4. The underlying natural material shall be scarified, leveled and rolled. The surface of the
natural soil shall be approved by the Engineer before placement of suitable material.
B Subgrade in Embankment
1. The 200 mm minimum depth of embankment immediately below top of subgrade shall
consist of selected, approved sub-grade material. The material shall be spread in one
layer over the full width of the top of embankment, brought to a uniform moisture content
within the specified range and compacted to 100% AASHTO T 180 (Method D) medium
density.
1. All finished elevations, lines and grades shall be in accordance with the details shown on
the Drawings. Each cross section shall be checked at maximum intervals of 25 m, at each
change in cross slope and elsewhere as directed.
2. The tolerances on elevations of finished sub-grade, top of embankment under the sub-
grade layer and sub-excavated (undercut) surface shall be as follows:
Surface Tolerance
Finished Sub-grade:
Soil +10 or -30 mm
For agricultural roads, tolerances on elevations are allowed to be as follows:
Surface Tolerance
Finished Sub-grade:
Soil +20 or -30 mm
86. When the finished subgrade surface is tested with a 4 m long straightedge placed parallel
to, or at right angles to the centerline, the maximum depression of the surface from the
testing by straight edge shall be 30 mm.

D Maintenance of Finished Subgrade
1. The finished and approved sub-grade shall be continuously maintained in a smooth, well
compacted and properly drained condition until the sub-base (or base) course is
constructed. Reapproval of the subgrade will be required if the overlying course is not
constructed within 14 days of sub-grade completion or if the subgrade layer is damaged by
traffic or any other causes prior to the placement of the sub-base layer.
2.6 GABIONS
2.6.1 GENERAL
A The work shall include the supply of all material, preparation of gabions and their
installation as indicated on the Drawings or as instructed by the Engineer. Such works will
be constructed for protection in valleys and flooding areas.
2.6.2 MATERIALS
A Gabions shall consist of approved type galvanized steel wire mesh baskets (or other
approved types such as heavy-duty plastic mesh) filled with selected rocks before
installation.
B Galvanized steel wire mesh shall conform to ASTM A 390 Class 3, or equivalent and with
the requirements shown on the Drawings. The wire mesh shall be twisted to form
hexagonal or rectangular openings of uniform size. The maximum nominal opening size
shall be 100 mm. Mesh shall be constructed so as to resist pulling apart at any of the
twists or connections forming the mesh when a single wire strand in a section is cut.
C Baskets shall be furnished in one or more sizes that can be assembled to provide the
minimum dimensions, stability, and structural integrity of the installation specified. Sizes of
gabion baskets will normally be 2 m long by 1 m wide by 0.5 m to 1 m high. Non-standard
sizes shall be provided to suit the particular installation, as shown on the Drawings.
D Baskets shall be fabricated in such a manner that the sides, ends, lid, and diaphragms can
be assembled on Site into rectangular baskets of the specified sizes. Gabion baskets shall
be of single unit construction. Long gabions assembled with diaphragms between
adjacent baskets, for use as foundation mattresses, etc., may not require lids.
E Base, lid, ends and sides shall be either woven into a single unit or one edge of these
members connected to the base section of the gabion in such a manner that strength and
flexibility at the point of connection is at least equal to that of the mesh.
F All perimeter edges of the mesh forming the basket shall be securely clip bound or
selvedged so that the joints formed by tying the selvedges have at least the same strength
as the body of the mesh.
G Perimeter (edge), tie, and connection wires shall conform to ASTM A 641, Class 3,
Medium Temper, and the minimum diameters shown on the Drawings.
H Riprap material for filling of gabion baskets shall consist of rocks conforming to Riprap
Class A size, clean, strong, durable and highly resistant to weathering. Dimensions shall
range from 250 mm to approximately 125 mm diameters. Not more that 5% shall be
smaller than 100 mm.
2.6.3 CONSTRUCTION
A The surfaces upon which gabions and similar slope protection works are to be placed shall
be excavated and compacted to the required grades and lines and a footing trench where

specified, shall be excavated along the toe of the slopes, all as shown on the Drawings or
as directed. Subgrade or base shall be firm or compacted as directed.
B Each gabion basket shall be assembled by binding together all vertical edges with wire ties
on approximately 150 mm spacing or by use of a continuous piece of connecting wire
stitched around the vertical edges with a coil every 100 mm.
C Empty gabion units shall be installed to line and grade as shown on the Drawings. Wire
ties or connecting wire shall be used to join the units together in the same manner as
described for assembling. Internal tie wires shall be uniformly spaced and securely
fastened in each cell of the structure. A standard fence stretcher, chain fall, or iron rod
may be used to stretch the wire baskets and hold alignment.
D The gabions shall be filled with riprap as specified, placed by hand or machine to assure
alignment and avoid bulges with minimum voids. Alternate placing of rock and connection
wires shall be performed until the gabion is filled. After filling with riprap, the lid shall be
bent over until it meets the sides and edges, and shall be secured to the sides, ends, and
diaphragms with wire ties or connecting wire in the manner described for assembling.
2.7 STONE PITCHING IN CONCRETE
2.7.1 GENERAL
A These works will be constructed in valleys and flooding areas.
B Stone pitching shall consist of broken stones, placed as indicated on the Drawings or in
locations as directed by the Engineer.
C Stone pitching shall be constructed to the shape and dimensions shown on the Drawings
in accordance with the provisions of the specification or as directed by the Engineer.
D Stone pitching shall be classified as stone pitching in concrete and shall have a thickness
of 200 mm, unless otherwise indicated on the Drawings.
2.7.2 MATERIALS
A Rock
1. The stones for this work shall be durable, angular field or quarry stones of approved
quality, sound, hard, free from seam and other structural defects and shall have a specific
gravity of not less than 2.40. At least 60% of the stone pitching shall consist of pieces
having a weight of not less than 15 kg and of the remaining 40% no piece shall have a
weight of less than 7 kg. The thickness of each layer shall be achieved by the thickness of
one rock piece. The thickness of the rock piece shall be within 50mm from the specified
layer thickness, measured at the thinnest section of the rock piece.
B Concrete
1. Concrete used for filling shall be of the same class as blinding concrete.
2.07.3 PLACING
A Ground surface to be protected by stone pitching shall be thoroughly compacted to the

approval of the Engineer and covered with 50 mm blinding concrete prior to placing of the
rock.
B Rock shall be placed starting with the lowest point of slopes.

C Approval of the Engineer is required for rock laying prior to pouring concrete. The rock
shall then be flushed with water to provide adequate bonding with concrete. Concrete
paring shall start with the lowest point of the area to be protected. Where more than one
layer of stone pitching is specified, or in keys, a layer of 50 mm blinding concrete shall be
placed below the first layer and between consecutive layers.
D The finished surface of the concrete shall be flush with the top of the surrounding stone
pieces.
2.8 GEOTEXTILES
2.8.1 GENERAL
A Geotextiles are used for protection and containment of the granular bedding and the first
dump layer around GRP pipes in the presence of water table in the trench.
B The work include the supply and installation of geotextile fabric as indicated on the
Drawings.
2.8.2 MATERIAL
A Drainage Fabric
1. Non-woven geotextile, specifically manufactured as a drainage geotextile; made from

 Water Flow Rate: 100 l/sec/m2 (ASTM D 4491)
B Separation Fabric
1. Woven geotextile, specifically manufactured for use as a separation geotextile; made from
 Water Flow Rate: 2.7 l/sec/m2 (ASTM D 4491)
2.8.3 WORKMANSHIP
A Store and handle geotextiles in accordance with ASTM D 4873. Place and install in
accordance with manufacturer’s written instructions and as follows, to the approval of the
Engineer.

 Overlaps shall not, in any case, be less than 25 mm
 Place bedding layer as soon as possible after placement of the geotextile, in accordance with
approved methods, to thickness shown on Drawings
 Remove and replace any geotextile damaged or punctured either before, during or after laying.
PART 3 PAVEMENT AND ROADS SURFACE FINISHING
3.1 SCOPE
A These works cover the supply of materials and construction of all components of the
roadwork specified in this Project. The roadwork components include sub-base and base
courses, bituminous materials, pavement repairs and trench reinstatement and
maintenance of traffic and detours.
3.2 GRANULAR SUBBASE AND BASE COURSES
3.2.1 GENERAL
A Contractors Responsibility
1. The Contractor shall locate sources of material, ensure adequate supply and ensure
compliance with the Specifications.
2. The Contractor shall obtain and test, in an approved laboratory, samples from sources and
stockpiles which are in compliance with the Specifications.
3. Samples provided by the Contractor shall satisfy all specified test requirements. The
Contractor shall permit the Engineer to inspect any and all materials used or to be used, at
any time during or after their preparation, or while being used during progress of the
Works. Unsatisfactory materials, whether in place or not, shall be removed promptly from
the Site. The Contractor shall furnish all necessary labor, transport, tools and equipment
required by the Engineer for such inspection.
4. The Contractor shall ensure that screening plants or crushing and screening plants shall
not be put into operation prior to their approval. If, after any plant is put into operation, it
fails to perform as intended, the Contractor shall either rectify the defects in the existing
plant to the satisfaction of the Engineer, or shall provide alternative approved plant.
5. Approval of the crushing and screening plants and other equipment shall in no way relieve
the Contractor of his responsibilities in respect of producing granular materials and
aggregates which conform to the Specifications and in the quantities required for the
completion of the Works on time.
6. The Contractor shall conduct necessary tests in the Field Laboratory in the presence of the
Engineer and the Contractor’s Materials Engineer.
7. Processed materials shall be tested and approved before being stockpiled on Site or
incorporated in the works and may be inspected and tested at any time during their
preparation, storage and use. Questionable materials, awaiting testing and approval, shall
not be unloaded and mixed with materials previously approved. If the grading and quality
of any materials delivered to the Site does not conform to the grading and quality of the
established control samples, the Engineer will reject such materials.
8. Samples shall satisfy all specified test requirements. The Contractor shall permit the
Engineer to inspect any and all materials used or to be used. At any time during or after
their preparation, or while being used during progress of the Works. Unsatisfactory
materials, whether in place or not, shall be removed promptly from the site. The
Contractor shall furnish all necessary labor, transport, tools and equipment required by the

Engineer for such inspections.
9. The contractor shall construct in accordance with the concerned authorities specification.
3.2.2 MATERIALS
A Subbase shall consist of naturally occurring gravel and sand, screened or crushed to
obtain the specified gradation.
B Base course shall consist of crushed gravel, crushed stone or sand with screenings as
required to obtain the specified gradation.
C The supplied material shall not contain any organic or harmful material e.g: tree, leaves,
D Material for subbase and base course shall conform to classification types: A-1-a, A-1-b
according to AASHTO classification system.
E Gravel, crushed gravel and crushed stone shall consist of hard, durable particles, free from
dirt, organic matters, shale and other deleterious materials, and shall not contain more
than 8% of clay lumps and friable particles. The fine material shall pass sieve no. 4 (4.75
mm) and shall consist of natural sand or crushed fine materials.
F Physical and chemical properties of granular materials used for subbase and base courses
shall conform to the requirements specified as follows:
1. Gradation: Subbase and Base shall conform to the following gradation in accordance with
AASHTO T-27.
Sieve Designation
Subbase
50 mm (2 inch) 100 50 mm (2 inch)

90-100
37.5 mm (1 ½ inch) 37.5 mm (1 ½ inch)
25 mm (1 inch) 55-85 25 mm (1 inch)
19 mm (3/4 inch) 50-80 19 mm (3/4 inch)
9.5 mm (3/8 inch) 40-70 -
4.75 mm (No.4) 30-60 30-60
2.00 mm (No.10) 20-50 -
0.425 mm (No.40) 10-20 10-25
0.075 mm (No.200) 0-15 2-10
87. Other Requirements for Subbase and base are indicated in the following table:
Test/Designation Subbase Base
Clay Content AASHTO T.88 max 5% max 5%
Fines Content AASHTO T.27 - passing No.200 shall be less than half
passing No.40

Los Angeles abrasion AASHTO T.96 < 50% < 45%
C.B.R ASTM D1883  30%  80%
(4 day-soaked sample compacted @
100% Modified proctor)
Soundness AASHTO T.104 In Sodium In Sodium
(Max. loss in weight after 5 cycles) Sulphate:  12% Sulphate:  12%
In Magnesium In Magnesium Sulphate:  18%
Sulphate:  18%
Fine aggregate AASHTO For passing No.40 For passing No.40
T.89, T.90 LL  30%, PI  6% LL  25%, PI  6%
Percentage of material with at least one _____ 90%
fractured face
88. If it is found necessary to add fine material in order to improve gradation requirements, this
material shall pass sieve 0.425 mm (no. 40) and shall be mixed with the crushed material
in the quarry and not in the project site.
89. The percent passing no. 200 sieve (0.075 mm) shall not be more than half the percent
passing sieve no. 40 (0.025 mm).
3.2.3 CONSTRUCTION
A Mixing and Spreading
1. The Contractor shall thoroughly mix aggregate and water to uniform moisture content.
2. The Contractor shall spread materials on prepared subgrade or subbase in uniform layers
not exceeding the following thickness before compaction:
 For subbase 300 mm
 For base 250 mm
90. All segregated material shall be removed and replaced with well-graded material
91. The Contractor shall compact each layer to the following density requirements:
 Subbase 100% of maximum density AASHTO T.180
 Base 100% of maximum density AASHTO T.180
92. Each layer shall be completely compacted and approved prior to delivery of materials for
the following layer.
B Tolerance
1. The Contractor shall conform to lines, grade and cross sections as shown on the
Drawings.
2. Tolerances on elevations for final layer at 20 m intervals and intermediate points as
follows:
 Base: +10 mm to - 15 mm.
93. For agricultural roads, tolerances on elevations shall be as follows:
 Base: +15 mm to - 15 mm.

94. The Contractor shall remove defective sections and replace to correct tolerances.
95. The Contractor shall maintain finished course in good condition until succeeding layer is
placed.
C Testing
1. The Contractor shall carry out in-situ testing as directed by concerned authorities
(Municipality/Ministry of Transport) and Engineer or as per the listed-below:
Required Tests Repetition Required for all Tests
1. Proctor Test for every 500 LM for each layer or as per specifications of the
concerned authorities (Municipality / Governamate / Ministry of
Transport)
2. Gradation of Materials When materials changed or whenever instructed by the Engineer
3. Plasticity Index "
4. C.B. R "
5. Abrasion "
6. Sand equivalent "
7. Clay lumps and friable particles "
8. Field Density "
9. Thickness Test for every 2000 sq.m. and for every layer
D Compaction
1. Compaction shall be tested in accordance with AASHTO T 191 or AASHTO T 205. If there
is a delay between the construction of any layer and the following layer, if necessary and
required by the Engineer the compaction of the lower layer may be re-verified to ensure
that it has not loosened due to traffic, passage of construction equipment, adverse weather
conditions or otherwise.
3.3 BITUMINOUS LAYERS
3.3.1 GENERAL
A Responsibility
1. The Contractor shall locate adequate sources and supply of material conforming with the
specifications.
2. The Contractor shall obtain the approval of the Engineer.
3. The Contractor shall sample and test all materials in an approved laboratory for
compliance with the specification.
4. The Contractor shall ensure crushing, screening and sampling materials shall be as
specified in section 3.02.1.
5. The Contractor shall construct as per specification of the concerned authorities
(Municipality / Ministry of Transport).
3.3.2 MATERIALS AND REQUIREMENTS FOR BITUMINOUS COURSES
A Materials
1. The materials specified for use in construction of pavement layers include:
 Coarse and fine mineral aggregate and filler.
 Bitumen products including penetration graded bitumen and cutback bitumen.

96. Physical and chemical properties of all materials used in the bituminous mixes and/or

bituminous layer construction shall conform to the requirements outlined in sub-sections B,
C and D below.
B Aggregates for paving layer
1. Aggregate shall be clean, hard, durable and sound and shall consist of crushed stone, of
uniform quality and free from decomposed rock organic matter or shale. Combined
aggregate grading for bituminous mixes including mineral filler shall conform to the
requirements indicated in the table below:
1" (25.0 mm) 100 ---
¾" (19.0 mm) 75-90 100
½" (12.5 mm) 65-80 90-100
3/8" (9.5 mm) 55-65 78-83
No. 4 (4.75 mm) 35-80 46-60
No. 10 (2.00 mm) 20-35 30-42
No. 40 (0.425 mm) 7-20 14-25
No. 80 (0.180 mm) 5-25 8-16
No. 200 (0.075 mm) 3-7 3-7
97. Other Aggregate Requirements:
 Percentage by weight of friable particles, clay lumps, organic material and shale shall not exceed
1% as determined by AASHTO T-112.
 Aggregate shall not contain more than 1% gypsum and 5% chert.
 The plasticity index of material passing 0.425mm should not exceed 4%.
 90% of crushed particles retained on No. 4 sieve (4.75 mm) shall have at least 2 or more fractured
faces.
 Flakiness index and elongation index tested in accordance with B.S. 812 shall be within the
following maximum limits:
Wearing Course Binder Course
Flakiness Index 25 30
Elongation Index 25 30
 Added mineral filler shall be fine particles of limestone or cement in accordance with ASTM D-242.
It shall be dry and free from organic material or clay.
 Loss in weight of aggregate after 500 revolutions shall not exceed 35% when tested in accordance
with AASHTO T-96.
 Soundness, when tested in accordance with AASHTO T-104 for aggregate retained on No 4 sieve
(4.75 mm) shall not show signs of disintegration, and the loss in weight after 5 cycles shall not
exceed 10% for the sodium sulphate tests and 12% for the magnesium sulphate test.
 When tested for resistance to water damage in accordance with ASHTO T. 283, the retained
strength should be greater than 80%.

 Combined mineral aggregate shall have a sand equivalence value not less than 50 when tested in
accordance with AASHTO T-176.
 Aggregates shall be washed if directed to remove any clay lumps, adherent dust and other
deleterious materials.
C Bitumen Products
1. Provide adequate transport and storage facilities for bitumen, and protect from
temperature under -5°C or over + 60° C.
2. Sampling of bitumen shall be in accordance with AASHTO T-40.
3. Binder and wearing courses shall be plant mixes in accordance with an established Job
Mix Formula (J.M.F)
4. The J.M.F. shall be established by the Contractor and approved by the Engineer. The mix
design procedures shall be in accordance with the Marshall method procedure given in the
Asphalt Institute Manual, M.S-2.
5. The J.M.F. shall be re-established if the source of aggregate, filler or bitumen is changed.
6. Unless otherwise specified the bitumen for binder and wearing courses shall be 60/70
penetration graded bitumen and shall conform generally to the requirement of AASHTO
M20.
7. The J.M.F. shall conform to table 3.1
Table 3.1: Job Mix Formula

Number of blows at each end of compacted 75 75
specimen
Stability (Marshall) (Kg) 1000 1000
Flow (Marshall) (mm) 2-4 2-4
Percent Air Voids 4-7 4-6
Percent Voids in Mineral Aggregate (V.M.A.) 14 15
Percent Voids filled with bitumen (V.F.B.) 50 - 70 50 - 75
Loss of Marshall Stability (AAHTO T 165) max 25% max 25%
Filler Bitumen Ratio 0.6 - 1.5 0.6 - 1.4
Bitumen content, percent by weight of total mix. * 3.5 - 4.5 3.5 - 4.5
* the optimum bitumen content shall be determined during the design mix procedure. (the given values
are tentative).
98. The maximum variations of the project mix from the approved J.M.F. are as shown in table
3.2:
Table 3.2: Surface Tolerances

Sieve Designation (square Specified Tolerances
openings)
9.5 mm (3/8 in.) and above + or -5.0%
4.75 mm (No. 4) + or - 4.0%
2.00 mm (No. 10) + or -4.0%
0.425 mm (No. 40) + or -4.0%
0.18 mm (No. 80) + or -4.0%
0.075 mm (No. 200) + or -1.0%
Bitumen Content to be recommended by the Engineer based on trials
conducted by the Contractor.
Temperature of Mix on discharge + or -50°C
Any deviation from these limits shall be made only with the approval of the Engineer.

For agricultural roads the specified gradation tolerances above can be increased by * 2%.
D Bituminous Prime and Tack Coats
1. Works shall consist of furnishing and applying MC cutback bitumen prime coat to a
previously constructed subgrade, sub-base, aggregate base course, or road shoulders,
and furnishing and applying RC cutback bitumen as a tack coat to a previously constructed
bituminous binder or wearing surface to provide bond for a superimposed bituminous
course; all as and where shown on the Drawings.
2. Unless otherwise specified MC-70 shall be used for prime coat. Properties to conform with
AASHTO M82.
3. Tack coat shall be RC-70 in accordance with AASHTO M-81.
4. Surface for application to be sufficiently dry for Tack coat, and sufficiently moist for prime
coat. Ambient temperature to be more than 10°C and no rain, dust or strong wind.
5. Spraying temperature shall be for RC-70 40 - 75°C. and for MC-70: 45 - 60°C.
6. Unless otherwise directed by the Engineer. The following rates of applications shall be
used.
 Prime coat 0.75 - 2.0 liters/ sq.m
 Tack coat 0.3 - 0.6 Kg/ sq.m
99. Prime coat shall be cured for 3 days or as directed by the Engineer.
100. Tack coat shall be allowed to dry to a suitable tacky condition before succeeding asphalt
layer is placed.
101. Traffic shall not be permitted on surfaces after they have been cleaned and prepared for
prime or tack coat application.
3.3.3 CONSTRUCTION
A Surface Preparation
1. When the bituminous mix is to be placed upon a granular subgrade subbase or base
course, the surface shall have been primed and approved by the Engineer.
102. When the bituminous mix is to be placed upon an existing bituminous surface, the surface
shall be cleaned of all foreign material and broomed free of dust; to the approval of the
Engineer. If required on the Drawings a tack coat shall be applied prior to placing the new
layer.
B Delivery Spreading and Finishing
1. The maximum temperature of the bituminous mix at the mixing plant shall be 170°C when
60 / 70 penetration bitumen is used. The application temperature shall be between 145°C
and 165°C.
2. The mix shall be laid by means of a paver, or spreader, and rolled and compacted to not
less than 97% of the average daily Marshall bulk density.
3. Unless otherwise directed, the schedule of testing shall be as shown in table 3.3.
4. The thickness of pavement surface layer equal to the initial pavement layer thickness with
a maximum thickness of 15 cm and with a minimum value of 8 cm and as per the
concerned authorities (Municipality / Government / Ministry of Transport)
C Tolerances
1. Elevation of finished course at intervals not exceeding 10 m shall be maximum * 10mm (or
15 mm for agricultural roads).

2. When tested with a 3 m long straightedge, parallel to and perpendicular to the centerline,
the maximum deviation between any two contact points shall not exceed 8 mm for the
binder course, and 5 mm for the wearing course (or 10 mm for binder course and 7 mm for
wearing course in case of an agricultural road).
Table 3.3: TESTS FOR BITUMINOUS PAVEMENTS

(A) Frequency for all (B) Frequency for
Work item Tests at Source tests mentioned Tests at road all tests
of material under (A) Site mentioned
under (B)
3-1 1. Specific gravity - Test for each
Materials used and water source
in Asphalt mix absorption - When
(at Batching 2. Abrasion test materials
plant) 3. Chert content quality
4. Clay lumps and changes
Friable materials - As requested,
5. Flaky and
elongated
Particles.
6. Soundness
3-2 1. Gradation - Test for each
Materials used 2. Specific gravity source
in Asphalt mix and water - When
(from hot bins) absorption. materials
3. Plasticity index quality
4. Sand equivalent changes
5. Stripping with - As requested,
asphalt
3-3 1. Complete mix - For each job
Asphalt mix design in mix
design each accordance with - When
layer (At American materials
batching plant) Asphalt Institute quality
(MS2) changes.
2. Loss of stability - When results
are not
consistent
with the mix
design
results.
- As requested,
3-4 At Batching plant - Test each 3 Behind spreader - Test for
Asphalt for 1. Stability working days 1. Stability each
each layer 2. Flow - Tests for each 2. Flow working day
3. Extraction batching plant 3. Extraction - Test for
(binder content - As requested, (binder each batch
and gradation) - Once a week content & - As
4. Air voids - As requested, gradation) requested,
5. Voids in mineral 4. Air voids - Test for
aggregates 5. Voids in each 200
6. Daily Marshall mineral lin.m, per
density aggregates. lane and for
7. Loss of Stability 6. Daily Marshall each layer
density - As
7. Road density requested,
and thickness
(after final
compaction)

103. The combination of permitted tolerances in the levels of the bituminous courses shall not
result in a reduction of thickness of 10 mm from the specified thickness nor a reduction in
the final wearing course by more than 5 mm from that specified.
104. Thickness of each bituminous course shall be determined by taking core samples, as
3.4 PAVEMENT REPAIRS AND TRENCH REINSTATEMENT WORKS
3.4.1 GENERAL
A Scope
1. Pavement repair and trench reinstatement Works shall consist of removing defective
bituminous pavement, preparing surfaces (after having properly backfilled all trenches and
potholes) to receive repairs, furnishing materials, placing and finishing new pavement, as
and where shown on the Drawings or as directed by the Engineer and the concerned
authorities (Municipality / Governmate / Ministry of Transport).
3.4.2 ASPHALTING
Pavement type “A”
Pavement type “A” shall be considered as asphaltic pavement for main roads with a total thickness for
base and pavement layers exceeding 15 cm in addition to a granular layer below base with thickness
greater than 15 cm.
Pavement type “B”
Pavement type “B” shall be considered as asphaltic pavement for collection roads with a total thickness for
asphalt of 10 to 15 cm in addition to a granular thickness below base with thickness exceeding 15 cm.
Pavement type “C”
Pavement type “C” shall be considered as asphaltic pavement for roads that are not main or collection
roads and where asphalting is not of type “A” or “B”.
3.4.3 MATERIALS
A General
1. All pavement materials shall conform with the relevant requirements and concerned
authorities mentioned in Section 3.02.2 - "Materials" and Section 3.03.2 - "Materials and
Requirements for Bituminous Construction".
2. Subgrade materials shall conform with the relevant requirements of Section 2.05 -
"Subgrade Construction and requirements of concerned authorities.
3.4.4 CONSTRUCTION AND REPAIR WORKS
A Preparation of Pavement
1. Cracks in bituminous pavement that, in the opinion of the Engineer, do not require
reconstruction shall be prepared by wire brushing and blowing out with compressed air.
2. Defective bituminous pavement which, in the opinion of the Engineer, requires
reconstruction shall be cut back to good material using pneumatic cutting tools.

Excavation of pavement layers for treching shall also be initiated with pneumatic tools or
milling machines or asphalt saws and later completed with regular excavating equipment.
The cut edges shall be square or rectangular and in line with the direction of traffic. The
depth of cut shall be determined by the Engineer and may include asphaltic layers, base
and sub-base layers and subgrade layers (in the case of failed pavement, excavation shall
include a minimum of 300 mm of subgrade material). All excavated materials shall be
removed and disposed of off-site. When the bottom of the excavation consists of earth or
granular material it shall be thoroughly compacted using mechanical compactors to the
satisfaction of the Engineer. Excavated bituminous surfaces shall be thoroughly cleaned
and wire brushed prior to receiving repair materials.
3. Utility trench reinstatements in bituminous pavement shall be prepared in the same way as
defective bituminous pavement. Excavation shall include a minimum of 300 mm of
subgrade material.
4. If cracks are present in asphalt layer due to trench excavation works for sewage and water
network, the Contractor shall reinstate the defects present as below:
 The crack and longitudinal and transverse joints shall be cleaned by a brush and by air.
 The cracks shall then be filled with bitumen binder after which crushed sand shall be spread
above this binder.
 If settlement is obtained in the existing asphalt then the Contractor shall identify these locations
which shall be saw-cut in a square or rectangular shape with the suitable equipment and shall then
be reinstated as it was before failure.
B Placing and Finishing Repair Materials
1. Cracks of 3 mm width or wider shall be filled with clean, coarse sand then saturated with
1:1 diluted emulsified bitumen or as directed by the Engineer. Cracks of less than 3 mm
shall be filled with emulsified bitumen or as directed by the Engineer. Cracks shall be filled
to the road surface. Any excess bitumen shall be removed with a squeegee and the
bitumen surface shall be sprinkled liberally with coarse sand.
105. Excavations below subgrade level shall be filled to a level specified by the Engineer with
subgrade material in layers not exceeding 150 mm and compacted using mechanical
compactors to conform with the requirements of Section 2.05 - "Subgrade Construction"
106. Sub-base and/or base course, if required, shall be placed in layers not exceeding 150 mm
and compacted using mechanical compactors. They shall comply with the relevant
requirements of Section 3.02.3 or as directed by the Engineer.
107. Prior to receiving bituminous material the excavations shall be thoroughly cleaned.
Subgrade, sub-base or base course material shall be primed with a light coating of MC
cutback bitumen and existing bituminous surfaces shall be lightly painted with RC cutback
bitumen, all in accordance with the requirements of Section 3.03.3.
108. The excavation shall be filled with bituminous pavement materials placed in layers not
exceeding 70 mm and compacted using vibratory compactors. Unless ordered to the
contrary by the Engineer, the top layer shall be compacted by steel wheeled roller, first
compacting the 150 mm strips adjacent to the traffic edges, then rolling in the direction of
traffic.
2. New utility trenches shall be backfilled according to Section 2.04 and to the details shown
on the Drawings, or ordered, including any surrounds, haunching or protective materials.
Construction of subgrade and pavement shall be as for pavement repairs.
3. No excavated areas shall remain open overnight.

1. Levels shall be checked by straight edge in relation to the adjacent existing pavement.
2. Surface tolerances for bituminous layers shall conform with the relevant requirements of
Section 3.03.3.
3. Any deficiency in the wearing course surface shall be corrected by cutting out and
replacing.
3.5 CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS
3.5.1 GENERAL
A Scope
1. These Works shall consist of furnishing materials and constructing concrete/limestone

curbs, gutters, curb-and-gutter combinations and concrete/limestone paving to sidewalks
and medians, using in situ concrete construction precast concrete units or limestone units,
as and where shown on the Drawings. The shapes and installation details of curbs and
gutters, sidewalks, and medians shall be coordinated with the concerned Authorities.
Preparation and construction methods shall comply with the requirements of the
concerned authorities (Municipality / Governmate / Ministry of Transport) or as per the
Engineers direction.
3.5.2 MATERIALS AND PRECAST MANUFACTURE
A Concrete
1. Portland cement concrete shall be Class 210/20 for all in situ and precast concrete, except
base course and backing concrete which shall be Class 170/60. All concrete shall
conform with the relevant requirements of Section 5.01 - "Concrete and Concrete Mixes
and Testing" and shall be produced by an approved commercial ready-mix plant.
B Mortar
1. Mortar shall consist of cement and fine aggregate having the same proportions as used in
the concrete construction and shall conform with all relevant requirements of Section 5.01
- "Concrete and Concrete Mixes and Testing".
C Reinforcement
1. Reinforcing steel shall conform with the requirements of Section 5.03 - "Steel
Reinforcement and Fixing".
D Precast Concrete Units
1. All precast units shall be manufactured to the dimensions shown on the Drawings.
Manufacturing tolerances shall be 3 mm in any one dimension. End and edge faces shall
be perpendicular to the base.
2. Each precast curb or gutter unit shall normally be 0.5 m in length and this length shall be
reduced to 0.25 m or as directed, where units are to be installed along curves of less than
10 m radius.
3. For horizontal curves of radius less than 10 m, curb and gutter units shall be manufactured
to the radius shown and, in such circumstances, where straight elements or portions of
straight elements shall not be used. Bullnoses and curved faces shall be of constant
radius with a smooth change from radius to plain face.
4. Unless shown otherwise on the Drawings, precast concrete tiles (paving slabs) shall be
400 mm by 400 mm by 40 mm thickness with 5 mm edge bevel. The tile face shall be
grooved in squares of a size agreed by the Engineer as appropriate to the tile dimensions.
Coloring of the top layer, where required, shall be achieved using mineral oxides.

5. Surfaces of precast units that will be exposed to view after installation, shall be true and
even, with a dense finish of uniform texture and color, free from cracks, holes, fins,
staining or other blemishes or defects. Units failing to meet these requirements will be
rejected. Surfaces that will not be exposed to view after installation shall have all fins and
irregular projections removed and all cavities, minor honeycombing and other defects
made good with mortar after the units have been saturated with water for at least 3 hours.
6. Precast units shall be cast upside down in approved steel molds under conditions of
controlled temperature and humidity. The units shall be steam cured or any other method
approved by the Engineer until the concrete attains the full specified 28-day strength.
7. The Contractor shall submit for approval, samples of each of the proposed units together
with the manufacturer's certificates and details of the method of manufacture and materials
to be used. The Engineer's approval of the samples will not be considered final and the
Engineer may reject any precast units delivered to the Site which do not meet the required
standards or specifications and requirements of concerned Authorities.
E Limestone
1. Approved best quality limestone shall be obtained from one strata from one quarry,
delivered in one shipment, free from vents, cracks, fissures, discoloration or other defects
which adversely affect strength, durability or ap¬pearance, thoroughly seasoned, dressed
and worked before delivery to site, and to the sizes shown on the Drawings, cut square
and true with clean edges.
F Preformed Expansion Joint Filler
1. Preformed expansion joint filler shall conform to AASHTO M 33.
G Epoxy Adhesive
1. Epoxy adhesive (for use in attaching precast units to existing concrete pavement surfaces)
shall be a two-component epoxy of high viscosity and rapid setting characteristics,
conforming to AASHTO M237, Class II.
H Ducts
1. Ducts (if required under sidewalks or medians) shall consist of uPVC plastic pipe
conforming to DIN 8061/2 or SAS 14 or approved equal. If jacking is required, duct shall
be approved galvanized steel tube.
I Bedding
1. Bedding material shall conform to the relevant requirements of Section 3.02 - "Granular
Sub-base and Base Courses" for Class A or Class B granular material.
A Cast In Situ Curbs and Gutters

1. The subgrade shall be excavated to the grades and sections shown on the Drawings. If
the section is not indicated, the width to be excavated shall be 300 mm each side of the
outside edges of the curb or gutter. The subgrade shall be of approved uniform density.
109. The subgrade foundation shall be excavated to a minimum depth of 150 mm and the
material replaced with bedding material which shall be compacted to at least 95%
AASHTO T180 maximum density. All foundations shall be rolled or compacted to provide
a smooth surface and shall be approved before placing concrete.
110. For stationary side form construction, forms for curb or gutter shall be of approved steel
type. All forms shall be sufficiently strong and rigid and securely staked and braced to
obtain a finished product correct to the dimensions, lines and grades required. Forms
shall be cleaned and oiled before each use. Forms may be removed as soon as
practicable after concreting, provided no damage results to the curb or gutter and in any

case not until 24 hours after completion of concreting.
111. For slip-form construction, curb or gutter may be constructed by use of approved slip-form
or extrusion equipment. The completed curb or gutter shall be true to shape, grade, and
line, and the concrete shall be dense and of the required surface texture.
112. Concrete shall be placed upon the previously prepared and moistened subgrade and shall
be consolidated with an approved type internal vibrator. The surface shall be shaped by
use of a steel screed to produce the section shown on the Drawings. The edges shall be
rounded with edgers to form the required radius, which if not shown on the Drawings shall
be 5 mm.
113. Contraction and construction joints of the required types shall be constructed at the
intervals and locations shown on the Drawings. Adjacent to flexible base or surface
courses, weaker plane contraction joints in curbs or gutters may be constructed by sawing
through the curb to a depth of not less than 30 mm below the surface of the gutter, or they
may be formed by inserting a suitable removable metal template in the fresh concrete, or
by other approved methods. Sealing of the joints will not be required unless shown on the
Drawings.
114. Exposed surfaces shall be finished full width with a trowel and edger. The top face of
curbs or gutters shall receive a light brush finish. Forms for the roadway face of curbs and
the top surface of gutters shall be removed 24 hours after concrete has been placed and
finishing of the surfaces shall be carried out, provided the alignment tolerances and other
requirements have been met.
115. Tolerances on tangent sections of curb and gutter shall be tested using a 4 m
straightedge. The finished surface of concrete shall not deviate from the straightedge
between any 2 contact points by more than 5 mm. Curved sections shall be true to the
specified radius plus or minus 5 mm and all joints shall be flush and neat in appearance.
116. All fins and irregular projections shall be removed and cavities produced by form ties and
all other small holes, honeycomb spots, broken corners or edges and other defects shall
be rectified. After saturating with water for a period of not less than 3 hours, the surfaces
shall be carefully pointed and made true with mortar. All construction and expansion joints
shall be left carefully tooled and free of all mortar and concrete. Joint filler shall be left
exposed for its full length with clean and true edges. The resulting surfaces shall be true
and uniform.
117. A rubbed finish shall then be carried out to surfaces that will be exposed to view after
completion of construction. Before rubbing, the concrete shall be kept saturated with water
for at least 3 hours. Sufficient time shall have elapsed before the wetting down to allow
the mortar used in the pointing of holes and defects to set. Surfaces shall by rubbed with
a medium carborundum stone, using mortar on its face. Rubbing shall remove all
remaining form marks, projections and irregularities, and result in a uniform surface. The
final finish shall involve rubbing with a fine carborundum stone and water until the entire
surface is of a smooth texture and uniform color. After the surface has dried, loose
powder shall be removed and the surface shall be left clean and free from unacceptable
flaws or imperfections.
2. Curbs and gutters shall be moist cured until stripped and finished, and then membrane
cured in accordance with the relevant requirements of Section 5.02 - "Concrete Handling,
Placing and Curing". Curing compound shall be applied immediately following completion
of rubbed finish.
3. The area adjacent to completed and accepted curbs and gutters shall be backfilled with
approved material to the top edges of the curbs or gutters or to the elevations shown on
the Drawings. Backfill shall be placed and compacted to 95% AASHTO T180 maximum
density.
B Precast Concrete/Limestone Curbs and Gutters
1. Subgrade for the concrete base shall be constructed as for in situ curbs and gutters.
2. Forms for the concrete base shall be approved wood or steel. All forms shall be

sufficiently strong and rigid and securely staked and braced to obtain a finished product
correct to the dimensions, lines and grade required. Forms shall be cleaned and oiled
before each use. If approved, forms for the concrete base may be omitted and the
concrete placed directly against undisturbed excavated faces.
3. Base course concrete shall be placed, compacted and shaped to the sections shown on
the Drawings. Concrete shall be compacted with an approved internal type vibrator or if
approved, by hand spudding and tamping. Edges shall be rounded if necessary by the
use of wood molding or by the use of an edger as applicable. The concrete base shall be
finished to a true and even surface with a wood float. Concrete shall be membrane or
water cured for at least 7 days before precast units are placed thereon.
4. Precast concrete units shall be soaked in water immediately before installation. Units shall
be set accurately in position in mortar on the concrete base. Joints between precast units
shall not be mortared unless otherwise shown on the Drawings. Units shall be closely
spaced and every 10 m run shall be provided with an expansion joint.
5. Where curbs or gutters are installed on existing concrete pavement using epoxy resin
adhesive, automatic devices for mixing epoxy adhesive shall be equipped so that the
separate components are delivered to the mixing head at the specified volume. The lines
feeding the mixing head shall be equipped with suitable valves that will allow samples to
be taken for checking the ratio of each component. The machine shall be capable of
metering the amount of adhesive required to secure each curb or gutter.
6. After curbs have been installed, steel forms shall be erected and concrete backing, if
required, shall be placed as shown on the Drawings. Pavement courses shall not be laid
against curbs until the concrete backing has membrane or water cured for at least 14
days.
7. The tolerances on alignment of completed precast units shall be as specified for in situ
concrete construction.
8. Backfilling shall be carried out as specified for in situ curbs and gutters.
C In Situ Concrete Paving
1. Excavation shall be carried out to the required depth and to a width that will permit the
installation and bracing of the forms. The foundation shall be shaped and compacted to
an even surface conforming to the sections shown on the Drawings. All soft and yielding
material shall be removed and replaced with approved material.
2. Bedding material shall be placed in layers not exceeding 100 mm in depth and each layer
shall be compacted to 95% AASHTO T180 maximum density. The total bedding course
thickness shall be as shown on the Drawings, or if not shown, 100 mm minimum
thickness.
3. Forms shall be of steel, wood, or other approved material and shall extend for the full
depth of the concrete. All forms shall be straight, free from warp, and of sufficient strength
to resist the pressure of the concrete without displacement. Bracing and staking of forms
shall be such that the forms remain in both horizontal and vertical alignment until their
removal. All forms shall be cleaned and oiled before concrete is placed.
4. The foundation shall be thoroughly moistened immediately prior to the placing concrete.
Concrete shall be deposited in one course in such a manner as to prevent segregation and
shall be consolidated by vibrators. The surface shall be finished with a wooden float and
light brooming. No plastering of the surface will be permitted. All outside edges of the
concrete tiles and all joints shall be edged with a 5 mm radius edging tool.
5. Forms may be removed only when there is no risk of damage to the concrete and in any
case not until at least 24 hours after completion of concreting.
6. The smoothness of paved areas shall be tested using a 4 m straightedge. The finished
surface of concrete shall not deviate from the straightedge between any two contact points
by more than 5 mm. Sections of defective paving shall be removed and replaced as
directed, at the Contractor's expense.

7. Expansion joints shall be of the dimensions specified and shall be filled with approved,
pre-molded expansion joint filler. The area being paved shall be divided into sections by
weakened plane joints formed by a jointing tool or other acceptable means as directed.
These joints shall extend into the concrete 0.20 to 0.25 times the depth and shall be
approximately 3 mm wide. Joints shall match as nearly as possible adjacent joints in curb
or pavements. Weakened plane joints may be sawn in lieu of forming with a jointing tool.
8. Construction joints shall be formed around all appurtenances such as valve chambers,
utility poles, etc., extending into and through the side-walk or median. Pre-molded
expansion joint filler of 10 mm thickness shall be installed in these joints. Expansion joint
filler of the thickness indicated shall be installed between concrete construction and any
adjacent fixed structures such as buildings or bridges, etc. The expansion joint material
shall extend for the full depth of the concrete.
9. Concrete shall be cured by membrane curing in accordance with the requirements of
Section 5.02 "Concrete Handling, Placing and Curing".
D Precast Concrete Tiles (Paving Slabs)
1. Excavation and the placing of bedding material shall be as specified for in situ concrete
paving. The surface of the completed bedding shall be dampened and base course
concrete shall be placed and finished to the thickness as shown on the Drawings or if not
shown, 40 mm minimum thickness.
118. The base course concrete shall be water or membrane cured as specified for in situ
concrete paving, for not less than 7 days before placing precast tiles.
119. Immediately prior to tile laying, the concrete base course shall be dampened and the
concrete tiles shall be immersed in water. Tiles shall then be laid true to line and grade on
a 10 mm to 20 mm thickness of mortar. Joints shall be 3 mm wide.
120. The tolerance on smoothness of precast concrete tiled areas and removal and
replacement of defective tiling, shall be as specified for in situ concrete paving.
121. Tiles shall be cleaned 24 to 36 hours after laying and joints shall be mortared using, if
approved, a plasticizer in the mortar to improve workability and to enable the mortar to be
readily smoothed and finished. As soon as the mortar has partially set, all mortar material
shall be raked from the top 3 mm depth of the joint, using a grooving tool to produce a
smooth circular section.
122. When the mortar is sufficiently set, the surface shall be sprinkled with water and covered
with plastic or nylon sheets during the curing period. The sheets shall be left in place until
final hardening of the mortar, or as directed. All foreign matter, wood, concrete, mortar
lumps, etc., shall then be removed and the surface cleaned of staining, discoloration and
other blemishes.
123. In cases where tiles are required to be cut at the boundaries of tiled areas, or due to the
presence of obstacles, poles, hydrants, etc., or in the construction of the driveways or side
roads, the Contractor shall cut the tiles or substitute in situ concrete of at least the same
quality as the tile concrete. The Engineer will decide, after trials, on the method to be
adopted. Cutting of tiles or substitution of in situ concrete shall be kept to a minimum. The
Contractor shall complete the areas using uncut precast tiles to the maximum extent
practicable.
124. The method of construction and sequence of operations, for areas constructed using
precast tiles, shall be the same as for areas constructed using in situ concrete. The
Contractor shall ensure that the final appearance of such surfaces, regardless of the
method of construction, is substantially the same for both types of construction.
125. Where a sidewalk crosses the entrance to a shop or a house, etc., which is higher than the
sidewalk, the Contractor shall construct steps, formed by a curb and a complete or partial
tile. Steps shall be backfilled with concrete of the same quality as specified for concrete
base course.
126. Steps shall be constructed wherever the difference in elevation between the entrance and
the sidewalk is more than 250 mm. The Contractor shall submit for approval, prior to

commencing any sidewalk construction, a list of locations where steps will be required,
together with design details for their construction.
3.6 MAINTENANCE OF TRAFFIC AND DETOURS
3.6.1 GENERAL
A Scope
1. These Works shall consist of supplying all materials and equipment, constructing detour
roads, bridges and culverts where necessary; and installing, operating and maintaining all
required temporary lighting, signing, signals, pavement marking, barriers and other safety
measures; all for the proper maintenance of vehicular and pedestrian traffic through and
around the Site of the Works during the Contract Period.
2. Temporary works shall conform with the general requirements of Section 1.04 "Temporary
Works" and as specified by the concerned Authorities (Traffic Directorate
/Municipality/Governmate/ Ministry of transport).
3.6.2 MAINTENANCE AND PROTECTION OF TRAFFIC
A General
1. The Contractor shall ensure the free movement of vehicular and pedestrian traffic and
shall maintain all highways including temporary detours and accesses in a clear and safe
condition free from obstructions. Adequate access to the Site shall be maintained at all
times to ensure that traffic on existing roads is not impeded unnecessarily by traffic turning
into the Site.
2. In order to facilitate movement of traffic through or around construction and when and
wherever required by the Engineer, the Contractor shall furnish, erect and maintain signs,
traffic barricades and other facilities necessary for safe and efficient direction and handling
of traffic at specified locations in or around the Site and as per specification of the
concerned authorities and Engineer.
3. The Contractor shall, if required by the Engineer, provide flashing signal lights by night and
provide sturdy barricades for the protection of workmen engaged on traffic control.
4. The Contractor shall, whenever necessary, provide flagmen at specified locations with the
sole task of directing traffic through or around the Site and shall provide and erect within or
near the Site any "warning" or "directional" signs the Engineer may require.
5. All barriers, traffic signs, signals and other such devices shall be erected, maintained and
removed when necessary, as directed by the Engineer and concerned authorities.
6. Whenever it becomes necessary to operate one-way traffic along any stretch of road in or
around the Site, the Contractor shall, for the purpose of maintaining traffic, provide a single
traffic lane not less than 3.5 m wide and shall keep it open to traffic.
7. Where, in the opinion of the Engineer, construction of a detour is inappropriate, new
construction may be limited to half the road width at a time.
8. The Contractor shall submit for approval, details of the layout, pavement construction,
drainage, lighting, signing and marking of any detours that he proposes. He shall give the
Engineer at least 7 days’ notice of such proposals.
9. The standard of lighting levels and uniformity for each detour shall be at least equivalent to
that existing on the road that it replaces. In addition to lighting of detours, the Contractor
shall provide and maintain illumination of all temporary traffic signs during the hours of
darkness.
10. Any obstruction associated with detours, including ramps, variations of lane widths, siting
of warning signs, etc., shall be marked by the use of cones, flashing beacons and warning
lamps, appropriate to the location concerned.

11. Detours shall be constructed in advance of the Works which interfere with the existing
highway or access and shall be regularly maintained in a condition acceptable to the
Engineer for as long as required.
12. Before any detour is opened, the Contractor shall obtain approval from the Engineer. The
diversion of traffic on the day on which the detour is initially put into operation shall be
carried out with the assistance and coordination of the Police Department.
13. All works under this section shall comply with the requirements of the Ministry of
Communication and traffic directorate and the concerned authorities.
14. The Contractor should install sufficient number of metal plates as bridges to cross the
excavations for pipelines according to the Engineer instructions and in coordination with
the citizens as per one bridge for each house. The shopping stores should be considered.
All required roads diversions should be paved.
127. Enough coordination should be done with the citizens to facilitate their movement during
the construction by printed notification prepared as per the requirements of the water
authority in the project area and sticked on each house.
PART 4 PIPE WORKS AND NETWORK ACCESSORIES
4.1 SCOPE
1. The works cover the supply of materials, installation, testing and commissioning of all
pipes, fittings, valves, and appurtenances.
4.2 GENERAL REQUIREMENTS
4.2.1 GENERAL
A Scope
1. This section outlines the sequence of construction works, aspects related to the right of
way (ROW) and the general requirements for supply and handling of equipments and
materials.
4.2.2 SEQUENCE OF CONSTRUCTION
A The Contractor shall adhere to the sequence of construction as set out below unless a
justified request for modifying this sequence is approved by the Engineer at least two
weeks prior to commencement of work on the affected section of the network:
 Stake out pipe alignments.
 Clear and grade the right of way.
 Conduct field surveys.
 Carry out exploratory trenching across existing roads to verify location, depth, size and type of
existing utilities.

 Prepare and submit to Supervision Engineer for approval composite Shop Drawings for all utilities
showing alignment, ground elevation, trench invert elevation, pipe size, class and length, station
and size of fittings, valves as applicable chambers, inlets, appurtenances and structures to be
demolished and reinstated (curbstone, rails, culverts, etc.). Cross sections showing location and
inverts of existing pipes and those proposed shall be prepared. Pipes, structures and other utilities
to be removed or relocated shall be indicated on the Shop Drawings. The Contract Drawings shall
be modified wherever required to produce the Shop Drawings.
 Relocate, demolish and reinstate existing utilities interfering with pipeline alignments.
 Remove pavement layers, excavate trenches, place bedding all as required.
 Lay and join pipes, fittings, appurtenances, valve chambers, etc…
 Place primary backfill material.
 Perform required air, hydraulic or other required testing.
 Install required house connections and or connections to existing utilities as required.
 Place final backfill.
 Restore or reinstate surfaces and structures as required.
 Carry out final surface works road surfacing curb stone, backing walls, side walk tiling, etc…
 Dispose of surplus materials.
4.2.3 RIGHT OF WAY (ROW)
A Extent
1. All utilities services shall be installed in the right-of-way of existing or proposed roads as
shown on the Drawings and as per concerned authorities directions.
B Clearing and Grading
1. The ROW shall be used for both access to works sites and for service roads for the
pipelines.
2. In case the pipelines run outside existing roads, the ROW shall be cleared and graded to
the required slopes; road cross-sections and all drains, shall be as indicated on the
Drawings.
3. Road surfacing / resurfacing works shall commence only after completion of pipe
installation and construction of all required works.
4.2.4 MATERIALS, PRODUCTS SUPPLY AND HANDLING
A Structural Materials
1. Concrete shall conform to the requirements specified in Section 5.01 "Concrete and
Concrete Mixes and Testing".
2. Reinforcement shall conform to the requirements specified in Section 5.03 "Steel

B Products supply requirements
1. Manufacturer's certificate: Materials shall be supplied with a certificate for each delivery.
The certificate shall clearly state that products comply with the specified Standards and
have been factory tested accordingly.
128. Marking: Unless otherwise specified in the relevant Standard products shall have legibly
cast, stamped or indelibly painted on, the following marks, as appropriate:
 Manufacturer's name, initials and identification mark.
 Nominal diameter.
 Class designation.
 Initials and number of relevant Standard.
 Length of pipe if shorter than standard length.
 Angle of bends in degrees.
 Date of manufacture.
129. Special tests: Whenever required by the Engineer, the Contractor shall supply and
transport samples of materials selected by the Engineer to a testing laboratory. The
number of samples shall not exceed 0.5% of total supplied. However, at least one sample
from each class, diameter and manufacturer shall be tested. Failure of any sample shall be
followed by a second and if necessary a third test from the same batch regardless of
whether the limits on number of tests has been exceeded or not. A third test failure shall
result in all material from that manufacturer being rejected and replaced by material from a
different manufacturer, subject to approval and satisfactory tests. Laboratory test report in
an approved form must be provided.
C Products handling
1. General
a) Manufacturer's recommendations on handling, repairing, laying, jointing, anchoring,
testing and other works for pipes and fittings shall be strictly followed.
b) For loading and unloading, the Contractor shall use cranes, hoists or skidways as
directed by the Engineer. Use of hooks, spreader beams, ropes, band or wire slings
etc. shall be as recommended by the manufacturer of each type of pipe and as
c) Pipes shall be stacked on horizontal surfaces. Pipes shall not be stored on their
sockets or jointing fairlings. End pipes in bottom row shall be secured by chocks.
The allowable height of stacks shall be to the manufacturer's instructions.
d) Material and equipment shall be handled with care whenever moved by hand,
skidways or hoists and any damage incurred shall result in the material being
rejected.
e) The Contractor shall provide safe storage for the material. The interior of pipes,
fittings etc. shall be kept free from dirt and foreign matter. Shade for materials shall
be provided as required by manufacturer's instructions and to the Engineer's
approval.
f) Cutting hacksaws, manually operated wheel cutters or pipe cutting machines shall
be used as per manufacturer's instructions. If, in the opinion of the Engineer, special
precautions are to be taken to eliminate airborne particles, methods and equipment
shall be used as directed by the Engineer. Ends shall be prepared according to type
of joint used and as per manufacturer's recommendations. Care shall be taken to

avoid any damage to the lining. Minor damage may be repaired on site as directed
by the Engineer.
g) The Contractor shall repair damaged coating, sheathing or lining in accordance with
the Specification and manufacturer's instructions. Material used for repair work shall
be compatible with that originally used. All repair works shall be approved by the
Engineer before incorporating materials into the work.
h) Bricks and cast iron frames and covers of valve chambers and all other construction
materials shall be loaded and unloaded by fitting with hoists or skidding so as to
avoid shock or damage. No hooks shall be used inside pipe. Under no
circumstances shall such materials be dropped. Pipe handled on skidways shall not
be skidded or rolled against the other pipe or other materials already on the ground.
i) All materials shall be delivered and distributed at the site by the Contractor. In
distributing the material at the site of the work, each pipe shall be unloaded opposite
or at the nearest possible place where it is to be laid in the trench.
j) A space of suitable width, clear of any spoil materials shall be left all along the
trench so that no pipes shall be placed on excavated material.
130. GRP Pipes and Fittings
a) For handling GRP pipes, fittings and rubber ring gaskets, instructions of the
manufacturer shall be strictly adhered to GRP pipes and fittings shall be suitably
wedged or braced to prevent damage during shipment and transportation and
rubber rings gaskets and lubricants shall be packed in suitable containers.
b) The allowable stack height is 2.5 meters or as per manufacturers specification.
When storing the pipes directly on ground, the ground shall be free of stones and
materials causing any damage.
c) While lifting, the supports shall be pliabe straps or ropes and shall not be steel
cables or chains unless sufficient padding is provided to protect pipes surfaces.
Pipes shall never be dropped.
131. HDPE Pipes and Fittings
a) Manufacturer’s instructions shall be strictly adhered to while handling pipes and
fittings. Extreme care shall be taken when handling pipes and fittings.
b) The pipes shall be loaded using enough supports to avoid any sort of bending,
distortion, damage, scratches to the barrel or ends or any part of pipes and fittings.
When off loading, pipes shall be lowered taking all precautions to avoid bending,
distortion, damage, scratches and never be dropped to the ground. Pipes shall be
given adequate and enough supports while stacking. Pipes shall never be stacked in
large piles or under direct sun light to avoid ultraviolet degradation and
manufacturer’s instructions shall be strictly adhered to. Any pipe with ends prepared
for jointing shall be stacked in layers with sockets placed at alternate ends of the
stack and with the sockets protruding to avoid unstable stacks.
c) For long term storage, pipes shall be stored in pipe racks providing continuous
support under a shed with insulated roof and shall never be kept under sunlight to
avoid ultraviolet degradation.
d) Also while loading pipes and fittings, care must be taken to avoid their coming into
contact with any sharp corners such a angle irons, sharp steel sheets, loose nail-
heads. While in transit, pipes shall be well secured over their entire length. While off-
loading, care shall be taken that pipes and fittings do not fall one upon another or to
any hard or uneven surfaces. pipes and fittings shall be transported to the site in
special pile rack type containerized units to facilitate loading, unloading, onsite
storage, retrieval and protection of pipes and fittings from sunlight and ultraviolet
radiations.
132. Reinforced Cement Concrete (RCC) Pipe
a) For handling RCC pipes, the instruction of the respective manufacturer shall be

strictly adhered to. RCC pipes shall be handled with great care while transporting to
the site and while installing. Each pipe shall be properly wedged to stop any
movement, which may cause damage to the bell and spigot or tongue and groove
ends of the pipes.
b) Each pipe shall be carefully inspected before being laid and no cracked or defective
pipe shall be used. Chipping of the bell and spigot or tongue and groove pipe ends,
which in the Engineer’s opinion may cause defective joints, shall be avoided. All
cracked and defective pipes shall be rejected.
133. Ductile Iron Pipes and Fittings
a) All ductile iron pipes and fittings shall be handled and stored strictly according to the
instructions of manufacturer.
b) Pipes, fittings, valves, hydrants, cast iron frames and covers and all other
construction materials shall be loaded and unloaded by lifting with hoists or skidding
so as to avoid shock or damage. No hooks shall be used inside the pipe. Under no
circumstances shall such materials be dropped. Pipe handled on skidways shall not
be skidded or rolled against pipe or other materials already on the ground.
c) In distributing the material at the site of the work, each pipe shall be unloaded
opposite or near the place where it is to be laid in the trench.
d) Pipe shall be so handled that coating and lining will not be damaged. If, however,
any part of the coating or lining is damaged, the repair shall be made by the
Contractor at his expense according to manufacturer’s specifications or in a manner
satisfactory to the Engineer or be replaced as determined by the Engineer.
134. Rubber Ring Gaskets
a) All gaskets for vitrified clay (VC), unplasticised polyvinyl chloride (uPVC), Glass fibre
reinforced concrete (RC) pipes and fittings shall be handled and stored strictly
according to their respective manufacturer’s instructions.
b) For storage of gaskets, the storage temperature is to be between + 5˚C and + 25˚C.
If stored at low temperatures and taken out for immediate use, their temperature
must be brought to approximately 30˚C prior to their use. The gaskets are to be
protected from direct sunlight and a strong artificial light with ultraviolet content. The
gaskets must be protected from the surrounding air either by wrapping them up or
storing them in hermetically sealed boxes.
D Materials and Equipment Furnished by the Contractor
1. The Contractor shall furnish all materials and equipment that will be incorporated in the
works and all other materials and equipment needed during construction. He shall also
furnish such constructional plant and equipment as in the opinion of the Engineer, is
necessary and adequate to perform all work within the scheduled time for completion.
135. The tenderer shall state in the schedule provided in the trade name of materials and
equipment he intends to incorporate in the works as well as the name of the manufacturer
and his full address. The Contractor shall be bound to use the same manufacturer
materials and equipment quoted in his Tender.
136. The Contractor shall, within 60 days after receipt of the order to commence, submit to the
Engineer in triplicate certified copies of the unpriced agreements with the manufacturers of
the materials and equipment to be used in the works. Such agreements shall embody all
the appropriate specification clauses including testing and inspection and shall state
delivery periods.
137. Materials and equipment furnished by the Contractor shall be brand new and of the type
and quality described in the specification. The Contractor shall procure all materials and
equipment, whether specified or substituted, from eligible sources. Where, because of
Employer’s priorities or other causes, materials or equipment required by the specification
become unavailable, substituted materials or equipment may be used.
138. The Engineer’s decision as to whether substitution shall be permitted and as to what

substitute materials.
E Inspection of Materials and Equipment
1. Materials and equipment furnished by the Contractor which will become a part of the
permanent works shall be subject to inspection at any one or more of the following
locations as determined by the Engineer: at the place of production or manufacture, at the
hipping point, or at the site.
2. The allow sufficient time to provide for inspection, the Contractor shall submit to the
Engineer, at the time of issuance, copies in triplicate of purchase orders, including
drawings and other pertinent information, covering materials and equipment on which
inspection will be made as advised by the Engineer, or shall submit other evidence in the
event such purchase orders are issued verbally or by letter. The inspection of materials
and equipment or the waiving of the inspection thereof shall in no way relieve the
Contractor of the responsibility for furnishing materials and equipment meeting the
requirements of the specification.
F Rejected Materials
1. Should any materials, equipment or manufactured articles prove to be, in the judgment of
the Engineer or as a result of testing, unsound or of inferior quality or in any way
unsuitable for the works in which it is proposed to employ them, such materials, equipment
or manufactured articles shall not be used in the works but shall be branded, if in the
opinion of the Engineer this is necessary, and shall forthwith be removed from the site and
replaced at the Contractor’s expense and in each case as the Engineer shall direct.
G Approved Manufacturer’s Instructions
1. The Contractor shall supply the equipment, materials or other items from the approved
manufacturers listed or equal and approved.
2. All equipment or materials shall be delivered to the site in the manufacturers’ original
unopened containers with the manufacturers’ brand and name clearly marked on.
3. All equipment or materials shall be assembled, mixed, fixed, applied installed or otherwise
incorporated in the works in accordance with the printed instructions of the manufacturer of
the equipment or materials and/or the relevant standards as specified.
H Certification and Third-Party Inspection
1. All material provided by Contractor shall be procured from ISO/BS certified manufacturers.
The certificate should cover all the processes associated with the production of the
manufactured item and should be submitted to the Engineer approval with the material
submittals by the Contractor. Upon the request of the Engineer, the Contractor shall
propose an internationally accredited and reputable audit firm to act as a third-party
inspector who shall certify that all material manufactured and shipped for the project have
been manufactured and conforms to the specified international standard governing the
manufacture of the finished item / product as specified in the project Tender Documents.
The scope of the third-party inspection shall cover at least the quality control tests listed in
the fourth coming sections of the Specification. The cost of the third-party inspection shall
be borne by the Contractor.
4.3 PIPES, FITTINGS AND ACCESSORIES
4.3.1 MATERIALS
The following pipe material for water supply network shall be used:
Usage Recommendations
Dry Areas Dry Areas Wet Areas

(Non-aggressive soil) (Aggressive soil) (Ground water)
(Aggressive soil)
For small diameters up to 200mm- pressure class 16 bars
For diameters greater than 200mm

For diameters greater than For diameters greater than 200mm
and operating pressure up to 24
and operating pressure up to 24
200mm and operating pressure bars with additional external
bars and with external protection
up to 24 bars protection (Polyethylene sleeves
(bituminous layers)
250 microns thickness)
Conveyance pipes outside cities with
diameters 400mm and greater and
Conveyance pipes outside cities with diameter of 400mm and greater
operating pressure not exceeding 16
and operating pressure not less than 16 bars with granular bedding.
bars with granular bedding and
textile protection
Conveyance pipes with diameters 1200mm and greater and operating

pressure up to 40 bars.
The following paragraph describes the specifications of each of these pipes:
A Ductile iron pipe
1. Use DI pipes Class K9 for water supply network for diameters greater than 200 mm and
operating pressure up to 24 bars.
2. Ductile iron pipe for water shall be to BS EN 545 or equivalent. Unless otherwise indicated
in the Bill of Quantities or the Drawings, Class K9 shall be used for all pipe diameters, and
in the case where pressure does not exceed 16 bars for large diameters, class K8 pipes
shall be used.
3. Ductile iron fittings shall be to IS02531 or BS EN545 [1] or equivalent with socket/ spigot
ends. Joint deflection at installation shall not exceed 50% of the maximum allowed by
manufacturer.
4. Spigot and socket ended pipes shall be used for straight runs and adjacent to elbows or
fittings. These joints shall be provided with rubber gaskets, and an external thrust block is
required at elbows or fittings. Anchored or self-restrained joints shall be used for sections
adjacent to elbows in areas where space is restricted or indicated on the Drawings or Bill
of Quantities. Anchored joints are to be push-in, self-anchored type able to take up the
axial forces thus allowing concrete thrust blocks to be dispensed with. The Contractor shall
submit calculations verifying the number of restrained joints required noting that pipe
pressure testing will be made when pipes are partially backfilled, and joints are exposed.
5. Rubber gasket shall be to BS/EN545 or ISO 4633 or equivalent.
6. Flanged pipes wherever specified shall have screwed-on or cast-on flanges to sustain
working pressure of - PN 16 minimum.
7. Flanges shall conform to ISO 2531 or BS 4504 [2] or equivalent.
8. Factory protection for pipes:
 Pipes shall be internally cement lined to confirm with ISO4179 or BS EN 545 [1] or equivalent and
according to specified thicknesses.
o The cement mortar lining shall be certified as suitable for use with potable water by
an internationally accepted organization such as UK’s WRC (Water Research Center)
 Externally, pipe shall be coated with metallic zinc to conform with BS EN 545 [1] or ISO 8179 or
equivalent and followed by a bitumen coat to BS 3416 [4] or ISO8179 or equivalent.

139. Additional Site Protection for Ductile Iron Pipes
1. Polyurethane Coating
The coating shall be 100% solid polyurethane consists of two components: one isocyanides-rich solution
and one oplyol-rich solution.
The coating shall be completely continuous and free from all holidays, voids, pinholes or other defects.
The test certificate shall state the property of the coating and shall specify the test method used.
The polyurethane coating system shall comply with the data included in the following Tables:
Technical Data of Polyurethane External Coating

Material Polyurethane, 2 Components airless applicator
Color Black
Density 1.6g/mm3
Tensile Strength 25N/ mm3
Adhesion to Steel > 8Mpa (Stee grit blasted SA21/2)
Dielectric Strength 200 Kv/cm
Water Absorption 3.5% at 25C
Impact Resistance > 15Nm
Temperature Resistance 90C continuous
Salt Water Spray No effect after 1000hrs
Elongation > 10%
Chemical Resistance Water solution of salts, acids, and bases of pH 1-14
Thickness 1-1.5mm
140. Polyethylene Sleeves
Protective polyethylene sleeves shall be used with all DI pipes and fittings to be installed in buried
condition and shall be in accordance with ISO 8180.
The minimum nominal thickness of the sleeve shall be 0.010 inch (250 microns) with a maximum minus
tolerance of 10%.
The material shall be made from a polymer with a melt flow index as measured according to BS 2782, of
10 or less and a density in the range of 0.915 to 925g/ml. The sleeve shall be free from pinholes, gels,
undispresed raw materials and particles of foreign matter. The film may not contain more than 5% by
weight of material other than polyethylene.
Polyethylene sleeving shall be stored in cool dry store away from direct sunlight or excessive heat, the
length of the roll, the pipe size for which it is intended.
141. Repair of Coating and Lining
In case of repairs are needed the Contractor shall take immediate action to correct the situation.
All the repairs to the coated or lined pipe and fitting shall be at the Contractor own expense.
The Contractor shall submit the repair procedure to the Employer for approval. The procedure for the
repair shall be as directed by the Engineer and the manufacture specification.

142. Anti-Corrosion Pipe Wrapping Tape
The tape shall be supplied 150 mm or 225 mm wide in 15 m or 25 m rolls or approved by Engineer
depending upon the requirements.
 Pipe diameters up to 200mm, 150mm width tape shall be used.
 Pipe diameters above 200mm, 225mm width tape shall be used.
The adhesive compound shall be of the pressure sensitive type (that is, not requiring a primer in order to
achieve bond to the substrata) and shall have thickness between 0.75 to 0.90 mm. Flow coefficient of
bitumen viscosity at 200˚C and 175˚C shall be 5.5 poise and 7.5 poise respectively.
The tape shall be supplied with a wider high quality silicon release paper covering complete tape. Both
sides of the tape shall have a minimum of 5mm wider silicon release paper to prevent edge contamination.
During storage at maximum storage temperature of 500 C for six months, the adhesive material shall not
flow out of the release paper and there shall not be any end blocking.
Wrapping tape shall be marked with the following information:
 Manufacturers name & logo
 Date of manufacture
 Width of the tape
 Batch number
143. Wrapping Procedure
To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-
automatic tape wrapping machine and for pipe diameters above 300mm, fully automatic wrapping machine
should be used.
144. Storage
Wrapping tape should be stored in dry, cool, well ventilated condition, out of direct sunlight.
145. Packing
Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage
shall separate each layer. The boxes shall be marked at two places given name and logo of manufacturer,
tender no., type, size and quantity of material in black/blue color letters with a minimum height of 50mm.
The wrapping tape shall also conform to the following specifications given below.
1 Color - - -
1.1 Backing - - Blue RAL
5000/5001/
5005/5010/2017
1.2 Adhesive Compound - - Black
1.3 Release Paper - - White / Cream
3 Backing Thickness Min. - mm 0.75
4 Total Thickness Min. - mm 1.5

5 Elongation BS 2782 % 270
6 Tensile Strength Tape BS 2782 N/mm2 14.8
7 Modules BS2782 N/mm2 50
8 Tear Strength ASTM D1004 N 50
9 Impact Resistance (Two Layers) DIN 30627 Nm 15

11 Adhesion to Steel ASTM D 1000 N/mm 2.75
12 Adhesion to Tape ASTM D 1000 N/mm 2.75
Electrical
13 Dielectric Strength BS 2782 kV 30
14 Insulation Resistance ASTM D 257 Ohm/cm2 1012
15 Cathodic Disbondment ASTM G 8 mm2 NIL
16 Water Vapor permeability BS 2782 g/m2/24h 0.4
17 Water Absorption ASTM D 570 % 0.1
18 Bacterial Growth Disbondment - - NIL
Temperature
19 For Wrapping - ˚C 0 to + 50
20 In Service - ˚C 0 to + 50
21 For Storage - ˚C Up to + 50
146. Factory protection for fittings
Fittings shall be coated internally and externally according to EN 545 Clause 4-5 using epoxy-based
material, minimum epoxy content 70% and minimum thickness 10 mil.
147. Testing on Ductile Iron Pipes
The following tests shall be carried out on samples from every batch of DI pipe delivered to site. A report of
the third-party inspector shall cover at least these tests all as approved by the Engineer. All tests shall be
carried out according to BS/EN545 or ISO 2531 or equivalent:
 Microscopic structure
 Elongation
 Brinell hardness
 Ring bending and detachment of lining for pipes > 500 mm diameter
B Polyethylene HDPE Pipe
1. Use HDPE pipes PN16 for small distribution pipe diameters up to 200 mm.
148. Pipes and fittings shall be to SASO 1401, ISO 4427, DIN 8074/8075 or AWWA C906-99.
Pipe 60m shall be supplied in straight pieces and not rolled on a drum. The ends of each
pipe shall be plain and suitable for heat fusion. Pipe and fittings shall be class 10 or 16

kg/cm2.
2. Materials used shall have a standard PE code designation 3408 and a minimum
hydrostatic design basis of 1600 psi (or 180 kg/cm2) according to AWWA C906 Table 1.
3. Manufacturers shall provide certification that stress regression testing has been performed
on the pipe products. Materials shall also meet elevated temperature requirements as
given in Table 2 AWWA C906.
4. Fittings shall be to AWWA C906, extruded or injection moulded suitable for class of pipe
required.
5. Joints for pipes and fittings shall be by butt fusion or by socket fusions and in strict
accordance with pipe manufactures recommendations. Joints shall have a tensile strength
equal to that of the pipe. Fusion temperature, interface pressure, alignment and cooling
time, shall be according to manufactures recommendations.
6. Tests on PE compounds: Where PE is used for potable water, PE compounds in pipes
and fittings shall contain no ingredients in an amount that has been demonstrated to
migrate into water in quantities considered to be toxic. PE compounds shall be tested and
certified suitable for potable water by the National Sanitation Foundation (NSF) Testing
Laboratory – USA, or the Canadian Standard Association (CSA) Testing Laboratory, or
other accredited testing agency. Tests shall be made in accordance with requirements no
less restrictive than those in the NSF Standard No. 14 (1976), Sections 3 and 4. The seal
and mark of the testing laboratory shall be included on pipes and fittings.
7. Tests on HDPE Pipes
The following tests shall be carried out on samples from every batch of pipes delivered to site by the third-
party inspection. The test report of the third-party inspector shall cover at least the following tests all as
specified and indicated by SASO ISO or DIN standards.
 Wall thickness
 Out of roundness
 Hydrostatic strength at 20˚ and 80˚ C
 Longitudinal reversion / shrinkage test
 Tensile properties
 Thermal stability – oxidation induction time
 Environmental stress crack resistance
 Density
C GRP Pipe
1. Use GRP pipe minimum stiffness 5000 N/m2 for transmission line outside cities for
diameters 400 mm and greater and working pressure not exceeding 16 bars.
149. Pipes and fittings shall be to BS 5480, 1990 [11] or AWWA C950-01 or equivalent.
2. Pipe and fittings shall include a corrosion resistant liner, a structural wall and a resin rich
exterior surface.

3. The liner shall have a nominal thickness of 1.0 mm. The liner surface shall be reinforced
with "C" glass. The remainder of the liner thickness shall be reinforced with an acid
resistant chopped "E" glass strand or mat.
4. The pipe structural wall shall consist of glass reinforcement, and fine silica sand, all
impregnated with resin. The fine silica sand shall be added to the structural layer to
achieve the design thickness for the required stiffness specified such that the overall hoop
flexural modulus (E) for pipe is not less than 24 GN/m2. Silica sand and filler content shall
not exceed 50%.
5. Pipes shall be provided with a resin rich outer layer reinforced with one layer of "C" glass
veil. The exterior layer shall have a minimum thickness of 0.2 mm. The layer shall be resin
rich and reinforced with one layer of C glass.
6. The resin used for the corrosion resistant liner of the pipe and fittings shall be high grade
polyester resin (isophthalic or better) type. For the structural wall and exterior layer of the
pipe a high grade isophthalic polyester resin shall be used. No dark pigments shall be
used in the pipe or fittings.
7. All glass reinforcements except for the inner and outer surfaces of the pipe and fittings
shall be of the "E" type. Surface reinforcement shall be of the "C" glass type.
8. Pipes shall be designed for a life of not less than 50 years. Contractor shall submit
calculations for initial and long-term deflection with Truck loads, Buckling, Vacuum,
Pressure Class, and Strain in accordance with Appendix "A" of AWWA, C-950-01 or
equivalent. The maximum calculated long-term deflection should not exceed 3%. Copies
of the design calculations shall be submitted to the Engineer for approval.
 Stiffness: Minimum 5,000 N/m2. Suitability of stiffness shall be verified by Contractor for the
various trench and pipe laying conditions and as recommended by the manufacturer. Pressure
class 6 kg/cm2 minimum or as shown on Drawings.
 Longitudinal Strength: Conform to BS 5480 [11] table 2 or ASTM D3262 table 7.
Hoop strength shall according to ASTM D3517 Table 8.
 Strain corrosion resistance tests shall be carried out as per ASTM D 3681 or BS 5480 strain
corrosion value at 50 years to equal or exceed 0.7%.
 Markings shall be to BS 5480 [11] clause 11.
 Joints shall be GRP double socket couplings with rubber rings to ISO 4633 or BS EN 681-2 [10].
The allowable angular deflection shall conform to the requirements of BS 5480 [11] Table 3.
150. Testing on GRP Pipes: The following tests shall be carried out on manufactured pipes.
Details of testing program shall be submitted to the Engineer for review and approval prior
to commencement of pipe manufacture. The manufacturer quality control scheme shall be
to BS 5750-8 [12] or ISO 9004. Guidance on quality control and sampling shall be BS
5480 Appendix Q [11]. At least the following tests shall be carried out and reported for
approval.
 Longitudinal Strength: to ASTM D3262
 Hydraulic Test: to ASTM 3517.
 Stiffness: to ASTM D 2412 or BS 5480 [11]

 Wall Thickness: to BS 5480 [11]
 Diameter: to BS 5480 [11]
 Hardness: to ASTM 2583
 Loss of Ignition: to ASTM D 2584
 Hoop Tensile: to ASTM 3517
D Steel Pipe
1. Use steel pipe for transmission lines of diameters 1200 mm and above, for operating
pressure up to 40 bars.
151. Steel pipe size 150 mm (6") and smaller shall be welded black steel, seamless or welded,
and shall conform to BS 1387 [15] medium class, ISO 65 or DIN 2440.
152. Steel pipe size 200 mm (8") and larger shall be welded black steel, and shall conform to
AWWA C200, grade A, or equivalent. Wall thickness shall conform to AWWA C200-97
Section 3-4. Minimum wall thickness shall be to BS 3600 [16] or as given in the Bill of
Quantities.
153. Steel pipe shall be round and straight and shall be free from injurious defects. Defects
shall be considered injurious when the depth of defect is greater than 12.5% of the
tabulated wall thickness. Pipe shall be free from rust.
154. Fittings normally made from manufactured and tested pipes or fabricated by welding to
AWWA C208. Material is to be same nominal pressure
155. Steel pipes shall be joined by welding. All welding including surface preparation methods,
welding procedures and qualification of welders and welding operators shall be performed
in conformance with AWWA C206 1997..
156. All steel pipes and specials shall be lined internally to the thickness specified with concrete
made from ordinary Portland cement to BS EN 197-1 [3] and fine aggregate. The materials
used for lining, the method of lining and curing of the finished lining and the manufacture
and testing of test cubes shall comply with BS 534 [17] and shall be carried out to the
approval of the Engineer.
157. Steel pipes, fittings and specials shall be protected externally with bituminous laminate
tape 1.6 mm thick and with 55% overlap or as recommended by the manufacturer.
158. Testing on Steel Pipes
The following tests shall be carried out on steel pipes delivered to site. The test report of the third-party
inspection shall cover at least the following tests all as specified by International Standards.
 Pipe wall thickness
 Weld seems
 Hydrostatic testing

A Pipe Bedding
1. Pipe bedding material shall be as specified in section 2.04.5 of Division 2 herein before
2. Type of Bedding shall be as indicated on the Drawings
B Pipe Laying and Jointing - Generally
1. The pipe shall be brought to grade and approved prior to the lowering of the pipe into the
trench. Pipes shall be laid to slopes shown on drawings.
2. Lowering of pipes into the trench shall be carried carefully in a manner that does not cause
damages to the pipes or trench itself. Lowering pipes shall be carried out using ropes, wire
slings, band slings, spreader beams etc. as recommended by manufacturer for each type
of pipe and as approved.
3. All material shall be carefully examined for damage and tested in accordance with
manufacturer's instructions before laying to the satisfaction of Engineer.
4. The Contractor shall examine material to ensure internal coating or lining and outer
coating or sheathing are undamaged. If damaged, make good or dispose of as directed.
5. Pipe Cleanliness: The Contractor shall remove dirt and other materials before lowering
and shall clear construction debris from inside of pipe before making joint.
6. Pipe Placement: The Contractor shall lay pipes on even formations true to grade and line,
with sockets (if any) facing up the gradient.
7. Pipe on Solid Ground: The Contractor shall cut holes in bottom of trench to allow proper
jointing and for barrel of pipe to bear evenly on the bedding for its full length.
8. Pipe on Granular Bedding: The Contractor shall scoop out locally at sockets/couplings to
enable pipe to rest uniformly on barrel and adjust to exact line and level. After testing the
Contractor shall lay and compact further granular material in 150 mm layers or as
approved to levels shown on the Drawings.
9. Pipe on Concrete Bed or Surround: The Contractor shall provide rectangular blocks of
concrete Class 210/25, made in approved moulds at least 14 days before use, and
hardwood folding wedges approved by the Engineer and also provide two concrete blocks
for each pipe, set and bone into correct level on formation bottom and lay pipe properly
centred and socketed. The Contractor shall insert two hardwood folding wedges of width
equal to width of concrete block between body of pipe and block and drive together until
pipe is brought to exact level required and leave blocks and wedges undisturbed while
pipes are being jointed and concrete bed and haunch or surround are being placed. The
Contractor shall ensure blocks and wedges are of sufficient size and strength to prevent
settlement of pipe and leave sufficient space to enable joints to be made, tested and
inspected.
10. Pipe Plugs: When pipe laying is not in progress, the Contractor shall close open ends of
pipes with properly fitted temporary wooden plugs or standard caps as directed. B.11Pipe
minimum cover shall be 1.0 m unless specified by drawings or Engineer directions.
C Jointing
1. Manufacturer's instructions shall be followed regard¬ing placement of bedding and
backfilling, cleanliness of joint surfaces, lubricant used, correct location of components,
provision of correct gaps between end of spigot and back of socket for flexible joints etc.
159. Deflection of Joint: The Contractor shall not deflect flexible joints beyond 50 percent
maximum permissible angles given by manufacturer and/or relevant Standard.
160. Patent Detachable and Flexible Joints: The Contractor shall strictly comply with special
instructions issued by manufacturers of proprietary joints when laying and jointing.
161. Differing Pipe and Fitting Material: The Contractor shall joint with adap¬tors as

recommended by pipe manufacturer.
D Line and Gradient
1. In Open Excavation: The Contractor shall provide and maintain sight rails and boning rods
properly painted to ensure correct alignment of pipe runs. Sight rails shall be positioned
either vertically above the lines of pipes or immediately adjacent thereto. At no time are
there to be less than three sight rails in position on each length of pipeline under
construction to any one gradient.
162. Wherever possible and as per the Engineer instructions the Contractor should use the
suitable recent surveying devices to adjust the line and gradient of pipelines.
163. In heading the Contractor shall provide and maintain marks to establish line and level of
pipeline. Marks shall be fixed in each working shaft and two further marks established in
each length of heading.
E Floatation
1. Prevention: Whenever water is excluded from interior of pipe the Contractor shall place
sufficient backfill above pipe to prevent floatation.
164. Removal of Pipe: The Contractor shall correct bedding and relay any pipe that has floated.
F Pipe Built into Structures
1. Treatment of External Surface: The Contractor shall thoroughly clean outside surface of
pipes to be built-in immediately before installation and remove protective coating to metal
pipes, where ordered. The Contractor shall roughen clay and concrete pipes as directed
and paint plastic pipes with appropriate solvent cement and sprinkle with dry coarse sand
whilst wet. The Contractor shall cut away sheathing from sections to be built-in and after
installation restore protection up to external face of structure with approved bituminous
material.
2. Flexible Joints: The Contractor shall install two flexible joints or flexible patented joints
adjacent to structures and place the first joint not more than one pipe diameter from face of
structure and second not more than the following distances away from first:
 Pipelines Not Exceeding 450 mm: 2 pipe diameters
 Pipelines Over 450 mm and Not Exceeding 1000 mm: 1.2 m
 Pipelines Over 1000 mm: 1.8 m.
In general, the length of the short pieces may be selected as recommended by the pipe manufacturer.
4.3.3 PIPE WORK TESTING
A Field Testing: Generally
1. Provision of Test Equipment: All items for test have to be provided on site before the test
i.e pressure gauges, instruments, water etc...
2. The Contractor shall carry out tests in the presence of the Engineer.
3. Fittings and Joints: The Contractor shall permanently anchor fittings before testing and
leave all joints exposed for checking.
4. Test Sections: The Contractor shall limit test sections to not more than 500 m.
5. Test Sections: The Contractor shall test pressure lines between valve chambers whenever
possible.
6. Test Sections: No testing shall be carried out against or through the pressure reducing

valves. The setting of the pressure reducing valves shall not be changed for testing
purposes.
7. Test Plug: The Contractor shall secure end of main and test plug by struts.
8. Closed Valve: The Contractor shall not test against a closed valve unless there is no
acceptable alternative.
165. The Contractor shall apply pressure by manually operated test pump or, in the case of
large diameter mains, by power driven test pump, if approved.
9. The Contractor shall examine exposed joints and repair visible leaks.
10. Failure: Should a test fail, the Contractor shall locate the leak and replace or make good
defective pipe or replace and make good faulty joint. The Contractor shall retest main.
166. Records: The Contractor shall keep test records in an approved form and hand original
copy to the Engineer immediately after completion of test.
11. Pressure Lines: The Contractor shall carry out hydrostatic test while pipeline is partially
backfilled.
B Hydrostatic Testing of Pressure Pipelines
1. The pipeline shall be filled slowly with water from the lowest point. After filling with water,
absorbent pipes shall be allowed to stand for at least 24 hours before testing to allow for
complete absorption.
167. Entrapped air shall be bled and pressurising shall then proceed until the specified test
pressure is reached in the lowest part of the pipeline section under test. Further quantities
of entrapped air shall be bled while the pressure is being raised.
168. Hydrostatic testing Pressure shall conform to (AWWA C500) specifications, and the testing
pressure should be equal to 1.5 times the maximum operating pressure for the pipeline as
per the Site Engineer directions without exceeding 75% of manufacture hydrostatic
pressure.
169. The test pressure shall be maintained for one hour by pumping using a separate test
pump. Pumping shall then be stopped for 2 hours; at the end of which time the line shall
be re-pressurized to the original test pressure and the volume of water pumped into the
line recorded.
170. The pipeline shall be deemed to have failed the test if visible leaks are detected
(regardless of leakage being within the allowable specified limit) or if the volume of water
pumped to restore original test pressure after the period when pumping was stopped
exceeds or 0.1 litre/day per km of pipe per mm of pipe diameter for each 3 kg/ cm2 of
applied pressure for other pipe material.
C Visual Inspection Test
1. Timing: The Contractor shall carry out test after total backfilling of length under test.
2. Limit of length to be tested at one time is three full- length pipes unless otherwise
approved.
3. Apparatus: The Contractor shall use rubber tyred bogies that do not damage lining of pipe
and an adequate supply of electric lamps.
4. The Contractor shall check joints by means of feelers to ensure rubber rings are correctly
located.
5. The Contractor shall check pipe barrel for visible cracks.
D Deflection Tests for GRP Pipes
1. The Contractor shall conduct deflection tests for GRP pipes as required by the Engineer at
3 stages. Deflection shall be measured at the spigot end at mid-point and at socket end.

 Stage 1: At completion of primary backfill (deflection at this stage should be below 0.5%).
 Stage 2: At final backfill (Maximum allowable deflection 2.5%).
 Stage 3: Six months after final backfill (maximum allowable deflection 4.0%).
171. Pipes not passing the deflection tests at stage 2 or stage 3 shall be removed and replaced.
E Testing of Water Retaining Structures
1. All water retaining structures such as reservoirs, tanks, basins ponds, regardless of the
construction material, lining or final surface treatment shall be tested or Water-tightness.
172. Tightness testing shall be carried out according to ACI 350.1-01/350.1R-01.
173. Allowable losses of water, after correction for evaporation, precipitation etc. shall be as set
in the table below:
Type of structure Test and Criteria*
Tanks/Reservoirs/Channels/Conduits for water HST-VIO & HST-NML
or wastewater, Concrete or metal, Open or
covered (Stormwater Channels not included)
Pressurized Tanks SHT-VIO & SHT-NML
PNT-VIO & PNT-NML
CPT-VIO & CPT-NML
As applicable or as directed by the Engineer
*For designations refer to ACI 350.1 - 01/350.1 R-01.
174. Notwithstanding satisfactory completion of the water absorption test, any leakage visible
on the outside faces of the structure shall be stopped. Any caulking or making good of
cracks in the wall section shall, where practicable, be carried out from the inside face, and
to the satisfaction of the Engineer.
175. Upon completion of the test, the Contractor shall empty the structure, dispose of the
contents and shall clean the structure and any equipment therein of all deposits left by the
water.
F Flushing and Disinfection of Water Mains
1. Procedure: To AWWA C651-92.

2. The Contractor shall provide equipment, gauges, temporary connections and chlorine
needed for flushing and disinfection and arrange with the Employer to draw water from
existing sources.
3. Sections: The Contractor shall flush and disinfect mains in sections as directed by the
Engineer.
4. Draining: The Contractor shall use washout valves and fire hydrants to drain flushing and
disinfecting water.
5. First Flushing: Before commencing disinfection, the Contractor shall flush mains until
effluent is clean and then clean as directed. 1 to 2 times volume of pipe is usually required
for such flushing.
6. Type of Chlorine: The Contractor shall disinfect with chlorine gas or solutions of calcium
hypochlorite or sodium hypochlorite and agree with the Engineer on method of application.
7. Initial dosing shall be 40-50 ppm.
8. Contact period shall be 24 hours.
9. Residual Chlorine: The Contractor shall measure residual chlorine by Orthotolidin test.
Residual chlorine shall not to be less than 5 ppm or the test shall be repeated as directed.
10. Final Flushing: After disinfection, the Contractor shall reflush network until chlorine

concentration in water leaving main is less than 1 ppm.
11. Tests: The Contractor shall perform bacteriological tests to AWWA C651-92, Section 9.
Number of samples shall be one per 1 km of main feeders and one per 0.25 km of
distribution lines.
12. Procedure after Cutting into Existing Main: To AWWA C651, Section 11.
G Field Protection and Coating
1. Iron Pipes: Polyethylene sleeving shall be to ANSI/AWWA C105, Section 4.1 or ISO 8180
or in accordance with the manufacturer's instructions. Sleeving shall be heavy duty blue
color polyethylene with a minimum thickness of 225 microns.
176. Patented Detachable and Flexible Joints and Flanged Connections: The Contractor shall
protect metal joints with mastic compound and protective tape in accordance with the
manufacturer's instructions. Minimum overlap shall be 55% and the Contractor shall press
out firmly all folds and irregularities.
H Anti-Corrosion Tape
1. The tape shall consist of a PVC backing bonded to a self-adhesive bituminous rubber
compound with a total thickness of approximately 1.65 mm.
2. The plastic backing shall be extruded PVC and shall have an approximate thickness 0.35
mm.
3. When the tape is to be applied with a 50-55 % overlap the tape shall have a “guide-line”
printed down the center of the tape to ensure accurate overlapping is achieved.
4. The tape shall be black, cold applied complying with AWWA C209. The tape shall have the
following minimum properties:
 Backing Thickness: 0.3 - 0.4 mm
 Backing Adhesive Thickness: 0.75 - 0.90 mm
 Tensile Strength: 14.8 N/mm2
 Adhesive Shear Strength: 0.10 N/mm2
 Impact Resistance: > 20 drops
 Dielectric Strength: 20 kv
177. Coatings and tapes shall be inspected prior to and after laying, and the Contractor shall
notify the Engineer of any defects. Any defective areas shall be repaired in accordance
with the manufacturer’s instructions and to the satisfaction of the Engineer.
I Waterproofing of Structures
1. Waterproofing of water retaining structures shall not be commenced until tested for
watertightness and found satisfactory.
178. The waterproofing compound shall penetrate and react with the concrete to form crystals
that seal all capillaries, tracts and shrinkage cracks in the concrete structure. The
compound shall consist of a mixture of chemicals, quartz, sand and cement supplied in
powder form ready to mix with water. Application shall be carried out in accordance with
the manufacturer's recommendations and as approved by the Engineer.
4.3.4 CATHODIC PROTECTION
A General

1. This Section includes passive cathodic protection systems that use zinc anodes to protect
steel piping.
B Performance Requirements
1. Engage a qualified corrosion engineer to design and supervise, test, and inspect
installation of cathodic protection systems.
2. Design cathodic protection for pipelines according to "The National Association of
Corrosion Engineers International (NACE)" RP0169.
3. Design cathodic protection for metal underground storage tanks according to "The
National Association of Corrosion Engineers International (NACE)" RP0285.
4. Select anodes and accessories relevant to level of protection. Design anodes for an
estimated life of 15 years before replacement.
5. Survey site and determine soil or water corrosivity (resistivity), current requirements,
potential surveys, stray currents, and water chemistry/corrosivity (pH).
6. Cathodic protection systems shall provide protective potential that complies with
referenced NACE standards.
7. As-Built Drawings: At project close-out, submit Record Drawings of installed cathodic
protection, in accordance with requirements of the Specification, Division 1.
8. Measure structure-to-earth according to NACE RP0169, using one of the following 2
methods:
a) 850-mV Negative Voltage: With cathodic system in operation, measure a negative
voltage of at least minus 0.85 V between pipe and a saturated copper/copper-sulfate
reference electrode contacting the earth directly over pipe.
b) 100-mV Polarization Voltage: Determine polarization voltage shift by interrupting
protective current and measuring polarization decay. An immediate voltage shift will
occur if protective current is interrupted. Use voltage reading, after immediate shift,
as base reading from which to measure polarization decay. Measure at least a
minimum polarization voltage shift of 100 mV between pipe and a saturated
copper/copper-sulphate reference electrode contacting the earth directly over pipe.
C Submittals
1. Submit product data for each of the following items:

a) Anodes.
b) Insulating flange sets.
c) Casings, insulation, and seals.
d) Dielectric unions.
179. Shop Drawings: Detail location of cathodic protection equipment, devices, and outlets,
with characteristics and cross-references to products. Include calculations and details of
anode designs. Include plans, elevations, sections, details for attachments to other Work,
and list of equipment and materials.
180. Field Test Reports: Indicate and interpret test results for compliance with performance
requirements. Include calculations of estimated life of anodes.
D Zinc Anodes for Buried Service Type Z-1
1. Comply with ASTM B 418, Type II.

2. Chemical composition as percent of weight shall be as follows:
a) Aluminium: 0.005 maximum.
b) Cadmium: 0.003 maximum.

c) Iron: 0.0014 maximum.
d) Zinc: Remainder.
181. Bare Anode Ingot Weight: 13.6 kg, 50 mm square and 760 mm long. Packaged weight of
anode bag shall be 32 kg.
182. Anode Wires: Cables, with copper conductors, suitable for direct burial; not less than 6
mm² with PVC insulation according to ASTM D 1248 and NEMA WC 5; long enough to
extend to accompanying junction box without splicing.
183. Anode Backfill: Backfill materials packaged in water-permeable fabric sack or cardboard
container. Anodes shall be factory installed in packaged backfill using methods that result
in dense packing of fill with factory-installed anode spacers to ensure centering of anode in
packaged anode backfill. Backfill material shall have the following chemical composition
by weight:
a) Hydrated Gypsum: 75 percent.
b) Bentonite Clay: 20 percent.
c) Anhydrous Sodium Sulfate: 5 percent.
E Wire and Cable
1. Direct-Burial Cable: Single-conductor Type HMWPE, insulated cable specifically designed

for dc service in cathodic protection installations.
a) Conductor: Stranded, annealed, uncoated copper, complying with ASTM B 3 and
ASTM B 8.
b) Insulation: High-molecular-weight polyethylene, complying with NEMA WC 5.
c) Minimum Average Thickness of Insulation: 2.8 mm for 10 mm2 through 35 mm2,
and 3.2 mm for 50 mm2 through 120 mm2; rated at 600 V.
d) Connectors: Copper compression type or exothermic welds.
184. Cables for Installation in Conduit: Type PVC copper conductors as specified in Division 16
Section "Conductors and Cables."
F Conduit
1. Rigid galvanized steel as specified in Division 16 Section "Raceways and Boxes."
G Test and Junction Boxes
1. Junction Boxes: Waterproof; PVC as specified in Division 16 Section "Raceways and

Boxes."
2. Test Stations: Flush-mounting type of high-impact-resistant PVC or polycarbonate, with
watertight conduit connections and cover and removable terminal board.
H Patch, Seal, and Repaired Coating
1. Sealing and Dielectric Insulating Compound: Black, rubber based, soft, permanently
pliable, tacky, mouldable, and unpacked; 3 mm thick.
2. Coating Compound: Cold-applied, coal-tar-based mastic.
3. Pressure-Sensitive, Vinyl-Plastic Electrical Tape: Comply with UL 510.
I Potting Compound
1. Cast-epoxy, two-package type; fabricated for this purpose and covered with heat-
shrinkable tape.
J Identification Materials
1. Materials are specified in Division 16 Section "Basic Electrical Materials and Methods."

a) Wire and Cables: Laminated-plastic material with black letters on yellow
background. Include identifier legend on the Shop Drawings.
b) Cable Warning Tape: Polyethylene tape.
K Insulating Flange Sets
1. Description: Insulating flange sets rated for operation at indicated pressure and
temperature of piping system, with full-faced gaskets, insulating sleeves and washers, and
steel washers.
a) Gaskets: ASME B16.21. Neoprene-faced phenolic material.
a. Insulating Washers and Sleeves: 2 sets of laminated phenolic insulating material.
Select washers to fit within bolt facing on flange over the outside of fabric-reinforced
phenolic sleeve.
b) Washers: Steel, cadmium plated, to fit within bolt facing on flange.
L Steel Flanges and Bolts
1. Steel Flanges: ASME B16.5; 68 kg.

2. Bolts: ASTM A 307, Grade B for bolts; ASTM A 194/A 194M, Grade 2 for nuts.
a) Dimensions: ASME B18.2.1 for bolts; ASME B18.2.2 for nuts.
b) Threads: ASME B1.1; Class 2A fit for bolts, Class 2B fit for nuts.
c) Extend bolts completely through nuts.
d) Bolts may have reduced shanks of diameter not less than diameter at roof of
threads.
M Dielectric Unions
Description: ASME B16.39, Class [1] [2] for dimensional, strength, and pressure requirements. Include
insulation barrier that limits galvanic current to 1 percent of short-circuit current in a corresponding metallic
joint and has insulating material impervious to material in pipe.
N Flexible Pipe Coupling Bonds
Description: Flexible copper straps with electrical resistance equal to 50 mm2 stranded copper wire and
with 5 holes for 5 exothermic welds to pipe.
O Exothermic Welds
1. Exothermic Weld Kits: Specifically designed by manufacturer for welding materials and
shapes required.
2. Exothermic Weld Caps: Dome of high-density polyethylene, 0.254 mm minimum
thickness, filled with mastic and containing a tunnel portion to separate lead wire from
exothermic weld.
P Zinc Anode and Cable Installation
1. Install zinc anode horizontally in a hole at least 76 mm larger than anode. Install anode
under new copper water tubing, including service lines, blow offs, and air releases.
Separate piping and anode by at least 600 mm, but not more than 1500 mm.
2. Install anode midway between both ends of piping. Install anode wire in piping trench and
connect to piping at an accessible location. Install anode wire in PVC conduit where rising
out of the ground to the aboveground connection.
3. Install conduit according to Division 16 Section "Raceways and Boxes." Minimum
conductor size is 6 mm2.

4. Install direct-buried cables according to Division 16 Section "Conductors and Cables."
a) Minimum Conductor Size: 10 mm2.
Q Test Stations
1. Install test stations as follows:

a) At 300-m intervals.
b) At insulating joints.
c) At both ends of casings.
d) Where pipe crosses other metal pipes.
e) Where pipe connects to existing piping system.
f) Where pipe connects to dissimilar metal pipe.
185. Install test stations on controlled backfill complying with requirements for trench bottom fill
for anode wires, unless otherwise indicated.
R Insulating Flange Sets
1. Cut piping and install flanges without stressing piping. Weld flanges according to ASME
B16.25. Cover flanges with sealing and dielectric compound.
S Pipe Joints
1. Electrical Continuity: Install bonding straps on metallic pipe to and across buried flexible
couplings, mechanical joints, and flanged joints, except at places where insulating joints
are specified. Welded and threaded joints are considered electrically continuous. Size
bonding strap to allow for a total of 25 mm pipe expansion or contraction. Connect
bonding strap to pipe, coupling follower rings, and coupling middle ring or sleeve. Connect
bonding strap to pipe and coupling with 5 thermowelds.
2. Insulating Unions: Install electrical isolation at each building entrance and at other
locations indicated. Cut pipe ends square, remove fins and burrs, and cut tapered pipe
threads according to ASME B1.20.1. Apply joint compound or thread tape to male threads
only. Install piping without stressing pipe. If joints are backed off to permit alignment of
threaded joints, reapply joint compound or tape. Engage threads so not more than three
threads remain exposed. Cover unions with sealing and dielectric compound.
T Dissimilar Metals
1. Underground Dissimilar Piping: Install electrically isolated joints for new and existing steel
piping, except valves. Coat insulating joint and pipe with sealing and dielectric compound
for a minimum distance of 10 pipe diameters on both sides of joint.
2. Underground Dissimilar Valves: Coat dissimilar ferrous valves and pipe with sealing and
dielectric compound for a minimum distance of 10 pipe diameters on both sides of valve.
3. Aboveground Dissimilar Pipe and Valves: If dissimilar metal pipe joints and valves are not
buried and are exposed only to atmosphere, coat connection or valve, including pipe, with
sealing and dielectric compound for a minimum distance of three pipe diameters on both
sides of junction.
U Casings, Insulation, and Seals
1. If piping is installed in casing, insulate piping from casing and seal annular space to
prevent intrusion of water.
V Reconditioning of Surfaces
1. Sod Restoration: Restore grass and lawn surfaces disturbed during installation of anodes
and wires to their original elevation and condition. Preserve sod and topsoil and replace
after backfilling is completed. If surface is disturbed in a newly seeded area, re-seed area

with same quality and formula of seed as that used in original seeding.
2. Pavement Restoration: Repair pavement, sidewalks, curbs, and gutters if removed or
disturbed during construction. Saw cut pavement edges. Graded aggregate base course
shall have a maximum aggregate size of 40 mm. Before paving, prime base course with
liquid asphalt, Grade RC-70, complying with ASTM D 2028.
a) Match base course to existing thickness, but not less than 150 mm.
b) Asphalt Aggregate Size: 13 mm.
c) Asphalt Cement: Comply with ASTM D 3381, Grade AR-2000.
d) Match asphalt concrete to existing thickness, but not less than 50 mm.
e) Repair Portland cement concrete pavement, sidewalks, curbs, and gutters using 21-
MPa concrete, complying with ASTM C 94. Division 3 Section "Cast-in-Place
Concrete." Match existing pavement, sidewalk, curb, and gutter thicknesses.
W Identification
1. Identify test station as indicated on the Shop Drawings.
X Field Quality Control
1. Testing: Engage a qualified testing agency acceptable to the Engineer, to perform the
following field quality-control testing:
2. Testing: Perform the following field quality-control testing under the supervision of a
qualified corrosion engineer:
a) Static Pull Test: Choose, at random, one completed anode of each type for this
destructive test. Demonstrate that anode wire connections have enough strength to
withstand a minimum tensile load of 136 kg. If test fails, replace all anodes and
repeat test at another randomly selected anode.
b) Insulation Testing: Before anode system is connected to pipe, test insulation at
each insulating joint and fitting. Demonstrate that no metallic contact, or short
circuit, exists between the two insulated sections of pipe and tank. Replace
defective joints or fittings.
c) Baseline Potentials: After backfilling of pipe, and anodes is completed, but before
anodes are connected to pipe, measure the static potential of pipe to soil. Record
initial measurements.
d) Anode Output: Measure electrical current as anodes or groups of anodes are
connected to pipe. Use a low-resistance ammeter. Record current, date, time, and
location of each measurement.
e) Pipe to-Reference Electrode Potential Measurements: On completion of installation
of entire cathodic protection system, make electrode potential measurements using
a copper/copper-sulfate reference electrode and a potentiometer-voltmeter, or a dc
voltmeter with an internal resistance (sensitivity) of not less than 100,000 ohms per
volt and a full scale of 1 or 2 V. Make measurements at same locations as those
used for baseline potentials. Record voltage, date, time, and location of each
measurement.
186. Location of Measurements for Piping: For coated piping or conduit, measure from
reference electrode in contact with the earth directly over pipe. Measure at intervals not
exceeding 120 m. Make additional measurements at each distribution service riser, with
reference electrode placed directly over service line.
187. Casing Tests: Test insulation between carrier pipe and casing. Correct short circuits.
188. Interference Testing: Test interference with cathodic protection from any foreign [pipes] in
cooperation with the Employer of foreign [pipes]. Report results and recommendations.
Y Adjusting and Demonstration

1. Adjust cathodic current using resistors as recommended by the Corrosion Engineer.
2. During first year after Substantial Completion, test, inspect, and adjust cathodic protection
system every 3 months to ensure its continued compliance with specified requirements.
3. Train the Employer's maintenance personnel to adjust, operate, and maintain cathodic
protection system installation.
4.4 VALVES, GATES, STOPS, WATER CONECTION S FIRE HYDRANTS AND SUNDRY WORKS
4.4.1 GENERAL
A Scope
1. These works shall consist of furnishing all materials, constructing, installing and
completing in all respects of works described in this Specification and indicated on the
Drawings.
4.4.2 VALVES
A Gate Valves Cast Iron
1. Type: Gate valves shall be used for diameters from 50 mm to less than 300mm and shall
be of Ductile Cast Iron (Ductile Cast Iron GGG40) to DIN3202 or equivalent and anti-
corrosive cast iron operation stem which does not rise during operation (Nonirising Stem)
and the gate in made of copper or cast iron covered with rubber.
189. Type: socket ends for diameters below 150 to BS 5163 or equivalent and flanged ends for
diameters 150 m and greater (in valve chambers) to BS 4504 or equivalent or ISO3606
and ISO4422 or equivalent.
190. Material of component for socket and flanged valves:
 The valve body from ductile cast iron to (GGG40) (EN –JS1030).
 The gate is covered totally with rubber.
 Valve non-rising stem from Stainless steel. The valve is operated either directly by hard wheel or
by a spindle.
 Testing of valves is done as per specification o DIN 3230 or EN 12266 – Part 4 or equivalent.
191. Operation is either by hand-wheel or by spur gear drive operated by removable key with a
rising stem depending on the depth of installation which may require inner gear as per
Engineers or manufactures direction.
192. Protection Type: Painting inner and outer surfaces by epoxy with a thickness not less than
250 microns as per specifications.
B Butterfly Valves:
1. Type: Butterfly valves flanged on both sides with a pressure 10/16 Bars shall be used for
diameters greater or equal to 300 mm manufactured to comply with EN593 specification or
equivalent.
193. Components:
 Butterfly value is of the fixed plate type not coaxial with the stem.
 Valve body is manufactured form ductile cost iron (GGG-40).

 Valve length is to comply with DIN3202 F4 series 14 and EN558-1 or equivalent.
 Valve stem is of anticorrosion cast iron.
 Flanges are to comply with DIN2501 or equivalent.
 Valve is opened and closed via the gear box mounted on the valve.
194. Operation by hand-wheel.

195. Protection Type: Painting the inner and exterior surfaces by epoxy with a thickness not
less than 250 microns as per specification.
C Check Valves:
1. Check valves for sizes 50-250 mm will be equipped with a gate that will open horizontally
compatible to an operation pressure 10/16 Bars.
a) Material of component parts: Valve body of cast iron (GG25) to specifications of EN-
JL 1040 or equivalent and the plate from cast iron or bronze, and the interacting
parts between plate and base should be cooper to rubber or cupper to cupper.
b) Parts connection will be flanged as per DIN2501 specification or equivalent.
c) Protection type is by epoxy paint with a thickness not less than 250 micron as per
specification.
196. Check valves for series greater than 300mm will be equipped with a stanted seat as per
EN12334 specification or equivalent for an operating pressure 10/16 bars.
a) Material of Component Parts:
 Valve body and the plate is of ductile coast iron GGG-40 as or EN-JS1030 specification or
equivalent.
 Valve stem is of stainless steel (I-4021).
 Closing base between valve and plate shall of welded Nickel.
b) Parts Connection shall be flanged as pr specification DIN2501 or equivalent.

c) Protection type is by epoxy paint with a thickness not less than 250 microns as
d) per specification.
e) Shocks Absorption Unit
Valves shall be suitable to be equipped with shocks absorption units that works hydraulically by valve
which will be the media to absorb shocks. Generally, these instruments are installed on valve sizes greater
than 400 mm.
D Flap Valves
It is valve to prevent backflow installed at pipe ends.
1. Type: To be flange mounted, designed for use on end closures to prevent entrance of
backwater. Seating plane is to have 10 deg. inclination.
2. Materials: Cast iron body and cover, bronze seat faces, bronze hinge pins and spring pins,
cast iron follow ring and plated steel ring draw bolts. Materials subject to de- zincification
or de-aluminuzation are not to be used.
3. End Connections: If flange mounted, flanges are to be toDIN2501 or equivalent.

4. Factory Protection: Painting surfaces with epoxy with layers not less than 250 microns as
per specification.
E Float Valves
1. Type: Globe pattern mounted horizontally or vertically used to control water level in tanks.
2. Control and operation shall be done through the valve external floater depending on water
level in the tank.
3. Valve positioning control consists of float operated linkage mechanism for remote
mounting which feeds water level changes back to main valve through low friction, flexible
push-pull cable supplied by same manufacturer.
4. Construction: Cast iron body (GGG-40) to ASTM A126 or equivalent, bronze valve trim
and valve operating mechanism to ASTM B62 and all stainless-steel valve float and pilots.
5. Factory Protection: Internal coating of epoxy to a thickness of at least 250 microns and
external coating of epoxy and nickel plating to a thickness of at least 250 microns.
F Air Valves for Water Mains
1. Generally: Valves are to have ductile cast iron body (GGG-40) to EN-JS 1030 or
equivalent and bolted cover rubber outlet seat, plastic or stainless ball. Valves are to be
dynamic type where there is no possibility of ball being drawn into orifice due to high air
velocities. Valves are to be factory tested to 1.5 times working pressure and factory
coated with epoxy to BS 4164 [5] or BS 3416 [4] respectively. Thickness of coat to be at
least 250 microns.
2. Double Air Valves (or Combination Air Valves): These are required for relieving air under
pressure and in bulk. Large orifice releases or admits air during charging or emptying of
mains while small orifice releases air accumulated at summits of mains under pressure.
Large orifice area is to be equal to or greater than inlet of valve. Valves are to be fitted
with nitrite rubber lined butterfly valve with nylon coated disc on stainless steel shaft
operated by lever handle with indicator and locking thumb screw. Valves are to be flanged
to BS 4504 [2] or DIN2501 or equivalent (PN16) and suitable for working pressures up to
NP16.
3. Single Air Valves: Type 1 (or air / vacuum valve) for releasing or admitting air during filling
or emptying of pipes. Type II (or air release valve) for automatically releasing, under
pressure, accumulated air at summits of mains. Air valves larger than 50 mm are to be
flanged to BS 4504 [2] or DIN2501 or equivalent and are to have nitrite rubber lined
butterfly valve or gate valve with nylon coated disc on stainless steel shaft operated by
lever handle with indicator and locking thumb screw. Air valves 50 mm and smaller are to
have B.S.P. thread with brass or gun metal male screwed stop valves. Valves are to be
suitable for working pressures up to NP16.
G Sluice Gates / Penstock
1. Material of Component Parts: Manufactured of stainless steel and insulation rings from
EPDM and may be circular, rectangular or squared.
2. Operation: Byhand-wheel or stainless-steel stem and may be operated by electric motor
as per specification or Engineers directors.
3. Protection: shall be manufactured from stainless steel (1.4301) or (1.4571) as per
specifications and manufacturer directions.
H Pressure Reducing Valves - Generally
1. Types: Installed where shown on the Drawings to pressure ratings and pressure settings
indicated, to automatically reduce higher inlet pressure to steady lower downstream
pressure regardless of changing flow rate and/or varying inlet pressure. Valves are to be
high pressure rating piston type and hydraulic pilot operated type.
2. Accessibility: Maintenance is to be possible without removing valve from pipeline.

3. Material of component: valve shall be to (DIN3202) F1 or (ISO5752 series 1) or equivalent
and the valve body and cover are of cast iron GGG-40 and the value base and disk from
stainless steel.
197. End Connections: Flanged to DIN2501 or BS 4504 [2] to pressure rating of 10, 16 or 25 as
appropriate and provided from factory with necessary bolts, washers, nuts and gaskets.
I Piston Pressure Reducing Valves
1. Type: Spring loaded type, balanced out against upstream pressure by high resistance
piston action.
2. Size: Valve shall be selected for maximum flow rate recommended by manufacturer and
for maximum water velocity of 1.5 m/s to prevent cavitation inside valve or in pipeline
downstream of valve. Valve diameter is to be same as pipeline but valve opening size is
to be suitable to ensure above requirements.
3. Balancing: The effect of upstream pressure on upper surface of main valve disc is to be
balanced by the effect of the pressure acting piston action from below. The effect of
downstream pressure acting under water on main valve disc is to be compensated by
adjustment of the spring compression.
4. Control Pressure: Valve shall control a constant downstream pressure to a maximum
variation of +/- 10% and close tight with zero flow rate.
198. Accessories: These shall include two pressure gauges with isolation cocks, one fitted
upstream and one downstream.
J Diaphragm Pressure Reducing Valves
1. Type: Pilot controlled, single seated, hydraulically operated, diaphragm type globe valve.
Control system is to be sensitive to slight pressure changes and is to immediately control
main valve to maintain desired downstream pressure. Pressure setting adjustment is to be
made with single adjustment screw protected by a housing that can be sealed.
2. Construction: Body and cover are to be cast iron, ductile iron or cast steel depending upon
operating pressure. Main valve trim is to be stainless steel and pilot system all stainless
steel. Main valve is to have single removable seat and resilient disc.
3. Diaphragm assembly shall be fully guided by a precision machined stem with bearings at
both ends in the valve cover and seat. Diaphragm is to be nylon bonded with synthetic
rubber.
4. Accessibility: Repairs are to be possible without removing valve from line. Valve is to have
no external packing glands or stuffing boxes.
5. Pilots: Valve is to have necessary factory fitted pilot valves, small interconnecting piping
and accessories to perform required functions. Pilot control is to be direct acting,
adjustable spring loaded, normally open, diaphragm valve designed to permit flow when
controlled pressure is less than spring setting. Control system is to include Y-strainer,
fixed orifice and isolation cocks. Pilot control system is also to include flow control device
to regulate closing speed of valve. Valve is to close tight at zero flow rate.
K Pressure Regulating Valves
1. Type: One-way valve to control water pressure and water shall be identical around inner
valve section and consisting of two annular plates perforated identically and in the same
manner with cone nozzles. Downstream plate is to be fixed and upstream plate is to slide
over fixed plate using a handwheel.
2. Function: These shall be used on by-pass of pump and on main pumping station by-pass
line to limit differential pressure and water flow across pump control valve and by-pass
valve.

3. Construction: Ductile Cast steel GGG-40 valve body, stainless steel fixed plate with 13%
Cr., bronze aluminium sliding plate, stainless steel valve shaft and perbuban 70 shore
gaskets.
4. Accessories: Hand-wheel is to have micrometric indicator to indicate valve position. Valve
is to be designed for working pressure of 25 bars.
5. Protection Type: interior and exterior layer of epoxy with a thickness at least 150 microns.
L Over-speed Isolating Valves
1. Type: Hydraulically controlled, butterfly valve opened by overhead hoist and closed by
weight. Valves are to automatically shut-off at rapid flow that may occur in case of pipe
bursts or increase in water velocity above normal average.
199. Install where shown on the Drawings, to the size, pressure ratings and water flow closing
settings shown.
200. Detection system shall comprise an apparelus connected to control panel supplied with the
valve to detect overspeed.
201. Shut-off mechanism shall consist of mechanical and hydraulic oil system ensuring
irrevocable shutting of valve when overspeed is detected.
202. Construction: Valve body, disc and accessories are to be as specified for butterfly valves.
203. Accessories shall include necessary devices to provide controlled operation, shut-off
delay, non-operation by temporary over speeding and remote signalling by limit switches.
Closing speed shall be adjustable.
M General Control and Operation Valves
1. General: Pump control valves, slow-closing slow-opening pump check valves, surge
control valves, air release and vacuum breaker valves and by-pass valves are to be
automatic, hydraulically operated, pilot controlled, piston actuated, single seated, globe or
angle pattern as shown on the Drawings, consisting of valve body, piston assembly and
cover with the piston assembly as the only moving part. Valves are to be size and
pressure rating shown on the Drawings and are to be the product of one reputable
approved manufacturer.
2. Construction: Valve body is to be ductile cast iron GGG-40 to EN-JS 1030standard,
flanged, with flange rating as shown on the Drawings and containing a removable seat
insert.
3. Accessibility: Repairs are to be possible without removing valve from line. Valve is to have
no external packing glands or stuffing boxes.
204. Pilots: Valve shall be supplied complete with factory fitted pilot valves, small
interconnecting piping and accessories to perform required functions. Pilot control system
is to be stainless steel to AISI type 303.
5. Design Data: The Contractor shall provide manufacturer with necessary and pertinent data
for setting control valves, at factory, to required settings to suit individual conditions of
different pumping stations.
205. Shop Drawings And Instructions: Prior to shipping valves from factory, submit shop
drawings for approval giving factory settings, range of adjustments, control diagram, wiring
diagram, size, arrangement and other pertinent data necessary for approval by the
Engineer of every control valve in the system. Submit with the shop drawings detailed
instructions for field adjustment and setting, installation, start-up and proper operation.
206. Factory Test: Each control valve is to be tested individually at factory and certified test
results submitted.
207. Field Adjustment: The Contractor shall provide the services of a specialized factory

technician or engineer to set, test, adjust and commission the control valves as specified.
N Washout Valve
1. Washout valves shall be gate valves as per flanged valves specifications and shall be
installed in valve chambers as indicated on drawings or as by Engineer’s direction.
2. Washout valves shall be installed at the lowest level in the main water as per drawings or
Engineer’s directions.
4.4.3 FIRE HYDRANTS
A General
1. These specifications shall corer fire hydrants installed on potable water pipes in the streets
and shall be of above ground hydrant type as to DIN 3222 specification or equivalent.
2. Fire hydrants shall be of Above Ground Type consisting of two separate parts connected
by a flange in the middle, and the bolts shall be designed in a manner that allow
dismantling the upper part from the lower part , and in a way that allows the fine hydrant to
receive shocks without allowing breakage of the fine hydrant body or leakage of water.
3. Fire hydrant shall be designed in a way that allows dismantling of inner parts such as
rising stem, control valve for maintenance needs without the need to dismantle the valve.
B Scope
1. Sizing: The height of upper part of the fire hydrant shall not be less than 60 cm above
ground, and the height of buried part of fire hydrant shall not be less then 120 cm below
ground level.
2. Parts
a) External Outlets shall be threaded in the upper part and the main internal nominal
diameter shall be 4 inch and the side outlets shall be 2.5 inch
b) Intermediate Plunge
Dimension of flange with respect to diameter and number of openings for upper part
should be identical to those in lower part.
c) Lower Inlet
Water inlet in the lower part shall be with a hollow end to hold a 100mm pipe, or the end
should be flanged as per request with dimensions to international specifications ISO 2531
or equivalent.
208. Material of Parts
1. Fire Hydrant Body and Upper Cover
Fire hydrant body shall have the Barrel Body shape that surrounds inner parts and
covered with a hydrant cap supplied by an insulating rubber ring bonnet gasket.
209. The fire hydrant upper barrel part shall be of ductile cast iron (GGG40/50) to international
or German or equivalent specification.
210. The Bury standing pipe and the upper cap shall be of the best ductile cast iron type or
ductile cast iron GG25.
211. The body and cap shall be coaled with epoxy on inside and outside surfaces with a layer
of thickness at least 250 microns or what is equivalent from other types of anti-corrosive
paints that does not react with water. The coating shall be applied to clean surfaces form
dusts or oil. The coating for the external upper part should be red color.
C Stem

1. The stem shall connect the upper and lower part in such a way to control with it the
opening and closing of the regulating valve at the upper part of hydrant.
2. The stem shall be anti-corrosive cast iron with chrome percentage not less than 13% and
Bronze plates.
3. The stem shall be mounted in the regulating valve body through a copper nut in such a
way where the opening can be done in a counter lock wise way.
D Outlet Nozzles
1. Unless otherwise stated, the fire hydrant shall be provided with 3 outlets, one main 4 inch
and 2 side threaded 2.5-inch outlets
2. All outlets shall be equipped with a metal cap connected to fire hydrant body in a suitable
way through a chain which allows rotation both way and do not make restrictions during
opening and closing of cap.
E Inlet Base
1. The lower part shall be supply be supplied with a Duck Food Bend with a socket end for a
100mm pipe or with a flanged end as required.
2. The Dock Foot Bend shall be of ductile cast iron GGG-40/50.
F Junction Diameter
1. The junction connecting the fire hydrant and the water main shall be 100 mm when the
water main is 100mm.
2. The junction diameter shall be 150 mm when the water main size greater than 150 mm
G Closing Valve
1. A gate valve shall be installed at a 1m distance from the fire hydrant and shall be to the
specification of gate valves.
H Overflow and in Release System
1. The fire hydrant shall be supplied with a suitable system to drain water from the hydrant
body and prevent it from freezing when the hydrant is closed.
2. The hydrant shall be designed to empty entrapped air inside it through air release valve or
any compatible system.
I Installation of the Hydrants
1. The fire hydrants shall be installed as specified on plans or as per Engineer’s direction at
easily accessible locations and reduce any damages due to vehicles passage.
2. Fire hydrant shall be supplied with safety bars for protection form traffic accidents.
4.4.4 HOUSE CONNECTION
A Water connection
1. Water connection shall constitute of saddle connection mounted on water line,

connections, connection pipes, water meter boxes, connections and any other item.
2. Locations and diameters of house connections, location of connections shall be as
drawings and as Engineer’s directions during project construction, and number and
diameters that shall be installed as per drawing and bill of quantities.
3. Connection Pipes
212. Domestic connection pipes shall be of high-density polyethylene as mentioned in item
(4.3.1) pressure category (16) or 16 Kg/cm2.

4. Connection to water main (saddle connection)
a) House connections shall be connected to water main through saddle as shown in
drawings and as per Engineer’s direction.
b) Type of saddle that will be used in connecting house connection will be ductile iron
in case the water main is ductile iron or from polyethylene as specified in case the
water main or polyethylene.
c) The saddle connections will be installed as per drawings and manufacturers
specification that should be applied precisely.
5. Water meter Boxes for house Connections
a) Water Meters
Water meter shall be manufactured from an approved factory by the ministry of water and electricity. The
meters shall comply with the international standards (ISO 4064-1) or American standards (AWWA) or
SASO 238 and shall be accompanied by test certificate, certificate of origin and shall comply with the
following requirements:
1. The water meter shall be of the metrological category Class- C. The dimensioning of the
water meter shall comply with the international dimensioning standards and shall be
installed into two positions vertical and horizontal, and the reading precision shall not be
less then Class-C.
2. The water meter shall be made of non-corrosive brass solder or bronze and shall not be
affected by temperature and bronze percentage shall not be less than 60%.
3. All internal and external parts shall be salt and temperature resistant and temperature
should be between 0 and 60 degrees and accompanied by a certificate and all submerged
parts shall be made of non-poisoned material so that water properties (quality, taste and
odor) are maintained.
4. The water meter shall be resistant to high pressures (10 to 16 bars).
5. Water meter shall be isolated from water line and evacuated from air and be of dry type.
6. Water meter glass shall be firmly treated against breakage and scratch and color change.
7. Each water meter shall have an external number that will be the meter number which will
be inscribed on the metal part of the meter and the year of manufacture shall be shown.
8. The water meter shall be measured in meter cube and should not be less than 5 digits in
addition to 3 decimal places in different colors.
9. The water meter material should be weather resistant and internal parts of meter should
be resistant to sand and water impurities.
10. There shall be a guarantee for the availability of spare parts of the meter and its parts for a
period not less than 10 years; during this period any part of the meter or its base or
measuring chamber could be exchanged.
11. The meter should be read clearly in addition to the possibility of being read remotely as per
the Ministry circulation No. 545/1 on 04/06/1428 h.
12. It should be printed on either side of the meter with big letters and numbers water meter
size and the flow direction with an arrow. Also the pins of the entrance shall be different
than the exit. This will ensure that the meter will not be installed wrongly.
13. It should be ensured that the meter shall not be affected by the cut of water supply or
being dry for a long time.
14. Each meter shall have a non-corrosive screen installed at the meter entrance before the
measuring instrument and shall have a removable flap valve after the measuring
instrument.
15. The readings gears shall be fixed in a manner that is not affected by internal and external
factors and shall be suitable for the water quality and temperature that reach 60o C.

16. All meter sizes up to 4 inch shall be available and the meter box shall be fixed with a lock
that can be opened only with a special key to avoid vandalism.
b) Meters Boxes
 Meter box body shall be made of fiberglass (25% glass).
 Box cover: the metal hinges are made of stainless steel that allow opening the box with an angle of
18 o.
 Reading opening made up of thermally treated glass to allow of taking clear readings with a
guarantee that the color will not change and shall be against scratch and resist temperature
effects.
 Box Key: the locking pin of the box cover shall be of stainless steel which does not rust, and shall
be opened by a special key (imported quantity equal 5% of number of imported boxes) and the key
shall be of stainless steel.
 Water pipe opening shall be 50 mm diameter in addition to two gaskets to fix the entering and
exiting pipes.
 A circular opening to fix the reading instrument by a touching system with a 40 mm diameter.
 Ministry of water and electricity logo.
 Bills collector fixed on the exterior side of the box made of polycarbonate, transparent and anti-
breakage or scratch or color change.
 Box color is white (RAL9010). Box thickness is 6mm for all surfaces. Surfaces shall be resisting for
all environmental deteriorating factors and sunlight with a guarantee that color will not change or
that the surface will not deteriorate.
c) Ground water meter shall be put in ground boxes as shown in drawings. The frame
and cover shall be prepared to be locked and resist a load of 10 tons and shall be
coated to specifications. And shall secure keys to open and close these frames, one
key for every 50 boxes.
6. Installation of house connections
The contractor shall clean site, excavate, backfill, install, and put the bedding for pipes and paving to the
specifications as in the main network.
7. Testing and Disinfecting House Connection
House connections shall be tested and disinfected to specifications and as done in the main network.
8. Files of House Connection Locations
The Contractor shall reserve accurate files for the locations of house connections showing diameter length
and the files shall be in a pre-specified format and available for revision and ready to be submitted to the
owner. The contractor shall transfer the information into charts in accordance with the Engineer in addition
to three copies that shall be submitted to the owner.
4.4.5 JOINTING MATERIALS AND ADAPTORS
A Generally

1. Gaskets: Elastomeric full face 3 mm thick joint rings to ISO 4633 or BS EN 681-2 [10] with
dimensions to BS 3063 [38].
2. Rings: Elastomeric to ISO 4633 or BS EN 681-2 [10] with dimensions to manufacturer's
recommendations to suit type of joint required.
3. Bolts and Nuts: ISO metric black hexagon to BS 4190 [39], minimum tensile strength 433
MN/m2, maximum elongation 17%. After fixing, bolt projection shall to be maximum 6 mm,
minimum 3 mm.
4. Washers: Black steel shall be to BS 4320 [40] or ISO/R 887.
5. Dielectric joints shall have insulating gasket between flanges and Teflon sleeves and
washers between bolts and nuts and flanges. Joints are to be suitable for operating
pressure of system.
B Flexible Couplings
1. Type: Gasket sleeved type, to allow angular deflection and axial movement of two joined
pipe ends and to maintain permanent, leak-tight joint.
2. Components comprise one centre sleeve, two end followers or flanges, two rubber-
compounded wedge-section gaskets and sufficient draw bolts and nuts to properly
compress gaskets. Tightening of bolts to draw end followers together is to compress
gaskets in recess between centre sleeve and followers onto pipe ends to effect positive
seal.
3. Size: Couplings are to have diameter specifically supplied for and to properly fit type of
joined pipe ends. Centre sleeve is to be of adequate thickness and whole coupling suitable
for minimum working pressures shown on the Drawings.
4. Centre Sleeve and Followers shall be true circular sections, free from irregularities, flat
spots or surface defects and formed from steel mill sections with space between sleeve
and follower designed to provide confinement of gasket.
5. Bolts shall be special steel having minimum yield strength of 2800 kg/cm2 (40,000 psi) and
ultimate strength of 4200 kg/cm2 (60,000 psi). Bolts shall be track-head design to prevent
turning when nut is drawn up and threads are to be rolled with a nominal diameter larger
than diameter of shank. Manufacturer shall supply information regarding recommended
torque to which bolts are to be tightened.
6. Gaskets shall be synthetic rubber-base compound with other products to produce material
which will not deteriorate from age, heat or exposure to air and which is resilient and able
to resist cold flow of material so that joint will remain sealed and tight indefinitely when
subjected to shock, vibration, pulsation, temperature and adjustment of connected pipes.
7. Factory Protection: Coupling shall be factory painted internally with 10 mils coating of
epoxy and externally with red primer to AWWA 203 Type B chlorinated rubber solution
compatible with bitumen, coal tar and general paints.
8. Installation: Couplings are to be assembled on site in accordance with manufacturer's
instructions to ensure permanently tight joints under all conditions of expansion,
contraction, shifting and settlement.
C Dismantling Couplings
1. Type: These shall ensure extensible connection between sections of pipework, to be

mounted next to valves to enable easy dismantling from pipework or to permit joining
pipework when butterfly valve is removed for maintenance.
2. Components: Dismantling piece shall be flanged type composed of two parts, one sliding
into the other, and a free flange to compress a trapezoidal section seal to ensure water
tightness. Coupling shall have locking devices to provide elements of complete rigidity.
3. Construction: All steel with flanges class PN 10, PN 16 or PN 25 depending upon coupling
location on pipework.
4. Size: Couplings shall have diameter specifically supplied for and to properly fit type of
joined ends of pipes and valves. Coupling shall permit tightening of end flanges without
risk of misalignment. Seal shall be locked after end joints are tightened.
D Flanged Adaptor: Ferrous
1. Material: Cast iron to BS EN 545 [1].

2. Length of adaptor shall be 200 mm for diameters up to 150 mm, 250 mm for diameters
between 200 and 300 mm and as approved for diameters larger than 300 mm.
3. Factory Protection: Coated with bitumen or coal tar to BS 3416 [4] or 4164 [5] respectively.
4.4.6 VALVE ACCESSORIES
A Accessories
1. Hand-wheels shall be to BS 5163 [25], of cast iron to BS EN 1561 [29]. Hand-wheels are
to be marked 'CLOSE' with an arrow to indicate clockwise direction of closure. Diameters
and other constructional details shall be to manufacturer's standards. Hand-wheels are to
be supplied at a rate of 1 in 5 valves.
2. Valve caps shall be to BS 5163 [25], of cast iron or malleable iron to BS EN 1561 [29] and
BS EN 1562 [41] respectively. Set screw of valve cap is to be mild steel M12.
3. Operation Keys: Combination prising bar and lifting key type, with 1.5 m vertical bar and
0.5 m horizontal bar. Keys are to be supplied at a rate of 1 in 5 valves.
4. Extension Spindles for Gate Valves Manufactured from: Steel to BS 2470 [42] - M12 for
diameters less than 300mm. And the spindle will have manual key of T Type Protection
Tubes: Cast iron. Shape, sizes and other constructional details are to be to
manufacturer's standards and/or as shown on the Drawings. Tubes are to have caps
circling extension spindles.
5. Surface boxes shall be to BS 5834 [43] Part 2. Frames and lids are to be cast iron to BS
EN 1561 [29], studs, bolts, nuts and hinge pins are to be mild steel M12, chains are to be
mild steel or wrought iron and lid is to have the letter 'W' cast on. Boxes are to be of the
following types:
 For carriageways (wheel loads
o up to 11.5 tons) : Heavy grade type A
 For use were heavy commercial
o vehicles are exceptional (7 tons) : Medium grade type M
 For use in places inaccessible
o to wheeled vehicles (2.5 tons) : Light grade type L
6. Lifting Key Sets: Malleable iron, supplied at the rate of 1 per 5 covers installed or fraction
thereof.
7. Guards for Underground Stop Valves: PVC, shape and size and other constructional
details to manufacturer's standards and/or as shown on the Drawings.
B Valve Chambers and Markers
1. Unless shown otherwise on the Drawings all backflow preventers, gate valves, pressure
regulators, electric solenoid valves, manual control valves, pressure gauges and water
meters shall be installed in chambers of suitable size for easy access. Chambers shall be
complete with access covers, ladder rungs and other incidental works.

2. Unless shown otherwise on the Drawings all chambers shall be installed on a suitable
base for proper foundation and easy leveling to proper grade, and also to provide for
sufficient drainage.
3. Valve markers showing the reference numbers of the valves shall be of materials and to
the dimensions, shapes and details as shown on the Drawings.
4.4.7 VALVE OPERATORS
A General
1. Gate, butterfly and ball valves are to be manually or electrically operated depending upon
size, torque applied on valve stem or as shown on the Drawings.
2. Valves 350 mm and smaller are to be operated manually with a maximum applied torque
on handwheel of 100 Nm
3. Valves 400 – 500 mm are to be operated manually with a maximum applied torque of 150
Nm
4. Valves of higher torque are to have appropriate thrust bearings, slides and gearboxes to
fulfill these requirements
5. Gate valves 600 mm and larger and ball valves are always electrically operated using
thrust bearings, gearboxes and motor actuators
6. Butterfly valves 600 mm and larger are to be either manually or electrically operated as
shown on the Drawings.
B Manual Gearboxes
1. Type: Totally enclosed, sealed construction to protect moving parts from damage and
corrosion. Gearbox is to be either spur or level type depending upon mounting position of
valve.
2. Components shall include corrosion resistant bearings, and gearbox of cast iron or
aluminium with unpermeabile cover. Housing cover is to have indicator window to show
position of valve. Gearbox is also to have stainless steel bolts.
C Electric Valve Operators
1. Type: These shall consist of suitable gearbox and electric motored handwheel for manual
operation.
2. Installation shall be suitable for flange mounting directly on valve body, for gate valves the
operating shall be of non-rising stem type.
3. Rating shall be of adequate horsepower and thrust ratings to open and close operated
valve smoothly at all conditions of load and pressure.
4. Components shall include adjustable mechanical stop- limiting devices to prevent over-
travel of valve in either direction. In addition, components will include safety key to
prevent increase in rotation momentum.
5. Construction: Weatherproof, with rugged cast iron housing and with handwheel having
appropriate gearing for emergency manual operation such that maximum applied torque is
150 Nm. Declutch lever is to disengage drive motor during handwheel operation and
prevent handwheel rotating during power operation for safety of personnel. Handwheels
are to close valve in counter clockwise direction and are to have arrows and the word
'CLOSE' cast on.
6. Controls shall comprise integral electric controls enclosed within weatherproof
compartment and including magnetic starter and reversing controller for motor, open-stop-
close push-button for local operation, and switches for manual or remote operation with
indication of operator condition.
7. Electric Motor: Totally enclosed, squirrel cage, induction type conforming to NEMA

Publication No. MG1 including characteristics, tests and ratings. Motor shall carry
maximum possible load encountered in valve operation under all normal and abnormal
operating conditions.
A Generally
1. Prior to Installation, the Contractor shall inspect for cleanliness of bores, seating surfaces
etc. and for handling damage, cracks, missing parts and tightness of pressure-containing
bolting.
2. The Contractor shall ensure gates and hydrants are in closed posi¬tion before installation.
3. Operate hydrants through one complete opening and closing cycle in the position in which
they are to be installed to ensure proper functioning.
B Installation of Valves
1. Prior to installation, valves shall be inspected for cleanliness of bore, seating surfaces etc.
and for handling damage, cracks, missing parts and tightness of bolting. Valves shall be in
close position before installation.
2. Valves shall be operated through one complete opening and closing cycle in the position in
which they are to be installed to ensure proper functioning.
3. Valves shall be set and jointed to the pipe in the manner specified for laying and jointing
pipe and in accordance with the manufacturer's recommendations. Each valve shall be
provided with a concrete pad as shown on the Drawings so that the pipe does not support
the weight of the valve. Valves shall not be used to spring misaligned pipe into alignment
during installation.
4. Valves without concrete pads shall be placed on firm footing to prevent settling and
excessive strain on connection to pipe.
5. All stressed bolts (bonnet, seal plate and end connections) shall be inspected for adequate
tightness after installation and prior to field testing.
6. Valves shall be protected against action of external agents by a coat of approved
bituminous compound, applied cold by hand brushing after pressure tests on pipelines
have been completed. Buried bolts etc., shall be protected against corrosion, with
approved paint or polyethylene wrapping.
7. For each installation, the wall thimble, operating mechanism, stem and stem guides shall
be installed in accordance with the manufacturer's recommendations. Tolerances between
seating faces shall be maintained and any warping avoided.
8. Tapped holes in thimbles shall be protected during concreting and setting. Surfaces of
thimbles and gates shall be protected from concrete spillage, paint, oil and debris.
Thimbles shall be supported to prevent shifting during pouring and braced horizontally and
vertically to prevent distortion.
9. Nuts shall be tightened in sequence after setting and the entire assembly shall be cleaned,
adjusted and lubricated after installation.
10. Sluice gates / Penstocks shall be operated through one complete cycle on installation to
ensure proper functioning.
11. Sluice gates / Penstocks shall be protected against action of external agents with one coat
of approved bituminous compound applied cold by brush after installation. Buried bolts,
etc. shall be protected against corrosion, with approved paint or polyethylene wrapping.
C Field Protection
1. Valves: The Contractor shall protect valves against action of external agents by a coat of
approved bituminous compound applied cold by brush after pressure tests on pipelines

have been completed.
2. Hydrants: The Contractor shall apply one coat of paint, of colour specified by the Engineer,
after backfilling and surface restoration is completed.
3. Gates: The Contractor shall protect against action of external agents with one coat of
approved bituminous compound applied cold by brush after installation.
4. Bolts: The Contractor shall protect buried bolts against corrosion with approved paint or by
polyethylene wrapping.
4.5 BEDDING, SURROUND, HAUNCHING, ENCASEMENT AND THRUST BLOCKS
4.5.1 GENERAL
A Scope
1. Pipe bedding surround and ways of securing pipe installations are specified in this Section.
4.5.2 MATERIALS
A Pipe bedding and/or surround, and filling materials under and around pipes shall comply
with the appropriate requirements of Section 2.04.
B All concrete work shall comply with the appropriate requirements of Division 5.
C Concrete bedding shall be Class 110/25.
D Concrete for encasements, thrust blocks, arches and haunches shall be Class 250/20.
E Compressible board shall be 20 mm thick fibrous material or similar approved material.
4.5.3 WORKMANSHIP
A Placing Concrete
a) After placing pipe the Contractor shall pour concrete in trench and thoroughly work
under pipe to provide solid and uniform bedding.
b) After pipe joint is completed the Contractor shall place the balance of concrete or
haunching and work into place on both sides simultaneously.
c) The Contractor shall form vertical construction joints in concrete beds, surrounds
etc. at the face of pipe joints with compressible board and finish to profile of the
concrete and pipe. The Contractor shall fill any gap between spigot and socket with
approved resilient material.
B Placing Material Other than Concrete
1. The Contractor shall place surround or bedding material in bottom of prepared trench and
carefully hand tamp to minimum thicknesses.
2. After pipe has been laid the Contractor shall place additional material or haunching in
successive layers not exceeding 150 mm thick on both sides simultaneously and
completely fill spaces between pipe and side of trench and carefully hand tamp without
disturbing the pipe.
C Thrust Blocks
1. Thrust blocks shall be constructed to prevent thrust at all bends, T connections, crossings,
pipe ends, tapers and fire hydraulic as per Engineers direction and design drawings.
Thrust blocks shall be constructed between the solid ground and the accessories that

need to be anchored as per the details of the design drawings or Engineer’s direction.
Polyethylene sheets of 3mm thickness shall be put between concrete and accessories to
prevent cohesion. Contractor shall submit shop drawings for thrust block constructed. No
pressure shall be applied to thrust blocks for 3 days after construction.
4.6 CHAMBERS AND INLETS
4.6.1 GENERAL
A Scope
1. This section specifies works related to valves chambers, for air valves, washout valves
and butterfly valves of diameter 300 mm and above.
4.6.2 MATERIALS
A Excavation and backfilling generally shall comply with Section 2 and section 3 of the
Specification.
B Concrete work generally shall comply with the appropriate requirements of Division 5 of the
Specification.
C Reinforcement shall conform to the requirements as specified in Section 5.03 "Steel

D Precast units to BS 5911 [13] Part 200 or ASTM C478. Except for thickness which shall be
as indicated on the Drawings. Concrete shall be Class 250/20. Cement shall be ordinary
Portland cement to BS EN 197 [3].
E Plain and reinforced concrete for cast In-Situ units shall be Class 210/25 and 250/25
respectively. Cement shall be ordinary Portland cement to BS EN 197 [3].
F Internal and External Coatings shall be as specified in A3, A4 and A5 of section 4.06.3.
Water proofing for external surfaces is given in Section 4.07.
G Covers and frames shall be non-rocking, locking, solid top to specifications followed by
Ministry of Transport and comply with British Standards BS2789 or ISO 1083 or DIN 1229
or BS EN 124 [31]. Equivalent, wording on cover shall indicate nature of network (water
supply), Grades shall be as follows:
 In Roadways: Heavy duty test load 40 tons
 In Sidewalks, Carriage Drive and Cycle Tracks: Medium duty test load 25 tons
 In Footpaths and Fields: Light duty, test load 7 tons
H Covers shall be of circular pattern with a minimum diameter of 600 mm or rectangular with
an opening 1200mm x 600mm unless otherwise indicated on Drawings. Frames shall be
provided with opening for fixing bolts which ensure solid frame embedment into manhole
concrete neck. Covers for air release valve chambers should be provided with holes for
ventilation. Covers and frames shall be coated with two layers coal tar epoxy (70% epoxy,
30% coal tar) to BS 3416 [4]. Minimum thickness 250 microns.
I Iron steps shall be mild steel to BS 4211 [51], galvanized to BS EN ISO 1461 [52] with 200
grams of zinc per square meter and covered with two layers of polyethylene (PE) or
polypropylene.

J Fixing bolts shall be steel, type suitable for particular purpose and use and to approval.
When used to fix galvanized material, washers are to be galvanized and fixing bolts and
nuts cut to pre-plating limits and electroplated with zinc to BS EN 12329 [53].
K Steel castings shall be mild to medium strength castings and shall conform to AASHTO
M103 (ASTM A27). Unless otherwise shown on the Drawings or instructed by the
Engineer, castings shall be grade 65-35 fully annealed. Steel castings shall conform to the
dimensions shown on the Drawings. Test bars shall be prepared and tested as specified
in AASHTO M103.
L Wrought iron plates and shapes shall conform to the dimensions shown on the Drawings.
Rolled wrought iron bars and shapes shall conform to the requirements of ASTM A207.
Wrought iron plates shall conform to ASTM A42.
M The Contractor shall submit to the Engineer all specified test coupons and Manufacturers'
Certificates of Guarantee for all structural steel, cast iron, cast steel and wrought iron parts
stating that the materials supplied meet the appropriate AASHTO or ASTM specification.
The submission of such test certificates shall not relieve the Contractor of his obligations to
carry out independent tests at an approved laboratory, as directed by the Engineer, at his
own expense.
A Valve Chambers
1. Construction shall be in situ concrete, precast concrete as indicated on the Drawings.

2. Conrete works shall comply to concrete specifications as per concrete and reinforcement
specification in section 5.
3. Bituminous slurry External concrete surfaces for valve chambers shall be coated with
bituminous slurry. External coating shall consist of two coats applied by brush in
accordance with manufacturer's instructions. Minimum thickness shall be 400 microns.
4. Internal surface for valve chambers shall be coated with two coats of epoxy.
5. The Contractor shall submit details of insulation material and thickness of coatings and
type of coating as per the manufacturer.
6. A.6 The covers frame shall be set solidly in mortar and fix firmly using fixing bolts. The
Contractor shall position the cover centrally over the opening and level and square with
surrounding finishes and set cover in position to prevent twisting.
4.7 RECORDS
The Contractor shall maintain accurate records details for whole project components and show details for
the following works. These records should be submitted in both hardcopy and digital forms, three copies
for each form. Digital data and drawings should be prepared in compliance with geographic information
system (GIS) and digital mapping in the directorate (if any):
A As-Built House Connection Plan
This record showing the sketch of the particular section indicating the mainline and the house connection.
Listed below is the information required for this record.
- Mainline number
- Mainline section number
- Length of mainline pipe

- Mainline pipe diameter and type of pipe
- Insert level of the mainline at the connection location
- Connection number & position
- Type of connection
- House connection pipe diameter
- Distance from centerline of mainline to the building
- Invert of end lateral at the building
- A column of remarks must be provided for future up-dating of house connections
B Mainline Records
There are three (3) important records to be maintained from constructed mainlines, these are the general
layout and benchmark, site plan and the line profiles. Description of these records are as follows.
1. For General Layout & Benchmark
This drawing must be prepared in A-0 size drafting film covering the whole area of work executed by the
contractor with an “appropriate” scale that will accommodate on drawing sheet. Required information is as
follows:
- Line numbers
- Valve chambers and fire hydrants numbers
- Name of street
- Name of important landmark in the area (i.e mosque, school, garden, hospital, clinic, shopping
mall, government offices, etc…)
- Location of bench marks with their designated numbers and elevations
- A separate table is to be allocated describing the complete bench marks used in the project.
2. For Site Plans
This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 showing in segments for the
entire area of work executed by the Contractor. Required information is as follows.
- Line numbers
- Numbers of valve chambers, fire hydrants and other network accessories
- Coordinates for each and every intersection, valve chamber and fire hydrant
- Lateral distance location for each and every chamber (i.e. distance from center of chamber to
property wall or sidewalk curb stone or street light post or fire hydrant traffic light post or any
favourable base of measurement)
- Name of street

- Name of important landmark in the area (i.e., mosque, school, garden, hospital, clinic, shopping
mall, government offices, etc…)
3. For Line Profiles
This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 horizontal and 1:100 vertical
for the entire mainlines constructed in the whole area of work by the Contractor. Required information is as
follows:
- Line number
- Surface condition
- Ground level
- Invert level
- Depth-to-invert
- Distance
- Chainage
- Pipe data (pipe diameter & type of pipe, slope and bedding)
- Rock levels
- Underground utilities crossing either below or over the mainline pipes

- Type of utility
- Description
- Top elevation
PART 5 CONCRETE WORKS
5.1 CONCRETE AND CONCRETE MIXES AND TESTING
5.1.1 GENERAL
A Scope
1. These Works shall consist of the Specifications for concrete materials including sampling,
testing and storage of such materials, concrete strength requirements, concrete testing
procedures and requirements, and job mixes.
5.1.2 MATERIALS
A Cement
1. Cement shall be Portland Cement, originating from manufacturers approved by the

Engineer and shall comply with ASTMC 150:97a and BS 12 or AASHTO M85 Type I in the
case of Ordinary Portland Cement and with BS 4027 or AASHTO M85 Type II or Type V
as directed by the Engineer in the case of Sulphate Resisting Portland Cement.
2. Only one type or brand of cement shall be used in any one structural member. Mixing of
types or brands will not be permitted.
3. All cement shall be subject to approval and shipments of cement shall be accompanied by
a manufacturer's Certificate of Guarantee and/or laboratory test certificate. Approval of
any cement sample shall not relieve the Contractor of the responsibility to fabricate

concrete of the specified strength.
4. When tests at the factory or field tests subsequent to the original approval tests show that
the cement does not comply with the specifications, the entire consignment from which the
sample was taken shall be rejected and the Contractor shall immediately remove the
rejected material from the Site and replace it with cement which meets the required
specifications.
5. Whenever low alkali cement is specified the total alkali content estimated as sodium oxide
equivalent, shall not exceed 0.60% by weight. Approval of any cement sample shall not
relieve the Contractor of the responsibility to fabricate concrete of the specified quality and
strength.
6. If no local test certificate is available, the Contractor shall obtain from each proposed
manufacturer a typical sample of cement which shall be fully and independently tested in
accordance with the appropriate standard and the results submitted for approval. Primary
and secondary sources of the required cements shall be given. All costs associated with
the testing shall be allowed for by the Contractor. All costs associated with the testing shall
be allowed for by the Contractor.
7. Details shall also be submitted of the manufacturer's name and address of producing
works, manufacturer's description of cement type and brand name and standards to which
compliance is guaranteed.
8. Average values and corresponding maximum and minimum values in respect of the
following composition and properties shall be submitted, covering a continuous production
period of at least 6 months ending not earlier than 3 months before submission of the data.
The Contractor shall state if any material or production process changes have been made
since the end of the above period; if any are proposed, brief details shall be given.
Composition Properties
nsoluble residue Lime saturation factor (LSF)

Silica (SiO2) Alumina-iron ratio (A/F)
Alumina (Al2O3) Tri-calcium aluminate (Ca3Al)
Total Iron (Fe2O3) Free lime in clinker (as CaO)

Calcium (CaO) Total acid solution alkalis
Magnesium (MgO) Heat of hydration
- at 7 days
- at 28 days
Potassium (K2O)
Sodium (Na2) Fineness (sq.m/kg)
Sulfate (SO3) Setting times
- Initial (min)
- Final (min)
Sulfur (S)
Chloride (Cl) Soundness (mm)
Loss on ignition Compressive strength
- 3 days
- 7 days

- 28 days
- 3 months
9. The requirement of item A.8 may be dispensed with at the discretion of the Engineer, who
shall give such dispensation in writing.
10. The manufacturer's bulk average test certificate for each consignment of cement shall be
submitted, showing the results for chemical composition and physical properties
determined in accordance with the relevant standard. Samples shall be taken for each
consignment of cement and tested as directed by the Engineer in an approved
independent laboratory, at the cost of the Contractor.
11. Where bulk cement deliveries are proposed, the Contractor shall provide all information
required by the Engineer concerning off-site storage and loading arrangements and shall
provide reasonable facilities for the Engineer to inspect these arrangements for approval
purposes. Consignments shall be used in the order in which they are delivered.
12. Storage capacity shall be sufficient to meet the schedule of work so that continuous work
is achieved. Cement shall be stored in moisture-proof storage sheds. Neither stale,
caked, nor reclaimed or re-sacked cement shall be used. The Contractor shall not store
cement in areas subject to flooding.
13. Cement remaining in bulk storage at the mill, prior to shipment, for more than 6 months or
cement stored in bags in local storage by the Contractor or a vendor for more than 3
months after shipment from the mill, must not be used for concrete works.
B Aggregates
1. Potential aggregate sources shall be examined and particular attention shall be paid to the
following aspects of the deposits and the actual or proposed extraction and production
arrangements:
 Name, location, local national grid reference, type of deposit, potential variability, methods of
extraction.
 Methods and degree of control exercised over extraction.
 Processing methods, types of plant, number of processing stages, standards of maintenance and
process control, producer's laboratory facilities and technical staffing.
 Stockpiling arrangements, loading and supply arrangements.
 Potential variations in end-products due to variations inherent in the deposit and in the existing
methods of extraction, processing and stockpiling.
 Possible modifications to existing extraction, processing, storage and handling arrangements, and
to supervision arrangements to reduce end-product variations.
 Possible requirements for supplementary processing on site.
 Photographs shall be provided of each of the proposed new sources and related production
arrangements. The source photographs should preferably include low level (helicopter) aerial
photographs and close-ups of working faces.
2. Aggregate deposits shall be sampled and tested in an appropriate and systematic manner
to assess their potential variability and to assist in determining appropriate methods of
extraction and processing.
3. The deposit investigation and sampling programs shall be relevant to each type of deposit

and shall be devised and supervised by an experienced approved engineering geologist,
after he has made a field reconnaissance of the potential deposit areas, or the existing
workings.
4. Each size of aggregate shall be sampled at the discharge points on the production plant
(i.e., conveyors or hoppers, not stockpiles) at three well-spaced intervals during the course
of each of three consecutive production days; these samples shall be designated
"production samples".
5. In addition, selected samples shall be taken from producer's stockpiles to represent any
readily visible variations in physical characteristics, or appearance, or materials ready for
loading, these samples shall be designated "stockpile samples".
6. All samples shall be taken by arrangement with and in the presence of the Engineer, or his
representative, and shall be tested as required below.
7. Representative portions of the above samples shall be taken for reference purposes and
shall be split and retained on site by the Contractor and by the Engineer.
C Testing Aggregates
1. Each production sample shall be tested for the following:
 Proportion of natural (uncrushed) material (% by weight) gradings, passing 75mm sieve (U.S.
Sieve No.200 to AASHTO M92 or ASTM M81) when tested in accordance to AASHTO T 11.
 Total acid soluble chloride content and total acid soluble sulfate content (% by weight).
 Flakiness and elongation indices.
2. Representative portions of equal weight shall be taken from each of the production
samples of each size of aggregate and then combined to provide composite production
samples for each size of aggregate. The composite samples shall be tested as for the
individual unless otherwise directed by the Engineer. The tests shall be as follows:
 Potential Reactivity tests for alkali-silicate and alkali-carbonate reactions: petrographic examination
in accordance with ASTM C295, rapid chemical method in accordance with ASTM C289 and rock
expansion test in accordance with ASTM C586.
 If one or more of the tests referred to above are positive, then the mortar prism test in accordance
with ASTM C227 shall be carried out.
 Partial chemical analysis, including insoluble residue (ASTM D3042-84), chloride content, sulfate
content and calculated approximate composition.
 ASTM Soundness Test C88, using sodium sulfate solution or ASTM Soundness Test C88, using
magnesium sulfate solution.
 Aggregate Impact Value by the Los Angeles test in accordance with AASHTO T96-83 ASTM
C131-81, ASTM C535-81.
 10% Fine Value to BS 812.
 Aggregate Abrasion Value to BS 812.
 Specific Gravities and Water Absorption to BS 812 or approved ASTM equivalent.
3. Stockpile samples shall be examined and tested in as many of the above-mentioned

respects as are considered relevant by the Engineer.

4. The properties of the aggregates shall be such that the Drying Shrinkage of concrete
prepared and tested in an approved laboratory in accordance with the United Kingdom
Building Research Station Digest No. 35 (Second Series) shall not exceed 0.045 percent.
The Initial Drying Shrinkage of all the proposed concrete mixes prepared and tested in an
approved laboratory in accordance with BS 1881 shall not exceed 0.06 percent.
5. Aggregate for use in concrete or mortar that will be subject to wetting, extended exposure
to humid atmosphere, or contact with moist ground, shall not contain material that is
deleteriously reactive with the alkalis in the cement, or any which may be additionally
present in the aggregates and mixing water or water in contact with the concrete or mortar,
in amounts sufficient to cause excessive localized or general expansion of concrete or
mortar. The following shall be observed:
 Under no circumstances shall the Contractor use Dacite, Andesite, Rhyolites, Opal Cherts and
Tuffs.
 Coarse and fine aggregates shall be tested for reactivity potential in accordance with the methods
listed above and shall satisfy the various criteria given for innocuous aggregates in the relevant
standard.
 In case the aggregate source has no previous records and no performance history, potential
reactivity should be evaluated using the specified tests. However, if the aggregate has been used
in previous works in adjacent location and performed well without showing signs of Alkali reaction,
the results of these tests should not be used as the only factor deciding the usage of the
aggregate. The Engineer shall then decide on this matter.
 The period of the tests is minimum 14 weeks to 26 weeks unless the accelerated test is used
instead of the mortar bar test (ASTM C227).
D Fine Aggregates
1. Fine concrete aggregates shall conform to AASHTO M6 and shall consist of natural sand
or crushed rock having hard and durable particles or, if approved by the Engineer, other
inert materials having similar characteristics, 100% passing 9.5 mm sieve and 2% to 10%
passing 0.15 mm sieve. It shall not contain harmful materials such as iron pyrites, coal,
mica, shale or similar laminated materials such as flat and elongated particles or any
materials which may attack the reinforcement in such a form or in sufficient quantity as to
adversely affect the strength, durability and texture of the concrete.
2. The Contractor shall, when directed by the Engineer, wash the fine aggregates to remove
deleterious substances or for consistency of concrete colour. Such washing shall be
carried out using fresh water. The water shall be replaced regularly as deemed necessary
to maintain its chloride and/or sulfate content low.
3. The total acid soluble sulfate content (BS 812: Part 118) of fine aggregate, expressed as
sulphur trioxide (SO3), shall not exceed 0.40% by dry weight (AASHTO T260-82, BS812:
Part 117). The total acid soluble chloride content, expressed as sodium chloride (NaCl),
shall not exceed 0.10% by dry weight of fine aggregate. The following additional
requirements shall apply to the concrete mix:
 Total sulfate content (as SO3) of any mix, excluding that present in the cement but including any
present in the other materials, shall not exceed 2.5% by weight of cement in the mix.
 Total chloride content (as NaCl) of any mix, including any chloride present in the other materials
and in the mix water, shall not exceed 0.35% by weight of cement in the mix.
4. Fine aggregate shall meet the following additional requirements:

 Fineness modulus, AASHTO M6: +0.20% of approved value which shall be not greater than 3.1 or
less than 2.3. Sieve analysis to AASHTO T27.
 Sodium or Magnesium Sulfate Soundness AASHTO T104: max 12%, 18% loss respectively.
 Content of Clay Lumps and Friable Particles, AASHTO T112-82: 3% max.
 Sand Equivalent AASHTO T176: min 75%.
 Coal and Lignite, AASHTO T113-82: 0.5% Max.
 Organic Impurities AASHTO T21-81: darker than standard colour.

5. The amount of hollow shells likely to form voids and present in material retained on a 2.36
mm sieve determined by direct visual separation, shall not exceed 3% by weight of the
entire sample.
6. When sampled and tested in accordance with the appropriate sections of BS 812 (using
BS 812 test sieves) the grading of fine aggregates shall be within the limits of the grading
zones given in Table 4 of BS 882. The fine aggregate shall be described as a fine
aggregate of the grading zone into which it falls.
7. If the fineness modulus varies by more than 0.2 from the value assumed in the concrete
mix design, the use of such fine aggregate shall be discontinued until suitable adjustments
can be made in the mix proportions to compensate for the difference in gradation.
E Coarse Aggregates
1. Coarse concrete aggregates shall conform to AASHTO M80 and shall consist of gravel,
crushed gravel, or crushed stone free from coating of clay or other deleterious substances.
It shall not contain harmful or any other materials which may attack the reinforcement in
such a form or in sufficient quantity as to adversely affect the strength and durability of the
concrete. If necessary, coarse aggregate shall be washed to remove deleterious
substances, or for consistency of concrete colour.
2. The total acid soluble sulfate content (BS812: Part 118) of coarse aggregate expressed as
sulphur trioxide (SO3), shall not exceed 0.40% by weight (AASHTO T260-82, BS812: Part
117). The total acid soluble chloride contents of coarse aggregates, expressed as sodium
chloride (NaCl), shall not exceed 0.05% by weight. These limits are subject to the
following overriding requirements:
 The total sulfate content (as SO3) of any mix, excluding that present in the cement but including
any present in the other materials, shall not exceed 2.5% by weight of cement in the mix.
 The total chloride content (as NaCl) of any mix, including any chloride present in the other
materials and the mix water, shall not exceed 0.35% by weight of cement in the mix.
3. Coarse aggregate shall also meet the following additional requirements:
 Sodium or Magnesium Sulfate Soundness AASHTO T104: 5 cycles: Max 12%, 18% loss
respectively.
 Abrasion, in Accordance with AASHTO T96 Max 40% loss.
 Content of Clay Lumps and Friable Particles AASHTO T112-81: Max 1% by weight.
 Soft Fragments and Shale AASHTO M80: max 5% by weight.
 Flakiness Index, BS812: 30% max. Elongation index, BS 812:30% max.

 Coal and Lignite, AASHTO T113-82: 0.5% max.
4. The grading of coarse aggregate shall comply with AASHTO M43.

5. The coarse concrete aggregate, when tested according to AASHTO T27, shall meet the
following gradation requirements and shall be graded within the limits stated in Table
5.1.1.
Table 5.1.1: Limits of Gradation for Coarse Aggregates

Sieve mm Grading Grading Grading III Grading Grading Grading

Size I II IV V VI
3' 75 100 - - - - -
2 1/2" 63 - 100 - - - -
2" 50 90-95 95-100 100 - - -
1 1/2" 37.50 - - 95-100 100 - -
1" 25.0 30-65 35-70 - 95-100 100 -
3/4" 19.0 - - 35-70 - 95-100 100
1/2" 12.5 10-30 10-30 - 25-60 - 90-100
3/8" 9.5 - - 10-30 - 20-55 40-70
No. 4 4.75 0-5 0-5 0-5 0-10 0-10 0-15
No. 8 2.36 - - - 0-5 0-5 0-5
No. 200 0.075 0-1 0-1 0-1 0-1 0-1 0-1
6. The type of grading for coarse concrete aggregates shall depend on the maximum size of
aggregate, which shall not be larger than one-fifth (1/5) of the narrowest dimension
between sides of forms, nor larger than two-thirds (2/3) of the minimum clear spacing
between reinforcing bars, whichever is least.
7. Before batching, all types of coarse aggregate shall be separated into fractions having
uniform grading as determined by the Engineer.
8. However, the number of fractions and their gradings shall be fixed on the basis of the
maximum size of the aggregates in the cement concrete as proposed below
 For fractions up to 1-1/4": between 3/8" and 3/4"
(31.5 mm) (9.5 - 19.0 mm).
 For fractions up 1-1/2" to 3": between 3/4" and 1-1/4"
(37.5-75 mm) (19.0 - 31.5 mm)
F Combined Aggregates
1. Combined aggregate is composed of a mixture of coarse aggregates and fine aggregates.

They shall be used only in proportions with the prior approval of the Engineer.
2. In no case shall materials passing the No. 200 (0.075 mm) sieve exceed 3% by weight of
the combined aggregate.
3. The combined concrete aggregate gradation used in the work shall be as specified, except
that when approved or directed by the Engineer. Grading 7 of Table 5.1.2 shall be used
for curbs, handrails, parapets, posts and other similar sections or members with
reinforcement spacing too close to permit proper placement and consolidation of the
concrete.
4. Changes from one gradation to another shall not be made during the progress of work,
unless approved by the Engineer.
5. For the proportion of each fraction of coarse aggregate and for the proportion of fine and

coarse aggregate, the combined gradings in Table 5.1.2 shall be utilized as a guideline for
the mix proportion design as to guarantee the maximum densities of the concrete. Before
batching, however, the Engineer or his representative shall check only the compliance of
the grading of the fine and coarse aggregate with the requirements of the Specifications,
since the grading of each fraction ultimately remains the sole responsibility of the
Contractor.
Table 5.1.2: Limits of Gradation for Combined Aggregates

Sieve mm Grading Grading Grading Grading Grading Grading Grading
Size 1 2 3 4 5 6 7
3" 75 100 - - - - - -
2 1/2" 63 88-95 100 - - - - -
2" 50 78-90 88-95 100 100 - - -
1 1/2" 37.50 66-81 74-86 80-92 93-98 100 - -
1" 25.0 51-70 56-75 63-80 70-88 87-96 100 -
3/4" 19.0 43-62 47-67 52-72 60-79 73-86 80-96 100
1/2" 12.5 32-53 36-58 41-60 47-66 57-74 61-80 73-86
3/8" 9.5 27-48 30-53 36-54 40-60 48-68 52-72 61-79
No. 4 4.75 19-38 22-42 23-43 28-49 34-55 38-56 43-64
No. 8 2.36 9-27 10-29 12-30 16-36 24-40 25-41 26-46
No. 16 1.18 4-19 5-21 6-22 7-25 9-28 11-29 13-33
No. 30 0.600 3-15 4-17 4-19 5-21 7-23 8-24 10-28
No. 50 0.300 2-11 2-13 2-14 2-15 4-17 5-19 5-21
No.100 0.150 1-7 1-8 1-8 1-9 2-10 2-11 2-12
No.200 0.075 0-3 0-3 0-3 0-3 0-3 0-3 0-3
G On Site Storage of Aggregates
1. Adequate stocks of tested and approved aggregates shall be maintained on site and the
capacity of the storage bins for each type and grading of aggregate shall be sufficient to
hold the respective quantities required for the maximum amount of concrete which the
Contractor is obliged or intends to pour in any continuous operation in one day. Stockpiles
shall be built in layers of 1.50 m maximum height and segregation of the aggregates
prevented. Different grades of aggregates shall be totally separated by concrete block
walls.
Dense concrete or bituminous slabs shall be laid with sufficient falls to cover all aggregate
stockpile areas or bins and shall extend to cover all surrounding areas where aggregates
are likely to be discharged or handled. These areas shall be swept and kept clean at all
times to ensure that the aggregates are not contaminated by the adjacent ground through
trafficking or otherwise and shall be constructed with adequate drainage for surplus water.
2. Windbreaks shall be provided where aggregates might suffer excessive contamination by
windblown materials. During periods of heavy rain the bins or compounds shall be
covered by tarpaulins or other approved means.
H Rejection of Aggregates
1. The general or localized build-up of fines in aggregate stockpiles shall not be allowed and
any material which, in the opinion of the Engineer, is so affected will be rejected after
testing.
2. Aggregates which have suffered segregation or contamination during processing, handling
at source, transportation to the site, stockpiling and handling on site, or which otherwise do
not conform with requirements of the Specifications, either locally or generally, will be
rejected and shall be removed promptly from the site.
3. H.3 Aggregates which are found to be contaminated during transportation or during
stockpiling or during handling shall be promptly removed from the site by the Contractor
notwithstanding any prior approval of the source which may have been given by the

Engineer.
I Washing and Processing Aggregate
1. The Contractor may be required to carry out on site supplementary processing or effective
washing of coarse and fine aggregates where the aggregate producer's methods, in the
opinion of the Engineer, may not result in end products which consistently comply with all
requirements of the Specifications, or where aggregates suffer unacceptable changes
during loading at source or during subsequent transportation to the site, or otherwise.
J Water
1. All sources of water to be used with cement whether for mixing or curing of concrete, or
compaction of backfill around the concrete structures, shall be approved by the Engineer.
If at any time during construction, water from an approved source becomes unsatisfactory,
the Contractor shall provide satisfactory water from other mains sources.
2. Water shall be free from injurious quantities of oil, alkali, vegetable matter and salt as
determined by the Engineer. The water shall be reasonably clear and shall contain not
more than one quarter (0.25) percent solids by weight. Water shall comply with the
requirements of AASHTO T26 and BS 3148. If the specific conductance is less than 1500
microohms per centimetre the total solids content requirement may be waived.
3. Non-potable water may be used when potable water is not available provided the
impurities do not exceed the values given in Table 5.1.3.
4. Mortar prepared with water submitted by the Contractor for approval shall show no marked
change in time of set, no indication of unsoundness and a reduction of not more than ten
(10) percent in mortar strength when compared with mortar made with water of known
satisfactory quality.
5. The water used in the mix design shall be the same as the water approved for site use.
6. Water used for prestressed concrete structures or for concrete containing or in contact
with aluminium fittings or fixtures shall not contain chloride ions.
Table 5.1.3: Maximum Permitted Impurities in Non-Potable Water

Impurity Max. Concentration Method
(ppm)
Chloride as (Cl-)
a) Prestressed concrete or concrete in 500 ASTM D512
bridge decks
b) Other reinforced concrete in moist 1000
environment or containing aluminium
embodiments or dissimilar metals or
with stay in place galvanized metals
form
Sulfates as SO4 300 ASTM D516
Alkalis as 600 AASHTO T-26
(Na2O+K2O)
Total solid 5000
K Admixtures
1. The quantity and method of using admixtures shall be in accordance with the
manufacturer's recommendations and in all cases shall be subject to the approval of the
Engineer.
2. In all cases the Contractor shall provide the following information for the Engineer's
approval:

 The quantity to be used, in kilograms per kilogram of cement and in kilograms per cubic meter of
concrete.
 The detrimental effects caused by adding a greater or lesser quantity in kilograms per cubic meter
of concrete.
 The chemical name(s) of the main active ingredient(s).
 Whether or not the admixture leads to the entraining of air.
3. The Contractor shall demonstrate the action of an admixture by means of trial mixes.
4. The use of calcium chloride in any form is prohibited.
5. Reference may be made to ACI Committee 212 report "Guide for Use of Admixtures in
Concrete".
L Admixture to Produce High Workability
1. Concrete for use in certain construction shall contain an approved super plasticising agent,
when so directed by the Engineer. The superplasticiser shall be stored and used strictly in
accordance with the manufacturer's instructions and must be fully compatible with all
proposed concrete mix constituents. The optimum dosage of the additive shall be
determined by site and laboratory trials to the Engineer's approval. The Contractor shall
submit to the Engineer full details of his proposed mix design which must ensure that the
minimum strength requirements as specified for the particular use of the concrete are
achieved. Only when the Engineer has approved the proposed mix design may such a
mix be used in full compliance with the Specifications.
2. The Contractor's mixing and transporting plant shall be so designed that accurate metering
of the super plasticising agent is possible and so that the additive may be introduced
immediately before placing.
5.1.3 DEFINITIONS
A Crushing Strength
1. The crushing strength of a test cylinder prepared in accordance with AASHTO T23 and
AASHTO T126. Alternative standard cubes may be tested in accordance to BS
specifications.
B Average Strength
1. The mean of the crushing strengths of specimens taken from a sample of concrete.
C Characteristic Strength
1. The value of the crushing strength below which 5% of the population of all possible
strength measurements of the specified concrete are expected to fall.
D Fresh Concrete
1. Concrete during the initial period of two hours from the addition of water to the cement.
E Batch
1. The quantity of concrete mixed in one cycle of operations of a batch mixer or the quantity
of concrete conveyed ready-mixed in a vehicle, or the quantity discharged during one
minute from a continuous mixer.
F Sample
1. A quantity of concrete taken from a batch whose properties are to be determined.

G Regular Sampling
1. G.1 The sampling of concrete nominally of the same mix received regularly from the
same source.
H Specimen
1. H.1 Cylinder or cube taken from a sample for testing.
5.1.4 CONCRETE STRENGTH REQUIREMENTS
A Design Mixes
1. Mixes for the classes of concrete shown in Table 5.1.4 shall be designed by the
Contractor, when specified for use in any part of the Works. The quantity of water used
shall not exceed that required to produce a concrete with sufficient workability to be placed
and vibrated in the particular locations required. Unless otherwise approved by the
Engineer, the mix designs shall be on the basis of continuously graded aggregates and all
mix designs shall be submitted to the Engineer for approval.
2. The Cement content in any mix shall not exceed 450 kg/cu.m.
3. The 7-day compressive strengths shall not be less than 75% of the specified 28-day
strengths. If the 7 days results are below 75% of the required 28 days strength, the
Contractor may postpone works related to the suspected concrete until the 28 days results
are available and successful, or if the Contractor decides to continue work, he may do so
under his own responsibility and risk.
4. The ultimate cylinder compressive strength of concrete shall be determined on test
specimens obtained and prepared in accordance with AASHTO T23 and AASHTO T126
except that six inch by twelve inch cylinders shall be used for all compression tests.
Alternatively, the Engineer may require ultimate compressive strength of concrete to be
determined on test specimen obtained by taking and airing cubes in accordance with BS
1881. The Contractor shall furnish single-use cylinder moulds conforming to AASHTO
M205, or when approved by the Engineer, re-usable vertical moulds made from heavy
gauge metal.
Table 5.1.4: Concrete Class and Design Mixes

Class of Cylinder Works Equivalent Works Maximum Size of Minimum Cement
Concrete Strength @ 28 Days Cube Strength @ 28 Aggregate Content kg/m3
kg/cm2 Days kg/cm2 mm
110/25 110 140 25 220
140/25 140 180 25 250
170/60 170 210 60 275
210/50 210 260 50 300
210/25 210 260 25 325
210/20 210 260 20 325
250/20 250 310 20 350
250/30 250 310 30 350
310/20 310 385 20 375
360/20 360 450 20 425
B Nominal Concrete Mix
1. Concrete for use as backfilling for structural excavation shall be either no-fines concrete or
cyclopean concrete as directed by the Engineer. The cement: aggregate ratio of such
nominal mixes shall be not greater than 1:15 and the minimum cylinder strength at 28 days
not less than 50kg/cm2.
No-fines concrete shall comply with the grading in Table 5.1.5 and shall be mixed and laid
in general conformity with this Section 5.01.

2. Plums used in cyclopean concrete shall consist of non-reactive broken stone spalls or
boulders ranging in size from 200mm to 300mm. They shall be free from sharp or angular
edges and shall not form more than 30% of the total volume of concrete. They shall be
evenly graded and shall be soaked in water prior to incorporation in the mix. Plums shall
be evenly distributed in the concrete mix with a minimum cover of 100mm.
Table 5.1.5: Grading for No-Fines Concrete

GRADING OF AGGREGATE % by Dry Weight
Sieve Size Passing
90 mm 100
40 mm 85-100
20 mm 0-20
10 mm 0-5
C Compliance with Strength Requirements
1. Cylinders (or cubes) from concrete as mixed for the Work will be tested in accordance with
AASHTO T22 (BS 1881 for cubes) after seven (7) days and twenty-eight (28) days. Test
specimens shall be made and cured in accordance with AASHTO T23. These specimens
will be the basis for acceptance of the concrete in the structure.
2. Prior to the commencement of any concreting work and subsequently, whenever a change
is intended, preliminary tests shall be carried out. From each of three samples of materials,
a trial mix shall be made. For each class of concrete, the trial mixes shall represent at least
two different water cement ratios. From each trial mix, six cylinders (or cubes) shall be
made, three for testing at 7 days, and three for testing at 28 days. The average strength of
the cylinders (or cubes) tested for each sample shall be taken as the preliminary cylinder
(or cube) strength of the mix.
3. The Engineer will require the preliminary test to be repeated if the difference in strength
between the greatest and the least strength is more than 20 per cent of the average.
4. The water /cement ratio and slump adopted in the preliminary tests for each class of
concrete shall be used in the works concrete. It shall be such that, if selected for use at the
Site, the concrete can be worked readily into the corners and angles of the forms and
around the reinforcement without permitting the materials to segregate, or free water to
collect on the surface.
5. Preliminary tests shall have these minimum ultimate strengths given in Table 5.1.6.
6. During the first four days of the commencement of concreting with any particular mix, two
sets of six works cylinders (or cubes) in each set shall be made each day. Three cylinders
(or cubes) from each set shall be tested at 7 days, and 3 at 28 days. The above works
tests shall be carried out for each class of concrete. Subsequently, the frequency of
making sets of test cylinders (or cubes) and the number in each shall be as directed by the
Engineer.
Table 5.1.6: Preliminary Tests for Strength

Class of Concrete Cylinder Strength (kg/cm2) Equivalent Cube Strength
(kg/cm2)
110/25 170 210
140/25 210 260
170/60 240 300
210/50 290 360
210/25 290 360
210/20 290 360
250/20 325 400
250/30 325 400
310/20 395 490
360/20 440 550
7. The cylinders (or cubes) shall be cured in the same manner and environment as the

members they represent. The cylinder (or cube) strength shall be accepted as complying
with the specified requirement for work cylinder (or cube) strength if none of the
compressive strengths of the cylinders (or cubes) falls below the minimum strengths given
in Table 5.1.4 or if the average strength is not less than the specified minimum works
cylinder (or cube) strength and the difference between the greatest and least cylinder (or
cube) strength is not more than 20 per cent of the average.
8. Alternatively, the criterion of acceptable test results shall be that not more than 5 per cent
of works cylinders fall below the specified strength. For this to be fulfilled, the mean
strengths of works cylinders (or cubes) less 1.64 times the standard deviation should not
be less than the required strength. This calculation shall be made for both 7- and 28-day
cylinder (or cube) tests as soon as 24 cylinders (or cubes) have been tested at each age.
Thereafter, it shall be repeated as further test results become available at a frequency
determined by the Engineer. The number of cylinders (or cubes) considered in each
calculation shall be the total number of cylinders (or cubes) of the mix in question tested
from the commencement of the Works.
Cores shall be taken in accordance with ACI 318-95, article 5.6.4, and tested in
accordance with AASHTO T24. Load testing shall be carried out in accordance with ACI
318-89, chapter 20. The Contractor shall hire an authorized independent laboratory to
carry out such tests at no extra cost to the Client.
9. The Engineer may make additional test cylinders to ascertain the effectiveness of the
methods by which the structure is being cured, and also to determine when the structure
may be placed in service. These cylinders shall be cured in the field in the same manner
as the concrete placed in the structure, and the Contractor shall protect the cylinders from
all damage.
10. The Contractor shall take every precaution to prevent injury to the test cylinders during
handling, transporting and sorting. He will be held solely responsible for any test failure
caused by improper handling and transportation, or any other cause which may be
detrimental to the test cylinder.
11. In order that the test cylinders may be transported from field to laboratory undamaged, the
Contractor shall provide a minimum of two (2) approved boxes. [One (1) for the
Contractor's use and one (1) for the Engineer's use.] Boxes shall be of such size to receive
a minimum of six (6) test cylinders and leave space for sawdust packing around all
surfaces of the cylinders. Boxes shall be approved by the Engineer. The Contractor shall,
when directed by the Engineer, provide as many additional boxes as may be required by
the remoteness and/or magnitude of the concrete work.
12. When test cylinders fail to meet minimum strength requirements, the Engineer may require
core samples to be taken to determine the acceptability of such structures. The Contractor
shall, at his own expense, furnish all equipment required for such core samples.
5.1.5 COMPOSITION OF CONCRETE
A Mix Proportions
1. The Contractor shall consult with the Engineer as to mix proportions at least forty-five (45)
days prior to beginning concrete work. The actual mix proportions of cement, aggregates,
and water shall be determined by the Contractor under the supervision of the Engineer.
2. The Contractor shall, in the presence of the Engineer, prepare trial-mixes for each class of
concrete required for the project, made with the approved materials to be used in the
Work. The proportions of the trial-mixes shall be such as to produce a dense mixture
containing the cement content specified and meeting the plasticity requirements and the
preliminary test strength requirements specified for the designated class of concrete.
3. If the materials supplied by the Contractor are of such a nature or are so graded that
proportions based on minimum cement content cannot be used without exceeding the
maximum allowable water content, the use of admixtures to maintain the water content
within the specified limit shall be permitted. At all times the concrete mix shall satisfy the
durability requirements by satisfying the minimum and maximum limits specified of cement

and water contents respectively. No additional payment shall be paid due to adding extra
amount of cement to the mix.
4. The Engineer will review the Contractor's trial - mixes and break the test cylinders at seven
(7) and twenty-eight (28) days. The Engineer will then determine which of the trial-mixes
shall be used. If none of the trial-mixes for a class of concrete meets the specifications, the
Engineer will direct the Contractor to prepare additional trial-mixes. No class of concrete
shall be prepared or placed until its job-mix proportions have been approved by the
Engineer.
5. The approval of the job-mix proportions by the Engineer, or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of the
responsibility of producing concrete which meets the requirements specified in these
specifications.
6. All costs connected with the preparation of trial-mixes and the design of the job-mixes shall
be borne by the Contractor, except that the Engineer shall not charge the Contractor for
laboratory supervision and the breaking of the test cylinders.
B Design Limits
1. The following will be designated by the Engineer within the limits of the specifications:
 The minimum cement content in sacks per cubic meter of concrete.
 The maximum allowable water content in litres per sack of cement, or equivalent units, including
surface moisture, but excluding water absorbed by the aggregates.
 The ratio of coarse and fine aggregates.
 Slump or slumps designated at the point of delivery.
C Changes to Mix Design
1. Changes in mix proportions requested by the Contractor to previously approved mix

designs shall only be made after new approval by the Engineer.
2. When, in the opinion of the Engineer, cement is being lost due to windy conditions, the
Contractor shall add additional amounts of cement as directed by the Engineer. No
additional payment will be made for the added cement.
As the work progresses, the Engineer reserves the right to require the Contractor to
change the proportions from time to time if conditions warrant such changes to produce
satisfactory results. Any such change may be made within the limits of the specifications
at no additional compensation to the Contractor.
3. When in the opinion of the Engineer, an adjustment for protection against concrete
deterioration due to salty environment is necessary, he may require the cement content be
increased ten (10) per cent over and above that cement content used in the approved trial-
mix design for non-salty environment. Water content shall be adjusted accordingly to
obtain a dense workable mix. All Structure footings and column lengths to the first
construction joint above the ground surface for the entire project are subject to this
increased cement content. No additional payment will be made for the increase in cement
content.
Failure of the mix to meet specifications determined by the Engineer under items A and B
in this sub-section will be grounds for the Engineer to reject the concrete.
4. Mortar for laying stone for grouted stone riprap, grouted stone wash checks or grouted
stone ditch lining shall be composed of one (1) part of portland cement and three (3) parts
of fine aggregate by volume with water added to make a workable mix of such consistency
as to perform properly the functions required for the work being done. Amount of water
added shall be approved by the Engineer. The following criteria shall be observed:

 Aggregates for masonry mortar shall conform to AASHTO M45.
 Portland cement shall conform to AASHTO M85, Type I, II or III.
5.1.6 REQUIREMENTS FOR COMBINING MATERIALS
A Measurement for Proportioning Materials

1. The cement shall be measured in bulk or as packed by the manufacturer; a sack of
cement shall weigh 50 kilograms. Measurement shall be accurate to within 3.0 per cent
throughout the range of use.
2. The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within 2.0 percent throughout the range of use.
The aggregates shall be measured by weight. The measurement shall be accurate to
within (+ or - 2.0% fine, coarse aggregates) throughout the range of use.
3. Additives shall be measured by volume if in liquid form and by weights if solid. The
measurement shall be accurate to within 3.0 per cent throughout the range of use.
B Assembly and Handling of Materials
1. Aggregates shall be assembled in such quantities that sufficient material approved by the
Engineer is available to complete any continuous pour necessary for structures. The
batching site shall be of adequate size to permit the stockpiling of sufficient unsegregated
materials having proper and uniform moisture content to ensure continuous and uniform
operation. Aggregates shall enter the mixer in a manner approved by the Engineer and so
as to ensure that no matter foreign to the concrete or matter capable of changing the
desired proportions is included. In the event that 2 or more sizes or types of coarse or fine
aggregates are used on the same project, only 1 size or type of each aggregate may be
used on one continuous pour.
2. All aggregates shall be stockpiled before use in order to prevent segregation of material, to
ensure a uniform moisture content, to provide uniform conditions for proportioning plant
control and to aid in obtaining concrete that is uniform as to materials and moisture
content. The use of equipment or methods of handling aggregates which results in the
degradation of the aggregates is strictly prohibited. Bulldozers with metal tracks shall not
be used on coarse aggregate stockpiles. All equipment used for handling aggregates shall
be approved by the Engineer. Stockpiling of aggregates shall be in the manner approved
by the Engineer, and in addition, every precaution shall be taken to prevent segregation.
Segregation shall be prevented by making no layer higher than 1.5 meters and if 2 or more
layers are required, each successive layer shall not be allowed to "cone" down over the
next lower layer. Aggregates shall not be stockpiled against the supports of proportioning
hoppers and weighing devices.
3. Segregated aggregates shall not be used until they have been thoroughly remixed and the
resultant pile is of uniform and acceptable gradation at any point from which a
representative sample is taken. The Contractor shall remix aggregate piles when ordered
by the Engineer.
4. If aggregates are to be transported from a central proportioning plant to the mixer in batch-
boxes or dump trucks, such equipment shall be of sufficient capacity to carry the full
volume of materials for each batch of concrete. Partitions separating batches shall be
approved by the Engineer and shall be adequate and effective to prevent spilling from one
compartment to another while in transit or being dumped.
5. Cement may be stored in bulk (unpacked) or in bags in securely locked dry places. The
following shall apply:

 All cement bags shall be marked with the date of manufacture. Additionally, all bags shall be
marked with the date of storage so that they can be taken out for use in the same order as they
were brought in to storage.
 Cement bags shall be placed on wooden shelves at least 100 mm above ground and 150 mm
clear of walls.
 Unpacked cement shall not be used six months after manufacture and bagged cement three
months after manufacture.
 No cement shall be used which has been affected by humidity, regardless of the date of
manufacture.
 Cement shall be transported to the mixer in the original sacks. Each batch shall contain the full
amount of cement for the batch. Batches where cement is placed in contact with the aggregates
may be rejected unless mixed within 1.5 hours.
C Mixing
1. Concrete shall be mixed in quantities required for immediate use. Concrete which has
developed initial set shall not be used. Retempering concrete by adding water or by other
means will not be permitted. Concrete that is not within the specified slump limits at the
time of placement shall not be used and shall be disposed of as directed by the Engineer.
2. If washed sand is used while still wet the mixing time starts with the addition of cement to
the aggregate, even if the water required for the mixing has not been added.
3. The concrete may be mixed at the site of the Works, in a central-mix plant, or in truck
mixers. The mixer shall be of an approved type and capacity. Ready-mixed concrete shall
be mixed and delivered in accordance with the requirements of Sub-Section 5.01.7
"Ready-Mixed Concrete and Central-Mixed Concrete".
4. The coarse aggregate shall first be loaded into the mixer followed by the fine aggregate.
Some mix water shall be added to the mix before the cement is loaded into the mixer.
Water shall be continually added throughout the mixing. Additives, if required and
approved by the Engineer, shall be added according to the manufacturers' instructions.
Retarders shall be added within one minute or 25% of the total mixing time whichever is
the smaller.
5. The manufacturers' instructions shall be followed in respect of overloading the mixer and
the selections of the rate of revolutions of the mixer.
6. To avoid segregation in the fresh concrete, the free drop height on emptying the mixer
shall be not greater than 1.5 meters.
7. After mixing, the concrete shall be homogeneous and comply with the provisions of these
specifications. The Engineer may, if the mix fails to produce concrete of the required
strength vary the mix time.
D Central Mixing
1. Means provided for storing cement shall be as approved by the Engineer. The Contractor
shall clean all conveyors, bins and hoppers of unapproved cement before starting to
manufacture concrete for the Works.
Coarse and fine aggregate to be used in concrete shall be kept in stockpiles and bins
apart from aggregate used in other work. Aggregate shall come from a source approved
by the Engineer. The Contractor shall clean all conveyors, bins and hoppers of
unapproved aggregate before starting to manufacture concrete for the Works.
2. The Contractor shall be responsible for producing concrete that is homogeneous and
complies with the provisions of these specifications.

3. Mixed concrete from the central-mixing plant shall be transported in truck mixers, truck
agitators, non-agitating trucks having special bodies or other approved containers.
4. The time elapsing from the time water is added to the mix until the concrete is deposited in
place shall be not greater than:
 For concrete produced on site and transported by means other than transit mixers or agitated
trucks.
 Thirty minutes when air temperature is 25°C or higher.
 Forty minutes when air temperature is 18°C or below.
 Interpolated time between 18°C and 25°C.
 For concrete transported by transit mixer or agitators, the time taken for 300 revolutions of the
transit mixer or agitator or 20 minutes, whichever is the lesser.
 The maximum haul time may be reduced at the Engineer's discretion if the slump changes or there
are signs of the concrete beginning to dry.
5. The Contractor when supplying concrete from a central plant shall have sufficient plant
capacity and transporting equipment to ensure continuous delivery at the rate required.
The rate of delivery of concrete during concreting operations shall be such as to provide
for the proper handling, placing and finishing of the concrete. The method of delivery and
handling the concrete shall be such as will facilitate placing with a minimum of rehandling
and without damage to the structure or the concrete. Methods of delivery and handling for
each site shall be approved, by the Engineer. The Engineer may delay or suspend the
mixing and placing of concrete at any site, for which he considers the Contractor's delivery
equipment inadequate, until such time as the Contractor provides additional approved
delivery equipment.
5.1.7 READY-MIXED CONCRETE AND CENTRAL MIXED CONCRETE
A General
1. "Ready-Mixed Concrete" and "Central-Mixed Concrete" shall consist of a mixture of

cement, water and aggregate, without air entraining or water-reducing admixture. When
air-entraining or water-reducing or any other type of admixture is required it shall be at the
Engineer's discretion. The terms ready-mixed or central-mixed concrete shall include
transit-mixed concrete and will be referred to hereinafter as ready-mixed concrete.
2. Ready-mixed concrete may be used in the construction of all Works, when approved by
the Engineer.
3. Approval of any ready mixed concrete plant will be granted only when an inspection of the
plant indicates that the equipment, the method of storing and handling the materials, the
production procedures, the transportation and rate of delivery of concrete from the plant to
the point of use, all meet the requirements set forth herein.
4. Ready-mixed concrete shall be mixed and delivered to the point of use by means of one of
the following combinations of operations:
 Mixed completely in a stationary central mixing plant and the mixed concrete transported to the
point of use in a truck mixer or tank agitator operating at agitator speed, or when approved by the
Engineer, in non-agitating equipment (known as "central-mixed concrete").
 Mixed completely in a truck mixer at the batching plant or while in transit (known as transit-mixed
concrete).

 Mixed completely in a truck mixer at the point of use following the addition of mixing water (known
as truck-mixed concrete).
5. Permission to use ready-mixed concrete from any previously approved plant may be
rescinded at any time upon failure to comply with the requirements of the Specification.
B Materials
1. All materials used in the manufacture of ready-mixed concrete shall conform to the
requirements of Sub-Section 5.01.2 "Materials".
C Equipment
1. Equipment shall be efficient, well maintained, and shall be of the type and number as
outlined in the Contractor's Program of Work. Transit mixers and agitator trucks shall
comply with the standards specified in ASTM C94. Non-agitating equipment used for
transporting concrete shall be water tight and be equipped with gates that will permit
controlled discharge of concrete and, when required by the Engineer, be fitted with covers
for protection against the weather.
D Supply
1. Where transit mixers are used, the constituent materials shall be mixed dry in the mixer
and water added directly before pour and mixed at the speed and number of turns in
accordance with the manufacturers' recommendations.
2. Where concrete is mixed at a central plant on or off site, the concrete may be supplied to
the pouring area by agitator trucks or transit mixers which rotate at the speed specified by
the manufacturers. Non-agitating trucks may be used if the central plant is on site.
3. Time of haul shall not exceed the maximum stated in sub-item D.5 of subsection 5.01.6 of
the Specification.
E Uniformity Tests
1. Four samples of fresh concrete shall be taken, two after 15% of discharge from the truck
mixer or agitator truck and two after 85% discharge and within 20 minutes. Slump and
compaction factor tests shall be carried out including any other tests specified or required
by the Engineer.
F Samples
1. Samples for strength test shall be taken as specified in Clause C of subsection 5.01.4 of
the Specification.
2. At least six specimens shall be prepared per sample. Three of these shall be tested at 7
days and three at 28 days.
G Control of Delivery
1. Driver of delivery trucks shall be provided with trip tickets, which shall be signed by a
responsible member of the central plant staff, for submission to the Engineer. The ticket
shall contain the following information.
 Name and address of the Central Plant.
 Serial number of the ticket and date.
 Truck number.
 Class and/or strength of concrete.
 Cement content of the mix.
 Loading time.

 Slump
 Any other type of relevant information.
 The Engineer may send his representative to the central plant who may:
 Check the batching and mixing.
 Verify loading time.
 Take a copy of the trip ticket.
2. The Contractor and/or concrete supplier shall afford the Engineer and/or his
representative, without charge, all facilities necessary to take samples, conduct tests and
inspect the central plant to determine whether the concrete is being furnished in
accordance with the Specification.
3. Concrete delivered in outdoor temperatures lower than 5 degrees C, or if the temperature
is expected to drop below 5 degrees C during the curing period, shall arrive at the Works
having a temperature of not less than 10 degrees C nor greater than 32 degrees C.
4. In supplying ready-mixed concrete, the plant shall have sufficient batching and
transporting capacity to ensure continuous delivery at the rate required. The rate of
delivery of concrete during concreting operations shall provide for the proper handling,
placing and finishing of concrete. If the rate of delivery does not provide a continuous
concrete operation, the Engineer may suspend all or parts of further concrete work until
such time as the Contractor provides sufficient additional delivery equipment which, in the
opinion of the Engineer, will provide for a continuous concrete operation.
5.2 CONCRETE HANDLING, PLACING AND CURING
5.2.1 GENERAL
A Scope
1. These operations shall consist of the placing, compacting and curing of concrete for mass
concrete, reinforced concrete and prestressed concrete structures.
5.2.2 MATERIALS
A General
1. All concreting materials shall comply with section 5.01 "Concrete and Concrete Mixes and
Testing" of the Specification.
5.2.3 PLACING
A. General
1. Before preparing and placing any concrete, the Contractor shall submit a work plan to the
Engineer for approval. Besides specifying the characteristics of the concrete to be
employed, this plan shall indicate the time at which placing is to start, the way in which it is
to be performed, and the time at which it is to finish. The Engineer's approval shall be
sought in writing by the Contractor at least 24 hours in advance.
2. The method and sequence of pour, the equipment to be used, the method of compaction
and curing procedure shall be approved by the Engineer, prior to concrete pour.
3. In order to allow proper vibration of the concrete, it shall be placed in horizontal layers
which, at no time shall be thicker than fifty centimeters (after vibration).
4. If the concrete is placed in successive phases, there shall be no separations, or

discontinuity, or difference of appearance between two successive placings. Before each
successive placing is made, the surface of the concrete already in place shall be carefully
roughened, cleaned, washed free of loose particles and dampened.
5. Concrete shall be placed in such a way that it shall be left undisturbed once it is placed (for
example, slabs shall be executed by starting to place the concrete at the side opposite the
one from which the concrete is poured, so that there shall be no risk of it being disturbed
by workers or equipment, or of tools falling in).
6. When concrete is placed for upright reinforced concrete structures, the placing must be
completed (for small structures) or interrupted (for large structures) before the concrete
which has already been placed has started to harden and might, therefore, be disturbed, if
the operation of placing were continued. In such cases placing shall be started again only
after twenty-four hours have passed. This procedure is intended to avoid the risk of the
concrete which has already been placed coming away from the reinforcing bars, because
it is moved or disturbed during setting and the initial phase of hardening.
When the concrete is placed, its temperature shall be nearly the same as that of the
reinforcing bars, in order to avoid poor adhesion due to the different coefficients of thermal
expansion of the two materials. The reinforcing bars shall, therefore, be protected from
the sun (or the cold in winter) or cooled by water jets prior to the placing of the concrete, or
the pouring shall start during the cooler hours of the day and be suspended when the
temperature rises above thirty-three degrees C.
7. The free-drop height of concrete shall be not greater than 1.5m and the method of placing
shall be such as to suit the conditions and prevent segregation.
Placing of concrete shall be continuous between predetermined points such as
construction joints, contraction joints and expansion joints.
8. Concrete shall be placed so as to avoid segregation of the materials and the displacement
of the reinforcement. Concrete shall not be deposited in large quantities at any point in the
forms and then run or worked along the forms, thus causing segregation of the materials.
9. The concrete shall be deposited in the forms in horizontal layers and the work shall be
carried on rapidly and continuously between predetermined planes agreed upon by the
Contractor and the Engineer.
The slopes of chutes, where used, shall be not greater than 1 vertical to 2 horizontal or
smaller than 1 vertical to 3 horizontals. The slope of the chute shall be constant along its
length. The capacity of the chute shall be adequate to deliver the required volume of
concrete at the required rate.
10. Aluminium pipes shall not be used for delivering concrete. The internal diameter of
delivery pipes, if used, shall be not less than 8 times the maximum aggregate size. At the
point of delivery, pipes shall be vertical.
11. Where bucket and hopper are used for delivery of concrete, the discharge opening shall
be not less than 5 times the maximum aggregate size. The sides of hoppers shall be
sloped at not less than 60 degrees to the horizontal.
12. When buggies are used to transport fresh concrete, they shall be run on level tracks which
are securely fixed. The buggies shall be run smoothly without sudden jerks and the
distance shall be not greater than 60 meters.
13. All chutes, buckets and hoppers, buggies and pipes shall be kept clean and free from
coatings of hardened concrete by thorough flushing with water after each run. The water
used for flushing shall be discharged clear of the concrete already in place.
14. The external surface of all concrete shall be thoroughly worked during the placing by
means of tools of an approved type. The working shall be such as to force all coarse
aggregate from the surface and to bring mortar against the forms to produce a smooth
finish, substantially free from water and air pockets, or honeycomb.
15. Concrete shall be deposited in water only with the permission of the Engineer and under
his supervision. The minimum cement content of the class of concrete being deposited in
water shall be increased 10 per cent without further compensation and the slump shall be

approximately 15 centimeters.
16. When depositing in water is allowed, the concrete shall be carefully placed in the space in
which it is to remain in a compact mass, by means of a tremie, bottom-dumping bucket or
other approved means that does not permit the concrete to fall through the water without
adequate protection. The concrete shall not be disturbed after being deposited. No
concrete shall be placed in running water, and forms which are not reasonably watertight
shall not be used for holding concrete deposited under water.
17. When casing is used in drilled shafts, the casing shall be smooth and properly oiled in
accordance with the manufacturers' manual and shall extend sufficiently above the grade
of the finish shaft to provide excess concrete to be placed for the anticipated slump due to
the casing removal. When the casing is to be pulled, the concrete placed in the casing
shall have such a slump and be of such workability that vibrating of the concrete will not be
required.
18. No concrete work shall be stopped or temporarily discontinued within 45 centimeters of the
top of any finished surface unless such work is finished with a coping having a thickness
less than 45 centimeters in which case the joint shall be made at the under edge of the
coping.
Concrete in simple slab spans shall be placed in one continuous operation for each span,
unless otherwise directed on the Drawings or directed by the Engineer.
19. Concrete in in-situ beam and slab construction shall be placed in one continuous
operation, or when so shown on the Drawings or approved by the Engineer, may be
placed in two separate operations, each of which shall be continuous: first, to the top of the
girder stems, and second, to completion. Where a construction joint is permitted between
the girder stem and the roadway slab, shop drawings including complete details of key or
other methods of bonding will be prepared by the Contractor and submitted to the
Engineer for approval. When such a joint is permitted, deck concrete shall not be placed
until the concrete in the girder stem has hardened sufficiently so as not to be damaged by
the concreting operations of the deck pour.
20. Concrete in arch rings shall be placed in such a manner as to load the centering uniformly.
Arch rings shall be divided into section such that each section can be cast for the full
cross-section in one continuous operation. The arrangement of the section and the
sequence of placing shall be as approved by the Engineer and shall be such as to avoid
the creation of initial stress in the reinforcement. The section shall be bonded together by
suitable keys or dowels. When permitted by the Engineer, arch rings may be cast in a
single continuous operation.
21. The method used for transporting concrete batches, materials, or equipment over
previously placed floor slabs or floor units or over units of structures of continuous design
types shall be subject to approval by the Engineer. Trucks, heavy equipment and heavy
concentrations of materials will be prohibited on floor slabs until the concrete has attained
its design strength.
22. ASlumb Limit
Concrete Type Slumb Limit * (mm)
Compacted by vibration 70 - 80
Compacted by rod 100
* If chemical additives are used to enhance the concrete super plasticization, then above limits will
not be valid.
B Pumping
1. The use of pumps will only be allowed after they have been carefully checked and
approved by the Engineer. Only low-pressure piston type pumps, which will work with a

water/cement ratio of not more than sixty-five hundredths (0.65), will be allowed. Using
superplasticisers to facilitate pumping for low water/cement ratios is allowed subject to
Engineer's review and approval.
2. In no case will "bell" or any other type of high-pressure pump be allowed, since they
require too high a water/cement ratio and because the concrete segregates as a result of
the high pressure at which it is expelled, even if filled with a suitable nozzle.
3. The mix design shall be checked for its suitability for pumping and the concrete shall be
tested regularly during pumping for its uniformity and that its properties have not been
altered by pumping. If changes to slump, water-cement ratio, consistency or any other
characteristics occur, corrective measures shall immediately be taken to ensure that
concrete delivered by the pump complies with the requirements of the Specification.
Samples shall be taken at discharge from the mixer/agitator truck, from the pump and at
discharge from the pump.
4. The internal diameter of delivery pipe of the pump shall be not less than 3 times the
maximum aggregate size. The pipes shall not rest on any part of the formwork; they shall
be supported independently and securely and be readily accessible so that sections can
easily be detached to remove any blockage.
5. Before approving the use of a pump, the Engineer shall verify that the Contractor has
sufficiently reinforced the concrete placing team and the equipment for placing and
vibrating the concrete.
6. Pumping will not be permitted from the inside of the foundation forms while concrete is
being placed. If necessary to prevent flooding, a seal of concrete shall be placed through
a closed chute or tremie and allowed to set.
5.2.4 COMPACTING
A General
1. The vibration of the concrete can be considered completed when a thin layer of cement
grout appears on the surface and when no more air bubbles, indicating the presence of
voids within the concrete, appear on the surface. At the same time, there must not be too
much vibration or this will produce segregation.
2. Vibration may be of three types:
o Internal
o External
o Mixed.
3. Vibration of the concrete and operation shall be undertaken in such a way that the proper
and complete vibrations, but avoiding over vibration, is achieved. The guidelines as given
in Standard Practice for Consolidation of Concrete (ACI 309) of Part 2 Concrete Practices
and Inspection, Pavements, of ACI Manual of Concrete Practice (latest edition) issued by
American Concrete Institute (ACI) shall be followed, if not otherwise directed by the
Engineer.
4. Internal vibration shall be executed in all sections which are sufficiently large to permit the
insertion and manipulation of immersion vibrators, previously approved by the Engineer, in
accordance with the following recommended practices:
 The concrete shall be placed in horizontal layers not thicker than fifty centimeters.
 The vibrator shall be inserted vertically into the concrete to its full length such as to reach the
bottom of the freshly placed layer.

 The distance between two successive insertions shall not exceed five times the diameter of the
vibrator itself.
 The vibrator shall not rest on or against either the formwork or the main reinforcing bars.
5. External form vibrators shall be used for external vibration when it is impossible to use
internal vibrators (heavily reinforced thin walls, pipes or other precast, small cross-section
element, etc). The water/cement ratio shall be low (0.4 to 0.45) in order to avoid the
segregation of the concrete and, at the same time, to provide rapid hardening and, in
consequence, the early removal of the formwork and the finished element.
6. Mixed vibration shall be used in the construction of reinforced or prestressed concrete
beams. External wall vibrators shall also be used. These shall be mounted on the outside
of the formwork after this has been suitably reinforced with ribs of U-bars. The mounting
places of the wall vibrators shall be welded to these reinforcements. They must be
symmetrically positioned on each side of the beam and produce a rotary movement within
the concrete during vibration from the bottom towards the top and from the part placed first
towards the part placed last.
7. Only the vibrators in the zone of the formwork with newly placed concrete will be used. As
the casting of the beam advances, the vibrators shall be dismounted and remounted as
necessary.
8. It is absolutely essential, that elastic supports be provided both under the bottom of the
beam and in correspondence with the braces or tie rods of the formwork walls.
9. The network of reinforcing bars and tensioning cables should not move as a result of the
vibration. To prevent this from happening, either special ties (passing through the
formwork walls), or spacers shall be used. It is better, if these last are made of concrete
and are of a size and shape that will ensure that the reinforcing and tensioning cables do
not move.
10. Before starting this kind of work the Contractor shall submit to the Engineer for his
approval a work plan giving the following details:
 The position of the external wall vibrators.
 Their power, frequency and amplitude.
 The number of such wall vibrators that will be utilized at the same time.
 The number and type (frequency and size) of the internal vibrators to be used for the consolidation
of the concrete.
 The position of the spacers, or the number of ties, to be used to ensure that the reinforcing bar
network and the tensioning cables (if any) do not move during vibration.
 The way in which the concrete is to be placed and the length of time this operation is expected to
take.
11. When required, vibrating shall be supplemented by hand spading with suitable tools to
assure proper and adequate compaction.
B Poker Vibrators
1. The type and size of poker vibrators shall suit the pour size, density of reinforcement and
member dimensions. Unless otherwise authorized by the Engineer, the vibrator shall be
selected from Table 5.2.1 below:

Table 5.2.1: Selection of Poker Diameter for Size of Pour
Size of Pour Poker Diameter Speed
(m3/h) (mm) (Vibrations/min)
2–4 20 – 45 9000
5 – 10 50 – 65 9000
10 – 20 60 – 75 7000
20 – 30 80 – 115 7000
30 - 40 140 - 170 6000
2. Poker vibrators shall be inserted into the concrete vertically at regular intervals which shall
be no greater than 0.5m. They shall be inserted quickly and withdrawn slowly. The
withdrawal rate shall be not more than 75mm/sec. A cycle of insertion and withdrawal
shall be between 10 and 30 seconds.
3. Poker vibrators shall be kept clear of formwork and concrete previously cast.
4. Vibrators shall be so manipulated as to work the concrete thoroughly around the
reinforcement and embedded fixtures and into corners and angles of the forms. Vibrators
shall not be used as a means to cause concrete to flow or run into position in lieu of
placing.
5. Compaction shall be sufficient to achieve maximum density without segregation in the
fresh concrete.
6. Standby pokers of the same type shall be provided at all times. The standby shall be not
less than half the number of pokers used for compacting the pour.
7. Vibrating shall only be carried out by professional technicians having experience in this
type of work.
C Other Vibrators
1. Form vibrators, vibrating tables and surface vibrators where required shall first be
approved by the Engineer and they shall conform to the requirements of ACI-309.
2. Where form vibrators are used, the form shall be adequately designed so that the vibration
will not cause joints to leak and dimensions and geometry to alter.
3. Unless otherwise permitted by the Engineer, the use of form vibrators shall be limited to
members whose thickness does not exceed 150 mm.
5.2.5 CURING
A Materials
1. Hessian or burlap shall be clean and free from harmful materials. Their unit weight shall
be not less than 230g/sq.m.
2. The following impermeable membranes may, with the Engineer's approval, be used:
Clear polyethylene film with no holes, tears, scratches and contamination of any type.
Hessian coated with white polyethylene of density not less than 300g/sq.m. The coating may be
on one side only but shall be not less than 0.1mm thick and shall not peel during and after use.
3. Curing compounds shall conform to AASHTO M148 (ASTM-C309).

4. Sand shall be natural sand, free of silt and clay and contaminants which can be harmful to
the concrete.
5. Water shall satisfy the requirements of Section 5.01 of the Specification.
B Method of Curing
1. The method of curing to be used shall be approved by the Engineer. It shall not cause any

undesirable blemishes such as surface discoloration and surface roughness. Curing
compounds shall not be used on construction joints and surfaces that are to receive
waterproofing, paint or membranes.
2. Curing by ponding may be used for horizontal surfaces such as bases, pile caps and
slabs. Large horizontal surface areas shall be separated into ponds not exceeding 5 sq.m.
The ponds shall first be filled between 12 to 24 hours after pour, unless otherwise
authorised by the Engineer, and shall be replenished from time to time so as to maintain
the ponding for the specified curing period. The concrete temperature and the temperature
of the curing water shall be not greater than 10°C.
3. Unless otherwise approved by Engineer, curing by spraying shall commence between 12
and 24 hours after the concrete pour. The concrete shall be maintained damp at all times
during the curing period by periodic light sprays.
4. Members to be cured by wet hessian or wet burlap shall be completely wrapped with the
material which shall be kept moist at all times during the curing period by regular spraying.
Unless otherwise approved by the Engineer, the overlap under normal conditions shall be
not less than one-quarter the width of the hessian or burlap and not less than one-half the
width in windy and/or rainy conditions. Before members are wrapped for curing, they shall
first be evenly moistened. Unless approved by the Engineer, burlaps shall be supplied
only in rolls and burlap bags shall not be used. Secondhand hessian and burlap, if
approved for use, shall be clean without holes and contamination of any kind that can
affect the concrete.
5. Waterproof sheets used for curing shall, unless directed by the Engineer, be spread
immediately after the pour. The sheet shall, unless approved by the Engineer, be clear of
the concrete surface but be arranged in such a manner as to prevent the movement by air
over the concrete surface. Waterproof sheets shall not be used when the air temperature
is 25°C or higher.
6. Curing compounds shall be applied in two applications at a coverage rate of not less than
1 ltr/ 7.4 sq.m. per application or as recommended by manufacturer and the following
criteria shall apply:
 The first coat shall be applied immediately after the removal of the forms and the acceptance of the
concrete finish and after the disappearance of free water on unformed surfaces. If the concrete is
dry or becomes dry, it shall be thoroughly wet with water and curing compound applied just as the
surface film of water disappears. The second application shall be applied after the first application
has set. During curing operations, any unsprayed surfaces shall be kept wet with water. The
curing membrane will not be allowed on areas against which further concrete is to be placed.
 Hand operated spray equipment shall be capable of supplying a constant and uniform pressure to
provide uniform and adequate distribution of the curing membrane at the rates required. The
curing compound shall be thoroughly mixed at all times during usage.
 The curing membrane shall be protected against damage for the entire specified curing period.
Any coating damaged or otherwise disturbed shall be given an additional coating. Should the
curing membrane be continuously subjected to injury, the Engineer may require wet burlap,
polyethylene sheeting, or other approved material to be applied at once.
 No traffic of any kind will be permitted on the curing membrane until the curing period is completed,
unless the Engineer permits the placement of concrete in adjacent sections, in which case the
damaged areas shall be immediately repaired as directed.
7. Steam curing shall be in accordance with ACI 516 and ACI 517.
C Curing Time
1. The minimum curing time shall be the number of days given in Table 5.2.2 unless the

average surface temperature of the concrete during the required number of days falls
below 10°C, in which case the period of curing shall be extended until the maturity of the
concrete reaches the value given in the Table.
2. The minimum curing time given in Table 5.2.2 above shall be compared with the time
required for cylinders (cubes), cured under identical conditions to those which the concrete
is subjected, to attain 70% of the characteristic strength. The greater shall be taken as the
minimum curing time.
D Limitation of Temperature Differentials
1. The Contractor shall limit the development of temperature differentials in concrete after
placing by any means appropriate to the circumstances including the following:
 Limiting concrete temperatures at placing lower than that set out in clause 5.02.6
 Use of low-heat cement, subject to the agreement of the Engineer.
 Insulation of exposed concrete surfaces by insulating blankets. Such blankets shall have a thermal
conductance C value less than 1.0 W/m2oC.
 Leaving formwork in place during the curing period. Steel forms shall be suitably insulated on the
outside.
 Preventing rapid dissipation of heat from surfaces by shielding from wind.
 Shielding concrete surfaces from clear night skies, together with the use of heaters where
appropriate.
2. The Contractor shall ensure that the temperature differentials in a pour do not exceed 20
oC by appropriate design of mix and use of insulation.
3. The Contractor shall take all necessary steps to limit temperature rise such that the
temperature of the concrete shall not, at any stage, exceed 70 oC.
4. Thermocouples shall be used in large concrete pours where the possibility of significant
thermal gain is, in the opinion of the Engineer considered to be likely. The disposition of
the thermocouples shall be agreed with the Engineer.
5.2.6 HOT WEATHER CONCRETING
A Definitions
1. For the purpose of this sub-section of the Specification, Hot Weather is as defined in ACI
305R Chapter 1.
B General
1. The production and delivery of concrete, the placing and curing and the testing and
inspection of concrete shall, in addition to the requirements of the Specification, accord
with the recommendations of ACI 305R.
Table 5.2.2: Normal Curing Periods

Minimum periods of protection for different types of cement
Conditions Under Number of Days (where the Equivalent Maturity (degree hours)
Which Concrete is Average Surface Temperature of Calculated as the age of the Concrete
maturing the Concrete Exceeds 10˚C During in Hours Multiplied by the Number of
the Whole Period) Degrees Celsius by which the Average
Surface Temperature of the Concrete
Exceeds Minus 10˚C

Other * Other * SRPC OPC
or SRPC OPC or
RHPC RHPC
1. Hot weather or 7 4 3 3500 2000 1500
drying winds
2. Conditions not 4 3 2 2000 1500 1000
covered by (1)
NOTE. Other* includes all permitted cements except OPC, RHPC and SRPC.
KEY. OPC = Ordinary Portland cement.
RHPC = Rapid-hardening Portland cement.
SRPC = Sulfate resisting Portland cement.
2. No concreting shall commence when the air temperature is 33°C and rising. The
Contractor shall schedule his operations to place and finish concreting during the hours
that the air temperature will be below 32°C. This should preferably be in the latter part of
the day after the maximum temperature has been reached, and subject to the approval of
the Engineer.
3. If air temperature rises above 33°C in shadow during concrete mixing or pouring, some or
all of the following precautions should be applied and according to the Engineer
recommendations:
 Covering the storing areas of the gravel. The big size gravel may be cooled using water
spays.
 If cement is stored in silos, it should be painted by reflective material. If stored in bags, it should
be stored in aired and covered areas.
 Cooling the water before adding it to the concrete mix.
 Painting the mixers using reflective paint.
 Spray water to the forms before pouring the concrete, in case of precast concrete, it should
be poured in shaded areas.
C Control of Temperature
1. Stockpile of aggregates shall be protected from direct sunlight by suitable covering. If

directed by the Engineer, they shall be regularly sprayed with clean water.
2. Water shall be stored in tanks away from sunlight and insulated by suitable means so as
not to be affected by high air temperature. Water tanks liable to be exposed to sunlight
shall be covered with suitable reflective paint such as white gloss paint.
3. If directed by the Engineer or as a condition for concreting in adverse weather conditions,
sufficient ice shall be added to the mix water to ensure that the temperature of the fresh
concrete shall not exceed 32°C.
4. The temperature of the concrete at the time of placing shall not be permitted to exceed 33
degrees C. Concrete materials shall be stored in a cool shaded position away from the
direct rays of the sun. Aggregates shall be cooled if necessary prior to mixing and water
shall be cooled by means of a proprietary water chilling plant.
5. Additives as recommended in ACI 305R shall be used to improve workability and/or delay
initial setting.
6. Retarding admixtures to facilitate placing and finishing of the concrete shall conform to

AASHTO M194, Type D and used only if approved by the Engineer.
D Mixing and Placing
1. The time available for handling and placing of concrete during periods of high temperature
may be considerably reduced and the Contractor must take appropriate precautions.
Concrete should be protected during transportation by use of damp hessian or similar
means. No additional water may be added at the time of mixing without the approval of
the Engineer, as this may lead to additional shrinkage of the concrete. On no account
shall water be added during transportation or placing of the concrete.
2. Aggregates and cement shall be thoroughly pre-mixed before adding water.
3. Transit mixers, if used, shall be coated with a reflective paint and while waiting to be
discharged, shall be kept out of direct sunlight.
E Concrete Protection
1. Before the concrete can be de-shuttered, the formwork and shutters shall be cooled by
spraying with water.
2. The concrete and the falsework shall be protected against sunlight, if directed by the
Engineer.
3. If curing is by hessian, it shall be coated with a white polyethylene backing.
4. Members exposed to strong winds shall be provided with windbreakers. The windbreakers
shall, if directed by the Engineer, be kept moist by regular spraying.
5.2.7 COLD WEATHER CONCRETING
A Definitions
1. For the purpose of this sub-section of the Specification, Cold Weather is as defined in ACI
306.1, Section 1, Part 1.2.
B General
1. ACI 306.1-90 "Standard Specification for Cold Weather Concreting" applies.

2. The production and delivery of concrete, the placing and curing and the protection
requirement shall be in accordance with the recommendations of ACI 306R-88 "Cold
Weather Concreting".
3. No concreting shall commence when the air temperature is 6°C and falling, unless
authorised by the Engineer.
C Mixing and Placing
1. Aggregates and water, forms, reinforcement etc. shall be free of snow, frost or ice.
2. Aggregates and water may be pre-heated in which case the aggregates and water shall, if
directed by the Engineer, be mixed prior to introducing cement in the mix. The aggregates
shall not be pre-heated to a temperature in excess of 100°C and the water in excess of
60°C with the additional requirement that the temperature of the water and aggregate mix,
before the introduction of cement, shall not exceed 38°C.
3. Water may be pre-heated by boiling and added to aggregates not pre-heated provided the
temperature of the water and aggregate mix, before the introduction of cement, does not
exceed 38°C.
4. The temperature of concrete at the time of discharge shall be between 10 and 27 °C and
for three days after the pour not less than 5°C.
D Protection
1. When directed by the Engineer, members shall be protected against cold winds by suitable

windbreaks.
2. Adequate insulation by way of insulation boards, planks, sheets etc. shall be provided to
maintain the required minimum concrete temperature during the curing period.
3. Protection measures shall be maintained for a period at which the concrete attains a
strength of at least 65% of the characteristic strength.
5.2.8 NIGHT CONCRETING
A Night concreting shall not be carried out unless prior approval of the Engineer, in writing, is
obtained.
B Details of the artificial lighting system shall be submitted in advance of the proposed
concreting for the Engineer's approval. In all cases, at least one stand-by generator shall
be available at all times of the concreting operation.
5.3 STEEL REINFORCEMENT AND FIXING
5.3.1 GENERAL
A Scope
1. These works shall consist of the supply and fixing of the unstressed steel bars, wires,
mesh and mats for the reinforcement of concrete in accordance with the Drawings and
Specification.
5.3.2 MATERIALS
A Reinforcing Bars
1. High tensile steel reinforcement bars shall conform to AASHTO M31 (ASTM A615) Grade
60 (with carbon content not exceeding 0.3%) or to BS 4449 with carbon percentage that
dose not exceed 0.3%.
2. Mild steel reinforcing bars shall conform to AASHTO M31 (ASTM A615) Grade 40 or BS
4461.
3. High tensile, low-alloy steel deformed bar shall conform to ASTM A706.
B Welded Fabric Reinforcement
1. Welded steel wire fabric shall conform to AASHTO M55 or BS 4482.

2. Cold drawn steel wire shall conform to the requirements of AASHTO M32 or in the case of
hard drawn steel wire to BS 4482.
C Fabricated Mat Reinforcement
1. Fabricated mat reinforcement shall conform to AASHTO M54 (ASTM A184).
D Certification and Identification
1. Three copies of a mill test report shall be supplied to the Engineer for each lot of billet steel
reinforcement supplied for use on the project. The mill test report shall be sworn to by a
person having legal authority to bind the manufacturer and shall show the following
information:
 The process or processes used in the manufacture of the steel from which the bars were rolled.
 Identification of each heat of open-hearth, basic oxygen, or electric furnace and/or each lot of acid
bessemer steel from which the bars were rolled.

2. The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator before
being offered for inspection. The tag shall show the manufacturer's test number and lot
number or other designation that will identify the material with the certificate issued for that
lot of steel.
3. The fabricator shall furnish 3 copies of a certificate which shows the heat number or
numbers from which each size of bar in the shipment was fabricated.
E Inspection and Sampling
1. The sampling and testing of reinforcement bars may be made at the source of supply
when the quantity to be shipped or other conditions warrant such procedure. Bars not
inspected and sampled before shipment will be inspected and sampled after arrival at the
site.
5.3.3 CONSTRUCTION
A General
1. Reinforcing steel shall be protected at all times from damage. All reinforcement shall be
free from detrimental dirt, loose mill scale, scaly rust, paint, grease, oil or other foreign
substance. There shall be no evidence of pitting or visual flaw in the test specimen or on
the sheared ends of the bars.
2. Rust shall be removed by wire brushing or, if directed by the Engineer, by sand blasting.
Light rust without visible sign of peeling need not be removed.
B Storage
1. Reinforcement shall be stored clear of the ground on platforms, skids or other supports
and be protected against contamination by dirt, grease, oil etc. at all times. If directed by
the Engineer, the Contractor shall provide cover to the reinforcement.
2. Reinforcement of different grades and different diameters shall be stored separately and
marked to facilitate inspection and checking.
C Cutting and Bending
1. Cutting and bending of reinforcement shall be based on an approved bar bending

schedule.
2. Reinforcement shall be cut in specialist cutting machines or cold cut by hand only. Cutting
with oxyacetylene torch is strictly forbidden.
3. Bars shall be bent to the following bend diameters:
Bar Diameter, d. Mild Steel High Yield Steel
Up to 25 mm 4d 6d
25 to 35 mm 6d 8d
35 to 60 mm 10d 10d
4. All reinforcement shall be bent at the temperature range of 5 degrees C and 100 degrees
C. Bending by heating, if approved by the Engineer, shall be carried out in such a manner
as not to impair the physical and mechanical characteristics of the bar.
5. The straight bar length for a hook of 180° shall be not less than 4 times the bar diameter or
65 mm whichever is the larger.
6. The straight bar length of a hook of 90° shall be not less than 12 times the bar diameter.
7. The straight bar length after hook in stirrups shall be 6 times the bar diameter or 60mm

whichever is the larger.
8. Cold worked bars and hot rolled high yield bars shall not be re-bent or straightened once
having been bent. Where it is necessary to bend mild steel bars projecting from the
concrete, the bend diameter shall comply with the requirements of item C.3 above.
9. If bending of the bar in accordance with this Specification causes the bar to crack, the bar
shall be rejected, irrespective of any prior approval that may have been given, and
removed from the Site.
10. Bars shall be cut and bent to the following tolerances:
Bar length (mm) Tolerance (mm)
Upto 1000 5
1000 - 2000 +5, -10
above 2000 +5, -25
11. No adjustment to bar length after bending will be permitted.
D Fixing
1. Reinforcement shall be placed and maintained in the position shown on the Drawings.
Unless agreed otherwise by the Engineer, all bar intersections shall be securely tied
together with the ends of the wire turned into the main body of the concrete. 1.2 mm
diameter stainless steel wire shall be used for in situ members having exposed soffits. 1.6
mm diameter soft annealed iron wire shall be used elsewhere.
2. The correct cover to reinforcement on all exposed faces of concrete shall be maintained by
using approved proprietary spacers. Where instructed by the Engineer the adequacy of
such spacers shall be demonstrated by site trials.
3. Concrete cover blocks, where permitted by the Engineer, shall be of approved dimensions
and designed so that they will not overturn when the concrete is placed. They shall be
made with 10 mm maximum size aggregate and the mix proportion shall be such as to
produce the same strength as the adjacent concrete. Tying wire shall be cast in the blocks
for subsequent tying to the reinforcement.
4. Wherever it is necessary for the Contractor to splice reinforcement at positions other than
those shown on the Drawings, the approval of the Engineer shall be sought and obtained
before the reinforcement is placed. Splices shall be staggered where possible and shall
be designed to develop the strength of the bar without exceeding the allowable unit bond
stress.
5. Proprietary mechanical splicing devices shall be used only with prior approval of the
Engineer in writing. They shall be able to withstand without any slippage a force of not
less than 1.25 times the characteristic yield stress of the smaller bar spliced multiplied by
the cross-sectional area of the smaller bar.
6. Mesh reinforcement shall comply with the sizes of sheets and diameter and spacing of
bars as shown on the Drawings. The sheets of mesh shall be lapped as shown on the
Drawings. The method of placing the mesh and securing it in position shall be approved
by the Engineer.
7. Welding of reinforcement bars, if allowed by the Engineer, shall be carried out in
accordance with the latest publications of the American Welding Society publication
"Structural Welding Code for Reinforcing Steel", and shall be able to withstand a force of
not less than 1.25 times the characteristic yield stress of the smaller of the welded bars
multiplied by the cross-sectional area of the smaller bar.
8. Cold worked steel bars shall not be welded.
9. Where galvanizing or epoxy coating is required to be applied to the reinforcement, specific

instructions will be given by the Engineer taking into account the particular design
conditions which apply.
10. Dowel Bars: Coat half of each bar with approved proprietary debonding compound or fit
with approved plastics sleeve. Fix bars securely at required level, perfectly level, at right
angles to and centred on the joint. Fit compressible caps to debonded ends of bars.
5.4 FORMS, FORMWORK AND FALSEWORK
5.4.1 GENERAL
A Scope
1. These works shall consist of the design, supply and use of forms, formwork and falsework
for the construction of concrete water tanks.
5.4.2 DEFINITIONS
A Forms and Formwork

1. The item of the temporary works used to give the required shape and support to poured
concrete. It consists primarily of sheeting material, such as wood, plywood, metal sheet or
plastic sheet, in direct contact with the concrete and joists or stringers that directly support
the sheeting.
B Falsework
1. Any temporary structure used to support a permanent structure while it is not self-
supporting.
C Scaffold
1. A temporarily provided structure that provides access, or on or from which persons work,
or that is used to support material, plant or equipment.
D Tower
1. A composite structure, usually tall, used principally to carry vertical loading.
5.4.3 MATERIALS
A Wood
1. Soft wood free of faults such as splitting, warping, bending, knots etc.
2. When imported softwood or hardwood is used for falsework, the minimum timber grade,
determined in accordance with BS 4978 shall be SC3.
3. Hardwood used as load-bearing wedges and packing shall be limited to those listed in
Table 5.4.1.
Table 5.4.1: Permitted Hardwoods for Load-Bearing Wedges and Packing

Standard name Botanical species
Ash Fraxinus excelsior
Beech Fagus sylvatica
Greenheart Ocotea rodiaei
Jarrah Eucalyptus marginata
Karri Eucalyptus diversicolor
Keruing Dipterocarpus spp
Oak Quercus spp

B Plywood
1. When plastic coated plywood is used, the Phenol resin on melamine shall be not less than
20% of the total coating weight.
C Steel
1. Except as otherwise specified or shown on the Drawings, the grades and qualities shall
conform to the following applicable standards of AASHTO and ASTM:
 Structural carbon steel shall conform to AASHTO M183M (ASTM A36M).
 Structural steel for welding shall conform to AASHTO M183M (ASTM A36M).
 High-strength low-alloy structural steel shall conform to AASHTO M222 (ASTM A588).
D Aluminium
1. Aluminium shall conform to the requirements of ASTM B221.
E Other Materials
1. Other materials, with the approval of the Engineer, may be used for falsework. These
include, but not limited to, fibre-glass reinforced plastic, polystyrene, polyethylene, rubber,
concrete, brick etc.
5.4.4 DESIGN
A General
1. Forms and formwork and falsework shall be designed by the Contractor and submitted to
the Engineer with full design calculations, detailed drawings, material specification and test
certificates for approval. Falsework shall be capable of temperature changes without
causing damage to the concrete.
2. Falsework design shall be in accordance with BS 5972 "Code of Practice for Falsework".
3. If the Contractor intends to use ready made proprietary type of falsework, he shall submit
all relevant data, including independent test certificates, which will enable the Engineer to
determine whether or not the Contractor's proposed falsework are acceptable.
4. Notwithstanding any approval of falsework design by the Engineer, the Contractor will not
be relieved of his responsibility for the adequacy and correctness of the design,
manufacture and assembly of the falsework.
B Fabrication of Steel
1. Except as otherwise specified or as shown on the Drawings, all details concerning

fabrication shall conform to "AASHTO Standard Specifications for Highway Bridges".
2. Fabrication of all metal for steel structures and the erection of steel structures shall be in
accordance with shop and erection drawings furnished by the Contractor and approved by
the Engineer before any fabrication is commenced.
3. Fabrication tolerances shall comply with tolerances stated on the Drawings.
4. Compliance with tolerances shall be achieved both during and after fabrication before any
surface preparation. Remedial measures to remove imperfections must be approved by
the Engineer.
5. Approval of Contractor's drawings shall in no way release the Contractor from his
responsibilities for work under the Contract. Three copies of each shop and erection
drawing prepared by the Contractor shall be submitted to the Engineer for his approval
and further copies of corrected or amended drawings shall be submitted if required before

final approval is given. These drawings shall conform to the general drawings, stress
sheets, design specifications and fabrication tolerances. Shop drawings shall include a full
and clear set of marking drawings.
6. Weld to be visually inspected by the Engineer. If testing is deemed to be required, the
Contractor shall bear all costs.
C Forms and Formwork
1. Formwork shall be sufficiently rigid so as to prevent any grout loss during concreting and
shall not distort due to environmental effects and concreting operations so that member
dimensions, shape, required finish and texture are within the tolerances specified.
2. Forms and formwork shall be designed to be readily assembled, stripped and transported
without distortion to panels and members of the formwork.
3. The method of stripping forms without damaging the concrete or special textured surface
finish, if incorporated, shall be fully considered in the design.
4. If form liners are to be used to achieve the specified surface finish, samples of a size as
directed by the Engineer shall be submitted for approval.
5. Form lining shall not bulge, warp or blister, nor shall it stain the concrete. Form lining shall
be used in the largest practicable panels to minimize joints. Small panels of the lining
material shall not be permitted. The joints in the lining shall be tight and smoothly cut.
Adjacent panels of form lining shall be so placed that the grain of the wood will be in the
same direction (all horizontal or all vertical). Thin metal form lining will not be permitted.
Undressed lumber of uniform thickness may be used as backing for form lining. Wooden
plyform, of adequate thickness, which is properly supported to meet the above
requirements, may be used in lieu of the lined forms specified herein.
Metal forms, if used, shall be of such thickness that the forms will remain true to shape. All
bolt and rivet heads shall be countersunk. Clamps, pins or other connecting devices shall
be designed to hold the forms rigidly together and to allow removal without injury to the
concrete. Metal forms which do not present a smooth surface or do not line up properly
shall not be used. Care shall be exercised to keep metal forms free from rust, grease or
other foreign matter. Under such circumstances the continued use of the metal forms will
depend upon satisfactory performance and their discontinuance may be required at any
time by the Engineer. Steel panels or panels with metal frames and wood or combination
shall be so designed as to leave no lipping or ridges in the finished concrete.
6. The width and thickness of the lumber, the size and spacing of studs and wales shall be
determined with due regard to the nature of the Work and shall be sufficient to ensure
rigidity of the forms and to prevent distortion due to the pressure of the concrete.
7. Form bolts, rods or ties and removable ties through plastic pipes shall be made of steel.
They shall be the type which permit the major part of the tie to remain permanently in the
structure or removed entirely. They shall be held in place by devices attached to the wales
capable of developing the strength of the ties. The Engineer may permit the use of wire
ties on irregular sections and incidental construction if the concrete pressures are nominal,
and the form alignment is maintained by other means. Form ties will not be permitted
through forms for handrail. Pipe spreaders shall not be used unless they can be removed
as the concrete is placed. Wood or metal spreaders shall be removed as the concrete is
placed. The use of cofferdam braces or struts will not be permitted except in unusual
situations and then only with approval of the Engineer.
8. Where the bottom of the forms is inaccessible, the lower form boards shall be left loose or
other provisions made so that extraneous material may be removed from the forms
immediately before placing the concrete.
9. Unless otherwise directed by the Engineer, the exterior side of forms shall be painted with
an approved, good quality high gloss white oil base enamel paint prior to placing concrete.
Paint shall be applied to metal forms only. When complete coverage is not obtained with
one coat, the Engineer will order additional coats as he deems necessary to obtain
complete coverage. Forms shall be repainted when ordered by the Engineer.

10. Unless provided otherwise on the Drawings or directed by the Engineer, all exposed edges
shall be bevelled by using dressed, millcut, triangular molding, having 20 millimeter sides.
11. Forms shall be maintained after erection to eliminate warping and shrinkage.
D Falsework
1. Falsework and centering shall be designed to provide the necessary rigidity to support all
loads placed upon it without settlement or deformation in excess of the permissible
tolerance for the structure given in the Specifications. Falsework columns shall be
supported on hardwood, concrete pads or metal bases to support all falsework that cannot
be founded on rock, shale or thick deposits of other compact material in their natural beds.
Falsework shall not be supported on any part of the structure, except the footings, without
the written permission of the Engineer. The number and spacing of falsework columns,
the adequacy of sills, caps and stringers and the amount of bracing in the falsework
framing shall be subject to approval of the Engineer.
2. All timber shall be of sound wood, in good condition and free from defects that might
impair its strength. If the vertical members are of insufficient length to cap at the desired
elevation for the horizontal members, they shall preferably be capped and frames
constructed to the proper elevation. Ends of the vertical members shall be cut square for
full bearing to preclude the use of wedges. If vertical splices are necessary, the abutting
members shall be of the same approximate size, the ends shall be cut square for full
bearing, and the splices shall be scabbed in a manner approved by the Engineer.
3. The Contractor shall compute falsework settlement and deflection for bridges so that when
the final settlement is complete, the structure will conform to the required camber, section
and grade as shown on the Drawings.
4. The Contractor shall provide means for accurately measuring settlement in falsework
during placement of concrete, and shall provide a competent observer to observe and
correct the settlement.
5. Screw jacks, if used, shall be designed for use with a slenderness ratio not exceeding 60.
The slenderness ratio shall be taken as the ratio of the clear distance between effective
bracing in both horizontal directions to the diameter of the screw jack measured at the root
of the thread. The manufacturers' certificate showing the ultimate load capacity of the
screw jack shall be submitted with the design calculations for the falsework. If directed by
the Engineer, the Contractor shall furnish a test certificate carried out at an approved
independent laboratory.
6. Props and towers supporting forms or partially completed structures shall be
interconnected in plan orthogonally at levels to be determined in the design. They shall
also be interconnected by diagonal bracings in orthogonal vertical planes.
5.4.5 FINISHES
A Types of Finishes
1. Class F1: This class of surface finish denotes a special finish required from aesthetic
considerations. In additions to the requirements of Class F2 finish, the following additional
requirements shall apply.
 It is of major importance that the special finishes required on F1 surfaces are uniformly and
consistently maintained with no variation in the colour or consistency of the concrete within the
same structure. In order to achieve this, the Contractor shall make trial panels of the formed
finishes specified. These panels shall be not less than 1.5 m high and 1 m wide and 250 mm thick
and shall be cast in the manner and with materials as proposed for the actual Work. These panels
are for the approval of the liners and are preliminary to the test samples carried out on site.

 The Contractor shall provide at his own expense as many panels as required by the Engineer until
a satisfactory trial panel has been accepted by the Engineer. The Contractor shall submit to the
Engineer and obtain his approval for all details before commencement of trials. These samples
when approved, will form the standard against which the corresponding finishes on the actual work
will be judged. In all cases of approvals, the decision of the Engineer alone will be final.
 Where forms and form-liners to be used for the special finishes specified are manufactured outside
the Country, the forms and form-liners shall not be permitted on Site until the Engineer has
inspected the forms and form-liners and is satisfied that they are suitable for the Works. Samples
and trial panels carried out at the place of manufacture to demonstrate to the Engineer that the
forms and formliners and the methods of assembling and de-shuttering them are acceptable shall
not be paid for and will not relieve the Contractor of the requirement for carrying out trial panels on
site as described above.
 If the required finish in the opinion of the Engineer, has not been obtained in the Works, the
Contractor shall promptly carry out at his own expense all measures required by the Engineer to
obtain the specified finish. These may include grit blasting followed by the application of polyester
or epoxy paint. Where such remedial action is ordered by the Engineer, the entire exposed
surface shall be so treated irrespective of whether or not the defective areas are localised or
extensive.
2. Class F2: Formwork shall be lined with a material approved by the Engineer to provide a
smooth finish of uniform appearance. This material shall leave no stain on the concrete
and shall be so joined and fixed to its backing so that it imparts no blemishes. It shall be of
the same type and obtained from only one source for any one structure. The Contractor
shall make good any imperfections in the finish as directed by the Engineer. Internal ties
and embedded metal parts will not be permitted unless otherwise approved by the
Engineer.
3. Class F3: Irregularities in the finish shall be no greater than those resulting from the use of
wrought thick square edged boards arranged in a uniform pattern. The finish is intended
to be left as struck. Imperfections such as fins and surface discoloration shall, however,
be made good as and when required by the Engineer.
4. Class F4: No special requirements.
5. Permanently exposed concrete surfaces to classes F1, F2 and F3 finish shall be protected
from rust marks and stains of all kinds. Internal ties and embedded metal parts will not be
permitted.
6. The Contractor shall submit to the Engineer all details of formwork, liners, joints, and
materials including fabrication drawings and stating procedures involved in the use of
formwork for approval before commencement of any work on fabrication. No formwork
shall be brought to site without the prior approval of the Engineer. Adequate time shall be
allowed by the Contractor in his programme for these approvals after consultation with the
Engineer.
B Unformed Finishes
1. Class U1: The concrete shall be uniformly levelled and screeded to produce a plain or
ridged surface as described in the Contract. No further work shall be applied to the
surface unless is used as the first stage for Class U2 or Class U3 finish.
2. Class U2: After the concrete has hardened sufficiently, the concrete Class U1 surface
shall be floated by hand or machine sufficiently to produce a uniform surface free from
screed marks.
3. Class U3: When the moisture film has disappeared and the concrete has hardened
sufficiently to prevent laitance from being worked to the surface, a Class U1 surface shall

be steel trowelled under firm pressure to produce a dense, smooth uniform surface free
from trowel marks.
5.4.6 TOLERANCES
A The tolerances in the forms and formwork shall be such that members formed shall be
within the tolerances for the size and type of the member specified elsewhere in the
Specification.
B Falsework shall be fixed such that the completed structure shall be within the required
tolerances in plan, elevation and slope for the size and type of structure specified
elsewhere in the Specification.
C Surfaces which are to receive deck waterproofing shall be finished to an accuracy such
that when tested with a three-meter-long straight edge, the maximum depression shall not
exceed five mm.
5.4.7 CONSTRUCTION REQUIREMENTS
A The forms and falsework shall be inspected by the Engineer after assembly on the work
area and immediately before concreting. No pour shall commence until the forms and
falsework have been approved by the Engineer.
B The inside surfaces of all forms shall, except for pavement formwork, or unless otherwise
agreed by the Engineer, be coated with a release agent approved by the Engineer.
Release agents shall be applied strictly in accordance with the manufacturer's instructions
and shall not come into contact with the reinforcement or prestressing tendons and
anchorages. Different release agents shall not be used in formwork which will be visible in
the finished work.
C Immediately before concrete is placed, all forms shall be thoroughly cleaned out.
D Forms that are to be re-used shall be thoroughly cleaned and re-oiled and, if necessary,
shall be reconditioned by revision or reconstruction. Unsatisfactory lumber will be
condemned by the Engineer, and shall be removed from the Site.
E Formwork shall be constructed so that the side forms of members can be removed without
disturbing the soffit forms. If props are to be left in place when the soffit forms are
removed, these props shall not be disturbed during the striking. Top shuttering is to be
provided to concrete if the slope angle exceeds 25 degrees.
F Runways used to move plant, equipment or materials shall be clear of the reinforcement
and shall be robust enough not to deflect excessively or cause movement to the forms due
to dynamic effects.
G During concreting, the forms and their supports shall be constantly monitored for signs of
imminent failure. There shall be skilled operatives in constant attendance during
concreting who are qualified to make immediate adjustments to the forms and falsework so
that concreting can satisfactorily be completed.
H The Engineer may suspend concreting operations if, in his opinion, the forms and
falsework are in danger of failure and that the actions taken by the Contractor are
insufficient or inadequate to guarantee the safe and satisfactory completion of concreting.
In such an event, the Engineer may instruct the Contractor to remove, at his expense, the
concrete already poured.
I If at any period of work, during or after placing of concrete, the forms show signs of
sagging or bulging, the Contractor, at his own expense, shall remove the concrete to the
extent directed by the Engineer, bring the forms to the proper position, and place concrete.
J Immediately after the removal of the forms, all fins caused by form joints and other
projections shall be removed and all pockets cleaned and filled with a cement mortar
composed of 1 part by volume of Portland cement and 2 parts sand. Sufficient white
Portland cement shall be mixed with the cement in the mortar, so that when dry the colour
will match the surrounding concrete. Patches shall be moistened prior to mortaring to
obtain a good bond with the concrete. When directed by the Engineer, the Contractor shall
at his own expense, substitute an approved epoxy grout for the Portland cement mortar or
provide an epoxy bonding agent to be used in conjunction with the Portland cement
mortar. If, in the judgment of the Engineer, pockets are of such extent or character as to
materially affect the strength of the structure or to endanger the life of the steel
reinforcement, he may declare the concrete defective and require the removal and
replacement of that portion of the structure affected. The resulting surfaces shall be true
and uniform. Portions of the structure which cannot be finished or properly repaired to the
satisfaction of the Engineer shall be removed.
5.4.8 REMOVAL OF FORMWORK AND FALSEWORK
A To facilitate finishing, forms on handrails, ornamental work, and other vertical surfaces that
require a rubbed finish, shall be removed as soon as the concrete has hardened
sufficiently that it will not be injured, as determined by the Engineer. In determining the
time for the removal of forms, consideration shall be given to the location and character of
the structure, weather and other conditions influencing the setting of the concrete.
B B.Formwork shall be removed in a manner not to damage the concrete, and at times to suit
the requirements for its curing and to prevent restraint that may arise from elastic
shortening, shrinkage or creep.
C Any remedial treatment to surfaces shall be agreed with the Engineer following inspection
immediately after removing the formwork and shall be carried out without delay. Any
concrete surface which has been treated before being inspected by the Engineer, shall be
liable to rejection.
D Where the concrete compressive strength is confirmed by tests on concrete cylinders

(cubes) stored under conditions approved by the Engineer that simulate the field
conditions, formwork supporting concrete in bending may be struck when the strength is 10
N/sq.mm or three times the stress to which it will be subjected, whichever is the greater.
E For ordinary structural concrete made with ordinary Portland cement only, in the absence
of control cylinders (cubes) the period before striking shall be in accordance with the
minimum periods given in Table 5.4.2 unless otherwise directed by the Engineer.
Table 5.4.2: Minimum Period Before Striking for Ordinary Structural
Concrete Made With Ordinary Portland Cement

Minimum Period Before Striking
Type of Formwork Surface Temperature of Concrete
16˚C 7˚C t˚C
Vertical formwork to columns, walls and 12 hours 18 hours 300
large beams hours
t  10
Soffit formwork to slabs 4 days 6 days 100
days
t  10
Props to slabs 10 days 5 days 100
days
t  10
Soffit to formwork to beams 9 days 14 days 230
days
t  10

Props to beams 14 days 21 days 360
days
t  10
5.5 PLAIN AND REINFORCED CONCRETE STRUCTURES
5.5.1 GENERALLY
A Scope
1. This Section of the Specification describes the construction of plain and reinforced
concrete structures.
5.5.2 MATERIALS
A Concrete
1. Concrete shall be produced and supplied in accordance with Section 5.01 "Concrete and
Concrete Mixes and Testing".
B Reinforcement
1. Reinforcement shall conform to Section 5.03 "Steel Reinforcement and Fixing".
C Formwork and Falseworks
1. Formwork and Falsework shall be designed and supplied in accordance with Section 5.04
"Forms, Formwork and Falsework".
D Plant and Equipment
1. Plant and Equipment shall conform with the requirements set in Volume 1 and shall be
according to the type and number outlined in the Contractor's detailed Program of Work as
5.5.3 CONSTRUCTION
A General
1. The Contractor shall notify the Engineer his intention to concrete at least 24 hours in
advance.
2. The Engineer shall check and certify that:
 The form and formwork meet the Specification requirements.
 The falsework and support props are in accordance with the approved Drawings.
 The reinforcement conforms to the Drawings and that the correct covers have been provided.
 The forms are free of dirt and other deleterious matter.
B Concreting
1. Handling, placing and curing shall be in accordance with Section 5.02 "Concrete Handling,
Placing and Curing".
C Slump
1. Slump shall be within the limits given in Section 5.02 of the Specification.

D Construction and Expansion Joints
1. Whenever the work of placing concrete is delayed until the concrete shall have taken its
initial set, the point of stopping shall be deemed a construction joint. So far as possible the
location of construction joints shall be as shown on the Drawings, but if not shown on the
Drawings, they shall be planned in advance and the placing of concrete carried out
continuously from joint to joint. The joints shall be perpendicular to the principal lines of
stress and in general be located at points of minimum shear.
Where dowels, reinforcing bars or other adequate ties are not required by the Drawings,
keys shall be made by embedding water-soaked bevelled timbers in soft concrete. The
key shall be sized as shown on the details, or as directed by the Engineer, which shall be
removed when the concrete has set. In resuming work the surface of the concrete
previously placed shall be thoroughly cleaned of dirt, scum, laitance or other soft material
with stiff wire brushes, and if deemed necessary by the Engineer, shall be roughened with
a steel tool. The surface shall then be thoroughly washed with clean water and pointed
with a thick coat of neat cement mortar, after which the concreting may proceed.
2. Expansion joints shall be constructed at the locations, of the materials and to the
dimensions shown on the Drawings.
E Cold Joints
1. When the continuous placement of concrete in any structural member is interrupted or

delayed, for any reason, for a period long enough for the previously partially placed
concrete to take its initial set, the Engineer shall declare such a joint a cold joint in which
case the Contractor shall immediately remove the previously partially placed concrete from
the forms. No extra payment will be made for the initial placement or the removal of
concrete which is wasted because of a cold joint. The Engineer may suspend all or any
part of the subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.
2. The Engineer may, with due consideration to the location of the cold joint and/or the
importance of the member, allow the Contractor to retain the partially placed concrete and
complete the concreting by a subsequent pour, which for permission, the Engineer shall
instruct the Contractor to carry out at his own expense some or all of the following
measures before completing the pour:
 Surface leitance shall be removed from the surface of the partially placed concrete by wire
brushing or light tooling or by sand blasting as directed by the Engineer without damage to
reinforcement and formwork.
 Shear keys shall be cut in the partially placed concrete. The shape, size and orientation of the
shear keys shall be as directed by the Engineer. The reinforcement and formwork shall not be
damaged.
 The cleaned surface of the partially placed concrete shall be coated with an approved bonding
agent before placing the subsequent pour.
 Additives to facilitate bonding shall be added to the concrete used for the subsequent pour.
 Dowel bars of a type and length to be approved by the Engineer shall be installed in the partially
placed concrete using non-shrink cement grout or resin grout as directed by the Engineer. The
size and spacing of the dowel bars shall be approved by the Engineer. Their installation shall not
damage the reinforcement or formwork.

 The partially placed concrete and the subsequent concrete shall be stressed by prestressing bars
of a size and type approved by the Engineer to achieve a level of compressive stress at the
interface approved by the Engineer. The method of installing the prestressing bars and type of
anchors used shall be approved by the Engineer. Unless otherwise agreed by the Engineer, the
drill hole shall be grouted with a cement grout containing expanding additive to the manufacturer's
recommendations.
F Finishing
1. F.1 To be as shown on Drawings.
G Concrete Cover to Reinforcement
1. The cover shall be not less than the size of the bar or the maximum aggregate size plus 5
mm or as shown on drawings. In the case of bundled bars, it shall be equal to or greater
than the size of a single bar of equivalent area plus 5 mm.
2. Where surface treatment such as grooved finish or bush hammering cuts in to the face of
the concrete, the expected depth of the treatment shall be added to the cover.
3. The cover to reinforcement should also be determined by considerations of durability
under the envisaged conditions of exposure. Minimum cover to reinforcement under
particular severe conditions shall be determined by Engineer on site.
H Tolerances
1. The horizontal and vertical dimensions of in-situ concrete members, but not cross-
sections, shall be within the following tolerances:
Up to 3000 ±3
3001-4500 ±6
Vertical lines out of plane ± 5 + 1 for every 3000 out of true line.
2. Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams, columns,
piers etc., shall be within the following tolerances:
Up to 500 6
501 -750 10
Additional for every subsequent 100 mm ±1 mm
3. The horizontal and vertical dimensions of pre-cast members, but not cross-sections, shall
be within the following tolerances:
Up to 3000 ±2
3000 and over ±5
4. Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams, columns,
piers etc., shall be within a tolerances of ± 3 mm.

Up to 500 6
501- 750 9
Additional for every subsequent
250 mm ±3 mm
5. For in-situ and pre-cast construction the tolerance between the short side and the long
side shall be within the following limits:
Member Size (mm) Tolerance (mm)
Up to 3000 ±3
3000 and over ±6
6. For in-situ and precast construction the straightness or bow, defined as deviation form the
intended line, shall be within the following tolerances:
Member Length (mm) Tolerances (mm)
Up to 3000 ±3
3000 and over ±6
7. The alignment of members shall be within the following tolerances:
 Column and Piers: 1:400 of column or pier length.
 Others: 1:600 of length.
8. The flatness of a surface, measured with a straight edge of 1.5 meter, shall be not greater
than 6 mm at any point.
9. Twist, measured as the deviations of any corner from the plane containing the other three
corners, shall be within the following limits.
Member Length (mm) Tolerance (mm)
Up to 6000 6
Above 6000 12
5.6 WATERPROOFING FOR STRUCTURES
5.6.1 GENERAL
A Scope
1. These works shall consist of furnishing and placing approved waterproofing membrane
and dampproofing course to external concrete surfaces in contact with earth and
furnishing and placing epoxy coating to internal surfaces of concrete walls, slabs, and
beds and furnishing and installing waterstops to waterproof construction and expansion
joints, all as shown on the Drawings or as directed by the Engineer.

5.6.2 MATERIALS
A Asphalt
1. Waterproofing asphalt shall conform to AASHTO M 115 (ASTM D 449); Type I for use
below ground, and Type II for use above ground.
2. Primer for use with asphalt in waterproofing shall conform to AASHTO M 116 (ASTM D
41).
B Bitumen
1. Waterproofing bitumen shall conform to AASHTO M 118 (ASTM D 450). Type II shall be
furnished unless otherwise specified.
2. Primer for use with coal-tar bitumen in dampproofing and waterproofing shall conform to
AASHTO M 121 (ASTM D 43).
C Waterproofing Fabric
1. Waterproofing fabric shall conform to AASHTO M 117 (ASTM D 173).
D Self-Adhesive Polyethylene Sheet
1. Flexible, preformed waterproof membrane comprising strong, high-density polyethylene

film with self-adhesive rubber/bitumen com¬pound, and having the following minimum
properties:
 Total thickness : 1.5 mm
 Weight : 1.6 kg/m2
 Tensile strength : 42 n/mm2
 Elongation : 210% long.; 160% trans.
 Tear resistance : 340 n/mm long.; 310 n/mm trans.
 Puncture resistance : 220 n 65 mm
E Tar for Absorptive Treatment
1. Tar for absorptive treatment shall be a liquid water-gas tar that conforms to the following
requirements:
 Specific gravity, 25/25ºC ............1.030 to 1.100
 Specific viscosity at 40ºC (Engler), not more than ........................3.0
 Total distillate, percent by weight, to 300ºC, not more than .........50.0
 Bitumen (soluble in carbon disulfide) not less than, percent ......98.0
 Water, not more than, percent.......................................................3.0
F Tar Seal Coat
1. Tar seal coat shall conform to AASHTO M 52, Grade RTCB-5 (ASTM D 490).

G Joint Fillers
1. Filler for use in horizontal and vertical joints in waterproofing work shall be a straight
refined oil asphalt conforming to the following requirements:
 Flash point : Not less than 232ºC.
 Softening point : 48.9ºC to 54.4ºC.
 Penetration : At 0ºC, 200 grams, 1 minute, not less than
15.At 25ºC, 100 grams, 5 seconds, 50 to 60.
At 46ºC, 50 grams, 5 seconds, not more than
300.
 Loss on heating : At 163ºC, 50 grams, 5 hours, not more than
0.5 percent.
 Ductility : At 25ºC, 5 centimeters per minute, not less
than 85.
 Total bitumen (soluble in carbon disulfide): not less than 99.5 percent.
H Waterstops
1. Extruded PVC, heavy duty, of the types and sizes shown on the Drawings, and complete
with junction pieces shall be obtained from any of the following manufacturers:
 Expandite Ltd.
 Greenstreak Plastic Products
 Servicised Ltd
2. Copper water stops shall be copper sheets of the thickness shown on the Drawings and
shall conform to the requirements of AASHTO M 138 (ASTM B 152).
3. Plain rubber water stops shall be formed from a stock composed of a high-grade
compound made exclusively from new plantation rubber, reinforcing carbon black, zinc
oxide, accelerators, antioxidants, and softeners. This compound shall contain not less
than 72 percent by volume of new plantation rubber. The tensile strength shall be not less
than 246 kg per sq.cm, with an elongation at breaking of 550 percent when tested in
accordance with ASTM D 412. The unit stresses producing 300 percent and 500 percent
elongation shall be not less than 77 kg. and 198 kg. per sq.cm, respectively. The Shore
Durometer indication (hardness) shall be between 55 and 65 when tested in accordance
with ASTM D 676. After 7 days in air at 126 degrees (plus or minus 1 degree) C or after
48 hours in oxygen at 126 degrees (plus or minus 1 degree) C both at 21 kg per sq.cm,
the tensile strength and elongation shall not be less than 65 percent of the original when
4. Synthetic rubber water stops shall be formed from a compound made exclusively from
neoprene, or SBR, reinforcing carbon black, zinc oxide, polymerization agents, and

softeners. This compound shall contain not less than 70 percent by volume of neoprene
or SBR. The tensile strength shall be not less than 175 kg. per square centimeter with an
elongation at breaking of 425 percent when tested in accordance with ASTM D 412. The
Shore Durometer indication (hardness) shall be between 50 and 70 when tested in
accordance with ASTM D 676. After 7 days in air at 126 degrees (plus or minus 1 degree)
C or after 48 hours in oxygen at 126 degrees (plus or minus 1 degree) C, and 21 kg per
sq.cm. pressure, the tensile strength shall be not less than 65 percent of the original when
I Proprietary Waterproofing Systems
1. Proprietary waterproofing systems shall be bituminous membranes reinforced with layers

of suitable reinforcement, bituminous coated polythene sheet, plasticized polyvinyl chloride
sheet, other approved membranes or applications of resinous reinforced coatings. The
type to be used shall be as indicated on the Drawings and shall be chosen according to its
location and serviceability. The specific system shall be approved after site trials, should
the Engineer decide these to be necessary.
J Epoxy Coating System
1. An approved epoxy coating system shall be furnished and applied to the internal concrete
surfaces of culverts and open channels as shown on the Drawings or as directed by the
Engineer. The thickness of the epoxy coating shall be at least 400 microns in accordance
with the manufacturer's recommendations.
K Chemical Water Proofing Coating
1. Cheical waterproof coating shall be surface-applied material that causes capillary

waterproofing system to protect concrete in-depth. Manufacturer's details are as follows:
Man: Xypex Chemical Corporation
Ref.: Xypex
Man: Meynadier
Ref.: Barra Slurry
Man: Vandex International Ltd.
Ref.: Vandex Super, Vander Premix
Man: Master Builders Technologies
Ref.: Masterseal 501/502.
5.6.3 SURFACE PREPARATION
A Waterproofing
1. All concrete surfaces which shall be waterproofed shall be reasonably smooth and free
from projections or holes which might cause puncture of the membrane. The surface shall
be dry, so as to prevent the formation of steam when the hot asphalt or tar is applied, and,
immediately before the application of the waterproofing, the surface shall be thoroughly
cleaned of dust projecting tying wire and loose material.
2. No waterproofing shall be done in wet weather, nor when the temperature is below 4
degrees C, without special authorization from the Engineer. Should the surface of the
concrete become temporarily damp, it shall be covered with a 50 mm layer of hot sand,
which shall be allowed to remain in place from 1 to 2 hours, or long enough to produce a
warm and surface-dried condition, after which the sand shall be swept back, uncovering
sufficient surface for beginning work, and the operation repeated as the work progresses.
B Dampproofing
1. The surface to which the dampproofing coating shall be applied shall be cleaned of all
loose and foreign material and dirt and shall be dry. When necessary the Engineer may
require the surface to be scrubbed with water and a stiff brush, after which the surface
shall be allowed to dry before application of the primer.
5.6.4 INSPECTION, DELIVERY AND STORAGE
A All waterproofing materials shall be tested before shipment. Unless otherwise ordered by
the Engineer, they shall be tested at the place of manufacture, and, when so tested, a copy
of the test results shall be sent to the Engineer by the chemist or inspection bureau which
has been designated to make the tests, and each package shall have affixed to it a label,
seal, or other mark of identification, showing that it has been tested and found acceptable,
and identifying the package with the laboratory tests.
B Factory inspection is preferred, but in lieu thereof and/or addition thereof, the Engineer
may order that representative samples, properly identified, be sent to him for test prior to
shipment of the materials. After delivery of the materials, representative check samples
shall be taken which shall determine the acceptability of the materials.
C All materials shall be delivered to the work in original containers, plainly marked with the
manufacturer's brand or label.
D Water proofing and damp proofing material shall be stored in a dry, protected place. Rolls
of waterproofing fabric and membranes shall not be stored on end.
5.6.5 CONSTRUCTION
A Asphalt and Bitumen Waterproofing Fabric
1. Asphalt shall be heated to a temperature between 148.7 degrees C and 176.5 degrees C
and tar for hot application shall be heated to a temperature between 93.3 degrees C and
121 degrees C with frequent stirring to avoid local overheating. The heating kettles shall
be equipped with thermometers.
2. In all cases, the waterproofing shall begin at the low point of the surface to be
waterproofed, so that water will run over and not against or along the laps.
3. The first strip of fabric shall be of half-width; the second shall be full-width, lapped the full-
width of the first sheet; and the third and each succeeding strip shall be full-width and
lapped so that there will be two layers of fabric at all points with laps not less than 50 mm
wide. All end laps shall be at least 300 mm.
4. Beginning at the low point of the surface to be waterproofed, a coating of primer shall be
applied and allowed to dry before the first coat of asphalt is applied. The waterproofing
shall then be applied as follows.
5. Beginning at the low point of the surface to be waterproofed, a section about 500 mm wide
and the full length of the surface shall be mopped with the hot asphalt or tar, and there
shall be rolled into it, immediately following the mopping, the first strip of fabric, or half-
width, which shall be carefully pressed into place so as to eliminate all air bubbles and
obtain close conformity with the surface. This strip and an adjacent section of the surface
of a width equal to slightly more than half of the width of the fabric being used shall then be
mopped with hot asphalt or tar, and a full width of the fabric shall be rolled into this,
completely covering the first strip, and pressed into place as before. This second strip and
an adjacent section of the concrete surface shall then be mopped with hot asphalt or tar
and the third strip of fabric "shingled" on so as to lap the first strip not less than 50 mm.

This process shall be continued until the entire surface is covered, each strip of fabric
lapping at least 50 mm over the last strip. The entire surface shall then be given a final
mopping of hot asphalt or tar.
6. The completed waterproofing shall be a firmly bonded membrane composed of two layers
of fabric and three moppings of asphalt or tar, together with a coating of primer. Under no
circumstances shall one layer of fabric touch another layer at any point or touch the
surface, as there must be at least three complete moppings of asphalt or tar.
7. In all cases the mopping on concrete shall cover the surface so that no gray spots appear,
and on cloth it shall be sufficiently heavy to completely conceal the weave. On horizontal
surfaces not less than 49 liters of asphalt or tar shall be used for each 10 sq.m. of finished
work, and on vertical surfaces not less than 61 liters shall be used for each 10 sq.m. The
work shall be so regulated that, at the close of a day's work, all cloth that is laid shall have
received the final mopping of asphalt or tar. Special care shall be taken at all laps to see
that they are thoroughly sealed down.
8. At the edges of the membrane and at any points where it is punctured by such
appurtenances as drains or pipes, suitable provisions shall be made to prevent water from
getting between the waterproofing and the waterproofed surface.
9. All flashing at curbs and against girders, spandrel walls, etc., shall be done with separate
sheets lapping the main membrane not less than 300 mm. Flashing shall be closely
sealed either with a metal counter-flashing or by embedding the upper edges of the
flashing in a groove poured full of joint filler.
10. Joints which are essentially open joints but which are not designed to provide for
expansion shall first be caulked with oakum and lead wool and then filled with hot joint
filler.
11. Expansion joints, both horizontal and vertical, shall be provided with sheet copper or lead
in "U" or "V" form in accordance with approved details. After the membrane has been
placed, the joint shall be filled with hot joint filler. The membrane shall be carried
continuously across all expansion joints.
12. At the ends of the structure the membrane shall be carried well down on the abutments
and suitable provision made for all movement.
B Proprietary Waterproofing Membranes
1. Proprietary waterproofing membranes shall be installed strictly in accordance with the

manufacturer's instructions and shall be laid so that no air is trapped between it and the
concrete surface or between successive layers of sheeting.
2. Unless otherwise specified joints between sheets shall be lapped with end laps of at least
150 mm and side laps of at least 100 mm. The joints shall be arranged so that at no
points are there more than three thicknesses of sheeting and, as far as possible so that
water will drain away from the exposed edge.
C Damage Patching of Waterproofing Fabrics
1. Care shall be taken to prevent injury to the finished fabric membrane by the passage over
it of workmen or wheelbarrows, or by throwing any material on it. Any damage which may
occur shall be repaired by patching. Patches shall extend at least 300 mm beyond the
outermost damaged portion and the second ply shall extend at least 75 mm beyond the
first.
2. Proprietary waterproofing membranes shall be repaired according to the manufacturer's
specifications and as directed by the Engineer.
D Dampproofing
1. Concrete, brick, or other surfaces that shall be protected by dampproofing shall be

thoroughly cleaned before the primer is applied. They shall then be brush or spray painted
with two or more coats (as indicated on the Drawings) of tar or asphalt for absorptive
treatment. Below ground not less than two coats shall be applied, using 0.56 L/sq.m. of
surface. On the well-primed surface one application of tar or asphalt seal coat shall be
applied by brush, using 0.45 L/sq.m.
2. Care shall be taken to confine all paints to the areas to be waterproofed and to prevent
disfigurement of any other parts of the structure by dripping or spreading of the tar or
asphalt.
E Protection of Waterproofing and Dampproofing
1. Over the waterproofing membrane and dampproofing course, there shall be constructed a
protection course which, unless otherwise specified or shown on the Drawings, shall be a
50 mm course of mortar mixed in the proportion of one part Portland cement and two parts
sand. This mortar course shall be reinforced midway between its top and bottom surfaces
with wire netting of 150 mm mesh and No. 12 gauge, or an approved equivalent. The top
surface shall be troweled to a smooth, hard finish and, where required, true to grade.
2. The construction of the protection course shall follow the waterproofing so closely that the
latter will not be exposed without protection for more than 24 hours.
3. Unless otherwise shown on the Drawings or directed by the Engineer, vertical faces
waterproofed or dampproofed shall be protected by a porous concrete block wall of not
less than 225 mm thickness. If approved by the Engineer, a proprietary synthetic sheeting
may be used as the protective layer in lieu of the porous concrete block wall.
F Chemical Waterproofing
1. Conditions and rate of application shall be in accordance with manufacturer's

recommendations.
G Water Stops
1. Copper sheets for water stops shall be of the width and shall be bent to the shapes shown
or ordered. The sheet copper in each joint shall be continuous, separate pieces being
connected by thoroughly workmanlike soldered joints to form a complete watertight unit.
The sheet copper shall be placed in such manner as to ensure its embedment in the
concrete on each side of the joints in the positions shown on the Drawings.
2. Rubber water stops shall be installed in accordance with the details shown on the
Drawings. The water stops shall be formed with an integral cross section which shall be
uniform within 3 mm in width and the web thickness or bulb diameter, within plus 1.5 mm
and minus 0.75 mm. No splices shall be permitted in straight strips. Strips and special
connection pieces shall be well cured in a manner such that any cross section shall be
dense, homogenous, and free from all porosity. All junctions in the special connection
pieces shall be full molded. During the vulcanizing period the joints shall be securely held
by suitable clamps. The material at the splices shall be dense and homogenous
throughout the cross section. Field splices shall be either vulcanized, mechanical, using
stainless steel parts, or made with a rubber splicing union of the same stock as the water
stop, at the option of the Contractor. All finished splices shall demonstrate a tensile
strength of not less than 50 percent of the unspliced material.
H Testing
1. Unless otherwise agreed by the Engineer in writing, at least one site trial application of the
waterproofing system shall be carried out to determine the suitability of the surface
preparation, method of application and effectiveness of the protective layer. The size of
membrane laid shall be not less than 2.0 meters wide and 5.0 meters long.
5.7 JOINT SEALING AND JOINT FILLER
5.7.1 GENERAL
A Scope

1. These works shall consist of furnishing and installing joint sealing and preformed
expansion joint filler materials as and where shown on the Drawings, or as directed by the
Engineer.
5.7.2 MATERIALS: JOINT SEALING COMPOUNDS
A Hot Type
1. This type shall be a mixture of virgin synthetic rubber or reclaimed rubber, or a

combination of the two, with asphalt plasticisers and tactified. Ground cured rubber scrap
shall not be used.
2. The joint sealing compound, after heating and application, shall form a resilient and
adhesive compound capable of effectively sealing joints in concrete against the infiltration
of moisture and foreign material through repeated cycles of expansion and contraction. It
shall be capable of being brought, by heating, to a uniform, smooth pouring consistency,
free from lumps, and suitable for completely filling the joints and without damage to the
material. It shall not flow from the joints or be picked-up and tracked by vehicle tyres at
summer temperatures.
3. The pour point shall be at least 11 degrees C lower than the safe heating temperature.
The safe heating temperature is defined as the highest temperature to which the material
can be heated and still meet all requirements of this specification. No sample of the
material will be tested until the manufacturer furnishes his recommended safe-heating and
pouring temperatures.
4. After 6 hours of continuous heating, with constant mixing in the laboratory at the
manufacturer's recommended pour temperature, the joint sealer shall meet all
requirements of this specification.
5. The penetration at 25 degrees C, 150 gm, 5 sec, shall not be less than 50 mm nor more
than 90 mm.
6. The flow at 60 degrees C and at a 75-degree angle shall not exceed 10 mm in 5 hours.
7. Ductility at 25 degrees C shall be not less than 350 mm.
8. The material when tested at minus 17.8 degrees C to 100 percent extension 1270 mm
extended to 2540 mm shall, after 5 cycles, show no surface checking, cracking, separation
or other opening in the material or between the material and the block. At least 2 test
specimens in a set of 3 specimens representing a given sample shall meet this
requirement.
9. Recovery shall be not less than 25 percent.
10. Compression recovery of bond specimens shall be not less than 10 mm in 15 minutes.
11. No failure in cohesion or adhesion shall occur.
12. Samples for testing shall consist of not less than a 4.5-kilogram sample from each batch of
the joint sealer. A batch shall be considered as all finished material that was
manufactured simultaneously or continuously as a unit between the time of compounding
and the time of packaging or placing in shipping containers. Each package or container
shall be marked properly to indicate clearly the batch of which it forms a part. The material
shall be sampled in accordance with the requirements of the "Standard Methods of
Sampling Bituminous Materials" (ASTM D140) for solid materials in cakes.
13. Testing shall be in accordance with AASHTO T 187 except that the tolerances on
dimensions of test specimens, Article 6.3 shall be + 0.13 cm and the temperature
tolerances, Article 6.4 shall be + 2.2 degrees C.
B Cold Type
1. This type shall be homogeneous material of such consistency that it can be applied by
means of high-pressure pump through suitable nozzles to completely fill the joints. The
compound may be blended with a suitable solvent or solvents by the manufacturer to

provide better workability during installation in the joints. The volatility of these solvents
must be such that they will evaporate within a short time after installation leaving a
material that is adhesive and resilient.
2. The flow during a 5-hour period at 60 degrees C shall not exceed 50 mm.
3. After evaporation of the solvent, the penetration at 25 degrees C, 150 gm, 5 sec, shall not
exceed 220 mm.
When the compound is tested at minus 17.8 degrees C, the development at any time
during the test procedure of a crack, separation or other opening which is at any point over
64 mm deep in the material or between the material and the concrete block, shall
constitute failure of the test specimen. The failure of more than 1 test specimen in a group
of 3 specimens, representing a given sample of joint sealing compound shall be cause for
rejection of the sample on the basis of this requirement.
4. Cold-type joint compound shall be tested in accordance with ASTM D 1851, except that
the material for test specimens Article 7(c) will be stirred manually rather than
mechanically.
5. Preformed Polychloroprene Elastomeric Joint Seals shall comply with the requirements of
AASHTO M 220 (ASTM D 2628).
C Joint Sealant for movement joints in water retaining structures shall be polysulphide-based
compound to BS 4254 or as manufactured by:
o Man: Expandite Ltd.
o Ref: Thioflex 600
o Man: Servicised Ltd.
o Ref: Paraseal
D Exposed Joint Sealant for movement joints is to be approved polysulphide rubber-based

compound unless otherwise specified.
o Man: Dunlop Ltd.
o Ref: High butyl mastic 421.8
o Man: Expandite Ltd.
o Ref: Thioflex 600
E Backing strip shall be the type recommended by joint sealant manufacturer.
5.7.3 PREFORMED EXPANSION JOINT FILLER
A Description
1. This type of filler shall be a non-extruding and resilient bituminous type and shall have
relatively little extrusion and a moderate to high amount of recovery after release from
compression.
B Requirement

1. Nonextruding and resilient type of expansion joint filler shall conform to all the
requirements of the Standard Specification for "Preformed Expansion Joint Fillers for
Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous
Types)", AASHTO M 213 (ASTM D 1751).
C Movement Joint Sheet Material Filler
1. For expansion joints in water retaining structures is to be bonded granular cork to ASTM D
1752 or ASTM D 1751 or as manufactured by:
o Man: Expandite Ltd
o Ref: Cork filler
o Man: Servicised Ltd
o Ref: Kork-Pak
5.7.4 CERTIFICATE OF GUARANTEE
A The Contractor shall furnish the Engineer with a manufacturer's certificate of guarantee for
each type of joint material delivered to the Site. The certificate shall note compliance with
the appropriate specifications and shall state the results of the tests performed on the
material, as required by the specifications. The Contractor shall, when so directed by the
Engineer, have the joint material tested for conformance to the applicable specifications at
an approved testing laboratory. All costs connected with certificate of guarantee and any
subsequent quality testing shall be at the Contractor's expense.
5.7.5 CONSTRUCTION
A Joints shall be:
 Straight, vertical, horizontal or as detailed or approved.
 Formed to accommodate projecting reinforcement.
B Movement joints are defined as:
 Formed expansion joints.
 Formed contraction joints.
 Induced contraction joints.
C Formed Movement Joints: Construct rigid stop ends and formwork at formed movement
joints to permit separate con¬struction of structurally separate parts of the work.
D Construction Joints: Where not coincident with movement joints submit proposals for
positions of construction joints and obtain approval.
E Construction Joints: Lightly roughen face to expose coarse aggregate unless otherwise
instructed. Wet and cover with 1:1 cement and sand grout immediately prior to placing
fresh concrete. Stop roughening 25 mm from arrises to sur¬faces exposed to view in
finished work. Remove small mortar lips from exposed arrises with carborundum stone.
Face is to be clean and damp before fresh concrete is placed against it.

F Concrete Floors: Side and end forms are to be square edged with steel top surface.
G Waterbars: Nail to forms prior to concreting and butt joint in accordance with the
H Sealing of Movement Joints: Preparation and application is to be strictly as manufacturer's

recommendations. Joints are to be thoroughly clean and dry, free from oil and loose
material. Vigorously wire brush or grit blast the joint faces and clean out with compressed
air. Prime faces of joint and allow to dry. Where exposed to view mask edges of joint with
tape before priming and remove immediately after sealing. Apply sealant ensuring
maximum adhesion to sides of joint and a neat, smooth and clean finish.
END OF SECTION

TABLE OF CONTENTS
PART 1 GENERAL 5
1.1 SCOPE 5
1.2 APPLICABLE STANDARDS 5
PART 2 QUALITY OF MATERIALS 5

2.1 SPECIFICATIONS 5
2.2 CONCRETE 5
2.3 QUALITY 7
2.4 MIXING 7
2.5 WATER 7
2.6 PLACING AND CLEANLINESS 8
2.7 CEMENT 8
2.8 ADDITIVES 8
2.9 SAMPLES 8
2.10 SAND (FINE AGGREGATE) 8
2.11 COARSE AGGREGATE 9
2.12 SIZE OF AGGREGATE 9
2.13 CEMENT MORTAR. 9
2.14 IRON AND STEEL WORK 10
2.15 STABILIZED BACKFILL 10
2.16 WATERPROOFING 10
PART 3 EXCAVATION SECTION 10

3.1 GENERAL 10
3.2 SUB-SOIL 10
3.3 PROTECTION OF EXCAVATED MATERIAL 11
3.4 TIMBERING, ETC. 11
3.5 OBJECTION 11
3.6 MECHANICAL EXCAVATORS 11
3.7 SILENCERS 11
3.8 PROTECTION PAVING 11
3.9 PILOT HOLES AND TRIAL EXCAVATIONS 12
3.10 SIDE SHAFTS 12
3.11 SUPPORTS 12
3.12 WIDTH OF TRENCH 12
3.13 STANDARD DEPTH 12
3.14 CHANGE OF LEVEL 13
3.15 TRENCHES FOR POLYETHYLENE CABLE 13
3.16 TUNNELLING 13

Telecom ICT Security ELV Ducting Technical Specifications 19-Sep-2022
3.17 GROUND WATER LOWERING 13
3.18 BLASTING OF ROCK 14
3.19 BUNDS 14
PART 4 DUCT AND CABLE LAYING SECTION 14

4.1 DRAWINGS 14
4.2 LINE OF DUCT 14
4.3 DUCT FORMATIONS 14
4.4 LAYING OF DUCT 14
4.5 DUCT LEADING INTO BUILDING 14
4.6 CLEARANCES FROM OTHER SERVICES 14
4.7 CLEARANCE FROM ELECTRICITY SUPPLIES 15
4.8 VARIATION OF DUCT 15
4.9 DUCT IN TUNNEL 15
4.10 CUTTING AND BENDING OF DUCT 15
4.11 COVERING OF DUCT 15
4.12 ROCKY SOILS 16
4.13 CLEANING AND TESTING 16
4.14 DEFERRED JOINTING CHAMBER 16
4.15 PLUGS 16
4.16 DRAW ROPE 16
4.17 ALIGNMENT TEST FOR DISTRIBUTED DUCT 16
4.18 SCRAP MATERIAL 17
4.19 UPVC DUCT – 100MM DIA 17
4.20 TRENCH 17
4.21 FORMATION 17
4.22 LAYING AND JOINTING 17
4.23 ALTERNATIVE METHOD OF JOINTING AND LAYING 19
4.24 BENDS 19
4.25 VARIATIONS 19
4.26 BACKFILL 19
PART 5 LEAD IN 19
5.1 DUCT SEAL 19
5.2 LEADS-IN TRACK 21
5.3 CAULKING 21
5.4 SEALING OF CONDUITS AND PIPES 21
5.5 UPVC DUCT – 50MM DIA 21
5.6 TRENCH 22
5.7 LAYING AND JOINTING 22

5.8 BENDS 22
5.9 VARIATIONS 22
5.10 BACKFILL 22
PART 6 POLYETHYLENE CABLE LAYING 22

6.1 POLYETHYLENE CABLE 22
6.2 MOLE PLOUGHING 23
6.3 CROSSING 23
6.4 TERMINATING POINTS 23
6.5 JOINT MARKER 23
6.6 CAPPING, STEEL OR PVC 23
6.7 CUTTING AND SEALING 23
PART 7 SLEWING AND / OR LOWERING OR RAISING OF DUCT 24

7.1 EXCAVATION 24
7.2 STRONG BACK 24
7.3 SUSPENSION 24
7.4 SLEWING ONLY 24
7.5 MOVEMENT 24
7.6 TRENCH BOTTOM 25
7.7 IRREGULARITIES 25
7.8 PULLED JOINTS 25
7.9 INSPECTION 25
7.10 TESTING 25
PART 8 JOINTING CHAMBERS SECTION 25

8.1 GENERAL 25
8.2 TYPES OF JOINTING CHAMBERS 25
8.3 VARIATIONS 25
8.4 CLEARANCE OF DUCTS 26
8.5 PROTECTION OF CABLES AND ASSOCIATED EQUIPMENT 26
8.6 DUCT ENTRIES INTO EXISTING STRUCTURES 26
8.7 DUCT ENTRY 27
8.8 JOINTING CHAMBER FITTINGS 27
8.9 IRON AND STEEL WORK 27
8.10 RECOVERED MATERIAL 27
8.11 SUMPS 28
8.12 JOINTS IN CONCRETE 28
8.13 CONCRETE QUALITY AND FINISH 28
8.14 COMPACTION AND TAMPING OF CONCRETE 29
8.15 WET SITUATIONS 29

8.16 SHUTTERING 29
8.17 REMOVAL OF SHUTTERING 29
8.18 FRAMES AND COVERS FOOTWAY, CARRIAGEWAY NOS. 1, 2, 3 (DOUBLE
TRIANGULAR TYPE) 30
8.19 INSTALLATION AND RENEWAL AND/OR CHAIN AGE LEVEL USING CEMENT OR
RESIN MORTAR OR RESIN BEDDING 30
8.20 CONCRETE SURROUNDING 31
8.21 JOINT MARKERS AND MARKING POSTS 31
PART 9 FILLING- IN AND RESTORATION OF PAVING SECTION 31

9.1 GENERAL 31
9.2 RAMMING 31
9.3 COMPACTION TEST 32
9.4 SEALING 32
PART 10 SAFETY PRECAUTIONS SECTION 33

10.1 GENERAL 33
10.2 P.V.C CEMENT AND METHYLATED SPRITS 33
10.3 RESIN PACK NO. 6A 33
10.4 RESI N BEDDING AND RESIN MORTAR 33
PART 11 POLYURETHANE SUB DUCT LAYING SECTION 34

11.1 GENERAL 34
11.2 PULLING OF SUB DUCTS 34
11.3 DUCT PULLING 35

TELECOM ICT SECURITY ELV DUCTING TECHNICAL SPECIFICATIONS
PART 1 GENERAL
1.1 SCOPE
A This document contains the required specification on civil work for ducting Networks to be
applied during implementation stage to support the telecommunication/ ICT/ Security/ ELV
services.
1.2 APPLICABLE STANDARDS
A The infrastructure telecom/ ICT design works shall comply with the following standards:
a) Smart Destination ICT Employer Requirements (Asset Design Guidelines) - Asset

Group - Hotel (Hotels Premium, Luxury, Ultra Luxury) issued by TRSDC.
b) Saudi Telecom Company requirements (STC).
c) Communications & Information Technology Commission (CITC) guidelines.
PART 2 QUALITY OF MATERIALS
2.1 SPECIFICATIONS
A All materials not otherwise specified are to be in accordance with the Specification of the
British Standards Institution, in so far as those Specifications apply. All material needs to
be submitted to TRSDC for approval.
2.2 CONCRETE
A Concrete shall be of the quality required by this Specification or as directed by the Site
Engineer.
B The contractor must use ready mixed concrete for any specified grade of concrete, subject
to approval of the concrete supplier and mix design, etc., by the Site Engineer. Already
mixed concrete shall conform to BS 5238, batches at the concrete plant, to be used to
approval and shall comply with all the requirements of the concrete.
C The concrete shall be carried out in purpose made agitators operating continuously, or
transit mixers specially designed to carry the product. The concrete shall be compacted in
its final position within a maximum period of two hours of its batching time at the plant
unless a longer period is agreed by the Site Engineer under special circumstances. The
time of batching concrete shall be recorded on the delivery note along with the details of
the constituents of each batch of mix.
D When truck mixed concrete is used water is to be added at the central batching plant of
quality and in quantity as specified or approved. With trucks mounted with proper water
dispensers the possibility of adding water, to dry mixed batch at site can be permitted if
agreed by the Site Engineer. Under no circumstances water shall be allowed to be added
either during the transit or at site to the ready mixed concrete.
E The transit mixers and their mixing and discharge requirements shall comply with the
requirements of BS 4251.

Table 1 Concrete Mix Design
(Grade of Concrete) SRC A B C D
Characteristic strength 40 35 25 15
days in N/mm2 28 0
Individual Test Results

To be more than (N/mm2) 32 28 20 12
Mixes to be designed for a 48 44 32 20

mean
Strength (N/mm2)
Slump Max (with plasticizer) 70 70 100 120
Max. water cement ratio 0.4 0.45 0.55 0.65
Minimum Cement (kg/m3) 400 370 300 250
Total Aggregate (kg/m3) 1650 1700 1750 1800

percentage of fine aggregate to
total Dry Aggregate
Zone (C) 45 – 40 45 – 40 50 – 35 50 – 35
Zone (M) 40 – 35 40 – 35 50 – 35 -
Zone (F) 35 - 30 35 – 30 50 – 35 -
Nominal maximum size of mm 20 20mm 20mm 10mm

aggregate
Method of compaction All (A – B – C – D) Vibrated
F For pump able concrete, admixture may be used to increase the workability. As there is
likelihood of higher strengths due to their use, the requirements of average of four cubes
and that of an individual test result have to be correspondingly increased and those figures
shall be agreed upon at the trial mix stage.
G 7 – Day’s strength is 0.8 of 28 days strength.
H All Materials are to generally conform to the standards as shown in Table 2:
Table 2 Material Standards
Material Standards
Cement BS 12
Water BS 3148 (also as specified for concrete works)
Aggregates BS 882
Admixtures BS 5075 Part I

I All concrete mixers are to be designed according to requirements of the above table. As
directed by Site Engineer.
2.3 QUALITY
A Where necessary, details of the concrete to be employed for Jointing Chamber

construction will be included on the construction drawing. In all other cases, Concrete
Quality “A” shall be used for the construction of jointing Chambers and for other operations
as specified.
B Concrete Quality “D” shall be used for concrete blocks in which ducts are laid andfor filling
Frames and Covers unless otherwise specified, also for duct concrete surround.
C Where a coarse concrete is required for supporting or protecting buried plant, Concrete
Quality “C” shall be used, unless otherwise specified.
D Concrete Quality “B” shall be used for insertion between electricity supplies andplant where
normal separation cannot be obtained, unless otherwise specified.
2.4 MIXING
A Concrete mixing will be done by machine however hand mixing may be allowed only at the
discretion of Site Engineer for minor works. Such minor works shall not exceed 0.5m3or 3
bags of cement whichever is less, provided 10% more cement is added for the same batch
of mixing. When mixed by hand, the ingredients shall be repeatedly turned over and mixed
in a dry state on mixing boards, after which water from the rose of a watering can shall be
added, and the material shall then again be turned over sufficiently to ensure thorough
mixing.
B When mixed by machine the ingredients shall be put into the machine dry without prior
mixing. The water may be inserted either first or last. Such machines shall, however, be
used only so long as they ensure thorough mixing and are maintained in clean condition.
They shall be of the “batch “type.
C Sand and aggregate, other than all-in aggregate, shall be stored separately on site.
2.5 WATER
A The standard cleanliness of water for mixing is that it shall be free from impurities. The
quantity used shall be sufficient, but not more than sufficient, to secure a plastic mixture
and shall not exceed that necessary to provide the maximum specified slump. The Site
Engineer may reject concrete which, in his opinion, is over watered to the extent that its
strength will be impaired.
B Further, the quality of water shall conform to BS 3148 The pH requirements of water shall
be from 7-9.
C The inorganic impurities or water shall not exceed the following:
a) Chloride = 600mg/litre
b) Sulphate = 500gms/litre
c) Total dissolves solid = 2000mg/litre
d) Alkali carbonate and Bicarbonate = 1000mg/litre

2.6 PLACING AND CLEANLINESS
A The concrete shall be deposited in its intended position as quickly as possible after being
mixed within the specified time period and all concrete footings and foundations shall be
tamped and carefully levelled.
B Concrete which has become hard, dry or dirty after being mixed shall not be used. If any
earth falls on the top of any concrete after laying and before the work is completed it shall
be carefully removed.
C Cleanliness shall be observed in all operations and in relation to all materials.
2.7 CEMENT
A All cement shall be fresh and of approved manufacturer. Wherever so specified ordinary
Portland cement shall be locally manufactured complying with 12 or ASTM 150 type 1
Sulphate-resisting cement to be used for all underground structure.
B Unless specifically any other type of cement is recommended to be used shall be to BS

4027 or ASTM 5. The soil conditions may require the cement to be type MSRPC, which will
take preference on any other type of cement.
C Cement brought to the site shall have prior approval and the contractor shall submit at all
times the manufacturers test certificate and proof that required specification has been
complied with together with a note of the date manufacture certificate by an independent
approved lab. The cement shall be rejected in case considered as unsuitable for the works.
D The cement shall be properly stored under cover and clear ground to well protect against
the effects of weather and contamination. Bags of the cement once opened shall be
completely consumed.
2.8 ADDITIVES
A No additives of any type shall normally be allowed unless approved by Site Engineer.
Wherever fair surfaced concrete is specified or for ready mixed concrete the contractor
shall use approved plasticizers to improve the workability of concrete. All plasticizers shall
be strictly used to the recommendations of the manufacturer.
B The concrete for all below ground structures has to be necessarily watertight. For this
purpose a suitable approved integral waterproofing compound described as a blend of
inorganic plasticizer shall be used.
2.9 SAMPLES
A Where required, the Site Engineer shall direct the contractor to provide the required
certificate of test report for the cement from approved independent laboratory.
2.10 SAND (FINE AGGREGATE)
A All sand shall be in accordance with BS 882; part 2 grading of sand shall be within the
limits of class C or M table 5 of BS 882. The percentage by weight passing BS 410 test
sieve 300mm shall not exceed 30%.
B Fine aggregates shall comply with the following specifications:
a) Clay lumps and flyable particles (to ASTM C142) – Max 1% by weight.
b) Coal, Lignite and shells (to ASTM C123) – max 1% by weight.

c) Acid soluble Chloride – Less than 0.06% by weight.
d) Acid soluble Sulphates – Less than 0.04% by weight.
e) Sodium Sulphate soundness test (ASTM C88-5 cycles) – loss less than 10%by
weight.
f) Sand equivalent (AASHTO M6) – Minimum 70%.
g) Water absorption (ASTM C128/127) – Maximum 2%.
2.11 COARSE AGGREGATE
A The coarse aggregate shall be in accordance with BS 882, part 2 Grading or coarse
aggregate shall be with Table 1 of BS 882 for nominal size of graded aggregate 20mm to
5mm.
B Coarse aggregates shall nominally comply with the following specifications:
a) Soft and flyable particles (to ASTM 142) – max 1% by weight.

b) Organic material of any nature – Not allowed.
c) Acid soluble Chlorides (BS 812) – less than 0.03% by weight.
d) Acid soluble Sulphate (BS 812) – Less than 0.03% by weight.
e) Magnesium Sulphate soundness test (ASTM C88) – Loss less than 10% by weight.
f) Fine value (BS 812 part 111) – More than 100kn.
g) Flakiness and Elongation Index (BS 812) – Less than 2.5%.
h) Abrasion loss (ASTM C131) – Less than 2.5%.
i) Water absorption (ASTM C128/127) – Maximum 2.3%
2.12 SIZE OF AGGREGATE
A Aggregate for each of the qualities of mix shall be graded up to and including:
a) A - 20mm
b) B - 20mm
c) C - 20mm
d) D - 10mm
2.13 CEMENT MORTAR.
A The Cement Mortar shall consist of:
B One measurement of cement confirming to the relevant BS.
C Three measures of sand conforming to BS 1200.
D The materials after being gauged shall be thoroughly mixed in a dry state on mixing boards
and then thoroughly mixed with sufficient water to form a stiff mortar.
E On no account shall water be added after mortar has once been mixed and mortar, after it
has once begun to set, shall not be used or mixed with other cement and sand.

F An excess of water shall in no case be used for mixing, and if more water than is
necessary be used, such mortar after it has begun to set shall not be mixed with further
quantity of sand and cement, but the whole shall be condemned.
2.14 IRON AND STEEL WORK
A All reinforcing bars (epoxy coated) shall be hot rolled high yield strength bars from an
approved manufacturer complying with BS 4449 or similar approved standard. Cold twisted
bars shall be to BS 4482 or equal approved standard. Steel Fabric reinforcement shall
comply with BS 4483 or equal approved standard. All steel received at site shall have
necessary mill certificate and shall be subject to confirmation tests from an approved
independent test for which samples shall be drawn from actual batch of steel employed for
the works.
2.15 STABILIZED BACKFILL
A Stabilized Backfill shall consist of excavated soil mixed with cement. The ratio of excavated
soil to cement shall be 10 to 1, or as otherwise specified, for the backfilling of trenches.
Mixing may be carried out by hand or machine in either case the mixing shall be sufficient
to give an even colour throughout.
2.16 WATERPROOFING
A All concrete works below ground and in contact with soil shall be water proofed in the
following manner.
B Externally all concrete surfaces shall be applied with a suitable primer and then with a self-
adhesive membrane equivalent to Bituthene 1000 XHc or equal approved. The membrane
shall be protected by 3mm thick protection board. The protection board shall be properly
wrapped and secured in place before any backfilling works.
C All such structures shall have heavy duty water stop min 250mm wide (Centre fix or
rearguard type depending on the situation at site).
D All application shall be strictly to the manufacturer’s recommendations.
PART 3 EXCAVATION SECTION
3.1 GENERAL
A The Contractor shall excavate in the Carriageway or Footway, in positions as he may be

directed by the Site Engineer carefully segregating the surface and foundation materials
from other excavated materials in the order that, unless otherwise directed by the Site
Engineer, they may be replaced, as possible in their original order.
3.2 SUB-SOIL
A Excavated subsoil shall be protected from weathering action which would cause a
damaging increase in the natural moisture content of the soil, leading to the formation of
voids and / or settlement after backfilling.
B The amount of excavated soil left exposed above ground overnight shall be kept to a
minimum.

C Normally a certain amount of subsoil, roughly equivalent to the volume of duct being laid is
surplus and carted to tip. Subsoil which is damaged or unsuitable shall be selected for
cartage to tip and, if required, suitable undamaged subsoil shall be brought from a newly
excavated length or imported to site to replace the subsoil carted away.
3.3 PROTECTION OF EXCAVATED MATERIAL
A The type of protection to be undertaken is as follows:

1. Wet weather excavated material shall be staked in a ridged heap and protected against
rain by covering with polyethylene or other waterproof sheeting. Where excavated
materials cover a channel, boards, or alternatively a length of duct, shall be laid beneath
the excavated material to maintain the water channel. Some of the excavated material
shall be placed to act as Adam to turn water away from any open excavation.
2. Dry weather subsoil being excavated and backfilled during the same day needs no special
protection unless it is in the form of large pieces of clay which may become baked hard, in
which case they should be covered with smaller material from the subsoil or with
polyethylene or other waterproof sheeting. Any subsoil left exposed above ground over
night or for longer periods should be protected with polyethylene or other waterproof
sheeting in order that natural water content is maintained.
3.4 TIMBERING, ETC.
A Except where otherwise provided, the excavation shall include all necessary timbering,
sheet piling and shoring to maintain stability of the excavation.
3.5 OBJECTION
A If the Contractor shall object, in writing to any position selected as being likely to cause
damage to adjoining property, the contractor shall give such modified directions as shall
remove
B the objection or shall submit the matter to the Engineer, and if he deem the objection to be
reasonable, the Contractor shall be relieved of liability for damage that may result from due
and proper execution of the work in the position so objected to. In this event the contractor
shall submit a proposal to specify the precautions that shall be taken to safeguard the
property which gives rise to the objection to the Engineer.
3.6 MECHANICAL EXCAVATORS
A Any mechanical excavator must be capable of allowing for and should be used in such a
manner as to fulfil the requirements of this specification in respect of segregation of
materials and width of trench obtainable by using manual excavation.
3.7 SILENCERS
A Where pneumatic drills or other power-driven road breaking appliance are used, they shall
be fitted with efficient silencing devices. The compressor and other power-driven machines
used for work shall be maintained in an efficient condition so as to avoid undue noise.
3.8 PROTECTION PAVING
A The contractor shall take all reasonable steps to prevent damage to pavings by his plant,
and to protect pavings from contamination by fuel and / oil from his equipment.

3.9 PILOT HOLES AND TRIAL EXCAVATIONS
A The contractor shall excavate in the carriage way or footway in positions as he may be
directed by the Site Engineer, such pilot holes or trial excavations as are necessary to
meet the requirements.
3.10 SIDE SHAFTS
A Where deemed necessary by the Site Engineer Side shafts shall be excavated alongside
the trench as required to negotiate obstructions.
3.11 SUPPORTS
A The supports of an excavation shall be so designed and placed to prevent loss of ground
from beneath adjacent paved surface and to permit, wherever possible withdrawal of such
supports and consolidation of the space occupied. The prior agreement of Site Engineer
must be obtained and recorded in the Works Diary where the withdrawal of supports is
considered to constitute a greater danger to the surrounding property than the subsequent
void produced by rotting timber
B Existing mains and services shall be adequately supported by temporary slinging or

strutting or where required by the Site Engineer, by brick or concrete piers. At the
discretion of the Site Engineer where existing mains or services render compaction of the
back fill beneath them difficult the backfill shall be stabilized by mixing it with cement in the
ratio of 10 parts soil 1 part cement by volume.
3.12 WIDTH OF TRENCH
A In no case shall be the width of trench excavated be greater than is reasonably necessary
for satisfactory execution of work. In unmade however, this requirement may be waived at
the discretion of the Site Engineer, if the Contractor desires to use a wide excavator in
such a position where a wide trench would not be determined to property or carriage way
haunches. Diary entries shall show the agreed necessary width, the actual width being
recorded as a note.
3.13 STANDARD DEPTH
Table 3 Standard Depths
Type of ducts Standard Depth of cover to top of upper most Barrel or for
ducts laid in concrete to top of concrete surround. In any
paving
.uPVC single way and 2 way 600 mm to 800 mm

100mm Dia Duct/ 50mm Dia Duct/ HDPE
.uPVC Multi way 600 mm to 800 mm

100mm Dia Duct /HDPE (Over 2 and up to
And including 20 ways)
.uPVC Multi-way 600 mm to 800 mm

100mm Dia Duct /HDPE (Leads-in
buildings

And over 20 ways for street tracks)
All other Types As specified
Polyethylene Cable 600 mm to 800 mm or laid in duct as above

Laid direct in ground
Vehicular crossings
Customers gardens or Cultivated ground)
3.14 CHANGE OF LEVEL
A In passing from foot path to carriage way and vice versa, or where ducts enter jointing
chambers below standard depth, or in any other circumstances where it is necessary to
change the level, the bottom of the trench shall rise or fall gradually as the Site Engineer
may direct.
3.15 TRENCHES FOR POLYETHYLENE CABLE
A Excavation for the laying of polyethylene cable direct to the ground shall be carried out by
the Contractor at such positions as may be directed by the Site Engineer.
B The trench may be “V” shaped provided that: The base of the trench is of sufficient width to
accommodate the cable or cables, laid adjacent with minimum separation, and It is of the
required depth.
C At points detailed on the schedule of work, or by the Site Engineer, where a cable has to
cross a boundary wall from a footway to a customers’ garden and it is not possible to lay
under the boundary wall, the Contractor shall break through the wall and insert a short
length of suitable duct. Any void around the duct shall be packed with concrete and the
ends of the duct well rounded to prevent the possibility of damage to the cable.
3.16 TUNNELLING
A In no case shall the width or height of any tunnel be greater than is necessary for the
satisfactory execution of the work.
3.17 GROUND WATER LOWERING
A Where site conditions are such that water could be removed from the area by suction
pumps working from sumps into which the water drains, the Contractor may, for his own
convenience and with the Site Engineer consent use of a dewatering system. The Site
Engineer’s consent to use in the vicinity of an excavation of de-watering system involving
riser pipes which draw water from the ground through fixed filters attached to the riser
pipes will be subject to:
1. The provision, where necessary of sand aggregates filters in the ground around the riser
pipes.
2. The absence of fine particles in the discharge after the first 20 minutes of pumping if, after
this period of time, fines are still being extracted with water, the riser pipes shall be
individually withdrawn to facilitate a check of the ball valve and gauze screens in each well
point head. The consent of the Site Engineer may be withdrawn at any time, if de-watering
operation appears to be causing subsidence due to soil migration or shrinkage.
3. Where site condition are such that the use of de-watering equipment is agreed by the
Engineer to be the only practical method of carrying out the work, then Client/ Supervision
Consultant will nominate a specialist firm or to the contractor having the knowledge and

facilities to carry out de-watering operations in the area without liability to the Contractor.
3.18 BLASTING OF ROCK
A Excavation of rock encountered below ground during duct laying operations may be
assisted by the use of explosives, the use of explosives will be allowed provided that:
1. Public and private property, above ground, are in no way endangered.

2. Client is satisfied as to the competence of the shot fires ability, which may require a trial
demonstration.
3. The contractor takes all necessary precautions for the safety members of the public, Client
and Contractor’s own staff.
4. The contractor has obtained all necessary permits from Government Bodies/ authorities.
3.19 BUNDS
A Bunds shall be constructed in such a manner that they can contain water with depth not
exceeding 750mm. The overall size will depend upon the volume of water to be contained
and/or conditions imposed by the Authority and Public Health Authority.
PART 4 Duct and Cable Laying Section
4.1 DRAWINGS
A Drawings as per design/ IFC drawings.
4.2 LINE OF DUCT
A The line of duct shall be kept as straight as possible.
4.3 DUCT FORMATIONS
A The duct formation shall be either specified for the type of duct concerned or as detailed on
the schedule of Work but subject to the discretion of the Site Engineer.
4.4 LAYING OF DUCT
A Duct laying shall be done only in accordance with this Specification and such directions
and instruction of the Site Engineer, which shall be closely followed. Duct laying may only
be done in the absence of client/ supervision representative when prior permission has
been given.
4.5 DUCT LEADING INTO BUILDING
A All ducts leading into buildings shall be both gastight and watertight.
4.6 CLEARANCES FROM OTHER SERVICES
A All types of ducts and cables laid in the grounds shall be kept well clear of gas or water
mains and service pipes, sewers and subways, manholes and joint boxes belonging to
other undertakers. In order to admit the use of “Tapping” machines on gas and water

mains, at least 300mm clearance shall be given, if practicable, to other classes of plant
mentioned above. In no case shall the clearance be less than 150mm and where two sets
of plant cross each other, the minimum vertical clearance shall be 150mm.
4.7 CLEARANCE FROM ELECTRICITY SUPPLIES
A Clearance of telecom plant from electricity supplies shall be as follows:
1. As much clearance as is practicable shall be given to the bases of trolley wire standards,
electric lamp standards, traffic signal posts and other similar plant. Where it is impossible to
provide a clearance of 150mm or more, a layer of concrete Quality “B” not less than 50mm
thick, shall be placed between the two sets of plant.
2. High voltage single-core cables for electricity supply, electric tramway or electric railway
systems, EXCEEDING 650 VOLTS, shall have a standard minimum clearance of 450mm. NO
exception to this requirement is permitted.
3. High voltage multi-core for the same systems referred to in (b) above and EXCEEDING
650 VOLTS, shall have a standard minimum clearance of 300mm.In difficult cases a reduced
separation will be permitted provided that where a separation of more than 150mm is
impracticable a layer of concrete Quality “B” shall be inserted between the two sets of
plant whether they cross each other or not. The concrete shall not be less than50mm
thick, and of such width and length that at every point the shortest path between the two
sets of plant, found the concrete shall exceed 200mm.
4. Medium and low voltage cables for supply systems NOT EXCEEDING 650 VOLTS shall
have a standard minimum clearance of 50mm. Where the two sets of plant cross each other
NO exception to this requirement will be permitted. At other points, where difficulties arise, a
reduced clearance down to 25mm will be permittedin which case the space between the two sets of
plant shall be filled with a layer of concrete Quality “B”. The concrete shall not be less than
50mm thick and such width and length that at every point the shortest path between the
two sets of plant, round the concrete, shall exceed 75mm.
4.8 VARIATION OF DUCT
A In any case in which the Site Engineer so directs, the type of duct may be varied for the
good and sufficient execution of the works.
4.9 DUCT IN TUNNEL
A Where duct is laid in tunnel, the heading and all spaces around the duct shall be
completely filled with a well compacted damp mix concrete Quality “C” unless otherwise
specified.
4.10 CUTTING AND BENDING OF DUCT
A The Contractor shall do any necessary cutting of duct to the requirements of the work.
B The inside edges of all cut ducts shall be thoroughly rounded off or so dressed that there
can be possibility of damages to cables.
4.11 COVERING OF DUCT
A All duct not laid in concrete, shall be covered by a layer of earth, free from stones, and
hand punned to a thickness of not less than 300mm, unless otherwise specified.

4.12 ROCKY SOILS
A In rocky or stony soils, earth free from stones shall be spread over the trench bottom and
rammed to afford a bedding approximately 100mm thick on which to lay the duct, as
directed by the Site Engineer. In such cases100mm of extra excavation of the trench will
be necessary to achieve the required depth of cover.
4.13 CLEANING AND TESTING
A On completion of the duct line (including compaction of the backfill) between any two jointing
chambers, or sites thereof, a cylindrical brush and an Iron Test
B Mandrel shall be passed once through each “way” to test the duct and to remove any
foreign matter which may have entered. The mandrel shall follow the brush tominimize
possible scoring or breaking of the duct.
C Where cable damage is suspected the contractor shall afford all reasonable assistance to test the
cable and shall arrange the labour required for the testingoperations.
D All tests shall be carried out in the presence of the Site Engineer, and if anyobstruction or
other defect be discovered it shall be rectified forthwith to hissatisfaction.
4.14 DEFERRED JOINTING CHAMBER
A When the building of a jointing chamber is deferred until after the completion of a section of
duct included in the work each “way” shall be tested, on completion of the jointing
chamber, by means of the mandrel and brush specified for the particular duct. A visual
check shall first be made by the Site Engineer, with the aid of a torch or similar means of
illumination, that no foreign matter or materials are likely to be pushed up the duct. All such
test shall be at the Contractor’s expense.
4.15 PLUGS
A A suitable plug shall be inserted at the end of each “way” of a duct route to prevent the
ingress of water and / or other foreign matter, until all work has been completed on that
section and the length tested and accepted by Client representative.
B In case of road crossing and dead ends, the plug shall be left buried ensuring the rope
properly tied to the plug.
4.16 DRAW ROPE
A An approved draw rope shall be threaded through and left in every “way” following duct
laying operations and satisfactory tests. Jointing together lengths of draw rope to make up
the necessary length between jointing chambers shall be carried out as directed by the
Site Engineer and in accordance with Drawing. Draw rope shall not be joined for the
purpose of conserving lengths shorter than 50 metres.
4.17 ALIGNMENT TEST FOR DISTRIBUTED DUCT
A When jointing chambers are provided on an existing route or when any disturbance takes
place which may affect the alignment of duct, and the Site Engineers directs, a test
mandrel and brush of the appropriate dimensions shall be drawn through each of the spare
“ways”.

4.18 SCRAP MATERIAL
A All the scrap ducts and draw ropes recovered from furniture not reusable shall be delivered
to the disposable location as approved by the Authorities.
4.19 UPVC DUCT – 100MM DIA
A 100mm Dia Duct is manufactured from upolyvinyl – Chloride (uPVC). It is manufactured in

6.0 metre effective lengths, has an internal diameter of 100mm. Each duct length has a
tapered socket at one end which will accept the barrel of the duct.
4.20 TRENCH
A The trench shall be excavated to the required width and depth. The trench bottom shall be
free from stones, level and well punned. The duct shall be laid at standard depths unless
otherwise specified.
4.21 FORMATION
A 100mm Dia Duct may be laid as a single duct or in multi-way formation as follows:
1. Up to and including 9 ways in rectangular formation.

2. Over 9 ways rectangular formation with concrete surround thickness 100mm.
3. Where required, the bottom side of the Multi way Duct may be R/Concrete for 150mm
thick. This shall be considered as extra.
4.22 LAYING AND JOINTING
A Single Way:
1. The open starting end of the trench shall be blanked off with a board or boards, to act as an anvil
against which the duct can be driven home. The duct shall be recessed into the wall of
jointing chambers 10mm from the inside surface. The surface of the duct shall be
roughened with glass paper or sand paper for its length in the jointing chamber wall.
2. The duct shall be laid on the trench bottom with the socket towards the duct layer, the
spigot end and the inside of the socket of the ducts to be jointed shall be thoroughly
cleaned with a dry rag.
3. The spigot end of the duct shall be offered to the socket initially pushed in by hand and then to
achieve proper engagement a suitable wooden batten is
4. placed across the remote socket and tapped with a hammer. Full engagement should be
ensured. Occasionally, due to variations in size, this cannot be achieved, in which case,
excessive force must not be exerted after a tight jointhas been affected.
5. When jointing short lengths of duct together with a coupling, Duct, BOTH SPIGOT ends
and the inside of the coupling shall be thoroughly cleaned with methylated spirits applied
with a clean rag. The spigot ends should be given a liberal coating of PVC. Cement and then
fitted into the coupling. This operation involves using nontoxic and inflammable materials.
B Multiway up to and including 9 ways:
1. The preparatory work and jointing shall be as outlined in this Specification.

2. The first layer of ducts shall be laid on the prepared trench bottom so that their outer surfaces
touch each other and a minimum gap of 100mm remains between the outside ducts and
the sides of the trench timbering where used. Wooden stakes or an approved alternative
shall be driven into the ground at 3 metre intervals along the trench to keep the ducts in
the correct position. Earth, free from stones shall be placed to fill the spaces between the ducts

and the next layer of duct when the latter is bedded down. The second and subsequent layers of
duct shall be laid between the wooden stakes so that they are vertically above and then
bedded down to touch the ducts in the layerbelow, the spaces between the ducts being filled in
the same way with earth, free from stones. The joints shall be staggered so that no joint
touches any other point.
3. At approximately 5 metres from the jointing chamber at each end of the track, the duct formation
shall open out to provide a gap between each duct, both vertically and horizontally, of 25,
using, spacers, Duct No. 2. Over this 5 metres section all spaces between the ducts and the
trench wall shall be filled with well compacted earth, free from stones, as directly by the Site
Engineer.
C Multiway over 9 ways:
1. The preparatory work and jointing shall be as outlined in this Specification.

2. The first layer of duct shall be laid on the prepared trench bottom so that their outer surfaces
touch each other and a minimum gap of 100mm remains between the outside ducts and
the sides of the trench, or trench timbering where used. Mild steel bars, 12mm diameter
and of the required length shall be driven into the ground at 1.5 metre intervals along the
trench to keep the ducts in the correct position. The second and subsequent layer of duct
shall be laid between the mild steel bars so that they are vertically above and touching the
ducts in the layer below. The joints shall be staggered so that no joint touches any other
joint. On completion of the assembly of the duct nest, 6mm diameter mild steel bars shall
be horizontally across the uppermost layer of ducts and tied to the vertical bars.
3. Where the total number of layers of duct in any one formation exceeds 8and the number of ducts in
each layer exceeds 2 the following shall apply. Between the two layers of duct midway, or
approximately midway, from the top and bottom of the duct nest and intermediate layer of
reinforced concrete, 100mm in depth and with 12mm mild steel reinforcing bars
conforming to the layout of reinforcing in the top cover detailed in Drawing, shall be placed
across the duct nest, the additional reinforcing required by this sub-paragraph shall not be
required in the 5 met resections detailed in sub-paragraphs (iv) and (v) below.
4. At approximately 5 metres from the jointing chambers at each end of the track, the duct formation
shall open out to provide a gap between each duct, both vertically and horizontally of
25mm. Banks of spacers, Duct No.2 shall be placed at 325mm and 1324mm from the
jointing chamber wall to provide this spacing. Each spacer bank shall enclose all the ducts
except those in the bottom layer on which the spacer bank shall rest. Where subparagraph
applies, the 100mm intermediate layer shall be reduced over the 5 metresections to provide
the required 25mm spacing at the jointing chambers.
5. Where the total number of layers of duct exceeds three, concreting of spaced formations shall be
in stages such that the number of layers of duct laid and concreted at each stage shall not
exceed three. The concrete shall be brought to a level which shall not interfere with laying of
subsequent layer of duct and spacer.
6. Concrete quality “D” made with Sulphate Resisting cement shall be used throughout and
shall have a slump of 100mm. The concrete shall be evenly placed around the duct to give a
finished minimum thickness of 100mm on both sides and to a depth of 150mm above the top
layer of ducts. Care must be taken to ensure that each batch, as it is placed, is properly
compacted without creating unbalanced side thrust against the ducts. Each batch shall be
vibrated using a vibrator having a maximum diameter of 51mm, the poker shallbe lowered into the
concrete between the wall of the trench and the outside of the duct nest and shall not
touch the duct.
7. In spaced formation sections care must be taken to ensure that the gaps between the ducts
are properly filled with concrete, the final layer of concrete shall be thoroughly trowelled. The
Contractor may use Ready mixed concretefor construction of the duct surround.
8. With formations of four or more ducts wide, mild steel reinforcing bars conforming to
Drawing shall be placed and wired in position before placing concrete over the uppermost
ducts of the completed nest.
9. In the case of column entry manholes, the duct formation shall open out to enter the

manhole as shown on the appropriate manhole drawing and at right angles to the entry
wall. The distance over which the transformation is made shall be no greater than is
necessary to satisfy the 5 metres minimum bending radius for 100mm Dia Duct. The ducts
shall be secured in position during concreting either with spacers, Duct Nos. 2 and3 built
up to the required centres or by reinforcing rods which may be encased in the concrete,
the volume between the separated duct formations shall be excavated and filled with concrete
of the same quality as that surrounding theduct formations.
10. Where required the Road crossings up to 9W shall be encased in concrete as required by the
authorities and the concrete shall be paid as extra as perschedule of rates.
11. The road crossings shall be extended up to the allocated reservations or to appoint as directed by
the Site Engineer at the approved depths if required.
4.23 ALTERNATIVE METHOD OF JOINTING AND LAYING
A Provided space permits. Duct may be jointed above ground and fed into the trench from
one end. The leading end of each duct way being guided into position using a suitable
hooked tool made from 6mm diameter mild steel reinforcing bar.
4.24 BENDS
A Normally bends are not recommended since the duct is sufficiently flexible to provide a
minimum bending radius of 5 metres. Tighter bends should not be attempted otherwise
kinking of the duct may result.
4.25 VARIATIONS
A Any variation of duct formation and / or depth shall only be carried out with the prior
agreement of the Site Engineer.
4.26 BACKFILL
A Backfilling of trenches where 100mm Dia Duct has been laid to Para4.22 (a) and shall be carried out
in accordance with the filling in and restoration of pavingsection of this Specification.
B Where 100mm Dia Duct has been laid to Para 4.22 (c) the end shuttering and trench
supporting timber, if used, shall be removed not less than 12 hours after the concrete has
been placed. Backfilling of the trench, in accordance with the filling inand restoration of pavings
section of this Specification shall not be carried out untila further 48 hours have elapsed.
A The iron test mandrel to be used for testing 100mm Dia Duct shall be 240mm long 83mm
in diameter. The cylindrical cleaning brush.
PART 5 LEAD IN
5.1 DUCT SEAL
A A duct seal, complete with glands, shall be constructed in accordance withdrawingand the
following sub paragraphs prior to any duct laying operations.
B The spigot end of 1.5 metre lengths of 100 mm Dia Duct shall be thoroughly cleanedwith
methylated spirits applied with a clean cotton rag. Jointing adhesive (PVC Cement) shall
be applied liberally to the full circumference of the outside end 100mm of the spigot with a

clean rag. The spigot end shall then be pushed into the back of a Gland, Caulking No. 2.
Surplus adhesive shall be wiped around the
C gland end to form a sealing fillet of adhesive, additional adhesive shall be applied, if necessary, to
form this sealing fillet.
D The external surface of the assembled duct and gland shall then be cleaned with methylated spirits
and coated with Compound No. 21 into which a 3:1mixture of dry sharp sand and cement shall
be pressed, a small area being treated at a timebecause of the speed with which
Compound No. 21 dries out. These applicationsshall continue until a 50mm length of the
gland and a 250mm length of the duct adjacent to the joint have been completely coated.
E Two plywood templates, each a minimum of 25mm thick and at least 150mm larger all-
round the duct opening, shall be drilled with 106mm diameter holes at 130mm centres to
match the number of ducts forming the lead-in. The template for the gland end shall be
positioned on the inner wall of the cable chamber / trench, reinforced and braced as necessary
to ensure that it will remain flat and in position during the subsequent operations.
NOTE: Where the lead-in is angled, the spacings of the centres of the holes in the
templates must beadjusted to provide a separation of approximately 35mm between
ducts.
F The jointed glands shall be fitted to the template and secured, each with two Collars, Gland,
Caulking, with their chamfered ends facing each other, and alack nut. Where the lead-in is angled,
the Contractor will be supplied with the appropriate angled collar’s information of which is given in
the following table:
Table 4 Angled collar’s information
AASHTO T180 Moisture-Density Relations of Soils Using a 4.54 kg Rammer and 457 mm
Drop
Collar Gland Caulking No. Angle
2 50
3 100
4 150
5 Straight
G As the ducts are fixed to the template they shall be temporarily supported so that no strain is
placed on the gland / duct joint. When all the ducts have been secured in position, the second
(outer) template shall be positioned 50mm along the socket,reinforced and braced. The Contractor
shall ensure that all ducts are parallel and except for angled leads-in, at right angles to the templates and
so, maintained during the subsequent concreting operations.
H Concrete Quality “D” having a slump of 50mm, shall then be carefully placed to completely
fill the interstices of the duct nest and to provide a minimum cover of 150mm on the top sides of the duct
nest. The concrete shall be placed in ‘Lift’ shallbe well compacted by using a vibratory poker (maximum
diameter of 50mm) on each side of the duct nest.
I When at least 2 days have elapsed after placing the concrete, the template shall beremoved
and the concrete examined. Small voids shall be filled and rendered flush with the existing face providing they
do not extend beyond two adjacent ducts or do not exceed 50mm in depth. If larger voids than this exist, the
concrete will be regarded as substandard and must be completely removed and replaced.

5.2 LEADS-IN TRACK
A 100mm Dia duct shall be used for all lead-in sections between the building and the
exchange jointing chamber. The duct shall be gastight and watertight, and, irrespective of the
number of ways, shall be laid in accordance with this specification, terminating with duct
sockets recessed 10mm from the inside face of the jointing chamber wall. Additionally prior
to joining, the spigot and socket of each duct shall be thoroughly cleaned with methylated
spirits applied with a clean cottonrag. The full circumference of the outside end 100mm of
the spigot shall then be liberally coated with jointing adhesive (PVC Cement) using a clean
cotton rag and the duct joint shall be made as quickly as possible. Finally, the surplus and, if
necessary, additional adhesive shall be wiped around the end of the socket and adjacent
surface of the duct with a clean cotton rag to form acontinuous sealing fillet.
B Plentiful supplied of clean, dry cotton rags shall be available and, in inclement weather
protection for the jointing operations shall be provided, e.g. a temporaryawning.
C The Lead-in ducts between the duct seal and the manhole (exchange manhole)shall be encased
in concrete.
5.3 CAULKING
A On completion of the cleaning and testing of the lead-in duct route and acceptance by the
Site Engineer, each duct way shall be caulked in the following manner:
1. Drill two 6mm diameter holes, 12mm from the edges, and on the same diameter line, of a
Disc Gland Caulking.
2. Tie a knot approximately 200mm from the end of the draw rope (a draw rope is left in each “way”
following completion of the duct route pass the end of the draw rope through one hole and
back through the other hole and tie a further knot, thus leaving a loop which can be used
to remove the inner disc.
3. Push any surplus draw rope into the duct and place the disc in the gland against the
internal shoulder or R/F concrete as directed.
4. Tightly pack the gland with thoroughly worked Compound No. 16 or approved alternative,
and slightly overfill.
5. Place a second disc into the recess of the end cap and screw onto the gland so
compressing the compound. Additional compound may be required after the original has
been compressed to ensure that there are no voids in the compoundbetween the discs.
6. At the exchange jointing chamber, the Contractor shall repeat the procedure in (a) -
7. above, and tightly pack the socket with thoroughly worked Compound No. 16, or approved
alternative. The compound shall be compressed with a second disc untilthis disc is released
approximately 3mminto the socket.
5.4 SEALING OF CONDUITS AND PIPES
A Small conduits and pipes into subscriber’s premises, call office, kiosks, posts etc., shall be
sealed by pressing a clean rag into the aperture and facing off with a layer of synthetic
rubber. A 25mm depth of rag and a 10mm depth of rubber shall be used. (Silicone Sealant
A, or an equivalent material, shall be used for this purpose).
5.5 UPVC DUCT – 50MM DIA
A General. 50mm Dia duct is manufactured from upolyvinyl-chloride (uPVC). It is

manufactured in 6.0 metre effective lengths, has an internal diameter of 51mm and a
nominal wall thickness of 1.55mm. Each duct length has a tapered socket formed at one
end which will accept the normal barrel of the duct.

5.6 TRENCH
A The trench shall be excavated to the required width and depth and the bottom shall be free
from stones, level and punned. The duct shall be laid at standard depths unless otherwise
specified.
5.7 LAYING AND JOINTING
A The duct shall be laid on the trench bottom with the socket towards the duct layer,the spigot
and the inside of the socket of the ducts to be jointed shall first be thoroughly cleaned with a dry
rag.
B The spigot end of the duct shall be offered to the socket, initially pushed in by hand, and then to
achieve proper engagement a suitable wooden batten displacedacross the remote socket
and tapped with a hammer. Full engagement should be ensured, occasionally, due to
variations in size, this cannot be achieved, in which case, excessive force must not be exerted
after a tight joint has been affected.
C Alternatively, the duct may be jointed above ground and lowered into position onthe trench
bottom where this is more convenient.
D All spaces alongside the duct shall be filled with earth, free from stones and hand punned to a
compacted thickness of not less than 75mm above the top of the ductbarrel.
5.8 BENDS
A The duct is sufficiently flexible to provide a minimum bending radius of 9.5 metres. Tighter
bends should not be attempted otherwise kinking of the duct may result. Bends, 50 mm
Dia Duct (900– 229mm radius) and (900-622mm radius) are only for termination purposes
at poles and small buildings respectively
5.9 VARIATIONS
A Any variation of duct formation and / or depth shall only be carried out with the prior
agreement of the Site Engineer.
5.10 BACKFILL
A Backfilling of the trench shall be carried out in accordance with the filling-in and restoration
of pavings section of this Specification.
A The iron test mandrel to be used for testing 50mm Dia shall be 216mm long and 43mm in
diameter, the cylindrical cleaning brush shall be 57mm in diameter.
PART 6 POLYETHYLENE CABLE LAYING
6.1 POLYETHYLENE CABLE
A The cable will be supplied on drums together with drum spindles and lifting jacks.

B The drum shall be set up at static positions and the cable drawn off and laid intothe trench.
Alternatively, the drum may be set up on a mobile vehicle and the cable paid off along the
trench. The method employed independent upon the circumstances, obstructions and access to
the trench.
C In rocky or stony soils, earth, free from stones, rammed to form a 100mm layer both below
and above the cable shall be provided as directed by the Site Engineer.
6.2 MOLE PLOUGHING
A The Contractor may use mole ploughing techniques in grass or unmade ground,
dependent upon the nature of the sub-soil position of other services, access to line of
route, the depth at which the cable is laid, the use of approved equipment and the Site
Engineer’s agreement. The Site Engineer’s agreement will not unreasonably be withheld.
6.3 CROSSING
A At carriage way crossings and vehicular crossings of the footway, polyethylene cable shall
be laid directly in the ground or drawn into duct, as directed by the Site Engineer. The
Contractor may be requested to draw distribution cable into duct already in use.
B Further a spare duct may also be considered to be laid in line with the cable for
maintenance purposes.
6.4 TERMINATING POINTS
A A sufficient length of cable for terminating purposes will be coiled, and the coil shall either
be buried in the ground or fastened to a pole or wall, as directed by the Site Engineer. In
the latter case, the cable coil shall be fastened at a point above a length of steel or PVC
Capping or Polyethylene Duct. Where Capping, or Polyethylene Duct or cable is fixed to a
wall, the wall shall be plugged to take the fixings.
6.5 JOINT MARKER
A A joint marker will be installed by the Contractor at each buried joint or terminating point as
directed by the Site Engineer.
6.6 CAPPING, STEEL OR PVC
A Steel or PVC capping will be supplied together with Nails, Bonding and Washers, No. 19,
and will be fitted by the Contractor in positions determined by Site Engineer.
6.7 CUTTING AND SEALING
A All cable cutting, temporary sealing of cut ends and jointing will be carried out by
contractor. Where two or more cables are to be jointed, a short length of cable will normally
be overlapped and laid along the line of trench.

PART 7 Slewing and / or Lowering or Raising Of Duct
7.1 EXCAVATION
A The size of the excavation for slewing and / or raising a duct line shall be asdirected by the Site
Engineer.
B Where lowering only is necessary the duct line shall be suspended and the required
excavation taken out down the side and under the duct line. When this method is impracticable the
duct line shall be slewed and raised or lowered temporarily as required by the Site Engineer
for a distance which is just sufficient to allow access for carrying out the excavation.
C With the exception of making slight adjustment to the duct line after slewing and lowering, the duct
line shall not be removed in any way without adequatereinforcement in the form of a strong
back being firmly lashed to it.
7.2 STRONG BACK
A The strong back shall be lashed to the duct line, with both ends of each duct firmly held, using
separate lashings or a continuous rope. The lashings shall be tightened, to the satisfaction
of the Site Engineer.
B Any forces which is necessary to be applied to the duct line to move it in any wayshall be
applied not directly to the duct line but to the strong back lashed to it. Such forces shall be
applied at points whose spacing is sufficiently close to keep the bending of the duct line and
strong back between the points to a negligible amount.
7.3 SUSPENSION
A When the duct line is to be lowered, the complete length shall be suspended from the
suitable beams or tripods and / or approved winching devices spanning the excavation. When the
duct line is to be slewed whilst suspended in this way, the suspending ropes shall be
fastened to slingpoles resting on the supporting beams and running parallel to the duct line
strong back and free to move across the beams. All suspending ropes shall be so
arranged that the duct line can be raised or lowered as required, smoothly and continuously, and
can be tied off firmly at any stage.
7.4 SLEWING ONLY
A When the duct line is to be slewed only, it may be moved without suspending it, provided
that:
1. The surface across which the duct line is to be slid shall be reasonably level and regular,
made so if necessary by setting boards in the surface.
2. The strong back shall be firmly lashed to the side of the duct line.
3. The moving force shall be applied to the strong back by rope, jack or other methodto allow
the duct line to be moved smoothly and without jerking.
7.5 MOVEMENT
A The slewing and / or lowering of the duct line shall be carried out by making a succession
of very small movements of the duct line, each made progressively along the affected length. The
curvature ofthe duct line at any intermediate stage between the initial and final positions shall not
exceed thedeviation limits laid down for laying new duct of the same type.

7.6 TRENCH BOTTOM
A Prior to finally placing the duct the trench bottom shall be prepared in the same way as isspecified
for duct laying.
7.7 IRREGULARITIES
A After the duct line has been finally lowered into its required position and the strong back has been
removed, any irregularities and bore crossings in the general line of the ducts shall be
corrected atthe direction of the Site Engineer.
7.8 PULLED JOINTS
A Where, following slewing and / or lowering or raising operations, a duct joint or joints have
pulledapart, short lengths of ordinary or split duct maybe inserted in the duct line and
satisfactory joints effected as directed by the Site Engineer.
7.9 INSPECTION
A After all operations are completed, the joints of all ducts shall be inspected to ensure that
they areforming an effective seal, any defects shall be made good to the satisfaction of the Site
Engineer.
7.10 TESTING
A All spare bores of the duct line shall be rodded and roped and / or cleaned and tested as
specified for the particular duct concerned and paid.
PART 8 JOINTING CHAMBERS SECTION
8.1 GENERAL
A Jointing chambers shall conform to the standard drawing/s and/or other drawing/s, Manholes
having less than 2000mm Headroom shall not be normally accepted.
8.2 TYPES OF JOINTING CHAMBERS
A JRC 14.
B JRC 12.
C JRC 4.
These manholes have a range of internal heights. The standard type of joint boxes with the code references
employed as per instruction by the Site Engineer.
8.3 VARIATIONS
A The presence of unforeseen obstructions in the ground, or adverse ground conditions, may
necessitate the construction of a type other than that specified, or a modification of one or more of
the dimensions stipulated on the relevant drawing. The Contractor shall be advisedof any
modifications to the drawings and/or schedule of Work by the Site Engineer. The Contractor shall
not carryoutmodifications without the approval of the Site Engineer.

8.4 CLEARANCE OF DUCTS
A Ducts shall enter manholes as shown on the relevant drawings or as directed by the Site
Engineer, unless otherwise required by the drawings or the Site Engineer, the ducts shall
enter the manholes at such depths as will ensure a minimum clearance of 450mm (min) 750mm
(max) above the duct to the roof.
8.5 PROTECTION OF CABLES AND ASSOCIATED EQUIPMENT
A During the cutting of duct entries into existing structures, irrespective of whether vibration-free
methods are used, or during the demolition and rebuilding of jointing chambers, the
Contractor shall take such measures as the Site engineer may direct to protect cables and
associated equipment. Suchmeasures may include any or all of the following requirements.
1. All movement of cables shall be carried out under the direction of the Site Engineer.
2. All ladders shall be provided by the Contractor for access into and out of manhole
excavations. Under no circumstances may cables, joint and associated equipment be used for
climbing, standing or sitting on.
3. Sufficient pumping capacity shall be made available and operated to ensure that when cables are
removed from their bearers they shall not be immersed in water at any time.
4. All cables shall be protected at duct entries by shielding as necessary against mechanical
damage and by packing with foam rubber toast as a cushion when any movements occur.
5. During demolition of the roof of a manhole, the Contractor shall erect a deck of timber
between the cables and the roof of the manhole to protect telecom plant from falling debris
in the following manner:
a) A minimum of four screw jacks shall be evenly spaced and placed horizontally
between the uppermost cables and the underside of the roof. A 25mm recess in
each wall is necessary for the screw jack plate; UNDER NO CIRCUMSTANCES shall
frictionjoints be used between the screw plate and wall. Lengths of poling boards or
other similar timber shall then be placed over the screw jacks to completely protect
cables and/or other equipment from falling debris.
b) Alternatively, the Contractor may use vertical and horizontal timber supports as
follows: a minimum of three 225mm x 75mm timber uprights shall be evenly spaced against
each long wall of the manhole with 225mm x 75mm timber shall be placed horizontally on
top of the uprights and secured, and between the uprights at the bottom, all
positions to be wedged and blocked to the satisfaction of the Site Engineer. Lengths
of poling boards or other similar timber shall then be placed on top of the horizontal
supports.
c) When the manhole roof and walls have been demolished down to the level of the
timber decking and all debris removed, the cables and any other equipment shall be
suspended from the surface to the satisfaction of the Site Engineer.
d) Cables and joints and other equipment shall be protected by dropping (not tying) with
several layers of sacking while the timber decking is being erected and dismantled
and during the demolition of the remainder of the walls.
6. During rebuilding operations, cables shall be supported on wooden benches with cushion of
sacking or similar material once the floor has been laid and the concrete allowedto set.
8.6 DUCT ENTRIES INTO EXISTING STRUCTURES
A General - structure such as jointing chamber, Telephone, Exchanges, Stations and other similar
buildings, which contain cables and / or equipment liable to damage by vibration, shall
have all new duct entries cut with substantially vibration free cuttingequipment.

B Approved Methods - Where vibration-free cutting equipment is necessary as specified on
the schedule of Works or as directed by the Site Engineer the Contractor shall only employ
Diamond Impregnated or Rotary-Percussion drilling methods, PNEUMATIC TOOLS,
SLEDGE OR CLUBHAMMERS AND OTHER TOOLSMUST NOT BE USED.
C Any alternate method by the Contractor will be employed ONLY after approval bythe Site
Engineer.
D NOTE: The Contractor may use the services of a firm specializing in diamonddrilling on a sub-
contract basis.
E Position of Entry - this will be specified in the Schedule of Work or as directed bythe Site
Engineer. Any departure from this position must be agreed with the Site Engineer prior to
the commencement of work.
F Protection - the Contractor shall carry out such protection of cables and/orequipment, prior
to drilling operations, as directed by the Site Engineer.
G Reinforcement – where the method used requires the reinforcing bars are cut asa separate
operation bar-croppers or hacksaws only shall be used. Gas cutting equipment must not
be used.
H Anchor Irons - where possible new duct entries should be positioned at least 300mm from
any existing Anchor Iron. Where this clearance cannot be obtained,the anchor iron concerned shall
be sawn off. Gas cutting equipment must not beused.
8.7 DUCT ENTRY
A The concrete around all ducts where they enter jointing chambers shall be carefully flushed upand
rendered in cement mortar.
8.8 JOINTING CHAMBER FITTINGS
A Anchor Irons and other fittings shall be fixed as and where shown on the relevant drawing, or insuch
other position as the Site engineer may direct.
8.9 IRON AND STEEL WORK
A All iron and steelwork, supplied by the Contractor andwhich has not been galvanized by an
approved method, shall be free from mill scale and given one coat of red lead and oil after
delivery, and two coats of an approved bituminous paint after fixing.
B Any UN galvanized iron or steel which is to be embedded in concrete shall be freefrom

mud, oil, loose mill scale, grease or any other substance which can be shownto affect,
adversely the steel or concrete chemic ally, or reduce the bond. Normal handling prior to embedment
in the concrete is usually sufficient for the removal rust and scale from reinforcement.
C All reinforcement in the floor, roof and shaft shall be secured together by means ofapproved wire ties
sufficient to prevent displacement of the reinforcements duringthe placing and compaction of the
concrete.
8.10 RECOVERED MATERIAL
A After the demolition or alteration of existing jointing chambers, any recovered material shall be
delivered to a nominated site or disposed of as instructed by the Site Engineer.

8.11 SUMPS
A Where a sump is provided the floor shall have a slight fall thereto.
8.12 JOINTS IN CONCRETE
A Construction joints shall be provided where shown on the relative construction drawing. A
minimum of 12 hours shall elapse between the constructions stages thus indicated. The
construction joint shall be affected by cleaning the existing concrete, wettingit and rendering with a
5mmlayer of well trowelled cement mortar before the new concrete is placed in position.
B Whenever possible, concrete walls shall be completed in one operation. Where this is not
practicable, construction joints shall be straight and well-furnished as shown in the drawing.
Before concrete is resumed the surface of concrete on first side of joint is to be thoroughly cemented
and the surface removed, so as to expose the aggregate. This may include proper hacking of the
surface if the concrete is hard enough. The previous concretesurface is then to be treated
with a SBR based bonding compounds as recommended by the manufacturers for such
applications before placing any concrete against it. The new concrete shall be well
compacted, but care shall be taken during its placing close to the joint. Such construction
joints shall be cited at least 150mm from any anchor iron position.
8.13 CONCRETE QUALITY AND FINISH
A Except where the quality of concrete is detailed on the construction drawing all concrete used for the
construction of jointing chambers shall be Quality “A” as specified inthe Quality of Materials
Section of this Specification.
B No unauthorized repair shall be allowed to remove the finish of the concretesurface. This shall be
allowed only with the prior approval of the Site Engineer with approved materials only.
C At his discretion, the Site Engineer may require test cubes to be taken of any batchof site
mixed concrete used for jointing chamber construction. Where ready mixed concrete is used, the
Site Engineer will require test cubes to be taken on the following basis:
Table 5 Test Cubes
Joint Boxes A minimum of three test cubes from any batch of concrete
Manholes A minimum of three test cubes from each batch of concrete
PS. All the cubes shall be clearly marked for identification.
D The equipment necessary for the making of the test cubes shall be provided by the
Contractor. The cubes shall be tested by an approved Testing Laboratory and the Contractor shall
supply a copy of the test report to the Site Engineer within 14 days ofthe cubes being tested.
E Work will not normally be delayed for the result of any test to be ascertained. The making
curing and testing of all of concrete for compressive strength tests shall be in accordance with BS
1881, the results shall satisfy the following table:
Table 6 Specifications for Cube Crushing Strength
Age of Minimum Concrete bsf/in Minimum Cube crushing strength

7 days Over 32 MN/m2
28 days Over 40 MN/m2
F Whether test cubes have been taken or not, the Site Engineer may as a result of inspection,
rebound hammer tests or the cube tests, condemn the jointing
G chamber. Alternatively test cores shall be taken and tested in accordance with BS1881, Part
4. The cores shall be examined and tested, and the estimated cube strength ascertained by an approved
and independent laboratory. The Contractorshall be provided with a copy of the test report as soon
as it is available and, if this indicates that the quality of the concrete in the structure is
unsatisfactory, thejointing Chamber shall not be accepted.
H On completion of a jointing chamber the floor shall be rendered with cement mortarin accordance
with the relevant drawing. The walls of concrete jointing chambers shall have a smooth finish; any
slight activities exposed when the shuttering is removed shall be made good with cement mortar, and
any projections removed. UNDER NO CIRCUMSTANCES SHALL THE WALLS BE COATED WITH A
CEMENT OR CEMENT/SANDWASH.
8.14 COMPACTION AND TAMPING OF CONCRETE
A In construction of concrete or reinforced concrete jointing chambers, the concrete shall be

thoroughly worked and tamped into all parts use of a poker type vibrator until a dense solid
mass without voids is obtained, exceptionally, hand tamping may be employed for unreinforced
concrete Footway joint boxes.
B Care should be taken not to touch reinforcement steel with the poker during compaction.
8.15 WET SITUATIONS
A In wet situations the Contractor shall carry out additional measures to protect cables and
joints, deemed as necessary or as per advice from Site Engineer may direct the Contractor
to implementsuch methods as are deemed necessary to prevent damage to freshly placed
concrete or mortar and to ensure a waterproof jointing chamber. These methods may
include an independent sump, or the use of heavy-duty polyurethane sheet or other
suitable material, or drainage beneath the concrete floor. The construction shall be watertight;
no leakage is permitted through the floor construction joint wall or roof.
8.16 SHUTTERING
A Subject to compliance with the drawings as regards dimensions, the Contractor shall be at
liberty to adopt any arrangement he may think fit for the make-up of shuttering. The shuttering
shall be oiled, or lime washed prior to concreting.
B In all cases the shuttering used shall be of such dimensions and so constructed as to
remain rigid and unyielding to weight and vibration during the laying and tamping of the
concrete. No shaking or jarring shallbe permitted during setting.
8.17 REMOVAL OF SHUTTERING
A The minimum periods after completion of any concrete and/or block work which must
elapse before:
1. The shuttering of jointing chambers is removed.

2. The restoration of pavings or surfaces may be commenced.
3. Traffic is allowed to pass, are as follows:
Table 7 For Manholes and Joint Boxes
A
Type of cement used
To removal of shuttering wall
Sulphate resisting or mud sulphate resisting hrs 24
8.18 FRAMES AND COVERS FOOTWAY, CARRIAGEWAY NOS. 1, 2, 3 (DOUBLE

TRIANGULAR TYPE)
A Ductile Carriage way iron Frames Nos. 1, 2 and 3 with suitable rating are used for the
followingjointing chambers. Covers of all chambers/ manholes should be marked as “ICT
Manhole”.
Table 8 For Manholes and Joint Boxes
Type of Frame and Cover Used for Jointing chamber
No. 1 All carriageway manholes
No.2 JRC12
No.3 JRC14
All the above Frame and Cover assembly shall be supplied with safety grids.
8.19 INSTALLATION AND RENEWAL AND/OR CHAIN AGE LEVEL USING CEMENT OR
RESIN MORTAR OR RESIN BEDDING
A Preparation of New Jointing chamber walls or shaft shall be terminated to and levelled off at
a depth of 175mm below the carriageway surface. Where the joint box wallsor manhole shaft is
constructed of concrete, and the frame and cover is to be set on resinmortar or mortar
bedding the walls or shaft shall terminate at this level with a course of suitable thickness
quarry tiles on cement mortar. Installation of the frame and cover must not be commenced
until the concrete has been allowed to set for at least 12 hours.
B Preparation of Existing jointing Chambers – the existing frame and cover shall be removed and the
top of the jointing chamber walls or shaft cutback or built up, as the case may be and levelled off to
approximately 175mm below the carriageway surface. Where building up is necessary bricks or quarry
tiles of suitable thickness shall be used and set oncement or resin mortar for cement mortar or
resin installations respectively.
C Preparations of Frames and Covers – prior to installation remove the triangular covers and
where provided the safety grid(s) and ensure that the frame is clean, dry andfree from grease.
Remove any loose rust or scale with a wire brush.
a) Setting of Frame
1. Using Cement Mortar (Frames and Covers, Carriageway No.1 ONLY). The top surface of
the manhole shaft shall be brushed clean, moistened with water and a 20mm layer of
cement mortar trawled over the entire surface to be covered by the frame. The frame, with
covers removed, shall be lowered carefully onto the cement mortar and gently tapped with

a wooden punner until the top edge is level with the
2. carriageway surface. Any surplus mortar shall be struck off flush with the inside wallsand in the case
of a new manhole, haunched around and over the lower flange of theframe. For at least 2 hours
after the frame has been set on the cement mortar, care must be taken not to disturb or
walk on the frame. The covers shall then be replaced and in the case of an existing
manhole.
3. The side of the excavation and frame shall be primed with bitumen emulsion and the space around
the frame shall be reinstated with coated macadam. The coated
4. macadam shall be well compacted in two layers with a suitable power rammer to finishlevel with
the top of the frame and the surrounding surface.
D Opening to Traffic. Before opening to traffic, it must be established that the covers do not foul the
safety grids or the sides of the shaft or joint box walls. If there is evidence offouling it shall be obviated in a
manner acceptable to the Site Engineer.
E Cement Mortar. The minimum period after installation of the frame which must elapse before
commencing reinstatement and opening to traffic shall be in accordance with this Specification, in respect of
the jointing chamber add bedding under the frame.
8.20 CONCRETE SURROUNDING
A Any Jointing Chamber fitted with a Carriageway frame and cover shall have a concrete surround of
concrete Quality “A” to the depth of a frame and cover. The width of this concrete surround
shall extend to the outside of the structure wall or 150mm whichever is the less.
8.21 JOINT MARKERS AND MARKING POSTS
A The position of each buried jointing point shall be indicated by means of a steel marker
post / protection post placed flush with surface immediately over the centres of the project, or a
Markingpost positioned as directed by the Site Engineer.
PART 9 FILLING- IN AND RESTORATION OF PAVING SECTION
9.1 GENERAL
A The Contractor shall execute interim restoration and permanent reinstatement tothe satisfaction of
the Site Engineer.
B The operation of filling-in a trench shall not normally be commenced until the workto be covered
thereby has been approved by the Site Engineer. Filling-in may only commence before
such approval is given, provided that, prior permission has beenreceived from the Site
Engineer, and the Contractor agrees to excavate fill and reinstate such test holes as may be
requested later by the Site Engineer.
9.2 RAMMING
A The periods of time between the placing of concrete and the commencement of back-filling
shall be in accordance with the requirements of the Duct and Cable laying Section and the Jointing
Chambers Section of this Specification and mustbe strictly followed.
B All spaces outside the walls of jointing chambers, duct laid in concrete in trench and all
other duct laid in trench shall be carefully filled in with granular material or concrete as directed by

the Site Engineer and rammed, care being taken to ensurethat the ramming does not
disturb any recently completed work.
C All ducts not laid in concrete shall be covered by a layer of earth, free from stones, and
hand punned to a thickness of not less than 75mm, or as otherwise directed by the Site
Engineer.
D Except where otherwise directed by the Site Engineer, all materials shall be replaced in 150 to
130mm layers, in the reverse order to which they were excavated and thoroughly compacted.
Mechanical punners shall normally be used.If this is impracticable and hand pinning is
employed, there shall be at least three punners to one filler.
E No excavation material shall be reused without the approval of the Site Engineer.
9.3 COMPACTIO N TEST
A Backfilled excavation shall be tested at various levels by applying and continuouslyoperating either,
an explosive type rammer weighing approximately 102 kg over anarea of one-half square metre
for a period of three minutes, or a vibration rammer weighing not less than 50 kg over
similar area for three minutes or less if the behaviour of the machine indicated maximum
compaction. Rammer used for the compaction test must be in efficient working order. At least one
test, in a position selected by, and in the presence of the Site Engineer, shall be carried out
during back-filling as follows:
B Carriageway trench excavations – within a 50-metre length of trench or between jointing chambers
and/or jointing chamber positions, whichever is the shorter; and
C In all other carriageway excavations.
D Further tests shall be carried out in the carriageway or footway, at such times andlocations
as the Site Engineer consider necessary.
E The compaction will be considered satisfactory providing the tests show no measurable
change level. A measurable change in level is a depression which cannot be rectified by
reshaping the tested area, and consequently requires additional material, which when
compaction will restore the surface of the test areato the original level. Should any
measurable change in level occur, then the area faulty compaction as defined by the results of
this and further check tests shall berectified as required by the Site Engineer, under the terms of
condition 1.16 of theStandard Conditions.
F At all times the results shall provide 98% MDD (Max. Dry Density) compaction. The local
authorities’ requirements and procedure are also applicable.
G Minimum two test per 50m run shall be considered inclusive per section in the schedule of
rates. Repeat test due to failure shall not be paid, additional test ifrequested by Site
Engineer only passed test shall be paid at schedule of rates.
9.4 SEALING
A A sealing coat capable of preventing the ingress of water shall, unless otherwisespecified,
be provided before opening to traffic any back-fill excavation in carriageways or footways which
have sealed paving that cannot be relayed as an interim measure. Tar or Bitumen Macadam
sufficiently well graded to be an effective seal or other similar approved material shall be used.
B Before the sealingcoat is inserted the cut edges of the existing paving must be brushed clean
andcoated with an approved emulsion. Paving of Flags and other similar types that canbe
relayed, as an interim measure will require the sealing coat where spaces are left unpaved,
at the interim stage. The sealing coat shall be not less than 50mm in thickness.

C The Site Engineer will not allow the inclusion of an interim sealing coat as part ofthe
permanent reinstatement unless:
D Prior approval of the Street Authority’s Surveyor is obtained via the Site Engineer.Where
the local authority elects to carry out the permanent reinstatement, the contractor shall
perform all the works related to interim restoration. However the thickness of interim
restoration of the paving shall not be less than 50mm and the compaction requirements
are fully met.
E The sealing coat to a minimum of 75mm whatever the materials used, or suchgreater depth
as shall be agreed with the surveyor.
F The method of inserting the sealing coat is to permanent reinstatementstandards, that is

trimmed and fluxed edges, agreed materials, etc.
G Little, if any, settlement has occurred after an adequate interim period. Thisperiod will
normally be 3 months but may be modified with the written agreement of the Site Engineer.
H Sealing coats less than 75mm will not be accepted by the Site Engineer as part of the
permanent reinstatement. Rates for the work must allow for complete removal of the
interim sealing coat at the permanent reinstatement stage.
I A temporary reinstatement shall cover all the work of the permanent reinstatement with the
exception of the top paving restored to 50mm thick.
PART 10 SAFETY PRECAUTIONS SECTION
10.1 GENERAL
A When using certain materials referred to in this Specification, the safety precautions contained in
the following paragraphs should be observed.
10.2 P.V.C CEMENT AND METHYLATED SPRITS
A When using P.V.C Cement and /or methylated spirits, care should be taken to ensure that
workingareas are adequately ventilated. Naked flames should not be used under any
circumstances and smoking should not be permitted.
10.3 RESIN PACK NO. 6A
A When mixing and / or using Resin pack No. 6A:
1. Barrier cream should be applied to the hands, and forearms if exposed, before handling
the resin.
2. Disposable gloves should be worn.
3. After use, all soiled containers waste and gloves should be disposed of in a refuse bin.
4. The resin should always be mixed in a well-ventilated place.
10.4 RESI N BEDDING AND RESIN MORTAR
A The contractor is responsible for the safety of the pedestrians, vehicles for theirown
working staff.
1. Proper approved traffic signboard and flashings, warning tapes shall be used throughout the

execution of the job to the entire satisfaction of the Site Engineer.
2. Access to the business and the residence, etc., shall be always maintained.
3. No time the excavation shall be left open unreasonably affecting the users offootpaths and road.
4. As far as possible the work at a new location may not be commenced in the same location
without completing the earlier commenced portion.
5. All safety measures required by any local authorities including appointment of safety officer
for field work should be followed without any delay or extra cost.
PART 11 Polyurethane Sub Duct Laying Section
11.1 GENERAL
A These guidelines describe the procedure to be followed for installing PESub Ductsinside a
Main (54D) PVC duct and F.O Cable inside a sub.
B Depending upon the requirement, a combination of 2 x 39mm sub ducts can be placed in one main
duct. Other combinations mixing 29mm and 39mm sub ductsare also possible.
C Sub Ducts are generally available in standard drum lengths max 1000 metres, andin future will be
available in segmented drums or in coils of suitable lengths.
11.2 PULLI NG OF SUB DUCTS
A The sub ducts, being as flexible, can be installed in main ducts very similar to pulling in cables in
ducts, using standard cable accessories and winches. All thesub ducts to be placed in a
main duct should be pulled-in simultaneously.
B While pulling in more than one sub duct simultaneously (four, for example), one ofthe following
methods may be followed for placing the sub-duct drums.
C All the four drums will be placed on a flatbed truck or ground.
D If no sufficient spaces are available for the truck or placing the four drums side byside, the required
lengths to be pulled in can be prewoundon a single segmenteddrum.
E 2 nr. Loops in each manhole.
F Using the special pulling eyes.
G A four-legged pulling – sling can also be used for pulling in four sub ducts in a single
installation. One leg is attached to each sub duct via a taper threaded pullingeye and small
swivel. The duct pulling member is attached to the pulling rope via a large swivel.
H The sub ducts can either be terminated at all the manholes and joint boxes or can be run through
more than one Joint Box or Manhole without cutting, depending upon the requirement and
availability of the main duct bores in the spans to follow.
I A sub duct is never to be cut flush with the manhole or joint Box wall. It is to be cutin such a way
that a tail of about 10cm is left beyond the end of the main duct.
J The sub duct can be connected with each other in the manholes or joint boxesor even inside the
main duct by using Aluminium Coupling. The thickness of the Aluminium Coupling is so
small that it does not greatly increase the overalldiameter of the sub duct.

K Another type of coupling can be used to make a pressure-tight joint. This couplingcan
withstand a pressure up to 10 Bar and as such can be used to joint the
L sub ducts where cable installation is being done by employing cable blowing-intechnique.
M Before jointing the two lengths of the sub duct, the Chamfering too is used to makethe sub
duct ends smooth. The act of cutting with this tool eliminates any burrs, clearing the path
for the cable during its installation.
N It is preferable to use only the vacant main ducts for sub ducting to avoid damageto the
existing cables.
O Where required a suitable lubricant may be used for pulling the sub ducts for longerspans.
11.3 DUCT PULLING
A The main duct that contains the sub ducts must be sealed at all manholes/ joint boxes by
using the Quad-plex or Tri-plex duct plugs. The main duct will be sealed with theDuct Plug whether
the sub ducts are cut or not at that particular Joint Box / manhole. The sub duct itself must also
be sealed using blank mini plugs.
END OF SECTION

TABLE OF CONTENTS
INFRASTRUCTRE ELECTRICAL (MV&LV) TECHNICAL SPECIFICATIONS 2
PART 1 SCOPE 2
PART 2 PARTICULAR SPECIFICATIONS 2

2.1 APPLIED SPECIFICATIONS 2
2.2 DEVIATION FROM STANDARD SPECIFICATIONS 2

19-Sep-2022
INFRASTRUCTRE ELECTRICAL (MV&LV) TECHNICAL SPECIFICATIONS
PART 1 SCOPE
This document contains the required specification on infrastructure electrical Networks
(Medium Voltage & Low Voltage) to be applied during implementation stage.
PART 2 PARTICULAR SPECIFICATIONS
2.1 APPLIED SPECIFICATIONS
The Standard Specifications that apply are the Saudi Distribution Material and
Construction Specifications (SDMS & SDCS) developed by the Saudi Electricity Company
(SEC). A copy of the general specifications that apply is included in Appendix A.
The Particular Specifications are the Sections in the Standard Specifications listed below
and as provided in these documents as well as any Specifications referred to in the
General and Project Specifications.
Table 1 Applied SEC Specifications
SDCS-02-17 Construction Standard for Underground Distribution Network Part 17: Cable Trenches
01-SDMS-01 General Requirements for All Equipment / Material
11-SDMS-01 Low Voltage Power and Control Cables
11-SDMS-03 XLPE Insulated Power Cables for Rated Voltages From 15 KV Up TO 36 KV
12-SDMS-01 Cable Joints, Terminations and Accessories Up to 36 KV
12-SDMS-02 Lugs and Connectors For MV/LV Distribution System
12-SDMS-03 Specification For Underground Warning Tapes
2.2 DEVIATION FROM STANDARD SPECIFICATIONS
As per the SDCS-02-17, the spacing between the LV cables shall be 100 mm. However,
the proposed spacing between LV cables (directly buried) and trench details shall deviate
from SDCS-02-17 considering small cable sizes requirement within the project and to
minimize ROW requirements.
0.5 from overall cable diameter is proposed for this project as highlighted in submitted
report and standard details drawings.
END OF SECTION
Red Sea Shura Program 7 Hotel Central #3 Page 2

Infrastructure Electrical (MV&LV) Technical Specification 19-Sep-2022
Appendices
A. Infrastructure Electrical (MV&LV) - Applied SEC Specifications 3

A. Infrastructure Electrical (MV&LV) -

Applied SEC Specifications

Infrastructure Electrical Specifications
Saudi Electricity Company (SEC) Specifications
Table of Content
SDCS-02-17 Construction Standard For Underground Distribution Network Part 17: Cable
Trenches
01-SDMS-01 General Requirements For All Equipment / Material
11-SDMS-01 Low Voltage Power And Control Cables
11-SDMS-03 XLPE Insulated Power Cables For Rated Voltages From 15 KV Up TO 36 KV
12-SDMS-01 Cable Joints, Terminations And Accessories Up to 36 KV
12-SDMS-02 Lugs And Connectors For MV/LV Distribution System
12-SDMS-03 Specification For Underground Warning Tapes
Saudi Electricity Company
Distribution Services Sector
CONSTRUCTION STANDARD FOR Issue Date: 8/2019 Page: 1 of 45

UNDERGROUND DISTRIBUTION NETWORK
SDCS-02-17 REV.01
PART 17: CABLE TRENCHES
SDCS-02-17
Rev.01
CONSTRUCTION STANDARD FOR UNDERGROUND
DISTRIBUTION NETWORK
This document contains proprietary information developed by and for exclusive use of Saudi Electricity
Company (SEC) Distribution Network. Your acceptance of the document is an acknowledgment that it
must be used for the identified purpose/application and during the period indicated. It cannot be used or
copied for any other purposes nor released to others without prior written authorization of SEC
Distribution Sector. SEC shall assume no responsibility for any type of misuse and/or misapplication,
and any arm resulting there from. SEC also reserves the right take any necessary actions to protect its
interest against unauthorized use.

SDCS-02-17 REV.01
SDCS-02-17
Rev.01
CONSTRUCTION STANDARD FOR UNDERGROUND
DISTRIBUTION NETWORK


SDCS-02-17 REV.01
Table of Contents
1 INTRODUCTION ............................................................................................................. 4
2 SERVICE CONDITIONS AND CONSTRUCTION PARAMETERS ............................ 4
3 REVISION AND ADDITIONS ........................................................................................ 4
4 DEFINITIONS ................................................................................................................... 4
5 RIGHT-OF-WAY .............................................................................................................. 4
6 DIRECT BURIED CABLE INSTALLATION ................................................................. 5
7 SOIL CLASSIFICATION: .............................................................................................. 15
8 SOIL AND ASPHAILT TEST ........................................................................................ 16
9 Specification of Installation of Duct Bank at Road Crossing .......................................... 21
9.1 General: ................................................................................................................... 21
9.2 Excavation: ............................................................................................................. 21
9.3 Duct Bank construction ...................................................................................... 22
9.4 Backfilling and reinstatement ............................................................................. 23
9.5 Duct cleaning and inspection .............................................................................. 23
9.6 Concrete Specification ....................................................................................... 24
10 General notes on Medium voltage HDD works ............................................................... 25

SDCS-02-17 REV.01
1 INTRODUCTION
This standard specifies the design, and installation practices to be applied in the
construction of MV and LV cable of underground distribution system. It is intended to
assist the engineers and field personnel to achieve standardization in construction and to
ensure a satisfactory and economical level of service without operating restrictions so
that the operational errors should be minimum for safety and reliability.
2 SERVICE CONDITIONS AND CONSTRUCTION

PARAMETERS
For construction and operation of underground cable distribution network, the service
conditions and system requirements shall be as given in the latest revision of SEC
General Specification No.01-SDMS-01.
3 REVISION AND ADDITIONS

This standard is subject to revision as new materials and methods of construction are
developed. The latest revision of this standard shall be applicable. Revised sheets shall
be issued from time to time and should be inserted as soon as these are received.
Superseded or obsolete sheets shall be removed immediately upon receipt of revised
sheets. The date of the latest issue of each sheet is printed at the top corner under the
standard number.
4 DEFINITIONS
Ultimate strength is the maximum load which a material will sustain when the load is
gradually increased until the rupture or failure takes place.
5 RIGHT-OF-WAY
If required by the local authority, the right-of-way (R-O-W) for the proposed route of an
underground cable must be obtained from the concerned authority-
(e.g. municipality, ministry of communication) during engineering stage of the project.
Given below is the procedure to be followed in obtaining R-O-W:
a. Prepare R-O-W drawing proposed showing proposed route of the underground
cable, cross-section of the trench or duct bank (if required) and location of other
utilities (e.g. telephone, water, sewer) lines along proposed route (if known).
b. Submit R-O-W drawing to the relations section in the concerned operating area.
c. The actual construction work shall not be started until the digging permit from
relevant authorities is obtained.
‫‪Saudi Electricity Company‬‬
‫‪Distribution Services Sector‬‬
‫‪CONSTRUCTION STANDARD FOR‬‬ ‫‪Issue Date: 8/2019‬‬ ‫‪Page: 5 of 45‬‬

‫‪UNDERGROUND DISTRIBUTION NETWORK‬‬
‫‪SDCS-02-17 REV.01‬‬
‫‪PART 17: CABLE TRENCHES‬‬
‫‪Standard R-O-W locations for underground utilities in streets of new areas have been‬‬
‫‪developed by the Ministry of Municipal and Rural Affairs in coordination with the‬‬
‫‪Ministry of Communications and the ministries having authority over the concerned‬‬
‫‪utilities.‬‬
‫‪6 DIRECT BURIED CABLE INSTALLATION‬‬

‫‪ 1.6‬شروط ومواصفات تمديد الخدمات في الطرق‪:‬‬
‫الشروط العامة (طريقة الخندق المفتوح)‪:‬‬
‫على جميع المقاولين التقيد بالشروط والمواصفات‪.‬‬ ‫‪.1‬‬
‫على جميع المقاولين الحصول علي التصاريح الالزمة من قبل الجهات ذات العالقة قبل البدء بالعمل‪.‬‬ ‫‪.2‬‬
‫على المقاول تجديد التصريح قبل انتهائه من قبل الجهات ذات العالقة وال يجوز استئناف العمل ما لم يجدد‬ ‫‪.3‬‬
‫الترخيص نظاماً‪.‬‬
‫على المقاول التنسيق مع مكتب تنسيق المشاريع والبلديات الفرعية حسب المتبع‪.‬‬ ‫‪.4‬‬
‫على المقاول تجميع المعلومات عن الخدمات تحت األرض مثل تمديدات الغاز والمياه والتليفون والصرف‬ ‫‪.5‬‬
‫والكهرباء ‪ .....‬الخ‪ ،‬والحصول على التصاريح الالزمة من الدوائر الحكومية والبلديات‪.‬‬
‫على المقاول التأكد من الحصول على التصاريح الالزمة بالمواقع الخاصة والمتنوعة المرافق األخرى‪.‬‬ ‫‪.6‬‬
‫‪ 1.6‬شروط السالمة‪:‬‬
‫يراعي المقاول اتخاذ إجراءات الحيطة والسالمة العامة و إنفاذ اآلتي‪:‬‬
‫وضع اللوحات أول الحفرية وأخرها و عند التقاطعات الرئيسية تحمل اسم المقاول (الشركة أو المؤسسة) و الشركة‬ ‫‪.1‬‬
‫السعودية للكهرباء (القطاع و اإلدارة) التابع لها و صورة تصريح العمل‪.‬‬
‫استعمال اللوحات اإلرشادية و التحذيرية الدولية العاكسة و الحواجز المرورية بصورة كافية و ظاهرة حسب‬ ‫‪.2‬‬
‫تعليمات المرور و إدارة الدفاع المدني‪ /‬قسم السالمة‪.‬‬
‫وضع إضاءة كافية أثناء الليل أمام و على جانبي الحفر و على مسافات ال تزيد عن ‪ 2‬متر و تكون اإلضاءة ملونة‬ ‫‪.3‬‬
‫و بطاقة ال تقل عن ‪ 15‬وات‪ ،‬أما بخصوص اللحام فيكتفي بوضع شرائط تحذيرية ملونة باإلضافة إلى عواكس‬
‫فسفورية مع إضاءة مناسبة‪.‬‬
‫وضع عبارات للمشاة و السيارات على الحفريات الطولية داخل المدن على مسافات ‪ 111‬متر على األكثر و في‬ ‫‪.4‬‬
‫المناطق غير اآلهلة بالسكان على مسافة ‪ 211‬متر كأقصى حد‪.‬‬
‫إذا كان الشارع مكون من جانبين فال يجوز إغالق أي من الجانبين إال في حالة النص صراحة على ذلك في‬ ‫‪.5‬‬
‫التصريح الممنوح للمقاول‪.‬‬
‫في حالة قفل أي طريق يجب على المقاول القيام بعمل تحويلة مسفلتة على حسابه و بالتنسيق مع مكتب تنسيق‬ ‫‪.6‬‬
‫المشاريع و إدارة المرور و إدارة الصيانة باألمانة‪.‬‬
‫‪ 1.6‬الشروط العامة الفنية‪:‬‬

‫كل األعمال المنفذة و المواد المستخدمة ينبغي أن تكون متوافقة مع الخطوط والمقاطع والمقاسات والشروط‬ ‫‪.1‬‬
‫واالحتماالت المذكورة في المواصفات‪.‬‬
‫المواد المستخدمة ينبغي أن تقبل من قبل الشركة قبل استخدامها في العمل‪.‬‬ ‫‪.2‬‬
‫جميع المواد المستخدمة في العمل ينبغي أن تتوافق مع المواصفات أو تزيد عنها‪.‬‬ ‫‪.3‬‬
‫على المقاول تحديد و حماية المرافق تحت األرض عند تنفيذه للعمل‪.‬‬ ‫‪.4‬‬
‫االختبارات الالزمة (بالموقع و المعامل) للتأكد من سالمة الد حيث تؤخذ حسب الحاجة‪.‬‬ ‫‪.5‬‬
‫على المقاول تجهيز المعدات الالزمة لسحب و شفط المياه أو المياه الجوفية التي تدخل الحفريات و مواقع العمل‪.‬‬ ‫‪.6‬‬

SDCS-02-17 REV.01
Note: Being the most economical way, direct earth buried cable laying has been
standardized except where the cable route intersects road, street and other utility mains.
The major activities associated with direct buried cable installation are trench excavation,
cable laying, are described in the following sections. through is trench constructions for
direct buried cable.
6.4 Trench Excavation

Before proceeding with actual work of trench excavation, following preparations should
be completed:
a. Review the cable route drawings, R-O-W drawings, digging permit, and inspect
the cable route from end to end.
b. Decide locating where cable drums shall be unloaded at site, keeping in view the
actual cable lengths on drums.
c. Decide locations of cable joints. Avoid street intersections. Joints should
preferably be made no closer than 10 meters from edge of any street
intersections.
d. Obtain necessary permissions from the traffic police for the work schedule,
warning and lights and design of detours.
e. Keep ready the necessary number of night warning lamps, stands, wooden/steel
bridges for maintaining pedestrian
f. Arrange necessary manpower keeping in view the work schedule and expiry date
of digging permit.
6.4.1 Trench Specification
-: ‫مواصفات الحفريات‬
‫ينبغي أن تكون الحفريات بالكابالت و المواسير مستقيمة قدر اإلمكان و أفقية و عمودية و في حالة وجود تحويل‬ .1
.‫يجب أن يكون بتدرج حسب المواصفات الخاصة بالكابالت منعا لتعرض الكابل للضرر‬
) ‫ مليمتر‬111 ( ‫ مليمتر ) من تحت الكيبل أو الماسورة للسماح على ما يقل من‬111 ( ‫الحفريات يجب أن تمدد إلى‬ .2
. ‫من الرمل الناعم حول و تحت الكابل‬
‫ مليمتر ) لحفريات‬811 ( ‫ مليمتر ) لحفريات كابالت الضغط المنخفض و‬651 ( ‫الحفريات يجب ان تكون بعمق‬ .3
‫كابالت الضغط المتوسط و في حالة الحفر زيادة عن هذا العمق يجب أن تتم إعادة الردم إلى العمق المطلوب بمواد‬
‫ ( أو‬211 # ( ‫ مار ) من المنخل رقم‬% 15 ( ‫ للتربة المحتوية على‬ASDM ‫ ) حسب‬%55 ‫مختارة بنسبة ( د‬
‫ ) للمادة الغير‬% 15 ( ‫ ) كثافة نسبية للتربة الغير الصقة المستخدمة لحرية الصرف المحتوية على أقل‬% 85 (
.) 211 # ( ‫بالستيكية التربة المارة من المنخل رقم‬
‫األجزاء اللينة أو الضعيفة في الحفرية يجب أن تد حسب ما سبق أو أن يتم تغيير التربة الضعيفة بمواد ردم‬ .4
.‫مختارة جيدة حسب المواصفات‬
.‫أسفل الحفرية يجب أن يكون متساوي و خال من الصخور و المواد الحادة التي يمكن أن تضر بالكابل‬ .5
( ‫ مليمتر ) للكابلين و‬611 ( ‫ مليمتر ) لكيبل واحد و عرض‬411 ( ‫عرض الحفرية العادية لكابالت الجهد المتوسط‬ .6
.‫ مليمتر ) لكل كيبل إضافي‬311 ( ‫ مليمتر) لثالث كابالت و يتم إضافة‬511

‫‪SDCS-02-17 REV.01‬‬
‫‪ .7‬عرض الحفرية العادية لكابالت الجهد المنخفض ( ‪ 411‬مليمتر ) لثالث كابالت و يتم إضافة ( ‪ 111‬مليمتر ) لكل‬
‫كيبل إضافي‪.‬‬
‫‪ .8‬يتم الردم حول المنشئات مثل غرف التفتيش و التجمع و غرف المحابس ‪ ....‬الخ‪ ،‬باستخدام مواد ردم مناسبة‬
‫يضاف لها مواد محسنة مع الرش بالماء و الخلط جيدا و الد حتى نسبة ‪ %55‬من الكثافة الجافة القصوى مع‬
‫مراعاه المدة التي يجب أن تفصل بين عملية الردم و صب المنشئات الخرسانية‪.‬‬
‫الحفريات الدقيقة ‪:‬‬
‫‪ .1‬عرض الحفرية الدقيقة (‪ 211‬مليمتر) لكيبل واحد سواء للجهد المتوسط‪.‬‬

‫‪ .2‬عرض الحفرية الدقيقة لكيبل الجهد المنخفض (‪ 211‬مليمتر) للكابل الواحد أو للكيبلين فقط‪.‬‬
‫خطوات التنفيذ ‪:‬‬
‫األعمال اإلدارية ‪ :‬و تشمل إصدار فسح و الحصول على التصاريح الالزمة لتنفيذ العمل‪.‬‬ ‫‪.1‬‬
‫تحديد الموقع على الطبيعة‪ :‬و يشمل ذلك تحديد مكان العمل و خط سير المشروع و عمل البرنامج الزمني للتنفيذ و‬ ‫‪.2‬‬
‫المدة الزمنية لكل مرحلة‪.‬‬
‫تأمين موقع العمل والعاملين‪ ،‬و يشمل‪:‬‬ ‫‪.3‬‬
‫‪ .a‬وضع اللوحة الخاصة بالمشروع و المتضمن اسم المشروع و ورقة الفسح والجهة التابعة لها المشروع‬
‫و اسم المقاول و كروكي المشروع (خريطة) و المدة الزمنية و ما إلى ذلك‪.‬‬
‫‪ .b‬وضع وسائل الحماية و األمان‪.‬‬
‫تخطيط الموقع ‪ :‬يتم تخطيط مسار الحفر تبعا للمرحلة المطلوبة تنفيذها والجدول الزمني المعتمد‪.‬‬ ‫‪.4‬‬
‫أعمال الحفر حيث يتم العمل تبعاً للشروط التالية‪:‬‬ ‫‪.5‬‬
‫‪ .a‬الحفر بواسطة الترنشز و بعرض ‪ 211‬مليمتر‪.‬‬
‫‪ .b‬نقل مخلفات الحفر مباشرة من الترنشز إلى القالب‪.‬‬
‫‪ .c‬مراعاة استقامة الحفر‪.‬‬
‫‪ .d‬يكون الحفر حسب العمق المحدد بنظام مكتب التنسيقات والمتابعة‪.‬‬
‫أعمال الردم ‪ :‬يتم استخدام مواد ردم مناسبة و معتمدة من األمانة و بكامل عمق الحفر ‪.‬‬ ‫‪.6‬‬
‫كما يمكن استخدام الخلطة الخرسانية العادية (‪ 1.8‬م‪ 3‬بحصى متدرج ‪ 1.4 ,‬م‪ 3‬رمل نظيف ‪ 251 ,‬كجم اسمنت)‪.‬‬
‫‪#211‬‬ ‫‪#111‬‬ ‫‪#51‬‬ ‫‪#31‬‬ ‫‪#16‬‬ ‫رقم المنخل‬

‫‪1-3‬‬ ‫‪16-15‬‬ ‫‪55-55‬‬ ‫‪54-55‬‬ ‫‪55-111‬‬ ‫نسبة المار‬ ‫التدرج‬
‫من المادة ‪%‬‬
‫جدول ‪ :1‬المناخل المعتمدة‪.‬‬
‫باإلضافة إلى معالج الشك ‪ 2( Accelerator‬لتر‪/‬م‪ 3‬كحد أدنى)‪ ،‬كما يجب خلط المكونات بطريقة ميكانيكية بشكل‬
‫يضمن تجانس الخلط‪:‬‬
‫‪ .7‬المادة الالصقة‪ :‬يستخدم المادة ‪ RC2‬بمعدل ‪1.5‬كجم‪/‬م‪ 2‬و مادة ‪ MC1‬بمعدل (‪ )1 ,75 -1 ,65‬لتر‪/‬م‪ 2‬و ترش‬
‫باألجهزة الميكانيكية و بطريقة منتظمة شك طبقات الردم و بعد تنظيف جوانب االسفلت المقصوص‪.‬‬
‫‪ .8‬أعمال االسفلت‪ :‬يتم الكشط لإلسفلت بعرض ‪ 1‬متر بعد إتمام الردم بسمك ال يقل عن ‪ 6‬سم للشوارع الفرعية و ‪8‬‬
‫سم للشوارع الرئيسة و إعادة السفلته لكامل الطبقات المكشوطة على أن يكون موقع الحفر في منتصف الكشط و‬
‫أن يراعى اآلتي‪:‬‬

‫‪SDCS-02-17 REV.01‬‬
‫‪ .a‬تنظيف الجوانب ورش مادة ‪.RC2‬‬

‫‪ .b‬تكون الخلطة االسفلتية معتمدة ومطابقة للمواصفات‪.‬‬
‫‪ .c‬االلتزام بالمنسوب و ميول الطريق‪.‬‬
‫‪ .d‬يتم استخدام الفرادة للقطوعات األطول من ‪ 311‬متر‪.‬‬
‫‪ .5‬إعادة مكونات الطريق‪ :‬يجب إعادة مكونات الطريق من أرصفة وعالمات مرورية على ما كانت عليه قبل بدء‬
‫العمل‪.‬‬
‫‪ .11‬أخذ عينات من طبقات الردم و اختبارها‪:‬‬
‫‪ .a‬مواد الردم‪ :‬يتم أخذ عينة كل ‪ 411‬متر طولي فأقل لكل يوم‪.‬‬
‫‪ .b‬التقييم البصري‪ :‬يتم تقييم المواد الالصقة‪.‬‬
‫‪ .11‬اختبار االسفلت‪ :‬حيث يتم د االسفلت بنسبة ‪ %55-53‬و يتم عمل االختبارات الخاصة بالخلطة االسفلتية لكل‬
‫إنتاج أقل من ‪ 511‬طن و عينة إضافية إذا كان هنا شك بالمواد‪.‬‬
‫قطع االسفلت‪:‬‬
‫‪ .1‬يكون القطع بالمنشار وباتساع ال يقل عن ( ‪ 151‬مم ) حسب مواصفات وزارة الشئون البلدية والقروية أو ( ‪211‬‬
‫مليمتر ) حسب مواصفات وزارة المواصالت زيادة عن عرض الحفرية من كل جانب بعمق ( ‪ 411‬مليمتر ) في‬
‫حالة وجود طبقة ما تحت األساس و في حالة عدم وجودها يكون بعمق ال يقل عن عمق طبقة االسفلت الموجودة في‬
‫الطريق‪.‬‬
‫‪ .2‬أما في حالة الحفريات التي يزيد عرضها عن متر يكون قطع االسفلت بزيادة عن عرض الحفرية بمقدار ( ‪151‬‬
‫مليمتر ) في كال الحالتين‪.‬‬
‫‪ .3‬في حالة الشوارع الفرعية فقط والمحددة من قبل اللجنة وإذا كان بعد الحفرية عن الرصيف أقل من متر أو أقل من‬
‫مترين عن حافة المبني (في حالة عدم وجود رصيف)‪ ،‬يكون عرض الحفرية حسب مواصفات صاحب المشروع‪.‬‬
‫‪6.4.2 Excavation‬‬
‫‪In deciding at what depth the trench should be excavated, it is necessary to take‬‬
‫‪intoconsideration the changes being made in the existing grade level by any earth cut or‬‬
‫‪fillwork to be carried out later. Such information should be gathered from the Ministry‬‬
‫‪ofcommunications or municipality so that ultimately the standard depth of cable can‬‬
‫‪beachieved.Trenches may be dug by hand or, if site conditions permit, a mechanical‬‬
‫‪excavator canbe used. Asphalt shall be cut by a motor driven saw. Manual digging shall‬‬
‫‪be used atlocations where existing underground facilities are encountered. Existing‬‬
‫‪facilitiesuncovered during excavation shall be protected, shored, braced and supported,‬‬
‫‪asnecessary. All protective covers, warning tapes, position markers, etc., pertaining‬‬
‫‪toexisting underground utilities shall be preserved during excavation and restored‬‬
‫‪inposition during backfilling.‬‬
‫أعمال الحفر‪:‬‬
‫‪ .1‬تتم عملية الحفر بالمعدات المناسبة مع االلتزام بوضع ألواح خشبية أو مطاطية علي طبقات االسفلت وتحت‬
‫المعدات ويمنع منعا ً باتا ً استخدام اآلالت ذات األرجل المنتهية بخوازيق‪ ،‬و تحمل نواتج الحفر التي ال يمكن إعادة‬

‫‪SDCS-02-17 REV.01‬‬
‫استخدامها مباشرة خارج موقع العمل ويتم تنظيف موقع العمل بصفة دائمة ويتم حمل مخلفات الحفر الخاصة‬
‫بالمشاريع الكبيرة إلي خارج المدينة ليرمي في األماكن المخصصة لذلك الغرض‪.‬‬
‫‪ .2‬يجب أن تكون الخنادق الخاصة بتمديد الخدمة خالية تماماً من المياه الجوفية و غيرها قبل عملية التمديد كما يجب‬
‫تدعيم جانبي للخندق لمنع انهيار األتربة إذا استلزمت طبيعتها ذلك مع التخلص من الحفريات الزائدة أوالً بأول في‬
‫أماكن يحددها المهندس المشرف‪.‬‬
‫‪ .3‬يجب المحافظة على خطوط الخدمات األخرى أثناء العمل‪.‬‬
‫‪ .4‬استخدام عامل تفتيت الصخور فائق الصمت‪:‬‬
‫‪ .a‬توريد واستخدام عامل تفتيت الصخور فائق الصمت عند الحفر في مواقع الصخور الرخامية و الجيرية شديدة‬
‫الصالبة‪.‬‬
‫‪ .b‬اسم المادة الكيميائية ( هيدروكسيد الكالسيوم ‪.) Calcium Hydroxide‬‬
‫‪ .c‬الكمية ( ‪ 03‬كجم ‪ /‬م‪.) 2‬‬
‫‪ .d‬طريقة االستخدام‪ :‬عمل ثقوب بالسطح بعمق ‪ 033‬مم والمسافة بين كل ثقب واالخر ‪ 233‬مليمتر (أي عدد‬
‫‪ 03‬ثقب لكل م‪.)2‬‬
‫‪ .e‬قطر الثقب ‪ 02‬مليمتر‪.‬‬
‫‪ .f‬يتم تعبئة الثقوب بالمادة الكيميائية الموضح اسمها بالفقرة ‪ b‬أعاله‪.‬‬
‫تدعيم جوانب الحفرية‬
‫يجب على المقاول تدعيم جوانب الحفرية في التربة الطينية المفككة والرملية أو التربة القابلة لالنهيار أو المشبعة‬ ‫‪.1‬‬
‫بالمياه أو في حالة وجود تسرب لمياه سطحية من األمطار أو غيرها‪ .‬ففي هذه الحاالت يجب على المقاول توريد‬
‫وتركيب كافة الصفائح أو الخوازيق اللوحية وأجهزة الدعامات الهيدروليكية الالزمة لتدعيم جوانب الحفرية‪ ،‬لمنع‬
‫االنهيارات الموضعية أو تحر التربة وذلك للمحافظة على عرض الحفرية بقدر االمكان وأال يؤثر على المنشئات‬
‫المجاورة كما هو مبين في الشكل‪ .‬وهنا نوعان للدعامات الهيدروليكية‪ :‬الدعائم الرأسية والدعائم الجدارية‪ ،‬ففي‬
‫النوع األول تؤثر الدعامات بقوة ضغط على جوانب الحفرية عند ضخ الزيت وعند فك الدعامات يتم تفريغ الزيت‬
‫وتنخفض قوة الضغط‪ ،‬وتستخدم الدعامات الرأسية المتباعدة في الحاالت العادية من عمليات الحفر وتركب الواحدة‬
‫تلوى األخرى‪.‬‬
‫ً‬
‫أما الدعامات الجدارية فيتم تركيبها أفقيا لتدعيم عدد من األلواح الرأسية تكون متصلة أو متباعدة حسب حالة‬ ‫‪.2‬‬
‫التربة‪ ،‬وقد يصل طول الدعامات الجدارية إلى خمسة أمتار‪.‬‬
‫وفي حال تجاوز عمق الحفرية ثالثة أمتار يجب على المقاول تقديم مخططات إنشائية تُبين طريقة التدعيم وال يسمح‬ ‫‪.3‬‬
‫بالبدء في أعمال تدعيم الجوانب إال بعد موافقة المهندس على هذه المخططات‪.‬‬
‫يتم نزع وسائل التدعيم بشكل تدريجي وبالتوافق مع أعمال الردم و الد ‪.‬‬ ‫‪.4‬‬
‫متطلبات حفر الخندق‬
‫يجب تدعيم جوانب الخنادق التي يزيد عمقها على ‪ 1.5‬متر أو تحدر إلى زاوية االستقرار كما في الشكل ‪.‬‬ ‫‪.1‬‬
‫يجب توفير حماية فعالة للخنادق التي يقل عمقها عن ‪ 1.5‬متر في األماكن التي يتوقع حدوث تفكك لتربة فيها و‬ ‫‪.2‬‬
‫انهيار جوانب الخندق‪.‬‬
‫أن تكون المواد الالزمة لتدعيم الجوانب والتغطية باأللواح قوية وتمتد إلى قاع الحفرة‪.‬‬ ‫‪.3‬‬
‫يستخدم تدعيم إضافي للجوانب في الخنادق التي تقع بجوار المناطق المردومة أو المعرضة لالهتزازات‪.‬‬ ‫‪.4‬‬
‫يجب حماية العمال الذين يدخلون إلى حفر القواعد أو األعمدة بتركيب إطار قوي قابل للنزع على مدى عمق‬ ‫‪.5‬‬
‫الحفرة لمقاومة تحر التربة المحيطة (باستثناء الحفر مخروطية الشكل) ويجب على العاملين استخدام حبل انقاذ‬
‫قويا ً بما يكفي إلخراج العامل من الحفرة‪.‬‬
‫الحد األدنى لمتطلبات تدعيم الخندق باألخشاب مبينة بالجدول التالي‪:‬‬ ‫‪.6‬‬

‫‪SDCS-02-17 REV.01‬‬
‫جدول ‪ :2‬القياسات لتدعيم الحفريات‪.‬‬
‫‪ .7‬يجب أن تستعمل في الخنادق التي يبلغ عمقها (‪ 1.2‬متر) أو أكثر ساللم تمتد على األقل (‪ 1.51‬متر) فوق سطح‬
‫الخندق‪ .‬ويجب ان توضع هذه الساللم في أماكن بحيث ال يزيد بعد السلم عن االخر (‪ 7.6‬متر)‪.‬‬
‫‪ .8‬الركائز المستعرضة أو رافعات الخندق يجب‪:‬‬
‫‪ .a‬أن توضع في وضعية أفقية صحيحة‪.‬‬
‫‪ .b‬أن تتر بينها فراغات عمودية‬
‫‪ .c‬أن تثبت بإحكام (تربط بربطات) بحيث ال تنزلق أو تسقط‪.‬‬
‫‪ .5‬يمكن استخدام صناديق الخنادق المتنقلة أو أغطية الخنادق االنزالقية بدال من تدعيم الجوانب أو إمالتها‪ ،‬وعند‬
‫استعمالها يجب ان تصمم و تنشا و تصان بحيث توفر من الحماية الالزمة لذلك الخندق ما هو معادل أو أفضل مما‬
‫توفره التغطية باأللواح أو تدعيم الجوانب‪.‬‬
‫‪ .11‬يجب أن يسير الردم و إزالة دعامات الخندق مع بعضهما و يتم العمل من قاع الخندق إلى أعلى و تحرر الرافعات‬
‫و األكتاف ببطء‪.‬‬
‫مالحظة‪:‬‬
‫ال يلزم تدعيم الجوانب من الصخور الصلبة أو الصخور البركانية أو الصخور المشكلة من الصلصال أو يمكن استبدال‬
‫الخشب بالركائز الفوالذية المستعرضة والركائز ذات المقاومة المعادلة حسب الرغبة‪.‬‬
‫‪6.4.3 Sand Bedding/Cover and Cable Tiles‬‬

‫‪A bedding of Clean, fine sand shall be placed at the bottom of the trench. After laying‬‬
‫‪the cable, all stone and rubble that have fallen in to the trench during the cable laying‬‬
‫‪shall be removed. A cover of clean, fine sand shall be placed over the cable. The‬‬
‫‪thickness of sand bedding/cover shall be as per the relevant trench construction drawing.‬‬
‫‪The sand bedding and cover shall be spread by hand tools to maintain an even thickness.‬‬

‫‪SDCS-02-17 REV.01‬‬
‫الرمل الناعم‪:‬‬
‫يتم وضع رمل ناعم أسفل وحول الكابل بسمك ( ‪ 111‬مليمتر ) أسفل وأعلى الكابل ويكون الرمل مطابقا للمواصفات اآلتية‪:‬‬
‫مقاس حجم المنخل‪:‬‬
‫جدول ‪ :3‬مقاسات المنخل‪.‬‬
‫بلك الحماية‪:‬‬
‫يجب حماية الكابالت المطمورة للجهود ‪. ٣٣‬ف و ذلك عند الربط بين المحطات الرئيسة فقط بواسطة بلك الحماية مقاس‬
‫‪ 51‬مم * ‪ 211‬مم * ‪ 411‬مم و يتم وضعه فوق رمل الحماية‪.‬‬
‫‪6.4.4 Backfilling and Reinstatement‬‬

‫‪Backfilling and reinstatement of the trench shall be in accordance with the requirements‬‬
‫‪of the authority (e.g. municipality. MOC, etc.) under whose jurisdiction the area falls.‬‬
‫‪Warning tapes shall be laid in the backfill.‬‬
‫الردم والدك‪:‬‬
‫يتم الردم في األماكن المطلوب ردمها بمواد مختارة حسب مواصفات وزارة الشئون البلدية والقروية أو وزارة‬ ‫‪.1‬‬
‫المواصالت و مع عدم اإلخالل بما ورد في هذه المواصفات‪.‬‬
‫في الطبقات بعمق أكثر من ( ‪ 611‬مليمتر ) من طبقة ما تحت األساس‪ ،‬يتم الردم علي طبقات بحيث ال يزيد سمكها‬ ‫‪.2‬‬
‫عن ( ‪ 311‬مليمتر ) كحد أقصى و يجب أن ترش بالماء و تخلط جيداً قبل أن توضع في الحفرية حسب النسب‬
‫المقررة للوصول إلى أحسن كثافة بموجب تجربة برمتو المعدلة و تهرس للوصول إلى نسبة ( ‪ ) %51‬من الكثافة‬
‫الجافة العظمى المقررة بموجب تجربة بركتو المعدلة‪.‬‬
‫في الطبقات التي تلي الطبقات أعاله على عمق أقل من ( ‪ 611‬مليمتر ) من تحت األساس فتردم على طبقات أيضاً‪،‬‬ ‫‪.3‬‬
‫و سمك كل طبقة ال يزيد عن ( ‪ 211‬مليمتر) و يجب أن ترش بالماء و تهرس حتى الوصول إلى ( ‪ ) %55‬من‬
‫الكثافة الجافة العظمى ‪ ،‬و يجب أن تكون المواد طبقا ً للمواصفات‪.‬‬
‫طبقة ما تحت األساس الحجري المتدرج تتكون من مخلوط متجانس من الحصمة المكسرة أو قطع الصخور و‬ ‫‪.4‬‬
‫الرمل و الطمي‪ ،‬و يجب أن تدرج مواد هذه الطبقة حسب اآلتي‪:‬‬

‫‪SDCS-02-17 REV.01‬‬
‫جدول ‪ :4‬قياسات المناخل‪.‬‬
‫توضع لوحات بأبعاد ‪ 1111‬ميلمتر * ‪ 611‬ميلمتر عند بداية الحفر ونهايته عند التقاطعات الرئيسية ويكتب عليها‬ ‫‪.5‬‬
‫اسم الشركة أو المؤسسة ورقم هاتفها والجهة التابعة لها واالستشاري ورقم المشروع وتكون الكتابة باللغتين العربية‬
‫واالنجليزية‪.‬‬
‫يجب عمل التحويالت المرورية وتزويدها باللوحات االرشادية والتحذيرية والحواجز حسبما بدليل أجهزة التحكم‬ ‫‪.6‬‬
‫النظامية في المرور بمناطق العمل الصادر من قبل وزارة المواصالت‪.‬‬
‫طبقا ً ما تحت األساس الحصوي واألساس الحصوي المتدرج تتكون من مخلوط متجانس من الحصمة المكسرة أو‬ ‫‪.7‬‬
‫قطع الصخور والرمل والطمي كذلك ينبغي أن تكون نسبة تحمل كاليفورنيا ‪ %61‬على األقل و إذا تعذر تحقيق ذلك‬
‫ينسق مع وزارة المواصالت للتوجيه بما يلزم ويجب أن ترش هذه المواد بالماء و تخلط جيداً و تفرش و تهرس إلى‬
‫درجة ‪ %111‬من الكثافة الجافة القصوى و يكون مستوى سطح أعلى مقطع منها على مستوى أقل من مستوى قاع‬
‫االسفلت القديم و تفرد على طبقات ال يزيد سمك كل منها عن ( ‪ 151‬ميلمتر )‪.‬‬
‫ينبغي علي المقاول المنفذ اجراء كافة االختبارات التي تطلبها مواصفات وزارة المواصالت والمواصفات الخاصة‬ ‫‪.8‬‬
‫بالمشروع وكذلك التقيد بتعليمات المهندس المشرف‪.‬‬
‫الردم حول المنشآت‪:‬‬ ‫‪.5‬‬
‫‪ .a‬المقصود بها األساسات‪ ،‬غرف التجمع و التفتيش‪ ،‬غرف الصمامات‪ ،‬غرف الغسيل ‪ ...‬إلخ ‪ ،‬و يجب أن‬
‫يكون الردم بمواد مطابق للمواصفات على طبقات ال يتعدى سمك الطبقة ‪ 151‬مليمتر و يجب أن ترش بالماء‬
‫و تخلط جيداً وتهرس حتى الوصول إلى نسبة ‪ %55‬من الكثافة الجافة المقررة وتعامل الطبقتين النهائيتين‬
‫بمثل طبقة ما تحت األساس الحجري بحيث تصل نسبة الكثافة العظمى إلى ‪.%111‬‬
‫‪ .b‬كذلك يجب أن تكون نسبة تحميل كاليفورنيا ‪ %61‬على األقل و يجب أن ترش هذه المواد بالماء وتخلط جيداً‬
‫ثم تفرش وتهرس إلى درجة كثافة ‪ %111‬من الكثافة الجافة المقررة بواسطة تجربة بروكتور المعدلة و‬
‫يكون سمك هذه الطبقة على طبقتين كل منها ‪ 151‬ميليمتر و يجب أن ترش بالماء وتهرس حتى الوصول إلى‬
‫درجة الد المطلوبة و يجب أن يكون معامل اللدونة ال يزيد عن ‪.%61‬‬

‫‪SDCS-02-17 REV.01‬‬
‫‪ .11‬إعادة السفلتة‪:‬‬
‫ً‬
‫‪ .a‬بعد جفاف طبقة ما تحت األساس الحجري المتدرج من الماء تماما ترش بطبقة من االسفلت المتوسط التجمد‬
‫(‪ )DCI‬بمعدل ( ‪ 1.5‬كجم ‪ /‬م ) و يجب أن ترش هذه المادة بالرشاشات الميكانيكية المعتمدة بعد ضبطها‬
‫لترش الكمية المقررة بشكل متجانس في جميع أجزاء المنطقة المراد سفلتتها أو باستخدام البراميل‪.‬‬
‫‪ .b‬هذا و تتر هذه الطبقة لمدة ‪ 24‬ساعة ثم تتم عملية السفلتة أو عملية وضع األساس األسفلتي و قبل وضع‬
‫األساس األسفلتي يجب أن يقوم المقاول بقص منطقة لحام األسفلت القديم بالمنشار عموديا ً ثم يجب عليه‬
‫تنظيف الموقع من أية شوائب أو أتربة مترسبة على السطح المراد سفلتته كذلك يتم دهان حواف األسفلت‬
‫القديم بمادة االسفلت سريع التجمد (‪ )RC2‬وكذلك بعد تنظيفها جيداً من األتربة يتم فرد طبقة األساس‬
‫االسفلتي بالسمك المناسب ليتم الوصول إلى سمك الطبقة المطلوبة بعد الهرس و يجب أن تخضع مواد هذه‬
‫الطبقة للتدرج التالي‪:‬‬
‫جدول ‪ :5‬التدرج‪.‬‬
‫‪ .11‬تكون نسبة االسفلت (‪ )%7-4‬بالنسبة لحفريات الترنشات وتكون على طبقتين و تفرد كل طبقة على حدة و يجب‬
‫رش الطبقة االسفلتية بمادة الربط سريع التجمد (‪ )RC2‬وذلك بمعدل ( ‪ 2:1‬كجم‪ /‬م ) ويجب الهرس حتى الوصول‬
‫إلى ‪ %55‬من الكثافة العظمى بواسطة المستخدم عند ‪ 135‬درجة مئوية على أال تزيد عن ‪ 162‬درجة مئوية أثناء‬
‫الفرد‪.‬‬
‫‪ .12‬يغلق الطريق لمدة ال تقل عن ‪ 24‬ساعة بعد وضع الطبقة النهائية وال يسمح بالمرور عليه قبل ذلك‪ ،‬يمنع منعاً باتاً‬
‫استعمال العمال في فرد األسفلت فرادات ذات أحجام صغيرة لسفلتة الترنشات حيث توفرت في األسواق من عرض‬
‫‪ 411‬ميليمتر فما فوق وذلك للحصول علي سطح متجانس ذو منسوب واحد مع األسفلت القديم مع الحديث بطريقة‬
‫سليمة ‪ ،‬أما بالنسبة للتواصل يلتزم المقاول التزاما ً تاما ً قبل وضع األسفلت بقص جوانب الحفر وبشكل عمودي حتى‬
‫ينكشف سطح جديد وكذلك أيضا ً قص جوانب الحفر بين عمل يومين متتابعين من السفلتة وتنظيف الجوانب من أي‬
‫مواد سائبة مع استعمال المعدات الميكانيكية وكذلك يجب على المقاول أيضا ً أن يقوم بدهان هذه الفواصل بمادة‬
‫االسفلت السريع التجمد (‪ )RC2‬و ذلك حتى يتم الترابط بين االسفلت القديم والجديد‪.‬‬
‫‪ .13‬إعادة األرصفة‪ :‬حيث يلتزم المقاول بأن يقوم بإصالح أي خلل في األرصفة ينتج سواء كان في البالط أو في‬
‫البردورات حيث يتم ازالة األجزاء التالية و إعادة وضعها إلى حالتها الطبيعية التي كانت عليها وكذلك االلتزام‬
‫بإعادة المناطق المرصوفة بمواد خاصة في منطقة وسط البلد أو غيرها بنفس نوعية المواد الموجودة علي الطبيعة‬
‫وعلى المقاول أيضا ً المحافظة علي األشجار والمزروعات وأحواض الزرع ويتحمل أي أضرار تنتج‪.‬‬
‫‪ .14‬إعادة الموقع إلى حالته الطبيعية‪:‬‬
‫على المقاول اعادة الطريق الي حالته الطبيعية التي كان عليها قبل بدء العمل بما في ذلك الدهانات وعيون القطط‬
‫وخالفه ويلتزم المقاول بتنظيف الموقع جيداً من جميع األتربة والمخلفات وذلك باستخدام المعدات الميكانيكية‬
‫المعتمدة بحيث يكون الشارع نظيفاً خالل مدة التصريح الممنوح له‪.‬‬

SDCS-02-17 REV.01
6.4.5 Concrete:
:‫ تتكون خلطات الخرسانة للمتر المكعب الواحد كاآلتي‬
.)‫ كجم أسمنت‬251 ،‫ مليمتر رمل نظيف‬411 ،‫ بحصى متدرج‬2‫ مليمتر‬811( ‫ الخرسانة العادية‬.1
2
.)‫ كجم أسمنت‬351 ،‫ رمل نظيف‬2‫ مليمتر‬411 ،‫ بحصى متدرج‬2‫ مليمتر‬811( ‫ الخرسانة المسلحة‬.2
.‫ تقديم عينات من الحصى و الرمل لالعتماد من قبل المهندس المشرف‬.3
1. All concrete surfaces in contact with ground shall be provided with two (2) layers of
polyethylene vapor barrier / Each layer shall be six (6) Mil Thickness and in
Accordance with ASTM-2103.
2. Concreting shall not be allowed without vibration at any time.
3. Curing of concrete shall be done by gunny bags for curing compound.
4. Cement shall be type 1 and in areas having water logging and salinity, Sulphate
resistant cement type 5 may be used. SEC Engineer shall direct to the type of
cement to be used.
5. Water shall be free from silt, organic matter, alkalies or other impurities.
6. The average grain size of sand is 0.35mm and the mud content shall not be more
than 5%.
7. Forms to be used, these shall be sufficiently tight to prevent loss of mortar from
concrete and shall be maintained rigidly in position until concrete has hardened
enough to prevent damage by the removal.
8. If required by SEC Engineer, the concrete foundation sample test of Pole and anchor
shall be carried out. The concrete sample to be crushed after seven days.
9. All lean concrete under reinforced base to be premixed from factory with 250 kg
cement/m2 of concrete minimum strength 14 N/mm2.
10. Lean concrete 15 cm thick shall be used all around the 15 Cm Dia P.V.C Pipes
running underground.
11. All R.C.C to be premixed from factory with 350 kg cement/m2 of concrete minimum
strength 21 N/mm2 (3000 P.S.I).
12. Sand should be coarse grained, clean and free from all foreign matter.
13. Aggregate should be well graded (19mm Max size), clean and free from all foreign
matter.
14. All steel reinforcing bar to be high yield deformed type conforming to metric BS
444.9 Min yield strength 410 N/mm2.
15. Reinforcement covers with in concrete to be as follows: Roof Slab 20 mm, Footing
60mm, others 40 mm.

SDCS-02-17 REV.01
7 SOIL CLASSIFICATION:
The soils are classified according to the A. B. Chance test probe method. The chance test
probe is a mechanical tool to identify soil in a simple and quick way from the earth
surface without core samples. To find out the soil bearing capacity the soil test probe is
screwed into the soil. As it displaces the soil, probe torque readings are measured in
inch-pounds on a torque gauge. The torque values obtained are translated into soil
classification using the chance Soil Classification Data chart. The table below shows the
soil classification as per A.
B. Chance method and the relevant SEC soil classification to be followed.
SEC Soil
Probe Values Ibs
Class Description of Soil Type Type
(N-m)
Classification
0 Sound hard rock, un-weathered N. A.
Very dense and / or cemented sands coarse 750-1600
1
gravel and cobbles (90-208)
Rock / Dense
Dense fine sand, very hard silts and clays 600-750
2 Soil
(may be preloaded) (78-98)
Dense clays, sands and gravel, hard silts 500-600
3
and clays (65-78)
Medium dense coarse sandy gravel, very 400-500
4
stiff to had silts and clays (52-65) Medium
Medium dense coarse sand & sandy 300-400 Soil
5
gravels, stiff to very stiff silts and clays (39-52)
Loose to medium dense fine to coarse 200-300
6
sand, firm to stiff clays & silt (26-39) Loose
Loose fine sand, alluvium, loess, soft firm 100-200 Soil
7
clays, varied clays, fill (13-26)
Table 6: BREAKING CAPACITY OF SOIL IS 1.5 KG/CM2


‫‪SDCS-02-17 REV.01‬‬
‫‪8 SOIL AND ASPHAILT TEST‬‬

‫‪ 1.6‬قص االسفلت‬
‫يجب أن يكون القص بالمنشار و باستقامة تامة و بعرض ال يقل عن ‪ 1‬متر في القطعيات و الشوارع الرئيسية و يتم‬
‫قص األجزاء المتهتكة من اإلسفلت بطول ‪ 5‬متر و إذا كانت المسافة بين قطعتين أقل من ‪ 5‬متر فإنه يتم إزالة الجزء‬
‫الفاصل بينهما‪.‬‬
‫و يستثنى من القص بعرض متر للعمل في الشوارع الفرعية التي يقل بعد الحفر عن الجدار فيها عن مترين أو يكون‬
‫بعد الحفر عن رصيف المواطن أقل من متر‪.‬‬
‫‪ 1.6‬األعمال الترابية‬
‫‪ 8.2.1‬جاهزية المواقع الترابية‬
‫يمكن تحديد جاهزية الموقع من خالل التأكد من جودة المواد التي يستخدمها المقاول لتنفيذ العمل بالتأكد من خلوها من‬
‫الصخور واألحجار الكبيرة التي يزيد قطرها عن ‪ 5‬سم و خلوها من المخلفات و المواد العضوية و األعشاب و الجذور و‬
‫مخلفات األشجار و كذلك بالتأكد من مطابقتها لمواصفات األمانة المطلوبة من حيث التدرج و التصنيف و الجودة و قابلية‬
‫التماسك ويعتبر الموقع جاهزاً لالختبار بعد التأكد من التالي‪:‬‬
‫جودة المواد المستخدمة‪.‬‬ ‫‪.a‬‬
‫عدم وجود تكهفات تمنع وصول الرصاصة للطبقة المراد دكها‪.‬‬ ‫‪.b‬‬
‫سماكة الطبقة (إنها مطابقة للسماكات حسب المواصفات)‪.‬‬ ‫‪.c‬‬
‫استواء الطبقة‪.‬‬ ‫‪.d‬‬
‫التأكد من سماكة الطبقة الترابية‪.‬‬ ‫‪.e‬‬
‫عدم وجود تربة مفككة‪.‬‬ ‫‪.f‬‬
‫عدم وجود انفصال حبيبي‪.‬‬ ‫‪.g‬‬
‫نظافة الموقع من المخلفات‪.‬‬ ‫‪.h‬‬
‫د جميع أجزاء الحفرية‪.‬‬ ‫‪.i‬‬
‫‪ 8.2.2‬معدل تكرار اختبارات جودة المواد الترابية‬

‫يجب أن ال يقل على المواد عن عينة واحدة لكل أسبوعين عند استخدام مصدر واحد للمواد أو وجود تخزين (تشوين)‬
‫كافي في حالة اختبار التدرج وتصنيف المواد‪ ,‬أما في حالة كاليفورنيا لنسبة التحمل واختبار لوس انجلوس للتآكل فإنه يتم‬
‫عمل االختبار كل شهر (على األكثر) و يتم أخذ عينة واحدة في الحاالت التالية‪:‬‬
‫‪ .a‬كلما تغير مصدر المواد ‪.‬‬
‫‪ .b‬كلما ظهرت دالئل على تغير مصدر المواد كتغير اللون أو الخواص أو النسيج‪.‬‬
‫‪ .c‬كلما زادت كمية العمل عن خمسمائة ( ‪ ) 511‬متر مكعب من األعمال المستمرة‪.‬‬
‫‪ 8.2.3‬معدل تكرار جودة التنفيذ ( الدك ) لألعمال الترابية‬
‫يمكن تحديد عدد االختبارات للكثافة الحلقية الواجب إجراؤها وفقا للقواعد التالية ‪:‬‬
‫‪ .a‬إجراء اختبار واحد لكل ‪ 151‬متر لكل طبقة من األعمال المتصلة لكل اتجاه من اتجاهات الحفر أو عند وجود‬
‫تغير واحد بالحفر (تغير اتجاه الحفر)‪.‬‬
‫‪ .b‬إذا كان العمل أقل طوال من ‪ 151‬متر أو كان هنا أكثر من تغير واحد في االتجاه فإنه يتم عمل اختبار واحد‬
‫لكل موقع لكل طبقة لكل اتجاه‪.‬‬

‫‪SDCS-02-17 REV.01‬‬
‫‪ 8.2.4‬متطلبات الجودة طبقات الردم (‪)Back Filling‬‬

‫المواصفة‬ ‫المتطلبات‬ ‫الخاصية‬
‫)‪(AASHTO–M145‬‬ ‫‪A-1-a or A-1-b or A-2-4‬‬ ‫تصنيف التربة‬
‫)‪(AASHTO–T180-74‬‬ ‫‪55‬‬ ‫نسبة الد ‪ -‬الكثافة الجافة العظمى (حد ادنى) (‪)%‬‬
‫)‪(AASHTO–D1883‬‬ ‫‪51‬‬ ‫نسبة تحمل كاليفورنيا (حد ادنى) (‪)%‬‬

‫)‪(AASHTO–176-73‬‬ ‫‪25‬‬ ‫المكافئ الرملي (حد أدنى)‬
‫)‪(AASHTO–T90-80‬‬ ‫‪6‬‬ ‫دليل اللدونة (حد أقصى)‬
‫)‪(AASHTO–D1883‬‬ ‫‪51‬‬ ‫النقص بسبب التأكل (لوس انجلوس) حد أقصى (‪)%‬‬
‫جدول ‪Back Filling:7‬‬
‫‪ 8.2.5‬متطلبات الجودة لطبقة ما تحت األساس الركامية (‪)Sub Base‬‬

‫‪15‬سم ‪ 15+‬سم‬ ‫سماكة الطبقة (حد أدنى)‬
‫‪A-1-a or A-1-b‬‬ ‫تصنيف التربة‬
‫)‪(ASTM –D4318‬‬ ‫‪25‬‬ ‫حد السيولة (حد أقصى)‬
‫)‪(AASHTO –T90-80‬‬ ‫‪6‬‬ ‫دليل اللدونة (حد أقصى)‬
‫)‪(AASHTO –T96-77‬‬ ‫‪51‬‬ ‫نسبة التأكل (حد أقصى)‬
‫)‪(AASHTO –176-73‬‬ ‫‪25‬‬ ‫المكافئ الرملي (حد أدنى)‬
‫)‪(AASHTO –D1883‬‬ ‫‪65‬‬ ‫نسبة تحمل كاليفورنيا (حد أدنى) (‪)%‬‬
‫‪2±‬‬ ‫نسبة الرطوبة من نسبة الرطوبة المثالية (‪)%‬‬
‫)‪(AASHTO –T180-74‬‬ ‫‪111‬‬ ‫نسبة الد من الكثافة الجافة القصوى بموجد بروكتر المعدلة (‪)%‬‬
‫جدول ‪Sub Base:8‬‬
‫‪ 8.2.6‬متطلبات الجودة لطبقة األساس الركامي (الطرق السريعة ) ‪Aggregate Base Course‬‬
‫)‪(AASHTO –D1883‬‬ ‫‪81‬‬ ‫نسبة تحمل كاليفورنيا ‪ ,‬حد ادنى (‪)%‬‬
‫‪12‬‬ ‫سالمة كبريتات الصوديوم والنقص ‪( ,‬االصالة) حد اقصى‬
‫)‪(AASHTO –T96-77‬‬ ‫‪45‬‬ ‫النقص بسبب التأكل (حد أقصى)‬
‫)‪(AASHTO –T89-80‬‬ ‫‪25‬‬ ‫حد السيولة (حد أقصى)‬
‫)‪(AASHTO –T90-80‬‬ ‫‪6‬‬ ‫دليل اللدونة (حد أقصى)‬
‫)‪(AASHTO–T180-74‬‬ ‫‪111‬‬ ‫نسبة الد من الكثافة الجافة القصوى بموجد بروكتر المعدلة (‪)%‬‬
‫جدول ‪Aggregate Base Course:5‬‬


‫‪SDCS-02-17 REV.01‬‬
‫‪ 1.6‬األعمال االسفلتية‬
‫‪ 8.3.1‬تحديد جاهزية األعمال اإلسفلتية لالختبارات‬
‫يمكن تحديد جاهزية الموقع الختبارات اإلسفلت بعد التحقق من خالل الفحص البصري لإلسفلت لجميع النقاط التالية‪:‬‬
‫استقامة قص اإلسفلت واالنتهاء من عمل السفلتة للطبقة المراد اختبارها‪.‬‬ ‫‪.a‬‬
‫تساوي منسوب اإلسفلت القديم بالجديد تماما‪.‬‬ ‫‪.b‬‬
‫جودة ربط اإلسفلت القديم بالجديد‪.‬‬ ‫‪.c‬‬
‫عدم وجود خشونة في اإلسفلت ( تجمع حصوي )‪.‬‬ ‫‪.d‬‬
‫عدم وجود نعومة باإلسفلت‪.‬‬ ‫‪.e‬‬
‫جودة مستوى اإلسفلت العام من حيث الشكل والمظهر‪.‬‬ ‫‪.f‬‬
‫عدم وجود خدوش أو انكسارات في اإلسفلت بسبب المعدات‪.‬‬ ‫‪.g‬‬
‫عدم وجود هبوط أو قص بجانب اإلسفلت بسبب التنفيذ‪.‬‬ ‫‪.h‬‬
‫التأكد من سماكة اإلسفلت كالتالي‪ :‬حيث يكون مساوي لسماكة اإلسفلت القديم وفي حالة أن يكون اإلسفلت القديم‬ ‫‪.i‬‬
‫اقل من ‪ 6‬سم للشوارع الفرعية أو ‪ 8‬سم للشوارع الرئيسية فانه يكتفي بـ ‪ 6‬سم للشوارع الفرعية و ‪ 8‬سم‬
‫للشوارع الرئيسية‪ ،‬أما إذا كانت سماكة اإلسفلت القديم أكثر من ‪15‬سم فيكتفى بوضع طبقة إسفلت بسماكة ‪15‬سم‬
‫فقط‪ ،‬ويتم وضع اإلسفلت على طبقات بسماكة ال تزيد عن ‪6‬سم لكل طبقة‪ ،‬ويجب أن تتم عملية السفلتة بنفس‬
‫اليوم‪ ،‬أما إذا لم تنفذ الطبقات بنفس اليوم فيجب رش السطح بطبقة الصقة من الـ ‪.RC2‬‬
‫‪ 8.3.2‬معدل اختبار جودة المواد اإلسفلتية‬

‫يجب اخ ذ عينة لكل يوم عمل لكل مقاول لكل خالطة لكل نوع من أنواع الخلطات والتأكد من درجة حرارة الخلطة‬
‫االسفلتية في الموقع بحيث تكون درجة الحرارة (‪ )163 -135‬درجة مئوية‪.‬‬
‫‪ 8.3.3‬تكرار اختبار نسبة دك اإلسفلت‬
‫يتم عمل اختبار نسبة الد كالتالي‪:‬‬
‫‪ .a‬إذا كانت الحفرية في اتجاه واحد يتم عمل اختبار واحد لكل ‪ 311‬متر طولي أو أقل من العمل اليومي لكل طبقة‬
‫متصلة‪.‬‬
‫‪ .b‬إذا كانت الحفرية متغيرة االتجاهات ( أكثر من تغير واحد في االتجاهات ) فيجب اجراء اختبار واحد لكل طبقة‬
‫في كل اتجاه من اتجاهات مسار الحفرية لكل ‪ 311‬متر فأقل لكل عمل متصل في نفس اليوم أو عمل اختبار‬
‫واحد لكل جزء منفصل ضمن نطاق التصريح‪.‬‬
‫‪ .c‬يتم عمل اختبار واحد لكل عدد خمس مواقع من وصالت المشتركين والتي تعمل في نفس اليوم ولنفس الحي‬
‫ومن نوع الخلطة ومن خالطة واحدة‪.‬‬

‫‪SDCS-02-17 REV.01‬‬
‫‪ 8.3.4‬معدل تكرار االختبارات‬
‫متطلبات جودة االسفلت‪:‬‬
‫تدرج ‪1‬‬ ‫تدرج ‪2‬‬ ‫تدرج ‪3‬‬ ‫الخاصية‬

‫‪1111‬‬ ‫‪1111‬‬ ‫‪1111‬‬ ‫الثبات حد أدنى (كجم)‬
‫‪4-2‬‬ ‫‪4-2‬‬ ‫‪4-2‬‬ ‫االنسياب (مليمتر)‬
‫ً‬
‫ال يزيد عن ‪ ( 35‬مواصفة اشتو ‪)T-96-77‬‬ ‫النقص بالتأكل للركام (لوس أنجلوس) (‪)%‬‬
‫‪6-4‬‬ ‫‪6-4‬‬ ‫‪5-3‬‬ ‫نسبة الفراغات في الخلطة (‪)%‬‬
‫تختلف على حسب الحجم األقصى االسمي للركام‬ ‫نسبة الفراغات المملوءة باإلسفلت (‪)%‬‬
‫‪6-4‬‬ ‫‪6-4‬‬ ‫‪6-4‬‬ ‫نسبة االسفلت (‪ )61/71‬بالوزن (‪)%‬‬
‫ال تزيد عن ‪25‬‬ ‫نسبة فقدان الثبات بدرجة حرارة ‪ 61‬درجة مئوية (‪)%‬‬
‫‪ 56 – 53‬من الكثافة العظمى ‪Gmm‬‬ ‫نسبة الد (‪)%‬‬
‫ال يقل عن ‪( 61‬مواصفة اًشتو ‪)T-176‬‬ ‫المكافئ الرملي للمواد الركامية (‪)%‬‬
‫جدول ‪ :11‬متطلبات الجودة لطبقة االسفلت السطحية‪.‬‬
‫النسبة المئوية المارة ‪%‬‬

‫صنف ج‬ ‫صنف ب‬ ‫صنف ج‬
‫قطر و رقم المنخل‬
‫التدرج (‪12,53‬مليمتر) الحد التدرج ‪15( 2‬مليمتر) الحد التدرج ‪15( 1‬مليمتر)‬
‫الحد األقصى اإلسمي‬ ‫األقصى اإلسمي‬ ‫األقصى اإلسمي‬
‫‪111‬‬ ‫‪111‬‬ ‫‪-‬‬ ‫‪ 15‬مليمتر (‪ 4/3‬انش)‬
‫‪51 – 75‬‬ ‫‪111 - 51‬‬ ‫‪111‬‬ ‫‪ 12.5‬مليمتر (‪ 2/1‬انش)‬
‫‪75 – 64‬‬ ‫‪83 - 78‬‬ ‫‪111 - 51‬‬ ‫‪ 5.5‬مليمتر (‪ 8/3‬انش)‬
‫‪56 – 41‬‬ ‫‪61 – 46‬‬ ‫‪68 - 54‬‬ ‫‪ 4.75‬مليمتر (رقم ‪)4‬‬
‫‪37 – 23‬‬ ‫‪42 – 31‬‬ ‫‪46 – 32‬‬ ‫‪ 2‬مليمتر (رقم ‪)11‬‬
‫‪21 – 7‬‬ ‫‪25 – 14‬‬ ‫‪25 – 14‬‬ ‫‪ 1.425‬مليمتر (رقم ‪)41‬‬
‫‪13 – 5‬‬ ‫‪16 – 8‬‬ ‫‪16 – 8‬‬ ‫‪ 1.18‬مليمتر (رقم ‪)81‬‬
‫‪8–3‬‬ ‫‪7-3‬‬ ‫‪7-3‬‬ ‫‪ 1.175‬مليمتر (رقم ‪)211‬‬
‫جدول ‪ :11‬متطلبات التدرجة لطبقة االسفلت السطحية‪.‬‬
‫تدرج ‪1‬‬ ‫تدرج ‪2‬‬ ‫تدرج ‪3‬‬ ‫الخاصية‬

‫‪1111‬‬ ‫‪1111‬‬ ‫‪1111‬‬ ‫الثبات حد أدنى (كجم)‬
‫‪4-2‬‬ ‫‪4-2‬‬ ‫االنسياب (مم)‬
‫ً‬
‫ال يزيد عن ‪ ( 35‬مواصفة اشتو ‪)T-96-77‬‬ ‫النقص بالتأكل للركام ( لوس أنجلوس ) (‪)%‬‬
‫‪7-5‬‬ ‫‪7-5‬‬ ‫‪7-5‬‬ ‫نسبة الفراغات في الخلطة (‪)%‬‬
‫تختلف على حسب الحجم األقصى االسمي للركام وتتراوح‬ ‫نسبة الفراغات المملوءة باألسفلت (‪)%‬‬
‫بين (‪)%75-61‬‬
‫‪6-3‬‬ ‫‪6-3‬‬ ‫‪6-3‬‬ ‫نسبة االسفلت (‪ )61/71‬بالوزن (‪)%‬‬

‫‪SDCS-02-17 REV.01‬‬
‫ال تزيد عن ‪25‬‬ ‫نسبة فقدان الثبات بدرجة حرارة ‪ 61‬درجة مئوية (‪)%‬‬
‫‪ 55 – 52‬من الكثافة العظمى ‪Gmm‬‬ ‫نسبة الد (‪)%‬‬
‫ال يقل عن ‪( 61‬مواصفة اًشتو ‪)T-176‬‬ ‫المكافئ الرملي للمواد الركامية (‪)%‬‬
‫جدول ‪ :12‬متطلبات الجودة لطبقة االساس االسفلتي‪.‬‬
‫النسبة المئوية المارة ‪%‬‬

‫صنف ج‬ ‫التدرج (‪ 25 )3‬مم التدرج (‪ 25 )2‬مم‬
‫قطر و رقم المنخل‬
‫التدرج (‪ 37.5 )1‬مم‬ ‫الحد األقصى‬ ‫الحد األقصى‬
‫الحد األقصى اإلسمي‬ ‫اإلسمي‬ ‫اإلسمي‬
‫‪111‬‬ ‫‪-‬‬ ‫‪-‬‬ ‫‪ 37.5‬مليمتر (‪ 1.5‬انش)‬
‫‪51 – 75‬‬ ‫‪111‬‬ ‫‪111‬‬ ‫‪ 25‬مليمتر (‪ 1‬انش)‬
‫‪81 - 65‬‬ ‫‪51- 75‬‬ ‫‪111 - 51‬‬ ‫‪ 15‬مليمتر (‪ 4/3‬انش)‬
‫‪71 – 51‬‬ ‫‪81 – 75‬‬ ‫‪53 – 78‬‬ ‫‪ 12.5‬مليمتر (‪ 2/1‬انش)‬
‫‪62 – 45‬‬ ‫‪65 – 55‬‬ ‫‪72 – 57‬‬ ‫‪ 5.5‬مليمتر (‪ 8/3‬انش)‬
‫‪46 – 31‬‬ ‫‪61 – 35‬‬ ‫‪58 – 43‬‬ ‫‪ 4.75‬مليمتر (رقم ‪)4‬‬
‫‪33 – 18‬‬ ‫‪35 – 21‬‬ ‫‪43 – 28‬‬ ‫‪ 2‬مليمتر (رقم ‪)11‬‬
‫‪18 – 5‬‬ ‫‪21 – 7‬‬ ‫‪28 – 13‬‬ ‫‪ 1.425‬مليمتر (رقم ‪)41‬‬
‫‪13 – 3‬‬ ‫‪25 - 5‬‬ ‫‪-‬‬ ‫‪ 1.18‬مليمتر (رقم ‪)81‬‬
‫‪5-2‬‬ ‫‪7-3‬‬ ‫‪7-3‬‬ ‫‪ 1.175‬مليمتر (رقم ‪)211‬‬
‫جدول ‪ :13‬متطلبات التدرج لطبقة االساس االسفلتي‪.‬‬
‫الفحص البصري للبالط واألرصفة‬

‫يجب أن تكون نوعية البالط من نفس نوعية البالط السابق وبنفس الجودة والمستوى والمنسوب ويجب مراعاة جودة تنفيذها‬
‫ويتم التأكد من أن لواحق البالط قد تم قصه بواسطة المنشار لجميع أجزاء الحفرية‪.‬‬
‫تقييم رش السائل االسفلتي ‪ MC1‬و دهن أطراف اإلسفلت القديم بـ ‪RC2‬‬

‫يجب التأكد من أن رش السائل االسفلتي على الطبقة الترابية بعد جفاف سطحها تم بشكل منتظم و بمعدل (‪)1 ,75 -1 ,65‬‬
‫لتر‪/‬م‪ 2‬لمادة ‪ ،MC1‬و كذلك التأكد من استقامة القص االسفلتي و نظافته و قص ‪ 15‬سم من كال جانبي اسفلت الحفرية‬
‫للشوارع الرئيسية و ‪ 11‬سم للشوارع الفرعية و أنه تم دهن ‪ RC2‬على األطراف الداخلية لقص اإلسفلت و بشكل منتظم و‬
‫بمعدل ال يزيد عن (‪ )1 ,25‬لتر‪/‬م‪ 2‬لمادة ‪.RC2‬‬
‫القطعيات للشوارع‬
‫يتم عمل اختبار القطعيات على طبقات بشكل منفصل عن بقية الحفر بحيث يتم عمل اختبار لكل طبقة من الطبقات الترابية‬
‫و االسفلتية على أن تعتبر الشوارع ذات الحركة الدائبة ضمن أعمال الطوارئ‪.‬‬

SDCS-02-17 REV.01
‫ تغير اتجاه الحفر من شارع إلى شارع يتم احتساب ثالثة اختبارات في هذه الحالة‬:) 6 ( ‫مسار رقم‬
.) ‫لكل طبقة دك حسب العمق ونوعية الشارع ( رئيس أو فرعي‬
‫شارع‬
‫شارع‬
‫شارع‬
‫مسار الحفر‬
‫ تغير الحفر في الشارع الواحد من جانب إلى جانب في هذه الحالة يتم احتساب ثالثة‬: ) 6 ( ‫مسار رقم‬
.‫اختبارات لكل طبقة دك حسب العمق ونوعية الشارع‬
‫شارع واحد‬
‫مسار الحفر‬
9 Specification of Installation of Duct Bank at Road Crossing

9.1 General:
This specification gives requirements for installation of underground duct banks at road
crossings The. duct bank consists of PVC conduits direct buried in compacted sand or
encased in concrete.
9.2 Excavation:
The excavation for a duct bank shall be completed to its full length at crossing before
any conduit is laid. Possible obstructions might be encountered which would make it
difficult to maintain proper grading or drainage of the duct run.

SDCS-02-17 REV.01
Asphalt shall be cut by a motor driven saw. Excavated materials shall be immediately
removed from site and hauled to an approved municipal dumping yard.
Manual digging shall be used at locations where existing underground facilities (e.g.
water pipes, sewage lines, cables etc.) are encountered. Existing facilities uncovered
during excavation shall be protected, shored, braced, and supported, as necessary.
All protective covers, warning tapes, position markers, etc. pertaining to existing
underground utilities shall be preserved during excavation and restored in position during
backfilling.
The excavation shall be properly sheeted and braced, as necessary, to prevent the sides
from caving in due to soft or sandy soil, traffic vibration, etc. All excavations exceeding
1.5 meter depth shall be properly sheeted and braced.
The depth of the duct bank shall be in accordance with the requirement of the
municipality or ministry of communication ( as applicable ) and it shall provide a
minimum cover of 500 mm. The excavation for the duct banks shall provide a minimum
grade or slope of 250 mm per 100 m. The bottom of the excavation shall be carefully
finished to the exact grade required for the duct bank and shall have a minimum bearing
capacity of 140 kpa.
The width of the duct bank shall be as per the figures
Multiple layer duct banks shall be constructed if there is any difficulty to temporarily
cover with steel plate the very wide ( greater than 1300 mm ) open duct banks.
Where the earth walls of the excavation are firm enough to sustain themselves, they may
be used to serve as the forms for a concrete encased duct bank.
9.3 Duct Bank construction

General:
Direct buried concrete encased duct banks shall be constructed with Type DB PVC
conduit.
In laying PVC conduit, each piece of conduit shall be inspected for breakage. Where
jointing conduits, the conduit end without socked only shall be coated with solvent
cement and the conduits joined with a twisting motion to spread the cement.
As far as possible, conduits shall be so installed that the cable will enter and leave
through the socket ends of the conduits. In case of difficulty in arranging this, a straight
coupling shall be installed on the plain end of the conduit and cable shall be pulled
through this coupling.
Direct buried duct bank:
Constructing a direct buried duct bank shall consist of installing conduits with compacted
sand around the conduits. The sand shall be clean, fine, free from organic matter, and

SDCS-02-17 REV.01
compacted in 150 mm layers to 85%. Relative density ( ASTM-D-2049 ) at a moisture

content not less than 80%.
Reinforced concrete bulkheads ( precast or cast at site ) shall be installed at each end of
the duct bank. Bulkheads shall be as per the figures concrete shall conform to the
specification of section 6 of this clause and shall be colored or painted red on the top of
the surface.
Concrete encased duct bank:
Construction of a concrete encased duct bank consists of installing the conduits on
spacers or fixing them to the reinforcing steel bars driven inside the ground along the
trench length and pouring the concrete encasement. Spacers or bars for supporting the
conduit are installed at intervals or approximately 2.5 meters.
If the concrete mix is sloppy it may be necessary to weight or brace the duct assembly to
prevent it from floating. Sandbag or other weights can be placed over the conduit spacers.
This is not required if conduits are already fixed to the reinforcing steel bars.
If it is necessary to interrupt the concrete pouring for any appreciable time, as from one
work day until the next, the joint between the pouring shall be made as near vertical as
possible and shall be reinforced with 12 mm dia. Concrete reinforcing bars which extend
in to the concrete at least 600 mm on each side of the joint. Bars shall be placed at each
corner of the duct bank and they shall have a minimum cover of 80 mm of concrete.
Concrete for duct bank construction shall conform to the specification given on section 6
and shall be colored or painted red on the top surface.
9.4 Backfilling and reinstatement:
Backfilling of the duct back excavation shall be in accordance of the requirements of the
municipality or ministry of communications (as applicable). If not specified, backfill
shall be clean, fine sand, free from organic matter, compacted in 250 mm layers to 95%
maximum dry density ( modified Proctor ).
Warning tape shall be laid in the backfill between the duct bank and the base layer of the
roadway. The spacing between the duct bank and the warning tape shall be as large as
site conditions permit up to 500 mm.
Reinstatement of sidewalks, streets, and roads shall be in accordance with the
specification of municipality or ministry of communications ( as applicable ).
9.5 Duct cleaning and inspection:
On completion of a duct bank, a test mandrel and wire brush cleaner shall be pulled
through each conduit. The test mandrel shall be 6mm less in diameter than the nominal
inside diameter of the conduit while the wire brush shall be slightly larger than the
conduit.
The testing and cleaning of a concrete encased duct bank shall be done the day after the
concrete has been poured to eliminate any concrete which may have seeped in to the
ducts.

SDCS-02-17 REV.01
A nylon pull line shall be installed in each conduit after cleaning. All conduits shall
remain plugged until cables are installed through them.
9.6 Concrete Specification:

Portland Cement:
Type V ( Sulphate resistant ) conforming to ASTM specification C-150
Aggregates:
All Aggregates shall conform to ASTM specification C-33 and the following:
a. Coarse aggregate – round maximum sized 20 mm.
b. Fine Aggregate – percent of total, 40% to 55%; fineness modulus, 2.6 to 2.9.
Water:
Must be potable, clean and free from deleterious amounts of acids, alkalis or organic
materials . salt water or sea water shall not be used.
Strength:
Minimum strength, 21.0 MPA ( 3,000 psi ) in 28 days.
Slump:
Shall not exceed 150 mm ( based on standard 150 mm dia. test cylinder ).
Ready mixed concrete:
Ready mixed concrete shall be mixed in an approved plant, using approved materials as
specified. Water shall be added at the mixing plant except where haul is greater than one
hour from mixing plant, in which case water shall be added at the jobsite.
Job mixed concrete:
Job mixed concrete shall be mixed in an approved manner, using approved materials as
specified. Each batch must be mixed not less than one minute after all materials are in
mixer.
Reservations:
SEC reserves the right to inspect and/or test all materials and equipment concerned with
the concrete covered by this specification.

SDCS-02-17 REV.01
10 General notes on Medium voltage HDD works:

10.1 All dimensions are in millimeters unless indicated otherwise noted.
10.2 The contractor shall submit a directional drilling package containing the
justification for the proposed cable formation/ spacing, PVC conduit , fill
compound ( if any ) and pipe size that will attain the required cable MVA rating
for technical review and approval of SEC.
10.3 Site condition shall be investigated by the contractor. The contractor shall take
full responsibility for maintaining and protecting all existing site utilities, soil
condition and stability.
10.4 It is contractor’s responsibility to provide and install a dewatering system if
found necessary due to high ground water table. The de watering system shall be
reviewed and approved by SEC. contractor shall be also responsible for disposing
off the ground water using water tankers.
10.5 PVC conduit shall be terminated with end bells.
10.6 A minimum of one circuit run of spare ducts shall be provided in every directional
drilling installation. All spare ducts shall have a 13 mm (112’’1 Nylon ) rope
installed inside all cable ducts shall be sealed with the use of duct sealing units.
10.7 Test mandrel ( 6mm less in diameter than the normal inside diameter of the duct )
and wire brush cleaner ( 6mm larger than the duct ) shall be pulled thru to each
duct. A nylon pull line ( 13 mm diameter ) should be installed in each duct line (
power and communication ) after cleaning, construction drawings which indicate
duct line, length and routing shall be verified and field noted in conjunction with
duct testing operation.
10.8 The two ends of every directional drilling installation shall be marked by a sign
post , warning sign applicable arrow sign, another log, a voltage rating plate shall
also be provided, the material, size, paint and color of the voltage rating plate
shall be identical to that of the arrow signs.
10.9 Upon completion of duct bank installation, the contractor shall provide As- built
drawings, showing duct bank location and details to include in the duct bank
location mark. Location shall be referenced from permanent ( existing ) objects.
10.10 End cups shall be provided for all spare ducts.
10.11 Directional drilling shall be used only if other alternative means of crossing are
not possible.
10.12 Ampacity adequacy shall be verified where directional drilling is required.
10.13 backfilling _and reinstatement shall be in accordance of the requirements of
appropriate authority.
10.14 The process of directional drilling shall be as per contractor’s methods of
construction procedures and requirements.

SDCS-02-17 REV.01
10.15 The number of directional drilling conduits shall also depend on required number
of cable circuits and available right of wa
10.16 The details of the directional drilling method tone with description of the
machinery that will. Be used shall be submitted for company review and approval.
the contractor shall explain in details how the required clearance between each
circuit, other circuit and other utilities will be maintained.
10.17 Prior to commencement of any directional drilling work, the contractor shall get
approval and permission from the concerned row approving agencies.
10.18 All the above requirements shall be submitted for company review and approval.
10.19 The joints of the pipes shall be flexible. the pull applied on_ the curved pipes shall
be prescribed by the manufacturer and contractor has to work within these limits.
10.20 The drilling angle from the horizontal shall be with respect to property of site
material.
10.21 The contractor ‘s responsible for damaging any existing underground facility /
relocating & reinstating any existing underground facility for his work.
The typical dimensions for spacing & depth are shown in the section drawing below.

SDCS-02-17 REV.01
Cable Trenches Figures
1. Normal trench single LV cable --- Fig. 1

2. Normal trench double LV cable --- Fig. 2
3. Normal trench 3 LV cables --- Fig. 3
4. Micro trench LV cable --- Fig. 4
5. Micro trench MV cable --- Fig. 5
6. Normal trench MV single cable --- Fig. 6
7. Normal trench MV double cable --- Fig. 7
8. Normal trench MV 3 cables --- Fig. 8
9. Normal trench single MV cable 33KV for interconnection between
2 primary substations --- Fig. 9
10.Normal trench double MV cable 33KV for interconnection
between 2 primary substations --- Fig. 10
11.Normal trench MV 3 cables 33 KV for interconnection between 2
primary substations --- Fig. 11

SDCS-02-17 REV.01
1- Normal trench single LV cable ---- Fig. 1
2- Normal trench double LV cable ---- Fig. 2


SDCS-02-17 REV.01
3- Normal trench 3 LV cables ---- Fig. 3
4- Micro trench LV cable ---- Fig. 4


SDCS-02-17 REV.01
5- Micro trench MV cable ---- Fig. 5
6- Normal trench MV single cable ---- Fig. 6


SDCS-02-17 REV.01
7- Normal trench MV double cable ---- Fig. 7
8- Normal trench MV 3 cables ---- Fig. 8


SDCS-02-17 REV.01
9- Normal trench single MV cable 33KV for interconnection between 2 primary substations ---- Fig. 9
10- Normal trench double MV cable 33KV for interconnection between 2 primary substations --- Fig. 11

SDCS-02-17 REV.01
11- Normal trench MV 3 cables 33 KV for interconnection between 2 primary substations ---- Fig. 11

SDCS-02-17 REV.01
TYPICAL DETAILS OF DIRECT BURIED CABLE AT

CROSSOVER /Figures
1. PVC Conduit ---- Fig. 12

2. PVC Conduit Accessories ---- Fig. 13
3. Typical Cannal Crossing ---- Fig. 14
4. Direct Buried Cable at Crossover ---- Fig. 15
5. Direct Buried Duct Bank 1 of 2 ---- Fig. 16
6. Direct Buried Duct Bank 2 of 2 ---- Fig. 17
7. Concrete Encased Duct bank 1 of 2 ---- 18
8. Concrete Encased Duct bank 2 of 2 ---- 19
9. Service Cable Post ---- Fig. 20
10.Sign Post ---- Fig. 21
11.Medium voltage horizontal directional drilling (HDD) and
installation of Hope (high density polyethylene on road crossing) --
-- Fig. 22

SDCS-02-17 REV.01
1- PVC Conduit ---- Fig. 12


SDCS-02-17 REV.01
2- PVC Conduit Accessories ---- Fig. 13


SDCS-02-17 REV.01
3- Typical Cannal Crossing ---- Fig. 14


SDCS-02-17 REV.01
4- Direct Buried Cable at Crossover ---- Fig. 15


SDCS-02-17 REV.01
5- Direct Buried Duct Bank 1 of 2 ---- Fig. 16


SDCS-02-17 REV.01
6- Direct Buried Duct Bank 2 of 2 ---- Fig. 17


SDCS-02-17 REV.01
7- Concrete Encased Duct bank 1 of 2 ---- Fig.18


SDCS-02-17 REV.01
8- Concrete Encased Duct bank 2 of 2 ----Fig. 19


SDCS-02-17 REV.01
9- Service Cable Post ---- Fig. 20


SDCS-02-17 REV.01
10- Sign Post ---- Fig. 21


SDCS-02-17 REV.01
11- Medium voltage horizontal directional drilling ( HDD )and installation of Hope ( high density
polyethylene on road crossing ) ---- Fig. 22
SPECIFICATIONS FOR LOW VOLTAGE Issue Date: 01/2021 Page: 1 of 13
POWER AND CONTROL CABLES 11-SDMS-01 REV.03
11-SDMS-01
Rev.03
SPECIFICATIONS FOR LOW VOLTAGE POWER AND

CONTROL CABLES
This document contains proprietary information developed by and for exclusive use of Saudi
Electricity Company (SEC) Distribution Network. Your acceptance of the document is an
acknowledgment that it must be used for the identified purpose/application and during the
period indicated. It cannot be used or copied for any other purposes nor released to others
without prior written authorization of SEC Distribution Sector. SEC shall assume no
responsibility for any type of misuse and/or misapplication, and any arm resulting there from.
SEC also reserves the right take any necessary actions to protect its interest against
unauthorized use.
11-SDMS-01
Rev.03
SPECIFICATIONS FOR LOW VOLTAGE

POWER AND CONTROL CABLES
Revision History
# Date Revision Revised By Major Revision Description
No.
1 01/2020 03 Add 1x800mm2 AL power cable
2 01/2020 03 Change warranty duration to 5 years
3
4
5
6
7
8
9
10
Table of Contents
1. Scope ........................................................................................................................................ 5
2. Cross references ........................................................................................................................ 5
3. Applicable codes and standards ................................................................................................ 5
4. Design and construction requirements ..................................................................................... 5
5. Tests .......................................................................................................................................... 8
6. Packing and shipping ................................................................................................................ 9
7. guarantee ................................................................................................................................. 10
8. Submittals ............................................................................................................................... 10
9. Technical data schedule .......................................................................................................... 11
List of Tables:
Table 1: List of applicable standards ……...…………………. 5
Table 2: Cable type overview…………….………………..…. 6
Table 3: Low voltage power and control cables – Design and Construction Requirements
(SEC Ref: 4.0)………………………………………. 11
Table 4: Low voltage power and control cables – Packing and Shipping (SEC Ref:
6.0)………………………………………………..….12
Table 5: Low voltage power and control cables – Submittals (SEC Ref:
8.0)……...……………………………………….. 12
1. Scope
This SEC Distribution Materials Specification specifies the minimum technical requirement
for design, engineering, manufacturing, inspection, testing and performance of XLPE
insulated, unarmored, four core Aluminum or single core Copper power cables, PVC
insulated multi core control cables rated up to 750V, suitable for direct burial or installation
in ducts or in air within cable guard on poles intended to be used in the low voltage system of
Saudi Electricity Company (SEC), Saudi Arabia.
2. CROSS REFERENCES
This Specification shall always be read in conjunction with SEC General Specification No.
01-SDMS-01 latest revision titled “General Requirements for all Equipment/Materials”,
which shall be considered as an integral part of this SDMS.
This SDMS shall also be read in conjunction with SEC Purchase Order or Contract Schedules
and the Scope of Work and Technical Specifications for project, as applicable.
3. APPLICABLE CODES AND STANDARDS

The latest revision of the following Codes and Standards shall be applicable for the
equipment/material covered in this SDMS. In case of conflict, the vendor/manufacturer may
propose equipment/material conforming to one group of Codes and Standards quoted
hereunder without jeopardizing the requirements of this SDMS.
Standard # Title
IEC 60228 Conductors of Insulated Cables
IEC 60502-1 Cables for Rated Voltages of 1kV (Um=1.2KV) and 3KV (Um=3.6KV)
Polyvinyl Chloride Insulated Cables Of Rated Voltages Up To And Including
IEC 60227
450/750V
Table 1: List of applicable standards
4. DESIGN AND CONSTRUCTION REQUIREMENTS
4.1. GENERAL
4.1.1 Cables shall meet or exceed the requirements of this Specification in all respects.
4.1.2 Manufacturer's drawings, as required by 01-SDMS-01 latest revision, shall show the
outline of the cables, together with all pertinent dimensions. Any variations in these
dimensions due to manufacturing tolerances shall be indicated.
4.2. DESIGN CRITERIA

4.2.1 Unless otherwise specified, the cable shall be manufactured and tested in accordance
with the referred standards.
4.2.2 Cables shall be designed for ambient temperature conditions specified in 01-SDMS-
01 latest revision.
4.2.3 The cable shall be designed for a maximum permissible continuous temperature of
90°C, emergency loading temperature of 105°C and maximum conductor short
circuit withstand temperature of 250°C.
4.2.4 The ratings and dimensions shall be as indicated in Data Schedule.
4.3. MATERIALS
4.3.1. CONDUCTOR
4.3.1.1 The conductor shall be uncoated annealed copper or aluminum class 2 as per
IEC 60228 and shall be compacted and stranded.
4.3.1.2 Copper power and control cable shall be soft drawn multi-strands with
4.3.1.3 minimum number of strands as specified in the relevant IEC. The conductor
size, shape and material shall be as specified in Data Schedule and shall be as
shown in Table 2 below:
Conductor size
Material Design Insulation Shape
(mm2)
2.5 Copper Control 2 core PVC Round
2.5 Copper Control 12 core PVC Round
70, 185, 300 Aluminum Power 4 core XLPE Sector
35, 120, 185, 630 Copper Power 1 core XLPE Round
800 Aluminum Power 1 core XLPE Round
Table 2: Cable type overview
4.3.2. INSULATION
4.3.2.1 Power cables insulation shall be extruded solid dielectric cross-linked
polyethylene (XLPE), Control cables insulation shall be polyvinyl chloride
(PVC). Insulation shall comply with the appropriate requirements specified in
IEC 60502-1.
4.3.2.2 The nominal insulation thickness shall be as per values specified in IEC
60502-1, with respect to voltage rating and cable cross-section.
4.3.2.3 The nominal minimum insulation thickness of control cables shall be

according to relevant standard.
4.3.2.4 The average insulation thickness shall not be less than the specified
nominal value.
4.3.2.5 The minimum thickness of the insulation at any point shall not fall below the
nominal value by more than 0.1 mm + 10% of the specified nominal value.
4.3.3. INNER COVERING AND FILLERS REQUIREMENTS
4.3.3.1 The inner covering is not required as power cables are unarmored, however,
the outer shape of the cable shall remain practically circular and no adhesion
occurs between cores and sheath.
4.3.3.2 Multi-core, sector shape cables shall have non hygroscopic film fillers in
order to form a compact circular outer shape.
4.3.3.3 Inner covering in control cables shall be according to relevant standard.
4.3.3.4 Filler material shall be compatible with the insulation and suitable for the
operating temperature of the cable.
4.3.4. OUTER SHEATH
4.3.4.1 The outer sheath material shall be black PVC, type ST2 as per IEC 60502-1.
4.3.4.2 The nominal thickness of the outer sheath shall be as per IEC 60502-1.
4.3.4.3 Minimum thickness at any point shall not be less than value specified as
per IEC 60502-1 of the nominal value.
4.34.4 Thickness in control cables shall be according to relevant standard.
4.4. CORE IDENTIFICATION

4.4.1 The XLPE insulation of the Four-core cable shall be colored, Red, Yellow,
Blue and Black.
4.4.2 Single core Copper cable shall be with Black XLPE insulation.
4.4.3 Single core (800mm2) Aluminum cable shall be with Dark green XLPE
insulation.
4.4.4 The core insulation of control cables shall be black PVC marked with indelible
clear white print numerals.
4.5. FABRICATION
All cables shall be free of material and manufacturing defects, which would prevent it from
meeting the requirements of this Specification.
4.6. MARKING
4.6.1 The jacket for all cables shall be marked by embossing at intervals not
exceeding one meter with the following minimum information:
a. The manufacturer's name (in English, Arabic or trademark)
b. Voltage designation (in English)
c. Type of insulation, XLPE (in English)
d. Conductor size and material (in English and Arabic)
e. Year of manufacture (in English and Arabic)
f. Cumulative length at every one meter with the highest length mark on
the outer end of the cable.
4.6.2 All cables shall be marked with “Property of Saudi Electricity Company” in
both Arabic and English.
4.6.3 All marking/numbering shall be indelible, marking by matrix print shall not be
acceptable.
5. TESTS
5.1. GENERAL
5.1.1 All cables shall be tested in accordance with the latest standards and as
specified herein. Supplier shall provide all test results for review and
acceptance by SEC.
5.1.2 The full range of Routine, Sample and Type tests specified in IEC 60502-1,
clause 14, 15, 16 and 17 shall be carried out as applicable.
5.1.3 Routine and/or special tests shall be carried out in the supplier’s factory. Type
test report/certificate from SEC approved independent testing laboratory shall
be submitted to SEC.
5.2. ROUTINE TESTS
The following routine tests shall be carried out on all finished cables:
5.2.1. ELECTRICAL RESISTANCE OF CONDUCTORS
resistance values shall be in accordance with IEC 60228.
5.2.2. AC VOLTAGE TEST
Cable shall be tested for 5 minutes at the following voltages:
a. Phase to ground = 3.5kV for single core cable
b. Phase to Phase = 6kV for multi core cable
5.2.3. SAMPLE TESTS
Conductor Examination shall be in accordance with IEC 60228.
Dimensional Check shall be in accordance with IEC 60502-1, clauses listed

below:
a. For insulation, clause 4.2 and table 3
b. For outer sheath, clause 12.3
Hot Set Test for XLPE insulation, as per IEC 60502, clause 15.10.
5.3. TYPE TESTS
Complete test (electrical and non-electrical) shall be carried out as per the relevant IEC
standards.
6. PACKING AND SHIPPING

In addition to the applicable items per 01-SDMS-01, packing and shipping of the cable
shall conform to the following:
a. The cable ends shall be sealed with a waterproof, heat shrinkable plastic
or elastomeric end cap with adhesive type sealing compound. Cable ends
shall be properly secured to the reel.
b. The cable shall be delivered without splices, on standard sized returnable
wooden reel of sturdy construction properly packed and lagged externally
to prevent possible damage to the cable during transportation. Wood
lagging or better material shall also be secured with steel straps to provide
physical protection for the cables during transit and during customary
storage and handling operations.
c. The minimum diameter of the drum of the shipping reel shall not be less
than the minimum bending diameter of the cable.
d. Cables shall be supplied in lengths of 500 meters. The allowable tolerance
on the specified length shall be ± 5%.
6.1. REEL MARKINGS

6.1.1. GENERAL REQUIREMENTS
Cable reels/drums shall be marked in legible and indelible letters on
aluminum plate 30x20 cm plate, giving the following particulars:
a. Cable voltage and conductor material and size
b. Type of cable
c. Length and weight of cable on reel
d. Gross weight
e. Dimensions of reel
f. Manufacturer's name and country of origin
g. SEC address and purchase order number

h. Serial number of reel
i. SEC stock number in bold numerals
j. Direction of rolling of reel
k. 11-SDMS-01
6.1.2 All markings shall appear on both sides of the reel.
6.1.3 Cable reel identification shall include any additional information as required by
SEC shipping instructions.
7. GUARANTEE
The Supplier shall guarantee the cables against all defects arising out of faulty design or
workmanship, or of defective material for a period of five (5) years from the date of
delivery.
8. SUBMITTALS
Submittals required with the tender:
a. The supplier shall complete and return one copy of the attached Data
Schedule for every type of cable offered
b. Guaranteed Ex-works delivery date
c. Type test certificates
d. Dimensional cross-sectional drawings of each cable and cable drum along
with technical data and catalogues shall be submitted by the supplier to
facilitate evaluation of the offer
Submittals required following the award of contract:
a. Details of manufacturing and test programs
b. Factory test reports
All of the above required shall be in hard and soft copy.
9. TECHNICAL DATA SCHEDULE

SEC Inquiry No: _____________________ Item No:_________________
Vendor
SEC Specified
No Description proposed
Values
values**
1 Reference manufacturing standard IEC 60502/IEC 60227-7
2 Max. permissible continuous conductor temperature 90°C
3 Max. permissible continuous temp. of outer sheath (°C) *
4 Rated voltage (control/power) 750/1000 V
5 No. of cores As per Table 2
6 Conductor material CU or AL
7 Shape of conductor Sector/round
8 Conductor cross-section (mm2) *
9 Approximate diameter of conductor (mm) *
10 No. of strands of conductor As per IEC
11 Insulation material PVC/XLPE
12 Nominal thickness As per IEC
13 Diameter over insulation *
14 Core identification (red, yellow, blue, black) YES
15 Filler material *
16 Outer sheath material PVC type ST2
17 Thickness of outer sheath As per IEC
18 Color of outer sheath Black/Dark green
19 Marking embossed as specification Yes
20 Overall diameter of the cable *
21 Net weight per km (kg/km) *
22 Conductor DC resistance at 20°C (ohms/km) *
23 Conductor AC resistance at operating temp. (ohms/km) *
24 Inductance (Mh/km) *
25 Inductive reactance (ohms/km) *
Conductor impedance at maximum continuous operating
26 *
temperature (ohms/km)
27 Capacitance *
Short Circuit Rating of Cable Based on maximum Conductor
28 *
Operating Temp. 1 sec. (kA)
Table 3: Low voltage power and control cables – Design and Construction Requirements (SEC Ref: 4.0)
SEC Specified Vendor proposed

No Description
Values values**
1 Drum type Returnable
2 Length of cable (m) 500 meters
3 Dimensions (m) *
4 Gros weight (kg) *
5 Net weight (kg) *
6 Marking as per the Specification Yes

Table 4: Low voltage power and control cables – Packing and Shipping (SEC Ref: 6.0)

No Description
Values values**
1 All submittals as per the Specification Yes
Table 5: Low voltage power and control cables – Submittals (SEC Ref: 8.0)
(*) – Values to be provided/proposed by the Vendor

(**) – Please provide explanation for deviations, if any
Low voltage power and control cables
SEC Inquiry No: ____________________ Item No: __________________
g. Additional Technical Information or Features Specified by SEC
h. Additional Supplementary Data or Features Proposed by

Bidder/Vendor/Supplier.
i. Other Particulars to be filled-up by the Bidder/Vendor/Supplier.
j. List of Deviations and Clauses to which exception is taken by the

Bidder/Vendor/Supplier. (Use separate sheet, if necessary).
Manufacturer of
Description Vendor/Supplier
Material/Equipment
Name of Company
Location and Office Address
Name and Signature of Authorized

Representative with Date
Official Seal / Stamp

Saudi Electricity Company ‫الشركة السعودية للكھرباء‬
11-SDMS-03, Rev. 02
SEC DISTRIBUTION MATERIALS SPECIFICATION
DATE: 01-12-2013
11-SDMS-03
REV. 02
SPECIFICATIONS
FOR
XLPE INSULATED POWER CABLES

FOR RATED VOLTAGES FROM 15 KV UP TO 36 KV (Um)
This specification is property of SEC and

subject to change or modification without notice
11-SDMS-03, Rev. 02
DATE: 01-12-2013
CONTENTS
SECTION T I T L E PAGE NO.
1.0 SCOPE 3
2.0 CROSS REFERENCES 3
3.0 APPLICABLE CODES AND STANDARDS 4
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS 4
5.0 TESTS 8
6.0 PACKING AND SHIPPING 9
7.0 GUARANTEE 10
8.0 SUBMITTALS 10
9.0 TECHNICAL DATA SCHEDULE 11-14
LIST OF FIGURES
FIGURE No. DESCRIPTION PAGE No.
1.0 Cross-Section of 1-Core Cable 15
2.0 Cross-Section of 3-Core Cable 16
3.0 Reel Marking Locations 17
Page 2 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
1.0 SCOPE
This SEC Distribution Materials Specification specifies the minimum technical

requirements for design, engineering, manufacturing, testing, inspection and performance
of XLPE insulated, single/three core aluminum or copper power cables for rated voltages
from 15 kV up to 36 kV (Um) suitable for direct burial or installation in ducts or in air
within cable guard on poles intended to be used in the medium voltage system of Saudi
Electricity Company (SEC).
Cables included in this specification are itemized in Table-1 and Table-2.
Table-1
15 kV Cables
S. No. Cable Size, mm2 Description

1 3x185/35 Three core, unarmored, copper
2 3x300/35 Three core, armored, copper
3 3x300/35 Three core, armored, aluminum
6 1x50/16 Single core, unarmored, copper
Table-2
36 kV Cables
S. No. Cable Size, mm2 Description

2.0 CROSS REFERENCES
This specification shall always be read in conjunction with SEC General Specification
No. 01-SDMS-01 (latest revision) titled "General Requirements for all Equipments
/Materials", which shall be considered as an integral part of this SDMS.
This SDMS shall also be read in conjunction with SEC Purchase Order or Contract
Schedules and the Scope of Work and Technical Specifications for Project, as applicable.
Page 3 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
3.0 APPLICABLE CODES & STANDARDS
The latest revision of the following codes and standards shall be applicable for cables
covered in this SDMS. In case of any conflict, the manufacturer/vendor may propose
cables conforming to one group of codes and standards quoted hereunder without
jeopardizing the requirements of this SDMS.
IEC INTERNATIONAL ELECTROTECHNICAL COMMISSION:
IEC 60228 Conductors of Insulated Cables.
IEC 60502-2 Power Cables with Extruded Insulation and Their Accessories for
Rated Voltages from 1 kV up to 30 kV (Um = 36 kV).
IEC 60811 Common Test Methods for Insulating and Sheathing Materials of
Electric Cables.
IEC 60229 Electric Cables – Tests on Extruded Oversheaths with a Special

Protective Function.
AEIC ASSOCIATION OF EDISON ILLUMINATING COMPANIES:
AEIC CS8 Specifications for Extruded Dielectric, Shielded Power Cables Rated
5 through 46 kV.
4.0 DESIGN & CONSTRUCTION REQUIREMENTS
4.1 General
4.1.1 The power cable shall meet or exceed the requirements of this specification in all
respects.
4.1.2 Manufacturer's drawings, as required by 01-SDMS-01, shall show the outline of
the power cable, together with all pertinent dimensions. Any variations in these
dimensions due to manufacturing tolerances shall be indicated.
4.2 Design Criteria
4.2.1 Unless otherwise specified, the cable shall conform to IEC 60502-2.
4.2.2 The power cable shall be designed for service conditions specified in 01-
SDMS-01.
4.2.3 Cable design shall facilitate heat shrink, cold shrink or pre-molded joints and
Page 4 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
terminations. This requirement shall include the use of an extruded inner

covering under armor where applicable.
4.2.4 The conductor semi-conducting layer, insulation and insulation semi-conducting
layer shall be a triple extrusion process.
4.2.5 The construction of the cables shall be essentially as shown in Figure 1 and
Figure 2. The ratings and dimensions shall be as indicated in Technical Data
Schedule.
4.3 Materials
4.3.1 Conductor
The conductor shall be uncoated annealed copper or aluminum Class 2 as per
IEC 60228, and shall be round, compacted and stranded. The conductor size,
shape and material shall be as specified in Technical Data Schedule.
4.3.2 Conductor Semi-conducting Screening
Conductors of the cables shall be screened. The conductor screen shall consist
of an extruded black semi-conducting material compatible with the insulation of
the conductor and shall have an allowable operating temperature equal to or
higher than the insulation. The outer surface of the conductor shield shall be
cylindrical and shall be firmly bonded to the insulation. The extruded shield
shall be easily removable from the conductor. The conductor screen shall meet
all the requirements of AEIC CS8.
4.3.3 Insulation
The insulation shall be extruded solid dielectric cross-linked polyethylene
(XLPE) complying with the appropriate requirements specified in Section 6.1 of
IEC 60502-2.
The nominal insulation thickness shall be as specified in IEC 60502-2, Table 6.

The cross linking process shall not expose the material to water or steam.
The average insulation thickness shall not be less than the specified nominal
value.
The minimum thickness at any point shall not fall below the nominal value by
more than 0.1 mm + 10 % of nominal value.
Page 5 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
4.3.4 Insulation Semi conducting Screening

Core insulation of the cables shall be screened. The insulation semi-conducting
screen shall consist of an extruded black semi-conducting material applied
directly over the insulation and shall comply with the requirements of AEIC
CS8.
The extruded insulation semi conducting screen shall be easily strippable
without damaging the insulation, leaving no conducting material that cannot
readily be removed. An insulation screen that requires heat for removal shall
not be supplied. The insulation shield shall comply with the stripping test
requirements of AEIC CS8.
4.3.5 Metallic Screening

All cores with semi-conducting insulation screening shall have a supplementary
copper wire screen helically applied in intimate contact with the non-metallic
semi-conducting screening.
A copper tape counter-helix shall be applied over the copper wires.
The screen size shall be as given below excluding copper tape.
- 16 mm2 for up to and including 70 mm² core.

- 35 mm2 for sizes in excess of 70 mm2 core.
The minimum size of copper tape binder shall be 0.1 x 15 mm.
4.3.6 Inner Coverings and Assembly of Cores
For three core cables, an extruded inner covering shall be provided over the
cores assembly. The metallic screens of the cores shall be in contact with each
other.
4.3.7 Inner Covering and Fillers Requirements
The inner coverings and fillers shall be of materials suitable for the operating
temperature of the cable and compatible with the insulation. The fillers shall be
non-hygroscopic. The inner covering material shall be PE compound.
Page 6 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
4.3.8 Armor Tapes
For armored cables, double steel tape of galvanized steel shall be applied
helically over the inner covering. Nominal thickness shall conform to IEC
60502-2, Table 10, and minimum thickness shall not be less than 90 % of
nominal value.
4.3.9 Outer Sheath

The outer sheath material shall be red PVC type ST2, as per IEC 60502-2. The
nominal thickness of outer sheath shall be as per IEC 60502-2. Minimum
thickness at any point shall not be less than 80% of nominal value.
4.4 Core Identification

For three core cables, Red, Yellow and Blue identifying tapes shall be used, and
insulation shall not be colored.
4.5 Fabrication
4.5.1 The conductor shield, the cross-linked polyethylene insulation and the outer
semi conductor shall be extruded by the triple extrusion method as given in
Clause 4.2.4.
4.5.2 The power cable shall be free of material and manufacturing defects, which
would prevent it from meeting the requirements of this specification.
4.6 Marking
4.6.1 The jacket for all cables shall be marked by embossing at intervals not exceeding
one meter with the following minimum information:
a) The manufacturer's name or trademark (in Arabic).
b) Voltage designation (in English).
c) Type of insulation, XLPE (in English).
d) Conductor size and material (in Arabic and English).
e) Year of manufacture (in Arabic and English).
f) Cumulative length at every one meter with the highest length marked on
the outer end of the cable.
4.6.2 All cables shall be marked with "Property of Saudi Electricity Company" in both
Arabic and English.
4.6.3 Marking by matrix print is not acceptable.
Page 7 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
5.0 TESTS
5.1 General
5.1.1 All cables shall be tested in accordance with the latest standards and as specified
herein.
The supplier shall provide all test results for review and acceptance by SEC.
5.1.2 The full range of routine, special and type tests specified in IEC 60502-2 shall
be carried out as applicable.
5.1.3 Routine and/or special tests shall be carried out in the factory. Type test reports
and certificates from an independent testing laboratory shall be submitted to
SEC at Inquiry stage.
5.1.4 Sheath of all cables shall be spark tested as per IEC 60229.
5.1.5 Cables shall be tested for strippability requirements for insulation shield as
given in AEIC CS8.
5.2 Routine Tests
The following routine tests shall be carried out on each manufactured length of cable.
5.2.1 Electrical Resistance of Conductors

Resistance measurement shall be made on all conductors of each cable length
submitted to routine tests. Resistance values shall be in accordance with IEC
60228.
5.2.2 Partial Discharge Test

The partial discharge test shall be carried out in accordance with IEC 60885-3.
The magnitude of the discharge at 1.73 Uo shall not exceed 10 pC.
5.2.3 Voltage Test

The power frequency test voltage shall be 3.5 Uo. Values for single phase test
voltage are given below:
Rated Voltage 15 (17.5) kV 30 (36) kV

Test Voltage 30.5 kV 63 kV
Page 8 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
If, for three-core cables, the voltage test is carried out with a three phase
transformer, the test voltage between the phases shall be 1.73 times the values
given above.
5.3 Special Tests
5.3.1 Conductor examination shall be in accordance with IEC 60228.
5.3.2 Dimensional check shall be in accordance with IEC 60502-2.
5.3.3 Hot set test for XLPE insulation, as per IEC 60502-2.
6.0 PACKING AND SHIPPING
In addition to the applicable items per 01-SDMS-01, packing and shipping of the cable
shall conform to the following:
6.1 The cable ends shall be sealed with a waterproof, heat shrinkable end cap with
adhesive-type sealing compound. Cable ends shall be properly secured to the reel.
6.2 The cable shall be delivered without splices, properly packed on a standard size non-
returnable reel of sturdy construction, and protected by means of wood lagging (or
any other suitable material) to prevent possible physical damage to the cable during
transit and customary storage/handling operations. Lagging shall be secured with
steel straps.
6.3 The minimum diameter of the drum of the shipping reel shall not be less than the
minimum bending diameter of the power cable.
6.4 Cables shall be supplied in lengths as specified in the Inquiry. The allowable
tolerance on the specified length shall be ± 5 %.
6.5 Reel Markings
6.5.1 Cable reels/drums shall be marked in legible and indelible letters giving the
following particulars:
a) Cable voltage and conductor material and size and number of cores.
b) Type of insulation.
c) Length and weight of cable on reel.
d) Gross weight.
e) Dimensions of reel.
Page 9 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
f) Manufacturer's name and country of origin.

g) SEC address, purchase order number, Inquiry number and year of
manufacture.
h) Serial number of reel.
i) SEC stock number in 10 cm high bold numerals.
j) Direction of rolling the reel.
k) 11-SDMS-03 (the latest revision).
6.5.2 All markings shall appear on both sides of the reel, as per Figure 3.
6.5.3 Cable reel identification shall include any additional information as required by
SEC shipping instructions.
7.0 GUARANTEE
The Supplier shall guarantee the cables against all defects arising out of faulty design or
workmanship, or of defective material for a period of two (2) years from the date of
delivery.
8.0 SUBMITTALS
8.1 Submittals required with the tender.
8.1.1 The supplier shall complete and return one copy of the attached Data Schedule
for every type of cable offered.
8.1.2 Guaranteed delivery date.
8.1.3 Type test certificates and reports.
8.1.4 Dimensional cross-sectional drawings of each cable and cable drum along with
technical data and catalogues.
8.2 Submittals required following the award of contract.
8.2.1 Details of manufacturing and test programs.
8.2.2 Factory test reports.
Page 10 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
9.0 TECHNICAL DATA SCHEDULE

15 KV TO 36 KV XLPE POWER CABLES
(Sheet 1 of 4)
SEC Inquiry No: Item No:
SEC SEC SPECIFIED VENDOR PRO-
REF DESCRIPTION VALUES POSED VALUES**
4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

1. Reference manufacturing standard IEC 60502-2
2. Max. permissible continuous conductor temp. (°C) 90
3. Maximum short circuit temperature (°C) 250
4. Max. permissible cont. temp. of inner covering (°C) *
5. Max. permissible cont. temp. of outer sheath (°C) *
6. Rated voltage (kV) 15 kV or 36 kV
7. Number of cores 1 or 3
8. Conductor material Cu or Al
9. Shape of conductor Round
10. Conductor cross-section (mm2) As per Inquiry
11. Approximate diameter of conductor (mm) *
12. Number of strands of conductor *
13. Minimum thickness of conductor shield (mm) *
14. Insulation material XLPE
15. Nominal thickness of insulation (mm) As per IEC
16. Min/max thickness of strippable semi-conducting
*
insulation shield material (mm)
17. Diameter under insulation semicon (mm) *
18. Number and nominal diameter of Cu wire screen (mm) *
19. Minimum thickness of copper tape and width (mm) 0.1x15
20. Inner covering material PE
21. Nominal thickness of inner covering (mm) *
22. Armor type and thickness (mm) *
23. Core identification (Red, Yellow, Blue) Yes
24. Diameter under inner covering (mm) *
25. Filler material *
26. Outer sheath material PVC Type ST2
27. Diameter under outer sheath (mm) *
28. Thickness of outer sheath (mm) As per IEC
Page 11 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013

(Sheet 2 of 4)
15 kV – Red
29. Color of outer sheath
36 kV – Black
30. Marking embossed as specified Yes
31. Overall diameter of the cable (mm) *
32. Net weight of conductor (kg/km) *
33. Conductor DC resistance at 20°C (Ω/km) *
34. Conductor AC resistance at 90ºC (Ω/km) *
35. Inductance (mH/km) *
36. Capacitance (uF/km) *
37. Inductive reactance (Ω/km) *
38. Capacitive reactance (Ω/km) *
39. Conductor impedance at 90º C (Ω/km) (R + jX)
40. Positive sequence impedance (Ω/km) (R1 + jXL1)
41. Zero sequence impedance (Ω/km) (R0 + jXL0)
42. Positive sequence charging admittance (µS/km) ( jB1)
43. Zero sequence charging admittance (µS/km) ( jB0)
44. Zero sequence impedance, assuming all currents
in screens:
R (Ω/km) *
X (Ω/km) *
45. Charging current (A/km) *
46. Earth fault capacitive current (A/km) *
47. Short circuit rating of cable based on maximum
conductor operating temperature (1 second)
- Conductor (kA) *
- Screen (kA) *
48. Conductor temperature before short circuit (o C) *
49. Conductor temperature at the end of short circuit (o C) *
50. Screen temperature before short circuit (o C) *
51. Screen temperature at the end of short circuit (o C) *
21 for 15 kV
52. System short circuit for one second (kA)
25 for 36 kV
Page 12 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013

(Sheet 3 of 4)
53. Permissible load in amps under maximum service

*
conditions given in this Specification (A)
54. Maximum pulling tension (kN) *
55. Maximum side wall pressure (kN/m) *
56. Maximum bending radius (m) *
57. Meets strippability requirement of AEIC CS-8 Yes
58. Maximum partial discharge at 1.5 times rated
Yes
voltage, 10 pC
59. Meets spark test requirement for jacket Yes
60. Meets all test requirements of IEC 60502-2 Yes
6.0 PACKING AND SHIPPING
1. Drum type Returnable
2. Length of cable (m) As per Inquiry
3. Dimensions (m) *
4. Gross weight (kg) *
5. Net weight (kg) *
6. Marking as per the Specification Yes
8.0 SUBMITTALS
1. All submittals as per the Specification Yes
Note: (*) - Values to be provided/proposed by the Vendor.

(**) - Please provide explanations for deviations, if any.
Page 13 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013

(Sheet 4 of 4)
SEC Inquiry No: ____________ SEC Item No:_____________
A) Additional Technical Information or Features Specified by SEC.
B) Additional Supplementary Data or Features Proposed by Bidder/Vendor/Supplier.
C) Other Particulars to be filled-up by the Bidder/Vendor/Supplier.
D) List of Deviations and Clauses to which exception is taken by the

(Use separate sheet, if necessary).
Manufacturer of
DESCRIPTION Vendor/Supplier
Material/Equipment
Name of Company

Page 14 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
Page 15 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
Page 16 of 17
11-SDMS-03, Rev. 02
DATE: 01-12-2013
Page 17 of 17
12-SDMS-01
REV. 04 (04-04-2018)
SPECIFICATIONS FOR CABLE JOINTS,

TERMINATIONS, AND ACCESSORIES UP TO 36 KV
12-SDMS-01 REV.04
1. SCOPE ............................................................................................................................................................ 4
1.1. REQUIREMENTS ON THE ACCEPTABILITY OF THE PRODUCTS ........................................................................................ 4

1.2. APPROVED SAMPLE FOR MASS PRODUCTION ........................................................................................................... 4
1.3. REQUIREMENTS FOR PRODUCT CHANGES................................................................................................................ 4
2. CROSS REFERENCES TO OTHER SEC STANDARDS ........................................................................................... 5
3. APPLICABLE CODES AND STANDARDS ........................................................................................................... 5
4. TESTING AND INSPECTION ............................................................................................................................. 6
4.1. GENERAL ......................................................................................................................................................... 6

4.2. TYPE TESTS....................................................................................................................................................... 7
4.3. TYPE TESTS DOCUMENTS ..................................................................................................................................... 7
5. MARKING ...................................................................................................................................................... 7
6. SUBMITTALS, DELIVERY, TRANSPORT, STORAGE, DISPOSAL .......................................................................... 8
6.1. SUBMITTALS REQUIRED WITH TENDER/INQUIRY ....................................................................................................... 8

6.2. DELIVERY, PACKING, AND SHIPPING ....................................................................................................................... 9
7. GENERAL REQUIREMENTS ON INSTALLATION INSTRUCTIONS ....................................................................... 9
8. DESIGN AND CONSTRUCTION REQUIREMENTS............................................................................................ 10
8.1. GENERAL REQUIREMENTS FOR ALL VOLTAGE LEVELS ............................................................................................... 10

8.2. LOW VOLTAGE CABLE ACCESSORIES REQUIREMENTS................................................................................................ 10
8.3. MEDIUM VOLTAGE CABLE ACCESSORIES REQUIREMENTS UP TO 36 KV........................................................................ 11
8.4. GENERAL REQUIREMENTS FOR SPECIFIC ACCESSORIES.............................................................................................. 12
8.4.1. Cable joints ........................................................................................................................................ 12
8.4.2. Long joints ......................................................................................................................................... 12
8.4.3. Terminations...................................................................................................................................... 12
8.4.4. Separable elbow connectors (T-body) ............................................................................................... 13
8.4.5. Inside cone plug-in type connectors .................................................................................................. 13
8.4.6. Injected cast-resin joints .................................................................................................................... 13
8.4.7. Cable end caps ................................................................................................................................... 13
8.4.8. Repair sleeves .................................................................................................................................... 14
2
12-SDMS-01 REV.04
8.4.9. Transition joints ................................................................................................................................. 14
9. GUARANTEE ................................................................................................................................................ 15
10. TECHNICAL DATA SCHEDULE ................................................................................................................... 15
11. APPENDIX................................................................................................................................................ 17
3
12-SDMS-01 REV.04
1. SCOPE
This SEC Distribution Materials Specification (SDMS) specifies the minimum technical
requirements for design, engineering, manufacture, testing, inspection and performance of all
kind of cable accessories for low and medium voltage, intended to be used in the distribution
system of Saudi Electricity Company (SEC).
1.1. REQUIREMENTS ON THE ACCEPTABILITY OF THE PRODUCTS
The prerequisite for product approval is the positive assessment and approval of the products in
the pre-qualification process by SEC. Compliance with the requirements of this SEC standard is
the basis for the manufacturer and product approval by SEC.
The approval of products or/and manufacturers requires inter alia the carrying out of
investigations as well as the submission of documents, samples and certificates. The documents,
test results, samples and certificates required for the assessment are to be made available to SEC
free of charge.
After specifying the kits, SEC reserves the right to make claims, amendments and additions
exceeding the provisions of this SEC standard. If the kits or any parts thereof are produced by
third parties on behalf of the manufacturer, these must be named with the manufacturer's
specification. SEC reserves the right to carry out audits at the manufacturer's production site at
all times in order to verify compliance with the requirements described in this SEC standard. For
this purpose, it is also possible to take kits out of the running production line. The SEC standard
can be modified or supplemented at any time. The approval of SEC is revocable at any time.
1.2. APPROVED SAMPLE FOR MASS PRODUCTION
At the request of SEC, for example before signing a new contract or in the case of coordinated
product changes, the supplier is obligated to make available one free retained sample, according
to the agreed design.
1.3. REQUIREMENTS FOR PRODUCT CHANGES
After placing the contract, product modifications by the manufacturer are only permitted with the
approval of SEC. Product changes of any kind must be coordinated in advance with SEC
Standardization department. If SEC identifies non-agreed changes, this leads to the blocking of
the manufacturer and the resulting costs are to be assumed by the manufacturer.
If the production location is relocated, or if the company has previously produced at its own
premises, SEC must be informed. Deviations from the SEC standard require the explicit written
approval of SEC. In the case of complaints or product defects, the technical product management
must be informed immediately in writing.
4
12-SDMS-01 REV.04
2. CROSS REFERENCES TO OTHER SEC STANDARDS

This specification shall always be read in conjunction with SEC General Specification No. 01-
SDMS-01 (latest revision) titled "General Requirements for all Equipment/Materials," which
shall be considered as an integral part of this SDMS. This SDMS shall also be read in
conjunction with SEC Purchase Order or Contract schedules and scope of work/technical
specifications for projects, as applicable.
The latest revisions of the following specifications shall be applicable with reference to cables.
 11-SDMS-01 Specification for low voltage power and control cables
 11-SDMS-03 Specification for insulated power cables for rated voltages from 15 kV
up to 36 kV (Um)
 12-SDMS-02 Lugs and connectors for MV/LV distribution system
Reference for cables, sleeve and lug connectors not covered by above specifications shall be as
per tender enquiry.

The latest revision of the following codes and standards shall be applicable for the
equipment/materials covered in this SDMS. In case of any deviation, the vendor/manufacturer
may propose equipment/materials conforming to alternate codes or standards. However, the
provisions of SEC Standards shall supersede the provisions of these alternate standards in case of
any difference.
Table 1: List of applicable standards for low voltage

Standard # Title
Specification for joints, stop ends and outdoor terminations for
HD 623 S1
distribution cables of rated voltage 0.6/1.0 kV
Compression and mechanical connectors for power cables for rated
IEC 61238-1 voltages up to 30 kV (Um = 36 kV) - Part 1: Test methods and
requirements
Test methods and requirements for accessories for use on distribution
EN 50393
cables of rated voltage 0,6/1,0 (1,2) kV
5
12-SDMS-01 REV.04
Table 2: List of applicable standards for medium voltage
Standard # Title
IEC 60060-1&2 High-voltage test techniques
IEC 60230 Impulse tests on cables and their accessories
Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 2:
IEC 60502-2
Cables for rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um =
36 kV)
Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 4:
IEC 60502-4
Test requirements on accessories for cables with rated voltages from 6
kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
Test methods for accessories for power cables with rated voltage from 6
IEC 61442
kV (Um = 7.2 kV) up to 30 kV (Um 36 kV)
Compression and mechanical connectors for power cables for rated
IEC 61238-1 voltages up to 30 kV (Um = 36 kV) - Part 1: Test methods and
requirements, (Class A)
Test requirements on accessories for use on power cables of rated voltage
HD 629.1 S2 + A1 from 3,6/6(7,2) kV up to 20,8/36(42) kV - Part 1: Cables with extruded
insulation
Artificial pollution tests on high-voltage insulators to be used on a.c.
IEC 60507
systems
Selection and dimensioning of high-voltage insulators intended for use in
IEC 60815-3
polluted conditions
Bushings above 1 kV up to 52 kV and from 250 A to 3,15 kA for liquid
EN 50180
filled transformers
Plug-in type bushings above 1 kV up to 52 kV and from 250 A to 2,50
EN 50181
kA for equipment other than liquid filled transformers
4. TESTING AND INSPECTION
4.1. GENERAL
All cable accessories shall be tested in accordance with the respective latest applicable standards
mentioned in Chapter 3 – Applicable codes and standards.
6
12-SDMS-01 REV.04
4.2. TYPE TESTS
The vendor shall provide certified test reports from independent / approved laboratory along with
the bid for the materials offered to show that product has been qualified according to the
applicable test sequence as mentioned in the respective standards.
A new type test has to be done in full conformance with the requirements of the latest version of
IEC standard if changes in the materials, the structure or the production process take place, which
could have an effect on the operating characteristics. SEC has to be informed about planned or
implemented changes (e.g. use of new materials, use of new manufacturing processes,
commissioning of new production plants or production sites) in order to coordinate the further
procedure in a particular case.
SEC reserves the right to review and / or verify the compliance with the standards, guidelines and
regulations as well as this Technical Specification, including the required type test.
4.3. TYPE TESTS DOCUMENTS
The test documents have to be in electronic format (readable with freely available PC software
such as Acrobat Reader), so that they can be provided by the manufacturer. The manufacturer
shall provide the test documents in hard-copy if requested.
5. MARKING
All components of the kits shall be clearly marked with the manufacturer's name and reference
numbers. The marking shall be done before coating the adhesive onto the component.
Electrically conducting components shall be marked 'conducting' clearly and permanently unless
they are very small to accommodate respective marking.
All components shall be capable of being stored without deterioration within the temperature
range of -10 ºC to +55 ºC. Components or materials, if subjected to a shelf life limitation, shall
have the final date of use prominently and permanently shown on all packages.
The electrical relevant components of cable accessories must be marked with the following data:
 Company name or logo
 Production indicator for traceability
 In the case of joints, cross-section, diameter, or application range should be marked as
well
Packaging for each cable accessory has to be printed with the following information:
 Manufacturer's name
 Manufacturer’s Type No. / catalog number
 Purchase order number/tender
7
12-SDMS-01 REV.04
 Cable size/diameter
 Nominal Voltage
 Year of manufacture
 Date of expiry
 SEC item number
 Possibly changed materials (look at chapter: Product change)
On the outer packaging which contains the cable accessories, following information should be
printed:
 Gross weight in kilograms (pounds)
 Position of slinging points and other relevant handling instructions
It has to be possible to read all information directly.
6. SUBMITTALS, DELIVERY, TRANSPORT, STORAGE, DISPOSAL

6.1. SUBMITTALS REQUIRED WITH TENDER/INQUIRY
Two copies or one set of reproducible of the following shall be supplied along with the tender.
Complete tender documents pertaining exactly to the offered items shall be submitted in line with
the relevant standard mentioned in Chapter 3 – Applicable codes and standards on an electronic
storage media or sent through email. These include:
 Certified Independent Test Reports from SEC approved test facility
o To show that the material offered meet the electrical type tests specified in
mentioned in Chapter 3 – Applicable codes and standards
o To show that the material offered meets the mechanical and physical type tests as
per the applicable standards
o The type test certificate issued by the laboratory should mention the range of the
item tested included in the type tests
 Full details of the proposed quality assurance procedures, sampling, routine tests, and
special tests.
 Data schedules of all offered items will be submitted along with the detailed kit
content list showing clear and colored image of each components.
 The supplier shall be liable to supply any component found missing at the time of
delivery/installation immediately without any delay, SEC reserves the right to take
suitable action.
8
12-SDMS-01 REV.04
6.2. DELIVERY, PACKING, AND SHIPPING
The joint/termination kits and accessories shall be delivered ready for service. All components in
the kit should be individually packed and labeled in the main packaging. Each group of same
material can be packed in one bag. Mastics and sealant tapes are to be packed in polybags. Stress
control mastics should be packed in aluminum foil to prevent moisture absorption.
Each kit along with appropriate installation instructions in English and Arabic languages shall be
packed separately in card board box. The kit should also contain a complete kit content list and a
manufacturer certificate guaranteeing the completeness of the kit content agreed with SEC.
Maximum 10 boxes shall be packed in properly palletized non-returnable wooden boxes or as per
specified requirements.
Packing shall be designed to protect against ingress of dust, moisture, and mechanical damage.
The kits shall not be packed in perishable material.
All components shall be capable of being stored without deterioration within the temperature
range of 0°C to + 55°C. Components or materials, if subject to a shelf life limitation, shall have
the final date of use prominently and permanently shown on all packages.
7. GENERAL REQUIREMENTS ON INSTALLATION INSTRUCTIONS

The installation instructions must be clearly assigned to the respective cable accessory according
to the application of this Technical Specification. All necessary steps for installing the final
product are to be described in an easy readable manner including images for each step. The
installation instructions have to be approved by SEC prior to tender. The installation instructions
must contain the required designations and sheath-opening (cutback) dimensions. The
joint/termination components, the kit content list, and the respective installation instructions have
to be clearly and unambiguously identifiable.
The installation instructions are to be enclosed in English and Arabic Language (where
applicable) and are printed in color. Any modifications to the assembly or the material, even
insignificant, which have an effect on the installation instructions, must be clearly noted on each
installation instruction and packaging unit for at least half a year (e.g. with a colored sticker with
exact reference to which point was changed), as agreed with SEC (see chapter: Product change).
The revision level, the date of creation or revision must be recognizable on the installation
instructions.
The final pages of each installation instructions is a full-page completely assembled cable
joint/termination in a cut-away/sectional view showing all active components of the kits.
The installation instructions for the complete cable accessory is to be also available in electronic
format (readable with freely available PC software such as Acrobat Reader), so that the
manufacturer can send it by e-mail.
9
12-SDMS-01 REV.04
8. DESIGN AND CONSTRUCTION REQUIREMENTS

8.1. GENERAL REQUIREMENTS FOR ALL VOLTAGE LEVELS
Joints/terminations and accessories shall meet or exceed the minimum requirements of this
specification and standards in Chapter 3 – Applicable codes and standards in all respects and
shall be designed such that no insulating or semiconducting tapes shall be required, except void
filler tape and sealing mastic.
The conductors of the cables consist of aluminum or copper, according to IEC, are round or
sector-shaped, stranded, compacted.
The cable construction is based on the 11-SDMS-01 and 11-SDMS-03.
The basic statements on design and implementation also apply to specific applications for cable
types or cross-sections are not listed above.
The joints must be easy to install (see also Chapter 7 – General requirements on installation
instructions) and have a compact design. The installation of the joint must be done under the
same temperatures as the cable.
The heat shrink tubes shall be made out of polyolefin or EPDM rubber, or a combination of both
and the longitudinal shrinkage of the sleeve must not exceed +5%/-10% of the original length.
The sealing overlapping distance (except the breakout overlap) should not be less than 100 mm
so that moisture can’t penetrate any side of the cable joint so that it’s completely sealed from
cable jacket to cable jacket.
All outer sleeves shall be identified by the name of manufacturer and should include an
embossed lot number for traceability purposes.
Sleeves or components supplied with mastic coatings shall have means to prevent the coated
surfaces from adhering to each other.
Cable joints shall meet all the test requirements mentioned in Chapter 4 – Testing and inspection.
8.2. LOW VOLTAGE CABLE ACCESSORIES REQUIREMENTS
The existing or used cables comply with IEC 60502-1 and the conductor cross-sections will be
from 35 mm² to 630 mm².
Technology of the cable accessories is heat-shrink.
The connection of sector-shaped conductors must be possible without a rounding tool for
mechanical connectors. In the case of crimp connectors, pre-rounding is mandatory.
10
12-SDMS-01 REV.04
8.3. MEDIUM VOLTAGE CABLE ACCESSORIES REQUIREMENTS UP
TO 36 KV
The existing or used cables comply with IEC 60502-2 and the conductor cross-sections will be
from 50 mm² to 500 mm².
Technology of the cable accessories are either pre-molded or cold-shrink.
Creepage distance for outdoor termination shall be also according to the latest revision of SEC
General Specification 01-SDMS-01 applicable for coastal areas.
The stress control grader or grading joint is to be designed in an easy-to-assemble design. The
stress grading via connectors can be integrated in the joint body.
As requested in the inquiry, the outer sealing can be made by either one of the following:
a.) two-single sleeves (parking position on one side mounting position)
b.) wrap around sheath so that the assembly is possible even in tight conditions
c.) injected cast-resin
The wrap around sheath repair sleeve for medium voltage shall be of the heat shrink type and
shall be coated with an adhesive which becomes activated on the application of heat and will
form a bond with cable jacket when shrunk.
Metal shields, such as copper tape or copper wire, should be connected by a solderless
connection system such as roll springs or mechanical connectors in combination with copper
mesh.
An inner jacket installed over the joint-body prior to reinstatement of the mechanical protection
of armored cables shall be provided in the joint kits.
For tape armored cables, all items required for connection (such as worm drive clamps) are to be
provided in the kit content. Moreover, inner sleeve shall be provided between the metallic screen
and the galvanized steel wraparound cover.
Reinstatement of mechanical protection for armored cables shall be in the form of galvanized
steel wire or sheet wraparound cover, not steel tubing. Ends of steel armor forming wraparound
shall not be sharp. The armor shall be protected by outer heat shrinkable sealing sleeves.
For identification of medium voltage joint and termination kits, identification marker shall be
supplied with blank, white-colored, adhesive-baked, wrap-around polyolefin, capable of
operating temperature minus 55°C to plus 135°C and recovery temperature of plus 100 °C.
Details are given in Figure 1.
11
12-SDMS-01 REV.04
8.4. GENERAL REQUIREMENTS FOR SPECIFIC ACCESSORIES
8.4.1. CABLE JOINTS
For heat shrink joints (LV cables only):
 For the central joint body, the minimum insulation thickness of the primary cable
insulation has to be replaced across the connector.
 The adhesive shall have a softening temperature not less than 90 ºC.
For pre-molded and cold shrink joints:
 Joints should be manufactured from EPDM rubber or high performance silicone.
 Connectors shall be of water-blocking type.
8.4.2. LONG JOINTS

Long joints are intended to repair damaged MV cables requiring extra length where applicable.
Length of connectors shall not be less than 440 mm.
All connectors shall be either compression or shear bolt type with very smooth surface.
It should be either pre-molded or cold-shrink.
8.4.3. TERMINATIONS
For heat shrink terminations (LV cables only), the anti-tracking tube shall be generally suitable
for indoor and outdoor installation, ultraviolet and chemical resistant and shall be capable of
being stored without damage at temperatures up to 55 ºC.
Low voltage cable terminations shall be suitable for outdoor conditions. All accessories required
for complete termination shall be included in the kit along with longitudinally sealed lugs,
sealing tube for lugs, and core sleeves in red, yellow, and blue color for phase and neutral
identification.
For pre-molded and cold shrink terminations, use of insulating tape along cable insulation is not
acceptable.
Terminations shall be supplied in complete kit form with all materials and components required
to complete the installation, including the cable lugs, steel mounting bracket and polymeric
insulators (in case of outdoor termination), in one box.
Outdoor overhead lines pole top termination kits for 17.5 kV or 36 kV cables shall include hot-
dipped galvanized steel mounting bracket with mounting slot suitable for M20 bolt and include
polymer insulators with M12 stainless steel stud for all the three cores. Lug connectors shall be
suitable for M12 stud and shall be longitudinally sealed (water-blocking) type.
12
12-SDMS-01 REV.04
8.4.4. SEPARABLE ELBOW CONNECTORS (T-BODY)
Separable elbow connectors shall be suitable for type C bushings according to EN 50180 and EN
50181.
The screened separable elbow connectors shall be manufactured from EPDM or high
performance silicone rubber, having a minimum thickness of 3.0 mm molded outer shield with
resistance of maximum 5000 ohm.
It should not require any special tools for installation and no components that need any heat for
shrinking except for breakouts and tails (for 3-core cables).
Use of insulating or semiconducting tapes along cable insulation is not acceptable.
8.4.5. INSIDE CONE PLUG-IN TYPE CONNECTORS
Plug-in connectors shall be suitable for inner cone plug-in type bushing according to EN 50180
and EN 50181. Pre-molded stress cone shall include geometric field control elements. Outer
surface of main connector body shall be screened and earthed. Outer jacket of all conductors
shall be 5.0 m long (tail length).
Table 3: Requirements for plug-in connectors
Interface
Current rating Conductor size Voltage
Type
2 800 A Copper: 185 mm2, 240 mm2 36 kV
3 1250 A Copper: 185 mm2, 240 mm2, 500 mm2 36 kV
8.4.6. INJECTED CAST-RESIN JOINTS

The joint-body is either pre-molded or cold shrink. Connectors shall be longitudinally sealed
(water-blocking), shear bolt type with very smooth surface. Outer protection is made with
electrical grade injected polyurethane resin. The polyurethane resin shall be provided in two
chamber cartridges, one chamber for the resin and one chamber for the hardener. Mixing shall be
done such that the resin is not exposed or in direct contact with the atmosphere and can be hosed
out from the cartridge manually or using automatic pumping gun. Injection of the polyurethane
resin to form the outer protection of the cable is through a nozzle/injection value and ensures to
prevent forming of bubbles.
8.4.7. CABLE END CAPS
Cable end caps shall be without hook or valve and be internally coated with adhesive to provide
environmental sealing to the cable jacket at the end of cable. Individual cap in proper packing
shall be supplied.
13
12-SDMS-01 REV.04
8.4.8. REPAIR SLEEVES
Wrap around sheath/repair sleeve for MV cables shall be heat shrink type and shall be coated
with adhesive that becomes activated on the application of heat and when shrunk will form a
bond with cable jacket.
Repair sleeves for LV cables shall be supplied in length of 1.5 meters complete with channels
and clips in proper packing.
The diameter of sleeve (as supplied and retainable/recovered after shrinkage) shall be marked on
the sleeve.
8.4.9. TRANSITION JOINTS
Transition joints shall be suitable for different types of cables specified in the tender/inquiry.
Connectors used for transition joints shall be of tinned copper or tinned aluminum alloy
compatible to both copper and aluminum conductors. The minimum thickness of tin coating is
20µm.
14
12-SDMS-01 REV.04
9. GUARANTEE
The supplier shall guarantee the kits against all defects arising out of faulty design or
manufacturing defects or defective material for a period of five years from the date of delivery or
one year from installation date, whichever comes first.

Table 4: Joints and terminations

No Description
Values values**
1 Joint/Termination *
2 Type (Heat Shrink, Cold Shrink, Pre-molded, Separable
Connector, Plug-in)
3 Outdoor/Indoor (termination only) *
4 Indoor termination length: *
Low voltage *
Medium voltage *
5 Conductor material, size, and number of cable cores *
6 Voltage designation (kV) *
7 Manufacturer catalog number *
8 Class of termination as per applicable standard Yes
9 Creepage distance (mm, for outdoor termination only) *
10 List of contents per kit supplied as per SEC approved sample Yes
11 Submittals required as part of tender/inquiry included Yes
12 Weight of each joint/termination (kg) -
13 Name of the manufacturer Yes
14 Country of origin Yes
15
12-SDMS-01 REV.04
Joints and Terminations
 Additional Technical Information or Features Specified by SEC
 Additional Supplementary Data or Features Proposed by Bidder/Vendor/Supplier.
 Other Particulars to be filled-up by the Bidder/Vendor/Supplier.
 List of Deviations and Clauses to which exception is taken by the

Manufacturer of
Material/Equipment
Name of Company

16
12-SDMS-01 REV.04
11. APPENDIX
Figure 1: Identification marker
17
SPECIFICATION FOR LUGS AND Issue Date: 01/2021 Page: 1 of 29
CONNECTORS FOR LOW-VOLTAGE &

MEDIUM-VOLTAGE DISTRIBUTION 12-SDMS-02 REV.06
SYSTEM
12-SDMS-02
Rev.06
SPECIFICATION FOR LUGS AND CONNECTORS
FOR LOW-VOLTAGE & MEDIUM-VOLTAGE
DISTRIBUTION SYSTEM
This document contains proprietary information developed by and for exclusive use of Saudi Electricity
Company (SEC) Distribution Network. Your acceptance of the document is an acknowledgment that it
must be used for the identified purpose/application and during the period indicated. It cannot be used or
copied for any other purposes nor released to others without prior written authorization of SEC
Distribution Sector. SEC shall assume no responsibility for any type of misuse and/or misapplication,
and any arm resulting there from. SEC also reserves the right take any necessary actions to protect its
interest against unauthorized use.
Name Employee 1 Name Employee 2 Name Employee 3 Name Employee 4 Name Employee 5 Name
Signature

SYSTEM
12-SDMS-02
Rev.06
SPECIFICATION FOR LUGS AND CONNECTORS

FOR LOW-VOLTAGE & MEDIUM-VOLTAGE
DISTRIBUTION SYSTEM
Signature

SYSTEM
Revision History
# Date Revision Revised By Major Revision Description
No.
1 Add 4-Holes Terminal Lug for 800mm² Aluminum
01/2021 06
Conductors
2
3
4
5
6
7
8
9
10
Signature

SYSTEM
Table of Contents
1 SCOPE ................................................................................................................................. 6
2 CROSS REFERENCE TO OTHER SEC STANDARDS ................................................................. 6
3 APPLICABLE CODES AND STANDARDS ................................................................................ 6
4 MATERIAL, DESIGN AND CONSTRUCTION REQUIREMENTS ................................................. 7
5 TESTING AND INSPECTION ................................................................................................... 9
6 PACKING AND SHIPPING .................................................................................................... 11
7 GURANTEE ........................................................................................................................ 12
8 SUBMITTALS ..................................................................................................................... 12
9 TECHNICAL DATA SCHEDULE ............................................................................................ 13
10 DRAWINGS ........................................................................................................................ 15
List of Figures (Illustrations):

Figure 1: Technical Lugs for Copper Conductors
Figure 2: Terminal Lugs for Aluminum Conductors
Figure 3: Mono-Metallic Aluminum Lug for Bi-Metallic Use for 185mm² Aluminum ‘
Conductors
Figure 4: Mono-Metallic Aluminum Lug for Bi-Metallic Use for 300mm² Aluminum ‘
Conductors
Figure 5: Bi-Metallic Terminal Lugs for 500mm² Aluminum Conductors
Figure 6: 2-Holes NEMA-Pad Bi-Metallic Terminal Lug for 300mm² Aluminum Conductors
Figure 7: 4-Holes NEMA-Pad Bi-Metallic Terminal Lug for 500mm² and 400mm² ‘
Aluminum Conductors
Figure 8: 4-Holes Terminal Lug for 630mm² Copper Conductors
Figure 9: 4-Holes Terminal Lug for 800mm² Aluminum Conductors
Figure 10: 2-Holes NEMA-Pad Terminal Lugs for National Grid SA Substations
Figure 11: 4-Holes NEMA-Pad Terminal Lug for National Grid SA Substations
Figure 12: Sleeve Connectors for Copper-to-Copper Conductors
Figure 13: Reduction Sleeve Connectors for Copper-to-Copper Conductors
Figure 14: Sleeve Connectors for Aluminum-to-Aluminum Conductors
Signature

SYSTEM
Figure 15: Reduction Sleeve Connectors for Aluminum-to-Aluminum Conductors
Figure 16: Aluminum Reduction Sleeve Connectors for Bi-Metallic Use for Aluminum-to-
Copper Conductors
List of Tables:
Table 1: List of reference SEC standards
Table 3: Low-Voltage Cables and Overhead & Earthing Conductor Sizes
Table 4: Sizes of Medium-Voltage Cables
Table 5: Technical Data Schedule
Signature

SYSTEM
1 SCOPE
requirements for design, engineering, manufacture, testing, inspection and performance of
cable/conductors lugs and sleeve connectors for connection and jointing of cables/conductors
up to 36 kV in the distribution system of Saudi Electricity Company (SEC) in Saudi Arabia.
2 CROSS REFERENCES TO OTHER SEC STANDARDS

This specification shall always be read in conjunction with SEC General Specification No.
01-SDMS-01 (latest revision) titled "General Requirements for all Equipment/Materials,"
which shall be considered as an integral part of this specification. It shall also be read in
conjunction with SEC purchase order and/or contract schedules, and scope of work/technical
The latest revisions of the following specifications shall be applicable with reference to
cables.
Standard # Title
Specification for 13.8kV and 33kV Overhead Line Conductors (ACSR/AW
10-SDMS-01
Type)
10-SDMS-02 Specifications for Bare Copper Conductors
11-SDMS-01 Specifications for Low-Voltage Power and Control Cables
11-SDMS-02 Specifications for Low-Voltage Overhead Line Conductors (Quadruplex Type)
Specification for XLPE Insulated Power Cables for Rated Voltages from 15kV
11-SDMS-03
up to 36kV (Um)
Table 1: List of reference SEC standards
3 APPLICABLE CODES AND STANDARDS

equipment/materials covered in this specification. In case of any deviation, the
vendor/manufacturer may propose equipment/materials conforming to alternate codes or
standards. However, the provisions of SEC standards shall supersede the provisions of these
alternate standards in case of any difference.
Signature

SYSTEM
Standard # Title
IEC 60228 Conductors for Insulated Cables
Compression and Mechanical Connectors for Power Cables for Rated

IEC 61238-1 Voltages up to 30kV (Um = 36kV) Part:1 – Test Methods and
Requirements
Copper and Copper Alloys – Seamless Copper Tubes for Electrical

EN 13600
Purposes
able Lugs for Compression Connections Cover Plate Type for Copper
DIN 46235
Conductors
DIN 46267-1 Non Tension-Proof Compression Joints for Copper Conductors
DIN 46267-2 Non Tension-Proof Compression Joints for Aluminum Conductors
DIN 46329 Cable Lugs for Compression Ring Type for Aluminum Conductors
Electric Connectors – Connectors for Use Between Aluminum-to-

Aluminum and Aluminum-to-Copper Conductors Designed for Normal
ANSI C119.4
Operation at or Below 93°C and Copper-to-Copper for Normal Operation
at or Below 100°C
NEMA CC1 Electric Power Connection for Substations
ASTM B545 Standard Specification for Electrodeposited Coatings of Tin
4 MATERIAL, DESIGN AND CONSTRUCTION

REQUIREMENTS
4.1. GENERAL
4.1.1 All cable/conductor lugs and connectors intended for electricity distribution or
industrial networks shall be Class-A in which they can be subjected to short-
circuit of relatively high intensity and duration.
4.1.2 Cable/conductor lugs and connectors shall meet or exceed the performance of
conductor in all respect.
Signature

SYSTEM
4.1.3 All cable/conductor lugs shall be compression type, and without inspection
hole based on lug drawing. Connectors shall be with middle stopper camber.
4.1.4 Cable/conductor lugs and connectors shall be suitable for cable sizes listed in
Table-3 and Table-4.
4.1.5 Manufacturer's drawings shall show the outline of the lugs and connectors
together with all pertinent dimensions. Manufacturing tolerances shall not
exceed the tolerance specified in this specification or related DIN standard.
4.2. MATERIAL
4.2.1 Cable/conductor lugs and connectors shall be made from copper or aluminum
or combination of both metals as specified in the technical data schedule.
4.2.2 All copper lugs and connectors shall be made of E-copper as per EN 13600
with tin plated surface of thickness not less than 5µm.
4.2.3 All aluminum lugs and connectors shall be made of E-aluminum with 99.5%
purity, tin plated surface of thickness not less than 20µm, and shall be
provided with proper conductive oxide inhibiting compound then capped with
plastic plugs.
4.2.4 All aluminum lugs shall manufactured from a round bar and not from a tube.
4.2.5 Bi-metallic use lugs unless otherwise specified shall consist of monometallic
aluminum body, or aluminum barrel and copper palm jointed together through
friction stir welding. Overall tin-plating thickness is 20µm and the barrel shall
be provided with proper conductive oxide inhibiting compound then capped
with plastic plugs.
4.3. CONSTRUCTION
4.3.1 The construction details and dimensions are given in the attached drawings
which form part of this specification.
4.3.2 A summary of cables and conductors for which the lugs and connectors shall be
used is given in Table-3 and Table-4.
Signature

SYSTEM
Cable / Conductor Size Material Design / Shape
(mm²)
35, 70, 120, 185, 630 Copper 1-CORE /Round
50, 120, 800, 67.44, 170.5 Aluminum 1-CORE /Round
70, 185, 300 Aluminum 4-CORE /Sector
Table 3: Low-Voltage Cables and Overhead & Earthing Conductor Sizes
Cable Size (mm²) Material Design / Shape
1 x 500/35 Copper 1-Core, Unarmored / Round
3 x 300/35 Copper 3-Core, Armored / Round
3 x 500/35 Aluminum 3-Core, Armored / Round
3 x 400/35 Aluminum 3-Core, Unarmored / Round
Table 4:Sizes of Medium-Voltage Cables
5 TESTING AND INSPECTION

All lugs and connectors shall be tested in full conformance with the latest edition of IEC
61238-1.
5.1. ROUTINE TESTS

These tests shall be carried out in accordance with the requirements of applicable standards to
which the lugs and connectors are offered, and shall be carried out at the factory.
Signature

SYSTEM
5.2. TYPE TESTS
5.2.1 The vendor shall provide certified copies of type test reports in full
conformance with IEC 61238-1 with the bid for the materials offered carried
out at SEC approved laboratory.
5.2.2 When the design of a lugs or connector meets the requirement of this standard,
then it is expected that during its service:
a. The resistance of the connection will remain stable.

b. The temperature of the connector will be of the same order or less than
that of the conductor.
c. The mechanical strength will be fit for the purpose.
d. Application of short-circuit currents must not affect items (a) and (b)
mentioned above.
5.2.3 For situations where a connector may be raised to a high temperature by virtue
of connection to highly rated plant, or where the connector is subjected to
excessive mechanical vibration or shock or to corrosive conditions. In these
instances, the tests in this standard may need to be supplemented by special
tests agreed between supplier and purchaser.
5.3. SAMPLE INSPECTION

Samples together with actual CAD drawings, routine test reports, and material certificate of
compliance with applicable standards shall be submitted for inspection/evaluation prior to
issuance of approval for mass production. The following attributes shall be checked:
a. Dimensional verification
b. Engraved markings or indelible ink markings (Cable/Conductors Size,

SEC Item Code, Manufacturer Logo or Initials, Manufacturer
Catalogue/Product Number, Die Number, Crimp Positions).
Manufacturer name shall be engraved to where it will not be affected
or erased by crimping.
c. Mono-metallic aluminum lugs and connectors must have a mark

saying “Bi-Metallic Use”.
Signature

SYSTEM
d. Uniformity of the product/samples
e. Finishing – practically smooth surface without any form of nicks,

deformations, and sharp edges.
6 PACKING AND SHIPPING

Packing and shipping shall generally be as per SEC General Requirements for
Equipment/Materials, 01-SDMS-01 latest revision.
6.1. HARD BOX PACKAGING
Each hard box shall be printed with the following information:
a. Purchase Order Number / Tender Number
b. Lugs/Connectors Catalogue Number
c. Manufacturer’s Name
d. Year of Manufacture
e. SEC Item Code
6.2. WOODEN BOX PACKAGING

Each wooden box shall be fixed with an aluminum plate bearing the following
information:
a. Purchase Order Number / Tender Number
b. Lugs/Connectors Catalogue Number
c. Manufacturer’s Name
d. Year of Manufacture
e. SEC Item Code
f. Gross Weight in Kilograms (Kg)
g. Position of Slinging Points and Other Relevant Handling Instructions
Signature

SYSTEM
7 GUARANTEE
The supplier shall guarantee the products against all defects arising out of faulty design or
manufacturing defects or defective material for a period of five (5) years from the date of
delivery.
The supplier shall guarantee the uniformity of the products delivered with the approved
samples.
8 SUBMITTALS
8.1.1 Summary in table form with the following information: list of items offered,
manufacturer, origin, catalogue number, and quantity
8.1.2 Clause-by-clause compliance with the latest revision of SEC specification 12-
SDMS-02.
8.1.3 Manufacturer’s Catalogue
8.1.4 Certificate stating that the raw material has been sampled, tested and inspected
in accordance with relevant standard specifications.
8.1.5 Product type test reports and certificates carried out from SEC approved
laboratories
8.1.6 Filled-up technical data schedule on each of the items offered
8.1.7 Manufacturer CAD drawings for each of the items offered
8.1.8 USB Flash Drive containing e-copy of all the documents mentioned above
8.2. SUBMITTALS REQUIRED FOLLOWING AWARD OF

CONTRACT
8.2.1 Samples in compliance with Clause 5.3 of this specification
8.2.2 Quality assurance tests
8.2.3 Manufacturing and routine test schedules
8.2.4 Special tests, if applicable
Signature

SYSTEM
9 Technical data schedule

Vendor
No Description SEC Specified Values proposed
values**
1 Lugs
1.1 Material Al / Cu / Bi-Metallica
1.2 Material Compliance **
1.3 Cable / Conductor Size (mm²) *
1.4 Bolt Size M10 / M12 / M16
1.5 Number of Holes 1/2/4
1.6 Tin-Plating Thickness (µm) 5 / 20a
2 Connectors
2.1 Material Al / Cu / Bi-Metallica
2.2 Material Compliance **
2.3a Cu - Cu Conductor Sizes (mm² - mm²) *
2.3b Al - Al Conductor Sizes (mm² - mm²) *
2.3c Cu - Al Conductor Sizes (mm² - mm²) *
2.4a Tin-Plating Thickness (µm) for Cu - Cu 5
2.4b Tin-Plating Thickness (µm) for Al - Al 20
2.4c Tin-Plating Thickness (µm) for Cu - Al 20a
Manufacturer **
Manufacturer Catalogue Number **
Country of Origin **
Submittals Required with Tender/Inquiry Included or
Not? **
Note: a – Overall Tin-Plating Thickness of Bi-Metallic Lugs and Connectors is 20µm
Signature

SYSTEM
Cable / Conductor Lugs and Connectors
 Additional Supplementary Data or Features Proposed by


Manufacturer of
Material/Equipment
Name of Company

Signature

SYSTEM
10 DRAWING
CONDUCTOR BOLT
DIMENSIONS, mm
SIZE, mm2 SIZE
A B C1 C2 D1 D2 D3 L S
16 M10 20 17 15 12 5.5 8.5 10.5 36 2.5
35 M10 20 19 15 12 8.2 12.5 10.5 42 2.5
35 M12 20 21 16 13 8.2 12.5 13 42 2.5
50 M12 28 24 16 13 10 14.5 13 52 4.0
70 M12 28 24 16 13 11.5 16.5 13 55 4.5
120 M12 35 32 16 13 15.5 21 13 70 5.5
185 M12 40 37 16 13 19 25.5 13 82 6.0
185 M16 40 37 19 16 19 25.5 17 82 6.0
240 M12 40 42 16 13 21.5 29 13 92 6.5
240 M16 40 42 19 16 21.5 29 17 92 6.5
300 M12 50 48 16 13 24.5 32 13 100 7.0
300 M16 50 48 19 16 24.5 32 17 100 7.0
500 M12 70 60 25 20 31 42 13 125 10
500 M16 70 60 25 20 31 42 17 125 10
Figure 1: Technical Lugs for Copper Conductors
Signature

SYSTEM
CONDUCTOR BOLT
DIMENSIONS, mm
SIZE, mm2 SIZE
A B C D1 D2 D3 L S
70 M12 52 25 15.5 11.2 18.5 13 72 5.5
120 M12 56 30 20 14.7 23 13 80 7.5
185 M12 60 30 20 18.3 28.5 13 91 8
300 M12 70 38 24 23.3 34 13 103 13
300 M16 70 38 24 23.3 34 17 103 13
400 M12 73 38 24 26 38.5 13 116 14
400 M16 73 38 24 26 38.5 17 116 14
500 M12 79 44 24 29 44 13 122 15
500 M16 79 44 24 29 44 17 122 15
Quail (67.44) M12 - 34 - 13.5 - 13 60 -
Merlin (170.5) M16 - 41 - 20 - 13 105 -
Note: Lugs are manufactured from a round bar and not from a tube
Figure 2: Terminal Lugs for Aluminum Conductors
Signature

SYSTEM
Figure 3: Mono-Metallic Aluminum Lug for Bi-Metallic Use for 185mm² Aluminum
Conductors
Signature

SYSTEM
Figure 4: Mono-Metallic Aluminum Lug for Bi-Metallic Use for 300mm² Aluminum
Conductors
Signature

SYSTEM
Figure 5: Bi-Metallic Terminal Lugs for 500mm² Aluminum Conductors
Signature

SYSTEM
Figure 6: 2-Holes NEMA-Pad Bi-Metallic Terminal Lug for 300mm² Aluminum Conductors
Signature

SYSTEM
CONDUCTOR BOLT DIMENSIONS, mm

SIZE, mm2 SIZE A D1 D2 L S
400 M12 73 26 38.5 125 10
500 M12 79 29 44 125 10
Figure 7: 4-Holes NEMA-Pad Bi-Metallic Terminal Lug for 500mm² and 400mm² Aluminum
Conductors
Signature

SYSTEM
Figure 8: 4-Holes Terminal Lug for 630mm² Copper Conductors
Signature

SYSTEM
Figure 9: 4-Holes Terminal Lug for 800mm² Aluminum Conductors
Signature

SYSTEM
CONDUCTO BOLT DIMENSIONS, mm

MAT’L
R SIZE, mm2 SIZE A B C1 C2 D1 D2 D3 L1 L2 S
185 Copper M12 40 37 16 16 19 25.5 14.2 82 44.5 6
240 Copper M12 40 42 16 16 21.5 29 14.2 92 44.5 6.5
300 Copper M12 50 48 16 16 24.5 32 14.2 100 44.5 7
Figure 10: 2-Holes NEMA-Pad Terminal Lugs for National Grid SA Substations
Signature

SYSTEM
CONDUCTOR BOLT DIMENSIONS, mm

MAT’L
SIZE, mm2 SIZE A D1 D2 D3 L1 L2 L3 L4 L5 L6 S
500 Copper M12 70 31 42 14.3 125 44.5 16 70 16 16 10
Figure 11: 4-Holes NEMA-Pad Terminal Lug for National Grid SA Substations
Signature

SYSTEM
SECTION, mm2 DIMENSIONS, mm

Copper Copper D1 D2 L
500 500 31 42 160
300 300 24.5 32 100
240 240 21.5 29 90
185 185 19 25.5 85
35 35 8.2 12.5 50
Figure 12: Sleeve Connectors for Copper-to-Copper Conductors
Signature

SYSTEM

Copper Copper D1 d1 L1 D2 d2 L2 L
300 185 32 24.5 60 25.5 19 45 115
Figure 13: Reduction Sleeve Connectors for Copper-to-Copper Conductors
Signature

SYSTEM

Aluminum Aluminum D1 D2 L
500 500 29 44 210
400 400 26 38.5 210
300 300 23.3 34 145
185 185 18.3 28.5 125
70 70 11.2 18.5 105
35 35 8 14 85
Figure 14: Sleeve Connectors for Aluminum-to-Aluminum Conductors
Signature

SYSTEM

Aluminum Aluminum D1 d1 L1 D2 d2 L2 L
500 300 44 29 105 34 23.3 73 215
300 150 34 23.3 73 25 16.3 63 155
185 120 28.5 18.3 63 23 14.7 56 130
185 95 28.5 18.3 63 22 13.2 56 130
120 70 23 14.7 56 18.5 11.2 53 120
95 70 22 13.2 56 18.5 11.2 53 110
Figure 15: Reduction Sleeve Connectors for Aluminum-to-Aluminum Conductors
Signature

SYSTEM
SECTION, DIMENSIONS, mm
mm2 Copper
Aluminum D1 d1 L1 D2 d2 L2 L
500 300 44 29 120 32 24.5 60 215
500 185 44 29 120 25.5 19 45 195
400 240 38.5 26 116 29 21.5 50 195
300 300 34 23.3 80 32 24.5 60 150
300 185 34 23.3 80 25.5 19 45 145
300 120 34 23.3 80 21 15.5 40 135
185 120 28.5 18.3 70 21 15.5 40 130
150 95 25 16.3 70 19 13.5 40 120
120 70 23 14.7 60 16.5 11.5 35 110
95 70 22 13.2 60 16.5 11.5 35 100
70 35 18.5 11.2 60 12.5 8.2 25 95
50 35 16 9.8 50 12.5 8.2 25 90
35 16 14 8 50 8.5 5.5 25 90
Figure 16: Aluminum Reduction Sleeve Connectors for Bi-Metallic Use for Aluminum-to-
Copper Conductors
Signature
12-SDMS-03
(22-06-2018)
SPECIFICATION FOR UNDERGROUND WARNING

TAPES
12-SDMS-03
1. SCOPE ............................................................................................................................................................ 3
2. CROSS REFERENCES TO OTHER SEC STANDARDS ........................................................................................... 3
3. APPLICABLE CODES AND STANDARDS ........................................................................................................... 3
4. MATERIAL, DESIGN AND CONSTRUCTION REQUIREMENTS ........................................................................... 3
5. TESTING AND INSPECTION ............................................................................................................................. 4
6. SUBMITTALS .................................................................................................................................................. 4
6.1. SUBMITTALS REQUIRED WITH TENDER/INQUIRY ....................................................................................................... 4

6.2. SUBMITTALS REQUIRED FOLLOWING AWARD OF CONTRACT........................................................................................ 4
7. TECHNICAL DATA SCHEDULE ......................................................................................................................... 5
8. DRAWING ...................................................................................................................................................... 7
2
12-SDMS-03
1. SCOPE
requirements of underground warning tapes to identify and give early warning to excavators
that a power cable is buried underneath.
2. CROSS REFERENCES TO OTHER SEC STANDARDS

This specification shall always be read in conjunction with SEC General Specification No.
01-SDMS-01 (latest revision) titled "General Requirements for all Equipment/Materials,"
which shall be considered as an integral part of this specification. It shall also be read in
conjunction with SEC purchase order and/or contract schedules, and scope of work/technical

equipment/materials covered in this specification. In case of any deviation, the
vendor/manufacturer may propose equipment/materials conforming to alternate codes or
standards. However, the provisions of SEC standards shall supersede the provisions of these
alternate standards in case of any difference.
Standard # Title
Test Methods for Density and Specific Gravity (Relative Density) of
ASTM D792
Plastics by Displacement
ASTM D882 Test Method for Tensile Properties of Thin Plastic Films
ASTM D2103 Specification for Polyethylene Film and Sheeting
Test Method for Wetting Tension of Polyethylene and Polypropylene
ASTM D2578
Films
4. MATERIAL, DESIGN AND CONSTRUCTION REQUIREMENTS

 All warning tapes shall be manufactured from high-grade virgin materials of low density
polyethylene polymers.
3
12-SDMS-03
 The warning tapes should be resistant to most soil types including alkaline and acidic
soils.
 Warning tapes shall have a minimum thickness of 200µm with allowable tolerance of
+50µm.
 Warning tapes shall have a width of 150mm and a roll size of 500m.
 The imprints in the warning tapes shall be indelible, lead-free, black color and shall be
overcoated to protect the imprints from acids, alkalis, and other soil substances.
5. TESTING AND INSPECTION

All underground warning tapes shall be tested in conformance with the applicable clauses of
the standards mentioned in this specification.
6. SUBMITTALS
6.1.1 Clause-by-clause compliance with the latest revision of SEC
specification 12-SDMS-03.
6.1.2 Manufacturer’s Catalogue
6.1.3 Certificate stating that the raw material has been sampled, tested and
inspected in accordance with relevant standard specifications.
6.1.4 Filled-up technical data schedule of the item offered
6.1.5 Proof that the product offered is already been supplied and used in
utility companies.
6.1.6 USB Flash Drive containing e-copy of all the documents mentioned
above
6.2. SUBMITTALS REQUIRED FOLLOWING AWARD OF CONTRACT

6.2.1 Samples
6.2.2 Quality assurance tests
6.2.3 Manufacturing and routine test schedules
4
12-SDMS-03

SEC Specified Vendor Proposed

No Description
Values (*) Values (**)
1 Warning Tape
Low Density
1.1 Material (Virgin Grade)
Polyethylene Film
Resistant to most soil types including alkaline
1.2 Yes
and acidic soils
1.3 Thickness + Tolerance 200m + 50m
1.4 Width 150mm
1.5 Roll Size 500m
Traffic Yellow
1.6 Color
(RAL 1023)
2 Imprints
2.1 Color Black
2.2 Material Indelible Lead-Free
2.3 Design As specified
2.4 Overlay Clear Coating Yes
Manufacturer **
Manufacturer Catalogue Number **
Country of Origin **
Submittals Required with Tender/Inquiry
**
Included or Not?
5
12-SDMS-03
Warning Tape
 Additional Supplementary Data or Features Proposed by Bidder/Vendor/Supplier.

Manufacturer of
Material/Equipment
Name of Company

6
12-SDMS-03
8. DRAWING
Figure 1: Underground Warning Tapes
150mm
Notes:
Width: 150mm
Roll Size: 500m
Thickness: 200µm
7
mottmac.com

R07 HC3D02 MML SPC Ci 0001

Uploaded by

Copyright:

Available Formats

R07 HC3D02 MML SPC Ci 0001

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

R07 HC3D02 MML SPC Ci 0001

Uploaded by

Copyright:

Available Formats

Red Sea Shura Program 7

T +91 22 4908 0100

Red Sea Shura Program 7

Mott MacDonald Private Limited.

Issue and Revision Record

Revision Date Originator Checker Approver Description

Document reference: R07-HC3D02-MML-SPC-CI-0001 | | 05

Information class: Standard

R07-HC3D02-MML-SPC-CI-0001 | | 05 | | 19 SEP 2022

Civil & Infrastructure Specifications Divisions

02 800 Irrigation System

Storm Water Technical Specifications

Telecom ICT Security ELV Ducting Technical

R07-HC3D02-MML-SPC-CI-0001 | | 05 | | 19 Sep 2022

Red Sea Shura Program 7 Hotel Central #3 TABLE OF CONTENTS Page 1

PART 4 ESTABLISHMENT OPERATIONS AND MAINTENANCE (365 DAYS) 39

Red Sea Shura Program 7 Hotel Central #2 TABLE OF CONTENTS Page 2

1.2 RELATED DOCUMENTS

BS 729 Hot dip galvanize

BS 3900 Method of test for paints.

BS 4027 1980 Sulphate resisting Portland cement.

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 3

BS 5155 Butterfly valves.

BS 5163 Cast iron gate valves for waterworks.

BS 5750 Quality systems.

BS 8010 1987 Code of practice for pipelines.

DIN 8061 General quality and testing of PVC-u pipes.

DIN 8062 Dimensions of PVC-u pipes.

ISO 161/1 PVC-u pressure pipe for potable water.

ISO 4427 Polyethylene (PE) pipes for water supply.

ISO 9000 Quality management systems.

1.5 QUALITY CONTROL

B. Products and materials shall be from a manufacturer/supplier who operates a quality

D. Hold & Witness points:

1. Submission of works construction program.

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 4

1. Endorsed or modified maintenance manuals.

1. Existing Irrigation System.

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 5

3. Shop Drawings and Verification of Dimensions

4. Materials and Equipment Schedules

5. Installations and Testing.

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 6

Certification by a recognized certification mark scheme such as “The

b) Valves and Special Steel Fittings

1. Recommendation of the Manufacturer

The Contractor shall submit manufacturers’ recommendation for each material or

5. Operation and Maintenance Manuals

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 7

Part. 1. - Pumping Station and Reservoir Ongoing Maintenance.

Part. 2. - Soft Landscape Ongoing Maintenance.

Part. 3. - Irrigation System Ongoing Operation and Maintenance.

Part. 4. - Hard Landscape Ongoing Maintenance

Note: This may vary depending on the project scope of works

a) Design basis of irrigation system.

 Guide to trouble shooting

Red Sea Shura Program 7 Hotel Central #3 02 800 Page 8

1.7 DELIVERY, STORAGE, AND HANDLING

2.2 PIPES AND FITTINGS