Specifications Fro Sewerage Plant

AL MADINA AL SHAMALIYA
SEWAGE TREATMENT PLANT
Volume 3A Specifications
July 2014
General Table of Contents
VOLUME 1
Section 1
Section 2
Section 3
Section 4
Section 5
INSTRUCTIONS TO TENDERERS
Instructions to Tenderers
Form of Tender and Appendix to Tender
Form of Initial Bond
Glossary of Terms
Evaluation Grids
VOLUME 2
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
CONTRACTUAL DOCUMENTS
Form of D/B Contract Agreement
General Conditions
Form of Performance Bond
Form of Advance Payment Guarantee
Form of Parent Company Guarantee
Form of Operation & Maintenance Contract Agreement
VOLUME 3A
Section 1
Section 2
Section 3
VOLUME 3B
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
SPECIFICATIONS
General Requirements
Process Specifications
Civil Specifications
SPECIFICATIONS
Mechanical Specifications
Electrical Specifications
ICA Specifications
Testing and Commissioning
Operations & Maintenance Requirements
Schedule of Limits and Basic Conditions for Alternative Proposals
VOLUME 4
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
SCHEDULES
Schedule of Prices
Dayworks Schedule and Schedule of Rates
Schedule of Guarantees
Technical Schedules
Cash Flow Schedules
Operation and Maintenance Schedule of Prices and Performance
Standards
VOLUME 5
Section 1
Design Documents (DRAWINGS)

Drawings for Information
VOLUME 6
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
OTHER INFORMATION
Soil Investigation Information
Bathymetric Data
STP Environmental Impact Assessment Executive Summary
STP Environmental Management Plan
Outfall Environmental Evaluation Report Non-Technical Summary
Outfall Construction Environmental Management Plan
Outfall Operation Environmental Management Plan
AL MADINA AL SHAMALIYA (AMAS)

Tender Documents
Volume 3 Section 1
July 2014
AL MADINA AL SHAMALIYA STP
Specifications
TABLE OF CONTENTS
GENERAL ............................................................................................................................ 1
1.1
Objective of the Works .................................................................................................. 1
1.2
Specification Documents ............................................................................................... 1
1.3
General Information Pertaining to the Site ................................................................... 1
1.4
Architectural Design and Treatment of the works ........................................................ 6
1.5
AMAS STP Landscaping.................................................................................................. 6
DESIGN OF THE WORKS .................................................................................................... 7
2.1
General .......................................................................................................................... 7
2.2
Design Lives ................................................................................................................... 9
2.3
Standards and Codes ..................................................................................................... 9
2.4
Planning Permission and Building Control Permits ....................................................... 9
2.5
Contractor's Documents for Review by the Engineer .................................................. 10
2.6
Final Documents to be provided by the Contractor ..................................................... 15
2.7
Other Documents to be provided by the Contractor ................................................... 16
2.8
Quality Assurance/Quality Control System ................................................................. 17
2.9
Contractors Company Quality Assurance System....................................................... 17
2.10
Control Plans for the Works included in this Contract ................................................ 17
2.11
Quality Assurance Plan (QAP) ..................................................................................... 17
2.12
Control Plans ............................................................................................................... 18
2.13
Contractors Control and Documentation .................................................................... 18
2.14
Defects Liability Period ................................................................................................ 19
2.15
Retention of Documents .............................................................................................. 19
2.16
Post Warranty Service Agreements ............................................................................. 19
ENVIRONMENTAL MANAGEMENT SYSTEM ...................................................................... 20
CONSTRUCTION OF THE WORKS .................................................................................... 20
4.1
Construction Permits ................................................................................................... 20
Vol 3, Section 1
Page i of ii
Specifications
4.2
Interpretation of Drawings ......................................................................................... 20
4.3
Continuous Working .................................................................................................... 20
4.4
Signboards ................................................................................................................... 21
4.5
Temporary/Security Fencing of Site ............................................................................ 21
4.6
Setting Out and Checking the Works .......................................................................... 21
4.7
Survey of Site............................................................................................................... 21
4.8
Interference with Land Interests ................................................................................ 22
4.9
Interference with Access to Properties ....................................................................... 22
4.10
Site Cleanliness and Environmental Protection........................................................... 22
4.11
Demolition, Damage and Making Good ....................................................................... 22
4.12
Site Drainage ............................................................................................................... 23
4.13
Monitoring of Existing Structures................................................................................ 23
4.14
Interface with Existing Structures .............................................................................. 23
4.15
Interface with Other Contractors ................................................................................ 24
4.16
Traffic Requirements ................................................................................................... 24
4.17
Maintenance of Access Roads...................................................................................... 24
4.18
Water for Testing ......................................................................................................... 24
4.19
Excavations for Water Mains and Sewers ................................................................... 24
4.20
Existing Services .......................................................................................................... 25
4.21
Electricity, Water Supply and Telecommunications .................................................... 25
4.22
Protection of Work ...................................................................................................... 26
4.23
Materials and Workmanship ........................................................................................ 26
4.24
Site Safety and Welfare ............................................................................................... 29
4.25
Site Offices, Attendance and Site Facilities ................................................................. 38
4.26
Public Relations ........................................................................................................... 43
Appendix I
Drawings and other information forming part of the Contract
Appendix II
Addresses of Statutory Organisations
Appendix III Source Countries

Appendix IV Plant species list
Vol 3, Section 1
Page ii of ii
Specifications
GENERAL
1.1
Objective of the Works

There are two separately identifiable elements of the Works forming the Al Madina Al
Shamaliya Sewage Treatment Plant (AMAS STP) Works included in this Contract. They are:
Provision of Sewage Treatment works with all associated intermediary pumping stations, rising
mains, discharge pipelines, TSE Storage tank and TSE pumping station and access roads,
including landscaping within the works boundary wall.
Provision of Operation and Maintenance Services of AMAS STP works for a period of five (5)
years starting after the Taking Over Certificate for the construction of the AMAS STP works is
issued.
1.2
Specification Documents
Volume 3 of the Contract Documents comprises the following specification documents:
Section 1 General Requirements;
Section 2 Process Specifications;
Section 3 Civil Specifications;
Section 4 Mechanical Specifications;
Section 5 Electrical Specifications;
Section 6 ICA Specifications;
Section 7 Testing and Commissioning;
Section 8 Operations and Maintenance Requirements.
If there is a conflict of requirements between the above specification documents and MoW
Standard Specification for Construction Works 2009, then the above documents take precedence.
The Employers Requirements may be amended or amplified during subsequent
correspondence with Tenderers prior to the award of Contract, or after award by the issue of a
variation under Clause 14 of the Conditions of Contract. The Employers Requirements are to
be found in this section and are amplified in the Specifications and Drawings which shall be
considered as part of the Employer's Requirements.
1.3
1.3.1
General Information Pertaining to the Site

Location
The site is located on a group of reclaimed islands off the north west coast of Bahrain know as Al
Madina Al Shamaliya (AMAS).
The AMAS STP will be located to the eastern edge of the AMAS development (Island 13c) in a
prepared area screened by a landscaped hill from the rest of the development.
A Location Plan is included in the Drawings.
Vol 3, Section 1
Page 1 of 43
Specifications
1.3.2
ACCESS TO SITE AND OTHER CONTRACTS
1.3.3
Contractors Access to the Site

Access to the Islands is via a causeway/s linking the islands to the mainland with further bunds
providing access across the channels between the individual islands making up the
development.
Access around the islands will generally be via unpaved site roads.
It should be noted that the main and secondary access roads will be shared with many
contractors carrying out construction at AMAS concurrently with this Contract including the
Contractor for the PPP area, MoH Housing & Infrastructure Contractors, EWA Contractors, STP
Contractors, Ahliya University Contractors and other Stakeholders (Mosques, Schools,
Recreation etc).
In particular, the access to Island 13c is via a bund currently wide enough only for single lane
traffic. This will be the main access route for construction of the STP and Terminal Lift
Pumping Station (TLPS) and will be shared with other contractors, primarily the primary
infrastructure contractor for the construction of the TSE pipeline on Island 13c and also the
termination of the deep gravity sewer at the TLPS
Details of the access arrangements are indicated on the Drawings.
1.3.4
Climate
Bahrain has a hot and arid desert climate with low and erratic rainfall. There are two main
seasons: a hot and humid summer (June to September) and a cool winter with some occasional
rainfall (December to February).
Bahrains large-scale climate is influenced by a number of regional features, including the Gulf
waters, the dust and sand basins of Iraq some 650km to the north-west and the Zagros
mountain range in Iran, 220km at their nearest to the north-east. The Gulf provides low level
moisture supply, while the Zagros hills influence pressure patterns and direct low level winds to
blow mainly from the north-west or south-east. The dust bowls of Iraq and northern Saudi
Arabia provide an abundance of fine dust particles, which are easily transported by northwesterly winds and can cause visibility reductions in Bahrain, mainly in the months of June and
July.
Rainfall
Rainfall in Bahrain is rare and irregular. The annual average rainfall is about 70mm, but this
figure may vary greatly from almost nothing (<2mm in 1946) to two or three times the annual
mean (225mm in 1995).
On average, rain falls on about 10 days a year. Two-thirds of the precipitation occurs in
December-March. The period between late May and the end of September is associated with a
dominant summer drought, in which rainfall is consistently close to zero.
Rain generally falls during thundershowers and squalls, and is often heavy, short in duration
and localised. Due to low infiltration rates, flash floods in natural drainage channels and
depressions are a fairly common occurrence.
Vol 3, Section 1
Page 2 of 43
Figure 1.1:
Specifications
Rainfall Data
2.5
70
Average no. of rain days
60
Average monthly rainfall

Highest rainfall in 1 day
Rainfall (mm)
1.5
40
30
20
0.5
10
0
No. of Rain Days
50
*29-year averages
Jan Feb Mar Apr May Jun
Jul
Aug Sep Oct Nov Dec
Humidity
Due to its proximity to the sea, Bahrain is humid throughout the year (except when hot, dry
winds blow off the mainland). Relative humidity is higher than in many other parts of the subregion. The mean daily maximum is about 85% and the average daily minimum usually ranges
between 50% and 60%. Between May and July the minimum may drop as low as 40%.
Potential evapo-transpiration (ETP) rates indicate a variation from about 75mm in January to
250mm in June.
Figure 1.2: Humidity Data
100%
90%
Relative Humidity (%)
80%
70%
60%
50%
40%
30%
20%
Average daily relative humidity: max
10%
* 16-year averages
Average daily relative humidity: min
0%
Jan
Vol 3, Section 1
Feb
Mar
Apr
May
Jun
Jul
Aug
Page 3 of 43
Sep
Oct
Nov
Dec
Specifications
Temperature
The average temperature in Bahrain is about 27C. The annual variation is considerable, with
temperatures ranging from a mean daily minimum of 14C in January to a mean daily
maximum of 38C in August. The lowest minimum temperature recorded is 2.8C and the
highest maximum is 46.7C. Ground surface temperatures are considerably higher, with
probable peaks above 60C.
Due to the proximity of the sea in all directions, the difference between day and night
temperatures is usually moderate.
Figure 1.3: Temperature Data
50
Temperature (deg.Celsuis)
45
*29-year averages
40
35
30
25
20
15
Average daily temperature: max
10
Average daily temperature: min

Highest maximum recorded
Highest minimum recorded
5
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Wind
As a result of its location and low topography, Bahrains islands are windswept. The
predominant wind direction is from the north-west. Over the course of a year, about 45% of
the winds blow either from the WNW, NW or NNW direction. The next most frequent wind
directions are west and north. All other directions are almost equally represented with
frequencies of more or less 5%.
During the summer, the winds are generally light to moderate and blow from the N and NW
directions. During the winter, the winds move eastwards as a result of low pressure systems
generated over the Mediterranean and Arabian Peninsula.
Mean wind speeds range from 6 to 8 knots (11 to 15 km/h), though shamal winds blowing
from WNW to NNW can reach 10 to 12 knots (18 to 22 km/h). The shamal is the predominant
dust-raising wind in the region, bringing airborne silts from Saudi Arabia or Iraq some 400 km
to the north-west.
1.3.5
Seismic Conditions
There is limited information and data on seismicity for Bahrain and the whole Gulf region. A
world-scale seismic hazard map produced by the Global Seismic Hazard Assessment
Programme (GSHAP) suggests that Bahrain is in a low risk earthquake zone (see figure below).
The nearest active fault zone is the Zagros Fault in southern Iran.
Vol 3, Section 1
Page 4 of 43
Figure 1.4:
1.3.6
Specifications
Seismic Hazard Map for the Gulf Region
Ground Conditions
The topography of AMAS STP is characterized principally by a flat terrain below a boomerang
shape hill extending to the northern, western and part of the eastern side of the plant area
while the seafront forms the southeastern boundary of the area. The ground elevation in the
STP site is approximately 2.65m above sea level.
Detailed soil investigation and topographical information are included in Volume 6.
The Contractor shall be fully responsible for the interpretation and use of any information
included in these reports.
The Contractor is deemed to have satisfied himself of the local ground conditions and its
suitability for his method of construction.
1.3.7
Hydrology
Hydrological information is included in Volume 6, Section 3.
1.3.8
Electricity, Water etc

In accordance with Clause 4.20 of the Conditions of Contract, the Contractor shall be entitled to
use any supplies of power, water and any other services that may be available on the site. The
Contractor shall pay the Employer for the use of such services in accordance with applicable
tariffs. If not available, the Contractor shall make his own provisions.
1.3.9
Other Information
Information provided to the Contractor in Volume 6 (Other Information) may be utilized by the
Contractor in his design but the Contractor is responsible for checking its validity and shall
accept full responsibility for any design based on the information used.
Vol 3, Section 1
Page 5 of 43
1.4
Specifications
Architectural Design and Treatment of the works

As part of their works, the Contractor is required to construct the following:
1)
Boundary Wall
A 3.5 meter high boundary wall shall be provided to the entire perimeter of the AMAS
STP site as indicated on the AMAS STP layout plan.
As well as its primary security function, the boundary wall shall also provide screening of
the plant to reduce its visual impact when viewed from the surrounding areas.
The proposed boundary wall shall consist of precast columns with precast wall panels
placed in between. The precast elements shall be textured and coloured as required.
The wall shall be designed with a decorative finish so as to present a pleasant, low
impact faade. In order to reflect the traditional Bahraini theme, a number of GRC
patterns shall be incorporated within the wall.
2)
Higher Structures
The Contractors architectural design and treatment of the higher structures will be dealt
with in such a way to give the impression of traditional Bahraini buildings, which will
blend in with the surroundings and ensure the aesthetically acceptable external
appearance of the STP. In addition, screening by trees shall be integrated into the
design (see also landscaping below).
The Contractor shall submit for the Engineer's approval his detailed architectural design for the
boundary wall and all AMAS STP higher structures.
1.5
AMAS STP Landscaping

In order to enhance the view of the STP works and reduce visual intrusion on surrounding
development, the Contractor is required to implement an integrated landscaping scheme for
the whole site of the STP designed by a specialist landscaping consultant familiar with the local
conditions. The scheme shall include:
1)
Mass planting within the STP site along the inside of all Boundary Screen walls. Minimum
width of boundary planting strip to be three metres.
2)
Mass planting to the STP site entry precinct between the access gate to the main plant
area.
3)
Planting works to a minimum of 5% of the total STP site. This 5% site area total may be
achieved through installing a number of mass planting beds with the minimum size per
planting bed to cover an area of not less than 50m2.
4)
All planting works shall be irrigated using a fully automatic drip irrigation system. The
irrigation system shall be designed by an approved irrigation design consultancy. The
system shall include but not be limited to:
a. Automatic multi-station controller system, directly wired to electrical supply. The
Controller shall be located in the Administration Building in an approved location.
b. Solenoid valve stations including manual isolation valve upstream of the solenoid valve,
disk filter, pressure regulator.
c. Inline drip line irrigation application using pressure compensating drippers with a
maximum flow rate of 2.3 litres per hour. Dripline shall be UV stabilised.
d. Irrigation application system shall include air relief valves and line flushing valves per
station.
The landscaping scheme shall be integrated with the architectural design (see above) to
provide supplementary screening of the plant structures, particularly any high structures.
Vol 3, Section 1
Page 6 of 43
Specifications
The Contractor is required to submit both planting and irrigation design to Ministry of Housing
for approval prior to commencement of any landscape works within the STP site. The planting
works stipulated do not refer to areas of turf/lawn. In designing the mass planting beds, the
Contractor shall implement the following guidelines:
Tree planting to the Entry Precinct is to be an avenue to either side of the entry road with
random tree planting behind.
Tree planting to the Boundary Screen Walls and Retaining wall is to be random spacings.
Tree planting within the STP Site proper is to be random spacings
Tree planting to provide screening to higher structures
60%of the trees to be palm trees. minimum height of palm trees at the time of planting will
be 2.5 metres clear trunk height.
Palm spacings are to be in the range of 4m minimum to 6m maximum. Palms are to be
planted in groups of minimum 3 No. palms to a maximum of 9 No. palms.
Canopy trees are to be spaced in the range of 6m minimum to 8m maximum. Minimum
height of canopy trees at the time of planting will be 2.5 metres clear trunk height.
Shrub, groundcover and vine densities are to be such that the planting mass will provide a
continuous covering of plant material within 2 growing seasons from the time of planting.
Plant species (palms, canopy trees, shrubs, ground covers, etc.) will be selected from the
list provided in Appendix IV.
2
DESIGN OF THE WORKS
2.1
2.1.1
General
Outline
The AMAS STP will be located on Island 13C and the contract will be awarded on a Contractor
design and build basis. The following outline principles must be adhered to when undertaking
the design:
2.1.2
The STP shall be located entirely within the boundary indicated on drawing number
D7570-01-C002
The height of structures and buildings shall not exceed 12m above zero datum
The electrical loading shall not exceed 6.0 MVA (including future STP expansion)
The STP shall be designed to accommodate phased sewage flows and loads in line with
the housing development construction and occupation.
The Works shall have a capacity (design flows and loads) as detailed in Volume 3,
Section 2 of the Tender Documents.
The quality of treated effluent and sludge produced by the Works shall be in
accordance with Volume 3 Section 2 of the Tender Documents.
Site Works
The Contractor shall investigate on site and verify all available information and inform the
Engineer of any discrepancies with information provided in the Tender Documents prior to
finalization of his design.
The Contractor shall use this information to design the proposed Works.
Vol 3, Section 1
Page 7 of 43
Specifications
The design shall be undertaken using current best practices and shall comply with the
Employers Requirements, current Bahrain design regulations and all construction standards
currently in force in Bahrain.
The Contractor shall be responsible for confirming all necessary site levels and geotechnical
information pertaining to the Works prior to tendering. The Contractor shall undertake
investigations necessary for the design and construction of the Works.
The design of all Works shall facilitate inspection, cleaning and repair and maintenance in a
safe environment to ensure satisfactory operation under all service conditions.
2.1.3
Pipelines
Pipework and pipelines shall be designed for all foreseeable load cases including the following:
a)
b)
c)
d)
2.1.4
maximum working pressures on completed pipelines;

minimum working pressures, especially if drain down and surge control vacuum can be
a problem;
field test pressure on completed parts of the pipeline and the whole of the pipeline
(field test pressures);
required hydrostatic test pressure on individual pipes and fitting at the place of
manufacture (works hydrostatic test pressures).
Buildings and Structures

Electrical systems for buildings shall be designed in accordance with the requirements of
paragraph 2 of Volume 3B, Section 5.
ICA systems for buildings shall be designed in accordance with the requirements of paragraph
2 of Volume 3B, Section 6.
Structures shall be designed to resist water loading due to maximum external water level
corresponding to ground level, brim of wall or potential flood level. Uplift forces on structures,
tanks and pipes shall be calculated assuming they are empty.
2.1.5
Chambers
Unless otherwise stated, general chambers not subject to traffic loads shall have anodised,
marine grade aluminium open or solid pattern covers. Covers shall be fixed in frames recessed
into the top of the chamber walls. Chambers that require man entrance (generally greater
than 900 mm deep) shall be provided with minimum access area through the cover of 800 mm
x 600 mm. Ladders shall be installed in all chambers over 1.5 m deep. Where vertical ladders
are installed in chambers over 2.5 m deep they shall be provided with hoop safety cages.
All chambers shall have a nominal floor slope to a sump.
2.1.6
Water Retaining Structures

Any structures containing any liquids or excluding any liquids shall be designed to the
appropriate standard for liquid retaining structures.
Structures that are to be water tested before back filling shall be designed accordingly.
Vol 3, Section 1
Page 8 of 43
2.1.7
Specifications
Sound Insulation
Noise levels at the Site boundary generated by the operational plant shall not exceed 45 dBA
during daylight hours and 40 dBA at night. The Contractor will be required to produce
calculations to show that noise levels generated at the Site boundary will satisfy these
conditions. In addition the noise level within any working area shall not exceed 80 dBA at any
time.
2.2
Design Lives
The Contractor shall ensure that the design complies with the requirements of the
Specification and the following design lives:
Facility
New civil work including pipelines, sewers, chambers, roads,
buildings and concrete structures
Mechanical and electrical equipment
Instrumentation and Control Systems
Analytical and Process Instruments
Design Life
50 years
15 years
7 years
7 years
Notwithstanding the requirements of the Specification the Contractor shall ensure that the
Works and all equipment and plant provided therein shall take into account the most extreme
conditions that will occur during construction and the life of the works, and will be suitable for
the design lives above.
2.3
Standards and Codes

Bahrain standards are referred to where appropriate. The Contractor shall be responsible for
obtaining these standards and translation if required.
During construction, the Works will be inspected by the Employer. The inspectors may require
seeing copies of international standards to which the Works have been designed. The
Contractor shall allow the Employer access to the Works to undertake the inspections.
2.4
Planning Permission and Building Control Permits

The Contractor shall employ an Engineer and/or Architect registered in Bahrain (in accordance
with legislative Decrees governing the Practice of Engineering) to prepare the necessary
applications for Planning and Building Control Permits.
The Contractor shall take note of the requirements to prepare the documentation for the
applications for all the permits and endorsements necessary to obtain Planning and Building
control permits for the execution of the construction works. The Contractor shall be responsible
for securing all necessary approvals of the designs provided and the designs produced by
himself, as required by the relevant Bahrain authorities and shall allow for this in his
programme at his expense.
The Contractor shall allow a realistic timescale for dealing with the third parties responsible, for
permits etc., in his planning and programming of the works.
Latest by the commencement date of the Works, the Contractor shall submit to the Employer
the following:
a)
The technical submissions required for obtaining the Planning and Building control
permits.
Vol 3, Section 1
Page 9 of 43
Specifications
The technical submission must be complete in full for all the required authorizations. The
Contractor shall be responsible for any rejection of the Planning and Building control permits
or any other authorization due to technical reasons.
Approvals for the design and construction shall be obtained from the Employer.
All costs associated for obtaining the Planning and Building control permits will be borne by
the Employer.
2.5
2.5.1
Contractor's Documents for Review by the Engineer

Design Documents
The contractor should submit to the Engineer for his approval three hard plus one electronic
copies of:
Process Design Criteria and Calculations for

1. Liquid Treatment processes (including nitrogen and phosphorus removal
treatment),
2. Sludge Treatment processes (including aerobic digestion, dewatering, thermal
drying, etc.) and
3. Odour treatment facilities
Process flow diagrams (showing mass balance data for max, average and min organic
and hydraulic loads)
Hydraulic Design Criteria and Calculations (for max, min, average flows, etc.)
Civil works Design Criteria (appropriate Geotechnical, Structural, etc.)
E/M Design Criteria
P & ID with tags

followed by:
Drawings of all principal components of the works including plans, sections and
preliminary elevations of proposed structures suitable for submission for application
for Planning and Building control approval
General Layout Plan of the Sewage Treatment Plant
Hydraulic profile for the STP
Landscape drawings
Security Fencing, alarms and Controls drawings
Lighting arrangement drawings
Laboratory facilities drawings
Hazardous area classification drawings
Electrical Single Line Diagrams
Preliminary motor & Load schedule
PLC/SCADA architecture
Manufacturers List for 1st stage approval
The Contractors final design shall be submitted to the Engineer for his approval in three hard
plus one electronic copies of:
-
complete working drawings,
all design criteria and calculations and
Vol 3, Section 1
Page 10 of 43
Specifications
details of construction of the works and other apparatus and all other parts as may be
required to give full information to the Engineer regarding the proposed design
at least 42 days prior to the programmed activity commencement.

Submissions shall be numbered using an agreed referencing system and shall comprise but not
be limited to the following:
a)
Site Layout and General Arrangement drawings with dimensions and setting out details.
b)
Details of modifications to existing manhole structures and connections to existing

structures.
c)
Details of treatment plant elements including mechanical, electrical and ICA equipment,
schematic layout of plant, details of pipe layouts, diameters, flow direction, invert levels
and cover levels.
d)
Process design calculations for the wastewater, sludge treatment plant.
e)
Hydraulic design calculations for the plant and effluent discharges.
f)
Hydraulic design calculations for the pumping stations, rising mains and other pipework
including determination of test pressures.
g)
Drawings and schedules showing all pipework, fittings, chamber and trench details and
thrust block arrangements.
h)
Manhole/access chamber schedules, schematic layout of each manhole and access

chamber providing details of pipe profile, layout, diameters, flow direction, invert levels
and cover level.
i)
Reinforcement drawings and calculations for thrust blocks to pipework and chambers.
j)
Drawings, calculations and method statements for all road crossings and connections to
existing pipework.
k)
Design criteria and methods covering the structural and geotechnical design of the Works.
l)
Detail of pumping stations including mechanical and electrical equipment.
m) Detail of maintenance and sludge disposal equipment

n)
Details of road construction and reinstatements.
o)
General arrangement and foundation drawings, complete with dimensions, for all
buildings, tanks, plant and associated equipment.
p)
Structural calculations and drawings including foundation design.
q)
Reinforced concrete details, structural steelwork and masonry drawings.
r)
Reinforcement drawings and calculations for insitu and precast concrete.
s)
Fabrication drawings for any structural steelwork/metalwork
t)
Architectural and building works drawings including masonry, cladding, roofing, etc, and
all specified fixtures and finishes both externally and internally.
u)
Details of protective coating design.
v)
Road construction drawings including kerbing and drainage details.
w)
Landscaping, land drainage, sub and top soiling and all ancillary works.
x)
Design Criteria and calculations for:

Power consumption for wastewater treatment (tanker reception facility pumps,
aerators, blowers, mixers, intermediary pumps, screens, washers, grit and grease
chambers air requirements, secondary treatment ASP and FST tanks, Tertiary
Treatment, disinfection and all associated wastewater treatment plant, chemical
Phosphorus removal, etc.)
Vol 3, Section 1
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Specifications
Power consumption for the operation of sludge treatment and all associated sludge
handling plant including liquor return pumps, etc.
Power consumption for odour control /treatment
y)
Design Criteria and calculations for Disinfection chemical consumption (related to

disinfection before final effluent disposal)
z)
Design Criteria and calculations for:

Chemicals consumption (related to Phosphorus removal).
Chemicals consumption (related to sludge treatment).
Chemicals required for disinfection
aa) Design Criteria and Calculations for:

Excess Sludge treatment products transport and disposal to landfill and/or land
spreading, and
Transport and disposal of residuals (grit and screenings), in accordance with the tender
documents.
bb) Design Criteria and calculations for mains water consumption for polymer dilution, or
elsewhere within the treatment process where treated effluent cannot be used - Criteria
and Calculations
cc) Technical information (including Design Criteria and Calculations) for noise suppression
and insulation, ventilation and odour control, fire protection and alarm systems, etc.
dd) Technical and functional description of all works (including the main and ancillary
equipment to be installed chemicals to be used, operational issues, etc.)
2.5.2
HAZOP Study
The Contractor shall arrange for a full HAZOP Study to be conducted once the STP designs are
substantially completed. The purpose of the HAZOP is to identify potential hazards and
operability problems which could arise in the AMAS STP through a structured examination of
the detailed designs of the project by a joint team of designers and operators drawn from
suitably experienced staff from the Client, Contractor and Supervising Engineer organisations.
Problem areas identified will be re-examined by the designers to eliminate or reduce the
severity of the identified problem. Resulting design amendments will be incorporated in the
final designs.
The HAZOP involves systematic and structured analysis of P&I drawings and operations and
maintenance procedures. During the study, deviations are deliberately introduced into the
process variables in normal operating procedures to study their effect on the process, plant and
machinery. Adequacy of the protection provided will be critically examined and
recommendations are made to improve safety, if the protection provided is found to be
inadequate.
An internationally accepted HAZOP procedure shall be followed whereby a qualified HAZOP
Chairperson will be engaged by the Contractor to conduct the study. A full HAZOP Report will
be produced to record the parties in attendance, areas and operations examined, the problems
identified, and the recommended actions with sign-off when completed.
2.5.3
Construction and Installation Method Statements

Construction and installation method statements shall be prepared for the principal elements of
the Works and shall be submitted to the Engineer for review at least 28 days prior to the
programmed activity commencement.
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Specifications
Construction and installation method statements shall make due allowance for all requirements
and restrictions imposed by the Contract. Each method statement shall comprise a step-by-step
schedule of specific operations or activities with description, date, times and duration of each
step. The statements shall be supported by sketches, diagrams or other supportive detail as
necessary to enable a clear understanding of the method and significance of each step of work
or operation.
The construction and installation method statements shall include, but not be limited to:
the method of working;
construction equipment to be used;
measures for controlling noise and vibration;
hours of working;
layouts of compounds storage facilities;
sources of Materials;
methods of movements and storage of bulk materials and spoil;
haulage routes;
site organization;
measures of controlling dust;
temporary lighting details;
temporary works details;
details of all disposal sites;
maintaining and cleaning of Site roads;
safety procedures and risk assessments;
pedestrian, light vehicular and emergency access;
any proposed demolition methods.
Method statement shall include for dealing with storm drainage and dealing with groundwater.
2.5.4
Production and Submission Procedures

The Contractor shall provide the Engineer with three paper copies of all technical documents
for review. Submissions will include:
for drawings:
one copy in DWG format and one copy in PDF format on a USB flash drive or CD ROM
where applicable (or alternative such as through shared directories on networked site
computers)
for calculations, FDS, valve schedules, instrument schedules, equipment schedules,

manufacturers data, etc:
one electronic copy in either pdf, or word/excel format.
On submission, the Contractor shall clearly identify previously submitted inter-related technical
documents and also changes to previously reviewed technical documents.
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Specifications
All designs, drawings and documents submitted by the Contractor to the Engineer for review.
shall be checked by the Contractor before submission and shall be signed by a senior member
of the Contractors staff in accordance with approved QA procedures, to confirm that the check
has been conducted. The Contractor shall use SI units only and shall likewise check
submissions from his sub-Contractors or from any other source before passing such
submissions to the Engineer.
A drawing and document register shall be kept and updated continuously by the Contractor. A
copy of the register shall be submitted to the Engineer every time a drawing or document is
issued.
Where it is considered that the technical documents do not comply with the requirements of
this Contract, the Engineer shall return one copy to the Contractor indicating where the
proposals are considered to be non-compliant. Where a Document requires alteration, the
Contractor shall make the necessary alterations and submit three copies of the altered
document to the Engineer. Any revisions to drawings and documents shall be clearly
highlighted by the Contractor. Drawing amendments shall be listed in the title box.
Amendments to Documents shall be redlined, struck out or marked in the margin.
All drawings submitted by the Contractor to the Engineer for consent shall be on ISO standard
size sheets with a maximum size of A0. Every drawing shall have a title box in the bottom right
corner showing:
Employers name;
title of scheme;
title of Contract;
Contractor's name;
title of work location;
title of drawing;
drawing number;
date;
author;
scale;
a separate revision box;
signature of Contractor to the effect that the drawing, whether his own or from any
other source, has been checked by him before submission to the Engineer.
All layout and arrangement drawings submitted by the Contractor shall be drawn to scale and
dimensioned and shall include a graphical scale to aid the use of photographic reproductions.
All clearances required for the installation, routine operation and maintenance of items of
Works shall be noted on the drawings.
Designs and documents submitted by the Contractor to the Engineer for review shall include:
contents list;
scope (description of the contents and purpose of the submission);
conclusions and recommendations;
references, specification requirements, codes, manuals and supporting documents used,

drawing numbers and titles of drawings which are based on the design;
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Specifications
description of design approach;
criteria, parameters and methods used;
test procedures, analyses and results;
calculations and schedules;
qualitative description and comments on results;
any other relevant information.
A statement explaining the principles of design and type of analysis adopted shall preface all
design calculations prepared by the Contractor. The statement shall also indicate the Codes of
Practice or Standard(s) upon which the design is based. Any computer programs used in the
design shall be fully described, and details of inputs and printouts shall be presented in a
manner that can be readily understood. Program manuals and any instructions to program
users shall be made available to the Engineer upon request.
Final works inspection reports shall be submitted to the Engineer before dispatch of the Works
from manufacturer.
The following documentation will not be specifically required for review but may be subject to
a random audit at the request of the Engineer:
All civil and structural calculations;
2.6
2.6.1
Services clash checks;
Services routing diagrams;
Safety Plan and Safety File.
Final Documents to be provided by the Contractor

As-built Documents
The Contractor shall submit to the Engineer copies of the As-built Drawings as detailed below:
2 full size, unbound, paper copies in English;
3 bound sets of A3 paper reductions in English;
2 copies in electronic format on DVD Rom as Microsoft Workstation files (latest release)
in English;
Subject to the consent of the Engineer, the Contractor may submit the As-built drawings in an
alternative electronic format provided that the Contractor provides to the Employer free of
charge the software required to read, edit, save and print the drawings.
All As-built drawings submitted by the Contractor to the Engineer shall be on ISO standard size
sheets with a maximum size of A1. A0 size drawings will not be acceptable. Every drawing shall
have a title box in the bottom right corner as detailed in Clause 2.5.3. All layout and
arrangement drawings submitted by the Contractor shall be drawn to scale and dimensioned
and shall include a graphical scale to aid the use of photographic reproductions. The Contractor
shall use SI units only.
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2.7
2.7.1
Specifications
Other Documents to be provided by the Contractor

Health and Safety Plan
A Health and Safety Plan shall be prepared by the Contractor and submitted to the Engineer
for his consent at least 14 days prior to any programmed construction activities on site. The
Health and Safety Plan shall include, but not be limited to:
Construction risk assessment and control measures;
Organization and management arrangements for implementing the plan;
Appropriate specified safety requirements;
Welfare arrangements for staff messing, first aid and sanitary arrangements.
The Contractor shall not take possession of the Site before the Engineer has approved his
Health and Safety Plan.
2.7.2
Organization Chart
Within 14 days of commencement, the Contractor shall submit to the Engineer details of the
Contractors Representative and other key personnel including respective job descriptions,
addresses, 24-hour telephone numbers and facsimile transmission numbers. The Engineer shall
be notified immediately of any changes to the details provided.
2.7.3
Programme
The Contractors detailed time programme shall be prepared on a programme software
package suitable for operation with a Windows operating system, as agreed with the Engineer
and shall include:
2.7.4
A detailed works contract programme in the form of a Gantt chart which clearly details
individual functions, actions and tasks and shows the period for design, approvals,
procurement, fabrication, main construction, installation, testing, commissioning and all
other such operations as may be applicable with key dates indicated. The planned input
of the joint venture partners and sub-contractors (if appropriate) shall be highlighted as
well as (in terms of activities undertaken, timing, etc.).
An associated Pert chart with all task linkages and the critical path clearly indicated;
Resource charts specifically related to but not limited to the activities shown on the
programme of work.
Photographic Records
A photographic record shall be kept of the Construction work on the following basis:
Prior to commencement of the Works, a joint photographic survey of the Site and the
surrounding area shall be carried out and agreed by the Engineer and Contractors
Representative;
Photographs of each structure shall be taken upon completion of the structure;
Photographs of each pipe laid shall be taken at 20m intervals immediately prior to
backfill of the trench;
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2.7.5
Specifications
Photographs of each connection to existing structures shall be taken before and after
connection is made;
Photographs of each structure affected by Modification shall be taken before and after
the work is carried out;
Two sets of the photographs shall be provided to the Engineer, together with the digital
computer format files. The photographs shall be high resolution, full colour and 150mm
by 100mm minimum size. The photographs shall be suitably titled, dated and coded in
numerical order.
Relevant Standards
The Contractor shall provide one copy of the relevant standards, which he consider applicable
to this contract.
2.8
Quality Assurance/Quality Control System

A Quality Assurance (QA)/Quality Control (QC) System covering all aspects of the Contract and the
Works must be implemented, documented and maintained by the Contractor during the period of
the Contract. The system shall comply with a recognized international Quality Assurance Standard
to ISO 9001/2000. The System shall as a minimum include the items referred to in 2.9 to 2.15.
2.9
Contractors Company Quality Assurance System

The Contractor shall provide a Quality Assurance System for the Company showing the overall QA
Organization and the lines of responsibility, monitoring and action. Furthermore, the overall
principles and procedures for establishing Quality Assurance Plans, Control Plans, QA Organization,
etc. for specific projects and contracts, sub-contractors and suppliers shall be provided.
The Contractors Foreman/Site Agent shall be certified in accordance with Bahrain Laws.
2.10 Control Plans for the Works included in this Contract

As a minimum the Contractor shall, as part of his tender, submit the QA System for the
Company, Quality Assurance Plan (QAP) and initial Control Plans (CP) for the Works included in
this Contract, providing all important and critical activities for controls, inspections and tests to
fulfill the specifications.
It is a general requirement that works are only sub-contracted to companies with an effective
QA System.
2.11 Quality Assurance Plan (QAP)
The QAP shall as a minimum cover the following issues:
The Contractor's staff and management organization for the project, management plan,
and the quality assurance organization. The person responsible for the Contractor's QAS
shall be authorized and qualified to take decisions on quality assurance issues, and his
reference and communication lines to the Company's overall quality assurance
organization and its responsible management shall be clearly shown.
Persons
performing quality control and testing shall be independent of those executing or
supervising the Works.
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Specifications
The Contractor's system of management of current documentation for the execution of

the Works shall include his sub-contractors and suppliers, and shall detail:
a) how it is ensured that only valid and approved documents are used for the execution
of the Works, and
b) the method of recording variations and amendments to the documentation.
Management of sub-contractors and suppliers, and requirements of their QAS's.
Management of documents.
Management of procurement.
Control of materials and workmanship, defects and material reconciliation, procedures

for corrective actions, etc.
Handling of deviations, additions or variations to the Contract Documents.
The Contractor's initial proposed Control Plans describing important and critical
verification activities based on the Tender Documents and the Contractor's own
considerations in respect of execution of the Works.
2.12 Control Plans

The Contractor shall present for the Engineer's approval his detailed Control Plan (CP) for all
quality assurance efforts or measures for the Works or sections thereof. Such CP shall be
presented to the Engineer not later than one week before the commencement of the Works or an
approved section of the Works. The CP shall include controls as specified in the Contract as well as
any other normal and special controls that the Contractor finds necessary in order to ensure the
quality of his work. The CP shall for each control activity describe type, method, criteria for
approval and documentation and who is responsible for performing the activity. If the Engineer
does not give the consent to the CP as submitted, then the CP shall be amended for next
submission. Subsequent changes in terms of the quality assurance work will not cause changes in
agreed deadlines or contract sums.
2.13 Contractors Control and Documentation
2.13.1 General
During the Contract period, the Contractor shall, to the satisfaction of the Engineer, document
that the Works comply with the quality assurance requirements stipulated in the Contract or
approved during the Contract period. Consequently, based on the approved QAP and the CP's,
the Contractor shall during the execution of the Works carry out and document the quality
control and its compliance with the stipulated requirements. The Contractor's quality control
does not limit his responsibility for the Works according to the Contract. If the Engineer, during
the period of the Contract, can substantiate that the Contractor's control and/or documentation
shall be extended, the Contractor shall follow the Engineers written instructions to this effect at
his own cost and within the agreed time for completion.
2.13.2 Method of documentation and filing during execution of the Works
All control activities specified in the Control Plan shall be documented. The CP's and all other
issues related to the QA System shall be kept and maintained by the Contractor in the QA filing
system, which shall be kept at the project site throughout the period of the Project. On the
basis of the QAP and CP's the Contractor shall produce the necessary forms for registration, log
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Specifications
books, and check lists, etc. before work is commenced. All documentation shall be provided
with identification, the date and signature of the person responsible for the documentation.
The identification shall as a minimum comprise: name of project, activity number as defined in
the CP, time and place of the control activity. The Engineer shall have full access to the filing
system and he may without notice commission a quality audit.
2.13.3 Security
The Contractor shall be responsible for the security of all plans, papers, books, typewriters or
instruments from theft or fire during the continuance of the Contract and his insurance policies
shall cover the office of the Resident Engineer.
2.13.4 Documents at delivery
At the time of delivery of materials and goods, the Contractor shall submit the following
documentation to the Engineer in two originals or in two certified copies:
All certificates, documentation of tests etc. of materials and goods to be used in the
Works;
All documents verifying that inspection, control and tests performed are in accordance
with the Specifications;
Identification lists with cross-references between documents and material and goods.
2.14 Defects Liability Period

The Contractors remedial works after completion is subject to the same control conditions as
the actual construction work.
2.15 Retention of Documents
The Contractor shall keep the filing system with the QA documentation for minimum 5 years
after the defects liability period has expired.
2.16 Post Warranty Service Agreements
Before taking over the Contractor will submit to the Engineer proposals for post warranty
service framework contracts covering all the equipment provided under the Contract. These
post warranty service contracts should cover the expected life of the equipment and clearly
specify:
The Bahrain company who will provide the service
Qualification of the proposed service company
Foreseen service schedule and attached costs
Schedules of prices and delivery duration for consumables, spare parts and accessories
Recommended minimum stock
Response time in assessing the breakdowns and repair works
Hourly labour costs and duration for the main repairs and service
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Specifications
Alternative proposal for provision of spare parts and consumables if these will be out of
current manufacture before expire of the equipment lifetime
The post warranty contracts will be agreed with the Engineer during the Defects Liability
period.
3
Environmental Management System

A Construction Environmental Management Plan (CEMP) covering all aspects of the Contract
and the Works must be prepared, implemented and maintained by the Contractor in
accordance Bahrain statutory requirements to ensure that impacts on the environment as a
result of construction activities are mitigated during the construction phase of the Contract.
The system shall comply with a recognised international Environmental Management Standards
and the requirements of Bahrains Supreme Council for Environment (SCE) including Supreme
Council for Environments (SCE) EIA-12 Construction Environmental Management Plan
Guidelines issued on 22 June 2011.
The aims of this CEMP are to:
raise environmental awareness of key personnel associated with the project.
provide and suggest practical measures for dealing with specific issues that may affect
sensitive receptors (e.g. noise, waste management, etc.).
provide easy access to key environmental regulations, roles and contact details of key
stakeholders (e.g. the SCE) and standards (and/or guidance) that have specific
pertinence to the project.
provide a framework for monitoring compliance with key mitigation advice.
CEMPs have been prepared as part of the EIAs for the STP and the long sea outfall. These
documents are included in Volume 6 and include reference to the relevant legislation and
Ministerial Orders. These documents shall be used as a basis and developed by the Contractor
to cover all environmental aspects of the construction.
An Environmental Consultant shall be appointed by the Contractor to audit and monitor the
implementation of the CEMP. In this capacity, the Environmental Consultant will be responsible
for liaising with the SCE and other regulatory authorities, as well as the Contractors HSE
Manager.
4
4.1
CONSTRUCTION OF THE WORKS

Construction Permits
The Contractor shall provide copies of any drawings and calculations as required for the issue
of construction permits and the cost shall be deemed to be included within the Contract Price.
4.2
Interpretation of Drawings
Neither the Employer nor the Engineer accept responsibility for any omissions from or for
correctness of the representation on the drawings of existing features.
4.3
Continuous Working
If, in the opinion of the Engineer, it is necessary for the safety of the Works or for any other
reason the Works, or portion thereof, shall be carried out continuously by day and night.
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4.4
Specifications
Signboards
Signboards shall be provided, erected, maintained and moved as required at the site, at the
offices of the Engineer and at the offices of the Contractor.
Primary signboards shall be provided in Arabic and in English giving the names of the Client,
Consultant and Main Contractor only. The construction, size and wording of all signboards shall
be subject to approval by the Engineer.
The signboards shall consist of a supporting structure securely anchored to the ground and
with sign plates fitted on it. All working details including siting and positioning shall be
submitted for approval and shall be approved before fabrication or erection commences.
Secondary signboards shall be provided where necessary to cater for specialist consultants and
sub contractors. These shall be of a standard and type of construction equal to the primary
signboards and shall be approved before fabrication or erection commences in the same way as
primary signboards. Each sign plate shall be the same size as those used for Consultant and
Contractor on the primary signboard.
Portable signboards shall be provided as necessary.
The Contractor shall comply with current regulations of the Municipality and obtain approval of
the Municipality. The Contractor shall keep clean and maintain the sign boards and remove
them and make good all works disturbed upon completion of the Contract. The Contractor
shall provide space for signboards at suitable locations.
4.5
Temporary/Security Fencing of Site

Security fencing shall be 2m high chain link fence as a minimum.
Other temporary site fences shall be post and wire or chestnut paling or similar approved by
the Engineer and shall have a minimum height of 1.2m.
For work in roads, the Contractor shall follow the requirements of the Employer and the local
Police.
The Contractor shall mark all open trenches and other obstructions by approved signs, fences,
barricades, and lights for the safety of the public.
The Contractor shall instruct all persons engaged in the Construction of the Works not to
trespass on land adjacent to or in the vicinity of the Site.
4.6
Setting Out and Checking the Works

Works temporary bench marks shall be established at suitable locations on the Site. During the
progress of the Works the value of the bench marks shall be periodically checked against the
value of the Master Datum. Temporary bench marks shall be located clear of construction
works.
4.7
Survey of Site
The Contractor shall be responsible for producing an accurate record of the existing site
showing the location of the existing structures and features and existing ground levels.
The existing ground levels are shown on the Drawings are indicative only.
Before any work commences on Site, the Contractor shall take colour photographs in sufficient
quantity in agreement with and in the presence of the Engineer to accurately portray the
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Specifications
condition of the existing works, plant and equipment and general site area. A set of prints of
these photographs of minimum size 200mm by 100mm is to be handed to the Engineer within
four weeks of the Commencement Date.
4.8
Interference with Land Interests

Constructional operations shall generally be confined within the Site, or such other areas of
land as may be negotiated. Contractor's employees shall be instructed not to trespass.
4.9
Interference with Access to Properties

Before obstructing the access to any property, satisfactory alternative arrangements must be
provided.
4.10 Site Cleanliness and Environmental Protection

The Site shall be maintained in a clean and orderly manner and particular attention shall be
paid to the protection and conservation of any local environmental features and local habitats.
Contractors refuse shall not be deposited indiscriminately and arrangements shall be made for
all waste and general refuse such as bags, packing cases, surplus concrete, waste timber and
tins to be transported to an authorised tip. No refuse is to be deposited into trenches or other
excavations before backfilling. Local facilities for recycling of wastes shall be investigated and
adopted wherever possible.
The public highways leading to the Site, and internal access roads, which are used for access
shall be kept clean and free from spoil and rubbish at all times.
Site personnel shall be prohibited from urinating or defecating on Site except in properly
constructed toilets provided by the Contractor
If the Contractor fails to keep the Site clean then the Engineer will instruct a third party to carry
out the work and the costs shall be recovered from the Contractor through the Contract.
No caravans or huts are to be brought onto the Site for use as sleeping accommodation unless
prior approval is obtained from the Engineer.
4.11 Demolition, Damage and Making Good
Care shall be taken when demolishing or cutting away existing work or dismantling existing
plant such that no adjacent work is unnecessarily damaged. Any work so damaged shall be
made good. For major structures in excess of 50 cubic metres the Contractor shall put forward
detailed proposals for demolition, dismantling, and temporary supports.
All materials arising from demolition work, except as otherwise provided for in this clause, shall
be disposed of by the Contractor as surplus material.
Any mechanical and electrical equipment, pipes, fittings and valves retrieved from demolished
or dismantled structures and pipelines shall, if required by the Employer, be delivered to and
stacked at one of the Employers depots to the instructions of the Engineer. Pipes, fittings and
valves not required by the Employer shall be disposed of as surplus material.
Unless otherwise specified, underground structures and chambers shall be demolished to a
depth of one metre below finished ground level, cleared out and filled with approved clean
material
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Specifications
Where existing sewers and conduits are connected to the new systems, the length of pipes
which are not incorporated into the new system shall be abandoned.
Buried pipelines to be abandoned shall be sealed with a mass concrete plug to a minimum
depth of 1,000 mm at either end and at any intermediate manholes.
Manholes and abandoned pipelines shall be demolished to a depth of 500 mm below final
ground level and the void filled with hard core or other approved fill material and surface
reinstated to a finish similar to that of the surrounding area.
Exposed raw faces of existing concrete or blockwork which will not have new work built on to
them shall be made good with cement rendering or new blockwork as applicable.
All trees and shrubs shall be protected, if necessary with fencing, unless written permission is
given to fell or lop.
Where any building, land, hedge, wall, fence or other existing feature is disturbed or damaged
in any way the permanent reinstatement shall be made with materials similar, and not inferior,
to those in the undamaged portion.
4.12 Site Drainage
At all stages of the work the Site shall be properly drained so that standing pools of water are
not allowed to form.
Drainage works shall be in accordance with all relevant laws and regulations and the Contractor
will be responsible for consultation and liaison with all relevant authorities. All proposals for
drainage works shall be approved by the Engineer, but such approval will not absolve the
Contractor from his complete responsibility for the Works in this regard.
Silt traps shall be provided as required on any permanent or temporary drains which may be
required for the removal of water during the construction period. All drains shall be maintained
clear of silt until completion of the Contract. Any silting of drains, whether within the Site or
not, which arises from the failure to observe this clause shall be removed.
4.13 Monitoring of Existing Structures
The Contractor shall monitor any structure in close proximity to any construction activities to
ensure that no damage or disturbance is caused to existing structures.
The Contractor shall submit his proposals for monitoring to the Engineer for his consent prior to
any construction activities on the site. The proposals shall include an assessment of the
structures likely to be affected by the construction activities together with details of the
proposed monitoring activities and details of proposed temporary support if necessary to
ensure no adverse effect on the structures concerned.
The Engineer shall have the right to suspend the Works at no cost to the Employer if in the
opinion of the Engineer the Works are causing excess or uneven settlement, damage or
disturbance to any structure affected by the Works, and the Contractor shall bear the cost of
any repairs, reinstatement, temporary supports and the like so occasioned whether by the
Contractors acts or omissions.
4.14 Interface with Existing Structures
Where the Works involve any modifications of, or connections to existing structures, the
Contractor shall maintain the integrity of the existing structure and ensure that all anticipated
loading conditions are fully considered, to the satisfaction of the Engineer, so that no cracking,
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Specifications
subsidence or any other adverse effect is caused to the existing structures, and the Contractor
shall bear the cost of any repairs.
4.15 Interface with Other Contractors
Whilst constructional operations shall generally be confined within the Site, the Contractor
should be mindful of interfaces with others at the project boundaries. Particular attention is
drawn to the construction of the Inlet Pumping Station (Terminal Lift Pumping Station) where a
high level of liaison, interfacing and cooperation will be required with the Contractor
responsible for the construction of the incoming Deep Gravity Sewer which will connect to the
Inlet Pumping Station.
Similarly, the TSE irrigation pipeline from the TSE pumping station will interface with the
contractor constructing the TSE network serving the rest of the AMAS development.
4.16 Traffic Requirements
The Contractor shall obtain approval from the Responsible Authorities for road closures, road
diversions and notifications. The Police and Fire Authority shall also be notified.
4.17 Maintenance of Access Roads
The Contractor shall maintain all public and private roads, drives and tracks which he has
permission to use during the Contract and shall leave them in the same state of repair as at the
commencement of the Contract.
The Contractor shall ensure that all the access routes and channel crossings are suitable for his
use and allow for any temporary measures that may be required to bring them up to the
standard he requires. The Contractor is to restore the routes and channel crossings to their
original state upon completion of the Works.
Should the use of any access routes arranged by the Contractor be considered by the Employer
to be detrimental or contrary to any undertakings or statements given by the Employer
regarding environmental aspects of the Contract, the Engineer may withhold his consent to the
use of the access route.
Prior to any construction work the Contractor shall prepare and agree with the Engineer a
schedule recording the condition of all structures, land and surfaces (including the depth and
condition of any topsoil, if present) within the site working areas and access routes and site
compounds.
4.18 Water for Testing
Water will be supplied to the Contractor for testing of pipes and structures after due
consultation and agreement with the Employer. The Contractor will pay at cost for the supply
of water.
Water may be taken subject to at least 24 hours written notice and the Contractor shall adhere
to all restrictions applied by the Employer on flow rates and times.
4.19 Excavations for Water Mains and Sewers
The Contractor shall comply with all the requirements of any national or local regulations or
codes of practice for buried Services.
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Specifications
If dewatering of excavations is required, the Contractor shall comply with the requirements of
any relevant national or local regulations or codes of practice.
In roads, compaction shall achieve not less than 95% of the natural ground compaction.
The Contractor shall bear the cost of road reinstatement, which shall be undertaken by the
relevant authority or an approved agent appointed by the authority in accordance with the
requirements of any national or local regulations or codes of practice.
4.20 Existing Services
The Contractors attention is drawn to the Code of Practice for Service Installation prepared
by the Ministry of Works, Power & Water. In collaboration with the Engineer and before any
work commences outside the STP site, the Contractor shall contact the local officials of each of
the service authorities and shall maintain close liaison with them throughout the construction.
The Contractor shall establish in advance the positions of all main services liable to interference
by the construction and shall mark the position physically on the ground. The Contractor shall
be in possession of a cable locator for this purpose.
Apart from verifying positions to prevent damage, scrutiny is needed to identify those main
services which might conflict with the Permanent Works where this is not indicated on the
Drawings. Early scrutiny of these services is essential to enable any such diversions to be
made in advance of the construction.
Notwithstanding the scrutiny referred to above the Contractor shall take all reasonable
precautions to prevent damage to existing buried main services and connections to buildings.
The Contractor should note in particular that the Electricity Directorate will not permit work in
close proximity to high voltage cables (11kV and above) during periods of high demand (which
are normally from about mid May to mid September) other than in exceptional circumstances.
The Contractor shall provide adequate temporary support to all existing services and
connections that are exposed or partially exposed or otherwise weakened by the excavation.
Should any damage occur he shall immediately notify the Engineer and service authority and
afford every facility for the immediate repair of the affected service.
The Contractor shall carefully preserve and replace all marker tapes and tiles affected by his
excavations.
In addition to the precautions to be taken with buried services the Contractor shall ensure that
his plant and equipment do not damage pipeline or pipe supports above ground or any
overhead electricity or telephone cables. He shall also take all precautions to prevent his plant
from operating too closely to overhead high tension cables, and he shall, in conjunction with
the Engineer and Electricity Directorate establish all necessary precautions for crossing under
such cables.
The Contractor shall afford the Engineer and the relevant service authorities such assistance as
they may require in the preparation of records of existing and diverted services.
Existing services on the site of the STP are generally the property of the Employer. Similar
procedures shall, however, be followed to also ensure the protection of these services.
4.21 Electricity, Water Supply and Telecommunications
Electricity, water supplies and telecommunications shall be provided to the Site for both
temporary and permanent requirements.
1.
Water Supply
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2.
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The Contractor shall provide adequate supplies of water for drinking and for all other
purposes where required.
The Contractor shall take note that it may not be possible to secure the provision of
water for commissioning and testing through a connection to a public water supply.
The Contractor shall allow for this in his programme for the completion of the works at
his expense.
Arrangements for permanent supplies shall be made with the Water Supply Directorate
P.O. Box 326, Manama.
Electricity Supply
The Contractor shall make arrangements for the supply of electricity to his own offices,
the offices of the Engineer and for use in the Works whether by means of site
generators or by connection to the public supply. In the latter case arrangements shall
be made with the Electricity Distribution Directorate, P.O. Box 2, Manama.
Where a permanent supply will ultimately be provided the Contractor shall not assume
that this is available during the construction of the Works.
Telephones
Where appropriate, the Contractor shall arrange with Bahrain Telecommunications
Company, P.O. Box 14, Manama for his telephone connections. He shall also arrange
for the telephone connections for the Engineer as specified.
4.22 Protection of Work

The Contractor shall, at his own expense, case up and suitably protect all work liable to injury,
either by the weather or by the method adopted for execution of the Works.
Precautions especially required for the protection of new concrete and brickwork are specified
elsewhere.
No other work requiring the use of cement or lime shall be carried out when the shade
temperature is above 40C (104F) nor shall any materials that have been exposed to the
direct rays of the sun during hot weather be used until, in the opinion of the Engineer,
sufficient time under favourable conditions has elapsed for the materials to reach a suitable
temperature for incorporation in the Works.
The Contractor shall provide a sufficient number of maximum and minimum thermometers so
that the Engineer may observe the shade temperature at each place of mixing, placing and
building.
4.23 Materials and Workmanship
4.23.1 Local and Environmental Requirements
All materials and manufactured items shall be suitable for the climatic and environmental
conditions in Bahrain described in this specification.
The environmental conditions may be different in different parts of the Works and materials
shall be selected and manufactured items designed accordingly to withstand the relevant
corrosive elements. In particular:
(i)
(ii)
all products or materials in contact with sewage or a sewage environment shall be

non-biodegradable.
all products or materials in contact with potable water shall not constitute a toxic
hazard, shall not support microbial growth, shall not cause taste or odour cloudiness
or discolouration of the water, and shall be approved by a recognised certifying
authority as being suitable for use in potable water supply systems.
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Specifications
All local customs, laws and regulations relating to the supply or source of materials shall be
complied with.
4.23.2 Quality of Manufacture and Standards
All materials and manufactured items supplied for incorporation in the permanent works shall
be new, of high quality and of sound workmanship. They shall be purchased only from
approved suppliers who shall be capable of demonstrating the suitability of their products by
reference to similar works or certified test results.
Materials and manufactured items shall normally be certified as complying with relevant
specifications of a recognised national or international standards organisation which shall be
subject to the approval of the Engineer.
Except where otherwise indicated in the Contract, the edition of an approved standard shall be
that current 42 days prior to the date for the return of tenders.
The Schedule of Approved Standards and Guidance Publications in Volume 3A, Section 3, Civil
Specifications (Section S) lists approved standards as a quality guide for the materials and
articles to be provided. This schedule in no way prejudices the approval of any other
equivalent or superior national or international standards. Also included in this schedule are
publications for guidance on procedure and practice.
Where the requirements of this specification and an approved standard differ, the more
stringent requirement shall apply. Should the requirements of this specification and an
approved standard be incompatible, the requirements of this Specification shall take
precedence.
Copies of the appropriate edition of any national or international Standards in English which
may be called for as being required in the execution of the Contract shall be provided for the
sole use of the Engineer. These may include alternative Standards to those to which the
materials are manufactured for use as a comparative quality guide. The Standards will remain
the property of the Contractor and will be returned to him at the end of the Contract.
Any reference to a Manufacturer/product is to be taken as indicative of quality only.
4.23.3 Approval of Suppliers, Manufacturers, Materials and Manufactured Items
Prior to the placing of any order for materials or manufactured items, the approval procedure
described under this clause shall be followed. All requests for Approval shall be submitted in
triplicate. The information shall be clearly and neatly presented in a standard format to be
agreed with the Engineer. All submissions shall have a document number and revision
reference in accordance with the Contractors quality assurance system. No orders shall be
placed until one copy of the final Request for Approval has been returned duly signed and
dated by the Engineer or his representative.
Generally a two stage approval procedure shall be followed as described below. The first stage
requires the Contractor to demonstrate that his proposed supplier/manufacturer has the
necessary experience, competency and reputation in the field of the proposed supply. The
second stage follows approval of the supplier and comprises a full technical submittal.
1.
Approval of Supplier/Manufacturer
The Contractor shall submit to the Engineer full
supplier/manufacturer. The submission shall include:
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Name and address of proposed supplier or manufacturer
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his
proposed
Specifications
Background and history to demonstrate compliance with the specified

requirement for experience, competency and reputation in the field of the
proposed equipment supply.
Reference numbers and title of relevant specifications of a recognised national or

international standards organisation with which the materials or manufactured
items will comply together with copies of the specifications in English where
required by the Engineer.
Manufacturers literature and data sheets for articles and fabricated items.
Details of reference sites.
Contact details for referees.
Any other information called for in particular clauses of the Specification
Period for approval is 14 days subject to submitted information being of a satisfactory

standard. For minor items of supply the approval of Supplier/Manufacturer stage may
be waived at the discretion of the Engineer.
2.
Full Technical Submission

Following approval of the supplier/manufacturer, a full technical submission shall be
made as described elsewhere under this clause.
Evidence (by copy of letter of enquiry or otherwise) that the attention of the
proposed supplier or manufacturer has been drawn to the particular climatic and
environmental conditions in Bahrain.
Samples of materials representing the quality of the bulk of such materials the
Contractor proposes to use.
Sufficient information to demonstrate that the materials or manufactured items

are suitable and comply with the Specification including reference to all relevant
Specification Clauses.
Detailed design calculations and design, fabrication and installation drawings
Any other information called for in particular clauses of the Specification.
Provided the information requested is satisfactory, the Engineers approval will be given within
a period of 21 days. Where additional information or clarification is required, the 21 day
approval period will commence on receipt of the satisfactory additional information.
Prior to despatch to Site or to a designated place of storage the following shall be provided:
i)
Facilities for inspection and testing at suppliers' pits or quarries, manufacturers works
or at approved independent testing centres as appropriate. Inspection and/or witness
testing may be carried out by the Engineer or the Engineer Representative or other
appointed Inspector.
ii)
Details of the suppliers or the manufacturers quality control test procedures.
iii)
The carrying out of tests as stated in the current quoted or appropriate British Standard
or other national standard as appropriate, and such other tests as are necessary in the
opinion of the Engineer, to determine that the Works comply with the Specification
either under test conditions at the manufacturers works, on site or elsewhere under
normal working conditions. Where tests and inspection have been completed to the
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Specifications
Engineers satisfaction and when the test certificates, etc., have been checked the
Engineer will confirm acceptance in writing and the items concerned shall not be
delivered or incorporated in the Works until this acceptance has been received.
iv)
Four copies of all test certificates where appropriate to be supplied to the Inspecting
Engineer within two weeks of any witnessed tests.
v)
Shipping and consignment identification details to be submitted to the Engineer.
vi)
Where witness tests are not required the test certificates and/or certificates of
compliance with the appropriate standard are to be forwarded to the Inspecting
Engineer within two weeks after instructions to waive witness tests have been received.
vii)
Each certificate shall give sufficient information to enable the Engineer to identify the
material or equipment to which it refers prior to the issuing of his release order.
viii)
No inspection or passing by the Engineer, or the Inspecting Engineer of the Work, or

manufactured item, or materials covered by this Contract, whether carried out or
supplied by the Contractor, shall release him from any of his obligations under the
Contract.
ix)
The Engineer reserves the right to require the Contractor to meet any extra costs which
are occasioned by failure of the Contractor to comply with the above testing and
inspection requirements including the provision of test certificates, curves, etc., or,
which in the opinion of the Engineer, are due to insufficient care having been taken by
the Contractor or his Sub-Contractor before presenting the item for inspection or test.
If unauthorised delivery has taken place the Contractor shall if required by the Engineer
return the item to the manufacturer for inspection and/or witness testing by the
Inspecting Engineer at the Contractors expense.
Samples of all building and civil works materials shall be supplied to the Engineer for approval.
Where appropriate, sample panels of built materials shall be constructed.
4.23.4 Approval of Construction Methods
For all elements of the Works, fully detailed method statements describing proposed
construction techniques and programme for execution shall be submitted to the Engineer in
duplicate. These shall be supported, where applicable, by calculations for temporary works for
supporting excavated faces and shuttering of concrete.
Written approval shall be obtained before any work is commenced.
Approval of the proposed construction techniques and methods shall not relieve the Contractor
of his contractual responsibilities for the care of the Works or of his liabilities for accidents or
damage.
4.24 Site Safety and Welfare
4.24.1 Safety, Health and Welfare
The Contractor shall be responsible for the health, safety and welfare of all persons working on
or visiting the Site. He shall obtain copies of the Ministerial Orders current at the date of
Tender and shall comply with these and with any legislation enacted during the Contract Period
that affects working conditions, safety, health or welfare of his employees or those of the
Engineer or Employer.
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The Contractors attention is drawn to the guidance manuals on health and safety referred to in
the Schedule of Approved Standard and Guidance Publications in Section S to which reference
should be made.
The Contractor shall appoint a full time Health and Safety Engineer/Co-ordinator whose role
shall be to promote, monitor and enforce safe working practices on the Site for the whole
duration of the execution of the contract. The Health and Safety Engineer/Co-ordinator shall be
a senior member of the Contractors staff.
The Contractor shall arrange and undertake regular safety briefings for all of his staff, workmen
and sub-Contractors staff. In addition, he shall ensure that regular safety liaison meetings are
held between the Contractor, Engineer and Employer. The Contractor shall carry out a safety
audit of the Site at intervals not exceeding one month.
The Contractor shall submit to the Engineer method statements for all safety proposals in
advance of the commencement of work, approval of which by the Engineer shall not relieve the
Contractor of his obligations to comply with all Decrees, Statutes, Ordinances, Regulations or
bye-laws. He shall make available for inspection by the Engineer all registers, reports and
certificates which the Contractor is required to keep or issue in respect of safety matters and
accidents.
Contractor shall ensure that all personnel engaged on this Contract, including his subcontractors, are aware and adhere to the safety requirements relating to the Contract and
associated site works and shall only employ personnel who have undergone recognised training
and experienced in the works to be undertaken. Experienced personnel shall supervise any
unskilled labour or trainees during the works.
The Contractor shall note that any site personnel found to be working in breach of the safety
requirements or procedures shall be first warned to correct their working methods or
procedures, if repeated breaches occur, the personnel shall be removed from site.
The Contractor shall ensure his personnel comply with any existing regulations in force at the
STP.
4.24.2 Permits to Work
All site works shall be covered by a Permit to work, issued by the proper Authorities (Employer,
Central Planning Unit, etc.). The Contractor will undertake all the necessary procedures to
ensure that all permitting requirements are identified, permits are obtained at an early stage
and then used as appropriate.
A System for issuing permits for the site works must be implemented, documented and
maintained by the Contractor during the period of the Contract. Details of the system proposed
shall be submitted for the approval of the Engineer, which if granted will not relieve the
Contractor of any of his responsibilities, nor shall reasonable refusal to approve entitle the
Contractor to extra payment.
The Contractor shall provide detailed method statements as appropriate to complete permit
authorisation. These method statements shall identify the working methods, risks and
precautions necessary to complete the works.
The Contractor shall not commence site works unless a valid Permit to work has been issued
for the site works to be undertaken.
Permits to site works issued will include, but not be limited:
i)
Handover of the site or working area by the Employer to the Contractor.
ii)
Works requiring access into confined spaces
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iii)
Works associated with existing or live electrical equipment.
iv)
Works requiring excavation.
v)
Pumping operations.
vi)
Hot works.
vii)
Operation and use of mobile or static cranes
All Permits shall be time limited and issued in accordance with the relevant Authority
procedures. Blanket permits shall not be issued for the works under any circumstances.
The Contractor shall adhere to the requirements of the Permit, including methods of works
agreed whilst the Permit to work is in operation.
4.24.3 Site Hazards
Hazards on the Site include:
i)
Underground pipes and cables.
ii)
Overhead cables.
iii)
Flammable materials.
iv)
Mechanical plant and equipment.
v)
Operational staff and their Contractors and Vehicles.
vi)
Confined spaces.
vii)
Sewage and Sewage products, and the risk of leptospiral jaundice from contact
therewith.
viii)
Live electrical equipment or services.
ix)
Deep tanks, chambers and manholes
x)
Sun radiation
xi)
High summer temperatures and high humidity
xii)
Falling excavations
4.24.4 Precautions Against Leptospiral Jaundice

The Contractor shall ensure all personnel engaged in the site works are aware of the risks and
precautions against Leptospiral Jaundice. The following provides guidance on working in
sewage-contaminated sites:
i)
After working in contact with sewage, or anything which might have been
contaminated by it, wash your hands and forearms thoroughly with soap and water.
ii)
If clothes or boots are contaminated with sewage, wash thoroughly after handling
them.
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iii)
It is particularly important to do this before taking any food or drink.
iv)
Wet protective clothing should be dried as soon as possible.
v)
Infection may enter through breaks in the skin so thorough first aid treatment of all
wounds is important.
vi)
Take particular care to wash thoroughly any cut, scratch or abrasion of the skin as
soon as possible whether the injury was caused at work or not.
vii)
Apply an antiseptic to the wound with a clean piece of cloth or cotton wool and protect
it with a strip of gauze completely covered with adhesive plaster.
viii)
Keep the wound covered until it is quite healed. Antiseptic gauze and impermeable
plaster are available at place of work.
ix)
If you suffer any cut, scratch or abrasions of the skin, it must be covered with a
waterproof plaster before entering the place of work.
x)
Avoid rubbing your eyes, nose or mouth with hands during work.
xi)
Every accident at work, however trivial, must be reported.
The Contractor shall ensure all personnel, including subcontractors are advised of the risks and
precautions relating to Leptospiral Jaundice and shall display the above guidance on site in the
appropriate languages of his personnel.
4.24.5 Excavations
Excavations shall be adequately supported against collapse.
The Contractor shall provide protective safety barriers and appropriate bunting for the
protection of the general public and personnel working on the STP.
The Contractor shall also provide suitable and safe bridging over trenches and excavations
where required for pedestrian and vehicular access.
4.24.6 Work in Public Highways
Before work commences, adequate advance warning signs, clearly signposted diversions for
traffic and pedestrians and traffic controls shall be provided to the approval and requirements
of the Traffic Directorate, the Ministry of Works, Power and Water and the Engineer. The
Contractor shall provide and maintain night lights and shall ensure their operation during hours
of darkness by night watchmen and/or night patrols.
4.24.7 Safety Equipment
All safety helmets, coats, gloves, footwear, goggles, breathing apparatus, ventilation equipment
and any other protective apparel or equipment deemed necessary by the Engineer for the
protection of the Contractors staff shall be provided by the Contractor and maintained in good
order.
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4.24.8 Welfare Facilities and Site Cleanliness

The Contractor shall provide and maintain in proper order suitable messing, sanitary
conveniences and washroom facilities, for use by all persons connected with the construction of
the Works. The welfare facilities shall be provided within 1 week of commencement of the
works on site and shall remain in place until handover of the works.
The Contractor as a minimum shall keep on site one full stocked first aid kit and adequate
potable water for drinking and washing for use of the site personnel.
Rubbish, surplus packaging and materials not required for the works shall be removed from the
Site on a weekly basis and the Contractor shall ensure that the site is kept in a clean and tidy
condition.
4.24.9 Use of Equipment
All manufacturers instructions and recommendations for the use, application, erection, or
construction of any material or item of equipment or plant shall be followed precisely.
Care shall be taken to protect all employees when using power tools or materials which will
produce a fine dust and in particular all asbestos based products. Precautions may include:
(a)
(b)
4.24.10
Operator to stand upwind of the operation and wear an approved respirator and
goggles.
Overalls to be worn consisting of 60% polyester fibre and 40% cotton, to be worn
whenever possible.
Testing of Contractor's Lifting Equipment
Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle used in constructing
the Works shall be thoroughly examined by a competent person at least once every 6 months,
be test loaded to 150% of the safe working load and then tagged with the safe working load
and date of successful testing.
All parts and working gear, whether fixed or movable, including the anchoring and fixing
appliances of every crane and lifting machine shall be of good construction, sound material,
adequate strength and be properly maintained. All parts and gear shall be examined by a
competent person at least once every twelve months.
An up to date register of all such equipment and examinations shall be maintained and shall at
all times be available for inspection by the Engineer.
4.24.11
Dangers of Working in Confined Spaces

Attention is drawn to the dangers of working in confined spaces. In addition to shafts, tunnels,
closed tanks, etc., any confined space with limited ventilation which is also connected with
water in or from a closed conduit or borehole, or is below ground level, should be treated as a
potentially hazardous location where dangerous gases may be present and prior to entry
adequate safety precautions must be taken in accordance with current good practice.
Reference shall be made to the relevant guidance publications listed in the Schedule of
Approved Standards and Guidance Publications in the document.
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4.24.12
Specifications
Dangers of Working in Sewers and at Sewage Treatment Works

1.
All personnel working on the Site shall be made aware of the dangers of working in live
sewers and at sewage treatment works; in particular the risks of physical injury, of
bacterial infection from contact with sewage, of exposure to dangerous gases; and of
explosion of sewage gases.
2.
Safeguards must be taken in accordance with current good practice and attention is
drawn to guidance publications listed in the Schedule of Approved Standards e.g.
National Joint Health and Safety Committee for the Water Service. Health and Safety
Guidelines:
3.
4.
No. 2 - Safe Working in Sewers and at Sewage Works
No. 3 - Respiratory Protective Equipment.
The Contractor shall not permit any employees to enter live chambers without the
express permission of the Engineer in writing.
Permission will only be given on the standard form Authority to work within a live
Sewer, copies of which may be obtained from the Engineer.
The following equipment shall be available at point of entry for personnel entering
sewage manholes, pumping stations or other structures into which sewage or sewage
gas can enter:
(a)
Oxygen deficiency and flammable gas and hydrogen sulphide gas detectors.
(b)
Rope, safety harness, helmet and safety lamp for each person entering the
sewer;
(c)
Two sets of compressed air breathing apparatus including 1800 litre capacity
cylinders, at least 70 linear metres of high quality rubber hose all for 45 minutes
of man working time;
(d)
One set of emergency escape breathing apparatus with minimum 800 litre
capacity cylinders in sling harness and face mask with gas tight seal. Air supply
operation to commence automatically when the face mask is fitted and breathing
begins.
5.
Naked lights shall not be used in the vicinity of the structure. No smoking shall be
permitted.
6.
At least two people shall remain close to the point of entry who shall have noted
beforehand the nearest telephone and telephone number of the nearest hospital, and
shall be thoroughly familiar with the use of emergency breathing apparatus and other
safety equipment and procedures.
7.
Ventilation shall be provided by removing manhole covers to upstream and

downstream manholes at least 15 minutes before the structure is entered or such other
method as is appropriate for the structure including, where necessary, forced
ventilation.
8.
The atmosphere shall be tested at points of entry and exit and continuously monitored
while personnel are present. If dangerous gases are present, either (a) breathing
apparatus shall be worn or (b) ventilation shall be continued and the atmosphere
retested until such time as no dangerous gases are detected.
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4.24.13
Specifications
9.
Entry shall be authorised by a responsible person. The Contractor shall supply a list of
the names of such persons to the Engineer before any work in live sewers etc., is
carried out.
10.
All electrical equipment, e.g. power drills, shall be intrinsically safe (i.e. non-sparking).
11.
All equipment shall be inspected and tested daily and all air cylinders for breathing
apparatus shall be filled with air from compressors manufactured for that specific
purpose and housed and used in accordance with the manufacturers instructions.
Emergency Arrangements
A current list of names, addresses and telephone numbers of the Contractor's staff responsible
for organising emergency work outside of normal working hours shall be provided to the
Engineer and maintained current.
4.24.14
Contractors Plant and Equipment

The Contractor shall at all times be responsible for the adequacy, efficiency and sufficiency of
his and his sub-contractors plant and equipment which shall be of such type and size, and
used in such manner, as the Engineer shall approve.
Details of the plant proposed shall be submitted for the approval of the Engineer, which if
granted will not relieve the Contractor of any of his responsibilities, nor shall reasonable refusal
to approve entitle the Contractor to extra payment.
If circumstances arise which in the Engineers opinion make it desirable that the use of plant or
equipment be changed or suspended, the Contractor shall make such changes at his own cost.
In particular the exhausts of diesel engined plant shall be modified if necessary to prevent
nuisance from smoke and noise. The Contractor shall also ensure minimum pollution of
working areas with fuel oils.
The Engineer shall be entitled to withhold or withdraw his authority for the use of plant or
equipment which is too noisy in the circumstances, or which may endanger members of the
public, passing vehicles, or adjacent roads, services and structures.
4.24.15
Abatement of Noise
The Contractor shall make every effort to keep the nuisance caused by noise to a minimum and
consideration must be given to using the quietest plant available. If instructed by the
Engineer, the Contractor shall use electric dewatering/overpumping pumps (with the generator,
if required, located remotely to reduce the noise). The cost of providing such electric pumps is
to be allowed for in the rates of work.
The Contractor shall comply with all relevant regulations, decrees, and statutory requirements
relating to restrictions placed on noise from construction work.
Blasting shall not be used unless otherwise approved by the Engineer. All pneumatic breakers
shall be fitted with mufflers. Noise mitigation measures, agreed by the Engineer, shall be
provided for diesel plant when instructed by the Engineer.
Methods of working shall be devised and arranged to minimise noise impacts, and experienced
personnel with suitable training shall be employed to ensure that these methods are
implemented.
Particulars of all constructional plant which is likely to cause excessive noise shall be submitted
to the Engineer. The particulars shall be submitted before the plant is used on site. Unless
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Specifications
otherwise permitted by the Engineer, trials of the plant shall be carried out to demonstrate that
the plant can be operated which will minimise noise during the works. The trials shall be
carried out in the presence of the Engineer. The plant shall not be used on site until agreed by
the Engineer.
The noise level of any construction work other than percussive piling, measured at site
boundary, shall not exceed an equivalent sound level (Leq) of 75 dB(A).
The Contractor shall, prior to commencement of the relevant construction work, carry out
baseline monitoring to determine baseline noise levels at the nearest properties along the
pipeline route. Baseline monitoring shall be carried out for at least one week, and at locations
and to a schedule to be submitted to, and agreed by, the Engineer.
Impact noise monitoring shall be carried out at all the agreed locations whenever construction
work is being carried out. The measurements will be determined by the Engineer to measure
the maximum noise impact during the period. Measurements will not be taken if the
Contractor is not working during these periods. Monitoring will be undertaken according to the
following schedule:
1.
2.
At least one Leq measurement between 0700 and 1900 Saturday to Thursday, three
times each week; and
As determined by the Engineer from time to time and when any powered mechanical
equipment is operating.
Whenever complaints are received, or if the maximum allowable levels are exceeded,
immediate action shall be taken by the Contractor in accordance with an action plan to be
submitted to, and as agreed by, the Engineer.
A weekly report of all noise monitoring data shall be prepared by the Contractor and submitted
to the Engineer, including at least the following:
1.
2.
3.
4.
5.
Copy of all data;

Highlighting of any failures to comply with the criteria set out herewith;
Implementation of the action plan when the levels are exceeded
Identification of reasons for non-compliance
Identification of additional mitigation measures take as a result of 2 above.
If monitoring of the noise level shows, in the opinion of the Engineer, an excessive noise level,
the Contractor shall take all necessary measures to ensure that the actions of the Contractor
are not contributing to the excess. The measures shall include, but not be limited to, the
following:
1.
2.
3.
4.
Checking all constructional plant;

Maintenance or replacement of any constructional plant contributing to the excess;
Installation of constructional plant soundproofing, provision of alternative
constructional plant, or erection of sound barriers; and
Review and modification of all working methods and scheduling of activities.
The Contractor shall inform the Engineer of all measures taken, and shall submit to the
Engineer a written report and proposal for action, whenever monitoring shows that an
excessive noise level is arising.
If the proposed remedial measures include the use of additional or alternative constructional
plant, such plant shall not be used on the works until agreed by the Engineer. It proposed
remedial measures include maintenance or modification of previously agreed plant, such plant
shall not be used on the works until the proposed maintenance or modification has been
completed and the adequacy of the maintenance or modification has been demonstrated and
agreed by the Engineer as being satisfactory.
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If approved remedial measures are not being implemented and serious impacts persist, the
Contractor shall cease related parts of the work until the measures are implemented.
Nuisance caused by noise shall be kept to a minimum with consideration given to the use of
the quietest equipment available. All pneumatic breakers shall be fitted with mufflers.
Equipment should not normally be operated during the night, weekends or public holidays
except for pumps dealing with sewage flow or dewatering excavations which are to be sited to
cause the minimum inconvenience to the public.
4.24.16
Accident Reporting
The Contractor shall notify the Engineer in the event of any/all accidents that occur on site,
with 24 hours. Each notification shall include the cause of the accident, personnel involved;
injuries sustained (if any) and proposed measures/methods to prevent re-occurrence.
The Contractor shall notify the Engineer and Divisional Head Occupational Health and Safety in
the event of any/all accidents that occur on site which involve lost time, medical treatment etc,
within 2 hours of the accident occurring. The Divisional Head Occupational Health and Safety
contact details will be provided at the Contract award meeting
All accidents notifiable to the Divisional Head Occupational Health and Safety shall be formally
reported to the Engineer and Divisional Head Occupational Health and Safety, in the form of an
accident investigation report. This accident report shall be submitted within 7 days of the
accident.
4.24.17
Electrical Safety
All temporary electrical installations required during the works, including generator supplies,
shall conform to the Safety Regulations stipulated by Ministry of Labour and Social Affairs
Ministerial Order No.33-1997 Precautions for protection of workers during work from hazards
of electricity and the current edition of the Ministry of Water and Electricity Regulations for
Electrical Installations. All equipment and cabling shall be in good condition and electrically
safe. The installation and equipment shall be tested at regular intervals with copies of
test/inspection certificates issued to the Engineer.
Any electrical supply derived from the public supply system shall have at its origin a suitably
rated earth leakage circuit breaker in addition to overload and short circuit protection devices.
The supply shall be distributed to the site from a metal clad MCB distribution board. Each
outgoing circuit shall be provided with a suitably rated MCB with neutral and earth connections.
The Contractor shall install an earth connection independent to the public supply earth for his
temporary electrical installation. This earth shall be in the form of diameter copper clad
earth electrodes driven into the earth, to achieve an earth resistance of not more than 2 ohms.
All site temporary distribution or sub-distribution cabling and cabling to fixed
equipment/installations shall be carried out using suitably sized multi-core armoured cables
with correct glanding arrangements into equipment. The contractor shall not rely upon the
cable armouring to provide the earth continuity conductor; one core of the cable shall be
connected to earth. The cables shall be routed as to prevent or reduce potential damage from
the construction works or equipment.
Sub-distribution boards shall be provided to enable portable equipment to be plugged-in
locally near the work area. The sub-distribution boards shall be metal clad MCB distribution
boards, fitted with suitably rated MCBs, with socket outlets provided for connection of portable
equipment. The preferred type of socket outlet and plug is to BS4343 design. The use of plug
adaptors is prohibited.
Vol 3, Section 1
Page 37 of 43
Specifications
Final circuit cabling to portable equipment shall be carried out in suitably rated multi-core
rubber sheathed flexible cables. All connections shall be made through proprietary plugs and
socket outlets only. One core of all flexible cables shall be connected to earth.
Jointing or splicing of cables is strictly prohibited.
All electrical equipment and services shall be weather proof to IP54 or provided with suitable
weatherproof enclosures. Where equipment is exposed to direct sun light suitable enclosures
shall be provided to shade the equipment or services.
4.24.18
Chemical Hazards
All chemicals brought onto site shall be stored within the manufactures containers and shall be
fitted with secure lids. The containers shall clearly indicate the contents and quantities within
the container for identification purposes. Chemicals may be in the form of solvents, resins,
alkalidies or acids including paints and adhesives.
The Contractor shall issue to the Engineer for approval and retain on site the manufactures or
suppliers chemical hazard data sheet. The chemical hazard data sheet shall be issued to the
Engineer prior to any deliveries to site. The Contractor shall remove chemicals that are
delivered without approval of the Engineer.
The Contractor shall limit the storage of chemical on site that are required for that days use.
Additional requirements or stocks shall be held off site at the Contractors stores until required.
The Contractor shall remove from site all unused chemicals or empty containers prior to
handover of the works. All unused chemicals shall be disposed of in accordance with the
manufactures instructions and in compliance with the current environmental legislation.
4.25 Site Offices, Attendance and Site Facilities

4.25.1 Location of Contract Offices and Other Contract Facilities
The site offices shall be located within the area allocated for the site.
A plan shall be submitted within two weeks of the award of the Contract showing the proposed
locations on the site of:
The offices for the Engineer.
The Contractors site offices.
The Contractors stores, plant and maintenance yard and materials stockpiling
facilities.
Areas for the temporary storage of excavated material.
The Engineers office shall be in close proximity to the Contractors office and shall have a
reasonable view of the site and the traffic entering and leaving the site.
The Contractor shall, within 4 weeks of the Commencement Date, hand over to the Engineer a
fully completed, furnished and equipped Engineers office. The contractor shall provide suitable
temporary office space for the Engineer until the office is completed.
Vol 3, Section 1
Page 38 of 43
Specifications
4.25.2 Offices and Facilities for the Engineer

Suitable offices with washing and toilet facilities and adjacent car parking facilities shall be
provided for the exclusive use of the Engineer and his staff. They shall be equipped,
maintained, cleaned, heated and provided with adequate lighting and power. The offices shall
be removed from the site after completion of the Contract and the site reinstated. No offices
or associated equipment shall be removed without the written consent of the Engineer.
(i)
Accommodation
The following will be required as minimum superficial areas

Senior Resident Engineers office 15 square metres
Resident Engineers Offices 2 no. at 12m2 each
Secretarys office/Reception Area/hot desk 15m2 (the office shall include a visitor hot desk
with power point, network connection etc.)
Meeting Room 25 square metres
Additional Staff Offices 6 no at 8m2 each
Car Ports shall be provided for 12 cars with a minimum roof area of 15m2/car
Kitchen
Toilets (internal)
The office shall be of approved design, insulated, air conditioned throughout and internally
wired for lighting and power. The floors shall be covered with a suitable approved hardwearing
surface for easy cleaning.
The walls and ceilings shall be well insulated with approved material in keeping with the
ambient temperatures in Bahrain. Ceilings shall be flush and flat and the office shall be
suitably decorated internally and externally. The height from floor level to ceiling shall be at
least 2.300 metres.
Windows shall be double glazed with a suitable number of openings which shall be fitted with
flyscreens. All window units shall be burglar-proof and fitted with venetian blinds.
Adequate tubular electric lighting fitted with diffusers shall be included together with all
associated wiring and switchboards, socket outlets and a separate 15 Amp supply to air
conditioning units.
There shall be 3 No. sockets for each room in addition to the A/C and cooker points.
One telephone line shall be provided with a telephone in each office and one fax machine. The
line shall be suitable for international calls. Use of the telephone for international calls will be
controlled by a method agreed with the Contractor.
The site offices shall be provided with a single broadband (min 4mbps, unlimited data) internet
connection networked throughout the offices.
(ii)
Furnishing and Equipment
The following furniture, fixtures and office equipment shall additionally be supplied to the
approval of the Engineer in sufficient numbers to service 10 full time staff, Employers staff,
visitors and meetings for up to 12 people. The Engineer reserves the right to reject, and
require the replacement of, any item which in his opinion is sub-standard. If any item of
equipment requires servicing or repair, an equivalent replacement shall immediately be
provided in the interim.
Vol 3, Section 1
Page 39 of 43
Specifications
General Items:
Air conditioning equipment sufficient to maintain the entire office below 24C throughout
the year
10 No adjustable padded swivel chairs.
12 No. additional padded chairs
2 No. drawing benches, 1.5m long with plan chest under.
4 No. four drawer lockable steel filing cabinet.
4 No. whiteboards with pens and cleaner.
2 No. table, minimum size 1.8m x 0.9m.
2 No. tables, minimum size 1.2 x 0.9m
4 No. lockable desks, 1.8 m x 0.9m.
6 No. additional lockable desks 1.2m x 0.7m.
Computer and printer desks/workstations to suit equipment specified below.
2 No. approved fire extinguishers.
1 No. approved first aid kit (wall mounted)
Shelving as required
Office Equipment:
4 number new personal computers with the following minimum specification:
i)
Quad core processor
ii)
4GB RAM
iii)
500GB hard drive
iv)
DVD rewriter (with supply of blank DVD-WR/R & CD-WR/R disks)
v)
Network port
vi)
22 flat panel LCD screen
vii)
All other ancillaries.
The computer shall be loaded with latest versions of Windows, MS Office, MS Project,
Abobe PDF reader/writer and drawing software compatible with that used for the
Contractors design. All software shall be original, licensed versions supplied with
original disks.
4 no. additional office computers and ancillaries suitable for word processing,
spreadsheets, internet etc loaded with office software.
Routers and switches as necessary for full networking of all computers
A4 Laser printer (networked)
A4 colour printer (networked) with supply of inks
1 no. 500GB portable hard drive (for backup)
Vol 3, Section 1
Page 40 of 43
Specifications
Desk top photocopier with A3 and A4 paper size copying facility and sheet feeder
complete with paper supply. Photocopier shall be network compatible to enable printing
from networked computers.
4 No. ten-digit scientific calculators.
Miscellaneous office equipment such as correspondence trays, waste paper bins, paper
punches, staplers etc
Supplies of expendable materials including pens, pencils, paper, level books, marker
paint etc.
Kitchen Equipment:
Electric water heater
Small microwave oven
Refrigerator with freezer compartment and ice-making facilities
Electric kettle
Water cooler
Sink unit with hot and cold running water
Cupboards
Working surface
Glasses, crockery and cutlery (sufficient to supply meetings of up to 12 people)
Toilet Facilities
Two European water closets (separate mens/ladies), each with one hand basin and wallmounted mirror shall be installed together with an approved water heater.
4.25.3 Attendance upon the Engineer
Attendance items to be provided for the Engineer and his staff shall be:
The daily cleaning of offices, toilets, etc. and car washing.
The provision of a regular supply of drinking water for the supervisory staff and their
visitors.
The provision of a regular supply of soap, toilet rolls, towels (including tea towels), tea,
coffee, sugar and milk.
The arrangement and payment of electricity, water and telephone services including
connection and disconnection.
Provision of labourers and chainmen as required by the Engineer to assist in any of his
supervisory duties at any time of the day or night.
Provision of Secretary/Receptionist for sole use.
Vol 3, Section 1
Page 41 of 43
Specifications
4.25.4 Vehicles for Overseeing Organisations

The Contractor shall provide four vehicles as described below for the exclusive use of the
Employer and his representatives for any purpose in connection with the Works. The
Contractor shall arrange the proper service and maintenance of the vehicles at the dealership
workshop. The vehicles shall be licensed and insured for use both off-road and on the public
highway and shall have comprehensive cover for any qualified driver authorised by the
Employer and/or his representatives together with any authorised passengers and the carriage
of goods and samples.
The Contractor shall provide maintenance in conformity with the vehicle manufacturers
recommendations and shall keep the vehicles clean inside and out on a regular basis. A
suitable replacement shall be provided for any vehicle out of service for more than eight
working hours.
The vehicle is to be suitable for off-road use with high ground clearance and an engine of
minimum power output of 130 ps, seating for a minimum of 5 persons, 4 wheel drive, all
terrain tyres, hill decent control, ABS braking, power steering, front, rear and side airbags and
an automatic climate control system. The vehicle shall be supplied free from markings
identifying any company associated with the Contract.
The equipment shall include fire extinguisher, hazard flashing unit, heavy duty suspension,
spare wheel, internal and external mirrors, mud flaps, floor mats to all foot wells and to the
rear load bay, tow rope, towing hooks front and rear, laminated windscreen and a roof
mounted amber flashing light bar comprising at least two lights. The light bar is to be operable
from a clearly identifiable switch mounted on the dashboard of the vehicle.
Vehicles shall be in as new condition and no more than 3 years old.
The Contractor shall submit a schedule of the proposed vehicles for the use of overseeing
organisations for the approval of the Engineer. The schedule shall be based on the above
requirements and detail the manufacturer, model and year of registration of each vehicle and
the type and duration of insurance for each vehicle. The schedule shall also indicate the
proposed date of supply for each vehicle. Following approval of the schedule, the Contractor
shall not vary any element of the supply without the written approval of the Engineer.
Supply of vehicles is covered by a Provisional Sum in the Schedule of Prices.
4.25.5 Protective Clothing for Engineer and Staff
Sufficient protective clothing shall be provided for the sole use of the Engineer and his staff and
visitors to site as listed below. Up to 6 sets of the following should be provided for use at all
times:
White safety helmets.
High Visibility site jackets.
Lightweight site jackets/coats
Safety boots
Plastic coated working gloves.
The numbers and sizes of each of the required items shall be confirmed on site by the
Engineer.
Vol 3, Section 1
Page 42 of 43
Specifications
4.25.6 Facilities for Checking and Setting Out, Examination, Testing and Measuring the
Works
The equipment listed below shall be provided, cleaned, serviced and maintained for the sole
use of the Engineer and his staff together with any other such items as may reasonably be
required for checking the setting out and for measuring the Works. All equipment must be to
the approval of the Engineer.
The equipment shall not be used by any of the Contractor's staff without authority from the
Engineer. All equipment supplied to the supervisory staff will be returned to the Contractor at
the end of the Contract.
1 Level, tripod and staff
50m Steel and cloth tapes
4 no. 5m steel tapes
Ranging rods
Reinforcement cover meter
Elcometer for measuring paint thickness
Sound level meter
Gas detection equipment (to detect hydrogen sulphide, inflammable gases, lack of oxygen).
Slump cone and tamping rods
Concrete thermometer
Asphalt thermometer
Maximum and minimum thermometer
3 No. access cover lifting keys
3 No. Waterproof torches and mirror (for pipeline inspection)
Electrical/electronic digital multimeter
1 no. digital SLR camera having the following minimum specification:
>10megapixels
18 -55mm lens
Including >8GB memory card and carrying case
In addition, the Contractor shall make available to the Engineer upon request, one theodolite
and tripod.
4.26 Public Relations
The Contractor shall appoint a full time Arabic and English speaking Public Relations Officer
whose role shall be to liaise in conjunction with the Engineer with public bodies, service
providers, local residents and others affected by the works in order to promote the effective
construction of the works with the maximum co-operation of and minimum disruption to the
public.
Vol 3, Section 1
Page 43 of 43
Specifications
The Public Relations Officer shall be a senior member of the Contractors local staff.
Vol 3, Section 1
Page 44 of 43
Specifications
APPENDIX I
Drawings and other information forming part of the Contract
Drawings and other information forming part of the Contract are contained in Volumes 5 and 6.
Vol, 3 Section 1
I-1
Specifications
APPENDIX II
Addresses of Statutory Organisations
NOT USED
Vol, 3 Section 1
II-1
Specifications
APPENDIX III
SOURCE COUNTRIES
The Contractor will be required to provide, prior to the signature of the contract, proof of origin of
materials and source of supply and manufacture of any item of plant not of the Contractors manufacture
in the form of a Certificate of Origin or other official documentation as prima facie evidence.
Where the provision of a Certificate of Origin is not possible (in many countries these are only issued
against presentation to the Chamber of Commerce of commercial invoices), the Contractor can in these
cases submit its own declaration. The official Certificates of Origin must then be submitted with the first
invoice. Failing this, the Employer cannot release any funds to the Contractor.
The rule of origin applies to all items tendered and supplied. Therefore, it is insufficient that only a
certain percentage of the goods tendered and supplied or a certain percentage of the total tender and
contract value comply with this requirement.
To establish origin, one must determine where the product in question has been obtained or produced. A
product cannot originate in a country in which no production process has taken place. On the other
hand, the country of production is not necessarily the country of origin.
Furthermore, the country of origin is not necessarily the country from which the goods have been
shipped and supplied. Where there is only one country of production, the origin of the finished product is
easily established. However, in cases where more than one country is involved in the production of
goods it is necessary to determine which of those countries confers origin on the finished goods. The
country of origin is deemed to be the country in which the goods have undergone their last, economically
justified, substantial transformation.
The supplier must certify that the goods tendered comply with the origin requirement specifying the
country or countries of origin. When tendering for systems comprising more than one item, the origin of
each item in the system must be specified. If requested to do so the supplier must provide any additional
information and/or a certificate of origin in support of the origin claimed in the tender application.
Except where otherwise specified, all materials and workmanship shall conform with the requirements of
the latest editions of the relevant Bahrain and International Standards and Codes of Practice and any
other Standards which are referred to in the Specifications.
The Schedule of Approved Standards and Guidance Publications in Volume 3A, Section 3, Civil
Specifications (Section S) lists approved standards as a quality guide for the materials and articles to be
provided.
Vol, 3 Section 1
III-1
Specifications
APPENDIX IV
PLANT LIST
ZONE A - Coastal Exposed,
ZONE B - Coastal Protected,
ZONE C - Inland Protected,
ZONE D - Environmentally Controlled
(shading and misting)
ITEM
BOTANICAL NAME
Palms
Caryota mitis
ZONE
DESCRIPTION
C, D
Chamaerops humilis
Cocus nucifera
C
A
Corypha umbraculifera
C, D
Pandanus veitchii
Phoenix canariensis
A, B, C
A, B
Phoenix dactylifera
A. B, C
Rhapis excelsa
Rhapis humilis
Rostonia regia
Syagrus romananzoffiana
Washingtonia filifera
Washingtonia robusta
D
C, D
D
A, B
A, B
A, B
Clumping palm to 8m high x 4m wide

crown
Clumping palm to 4.5m x 4m wide crown
Solitary palm to 20m high x 7m wide
crown
crown
Palmlike to 9m.
crown
crown
Clumping palm to 2.5m high x 1m wide
Clumping palm to 2.0m high x 1m wide
Solitary palm to 25m x 5m wide crown
Solitary palm to 15M
Trees
Acacia aurecoliformis
B, C
Acacia farnesiana
B, C
Acacia tortilus
Albizzia julibrissin
A, B
C, D
Albizzia lebbeck
Arbor vitae (Cypress)
Azadirachta indica
Bauhinia blakeana
B, C, D
Bombax ceiba
B, C, D
Cassia fistula
Cassia javanica
Casuarina equisetifolia
Chorisia speciosa
Coccoloba uvifera
Conocarpus
Cordia sebestena
A
B, C
A
A, B
B, C, D
Vol, 3 Section 1
B,C
IV-1
20-25m tall spreading open canopy shade

tree. Bright yellow flowers
Small spreading open canopy tree.
Flowers yellow with pleasant fragrance.
Small open crown spreading tree
Spreading tree to 12m. White - pink
flowers
8 - 12m open crown deciuous tree.
Evergreen Cypress
Spreading evergreen shade tree to 20m.
Small white flowers
Rounded spreading tree to 12m. Purple
flowers
Tall deciduous tree. Red flowers in spring
prior to leaf sprout.
Upright tree to 30m

Spreading tree to 15m. Pink to red flowers
Vase shaped tree to 15m. White flowers
Small spreading tree
Small spreadingevergreen tree to 8m.
Red flowers in summer
Specifications
Dalbergia sisso
B, C
Delonix regia
B, C, D
Erythrina variegata
A, B
Eucalyptus camaldulensis
Ficus altissima
Ficus benghalensis
B, C
B, C
B, C, D
Ficus benjamina
B, C, D
Ficus elastica
Ficus jamba
Ficus microcarpa
Ficus nitida
Ficus religiosa
Ficus retusa
Hibiscus tiliaceus
Jacaranda acutifolia
B, C
Lagerstroemia speciosa
B, C, D
Leucaena leuccoephala
Melia azedarach
A, B
B, C
Olea europea
Parkinsonia aculeata
C
A, B
Pithecellobium inga-dulce
Plumeria obtusa
Polyalthia longifolia
B
A, B, C,
D
A, B, C,
D
B, C
Pongamia pinnata
A, B
Prosopis alba
Prosopis juliflora
Psidium guajava
Tabebuia pentaphylla
A, B
A, B
A, B, C,
D
B, C
Tabebuia rosea alba

Tamarindus indica
B,C
C, D
Tamarix arabica
Terminallia catappa
Thespesia populnea
Vitex agnus castus
Ziziphus spina-crista
A, B
A, B
Plumeria rubra acutifolia
Vol, 3 Section 1
A, B
B, C, D
B, C, D
B, C
A, B
C, D
A, B
IV-2
Erect deciduoud tree to 20m.

White/yellowish white flowers
Spreading tree 10m high x 15m wide. Red
flowers
Spreading tree 18m high x 10m wide. Red
flowers
Tall spreading evergreen tree
Tall spreading evergreen tree to 25m high
Spreading evergreen shade tree to 12m x
12m.
Large spreading tree 20m high x 25m
wide.
Large spreading tree to 30m high
Spreading evergreen 18m x 9m
Spreading evergreen tree, 12m x 12m
Small tree to 8m high. Yellow flowers
Spreading tree to 15m. Ultraviolent
flowers
Deciduous spreading tree to 20m. Purple
flower
Small tree with white flowers
Rounded crown tree to 15m. Purplish
flowers
Open canopy tree to 10m
Weeping canopy tree to 7m. Yellow
flowers
Rounded canopy tree to 8m. White
flowers
Rounded canopy tree to 8m. Red flowers
Symmetrical pyramidal tree tp 12m high x
1.2m wide
Spreading tree to 13m x 12m. White, pinkpurple flowers
Open canopy tree to 15m. White flowers
Open canopy tree to 9m
Small evergreen tree to 8m
Rounded crown tree to 12m. Yellow
flowers.
Rounded canopy tree to 15m. Pale yellow
flowers
Small open canopy tree
Tall symmetrical tree to 35m
Small open canopy tree to 10m. Yellow

green flowers
Shrubs
Acalypha wilkesiana
Adenium obesum
Agave spp.
Cassia alata
Cassia occidentalis
Caesalpinia gillese
Caesalpinia pulcherrima
Specifications
B, C, D
C
A, B, C,
D
C, D
B, C
B, C
Callistemon viminalis
Carissa grandiflora 'Carpet Green'
Cestrun diurnum
Clerodendron inerme
B, C
Codiaeum variegatum
Dodonea viscosa 'Purpurea'

Duranta repens "Golden"
Euphorbia milli
Gardenia jasminoides
A, B, C
C, D
B, C
D
Hibiscus rosa sinensis

Ixora chinensis
Ixora coccinea
Ixora javanica
Jatropha multiflora
Lawsonia inermis
B, C
D
D
D
B, C
B, C
Leucophyllum frutescens
Leucophyllum frutescens "Green
Cloud"
Lycium arabicum
Musa paradisica
Nerium oleander
B, C
B, C
D
C, D
Dense shrub to 3m. Multi coloured foliage

Succulent shrub to 1.8m. Red flowers
Clumping succulent to 1.5m.
Open crown shrub to 2.5m. Yellow flowers
Spreading shrub to 2.5m. Orange &

yellow flowers
Tall open shrub to 5m. Red flowers
Open shrub to 2.0m. White flower
Shrub to 2.4m. White flower. Poisonous
Scrambling dense shrub to 3.0m. White
flowers
Compact shrub to 1.2m. Variegated
leaves
Dense shrub to 1.5m. Golden foliage
Open canopy shrub. Red flowers
Dense canopy shrub to 1.5m. White
flowers
Shrub to 3m. Yellow, orange, red flowers
Dense shrub to 1.5m. Orange flowers
Dense shrub to 2m. Red flowers
Dense shrub. Scarlet red flowers.
Open canopy shrub to 2.5m. Red flowers
Tall open shrub to 6m. White, red, pink or
yellow flowers.
A, B
D
A, B, C,
D
A, B, C,
D
B, C
A, B, C,
D
C
A
Shrub 1.0m x 0.5m
Sueada fruiticosa
Tecomaria capensis
Clumping strapleaf to 1.2m. Oragne

flowers
C, D
Tecoma stans
Thevetia peruviana
Vitex agnus castus
Yucca aloifolia
C, D
C, D
A, B
A,B,C
Scrambling shrub to 3m. Red orange

flowers
Compact shrub to 7m. Yellow flowers
Tall shrub to 5m. Yellow flowers
Sprawling shrub to 6m. Purple flowers
Clumping strapleaf to1.5m. White flowers
Nerium oleander 'White'

Opuntia ficus indica
Pittosporum tobira
Portulacaria afra
Rosmarinus officinalis
Scaevola tocata
Strelitzea reginea
Vol, 3 Section 1
IV-3
Upright shrub to 5m. Pink flowers

Upright shrub to 5m. White flowers
Succulent shrub to 1.8m. Red flowers
Opn shrub to 3.0m
Woody shrub to 1.8m. Pale blue flowers
Specifications
Groundcovers
Aerva javanica
Aloe vera
A, B
B, C
Alternanthera ficoidea var. amoena
Alternanthera red
Aptenea cordifolia
Asparagus sprengerii
Atriplex halimus
Atriplex semibaccata
Bougainvillea 'Nana Red'
Canna indica 'Yellow'
Carissa prostrata
Carnation
Carpobrotus edulis
Catharanthus rosea
Cenchrus cilaris
Crinum asiaticum
Clumping groundcover to 0.5m

Clumping succulent to 0.8m. Yellow
flowers
Clumping groundcover to 0.12m.
Colourful foliage
C, D
A, B
A, B
B, C, D
D
Trailing groundcover.
A, B
Sprawling groundcover to 0.15m high.

Yellow flower fading to pink.
A, B
C, D
Clumping strapleaf to 1.0m. Yellow flower
Dipterygium glaucum
Europs pectinatus
Gazania hybrida
Gazania rigens
Gazania rigens var. Uniflora
Gazania rigens white
Gazania rigens yellow
Heliotropium curassavicum
Hymenocallis littoralis
A
C, D
Clumping grass to 0.45m high

Clumping strap leaf top 1.0m. White
flowers
Small open shrub to 0.6m
Low clumping groundcover. Yellow flower
A, B, C
A, B, C
Spreading groundcover. Yellow flower

Spreading groundcover. Yellow flower
A, B
C, D
Ipomea pes-capre
A, B
Lampranthus spectabilis
C, D
Lantana camara dwarf 'Pink Mound'
C, D
Lantana montevidensis
C, D
Malephora crocea
Mammillaria seitziana
Nerium oleander 'Pink Petite'
Ophiopogon jaburan
Osteospernum fruiticosum
Succulent groundcover. White flower

Clumping strap leaf groundcover to 1.0m.
White flower
Sprawling groundcover vine to 30m. Pink
flowers.
Succulent groundcover to 0.3m. Pink purple flower
Clumping groundcover to 0.3m. Pink
flowers
Clumping groundcover to 0.45m. Lilac
flower
A, B
C, D
D
B, C
Pelargonium graveolens
C, D
Pennisetum setaceum
A, B, C
Pennisetum setaceum 'Rubrum'
A, B, C
Petunia hybrid
Portulaca grandiflora
C, D
Vol, 3 Section 1
IV-4
Clumping groundcover. Pink flowers

CLumping groundcover to 0.3m. White
flowers
Clumping groundcover to 1m x 1m.
Purplish - white flowers.
Ornamental grass to 1.0m. Rose coloured
flower spikes
Ornamental grass to 1.5m. Burgundy red
coloured flower spikes
Prostrate goundcover to 0.15m. Rose,
pink-white flowers.
Specifications
Portulaca grandiflora 'Red'
C, D
Pseuderanthemum atropurpureum
Rhoeo discolor
Ros marinus prostrata
Ruella ciliosa
Russellia equisetiformis
Sanservia trifasciata
Scaevola aemula
Senecio cineraria
A, B
Sesuvium 'Green carpet'

Setcreasea purpurea
C, D
D
Setcreasea purpurea
Stenotaphrum secundatum
Verbena tenera
C, D
C, D
Vinca pacifica 'Red'

Wedelia trilobata
D
B, C
Zamia furfuracea
Fronds to 1.5m in leangth
B, C
Scrambling vine to 3m. Yellow flower
B, C, D
B, C, D
B, C, D
C, D
C, D
Scrambling vine to 6m. White flowers

Scrambling vine to 6m. Pink flowers
Scrambling vine to 6m. White flowers
Vine to 3.5m. White flowers
Scrambling vine to 3m White flowers
Passiflora caerulea
Quisqualis indica
D
D
Twining vine to 9m. Blue flowers

Scrambling vine to 15m. White - red
flowers.
Lawn
Paspaulum
C, D
Climbers/Vines
Allamanda cathartica
Antigonum leptopus
Bougainvillea glabra 'White'
Boagainvillea 'Pink Pixie'
Bougainvillea 'Texus Dawn'
Cestrum nocturnum
Jasminum sambac
Vol, 3 Section 1
B, C, D
C, D
D
IV-5
Prostrate goundcover to 0.15m. Red

flowers.
Low clumping groundcover to 0.15m.
Chocolate brown leaves.
Clumping strapleaf groundcover to 0.3m
Weeping canes to 1.0m. Red flowers

Clumping strapleaf groundcover to 0.75m
Sprawling groundcover to 0.5m. Blue lilac,
white flowers.
Clumping groundcover to 0.6m. Silvergrey foliage
Spreading Groundcover to 0.3m high.
Purple foliage. Pink - Purple flowers
Grass to 60mm high.
Low sprawling groundcover to 0.2m high.
Purple flowers
Clumping groundcover.
Sprawling groundcover to 0.25m. Yellow
flower

Tender Documents
Volume 3 Section 2
Process Specifications
July 2014
Specifications
TABLE OF CONTENTS
1.
GENERAL PROCESS DESIGN REQUIREMENTS .............................................................. 1
1.1
Process Elements ............................................................................................................................... 1
1.2
Design Flows ....................................................................................................................................... 1
1.3
Flow Build-Up and Treatment Trains .......................................................................................... 2
1.4
Design Loads ....................................................................................................................................... 3
1.5
Treated Effluent Quality .................................................................................................................. 3
1.6
Sludge Quality ..................................................................................................................................... 4
1.7
Odour Quality ...................................................................................................................................... 4
2.
INLET PUMPING STATION (TERMINAL LIFT PUMPING STATION) .............................. 5
3.
TANKER RECEPTION FACILITY .................................................................................... 6
4.
INLET WORKS PRELIMINARY TREATMENT AND TANKER RECEPTION FACILITY........ 7
5.
SECONDARY TREATMENT BIOREACTORS AND FINAL SETTLEMENT TANKS ........... 12
6.
TERTIARY TREATMENT ............................................................................................... 21
7.
DISINFECTION ........................................................................................................... 25
8.
TSE STORAGE TANK AND PUMPING STATION ........................................................... 27
9.
SLUDGE THICKENING ................................................................................................. 29
10.
SLUDGE AEROBIC DIGESTERS................................................................................ 32
11.
SLUDGE DEWATERING ........................................................................................... 34
12.
SLUDGE THERMAL DRYING .................................................................................... 37
13.
CHEMICAL PHOSPHOROUS REMOVAL .................................................................... 41
14.
ODOUR CONTROL ................................................................................................... 42
15.
SCUM & FOAM REMOVAL ........................................................................................ 46
16.
EFFLUENT OUTLETS ................................................................................................ 47
17.
ALLOWANCES FOR FUTURE PLANT EXPANSION .................................................... 48
Vol 3, Section 2
Process Specification
Page i of i
1.
Specifications
GENERAL PROCESS DESIGN REQUIREMENTS

The Process Specifications shall be read in conjunction with the Process Flow and Process and
Instrumentation Drawings nos. D7570-01-P100 to P114.
1.1
Process Elements
The following principal process elements shall be provided:
1.2
Inlet pumping station

Tanker reception facility complete with reception sump and transfer pumps.
Inlet works with flow measurement; emergency overflow, automatic fine screens with
screenings handling, washing, and compacting equipment, grit removal with collection
and washing, grease removal and collection;
Process tanks with mixers, aeration and recirculation systems, distribution chamber,
effluent collection channel and chemical dosing system.
Final Settlement Tanks with associated flow distribution, treated effluent and sludge
collection; RAS/SAS pumping station; and scum removal system.
Tertiary Treatment.
Chlorination downstream prior to a chlorine contact tank.
Treated final effluent (TSE) storage tank and TSE pumping station for irrigation
Long sea outfall.
Mechanical sludge thickening utilising gravity belt thickener and associated sludge
handling and polymer preparation and dosing.
Aerobic sludge digestion with aeration and mixing with outlet balancing tank.
Mechanical sludge dewatering utilising double decked gravity belt thickener/belt filter
presses or centrifuge and associated sludge handling, polymer preparation and dosing,
and sludge cake collection and storage.
Thermal sludge drying with associated sludge handling, collection and storage.
Odour treatment unit and associated fans, ductwork, covers, enclosures, etc.
Design Flows
The AMAS STP shall cater for Islands 3 to 14 flows. The average influent daily flow for Islands
3 to 14 is 39,680 m3/d when fully developed. An allowance of 50% shall be made in the design
for future plant expansion, giving a future influent average daily flow of 59,520 m3/d. The
process design flows for current and future flows are summarised in Table 1.1.
Table 1.1: Process Design Flows
Description
Units
Flow
Current Flows (Islands 3 14)

Average daily flow (ADF) (net of liquor returns)
Peak daily flow (PDF) (net of liquor returns)
Ultimate peak flow (PHF) (net of liquor returns)
Vol 3, Section 2
Page 1 of 49
m/day
39,680
l/sec
459
m /day
61,953
l/sec
717
m/day
85,319
l/sec
987
Specifications
Future Flows (Islands 3 19)

Average daily flow (ADF) (net of liquor returns)
Peak daily flow (PDF) (net of liquor returns)
Ultimate peak flow (PHF) (net of liquor returns)
m/day
59,520
l/sec
689
m /day
92,851
l/sec
1,075
m/day
127,968
l/sec
1481
Sewage treatment plants are usually designed to treat the peak daily flow and any flows above
this would overflow to the sea via an outfall. Therefore flows up to 61,953 m3/d (92,851 m3/d
future) will receive full treatment and flows above this will receive preliminary treatment
(screenings, grit and grease removal) prior to discharge.
1.3
Flow Build-Up and Treatment Trains

Since AMAS is a new development, flows will build up over a period of time, based on the
domestic dwellings construction phases for Islands 3 to 14. It shall be assumed that 75%
occupancy will take place immediately after the completion date of each package. The
remaining 25% occupancy is expected to take place over 4 years after the completion of the
last scheduled package.
The evolution of flows determines the number and sizes of biological process trains as
indicated in Table 1.2. This enables flexibility in plant operation during the early stages of
flow build-up.
Table 1.2: Number and Sizes of Process Streams
Sewage Flows (75% Occupancy)
Islands 13 & 14 Average Daily Flow, m3/d
3
Islands 11 to 14 Average Daily Flow, m /d

3
9,999
17,904
Islands 9 to 14 Average Daily Flow, m /d
26,904
Islands 3 to 14 Average Daily Flow, m3/d
29,760
Islands 3 to 14 100% Occupancy Average Daily Flow, m3/d
39,680
STP Streams
Number of Trains
Average Capacity Per Train, m3/d
9,920
2No Process Trains Average Capacity, m3/d
19,840
29,760
39,680
The philosophy shall be to design the Biological treatment process in identical 9,920 m3/d
treatment capacity trains, i.e. 4 No. biological treatment streams of 9,920 m3/d capacity each
to treat the flows from Islands 3 to 14.
Vol 3, Section 2
Page 2 of 49
Specifications
Full provision shall be made in the design for the future addition of another 2 No. identical
streams (outside of this contracts scope) to cater for the flows from Islands 15 to 19, giving an
ultimate plant capacity of 59,520 m3/d average.
1.4
Design Loads
The plant shall be designed to treat the raw sewage with the characteristics presented in
Table 1.3.
Table 1.3: Influent Concentrations
Description
Average
Peak Month
95%ile
Maximum
Concentration Concentration Concentration Concentration
BOD
mg/l
238
286
368
428
COD
mg/l
471
565
759
800
Suspended
solids
mg/l
246
295
394
443
Total P
mg/l
TKN
mg/l
34
41
52
59
Ammonia
mg/l
22
26
32
40
Alkalinity
mg/l
250
286
FOG
mg/l
67
80
116
121
7.3
7.7
9.0
24 (min)
36 (max)
pH
Temperature
1.5
Units
Treated Effluent Quality
The effluent shall be treated to achieve a quality that will satisfy the end use requirements for
unrestricted reuse and also meet the stringent nutrient removal requirements associated with
marine discharge, as described in Table 1.4.
Table 1.4: Treated Effluent Standard
Parameter
Units
pH
Value
Basis
6.5 - 9
TDS
mg/l
3,500
Monthly average
TCOD
mg/l
40
95%ile
TBOD 5ATU
mg/l
10
95%ile
TSS
mg/l
10
95%ile
Turbidity
NTU
95%ile
Turbidity
NTU
Maximum
NH 4 -N
mgN/l
average
NH 4 -N
mgN/l
Maximum
Vol 3, Section 2
Page 3 of 49
Specifications
Parameter
1.6
Units
Value
Basis
Fats, oil and grease (emulsified)
mg/l
Monthly average
SO 4 2-
mg/l
300
Monthly average
Sulphide (S2-)
mg/l
0.5
Monthly average
Faecal Coliforms
MPN/100 ml
< 2.2
Monthly average
Viable Helminth Eggs
MPN/100 ml
<0.1
Monthly average
Parasitic Helminth worms
MPN/100 ml
Nil
monthly average
Chlorine residual
mg/l
0.5
average
Chlorine residual
mg/l
maximum
Total Nitrogen
mg/l
10
average
Total Nitrogen
mg/l
15
maximum
Total Phosphorus
mg/l
average
Total Phosphorus
mg/l
maximum
Sludge Quality
The sludge shall be treated to a standard suitable for re-use for landscaping and agriculture,
and for landfill disposal, as described in Table 1.5, in line with USEPA 503 guidelines for Class
A sludge grade.
Table 1.5: Treated Sludge Standard
Description
Units
Value
>90
% reduction
>40
mgO 2 /hour/g total

solids
<1.5
Faecal coliform bacteria
MPN/g DS
<1,000
Salmonella
MPN/4g DS
<3
Helminth ova
No./4g DS
<1
Enteric viruses
PFU/4g DS
<1
Dry solids (DS)

Volatile solids
o
Specific Oxygen Uptake Rate for biosolids at 20 C
1.7
Odour Quality
There shall be no odour nuisance from the STP to the nearby communities. Odour treatment
shall therefore achieve the following standard:
5 OU on a 99.8%ile 1 hourly averaging basis measured at the nearest receptor, based on BS
EN 13725:2003 standard odour control method.
Vol 3, Section 2
Page 4 of 49
2.
Specifications
INLET PUMPING STATION (Terminal Lift Pumping station)

Sewage from AMAS will be collected via a new sewerage system to be constructed (by others)
concurrently with the STP. The primary sewerage network comprises shallow and deep gravity
sewers terminating at Island 13c with a 1200mm diameter sewer at an invert level of
approximately -11.610m. The Inlet Pumping Station is to be constructed under the STP
Contract to lift the flows from the deep gravity sewer to the inlet of the STP. A high degree of
coordination and cooperation will be required with the sewer contractor during design and
construction and the pumping station.
Note that the location of the Inlet Pumping Station is fixed as indicated on the drawings based
and ensuring a safe distance from the underlying Alat aquifer and associated Water Resources
Directorate approvals.
The pumping station shall be designed to cater for the current design flows listed in Table 1.1.
The following is proposed for the design of the pumping station:
Table 2.1 summarises the design parameters and requirements of process units used as part
of the Inlet Pumping Station.
Table 2.1: Inlet Pumping Station
Item
2.1
Process stage
Inlet Pumping
Station
Sub Category
Inlet Screen
Design Criteria
Process Output
Minimum number of duty

units: 1
Protection
of
pumps
from
damage by coarse
material and debris
from the sewerage
system
Type: Mechanically raked bar

screen
Maximum aperture: 40 mm
By-pass
Inlet Screenings
Washer /
Compactor
Peak capacity: 987 l/s

Hydraulic by-pass to be
provided for the Inlet Screen
for automatic by-pass in case
of blockage
Number: 1
Type: Washpactor or
equivalent
Capacity per unit: to be
agreed based on flowrate,
bar spacing and supplier
local experience
Washer:
Must wash organic material
from screenings. Washed
screenings must have a BOD
of less than 20 mg/g of dry
solids
Compactor:
Must achieve a minimum
screenings solids content of
40%ds.
Vol 3, Section 2
Page 5 of 49
Clean, dewatered,
disposable
end
product with a
minimum dry solids
content
of
the
washed screenings
product of 40 %
and a BOD of less
than 20 mg/g of
dry solids
Item
Process stage
Sub Category
Station
Specifications
Design Criteria
Process Output
Type: Dry well (dry installed

pumps)
Full duty/standby
wet
wells
and
rising mains
Wet well:
wet wells
Twin duplicate
Rising mains: Twin duplicate

with flow measurement
Lift Pumps
Number of pumps: 3/wet

well (total 6)
To lift flows to the

inlet works
Mode of Operation:
Duty/assist/standby
(may be operated
duty/assist/assist if one
rising main out of service)
System
to
be
designed
with
maximum flexible
to deal with daily,
weekly
and
seasonal
flow
variations as well
as lower start-up
flows.
Capacity: 329 l/s each

Indicative total head: 35m
Type: Variable speed
On-line
Monitoring
Minimum number of on-line

monitoring instruments for
each parameter:1
Early warning of
high acid/alkali in
sewerage system
Parameters to be monitored:
pH
Located in common inlet
Odour Control
3.
See Section 14
TANKER RECEPTION FACILITY

A tanker reception facility shall be provided to receive sewage from AMAS in the early days of
plant operation, in the event that the sewerage network is not connected to the STP or some of
the new dwellings are not connected to the sewerage network.
of the tanker reception facility.
Vol 3, Section 2
Page 6 of 49
Specifications
Table 3.1: Tanker Reception Facility Description

Item
3.1
Process stage
Tanker
Reception
Facility
Sub Category
Delivery area
Design Criteria
Process Output
Number of tanker unloading

stations: 6
c/w Bauer type connections
with Camlock fittings and
vent
valves,
washdown
facility of tanker delivery
area
Delivery sump
Number of delivery sumps: 1

Volume: 330 m3
Transfer pumps

pumps: 1
Minimum number of standby
pumps: 1
Transfer
sewage
from delivery sump
to the inlet works
Pump duty: 200 l/s
4.
INLET WORKS PRELIMINARY TREATMENT AND TANKER RECEPTION FACILITY

Flows from inlet pumping station and tanker delivery sump will be transferred to the inlet works
comprising of screenings, and grit/grease removal.
The raw sewage shall first be screened through inlet screens to remove any solids greater than
6mm. The screenings shall then be washed to reduce the quantity of odorous material and
compacted in dedicated units, before being discharged to skips for off-site disposal.
The pre-screened sewage shall flow by gravity into aerated grit channels for grit and grease
removal. The accumulated grit shall be pumped to grit classifiers where it shall be washed and
discharged to a skip for off-site disposal. Grease shall be discharged to a skip or tank.
From the grit channels, sewage shall pass to a distribution chamber which divides the flow into
equal streams for secondary biological treatment.
of the preliminary treatment stage.
Table4.1: Inlet Works Description
Item
4.1
Process stage
Inlet Flow
Measurement
Vol 3, Section 2
Sub Category
Design Criteria
Type: Electromagnetic
Number: One per inlet pipe
Page 7 of 49
Process Output
Item
4.2
Process stage
Raw Influent
Sampling
Sub Category
Sampler
Specifications
Design Criteria
Type: Automatic refrigerated
programmable
composite
and spot sampler
Minimum
samplers: 1
On-line
Monitoring
4.3
Inlet Chamber
4.4
Emergency
Overflow
Process Output
number
Sampling
sewage
of
raw
of
Minimum number of on-line

monitoring instruments for
each parameter:1
pH
Chamber shall be sized to
receive all incoming flows
(inlet pipelines, flows from
tanker
reception
facility
return
liquors)
Plus
allowance for future inlet
connection.
Overflow weir to be provided
in the event of total plant
failure or inlet flow exceeding
design Ultimate Peak Flow
Inlet Works to overflow to
the outfall.
4.5
Inlet Screens
Screens

units: 2
units: 1
Type: Band screens
perforated plates
4 channels to be
provided
(the
fourth closed off
for future)
with
Maximum aperture: 6 mm
Peak capacity: 494 l/s per
screen (excluding return
liquors)
Inlet Screenings
Washer /
Compactors

units: 1
units: 1
Type:
Washpactor
equivalent
or
Indicative capacity per unit:

2m3/h
Washer: Must wash organic
Vol 3, Section 2
Page 8 of 49
Clean, dewatered,
disposable
end
product with a
minimum dry solids
content
of
the
washed screenings
product of 40 %
and a BOD of less
than 20 mg/g of
dry solids
Item
Process stage
Sub Category
Specifications
Design Criteria
Process Output
material from screenings.

Washed screenings must
have a BOD of less than 20
mg/g of dry solids
Compactor: Must achieve a
minimum screenings solids
content of 40% ds.
Compactor
by-pass
with
direct chute to screenings
skip to be provided in the
event of compactor failure.
4.6
Grit / Grease
Removal
Inlet Screenings
Collection
Inlet screenings shall be

collected directly into a large
screening bag or into a skip
lined with a plastic liner, for
ease of transport and off-site
disposal and to minimise the
development of unpleasant
odours.
Grit Channels

units: 2
Type: Aerated Grit Channel
Hydraulic Capacity: 987 l/s
per channel (excluding return
liquors)
Retention time: not less than
10 minutes per tank at peak
flow (grease removal).
Indicative Peak grit load:
ultimate 2,559 kg/d for
Phase 1.
Indicative average grit load:
1,200 kg/d.
Minimum grit removal: 95%
of all grit down to 200
microns.
Minimum
grit
particle specific gravity of
2.65.
Design of the aerated grit
channel should maximise the
level of fine sand removal to
prevent settlement within the
anaerobic and anoxic zones.
Vol 3, Section 2
Page 9 of 49
Removal of more
than 95% of all grit
down
to
200
microns. Minimum
grit particle specific
gravity of 2.65.
Item
Process stage
Sub Category
Grit pumps
Specifications
Design Criteria
Process Output

units: 1 per grit channel
Removal of grit
from aerated grit
channels

units: 1 per grit channel
Type: airlift pumps or grit
pumps or screw conveyor
and grit pumps (depending
on manufacturer)
Indicative capacity: 21.16 l/s
each nominal to suit classifier
capacity. Capacity to be
chosen to get a reasonable
scour velocity.
Hopper flushing using
Recycled Effluent (RE) shall
be provided to fluidise the
settled grit during the grit
pumping stage and prevent
rat holing and grit build up
within the hoppers.
A flushing line shall also be
included on the suction side
of each grit pump which shall
allow the grit pumps and
transfer lines to be flushed
through with clean water to
prevent deposition of grit
within the pipelines during
pump idle time.
Grit blowers

units: 1, i.e. 1 No. blower
can feed both grit channels
units: 1
Indicative capacity: 1791
m3/hr nominal but Contractor
to select (depending on
manufacturer)
Grit aeration
Type: Coarse bubble, swingarm wide band diffusers

Indicative
m3/hr/m
operation
Vol 3, Section 2
air
for
Page 10 of 49
flow: 36
average
Air supply for grit

and
grease
removal
Item
Process stage
Sub Category
Grit classifier/
washers
Specifications
Design Criteria
units: 1
units: 1
Type: Screw Classifier with
washing or equivalent
Minimum Capacity: 21 l/s
each
Minimum organics removal:
95%
Grit Collection
Grit shall be collected directly

into a large grit bag or into a
skip lined with a plastic liner,
for ease of transport and offsite disposal and to minimise
the
development
of
unpleasant odours.
Grease Removal
Grease removal shall be

combined with grit removal
in the aerated grit channel.
The design shall be based on
the specialist suppliers best
design
experience
to
maximise
FOG
removal
(design shall be supported by
reference plant data)
Grease tank
Minimum number of grease

tanks: 1
Minimum storage capacity: 7
days
Tank to be fitted with Valve
and bauer coupling for
removal of grease by tanker
and include washing down
facility and drainage.
Vol 3, Section 2
Page 11 of 49
Process Output
Removal
organics no
than 95%
of
less
Specifications
5. SECONDARY TREATMENT BIOREACTORS and FINAL SETTLEMENT TANKS

The secondary treatment system shall be based on the activated sludge process (ASP) modified
for nitrogen removal. Organic constituents in the sewage shall be removed through biological
activity. Each bioreactor shall have anoxic and aeration zones and an upstream selector. The
influent sewage enters the selector and is mixed with RAS. From there it enters the anoxic
zones where it is mixed with recycled biomass (A recycle) from the aerobic zone to remove
nitrates. The sewage then flows to the aerobic zone for BOD and ammonia removal.
The bioreactors shall be equipped with mixers in the anoxic basins to keep solids in suspension,
and fine bubble air diffusers in the aeration tanks. Each bioreactor shall have dedicated sets of
submersible recycle pumps.
A facility to dose ferric chloride to the bioreactors shall be provided for phosphorous removal.
The plant configuration shall allow for the plant to be adapted to either chemical or biological
phosphorus removal. To maintain the correct alkalinity balance when dosing with ferric
chloride for P removal, provision for dosing caustic soda to the bioreactors shall also be
provided.
Flow from the bioreactors will then gravitate to the final settlement tanks (FSTs). To control the
sludge blanket in the FSTs, sludge must be transferred from the FSTs back to the selectors.
This shall be achieved with a set of duty/standby return activated sludge (RAS) pumps. It is
proposed for the surplus activated sludge (SAS) to be wasted directly from the bioreactor. This
will allow more accurate control of the sludge age as the chemical dose changes. This can be
achieved by pumps from each lane or gravity discharge via an actuated penstock in the effluent
channel of the bioreactors, prior to flow splitting to the FSTs.
Phosphorous can be removed in an ASP via biological methods or via chemical precipitation.
Bio-P removal is most effective with strong wastes with a high readily biodegradable COD
(rbCOD) fraction. For weak waste waters, as may be expected at AMAS, care must be taken to
ensure that this rbCOD is not used preferentially in dentrification.
The ASP design shall, therefore, be based on maximising the carbon for N-removal, with
chemical dosing for P-removal. The plant shall however also include the facility to allow Bio-P
removal, should the waste be suitable. A possible configuration is illustrated in Figure 4.1
below. The lower part of the diagram shows the configuration for N-removal and chemical Premoval. The upper part of the diagram shows that by moving the discharge point of the
mixed liquor recycle and extending the unaerated fraction, a configuration to promote
biological P-removal can be achieved. The first zone prior to the recycle discharge is now
anaerobic and will promote the growth of P-removing organisms. The Contractor may make
his own proposals for complying with the specified requirement for flexibility in the method of P
removal (chemical, biological, combination of each) with aim of minimising chemical
consumption.
Vol 3, Section 2
Page 12 of 49
Specifications
Figure 5.1: ASP Configuration
Anoxic Zones
The anoxic basins are operated in an oxygen deficient mode requiring the bacteria in the
biomass to use the nitrates (NO 3 -N) in the returned sludge as their oxygen source to sustain
their activity. The stripping of the oxygen from the nitrate compound results in the release of
nitrogen gas molecules and its removal from the waste stream. The anoxic basins also perform
the task of providing some foam control by inhibiting the growth of filamentous bacteria.
The nitrification process consumes alkalinity. The main way to minimise alkalinity depletion is
to provide sufficient denitrification in the anoxic zone to recover the alkalinity, as for each g of
nitrate converted to nitrogen gas 3 g of alkalinity is recovered.
The level of denitrification is governed by four factors:
Anoxic mass fraction of the reactor

Degree of nitrates recycled back to the reactor by the Mixed Liquor Recycle (MLR)
pumps (as discussed this may be from the end of the aeration zone/tank)
Temperature; like most biological processes the denitrification rate is temperature
dependent and so it is important that the anoxic zone sizing is based on the minimum
reactor temperature of 24oC
COD fractionation; the higher the level of ready biodegradable soluble COD, the quicker
the denitrification rate.
The anoxic volumes for alkalinity recovery and for achieving the total nitrogen standard must
be sized based on dynamic modelling.
Baffling of the anoxic basins shall be installed to create multiple zones to be operated in series.
Submersible mixers provide agitation to keep the contents of the basins in suspension.
Vol 3, Section 2
Page 13 of 49
Specifications
Aeration Zones
The aeration system shall be a membrane diffused aeration system. It will be required to
provide full-floor coverage in a tapered pattern. This will provide greater air (oxygen) at the
start of the basins to match the oxygen demand of the mixed liquor as it exits the anoxic zone.
The later portion of the basins shall have a lower concentration of aeration devices providing
air to assure mixing while being adequate to provide nitrification. A minimum of 2 separate
grids shall be provided per basin to allow adjustment of the air flow to the grid based on the air
demand in that portion of the basin. This will allow the Dissolved Oxygen (D.O.) at the start of
the aeration basin to be controlled at 2.0mg/l and the D.O at the end of the tank to be
controlled at 0.5-1.0mg/l to thus reduce the D.O. of the internal mixed liquor recycle and
aeration costs.
By configuring the bioreactors in a U shape, a plug flow pattern can be created, optimising the
performance of the reactors for nitrification. The U shape also allows the MLR A recycle to
occur through or over the wall.
In the case of diffused aeration system, the blowers, air piping and diffuser grid, must be sized
to provide sufficient air for aerobic treatment of the influent sewage under PHF conditions as
well as when one treatment train is out of service. The design must take into account operation
during the summer (bioreactor MLSS temperature = 36C) as well as during colder conditions
(bioreactor MLSS temperature = 24C).
The design of aeration systems is commonly based on maximum month loading conditions,
with one bioreactor off-line for maintenance purposes, i.e. the peaking factor is 1.2 x 4/3 =
1.6. Thus ensuring that sufficient aeration is installed to cope with the design 95%ile influent
concentrations.
The aeration blowers shall be sized on the peaking factor of 1.6, maximum ambient air
temperature (55 degrees Celsius) and MLSS temperature (36 degrees Celsius) and the
maximum relative humidity (100% RH). Fine bubble diffusers of the membrane (EPDM) type
configured in a full floor grid pattern shall be installed. Separation of the grid pattern into
several diffuser grids with isolation valves on the drop lines allows the air to be more efficiently
applied where it is needed for treatment. Ten-percent spare diffusers (including membrane
disks and holder components) shall be provided for quick replacement.
of the secondary biological treatment stage.
Vol 3, Section 2
Page 14 of 49
Specifications
Table 5.1: Bioreactors Description

Item
5.1
Process
Stage
Bioreactor
Sub
Category
Tanks
Design Criteria
Number: 4 lanes
Type: double-pass arrangement (Ushape) for each bioreactor
Indicative sizing:
Volume: 11,400 m3 per bioreactor
Bioreactor length: 49m
Bioreactor width: 35m (7.5m per pass)
Water depth: 6.5m
Zones per bioreactor: 7 (4 anoxic, 3
aerobic)
Process Output
To
provide
biological treatment
of peak daily flow
Total sludge age: 9.5 days

Mode of Operation:
Plug flow with internal recycle, from
end of aerobic zone to the start of the
anoxic zone 1.
Weir inlet and outlet arrangement
must allow free passage of foam
through the ASP for eventual collection
and removal from the FSTs.
5.2
Selector Zones
Zones
Number: 2 (1 per bioreactor feeding 2

lanes)
Designed as a channel to transport the
combined wastewater and RAS flow
from the distribution chamber to the
inlet of the anoxic zone.
Indicative sizing:
Length 49m
Width 3m
Depth 3m
Mixers
Number: 1 per zone

Minimum mixing energy input: 5 W/m3
Type: Submersible, turbine/propeller
Vol 3, Section 2
Page 15 of 49
To keep solids in
suspension
Item
5.3
Process
Stage
Anoxic Zones
Sub
Category
Zones
Specifications
Design Criteria
Process Output
Number: 2 per lane
For denitrification
Indicative sizing:
Volume: 1,924 m3 per lane
Dimensions of each zone:
Depth 6.5m
Length 18.5m
Width 8m
Zones separated by internal baffle
walls. Baffle walls shall finish below
outlet weir level to allow pass forward
of foam and scum to the aerobic
zones.
Baffle walls shall have bottom orifices
so that flow is both through orifices
and over the top of the baffle.
Mixers
Number: 1 per zone (8 total)

Minimum mixing energy input: 5 W/m3
To keep solids in
suspension
Type: Submersible, turbine/propeller

5.4
Aerobic Zones
Zones
Indicative sizing:
For
BOD
and
ammonia removal
Number: 3 per lane

Volume: 3,120 m3 per lane
Dimensions:
Depth 6.5m
Length 60m total
Width 8m
Zone sizing to be
refined
during
detail design to
provide best taper
and balanced air
flow
Aerobic mass fraction: 0.6

Maximum design MLSS concentration:
3,500 mg/l at maximum monthly load
Minimum
aeration
temperature: 24oC
basin
MLSS
Maximum
aeration
temperature: 36oC
basin
MLSS
Maximum design air humidity: 100%

RH
Maximum ambient temperature: 550 C
Aeration
Diffusers
Vol 3, Section 2
Type: Fine Bubble Diffused Aeration

(FBDA) with full floor coverage and
multiple grids aeration
Page 16 of 49
To provide mixing
to prevent solids
settlement
and
meet peak SOTR
Item
Process
Stage
Sub
Category
Zone DO
Control
Specifications
Design Criteria
Process Output
1 DO probe per zone plus

1 modulating air control valve per zone
to control DO.
Maintain
tight
control of aerobic
zone DO in order to
maintain
optimal
ammonia removal
and
minimise
aeration energy.
DO set points:
Zone 1 minimum DO: 2.0mg/l
Zone 2 minimum DO: 0.5 - 2.0mg/l
(depending upon ammonia trim
control)
Type of DO probe:
Dissolved Oxygen (LDO)
Luminescent
1 Ammonia probe in the middle of the

last aeration zone to detect complete
nitrification and automatically reduce
the DO set-point in that zone until the
air flow is at the minimum mixing level
Type
of
wavelength
ammonia
probe:
UV
1No flowmeter on main air header

Design alpha factor,
3,500mg/l
MLSS concentration: 0.65
based
on
Maximum Oxygen Transfer Efficiency,

OTE: 5.5 %/m (including fouling
factor)
Blowers
Minimum number of duty blowers: 5

Mode of operation: 4No duty/1No
standby
Indicative nominal peak air flow rate to
bioreactors: 19,210 Nm3/hr
The blowers shall have the same
capacity.
Blower
Type
Type: centrifugal
Blowers to be variable output, feeding
into a common header, incorporating
appropriate isolation valves, discharge
silencers, inlet silencers, filters, and
Maximum
acoustic
enclosures.
discharge pressure: Not to exceed
manufacturers requirements.
Maximum discharge temperature: Not
Vol 3, Section 2
Page 17 of 49
To provide aeration
for the bioreactors
Item
Process
Stage
Sub
Category
Specifications
Design Criteria
Process Output
to exceed 80C (or lower limit specified

by the diffuser supplier) at bottom of
down pipe. Heat exchangers to be
provided on the discharge line
accordingly.
To
safeguard
process and diffuser
system
Pipes external to the tank to be

stainless steel and protection to be
provided
due
to
high
surface
temperature.
Blower + Design and construction of the blower
pipework
and associated pipeline systems shall
ensure that resonant frequencies are
Noise
critically damped throughout the
operating range of the aeration
system.
Max air velocity through pipework:
12m/s (to prevent noise).
Acoustic enclosures on each blower,
with access doors for easy access for
maintenance.
On-line
Monitoring
< 85dBA at 1m
Minimum number of on-line monitoring

instruments for each parameter: 1
pH
MLSS
Temperature
Ammonia (UV type)
DO (Luminescent type)
5.5
A Recycle
pumps
Pumps
Number: 2 per bioreactor (8 No. in

total)
Mode of operation: Duty/standby
Type: Axial flow / canister pumps
Indicative capacity: 694 l/s per pump
peak
All pumps on variable speed drives to
allow adjustment of recycle rate.
Duty pump speed linked to influent
flow meter so that recycle rate reduces
overnight and increases during the
day. A facility to monitor and control
the A recycle via nitrate monitors
positioned on the tertiary filter outlet
Vol 3, Section 2
Page 18 of 49
To transfer MLSS
from the end of
aerobic zone 1 to
the start of anoxic
zone 1 in order to
achieve
denitrification.
Item
Process
Stage
Sub
Category
Specifications
Design Criteria
Process Output
shall also be provided.

Discharge pipe to be submerged to
prevent air entrainment.
Maximum
design
MLSS
concentration: 3,500mg/l
5.6
Final
Settlement
Tank (FST)
Tanks
solids
Number: 3 (with provision to add a

fourth tank at a later date)
Separation
&
removal of solids
Type: Circular settlement tank with

peripheral v notch weir, sludge
scrapers
and
scum
skimming,
collection and removal system.
Indicative sizing:
Diameter 39 m per tank
Side wall depth 4 m
Floor slope 6.5 o
Maximum
design
MLSS
solids
concentration at MML: 3,500 mg/l
Maximum
design
concentration
at
3,500mg/l
MLSS
average
solids
load:
Mixed liquor flow from each bioreactor

is to be combined in a common inlet
channel and split evenly via a flow
distribution chamber.
An energy-dissipating inlet (EDI) inside
a 20% diameter diffuser drum,
provided with scum
suppression/removal systems,
accessible from the scraper bridge is
required.
The launders shall be internal with vnotch weirs. Scum boards shall be
fitted to prevent discharge of scum
with the clarified effluent.
Isolation at inlet to each tank using
penstocks in the distribution chamber.
Auto-Desludging
Vol 3, Section 2
Number: 1 per tank

Type: Actuated telescopic bellmouth in
sludge draw-off chamber.
Page 19 of 49
Desludging of Final
Tanks
Item
5.7
Process
Stage
RAS/SAS
Pumping
Station
Sub
Category
Scum
removal
Wet Well
RAS
Pumps
Specifications
Design Criteria
Automatic system for surface scum
collection and removal to be provided.
System shall include a full surface
scum skimmer and high capacity
collection system.
Scum to be discharged to the aerobic
digester or alternative treatment
system proposed by the Contractor.
Number: 1
Number: 2
Type: Submersible, variable speed,
centrifugal.
SAS
Pumps
Mode of Operation:
Duty/standby
Number: 2
Type: Submersible, variable speed,
centrifugal.
Mode of Operation:
Duty/Standby
Vol 3, Section 2
Page 20 of 49
Process Output
To house 2 No RAS
and 2 No SAS
pumps and allow
sufficient
storage
volume to avoid
excessive
pump
starts.
Maintain
blanket
level in FSTs to
within
required
range. Return RAS
upstream of the
Selector Tank.
Waste
surplus
activated sludge to
sludge
treatment
process.
6.
Specifications
TERTIARY TREATMENT
To consistently meet low effluent solids and nutrient levels, and to achieve high level
disinfection, it is necessary to minimise the solids in the effluent that can shield pathogens from
the effects of chlorine or ultraviolet light. Tertiary filtration effectively strains the solids out prior
to disinfection.
Conventional media filtration is the preferred filtration option for AMAS STP. It is a robust
process that is well established internationally and in the Middle East.
Upstream chemical dosing with ferric and polyelectrolyte is to be employed to meet the tight
phosphorus, turbidity and parasite standards.
Rapid dispersion of coagulant is essential to ensure maximum efficiency to ensure that the
quantity of chemicals required is minimised. In turn this keeps solids loading levels low and
cost of chemicals minimised. Mechanical mixing shall be supplied accordingly.
In order to promote high hydraulic loading rates, strengthening of floc can be carried out
though the addition of a small quantity of polyelectrolyte.
The chemical selected for upstream conditioning is dependent upon the function of the
filtration system. Ferric is the preferred choice for P-removal and can be dosed from the main
storage and dosing facility.
Depending upon the quality of the secondary effluent from the FSTs, it may be possible to
dispense with the chemical dosing altogether and rely on capturing the biological floc already
formed.
Disc filtration may also be considered as an alternate filtration method, particularly as it
provides a lower footprint solution. Disc filtration may be considered suitable if the Contractor
is able to present sufficient process performance guarantees and justification for this
alternative to be adopted over conventional filtration.
Conventional filtration uses a bed of media to capture suspended particles. Head loss through
the media increases over run time, as particles accumulate in the media bed. To remove the
particles from the media, a filter cell is taken out of service and backwashed with filtered water.
The waste from the backwashing is contained in a storage tank prior to return to the head of
the plant for treatment.
Conventional filters may be dual media or single media. Where solids blinding is a concern a
dual media system (provision of a coarse layer of anthracite above the sand layer) is
recommended. However, following the high level of secondary treatment proposed for these
works a single media sand filter is considered appropriate.
Clean and dirty backwash tanks are to be provided, to allow backwashing of the filters.
Table 6.1 summarises the design parameters and details of the process units used for Tertiary
Treatment
Vol 3, Section 2
Page 21 of 49
Specifications
Table 6.1: Tertiary Treatment Description

Item
6.1
6.2
Process
Stage
Coagulation
Tertiary
Filtration
Sub
Category
Tanks
Mixers
Sand Filters
Design Criteria
Number of tanks: 1
Indicative sizing:
Total working volume: 77 (83.4)m3
Tank dimensions:
Depth: 6 m
Width: 4 m
Length: 4 m
Mixer type: Paddle
Peak filtration rate :
All cells in operation = 7.1 m/h
1 cell out backwashing = 8.1 m/h
Filter Configuration: Single
Indicative sizing:
Number of units: 8
Filter bed length: 7
Filter bed width: 7
Bed type: twin
Media
Media depth: 2 m
Media type: Sand
Media effective size: 1.8 mm
Depth from media surface to top of
washout weir:
Filter
inlet
and
distribution
Minimum 500 mm Contractor to

confirm & note the effect of TWL on
b/w flow rate
Free discharge into each filter to allow
individual control of filters based upon
level.
Even hydraulic split between
filters.
Overflow bypass to pass flows to the
outlet channel and thus to the effluent
pumping station, flows will then be
diverted to the outfall.
Underdrain
arrangement
Monolithic Concrete Floor or proprietary

floor
Nozzle specification : Contractor design
Control
Filter control basis: Level

Backwash initiation:
In order of priority operator over-ride,
outlet turbidity, headloss, throughput,
time.
Vol 3, Section 2
Page 22 of 49
Process Output
Item
6.3
Process
Stage
Backwash
System
Sub
Category
Indicative
Backwash
Regime
Specifications
Design Criteria
Process Output
Backwash: combined air and water

Main backwash rate 30 m/h
High rate rinse rate: 60 m/h
Air scour: 70 m/h
Design backwash water per wash:
294 m3
The backwash system shall include
chlorination of the backwash water to
control growth of algae and parasites in
the filters.
Backwash
Pumps
Number pumps:2 (duty/assist/standby)

Type pump: Centrifugal VSD
Indicative peak output: 2,940 m3/h
Dirty bed headloss 3.7 m
Air
scour
Blowers
Number blowers: 2 (duty/standby)

Indicative peak output: 3,430 m3/h
Temperature compensation is required
on the pump output to ensure the
correct bed expansion across the
operating temperature range of the
plant.
Clean
backwash
water Tank
Dirty
backwash
tank
Dirty
backwash
Mixers
Vol 3, Section 2
Number tanks: 1
Indicative sizing:
Working Volume: 590 m3
Width 9 m
Length 19 m
Minimum depth 3.5 m
Floor slope 1o
Number tanks: 2
Indicative sizing:
Working Volume: 577 m3 each
Width 9 m
Length 19 m
Minimum depth 3.5 m
Floor slope 1o
Number mixers: 2
Power: 5 kW
Page 23 of 49
(May be combined with

the Return Liquors
Pumping station)
Item
6.4
6.5
Process
Stage
Filter effluent
Quality
Tertiary
Effluent
Pumping
Station (if
required
subject to
hydraulic
design)
Vol 3, Section 2
Sub
Category
On-line
Monitoring
Tertiary
Effluent
Pumps
Specifications
Design Criteria
Process Output
Minimum number of on-line monitoring

instruments for each parameter: 1
Turbidity
Nitrate
Phosphorous
Number of pumps: 3
Mode of Operation: Duty/assist/standby
Capacity: 386 l/s each
Space shall be allowed in the pumping
station for a minimum of 1 No. extra
duty
pump
to
serve
future
requirements
Page 24 of 49
To lift flows to chlorine

contact tank
(if required)
7.
Specifications
DISINFECTION
Disinfection shall be provided by chlorine gas injection to ensure compliance with
microbiological standards and to provide a residual chlorine concentration for the inhibition of
bacterial and algae growth in the TSE storage and distribution system. Effluent from the filters
shall be chlorinated with chlorine gas solution prior to entering a chlorine contact tank which
will include suitable baffling to provide adequate contact time for disinfection.
After disinfection, the treated effluent will be stored in a TSE storage tank for onward
distribution to the irrigation system via a final effluent pumping station.
Table 7.1 summarises the design parameters and details of the process units used for the
disinfection of biologically treated sewage.
Table 7.1: Description of Disinfection
Item
Process Stage
7.1
Chlorine Dosing
System
Sub
Category
Dosing
Design Criteria
Chemical: Chlorine gas
Expected disinfection dose range: 2-8
mg/l,
Expected average disinfection dose:
7.5 mg/l
Indicative
average
disinfection
chlorine gas consumption: 150 kg/d
Indicative maximum chlorine draw-off
rate: 20 kg/h at 20C
Storage
Chlorine drum storage room to be

temperature-controlled to maintain
room at >20C to guarantee
maximum gas draw-of rate.
Storage type: chlorine drums or bulk
storage
Storage period: 21 days
Max number of on-line drums: 16
Total number of drums: 16 duty and
16 standby.
Total storage capacity: 6,400kg
Disinfection
chlorine
dosing
control
Mixing of chemical with main process

stream is to be achieved using a
static mixer or alternative proprietary
mixing system providing equivalent or
better performance.
Dosing is to be flow paced using a
flowmeter on the Tertiary Filter
outlet.
Vol 3, Section 2
Page 25 of 49
Process
Output
Disinfection of
final effluent
Item
7.2
Process Stage
Chlorine Contact
Tank
Sub
Category
Tank
Specifications
Design Criteria
Chlorine residual to be sampled and
measured
by
on-line
chlorine
analysers which will trim the chlorine
dose to achieve the set residual
chlorine concentration.
Number: 2
Retention time at maximum future
flow (ultimate peak flow): 49 min
Tank arrangement: double-pass (Ushape)
Indicative sizing:
Capacity: 2,278 m3
Length: 26.13 m
Width: 8.71 m (4.35 m per pass)
Depth: 5 m
Tank shall be covered to restrict algae
growth
and
protect
against
contamination from external sources.
Internal
requirements
Vol 3, Section 2
Flow: The flow should be purely

serpentine, with internal baffles to
promote plug flow
Page 26 of 49
Process
Output
Capacity
shall
be sized for
future
plant
extension
8.
Specifications
TSE STORAGE TANK AND PUMPING STATION

After disinfection, the treated effluent shall be stored in a TSE storage tank for onward
distribution to the irrigation system via a final effluent pumping station or to sea via the long
sea outfall. The TSE storage tank is required to balance the flows to suit the diurnal irrigation
demand. Table 8.1 summarises the design parameters and details of process units used for
the balancing and pumping of final effluent.
The sea outfall is to be provided under this contract along with the on-site section of the TSE
distribution pipeline. The latter will terminate/connect at a point to be agreed in the vicinity of
the site boundary to the network irrigation pipeline being provided under a separate contract.
A set of pumps should also be provided to feed a final effluent ring main which will provide TSE
to a number of process applications such as washwater for the sludge dewatering units, cooling
water for dryer exhaust air, inlet screens washwater, on-site irrigation system, etc.
Table 8.1: Description of TSE Storage Tank and Pumping Station
Item
8.1
Process Stage
Sub
Category
Effluent Storage
Tank
Process
Output
Design Criteria
Number of storage tanks: 1
Retention time at average flow: 6
hours for current flows
Minimum Capacity: 10,000 m3
To
balance
flows
going
forward to the
TSE
irrigation
network
Minimum number of compartments:

2, to enable isolation of 1 No.
compartment in the event of
maintenance
Tank shall be covered to restrict algae
growth
and
protect
against
contamination from external sources.
8.2
TSE
Pumping
Station
Treated
Sewage
Effluent
(TSE) Pumps
Minimum number of pumps: 3

Mode
of
Duty/assist/standby
Operation:
Capacity: 230 l/s

Max. pressure: 7.5 bar
Mode of operation: auto control to
maintain pressure at set-point
Space shall be allowed in the
pumping station for a minimum of 1
No. additional duty pump to serve
future requirements
Vol 3, Section 2
Page 27 of 49
To pump TSE to
the
irrigation
network
Item
8.3
Process Stage
Washwater
Sub
Category
Washwater
Ring
Main
Pumps
Specifications
Design Criteria
Minimum number of pumps: 3
Mode of operation:
Duty/assist/standby
Process
Output
To feed
effluent
main
final
ring
Sampling
effluent
of

Capacity: Contractor to design to
meet demand from different plant
applications.
Operating pressure: 6 bar
8.4
8.5
TSE Flow
Measurement
TSE Sampling
Type: Electromagnetic
Number: One on each TSE outlet
(including irrigation, sea outfall and
washwater)
Sampler
Type:
Automatic
refrigerated
programmable composite and spot
sampler
Minimum number of samplers: 2
i.
TSE to irrigation
ii. Effluent/emergency overflows
discharged to the Outfall
Vol 3, Section 2
Page 28 of 49
9.
Specifications
SLUDGE THICKENING
A proportion of the wasted sludge (SAS) will be thickened on a gravity belt thickener (GBT) and
then blended with unthickened SAS in a mixing and storage tank, to achieve a target solids
feed to the aerobic digester of 1.5%. Alternative arrangements may be considered, such as inline mixing with progressive cavitation pumps or the thickened and unthickened sludge fed
direct to the aerobic digester. In this latter arrangement the bypass feed pump would be on a
direct control loop from the aerobic digester solids monitor.
The GBT requires a constant flow of washwater. TSE shall be used for washing, taken from
either the site washwater system or a dedicated system for the belts. Filtrate from the belts
shall not be used for belt washing.
Table 9.1 summarises the design parameters and details of process units used to thickener
the sludge.
Table 9.1: Description of Sludge Thickeners
Item
9.1
Process
Stage
Unthickened
SAS Tank
Sub
Category
Tank
Design Criteria
Number: 1
hours for current flows (3.3 hrs for
future flows)
Process
Output
To balance SAS
feed
to
the
dewatering
units
Capacity: 246 m3
Aeration
Air mixing requirement: 1.8 Nm3/m3.h

Indicative air flow: 810 Nm3/h
9.2
Thickening
System
Thickening
units
Type: gravity belt thickener

Number: 2
Indicative total Capacity: 117 m3/h
peak
98 m3/h average
Mode of operation: 1 duty/1 standby
Thickened sludge concentration: 6%
dry solids
Solids capture rate: 95%
Operating time:
24hours per day (based on peak
sludge flow)
Vol 3, Section 2
Page 29 of 49
To keep solids
in suspension to
ensure
consistent
quality of feed
sludge to the
thickening
system and to
keep
sludge
aerobic.
To thicken SAS
Item
Process
Stage
Sub
Category
Specifications
Process
Output
Design Criteria
7 days per week
Indicative washwater
920m3/d (Peak)
Thickener feed
pumps
requirement
Number: 2
Indicative capacity: 32.5 l/s peak,
27 l/s average
To
transfer
sludge from SAS
Tank to the
thickening units
Mode of operation: duty/standby

Type: positive displacement, variable
speed flow control
Common manifold to allow each
pump to feed each machine
9.3
Polyelectrolyte
Dosing System
Dosing system
Maximum polyelectrolyte dose rate: 6

kg/TDS
Number of polyelectrolyte make-up
and dosing systems: 1
To
condition
sludge prior to
thickening
Mode of operation: duty

Type: system to be suitable to use
both powder (25 kg bags) and liquid
polyelectrolyte
Powder
polyelectrolyte
make-up and
dosing tanks
Number of make-up tanks: 1 (duty)

Make-up tank retention time at
maximum polyelectrolyte demand: 1
hour at future flows
Polyelectrolyte
concentration: 0.5% w/w
make-up
Capacity of make-up tank: 1.2 m3

Make-up tank indicative potable water
requirements: 910 l/h average (1,370
l/h at peak flows)
Vol 3, Section 2
Page 30 of 49
System sized for

future flows
Item
Process
Stage
Sub
Category
Specifications
Design Criteria
Process
Output
Number of dosing tanks: 1 (duty)

Dosing tank retention time at
hours at future flows
Polyelectrolyte dosing concentration:
0.1%
Capacity of dosing tank: 0.6 m3
Reclaimed effluent required for postdilution: 1410 l/h (2115 l/h at future
flows)
Polyelectrolyte
dosing pumps
Number: 2
Indicative duty: 316 l/h
Type: variable speed (flow paced)
Mode of operation: Duty/standby
9.4
9.5
Thickened
Sludge Pumps
Pumps
Thickened
Sludge Tank
Tank
Number: 2 (1 No. per machine)

speed flow control
Number: 1
Type: Tank
Retention time at average sludge
production: 5 hours for current flows
To transport
thickened
sludge to
thickened
sludge tank
To blend
thickened and
unthickened
SAS prior to
feeding digester
Indicate capacity: 104 m3

Mixing

9.6
Thickener
bypass pumps
Vol 3, Section 2
Pumps
Number: 2 (duty/standby)
Indicative capacity: 16.2 m3/h at
average production
Page 31 of 49
To keep solids
in suspension,
mix
sludges
and keep sludge
aerobic
10.
Specifications
SLUDGE AEROBIC DIGESTERS

Thickened sludge shall be aerobically digested in two separate tanks. Aerobic digestion will help
compliance with the effluent phosphorus limits by minimising the release of phosphorus from
the bio-mass and its return to the main process stream. The digesters are periodically
oxygenated to stabilise the sludge by biological reduction of the volatile solids and to reduce
pathogen levels and risk of odours. Aeration is to be intermittent to provide some denitrification
and thereby recover some of the alkalinity destroyed in the nitrification process within the
reactor. However, chemical dosing will be required to maintain alkalinity above 50 mg/l as
CaCO 3 .
The aeration within the aerobic digester can either be diffused aeration system with mechanical
mixing during the un-aerated phase or a hybrid aeration/mixing system.
Table 10.1: Description of Aerobic Digesters
Item
10.1
Process Stage
Digester Tanks
Sub
Category
Tanks
Process
Output
Design Criteria
Number: 2 (2 trains, 2 zones per
train)
Indicative sizing:
Capacity: 4 zones, 1,309 m3 each
Tank dimensions (each):
Depth: 6 m
Length: 30 m
Width: 15 m
Number
of
digester: 2
pockets/zones
per
Actual design MLSS concentration:

15,000 mg/l.
Maximum design MLSS concentration:
18,000 mg/l (if pre-thickening is
included)
Min aerobic sludge age (ASP aeration
tanks + aerobic digesters): 29.5 days
Minimum volatile destruction: 40%
Maximum SOUR of stabilised sludge:
1.5 mgO 2 /hour/g total solids at 20oC
Minimum
aeration
temperature: 24C
basin
MLSS
Maximum aeration
temperature: 36C
basin
MLSS
Aerobic mass fraction: 0.5

Anoxic mass fraction: 0.5
Vol 3, Section 2
Page 32 of 49
Item
10.2
Process Stage
Specifications
Sub
Category
Aeration &
Mixing System
Design Criteria
Mode of
aeration.
operation:
Process
Output
intermittent
i.e. Train 1, Zone 1 and Train 2, Zone

2 aerated, other Zones just mixed
and vice versa.
Number of mixers: 1 No. per zone
Installed power per mixer: 3 kW
Aeration type: coarse bubble
Blowers
Number: 2 (duty/standby)
Indicative nominal peak air flow rate
to aerobic digesters
5,879 Nm3/hr
10.3
Alkalinity dosing
Chemical
storage
Chemical
dosing
pumps
Vol 3, Section 2
Number: 1
To store chemicals to replace
alkalinity lost due to nitrification in
the digester
2 No. duty/standby
Intermittent dosing, controlled on
ammonia and pH
Page 33 of 49
Chemical may
be
sodium
hydroxide,
sodium
bicarbonate or
other chemical
to increase the
alkalinity of the
digester
contents.
11.
Specifications
SLUDGE DEWATERING
The stabilised sludge will be taken to a feed averaging tank (FAT) before being mechanically
dewatered by duty/standby double-decked gravity belt thickener (GBTs)/belt filter press (BFP)
or centrifuges, to achieve a target dry solids of 18%. This minimises the size of the
downstream sludge dryers.
The liquors recovered from the dewatering process are pumped back to the inlet works via the
return liquor pumping station/balancing tank and the dewatered sludge cake is then stored in a
sludge silo.
Table 11.1 provides the design characteristics for the dewatering system.
Table 11.1: Dewatering System Description
Item
11.1
Process Stage
Feed Averaging
Tank (FAT)
Sub
Category
Tank
Design Criteria
Number: 1
hours for current flows (3.3 hrs for
future flows)
Indicative capacity: 110 m3
Aeration

11.2
Dewatering
System
Dewatering
units
Type: centrifuge or double-decked

gravity belt thickener and belt filter
press
Number: 2
Indicative capacity: 31 m3/h average
Dewatered sludge
18% dry solids
concentration:
Solids capture rate: 95%

Operating time:
24 hours per day (based on peak
sludge flow)
7 days per week
Vol 3, Section 2
Page 34 of 49
Process
Output
To
balance
aerobically
digested sludge
feed
to
the
dewatering
units
To keep solids
in suspension to
ensure
consistent
quality of feed
sludge to the
dewatering
system and to
keep
sludge
aerobic.
To
dewater
digested sludge
Peak capacity is
provided
by
increasing run
times
Item
Process Stage
Sub
Category
Dewatering
feed pumps
Specifications
Design Criteria
Number: 2
Indicative capacity: 10 l/s
Process
Output
To transfer
sludge from FAT
to dewatering
units

speed flow control
11.3
Polyelectrolyte
Dosing System
Dosing
system
Maximum polyelectrolyte dose rate: 6

kg/tds
Number of polyelectrolyte make-up
and dosing systems: 1
To
condition
sludge prior to
dewatering
Mode of operation: duty

Type: system to be suitable to use
both powder (25 kg bags) and liquid
polyelectrolyte
Powder
polymer
make-up and
dosing tanks
Number of make-up tanks: 1 (duty)

Make-up tank retention time at
hour at future flows
Polyelectrolyte make-up
concentration: 0.5% w/w
Capacity of make-up tank: 1.2 m3
Make-up
tank
potable
water
requirements: 910 l/h average (1,370
l/h at peak flows)
Number of dosing tanks: 1 (duty)
Dosing tank retention time at
hours at future flows
Polyelectrolyte dosing concentration:
0.1%
Capacity of dosing tank: 2.4 m3
Final effluent required for postdilution: 3,260 l/h (4,880 l/h at future
flows)
Vol 3, Section 2
Page 35 of 49
System to be
sized for future
flows
Item
Process Stage
Specifications
Sub
Category
Polymer
dosing
pumps
Design Criteria
Process
Output
Number: 2
Indicative duty: 815 l/h (1,220 l/h at
future flows)
Type: variable speed (flow paced)
11.4
Dewatered
Sludge
Conveying
System
Conveying
system
Minimum number of conveying

systems: 2 (1 No. per machine)
Or discharge direct to the cake silo
To
transport
dewatered
sludge to cake
storage silo
Type: belt conveyor

11.5
Dewatered
Sludge Storage
Storage
Number: 1
Type: Silo
production: 3 days for current flows
Fitted with active outloading system
Capacity 120 m3
11.6
Liquor
Return
Pumping Station
Pumping
station
Number of pumping station: 1
Liquor return
pumps
Minimum number of duty pumps: 2
Flows to be returned to the inlet

works include:
liquors and washwater from GBT/belt
filter press, sand filter backwash,
sludge dryer condensate and wet
scrubber liquors, tank drains, surface
water drainage etc.

Type: variable speed
Capacity: to be determined by the
Contractor depending on type of
technologies chosen for different
treatment processes
Vol 3, Section 2
Page 36 of 49
To store
dewatered cake
prior to drying
12.
Specifications
SLUDGE THERMAL DRYING

A thermal sludge dryer shall be used to produce pellets suitable for re-use for land application
and disposal to landfill. Table 12.1 summarises the design parameters and details of process
units used to dry dewatered sludge.
The thermal drying plant shall dry the dewatered sludge to 90% dry solids. This sludge product
will provide the greatest security of operation and minimise the number of truck movements to
remove the sludge from the STP. The dying process shall destroy any pathogens in the sludge
to produce an end product suitable for unrestricted reuse.
The single thermal dryer shall be powered by diesel but shall also be suitable for natural gas.
Most of the exhaust gases shall be recycled back to the dryer. A small proportion of air will be
wasted and discharged to the main odour control facility. The waste air will be cooled by TSE
water in air condensers to reduce the air temperature down to a level suitable for the GRP
ductwork and the main odour control facility, approximately 40 degrees Celsius. The TSE will
be taken from the TSE ring main, pass through the closed loop condenser and discharge back
to the TSE storage tank.
The waste air will be pre-treated in a quench tower to remove dust particles prior to receiving
further treatment in the odour control unit.
The dry sludge shall be processed through a pelletising unit to prevent dust issues during
product handling. Pellets shall be stored in a silo before being taken off-site for re-use or
disposal to landfill. The Contractor shall also price for a pellet bagging plant (25 kg bags).
The sludge dryer system, pellet conveying system, pelletising system, pellet storage and
bagging plant shall be designed with safety provisions to minimise the danger of dust
explosions and fires. The system shall be designed in line with the UK HSE guideline Sewage
Sludge Drying Plants - 847/9 and demonstrate the basis of safety within the dryer design and
operation. It is important that each Vendor has direct experience of sludge drying and sludge
pellet handling.
Table 12.1: Description of Sludge Drying System
Item
12.1
Process Stage
Sludge
Conveying
System
Sub
Category
Conveying
system
Design Criteria
Number: 1
Type: belt conveyor
Indicative sludge cake production:
Average: 21m3/d (future: 30 m3/d)
Peak: 30 m3/d (future: 45 m3/d)
Conveying arrangement to cater for
transfer of sludge from cake storage
silo to thermal dryer or to tanker (for
off-site disposal)
Vol 3, Section 2
Page 37 of 49
Process
Output
To
transport
dewatered
sludge
from
cake
storage
silo to dryer
Item
12.2
Process Stage
Specifications
Sub
Category
Dewatered Cake
Characteristics
Minimum dry solids concentration:

17%
Average
18%
12.3
Sludge Dryer
Process
Output
Design Criteria
Dryer
dry
solids
concentration:
Number: 1
Type: Low heat direct belt dryer or
drum dryer, c/w dual burner (diesel
and natural gas), fans, condensers,
heater, cooler, and back mixing
systems as required.
To
dry
dewatered
sludge
the
Required dry product concentration:

90%
Sludge quality: Grade A US EPA Rule
503 Guidelines
Operating time : 24 hours per day
Indicative evaporation capacities:
Average: 0.5 Tonnes per hour
Peak: 1.3 Tonnes per hour
Sized for future

flows
Dry sludge final temperature: 400C

Open
Loop
Heat
Recovery
Number: 2
To cool dryer
exhaust air
Indicative flows:
Condenser 1:
Cooling water flow: 29 m3/h
Condensate flow: 0.5 m3/h
Condenser 2:
Cooling water flow: 66 m3/h
Condensate flow: 1.8 m3/h
Cooling
water:
(disinfected)
final
effluent
Mode of operation: duty/duty, in

series
Maximum temperature of return line:
60C
Seasonal temperature range of flow
line: 24 - 36C
Vol 3, Section 2
Page 38 of 49
Item
12.4
Process Stage
Dryer Fuel
Specifications
Sub
Category
Fuel
Process
Output
Design Criteria
Fuel type: Diesel (with an allowance
for natural gas in the future)
Number
of
diesel
(duty/standby)
pumps:
To feed the
burners used to
produce hot air.
Indicative diesel pump capacity: 207

l/hr
Diesel storage requirements: 21 days
Number of diesel storage tanks: 2
Storage based
on future flows.
Capacity of diesel storage tanks: 42

m3 each
(Note that diesel storage does not
include
for
fuel
required
for
emergency power generation on site)
12.5
12.6
Dry Sludge
Conveying
System
Conveying
system
Minimum number
systems: 1
of
conveying
Type: screw conveyor
Pelletising
System
To
transport
dried
sludge
from dryer to
sludge pelletiser
and/or directly
to dry sludge
storage silo
A pelletising system may be required

depending on the selected type of
sludge dryer. If pelletisers are
required then:
Minimum number of duty pelletisers:
2
Type: Drum mill pelletiser
Pellet size: 3-5mm
12.7
Dry
Storage
Sludge
Storage
Minimum number of storage tanks: 1

Type: Silo
Complete with: pellet conveyor from
dry sludge storage silo to bagging
plant
production: 4.5 days for current flows
Indicative capacity: 95 m3
Vol 3, Section 2
Page 39 of 49
To store dry
pellets prior to
disposal off-site
or bagging
Item
12.8
Process Stage
Pellet
Plant
Sub
Category
Bagging
Specifications
Design Criteria
Minimum number of pellet bagging
plant: 1
Complete with: pallet stacking and
wrapping equipment, fork lift pallet
truck.
Process
Output
To store dry
sludge pellets in
25 kg bags
Fully automatic
Bag size: 25kg bags
12.9
Dryer
Exhaust
Air Scrubber
Vol 3, Section 2
Scrubber
Minimum number of scrubbers: 1

Type: Quench tower
Page 40 of 49
To remove dust
particles
from
the exhaust air
13.
Specifications
CHEMICAL PHOSPHOROUS REMOVAL

Chemical dosing is to be to primary means of phosphorus removal under normal operating
conditions although the design of the activated sludge plant shall be flexible to allow biological
removal of P if the influent proves suitable (see Section 4). Chemical dosing for P removal
provides the additional advantage of allowing the final effluent to be tuned to suit its disposal
route e.g. phosphorus removal can be turned off when the effluent is to be used for irrigation,
improving its nutrient value for the planting and reducing cost - this will also maximise the
available carbon for denitrification, improving compliance with the Total N standard and
reducing the need for supplementary carbon dosing.
Table 13.1 summarises the design parameters and details of process units associated with
chemical phosphorous removal.
Table 13.1: Description of Chemical Phosphorous Removal System
Item
13.1
Process Stage
Chemical Dosing
System
Sub
Category
Dosing
system
Design Criteria
Chemical: Ferric chloride
Indicative dose rate: 972 kg/d as Fe
Dose location: RAS
Note: ferrous salts may be dosed as
an alternative into the aeration lanes.
Storage tank
Number of storage tanks: 2

Storage retention time at maximum
demand: 21 days for current flows
Storage tank capacity: 25 m3
Dosing
pumps
Number: 2
Indicative Duty: 208 l/h (peak 365
l/h)
Type: variable speed, 100:1 turndown
(for P trim)
Vol 3, Section 2
Page 41 of 49
Process
Output
To
chemically
remove
phosphorous
14.
Specifications
ODOUR CONTROL
To ensure adequate odour management on site, all tanks, channels, screens, and conveyors
that have the potential to release detectable odours off-site shall be enclosed and directly
exhausted to an odour control system. Specifically, all pumping, screenings, grit, water
surfaces upstream of the aerobic activated sludge process, and sludge processes shall be
covered or enclosed and directly exhausted to an odour control system. This includes:
Inlet pumping station

Inlet works tanker reception facility
Preliminary treatment: inlet and fine screens, grit removal, screening and grit skips
Secondary process inlet distribution chamber
Bioreactors inlet channels and tanks
Bioreactors anaerobic and anoxic zones
Sludge tanks
Sludge thickening and dewatering
Sludge dryers. Note that dryer air will be pre-treated through a wet scrubber to cool
the gases and remove dust particles prior to entering the odour treatment unit
Sludge silos
Other process areas to be covered but the extracted air may be dispersed only, (i.e. not
treated through an odour control unit) via a stack. This includes:
Aerobic digester
The position of the extract points must be such that air is drawn across the surface of liquid
from the air intake to the point of extract. The level of air extraction shall be sufficient to
maintain negative pressure.
Odour control systems shall be designed for the following design conditions:
STP will be operated, maintained, and managed under Good Industry Practice.
Worst-case meteorological events: calm conditions, wind speed of approximately 1 m/s.
Prevent odour complaints from the public by reducing concentrations of hydrogen
sulphide, mercaptans, other sulphur-containing compounds and Volatile Organic Carbons
(VOCs) such that those from the site are undetectable at the site boundaries.
The boundary standard is normally defined in terms of olfactory requirements but the required
standard shall be:
The odour level at the sites boundary shall not be above 5 OU/m3 on a 99.8%ile,
one hourly average basis based on the BS EN 13725:2003 standard odour control
method.
The odour control discharge stack shall be tall enough to disperse the discharge and have an
exit velocity of 18m/s to aid the dispersion. A silencer may be fitted if required to meet the
specified noise levels at the site boundaries.
Condensation drains/demister shall be installed at low points of ductwork to drain
condensation. Ductwork shall be designed to fall to suit drain location.
Two (2) types of dampers shall be required (function may be combined in a single unit):
Flow control dampers

Isolation dampers shall be 100% isolating to allow maintenance on equipment
Vol 3, Section 2
Page 42 of 49
Specifications
The Contractor shall design and supply all necessary supports for the odour control covers,
with adequate sealing. Sealing arrangements must be such that liquid surface in process tank is
not affected and free passage of foam and scum is allowed.
Intake and extract points should be positioned to allow cross flow of air over liquid surface
across the tanks. A negative pressure must be maintained below the covers to avoid escape of
odorous air to outside atmosphere.
Table 14.1: Description of Odour Control System
Item
14.1
Process Stage
Odour
Treatment
System
Sub
Category
Odour
Control
(OCU)
Unit
Design Criteria
The OCU needs to achieve < 500
OU/m3 (odour dispersion modelling
based on this figure) to achieve the
following standard:
Process
Output
To treat
odorous gases
5 OU/m3 on a 99.8%ile 1 hourly

averaging basis measured at the site
boundary.
Fans
Consideration is to be made to the

overall pressure drop when specifying
the fans. The contractor shall
determine whether booster fans are
required in order to optimise the
selection of the main extraction fans
Accoustic enclosure on each fan: <85
dBA at 1m
Airflow velocity in GRP ductwork < 10
m/s to prevent noise and vibration
and > 3.5m/s to allow for balancing
of ductwork
Instruments
Minimum
number
of
on-line
monitoring instruments for each
parameter: 1
OCU
inlet
hydrogen
sulphide
concentration, range: 0 1,000 ppm
Stack outlet hydrogen sulphide
concentration, range: 0 100 ppm
Table 14.2 shows minimum concentration of air contaminants for guidance, the Contractor
shall confirm actual design concentrations.
Vol 3, Section 2
Page 43 of 49
Specifications
Table 14.2: Guidance Minimum Air Contaminants Concentration
Inlet
Pumping
Station
Tanker
Reception
Sump
Screens Area
Skips
Grit Channel
Grit Tanks
Reactor
Distribution
Chamber
Reactor Inlet
Channel
Anaerobic
Tanks
Anoxic Tanks
FAT tank
Dewatering
Cake Silo
Dryers
Pellet Silo
Aerobic
Digesters
Air
changes
hr-1
12.0
H 2 S (ppm)
Av
peak
200
600
R-SH
(ppm)
Av peak
2
4
NH 3
(ppm)
Av peak
2
5
VOC
(ppm)
Av peak
5
60
DMS
(ppm)
Av peak
1
3
12.0
200
600
60
12.0
6.0
12.0
1.2
6.0
200
10
200
200
10
600
20
400
400
30
2
2
2
2
1
4
4
4
4
3
2
2
2
2
0
5
5
5
5
5
5
5
5
30
1
60
60
60
100
3
1
1
1
1
1
3
3
3
3
3
6.0
10
30
6.0
15
10
6.0
1.2
10.0
2.0
1.0
2.0
1.2
2
2
2
2
2
2
5
5
5
5
5
5
1
1
0
0
0
0
3
0
0
1
3
0
0
20
1
0
0
2
1
0
0
2
1
0
0
2
1
0
0
2
Aeration: 0.44 OU/m2/s
Anoxic: 0.43 OU/m2/s
3
50
5
5
5
5
1
1
1
1
1
1
3
3
3
3
3
3
The required air quality discharged from the OCU is shown in Table 13.3.
Table 14.3: Required OCU Discharge Quality
Design %
removal at peak
inlet design load
Maximum
discharge
concentration at
peak load (ppm)
Hydrogen sulphide (H 2 S)
99.9%
0.1
Dimethyl sulphide (DMS)
99.0%
0.03
Mercaptans (R-SH)
99.9%
0.003
Contaminant
VOC (average Mol. Wt

120)
Vol 3, Section 2
There shall be sufficient removal of VOCs

to achieve stack discharge max.
concentration specified (at peak load)
Page 44 of 49
Maximum discharge
concentration at peak
load
Total including all
contaminants not to exceed
500 OU/m3
Specifications
Table 14.4: Indicative Air Production Rates for Aerated Processes (Based on Future
Flow)
Process Air
m3/hr
Aerated grit removal
2,687
Aeration tanks
28,815
Aerobic Digesters
8,819
Negative pressure is to be maintained under the covers of the process tanks. This is to ensure
fugitive emissions from the tanks do not occur.
Vol 3, Section 2
Page 45 of 49
15.
Specifications
SCUM & FOAM REMOVAL

To avoid accumulation of filamentous organisms, foam and scum should not be returned to the
process.
Table 15.1: Scum & Foam Removal

Item
Process Stage
Sub
Category
Foam/scum
removal
system
Design Criteria
Process Output
Foam removal spray system (using

recycled effluent) to be included
Drives
accumulated
foam and scum into
suspension so that
passes forward to the
FSTs.
Inlet and outlet weir arrangements shall

be provided on all bioreactors so that
accumulated foam and scum flows over
weirs and passes forward to the FSTs.
A spray bar system connected to the
plant washwater network shall be
provided
at
the
end
of
the
anoxic/anaerobic
zones
in
each
Bioreactor where foam and scum
typically collect. The system shall be
designed to re-entrain the scum and
move it forward over the Anoxic Zone
division wall and into the Bioreactor
Aerobic Zone.
Vol 3, Section 2
Page 46 of 49
16.
Specifications
EFFLUENT OUTLETS
The management of effluent from the treatment works needs to be carefully addressed. There will
be 2 different types of effluent to be disposed of:
Effluent which meets the unrestricted irrigation quality requirements, in-spec effluent,
during normal plant operation
Effluent which does not meet the prescribed unrestricted irrigation quality standards, offspec effluent, during plant upsets
The above 2 No. types of effluent shall be managed differently as off-spec effluent shall not be
allowed to enter and contaminate the irrigation system.
During normal operation, in-spec effluent shall be pumped from the TSE storage tank to the
irrigation network by the TSE pumping station. Any surplus effluent produced during periods of low
irrigation water demand shall be discharged to sea via the new plant outfall.
During emergency scenarios, any raw sewage or off-spec effluent shall overflow directly to the
new long sea outfall, by-passing the TSE storage tank (and optionally the Chlorine Contact Tank)
to avoid contamination.
The proposed system is schematically shown in Figure 16.1 below.
In-spec
Effluent
STP
Off-spec
Effluent
(Alternative)
Chlorine
Contact Tank
Off-spec
Effluent
TSE
Storage
Tank
Irrigation network
TSE
Pumping
Station
Outfall
Sea
Figure 16.1: Schematic Diagram of STP Effluent Management Facilities

A facility to disinfect/flush the effluent outlet pipes shall be provided in order to prevent the
irrigation network from becoming contaminated after a plant upset.
Vol 3, Section 2
Page 47 of 49
17.
Specifications
ALLOWANCES FOR FUTURE PLANT EXPANSION

The first phase of AMAS STP to be built shall cater for Islands 3 to 14 flows. The average
influent daily flow for Islands 3 to 14 is 39,680 m3/d when fully developed. An allowance of
50% shall be made in the design for future plant expansion, giving a future influent average
daily flow of 59,520 m3/d.
The minimum requirements to be put in place under Phase 1 are illustrated in Table 17.1.
Critical for the completion of the first phase is the supply, installation and commissioning of the
thermal dryer. Long lead times can be expected from suppliers therefore the supply of the
thermal dryer must be given the highest implementation priority and procurement procedures
shall start at the initial phase of the main contract.
Table 17.1: Civil and M&E Staging of STP
Phase 1
Phase 2 - Future
Inlet Works
Civil
M&E
Process Tanks
Civil
M&E
Contact Tank,
TSE
Storage Tank and TSE
Pumping Station
Civil
M&E
Aerobic Digesters
Civil
M&E
Sludge Dewatering
Civil
M&E
Sludge Dryer
Civil
M&E
Structures for the ultimate

59,520 m3/d
Capacity for 39,680 m3/d
4 No. Process Trains

(39,680 m3/d)
6 No. Process Trains

(59,520 m3/d)

59,520 m3/d
2 No. aerobic digesters

3 No. aerobic digesters


59,520 m3/d
(2 No. dewatering units)
Polyelectrolyte make-up
capacity for the ultimate
59,520 m3/d
59,520 m3/d
Capacity for the ultimate
59,520 m3/d

(3 No. dewatering units)
Distribution Chambers
and Pumping Stations
Civil
M&E
Chemical and Diesel
Storage
Vol 3, Section 2

59,520 m3/d
Page 48 of 49
Civil
M&E
Odour Control
Civil
M&E
Buildings
Specifications
Phase 1
59,520 m3/d
59,520 m3/d
59,520 m3/d
59,520 m3/d
All buildings for the
ultimate 59,520 m3/d
Phase 2 - Future
-
Sea Outfall
Civil
M&E
Pipeline for the ultimate

59,520 m3/d
59,520 m3/d
Notes:
Values quoted in the above table for plant capacity are cumulative
The work for any particular stage is to include all instrumentation, control cabling, piping
etc required for the operation of the plant at that stage.
Inlet Works shall include provision for the option to connect a future rising main to the
Inlet Chamber to deliver the expanded plant flow.
Vol 3, Section 2
Page 49 of 49

Tender Documents
Volume 3 Section 3
July 2014
Specifications
TABLE OF CONTENTS
SECTION A -
PARTICULAR REQUIREMENTS
SECTION B -
Not Used
SECTION C -
EARTHWORKS
SECTION D -
CONCRETE
SECTION E -
PIPELINES AND PIPEWORK
SECTION F -
BRICKWORK AND BLOCKWORK
SECTION G CORROSION PROTECTION AND SURFACE COATINGS

SECTION H -
FITTINGS AND FABRICATED ITEMS
SECTION I -
Not Used
SECTION J -
ROADWORKS AND LANDSCAPING
SECTION K Not Used

SECTION L -
BUILDING WORKS
SECTION M - GRP FABRICATED COVERS FOR ODOUR CONTROL SYSTEM

SECTION N PILE FOUNDATIONS
SECTION O -
Not Used
SECTION P -
Not Used
SECTION Q -
Not Used
SECTION R -
Not Used
SECTION S - SCHEDULE OF APPROVED STANDARDS AND GUIDANCE

PUBLICATIONS
Vol 3, Section 3
Page i
of i
Specifications
TABLE OF CONTENTS
Page No.
SECTION A - PARTICULAR REQUIREMENTS
A1
A2
GENERAL
A1.1
Scope of Work
A1.2
Description of Works to be Undertaken
A1.3
Drawings
A1.4
Provision for Future Connection at the Inlet Works
DESIGN
A2.1
Structural Design Criteria
A2.2
Design Standards, Regulations and Other Documents
A2.3
Loads
A2.4
Structural Stability Factors of Safety
A2.5
Exposure Conditions
A2.6
Fire Resistance
A2.7
Concrete Cover To Reinforcement
A2.8
Joints In Structures
A2.9
Other Criteria - Crack Width
A2.10
Foundation Design - Design Standards and Design Data
A3
LAYOUT PLAN AND PROCESS UNITS
A4
STP ACCESS ROAD
A5
PLANT HYDRAULICS
A6
BUILDINGS AND STRUCTURES
A6.1
Administration and Control Building
A6.2
Workshop, Store and Laboratory Building
A6.3
Gatehouse
A6.4
ASP Blower House Building
A6.5
Tertiary Filter/Aerobic Digester Blower House
A6.6
TSE Pump House Building
10
A6.7
Sludge Dewatering & Cake Storage Building
10
A6.8
Sludge Dryer Building
11
A6.9
Dried Sludge Pellet Storage Building
11
A6.10
Polyelectrolyte Storage and Dosing Building
11
A6.11
Odour Control Building
12
A6.12
Chlorination Building
12
A6.13
Emergency Generator Building
12
Vol 3, Section 3
Page i of iii
A7
A8
A9
Specifications
A6.14
Electrical Sub-station and Control Buildings
12
A6.15
Chemical Storage and Dosing Facility
13
A6.16
Diesel Storage and Fuelling Facility
13
A6.17
Operator ablution block
13
BUILDING SERVICES
13
A7.1
13
A7.2
Lighting
14
A7.3
Small Power
15
A7.4
Air Conditioning
15
A7.5
Ventilation
15
A7.6
Foul drainage
15
A7.7
Potable Water Supply
15
A7.8
Fire Protection, Detection and Alarm
15
A7.9
Telephones
16
A7.10
Lightning Protection
16
A7.11
Furniture
17
ROADWORKS, LANDSCAPING AND OTHER EXTERNAL WORKS
17
A8.1
Roadworks
17
A8.2
Landscaping
17
A8.3
Pathways
18
A8.4
Site Boundary Wall / Fencing and Security Gate
18
A8.5
Potable Water Supply, Irrigation Main and TSE re-use line
18
A8.6
Cable Ducts and Drawpit Chambers
19
A8.7
Other External Works
19
INTERNAL SEWERAGE AND DRAINAGE
19
A10 TERMINAL LIFT PUMPING STATION (Inlet Pumping Station)
19
A10.1
Location
19
A10.2
Coordination and Interfaces
20
A10.3
Future Connection Manhole
20
A10.4
20
A10.5
Earthworks and Retaining Wall
20
A10.6
Access Roads
21
A10.7
Boundary Wall, Compound and Gate
21
A10.8
Landscaping and Irrigation
21
A10.9
Washing Down and Drainage
21
A10.10 Rising Mains
22
A10.11 Site lighting
22
A10.12 Odour Control
22
A10.13 Potable Water Supply
22
A10.14 Buildings and structures
22
A10.15 Other External Works
22
Vol 3, Section 3
Page ii of iii
Specifications
A11 LONG SEA OUTFALL
22
A11.1
General
22
A11.2
Environmental Impact Assessment
23
A11.3
Outfall Designer
23
A11.4
Design Data
23
A11.5
Other Features
25
A11.6
Initial Outline Design
26
A11.7
Pipeline Stability Analysis
27
A11.8
Pipeline Construction, Materials and Method of Installation
27
A11.9
Hydrographic Surveys
28
A11.10 Materials
29
A11.11 Cleansing of Pipelines
32
A11.12 Testing of Pipelines
32
A11.13 Construction Records and Quality Control
32
A11.14 Operation and Maintenance
32
A10 PLANT SCALE MODEL
Vol 3, Section 3
32
Page iii of iii
Specifications
SECTION A - PARTICULAR REQUIREMENTS

A1
GENERAL
A1.1
Scope of Work
The project involves the design, construction, operation and maintenance of a new
Sewage Treatment Plant (STP) to be located on Island 13C to treat a projected flow
arising from the Al Madina Al Shamaliya development.
The extent of the Works includes the design, supply, installation, construction, testing,
commissioning and putting to reliable, efficient service of all equipment necessary for a
complete, workable installation to treat the specified volumes and quality of raw sewage
to a standard suitable for restricted irrigation use as specified.
Operation and maintenance of the plant is to be undertaken for a minimum period of five
years after which the client will have the option to renew and / or amend the O&M
contract.
Further details of the scope are given in the Particular Requirements specifications.
A1.2
Description of Works to be Undertaken

The new works to be constructed, together with all necessary equipment and ancillaries,
shall include, but not be limited to, the following:
Inlet Pumping Station (Terminal Lift PS at the termination point of the deep gravity
sewer constructed by others) with coarse screen, screenings washing and odour
control unit
Tanker discharge facilities for 6 No tankers
Inlet works with flow measurement and storm water overflow facilities
Screening (6mm) with screenings washing and compaction
Grit and Oil/Grease removal utilising aerated grit channels with associated handling
and disposal systems
Selector/ Anoxic / Aeration double pass Bioreactor Tanks with internal recycles
Final Settlement Tanks (FSTs)
RAS/SAS Submersible Pumping Station
Tertiary Sand/disc Filters
A Chlorination Building for gas storage, preparation of chlorine solution
Chlorine Contact Tank
TSE Storage Tank, capacity 10,000 m3 with overflow facility
TSE Pumping Station
Intermediate Lift Pumping Station
A Return Liquors Submersible Pumping Station
Aerobic Digester Tanks
Sludge Dewatering system employing Gravity Belt Thickener, Belt Filter Press, or
Centrifuge, with associated sludge conveyance system and building
Polyelectrolyte Dosing system
Vol 3, Section3
Page A-1 of 33
A1.3
Specifications
Dewatered Sludge Storage Silo
Sludge Dryer, dry sludge silo and associated building
Diesel Storage Tanks and Pump Room
Ferric dosing system, ferric chloride storage tank and dosing pumps
Odour Control unit.
An Administration/Laboratory/Control Building
Workshop and Storage Buildings
Blower House Buildings
Final effluent high pressure washwater system throughout the STP
Architectural screen wall, security gate & kiosk,

landscaping of the Site
Associated channels, pipelines, pipe work, chambers, manholes and flow meters
Electrical works including power supply and distribution, control buildings, ICA
system, SCADA system, standby generators, site lighting and other ancillaries
Outfall Pipeline from the new works to the approved sea discharge point (approx.
4.5Km).
site road works, filling and
Drawings
Tender Drawings are included in Volume 4.
Except where otherwise stated, the Drawings indicate the conceptual and outline design of
the new plant and show the envisaged arrangement of the finished works. The Drawings
shall generally be used as the basis for the development of the design of the new plant.
A1.4
Provision for Future Connection at the Inlet Works

The Inlet Works Inlet Chamber, which will receive all flow to the plant, shall include
provision for the future connection of a 500mm diameter pumping main. The provision
shall include installation of the pipe from the Inlet Chamber to a suitable future connection
point at the plant boundary close to the main gate. The pipe shall be tested on
completion and blanked off with the termination point marked with a permanent marker
stating the diameter and depth at the interface point for future connection.
Vol 3, Section3
Page A-2 of 33
A2
Specifications
DESIGN
Design calculations and details shall be submitted to the Engineer for approval.
Construction will not be permitted to commence before approval of the design.
The sizing of structural members shown on the Drawings is indicative only and shall be
subject to the Contractors detail design, carried out in accordance with the Specification.
All concrete shall have additional corrosion protection as specified.
Structures shall generally extend a minimum of 200mm above finished ground level
(FGL=+2.65m AOD).
Excavations for structures will not be permitted to penetrate the local groundwater table
estimated to about -6.0m AOD. This will be confirmed in the Geotechnical Investigation
Report in to be provided in Volume 6 Other Information.
Handrailing shall be provided where any drop exceeds 500mm and around open tanks
where the coping level is less than 900mm above finished ground level.
Any consultants employed by the Contractor shall be designated Ministry Grade A and shall
be subject to the approval of the Engineer
A2.1
Structural Design Criteria

The design shall be carried out in accordance with the relevant codes of practice and
standards for all aspects of structural design work.
The detailed structural design criteria described here shall apply to:
A2.2
Structures and sections of concrete structures designed to retain or exclude aqueous

liquids.
Normal concrete buildings and structures
Steel work design
Design Standards, Regulations and Other Documents

The structural design shall be carried out by suitably qualified professionals and shall
comply with the relevant standards, code of practice, local laws, regulations and
requirements of the relevant authorities and all laws in existence in Bahrain.
The relevant design standards for civil engineering structures include (see also Section S of
the General Technical Specifications):
Bahrain Design Standards
CP 3
Wind Loads
BS 648 -
Schedule of Weights of Building Materials.
BS 8110 -
Structural Use of Concrete
BS 8007 -
Code of Practice for the Design Of Concrete Structures for Retaining

Aqueous Liquids.
Vol 3, Section3
Page A-3 of 33
Specifications
BS 5950 -
Structural Use of Steelwork in Buildings.
BS 8004 -
Code of Practice for Foundations.
BS5628 -
Code of Practice for use of Masonry
Reference may also be made to the following documents :

a)
Reinforced Concrete Designers Handbook Charles E. Reynolds & James Steadman.
b)
Design Guide to BS 5950: Part 1 : Volume 1 The Steel Construction Institute.
c)
Steel Designers Manual The Steel Construction Institute.
The Standards and Codes shall be the latest edition, current at time of Tender.
A2.3
Loads
a. Units
SI units shall be used throughout
b. Dead Loads
Concrete
24 kN/m3
Water (including sludge)
10 kN/m3
Steel
78 kN/m3 or weight/m for structural members
c. Superimposed Dead Loads

Roof Finish
To be assessed as appropriate
Ceiling & minor services
0.5 kN/m2
Floor Finishes
Partitions
To be assessed as appropriate to form of

construction but not less than 1 kN/m2.
d. Superimposed Live Loads

The minimum assumed loads shall as follows. The designer shall ensure that the loads
assumed are adequate for the particular situation.
Roof (with access for maintenance only) 0.75 kN/m2
Roof with general access
Stairs
5 kN/m2
Landings
5 kN/m2
Floors
5 kN/m2
e. Equipment and Machinery
Vol 3, Section3
Page A-4 of 33
Specifications
The weight of equipment and machinery shall be derived from manufacturers data and will
include control panels, auxiliary machinery piping, etc.
Dynamic loads from mechanical equipment/plant shall be assessed. Where exceptional
loads are expected, allowance shall be made for the heaviest loading combination that
could occur if plant is stored temporarily near installed units. Where loads are not known,
for general areas uniform disturbed load shall be 7.5 kN/m2.
f. Crane Loads and Moving Loads
Crane and moving loads (e.g. from travelling cranes) shall be assumed at their maximum
values, including the lifting capacity as well as maximum horizontal loads caused by
braking or acceleration, but not acting simultaneously with maximum wind forces.
For the design of each structural element, the most critical position of crane or other
moving loads will be considered. For moving loads, an appropriate dynamic factor shall be
used.
g. Hydrostatic and Soil Pressure
All water retaining structures (except in special circumstances) shall be designed to resist
internal lateral hydrostatic pressure without the presence of exterior backfill.
Density of soil shall be assumed to be 18 kN/m3.
Structures buried in ground shall be designed to resist both lateral soil pressure and
ground water pressure where appropriate.
Division walls in structures such as the Aeration Tanks, shall be designed for lateral
hydrostatic pressure in both directions to take account of sections being emptied for
maintenance. The structural design shall also include loads from any proposed future
extensions where the drawings indicate shared walls.
h. Wind Load
The wind load on any structure where appropriate shall be based on the wind pressures
given in the Code of Practice on Wind Effects and shall not be less than that used locally.
The basic design wind velocity for Bahrain is 45m/s.
i. Seismic Load
Bahrain is located in an area with very minor seismic activity.
structures to be designed for earthquake loading.
A2.4
It is not necessary for
Structural Stability Factors of Safety

a. General
The Factors of Safety shall be in accordance with the relevant sections of the BS unless
otherwise indicated below. The effect of the specified concrete protection systems shall be
carefully considered in the stability calculations.
b. Overturning
The Factor of Safety against overturning shall not be less than 1.5 due to wind loads and 2
for loads other than wind loads.
c. Sliding
Vol 3, Section3
Page A-5 of 33
Specifications
The Factor of Safety against sliding shall not be less than 1.5.
d. Flotation
The Factor of Safety against flotation of the empty structure shall be not less than 1.1.
A2.5
Exposure Conditions
Exposure conditions are defined in Table 3.2 of BS 8110: Part 1.
For water retaining structures the exposure condition shall be most severe in accordance
with BS 8007.
Concrete elements in dry non-aggressive environments shall be subject to moderate
exposure.
A2.6
Fire Resistance
Unless required otherwise the fire resistance period shall be taken as 2 hours.
A2.7
Concrete Cover To Reinforcement

Unless otherwise stated, the minimum concrete cover to all reinforcement shall be 75mm
(water retaining structures and below ground concrete) and 50mm (above ground).
A2.8
Joints In Structures
Movement Joints in structures shall be provided in accordance with the relevant clauses of
BS 8110 and BS 8007 with the emphasis on minimising the number of joints where
appropriate.
A2.9
Other Criteria - Crack Width

The maximum design surface crack width (for direct tension and flexure or restrained
temperature and moisture effects) for structural members in contact with soil or water and
exposed to damp and corrosive environment shall be 0.2mm, and 0.3mm for all other
members.
A2.10
Foundation Design - Design Standards and Design Data

The design shall be in accordance with the requirements of BS 8004 Code of Practice for
Foundations, and other applicable standards in accordance with the Specification.
Negative skin friction, if applicable, shall be based on ground investigation data and
calculated using recognised foundation engineering principles. The effect of the specified
concrete protection systems shall be carefully considered.
A3
LAYOUT PLAN AND PROCESS UNITS

The preliminary sizing and arrangement of the process units is shown on the layout
drawing (Volume 5). Detailed description of process units is given under Volume 3,
Section 2 of the tender document.
A4
STP ACCESS ROAD
Vol 3, Section3
Page A-6 of 33
Specifications
All roads on Island 13c shall be constructed by the STP Contractor. The extent of the
roadworks is indicated on the Drawings and includes:
1.
2.
3.
4.
5.
Connection to the Primary Road on Island 13 at the culverted channel crossing near
the TLPS as indicated on the drawings. Road width at connection = 7.5m. Road
level at connection = +2.5m.
Access road to the north of the TLPS for total distance of approx. 60m including a
90 degree bend in the road (for future car parking area for visitors to the hill).
Minimum road width = 7m
Access road to the south of the TLPS running close to the water channel for a
distance of approximately 250m to the STP entrance gate. Min. Road width = 7.5m.
Access road from the main road to the TLPS. Min. width 6m.
All road markings and signage including signs to the STP and the TLPS.
Roads shall to be designed with regard to the types of heavy vehicles requiring access
including cranes, trucks, tankers etc.
Roads shall be provided with a minimum 1.75m wide verge each side and shall have a
nominal 2% cross fall for drainage.
A5
PLANT HYDRAULICS
The Hydraulic design for the new AMAS STP shall provide accurate and consistent flow
splits between parallel process units over the full range of present and future design flows,
to assist in the achievement of optimum process performance, while minimising headlosses to reduce construction cost and long-term operating cost.
Contractor shall design the plant hydraulics considering the average daily, peak daily and
ultimate peak flows for whole design life as given under Volume 3, Section 2- Process
Specifications.
The major dimensions such as interconnecting pipe diameters, channel widths and levels,
weir lengths and levels and tank internal sizes shall be fixed in accordance with the process
and hydraulic design. The design shall be subject to the approval of the Engineer.
The existing site ground levels are indicated on the Drawings.
All process units, chambers and structures top level shall be at least 300mm above
finished ground level to minimise intrusion of fine, wind-blown sand and provide a barrier
to vehicles.
A6
BUILDINGS AND STRUCTURES

In general various buildings (process and control buildings) at STP shall be as indicated on
the Layout drawing. Buildings may be either concrete or steel framed structures. Buildings
shall be architecturally designed to produce aesthetically pleasing structures and finishes and
to minimise the visual impact. All buildings shall be architecturally similar. Contractor shall
design the buildings considering regulatory, functional, operational and maintenance
requirements and submit the drawings for approval before starting any work on ground.
Proposed process/ control buildings and miscellaneous structures includes but not limited to
the followings:
1.
2.
3.
4.
Inlet Pumping Station

Aerated grit/grease removal blower room
Vol 3, Section3
Page A-7 of 33
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Specifications

Tertiary Filter/ Aerobic Digester Blower House Building
Intermediate Lift Pumping Station Building
TSE Pumping Station Building
Sludge Gravity Belt Press & Cake Storage building
Polymer Storage and Dosing Building
M.V. Substation Building/s
Electrical Substation 1, 2 & 3 Building
MCC Control Rooms at various location to cover site mechanical equipments control
Chemical (Ferric Chloride) Storage and Dosing Facility
Diesel Storage and Dosing Facility
Contractor can propose a common structure for various buildings based on unit locations,
available area, unit functionality and operation and maintenance requirement. Proper care
should be taken in the design of safety and fire fighting requirement of such common
buildings. Adequate number of MCC control rooms shall be designed to cover the various
units mechanicals equipment control. Contractor shall submit a concept design proposal for
process and control buildings for approval before details design.
All buildings shall include lifting equipment suitable for the removal and installation of
equipment and for routine maintenance. It shall be designed so that equipment can be
loaded/unloaded from a truck (Hiab) without the need for double handling.
A6.1

Administration and Control Building shall be a two storey (G+1) structure. Building shall
include the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Entrance Hall with scale model display area.

Elevated control room having panoramic view of the site including desks suitable for
SCADA computer and printers and telephone link.
Control Panel Room with main control panel. The room size for the Control Panel
Room shall be based on actual control panel size.
Engineer Office Room (two nos.) with telephone line.
Plant Operator Room ( 1 no.) with telephone line
Locker Room
Kitchen/Mess Room with sink, water heater and kitchen units
Toilet with two western style W.C.s, shower and two sink units (on both floors).
Office/meeting room with telephone and link to external line.
A car parking area for twelve vehicles with sunshade (common for
Administration/control and Workshop building)
Building size and various rooms dimensions shall be designed to fulfil functional, operation
and maintenance requirement. The structure of the building may be either concrete or steel
framed with reinforced concrete foundations.
A6.2

Workshop, Store and laboratory Building shall be of two storey (G+1) structure. Building shall
include the following:
i.
Vol 3, Section3
Entrance Hall
Page A-8 of 33
ii.
iii.
iv.
v.
vi.
Specifications
Workshop rooms for mechanical, electrical and instrumentation (Ground Floor).

Equipment/ material store room (Ground Floor).
Laboratory Room (First Floor)
Office Room (First Floor)
Toilet with two western style W.C.s, shower and two sink units (on each floor)
Building size and various rooms dimensions shall be designed to fulfil functional, operation
and maintenance requirement and shall be complete with an overhead travelling electric
crane. The structure of the building may be either concrete or steel framed with reinforced
concrete foundations.
A6.3
Gatehouse
A gatehouse shall be provided at the main STP entrance to control access to the plant and
for security. The building shall include the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
A6.4
Windows to provide a clear view of the main access area and approach road
Local and general site lighting control as specified
CCTV system monitoring base as specified
Security alarm system base
Vehicle logging system as specified
Sufficient space for a minimum of two personnel
Kitchen and toilet facilities
Gate remote operation
Telephone connection to Administration building
Local car parking for two vehicles

The ASP blowers and associated equipment shall be housed in the Blower House. The
Blower House shall include a separate control panel room. The Blower equipment and
pipework shall be supplied as a complete single package from a reputable, experienced,
specialist manufacturer and supplier. Equipment arrangements and details shall be generally
as required by the supplier but subject to the Engineers approval.
A cross flow ventilation system shall be provided in the blower room. A minimum of 4 air
changes/hour shall be provided.
The building shall be sized to suit the equipment supplied with adequate access to all areas
for maintenance and an overhead travelling electric crane shall be provided. The building
structure shall be designed to minimise the noise pollution.
Aluminium folding, double or roller shutter doors, of sufficient width for blower installation
and removal, shall be provided for each blower with ramp up from road level.
Pipe and cable trenches shall be covered with RTR or aluminium chequer plate installed in a
frame. The covers shall be designed with regard to the likely loads from any equipment
passing over the trenches.
A6.5
Tertiary Filter/Aerobic Digester Blower House

The Tertiary Treatment and Aerobic Digester blowers and associated equipment shall be
housed in the Blower House. The Blower House shall include a separate control panel room.
The Blower equipment and pipework shall be supplied as a complete single package from a
reputable, experienced, specialist manufacturer and supplier. Equipment arrangements and
details shall be generally as required by the supplier but subject to the Engineers approval.
Vol 3, Section3
Page A-9 of 33
Specifications
A cross flow ventilation system shall be provided in the blower room. A minimum of 4 air
Aluminium folding, double or roller shutter doors, of sufficient width for blower installation
and removal, shall be provided for each blower with ramp up from road level.
Pipe and cable trenches shall be covered with RTR or aluminium chequer plate installed in a
frame. The covers shall be designed with regard to the likely loads from any equipment
passing over the trenches.
A6.6
TSE Pump House Building

TSE pumps, washwater/irrigation pumps along with associated equipment shall be housed in
TSE pump house building. The Building shall include a separate control panel room for
pumps and adjoining equipment control. Equipment arrangements and details shall be
generally as required by the supplier but subject to the Engineers approval.
Aluminium folding, double or roller shutter doors, of sufficient width for pump installation and
removal, shall be provided with ramp up from finished level.
A6.7
Sludge Dewatering & Cake Storage Building

It will be a two storey (G+1) building. The sludge Gravity Belt Presses and associated
equipment or alternative Centrifuges shall be housed on the first floor having sludge cake silo
at Ground Floor. A cross flow ventilation system shall be provided in the building. A
minimum of 4 air changes/hour shall be provided.
for maintenance and an overhead travelling electric crane shall be provided. Specifically, for
the belt press, space must be provided for routine maintenance operations such as roller
removal and belt changing.
Floors and wall finish shall be as per Civil Specification Section G.
All pipework and ducts laid beneath the building foundation shall be surrounded in concrete.
Rigid pipelines shall have flexibility at the edge of the concrete surround. Floor drains and
washing down connection points, shall be provided in the building. Floors shall have a fall to
the drains. All drains from the building shall be trapped. Drainage from the dewatering
equipment and the building shall discharge back to the Liquor Return sump.
Equipment installation access provision shall be made to the silo room and dewatering room.
A potable water supply connection shall be taken from the water supply ring main to a hand
wash basin located in the belt press / centrifuge room.
The building shall be designed for the loads from the equipment installed, the overhead
electric travelling crane and the specified wind and other imposed loads.
Vol 3, Section3
Page A-10 of 33
A6.8
Specifications

The sludge Belt Dryer and associated equipment shall be housed in the dryer building. A
cross flow ventilation system shall be provided in the building. A minimum of 4 air
for maintenance and an overhead travelling electric crane shall be provided. Specifically,
space must be provided for routine belt dryer maintenance operations such as roller removal
and belt changing.
Floors and wall finish shall be as per Civil Specification Section G.
Floor drains and washing down connection points, shall be provided in the building. Floors
shall have a fall to the drains. All drains from the building shall be trapped. Drainage from
the dryer building shall be back to the Liquor return sump.
Aluminium folding, double or roller shutter doors, of sufficient width for dryer installation and
removal, shall be provided with ramp up from finished level.
A potable water supply connection shall be taken from the water supply ring main to a hand
wash basin located in dryer room.
A6.9

The sludge pallet silo, bagging plant and associated equipment shall be housed in the pellet
storage building. The building shall be sized to suit the equipment supplied with adequate
access to all areas for maintenance and an overhead travelling electric crane shall be
provided. Specifically, space must be provided for baggage storage.
Floor drains and washing down connection points, shall be provided in the building. Floors
shall have a fall to the drains. All drains from the building shall be trapped. Drainage from
the building shall be back to the Liquor Return sump.
Equipment installation access provision shall be made to the silo building.
A6.10
Polyelectrolyte Storage and Dosing Building

The building shall have separate rooms for polymer storage and polymer preparation and
dosing. Powder polymer bags and equipment for polymer transfer shall be stored in the
storage room. Another room shall house polymer preparation (making-up) and dosing tanks,
dosing pumps and associated equipments.
for maintenance and an overhead travelling electric crane shall be provided. GRP open mesh
flooring (anti skid) shall be provided at the working area.
All pipework and ducts laid beneath the building foundation shall be surrounded in concrete.
Rigid pipelines shall have flexibility at the edge of the concrete surround.
Floor drains and washing down connection points shall be provided in the make-up and
dosing room. Floors shall have a fall to the drains. All drains from the building shall be
trapped. Drainage from building shall be back to the liquor return sump. The polymer makeup room door shall be sized according to the make-up and dosing tank sizes.
Vol 3, Section3
Page A-11 of 33
Specifications
A potable water supply connection shall be taken from the ring main to the site. The water
shall supply a header tank which will provide water for polymer make-up and a supply to a
hand wash basin. The polymer store shall be sized to provide at least 30 days supply of
polymer at average loading rates.
A6.11

The Odour Control Building shall comprise Odour control units and odour extraction fans with
associated equipment. The building shall be sized to suit the equipment supplied with
adequate access to all areas for maintenance and an overhead travelling electric crane shall
be provided. Building shall have a separate MCC control room for equipment control.
A6.12
The Chlorination Building shall comprise a chlorine drum store, a chlorinator room, a control
panel room, motive water pump room and any other additional equipment rooms required
for the chlorination system. The chlorination system shall be designed by a reputable,
experienced, specialist manufacturer and supplier.
The chlorine drum store shall be sized to suit the number of chlorine drums to be supplied.
The equipment shall be designed so that the delivery vehicle can draw up alongside the
drum store and the drums lifted directly from the vehicle into their final position. A folding
or roller shutter door shall be provided for access to the drums. All materials used in the
drum store shall be suitable for exposure to low levels of chlorine.
All services and process pipework beneath the building foundation shall be laid in sleeves
with concrete surround. Chlorine dosing pipes shall be laid either in covered pipe trenches
or against interior room walls. All interior pipework shall be protected from accidental
damage.
The drum store shall include an emergency shower and eye-wash and hand wash basin.
Doors in the drum store and chlorinator room shall have panic bars and windows to allow
inspection of the rooms before entering.
Gas detection, ventilation and other safety aspects of the design of the Chlorination
Building are specified in the Mechanical Specification.
A6.13

The Generator Building shall house standby generators, day fuel tank with associated
equipment. The building shall be sized to suit the equipment supplied with adequate access
to all areas for maintenance. Building shall have a separate MCC control room for equipment
control.
A cross flow ventilation system shall be provided in the building.
A minimum of 4 air
A6.14
Electrical Sub-station and Control Buildings

Following electrical buildings are proposed based on plant base line design:
1. M.V. Substation Building
2. Electrical Substation no. 1,2 &3
3. MCC Control Rooms
Vol 3, Section3
Page A-12 of 33
Specifications
Details of various electrical buildings are give in Volume 3, Section 4.2 Electrical
specifications. The buildings shall be sized to suit the equipment (panels, transformers,
switchgear etc) supplied with adequate access to all areas for maintenance and as per
regulatory requirement.
A6.15
Chemical Storage and Dosing Facility

FRP Chemical storage tank and dosing pumps shall be house within the reinforced concrete
bunded area to contain the any leakages from the tank. Volumetric capacity of bund shall be
equal to the 110% of the capacity of chemical storage tank. Chemical transfer area shall be
designed to contain and transfer, any spillage occur during the chemical transfer, to the
bunded area. Facility shall be covered from the top by steel/concrete roof structure.
Eyewash and shower facility shall be provided near chemical storage facility. Facility shall be
designed considering health and safety issues.
A6.16
Diesel Storage and Fuelling Facility

Steel Diesel storage tanks for dryer and generators shall be house within the reinforced
concrete bunded area to contain the any leakages from the tank. Volumetric capacity of
bunds shall be equal to the 110% of the capacity of diesel storage tank. Diesel storage area
shall be covered from the top.
Diesel transfer pumps for dryer and generators shall be housed in the diesel pump house.
Pump house shall be sized to suit the equipment supplied with adequate access to all areas
for maintenance
A6.17

A separate building comprising toilet and shower facilities shall be provided for the use of
plant operators. The building shall be designed to suit the likely number of plant operators
but shall as a minimum include three WCs and two showers along with sinks and changing
areas.
A7
BUILDING SERVICES
A7.1
Building services shall be provided to all buildings, control panel enclosures and generator
housings. The building services installation shall generally be in accordance with the
electrical and mechanical specifications. In particular the design and installation of all
building services shall take into account the requirements of the following standards:
a.
Chartered Institution of Building Services Engineers Guides

i.
ii.
iii.
iv.
v.
vi.
b.
CIBSE
CIBSE
CIBSE
CIBSE
CIBSE
CIBSE
Guide A - Environmental Design.

Technical Memoranda TM04 Design notes for the Middle East.
Guide C Reference Data.
Guide B2 Ventilation and Air Conditioning.
Code for Interior Lighting.
Technical Memoranda TM12 Emergency Lighting.
British Standards
i.
Vol 3, Section3
BS 5266 Part 1: 1988 Emergency Lighting Code of Practice for the

emergency lighting of premises other than cinemas and other specified
premises used for entertainment.
Page A-13 of 33
ii.
iii.
iv.
v.
vi.
vii.
c.
BS 5839: All relevant parts - Code of practice for fire detection and alarm
systems for buildings.
BS 7430: 1998 Code of Practice for earthing.
BS 7671: 2001 Requirements for electrical installations (IEE wiring
regulations 16th Edition).
BS 5250: 1995 Code of practice for control of condensation in buildings.
BS 7120: 1989 Specification for rating and performance of air to liquid and
liquid to liquid chilling packages.
BS 7206: 1990 Specification for unvented hot water storage units and
packages.
Bahrain Standards
i.
A7.2
Specifications
Ministry of Electricity and Water: EDD/R-1: 1985 - Regulations for electrical

installations.
Lighting
Lighting shall be provided for operation and maintenance function to be undertaken safely.
The contractor shall submit all lighting design schemes for the Engineers approval.
The following minimum illumination levels shall be achieved at floor level: a.
Control Rooms 500 lux using modular fluorescent fitting with Category 3 louvers.
b.
Offices - 500 lux using modular fluorescent fitting with Category 2 louvers.
c.
Control panel rooms, substations and Generator enclosures 300 lux using liner
fluorescent fittings with prismatic diffusers. IP 65 rated fittings shall be provided in the
generator enclosures.
d.
Kitchen/Mess room, locker rooms and toilets 300 lux using modular fluorescent
fittings or compact fluorescent fittings fitted with prismatic diffusers.
e.
Process plant areas 300 lux using linear fluorescent fittings IP 65 rated prismatic
diffusers. All Other Rooms/Corridors. The average illumination in these areas shall be
300 lux.
All fluorescent fittings shall be provided with T8 colour 3500 lamps, the contactor shall design
the lighting systems to minimise the number of different fluorescent lamp wattage ratings.
All lighting shall be switched from manual switches located at doorways to suit the
installation. Two way switching shall be provided as required.
All buildings shall be provided with emergency lighting to provide illumination of the escape
routes. The minimum illumination level at floor level to be achieved is 2 lux. Emergency
lighting shall be self-contained non-maintained type, fitted with 3-hour duration batteries.
Each emergency lighting circuit shall be provided with a secret key test switch. The
contractor shall issue test and completion certificates within the test log book for the
emergency lighting systems installed.
External Lighting - A comprehensive site lighting system shall be provided to illuminate all
areas around the whole of the new works including the areas of the existing works which are
to be modified and incorporated into the new works.
An illumination level of 150 lux average shall be provided to illuminate each major item of
mechanical plant, valves, penstocks, remote mounted instrumentation etc.
An illumination level of 20 lux average shall be provided to illuminate all walkways and paving
areas.
The main switch system for all external site lighting shall be located within the control room.
Vol 3, Section3
Page A-14 of 33
A7.3
Specifications
Small Power
Small power services shall be provided in the form of 13A twin switched socket outlets in
office type areas, BS4343 style socket outlets (240V and 415V) in process areas and switched
fused spurs for connection to fixed equipment. The contractor shall submit the small power
schemes for the Engineers approval.
The number of socket outlets required in any area shall be determined by the contractor to
suit the equipment to be installed/supplied and the requirements for undertaking
maintenance operations on the equipment/plant installed. In addition to the socket outlets
required the contractor shall install 50% additional socket outlets for future development.
The minimum number of sockets to be provided in any area is two.
A7.4
Air Conditioning
The Administration, Workshop and Control building shall be air-conditioned. Control panel
rooms in other buildings shall be similarly air-conditioned using split units. RTR enclosures for
MCCs and any other enclosure where contained equipment may generate high temperatures,
or where the contained equipment is temperature sensitive, shall also be air conditioned in
accordance with this specification. The contractor shall submit the air conditioning schemes
for the Engineers approval. The units shall be sized and thermostatically controlled to
maintain the temperature within each room below 23C under the specified climatic
conditions.
A7.5
Ventilation
Ventilation shall be required for process buildings, pump house wet wells, valve chambers
and underground structures. In general a minimum of four-air changes/hour shall be
provided. The contractor shall submit the ventilation schemes for the Engineers approval.
The ventilation system shall comprise ductwork and in-line ventilation fans. The location of
the duct terminal grills shall be determined to suit the location of the plant/equipment
installed.
RTR panel enclosures shall have a cross flow ventilation system of at least 2 air
changes/hour.
A7.6
Foul drainage
The foul drainage system shall consist of PVC or HDPE pipe. Floor gulleys shall be of PVC or
other approved material to suit likely loadings. All drains shall be trapped. All foul drainage
shall discharge to the STP drainage system.
A7.7

Potable water shall be supplied to building roof tanks from the potable water supply
network.
A7.8
Fire Protection, Detection and Alarm

Buildings shall be protected by fire protection systems according to local fire and Civil
Defence Regulations. The contractor shall submit the fire protection, detection and alarm
schemes for the Engineers approval.
The administration/control building, blower houses, sludge belt press house, dryer room,
diesel storage area, control panel rooms, intake substation, chlorination building and any
other buildings housing sensitive equipment which may be susceptible to fire shall be fitted
with an automatic fire detection and alarm systems. The detection system shall be based
Vol 3, Section3
Page A-15 of 33
Specifications
upon optical smoke detectors and where necessary fixed temperature heat detectors. A
minimum of two sounder circuits shall be utilised in the design.
All fire detection and sounder circuits shall be wired in fire resistant cabling such as MICC with
orange oversheaf. The contractor shall issue test and completion certificates within the test
log book for the fire detection and alarm systems installed.
A7.9
Telephones
The security kiosk, administration, workshop and MCC control Building shall have telephone
connections. Each telephone connection shall terminate in a RJ-45 socket, the location of
which to be agreed on site. The installation of the telephone service shall be in accordance
with BATELCO requirements and standards.
Each telephone socket shall be provided with a BATELCO compliant handset.
A7.10
Lightning Protection
1.
Assessment of Risk
The Contractor shall assess the risk of lightning strikes and whether lightning protection is
necessary for the building fabric. This assessment shall be carried out in accordance with
BS 6651: Code of Practice for Protection of Structures against Lightning - 1999. All the
contractors calculations shall be issued to the Engineer, as part of the Contractors detailed
design.
2.
Protection System
If the risk assessment shows that lightning protection is required, it shall be carried out in
accordance with BS 6651: 1999. The protection system shall provide protection for the
building fabric and internal electrical and electronic equipment, to comply with a risk level
of low exposure level.
3.
Design Requirement for Protection System (Building Fabric)
The lightning protection system shall be designed in accordance with BS 6651: 1992 and
the contractor shall consider using the rolling sphere method to determine zones of
protection to ensure the sides of the structure are protected from damage. The Contractor
may consider using reinforcement bars, structural steelwork etc. as part of the down
conductor system providing it can be demonstrated that they offer good electrical
conductivity.
Earthing rods shall be installed and connected to each down conductor to provide a low
resistant earth connection. This resistance shall not exceed 10 times the number of earth
electrodes provided. The whole earth termination network resistance shall not exceed 10
ohms, without taking account of any bonding to other services. The Contractor shall carry
out a soils resistivity survey to calculate the number and depths of earth electrodes
necessary to achieve the specified resistance.
4.
Design Requirements for Protective System (Electronic Equipment)
The contractor design shall incorporate the following measures within the design of the
protective system.
Earthing and bonding of all electrical services, cabling entering/existing structure to a
common earth point.
Vol 3, Section3
Page A-16 of 33
Specifications
Power and data cabling between building/structures to be installed within metallic conduit
or trunking with all metalwork bonded to the common earth reference at both ends.
The Contractor shall consider locating sensitive equipment away from those areas in which
lightning currents will preferentially flow.
Earthing systems between adjacent building/structures to be interconnected creating a
single earth reference for all equipment.
Protection of incoming mains power supply and telephone lines from transient
overvoltages.
Minimisation of inductive coupling loops between mains and data cabling by installing on/in
adjacent conduit/trunking/tray work. Note requirements of circuit segregation still remain.
The system of protection shall prevent lightning surge voltages/currents from entering the
electrical system with the building.
Mains borne lightning surges shall be limited to a let through voltage of 600 volts. Each
source of incoming supply shall be provided with surge protection.
A7.11
Furniture
The adequate furniture and utilities shall be provided in the Control/Administration and
Workshop/Laboratory Buildings to meet the functional and operational requirement of
buildings. Furniture/ utilities shall be new and of good quality. The Contractor shall submit
full details of his proposed furniture and utilities for the Engineers/Employers approval.
A8
ROADWORKS, LANDSCAPING AND OTHER EXTERNAL WORKS
A8.1
Roadworks
Minimum of 6m wide Roads shall provide vehicular access to all the major items of plant
generally as shown on the layout drawing. Road shall be designed as per governing
regulatory authority standards.
Roads shall be kerbed with gullies at low points. Drainage system for road shall be designed
in co-ordination with whole site. Raised kerbs shall generally be provided where protection is
required to adjacent structures or services or to protect sloping embankments. In other
areas flat kerbs shall be used with drop kerbs at the transitions. In addition, drop kerbs and
lengths of flat kerbs shall be provided at suitable locations to give access off the road. In
some areas this may include the construction of suitable access ramps from the road.
Suitable vehicle standing areas shall be provided at areas where loading/off-loading is
planned and at planned crane locations for equipment maintenance. The standing areas
shall be designed so that access and free flow of traffic is not impeded during
loading/unloading/maintenance operations.
A8.2
Landscaping
Plant landscaping shall be designed to suit the island landscaping. Hard landscaping of
concrete interlocking paving block may be required between units and road to access the
plant and equipments. The landscaping scheme shall
i.
ii.
Wherever feasible use trees and bushes of different types and sizes suitable for the
climate in Bahrain.
Provide local areas of greenery around the main Administration/Control Building.
Vol 3, Section3
Page A-17 of 33
iii.
Specifications
Include any necessary soil conditioning and fertiliser (sludge from the existing drying
beds may be utilised).
The final landscaping scheme shall be subject to the approval of the Engineer.
A8.3
Pathways
Frequently used accesses (this applies to all external doors to buildings and to main access
points to external tanks), shall be accessible by means of minimum 900 wide pathways.
For the balance of accesses, such as building and process tank perimeters, access shall be
by means of minimum 700 mm wide pathways. Pathways shall include steps as
appropriate. Pathways shall be edged with hydraulically pressed, precast concrete edgings
with concrete backing, laid flush with the surfacing. Pathways laid against structures shall
have a slope of 1:50 away from the structure.
Pathways shall be constructed from either:
i.
75mm thick structural concrete placed on 1000 gauge polythene sheet with brushed
finish and suitable joints.
ii. Interlocking block paving.
iii. Pre-cast concrete paving slabs.
Pathways shall be provided to give access as follows:
i.
Around buildings to all accesses.
ii.
Along the edge of the new Aeration Tank.
iii.
Around the perimeter of each Final Settlement Tank.
iv.
To and around the FST distribution chamber.
v.
Around the Tertiary Filters.
vi.
To all the filter access staircases.
vii.
To all access staircases indicated on the Drawings
viii. To all pumping stations and associated valve chambers.
ix.
To all control equipment.
x.
To all washwater tap locations.
The pathway in front of the Administration/Control Building shall be interlocking block paving
with pre-cast concrete edgings.
A8.4
Site Boundary Wall / Fencing and Security Gate

Contractor shall provide a pre-cast boundary wall around the entire perimeter of the STP site.
The wall shall be architecturally designed to produce an aesthetically pleasing faade and
reduce the visual impact of the STP plant and equipment.
A full road width security gate and security kiosk will also be provided at the main STP access
point.
The gate shall be automatic sliding type to suit a minimum 6m wide clear opening with
recessed wheel running on raised rail. Minimum height shall be 2.4m. Wheel/s shall be cast
iron with sealed bearings. Gate shall be fabricated from mild steel in a decorative pattern
coordinating with the boundary and finished with high quality epoxy paint. The gate shall
retract along the inside of the boundary wall into a guide rail system. The gate shall be
provided with internal and external sensor systems to prevent closing when obstructed. Gate
opening and closing shall be controlled remotely from inside the Security Kiosk.
A8.5
Potable Water Supply, Irrigation Main and TSE re-use line

Potable water shall be required for drinking, washing, shower, polymer makeup and
emergency eyewash/ shower purpose at various process units and buildings. TSE water
Vol 3, Section3
Page A-18 of 33
Specifications
shall be used for landscaped area irrigation and at various process units wash-down,
cleaning purpose.
Contractor shall provide a potable water ring main, irrigation ring main and TSE re-use ring
main along the plant road to cover various process units/ buildings/ landscaped area
potable water/ irrigation water/ TSE reuse water demand.
A8.6
Cable Ducts and Drawpit Chambers

Cable ducts shall be 150mm diameter uPVC bedded and surrounded with sand. All cable
ducts shall be threaded with nylon draw cord and have warning tape. Ducts crossing roads
and other trafficked areas shall be surrounded in grade C45/20 concrete and have
additional spare capacity of 30% for future use. In general main duct routes in other
areas shall have additional spare capacity of 20%.
Chambers shall be located at all changes of direction and generally at a spacing not
exceeding 30m. Exceptions will be subject to the Engineers approval. The chambers shall
generally be constructed from reinforced concrete in accordance with the Contractors
detail design. Plastered blockwork construction will only be permitted in non trafficked
areas where the entire chamber is above the maximum groundwater level. Concrete
protection shall be as specified for other reinforced concrete structures. Chamber covers
shall be appropriate to the likely loading in the location of the chamber generally medium
duty. Solid pattern anodised aluminium decking covers (as specified for the Inlet Works,
Clause 6.2.1) may also be used as an alternative to the cover details shown provided it can
be demonstrated to the Engineers satisfaction that the cover is suitable for the required
loading condition.
A8.7

Other external works include foundations and base slabs for equipment such as control
panels (and enclosures), generators and skips. These shall be designed by the
Contractor to suit the equipment being supplied in accordance with the principles
described in this specification. Concrete protection shall be as specified here and
indicated on the drawings.
A9
INTERNAL SEWERAGE AND DRAINAGE

Contractor shall provide the internal sewerage system covering administration and workshop
buildings and other control/ process buildings with sanitary facility.
Site drainage system shall be designed considering surrounding area topography, plant units
and road profile. In particular the drainage system should intercept surface water /
stormwater flows from the adjacent hill.
A10
TERMINAL LIFT PUMPING STATION (Inlet Pumping Station)
A10.1
Location
The TLPS is to be constructed at the location shown on the Drawings at the termination point
of the main deep gravity sewer serving the AMAS Islands.
The location is on west Island 13c on the opposite side of the screening hill to the STP.
The location has been fixed on the basis of ensuring a safe distance from the underlying
Alat aquifer and associated Water Resources Directorate approvals.
Vol 3, Section3
Page A-19 of 33
A10.2
Specifications
Coordination and Interfaces

The deep gravity sewer is to be constructed by others concurrently with the STP.
The interface point between the sewer and the pumping station is at the termination point of
the deep gravity sewer at the entry to the pumping station excavation shaft as indicated on
the drawings.
Close coordination with the tunnelling contractor will be essential for completion of the final
tunnelling operations to the TLPS since the STP contractor is responsible for the excavation of
the TLPS shaft to suit the pumping station design.
The invert level of the deep gravity sewer at the interface point is -11.610m.
A10.3
Future Connection Manhole

A manhole shall be constructed on the incoming deep gravity sewer within the TLPS
excavation shaft for future connections. The requirements for the manhole are outlined
below:
A10.4
Manhole details shall generally be in accordance with the details shown on the
manhole standard details drawings
Minimum internal diameter to be 3100mm to at least 2m above the crown of the

sewer pipe. Diameter may reduce to not less than 2100mm at higher level.
Manhole to have full internal RTR liner and heavy duty cover
1200mm diameter stub-out pipe, extending a minimum of 3 metres outside the

manhole wall, is to be provided as indicated on the Drawings.
Outline general arrangement details of the TLPS are included in the Drawings. The
arrangement details are to be developed by the Contractor based on his proposed equipment
whilst maintaining the indicated concept.
The TLPS will be visible from the private development area on Island 13. The station shall
therefore be designed so that the visual impact is minimised. This shall include a decorative
boundary wall (matching the STP wall), carefully considered structure designs and
architecture and external landscaping with graded slopes, bunds, plants and trees.
A10.5
Earthworks and Retaining Wall

The area allocated for the TLPS is currently raised as indicated by the contours and existing
ground levels shown on the Drawings (G002). The ground level in the area of the TLPS is
between approximately +7m and +8m rising steeply at the east side up to approx.. +12m
(and up to +16m at the top of the hill).
The Contractor shall be responsible for preparing and grading the area to a suitable level for
the TLPS construction. It is likely that a retaining wall will be required along the east side of
the pumping station compound area.
The maximum slope allowed to the side of the screening hill is 1:3.
Overall it is expected that the TLPS excavation shaft for the station construction will be
approximately 20m deep.
Vol 3, Section3
Page A-20 of 33
A10.6
Specifications
Access Roads
The TLPS shall have a min. 6m wide access road from the STP access road which connects
with the main Islands. The access road bend radii and slopes shall be designed to suit the
heavy vehicles requiring access to the station including cranes, trucks and tankers.
Internal access roads shall be provided for access to all equipment. Equipment requiring
regular service and maintenance access such as the standby generator, screenings skip and
odour control equipment shall be provided with drive through access where possible within
the compound limitations imposed by the slope of the screening hill. Where provision of
suitable drive through access is impractical, turning areas shall be provided.
Internal access roads shall also provide access for cranes/hiabs for pump, screen and other
M+E equipment maintenance and removal.
A10.7
Boundary Wall, Compound and Gate

The TLPS and all associated equipment shall be enclosed in a compound. This shall include
the substation, standby generator, odour control equipment, valve chambers and the main
station.
The compound wall shall be as specified for the STP although contrasting, rather than
matching, designs are acceptable
The main compound gate shall be hinged and comprise twin leaves opening inwards. The
gate shall be constructed from epoxy coated mild steel or aluminium and shall have a high
quality design and finish in keeping with the overall architectural design concept for the with
pumping station and compound. Separate gated pedestrian access shall be provided either
as part of the gate construction or entirely separate. All gates shall have provision for
padlocking and appropriate, high security padlocks shall be supplied.
A10.8
Landscaping and Irrigation

A landscaping scheme shall be implemented at the TLPS similar in concept to that specified
for the STP. The aim of the landscaping shall be to create a pleasant vista when viewed
from the main AMAS Islands area and thereby minimise the visual impact of the station.
The landscaping scheme shall include perimeter plant and tree planting around the perimeter
of the compound, outside the perimeter wall. A minimum width of 2m outside the wall shall
be landscaped (min. clearance of 3m to be provided between the compound wall and the
STP access road).
The landscaping scheme shall include and automatic irrigation system coving all planted
areas utilising TSE supplied from the STP washwater system.
A10.9
Washing Down and Drainage

The compound shall be provided with a drainage system connected to the pumping station
wet well. The system shall be provided with water traps to prevent odours and gas
escaping from the station. As well as general site drainage, the drainage system shall also
accommodate run from the adjacent hill (including any retaining wall seepage holes).
Washing down points comprising 12mm taps supplied from the STP washwater system
shall be provided around the compound, in particular, washing shall be provided at the
screenings skip area.
Vol 3, Section3
Page A-21 of 33
A10.10
Specifications
Rising Mains
Twin rising mains shall be constructed from the TLPS to the STP inlet works.
Cross connection valves and chamber shall be included to allow either main to be used by
either set of wet well pumps.
A10.11
Site lighting
The compound shall be provided with lighting to the specified lux levels. Lighting columns
shall be standard roads design and lighting shall generally be directed downwards.
A10.12
Odour Control
The pumping station shall include an odour control system as specified in the Mechanical
Specification.
The isolation, inlet, screen chambers, wet wells and any other potential source of odour
shall be covered with sealed covers and connected to the odour control system.
A10.13

The Contractor shall apply to the EWA for a potable water supply to the station in
accordance with standard procedures.
Potable water shall be supplied to roof mounted storage tank/s for supply to showers,
toilet, kitchen and hand washing areas.
A10.14
Buildings and structures

Buildings shall comply with the specification for the STP buildings and the standard
specification. This shall include fire protection and alarms.
The EDD substation shall be in accordance with EDD standard design and include
independent access from outside the compound.
A10.15

Other external works include foundations and base slabs for equipment such as generators
and skips. These shall be designed by the Contractor to suit the equipment being supplied
in accordance with the principles described in this specification. Concrete protection shall
be as specified here and indicated on the drawings.
A11
LONG SEA OUTFALL
A11.1
General
A sea outfall is to be provided to discharge treated effluent from the STP during periods
when flow is in excess of the irrigation demand and STP storage capacity. The outfall will
also provide a disposal route for emergency overflows and out-of-spec effluent not
suitable for delivery to the TSE irrigation network.
Preliminary outline details of the outfall are shown on the Drawings (Volume 5). The
details shown shall form the basis of the Contractors design and shall be developed into
the final design to suit the Contractors construction methods.
Vol 3, Section3
Page A-22 of 33
A11.2
Specifications
Environmental Impact Assessment

An EIA has been prepared for the outfall in accordance with Bahrain legislation and the
requirements of Bahrains Supreme Council for Environment.
The EIA included
hydrodynamic modelling of the outfall discharge and the discharge location has been
finalised accordingly.
Further details of the EIA for the outfall and associated environmental management plans
are included in Volume 6.
The Contractor is required to develop the Construction and Operation Environmental
Management Plans for the outfall included in Volume 6 and comply with the stated
requirements.
All dredging work shall be carried out in compliance with the Construction Environmental
Management Plan (ref. Volume 6) and the Supreme Council for the Environment document
EIA-9 Guidelines on the TSS Monitoring Program of Large Scale Projects Involving
Intensive Dredging and Reclamation Operations.
A11.3
Outfall Designer
The Contractor shall employer a suitably qualified, specialist outfall designer with a
minimum of 10 years experience in similar work. The designer shall be subject to the
Engineers approval.
A11.4
Design Data
A11.4.1
Concept
The design concept for the outfall is for gravity discharge of the specified flows from the
TSE Storage Tank overflow, various TSE Tank by-passes and Inlet Works emergency
overflows.
It is expected that the flows will be collected at an Outfall Chamber which will also function
as an air release chamber to prevent air being carried into the outfall. The head available
at the chamber shall then be sufficient for gravity discharge via the outfall of the peak
specified design flows.
A11.4.2
Flows
Initial Average Flow (IAF)

Future Average Flow (FAF)
Future Peak Daily Flow (FPDF)
Future Ultimate Peak Flow (FUPF)
=
=
=
=
39,680 m3/day (459 l/s)

59,520 m3/day (689 l/s)
92,851 m3/day (1075 l/s)
127,968 m3/day (1481 l/s)
The outfall shall be designed with sufficient capacity for gravity discharge of the Future
Peak Daily Flow. Space shall be allocated for a future outfall pumping station to meet the
requirement for any further increase in capacity which may be required in the future.
A11.4.3
Design Pressure
The outfall shall be designed for a minimum operating pressure of 1.5 bar (to allow for
capacity increases). Pipes shall have a minimum pressure rating of 2.5 bar.
A11.4.4
Route & Discharge Point
Vol 3, Section3
Page A-23 of 33
Specifications
The new outfall pipeline shall run along the route indicated on the Drawings to the effluent
discharge point. The total length of the outfall is approximately 4,510m with approx.
3,492m in the channel sections (canals) between islands and the remaining length of
1,018m offshore from the AMAS islands.
The coordinates of the discharge point of the outfall are E 445230, N 2904170. Sea bed
level at the discharge point is approximately -7.9m.
Channel bed level is approximately -3.3m.
A11.4.5
Design Life
The required design life of the outfall is 50 years.
A11.4.6
Waves and Current

Marine pipelines shall be designed to provide stability against a wave with 100 year return
period and a current speed of 1 in 10 years. The Contractor shall obtain the latest data on
extreme wave heights at the project location.
Wave and current design data is summarised below:
Offshore
Significant wave height Hs at -7.9mMSL = Contractor to obtain latest data

Wave Direction to Outfall = 90 deg (worst case)
Current at -7.9mMSL = 1.0m/sec.
Current Direction to Outfall = 45 deg
Channel Sections (waterways between islands)
A11.4.7
Significant wave height Hs at -3.3mMSL = 1.0m (assumed sheltered to offshore

conditions)
Wave Direction to Outfall = 90 deg (worst case)
Current at -4.0mMSL = 0.5m/sec.
Current Direction to Outfall = 45 deg
Bathymetry and Geotechnical Data

Bathymetry data and geotechnical data is included in Volume 6.
The Contractor shall be responsible for any additional survey or investigation required for
his design.
A11.4.8
Tide Levels
Tide level data for the area is given in the following table. The outfall hydraulic design
shall be based on satisfactory discharge of the specified flow at the HAT.
Datum Elevation
Mean Sea level (mMSL)
Highest Astronomical Tide (HAT)
+1.3
Vol 3, Section3
Page A-24 of 33
Specifications
Datum Elevation
Mean Sea level (mMSL)
Mean High Water Springs (MHWS)
+0.9
Mean High Water Neaps (MHWN)

+0.4
Mean Sea Level (MSL) = Bahrain National
+0.0
Survey (NSD) Datum
Mean Low Water Neaps (MLWN)
-0.5
A11.4.9
Mean Low Water Springs (MLWS)
-0.9
Lowest Astronomical Tide (LAT)
-1.4
Chart Datum (CD)
-1.5
Diffusers and Initial Dilution

The diffuser configuration indicated in the tender drawings has been designed to provide
at least 1:10 near field initial dilution. Flanged Wide-Bill Variable Orifice Duckbill Diffuser
Check Valves (Tideflex or equivalent) are to be installed at each discharge port to enable a
higher velocity of discharge and to mitigate the risk of sediment and saline intrusion,
during no flow periods.
Specification for the check valves is included under the outfall materials specification
below.
A11.4.10 Air Transport

The outfall shall be designed with sufficient gradient over the initial section within the tidal
zone to ensure that air is not transported forward in to the outfall pipeline. Air release
shall be provided at the STP end (e.g. at the Outfall Chamber).
The indicative minimum critical pipe gradient at the FDPF is 1 in 99 for gravity flow.
A11.4.11 Pipe Roughness
Hydraulic calculations shall be based on the Colebrook White formula using a value for the
roughness coefficient ks of 1.0mm for all pipe materials. The ks values is based on
pipelines that have been in operation over a number of years.
A11.5
Other Features
A11.5.1
Maintenance Access
Access for observation and maintenance shall be provided at strategic points along the
outfall including close to major bends. Typical details of access manholes are included in
the Drawings. The access manholes will be mainly used for inspecting the internal
conditions of the pipe by CCTV or ROV, man entry will not be available.
A11.5.2
Diffuser Protection Domes

The diffusers are to be provided with protection domes for protection against damage
from shipping. The domes shall be reinforced concrete with openings for discharge of the
effluent and removable top opening for inspection and access.
Vol 3, Section3
Page A-25 of 33
Specifications
The size, dimensions and material of the diffuser protection domes is to be further
developed by the Contractor during his detail design.
A11.5.3
Scour Protection
The seabed area around the diffuser discharge location shall be protected from scour with
rock armour. The diffuser pipe section and dome protection units are to be founded on
suitable granular bedding and surround material approx. (40 - 100mm gravel, 0.20m
minimum cover to pipe) with the scour protection (min 10 - 100kg rock armour, minimum
layer thickness 0.50m) placed above the surround material to the existing seabed level.
All imported rock is to be in accordance with CIRIA Report 169 Manual on the use of rock
in Hydraulic Engineering.
Additional scour protection shall be provided to ensure proper protection of the pipeline for
its design life to suit the contractors design e.g. type of ballast used.
A11.5.4
Marking of Outfall and Discharge

Marking of discharge location for navigational purposes and the route of the outfall shall
be in accordance with local regulations.
A11.5.5
Flowmeter
All flow discharged via the outfall shall be metered by an electromagnetic flowmeter. The
meter shall be installed in a chamber and appropriately located to ensure full bore pipe
flow (unless special meter designed for partially full pipe flow metering is employed).
A11.5.6
Automatic Sampler
An automatic sampler shall be provided for sampling of the effluent discharged via the
outfall.
A11.6
Initial Outline Design

The initial outline design for the outfall is included in the Drawings. The basis of the
design and the results of the preliminary hydraulic analysis are given in the following
table:
Flow Scenario
IAF
FAF
FPDF
FUPF
Pipe I.D (mm)
1100
1100
1100
1100
Pipe roughness (mm)
1.0
1.0
1.0
1.0
Flow velocity (m/s)
0.5
0.7
1.1
1.6
Diffuser length (m)
10
10
10
10
No of Risers / Riser I.D.(mm)
2 / 500
2 / 500
2 / 500
2 / 500
No. of Ports / Port I.D (mm)
8 / 300
8 / 300
8 / 300
8 / 300
Duckbill Valves (no.)
Port Jet velocity (m/s)
1.7
2.1
2.6
3.1
Vol 3, Section3
Page A-26 of 33
Specifications
Flow Scenario
IAF
FAF
FPDF
FUPF
Total system loss (m)

Required hydraulic level at HAT
(mMSL)
1.2
2.6
6.1
11.5
2.7
4.1
7.6
13.0
This indicates that a minimum water level of +7.6m is required at the Outfall Chamber for
satisfactory discharge of the Future Peak Daily Flow (FPDF) and +13m is required for the
Future Ultimate Peak Flow (FUPF).
A11.7
Pipeline Stability Analysis

A pipeline stability analysis shall be carried out for the outfall to ensure it has sufficient
weight to resist the action of wave and current generated forces. The analysis shall be
based on the wave and current data given above and shall be carried out as prescribed in
BS PD 8010-2:2004, Code of Practice for pipelines - Part 2: Subsea pipelines.
Ballast shall be provided accordingly to ensure the stability of the pipeline under all
operating conditions. Ballast may be in the form of either traditional, discrete concrete
collars or continuous concrete collars.
A11.8
Pipeline Construction, Materials and Method of Installation
A11.8.1
Minimum Cover
The outfall pipeline shall be laid in a trench with a minimum cover of 1.0m within the
channels and 1.5m in the offshore area.
A11.8.2
Material Options
The pipe material for the offshore section of the outfall shall be HDPE. The outfall laid in
the channels/canals between the islands may be HDPE or RTR.
A11.8.3
Methods of Installation
Suitable measures are to be taken during the installation operation to ensure that stresses
induced in the pipeline do not exceed the safe limits. Before commencing any installation
works or purchasing any pipe materials, the Contractor shall submit calculations proving
that the method of installation proposed will not over-stress the pipeline and that the wall
thickness and class of pipeline shown on the Drawings is suitable for installation. The
Contractor shall make his own investigations regarding the risks of storm or other weather
conditions and the effects of the movement of the sea bed material in terms of either
delaying the installation or other operations and/or damaging the pipeline or temporary
works.
It is expected that the most appropriate method of installation for the offshore section of
the pipeline will be a float and flood method. Installation tolerance for this section shall be
within 3m horizontally and to a vertical tolerance of plus zero and minus 300mm.
In the channels and the shallow area near the STP, it is likely that sections may be bunded
off and dewatered so that the pipeline may be laid in dry conditions utilising conventional
methods thus allowing the use of RTR pipe. In this case, installation tolerances shall be in
accordance with the standard specifications for pipe laying.
The Contractor shall be responsible for construction of suitable bunds and shall not rely on
any existing bunds installed by others. Bunds shall be properly designed to ensure
Vol 3, Section3
Page A-27 of 33
Specifications
stability under all conditions and the Contractors method of working shall include regular,
documented inspection of all bunds to ensure construction safety when working inside the
dewatered sections.
The following shall also be noted with regard to construction of the outfall in the channel
sections:
A number of services, including HDPE duct banks with concrete surround, cross the
channels and the outfall will need to be laid below these services.
A number of temporary bunds are currently installed at several locations. These

shall be retained and will need to be crossed in sections e.g. lay to half way and
complete backfill before commencing second half. The Contractor shall develop his
method of working accordingly.
Bridges will be constructed at the main road crossings of the main channel between
Islands 10/11 and 9/12. This work is likely to be carried out concurrently with the
outfall installation. Careful coordination will be required with the bridge Contractor.
The Contractor shall also make arrangements for having standby plant available to
complete the installation operation in the event of mechanical breakdown, including full
standby dewatering pumps.
A11.9
Hydrographic Surveys
The Contractor shall provide and operate a hydrographic survey vessel for echo sounding
and side-scan sonar surveying of the trench areas, outfall pipelines and backfilling. The
hydrographic survey vessel shall be available throughout the duration of the Marine Works
and for the specified surveys.
For the reduction of soundings an automatic recording tide gauge is to be installed at a
location as close to the Site as possible and checked daily for correct operation for the
duration of the Marine Works and the specified surveys.
The detailed requirements of the surveys are to be agreed by the Contractor before the
start of each survey.
In the inter-tidal area land survey methods may be adopted during suitable tides.
The Contractor shall be required to carry out the following surveys:
a)
Initial Surveys
Following the award of the Contract the Contractor shall carry out an initial bathymetric
survey and side-scan survey of the pipeline route. The surveys shall consist of longitudinal
lines with cross-checks across survey lines taken along the pipeline route as agreed with
the Engineer. The survey shall also extend over the proposed temporary spoil areas, which
the Contractor is proposing to occupy.
b)
Pre-Excavation / Dredging Survey
As soon as the Contractor intends to commence excavation / dredging works the

Contractor shall carry out a bathymetric survey of the area to be excavated / dredged.
c)
Pre-Installation Survey
Immediately prior to installing the pipeline sections the Contractor shall carry out a
bathymetric pre-installation survey of the pipeline trench. Survey charts and crosssections showing all results of the survey shall be produced.
Vol 3, Section3
Page A-28 of 33
d)
Specifications
Pre-Backfilling, Backfilling and Armour Surveys
After the installation of the pipeline and prior to backfilling the pipe trench or constructing
the rock armouring, the Contractor shall repeat the survey detailed in (b) above. The
surveys shall be again repeated during backfilling and construction of the scour protection
as deemed necessary in order to establish the extent of fill placed.
e)
Diver Video Surveys
The Contractor shall carry out diver video surveys of the diffuser section of the outfall.
These surveys shall be carried out immediately following backfilling and within one month
prior to the expiry of the Maintenance Period.
f)
Maintenance Period Surveys
As agreed with the Engineer.

A11.10
Materials
A11.10.1 Concrete
All concrete shall comply with the Standard Specifications. Minimum cover to
reinforcement to be 75mm.
A11.10.2 Steel
All steel exposed directly to seawater shall be either designed for a 50 year corrosion
allowance or be marine grade stainless steel minimum grade 316 L or 254 SMO (where
appropriate) or similar approved.
A11.10.3 RTR Pipes
RTR pipes shall be accordance with the Standard Specifications
A11.10.4 Flanged Wide-Bill Variable Orifice Duckbill Diffuser Check Valve
Supplier
The supplier shall have at least ten years experience in the manufacture of duckbill style
elastomeric, variable orifice valves for diffuser applications, and shall provide references and
a list of installations.
Technical Submittals
The technical submittal for the valves shall include the following documentation:
A.) Product literature that includes information on the performance and operation of the
valve, materials of construction, dimensions and weights, elastomer characteristics, and
pressure ratings.
B.) Diffuser Dimensional Drawing the drawing shall be a scaled version of the actual
nozzle, generic drawings with listed dimensions will not be accepted.
C.) Hydraulic curves for each inlet nozzle showing headloss, jet velocity, and effective open
area all versus flow rate. The hydraulic curves must accurately reflect the variable
orifice characteristics inherent to duckbill valves. The backpressure rating of diffuser
shall be indicated.
D.) Verification of independent hydraulic testing to determine headloss and jet velocity
characteristics on a minimum of eight (8) sizes of duckbill valves ranging from 2
Vol 3, Section3
Page A-29 of 33
E.)
F.)
G.)
H.)
I.)
Specifications
through 48. The testing must include multiple constructions (stiffness) within each
size and must have been conducted for free discharge (discharge to atmosphere) and
submerged conditions.
Verification of Independent Laboratory Testing for Manufacturing Consistency - the
nozzle manufacturer shall provide summary documentation of a report conducted by an
Independent Laboratory for hydraulic testing where multiple nozzles (at least four) of
the same size and construction (stiffness) were tested to validate the submitted headloss
characteristics and to prove the repeatability and consistency of the manufacturing
process to produce the same hydraulic characteristics.
Verification of Finite Element Analysis (FEA) - the nozzle manufacturer shall provide
summary documentation of Finite Element Analysis modeling on representative
duckbill nozzle sizes to determine deflection, stress and strain characteristics under
various load conditions. Modeling must have been done for flowing conditions
(positive differential pressure) and reverse differential pressure.
Report of independent testing that studied the flow distribution characteristics of
duckbill valves installed on multiport manifolds. The manufacturer must have been in
the business of manufacturing duckbill valves at the time the report was published.
Report of independent testing that studied the initial dilution characteristics of duckbill
valves. The manufacturer must have been in the business of manufacturing duckbill
valves at the time the report was published.
Report of independent testing that studied the salt water purging characteristics of
duckbill valves. The manufacturer must have been in the business of manufacturing
duckbill valves at the time the report was published.
Technical Details
J.) The Flanged Diffuser Check Valves are to be all rubber and the flow operated check
type fabricated integrally with a wire-reinforced riser and elbow. The port area shall
contour down to a duckbill, which shall allow passage of flow in one direction while
preventing reverse flow. The flange, riser, elbow, and Duckbill Diffusers shall be onepiece rubber construction with nylon reinforcement.
K.) The integral riser and elbow shall consist of an elastomer inner tube, a fabric reinforced
body section with a helical wire reinforcement embedded in the body. The elbow shall
be covered with a synthetic rubber cover stock for protection against abrasion and
gouging.
L.) The linear bill slit dimension to nominal valve size ratio shall be greater than 2.0.
M.) The flange drilling shall be to PN16 standard. The valves shall be furnished with
stainless steel 316 back-up rings for installation.
N.) The Diffuser Check Valves shall be a variable orifice providing a non-linear jet velocity
vs. flow characteristic, which maximizes jet velocity at low flow rates compared to
fixed orifice nozzles, and a linear headloss vs. flow characteristic.
O.) Manufacturer shall have conducted an independent hydraulic test where multiple valves
(at least four) of the same size and construction (stiffness) were tested to validate the
submitted headloss characteristics and to prove the repeatability of the manufacturing
process to produce the same hydraulic characteristics.
P.) Manufacturer shall have conducted independent hydraulic testing to study the flow
distribution characteristics of duckbill valves installed on multiport manifolds.
Q.) The inlet ports/nozzles shall discharge an elliptically shaped jet. The nozzle must have
been modeled by an independent laboratory using Laser Induced Fluorescence (LIF).
R.) Company name, plant location, valve size and serial number shall be bonded to outside
of the check valve.
Function
Vol 3, Section3
Page A-30 of 33
Specifications
S.) When line pressure inside the valve exceeds the backpressure outside the valve, the
differential pressure forces the bill of the valve open, allowing flow to discharge. This
restriction causes an increase in the jet velocity of the discharge, while the shape of the
opening creates a flattened elliptically-shaped jet to increase dispersion. When
backpressure exceeds the line pressure, the bill of the valve is forced closed preventing
backflow.
Installation
T.) Valve shall be installed in accordance with manufacturers written Installation and
Operation Manual and approved submittals.
A11.10.5 Polyethylene Pipe
All Polyethylene pipe work shall be solid wall black, PE100 and in compliance with WIS 432-03. Minimum SDR as specified below:
PE
PE
PE
PE
100
100
100
100
1200mm OD SDR 26 (Main Outfall and Diffuser)

560mm OD SDR 21 (Diffuser Risers)
355mm OD SDR 21 (Diffuser Ports)
1000mm O.D SDR 26 (Inspection Chamber).
Polyethylene pipes complying with the provisions of German Standards DIN 8074 and DIN
8075, or Finnish Standards SFS 2336:E, SFS 3421 and SFS 2335 shall also be acceptable.
A11.10.6 Jointing of Polyethylene Pipes
Pipe ends are to be finished square to the axis of the pipe for jointing by butt fusion
welding in accordance with UK Water Industry Specification WIS 4-32-08, April 2002 or
equivalent.
Only welding using purpose made, pipe manufacturer approved automatic welding
equipment shall be allowed. All operators shall be trained in the use of the equipment and
certified by the equipment supplier. The equipment shall automatically record all the weld
parameters and reject any non-compliant welds. Records of all joints shall be logged and
downloaded for record purposes.
Pipes and fittings shall be supplied by the same manufacturer.
Approximately one in every twenty welds shall be tested in accordance with BS 2782 Part
3 (Method 320). The weld bead shall be removed cleanly from both sides of the test
piece. The weld shall be deemed satisfactory if:
The weld factor is not less than 0.95, and

The weld itself shows a large elongation prior to failure.
For all flanged and mechanical connections, all flange backing rings bolts and nuts are to
be designed for a 50 year corrosion allowance or be marine grade stainless steel minimum
grade 316 L or 254 SMO (where appropriate) or similar approved.
A11.10.7 Rock Armour
All imported rock is to be in accordance with CIRIA Report 169 Manual on the use of rock
in Hydraulic Engineering.
Vol 3, Section3
Page A-31 of 33
A11.11
Specifications
Cleansing of Pipelines
If, in the Engineers opinion, the Contractor fails to keep an inspected pipeline satisfactorily
isolated after it has been inspected and shown to be clean, he shall, if instructed, again
clean it and demonstrate the cleanliness, as described above, before issue of a Certificate
of Completion.
A11.12
Testing of Pipelines
Testing of pipelines shall be carried out in accordance with the Standard Specifications.
A11.13
Construction Records and Quality Control

The Contractor shall carry out all necessary tests for the purposes of checking the
compliance of materials and workmanship with the requirements of the specification in
accordance with the approved test procedure.
The Engineer may require his representative to be present at any test or tests. The result
of such tests shall be submitted to Engineer at the times specifically stated or if none is
stated, as soon as possible.
The Contractor shall operate strictly in accordance with the approved QA system that will
provide assurance on the quality of the work and that complies with ISO 9001. The Test
reports are part of the Contractors Documents.
In the execution of the Works the Contractor shall be responsible for accurately recording
services, features and strata encountered. Prior to the Completion of the Works, the
Contractor shall furnish the Engineer with a full copy of these records.
Prior to the commencement of the Works, the Contractor shall provide a photographic
record of the working areas including inter-tidal areas and any adjacent buildings,
structures, roads, paths and walls. The Contractor shall supply two sets of progress
photographs at monthly intervals submitted in time for the monthly progress meeting.
Each set will comprise a minimum of 12 No. colour photographs, and shall be issued as
both a hard copy and in an electronic format approved by the Engineer.
Upon completion of the Works, the Contractor shall prepare as built drawings and provide
all information required for incorporation into the health and safety file.
A11.14
Operation and Maintenance

Potentially the outfall will be operated intermittently and flows will be introduced to the
STP on a phased basis. The operating regime shall consider periodic flushing of the outfall
(once every 2 months) with flows generating velocities within the main pipe of greater
than 0.7m/s to allow sediments to be mobilised and reduce the potential for marine
growth to develop. The frequency of this flushing shall be determined once the operating
regime is finalised.
In terms of inspection surveys, annual inspection of the diffuser should be carried out by
diver surveys (visual and CCTV) to observe flows and operation. CCTV or ROV surveys
should also be carried out at the maintenance manhole locations provided for internal
inspection of the pipe condition. Any maintenance then deemed necessary shall be carried
A10
PLANT SCALE MODEL

A high quality scale model of the plant shall be provided for display purposes. The model
shall normally be housed in the entrance of the Administration Building.
Vol 3, Section3
Page A-32 of 33
Specifications
The model shall be supplied by a professional artistic model building company having a
minimum of 10 years experience of industrial model building. Details of the proposed the
model building company shall be submitted for approval, including photographic details of
previously constructed models of a similar nature, before any building work is commenced.
The model shall:
Be of high quality in keeping with its intended use for display purposes
Use high quality paints and finishes matched to the actual plant finishes
Have a minimum area of 3m2
Be a life-like and accurate representation of the plant, accurately built to scale
Incorporate sufficient detail to illustrate the workings of the plant including
equipment installed in tanks and buildings
Include plant and equipment labelling plus name plate with the plant name and
Employers logo
Include a high quality finish wooden display stand/cabinet
Have a removable acrylic cover
Be designed so it can be dismantled and safely transported for use by the
Employer at exhibitions etc.
A representative from the model building company shall be on-site for the model
installation to check the model is undamaged and properly assembled.
The Administration Building shall include lighting, with local switch, designed specifically for
the best illumination of the finished model.
Vol 3, Section3
Page A-33 of 33
Specifications
CONTENTS
Page No.
SECTION B - GENERAL OBLIGATIONS

B1
B2
B3
B4
DEFINING AND MAINTAINING THE SITE
B1.1
B1.2
Survey of Site
B1.3
B1.4
B1.5
Site Cleanliness and Environmental Protection
B1.6
Demolition, Damage and Making Good
B1.7
Location of Existing Pipelines, Services, Manholes and Chambers
B1.8
Not used
B1.9
Site Drainage
B1.10 Billposting and Advertising
OTHER UTILITIES
B2.1
Existing Services
B2.2
Electricity, Water Supply and Telecommunications
SITE SAFETY AND WELFARE
B3.1
Safety, Health and Welfare
B3.2
Permits to Work
B3.3
Site Hazards
B3.4
Precautions Against Leptospiral Jaundice
B3.5
Excavations
B3.7
Protective Clothing and Safety Equipment
B3.8
Welfare Facilities and Site Cleanliness
B3.9
Use of Equipment
B3.10 Testing of Contractor's Lifting Equipment
B3.11 Dangers of Working in Confined Spaces
B3.12 Dangers of Working in Sewers and at Sewage Treatment Works
B3.13 Emergency Arrangements
10
B3.14 Contractors Plant and Equipment
10
B3.15 Accident Reporting
10
B3.16 Electrical Safety
10
B3.17 Chemical Hazards
11
PROCEDURES AND PRACTICE
12
B4.1
12
B4.2
Continuous Working
12
B4.3
Interface with Other Contractors
12
B4.4
Abatement of Noise
12
B4.5
Pollution
14
B4.6
Protection of Work
14
Volume 3, Section3
Page
i of ii
Specifications
CONTENTS (Continued)
Page No.
B5
MATERIALS AND WORKMANSHIP
14
B5.1
Local and Environmental Requirements
14
B5.2
Quality of Manufacture and Standards
15
B5.3 Approval of Suppliers, Manufacturers, Materials and Manufactured

Items 15
B5.4
B6
Approval of Construction Methods
18
DESIGN
18
B6.1
Planning Permission and Building Permit
18
B6.2
Design Life - General
18
B6.3
Pipelines
18
B6.4
Structures
18
B6.5
Chambers
18
B6.6
19
B6.7
Sound Insulation
19
B6.8
Calculations and Drawings for Approval
19
Volume 3, Section3
Page ii
of ii
Specifications
SECTION B - GENERAL OBLIGATIONS

B1
DEFINING AND MAINTAINING THE SITE
B1.1

Works temporary bench marks shall be established at suitable locations on the Site. During
the progress of the Works the value of the bench marks shall be periodically checked
against the value of the Master Datum. Temporary bench marks shall be located clear of
construction works.
B1.2
Survey of Site
The Contractor shall be responsible for producing an accurate record of the existing site
showing the location of the existing structures and features and existing ground levels.
The existing topography and ground levels shown on the Drawings in Volume 6 Other
Information are indicative only.
Before any work commences on Site, the Contractor shall take colour photographs in
sufficient quantity in agreement with and in the presence of the Engineer to accurately
portray the condition of the existing works, plant and equipment and general site area. A
set of prints of these photographs of minimum size 200mm by 100mm is to be handed to
the Engineer within four weeks of the Commencement Date.
B1.3

Constructional operations shall generally be confined within the Site, or such other areas of
land as may be negotiated. Contractor's employees shall be instructed not to trespass.
B1.4

Before obstructing the access to any property, satisfactory alternative arrangements must
be provided.
B1.5
Site Cleanliness and Environmental Protection

The Site shall be maintained in a clean and orderly manner and particular attention shall be
paid to the protection and conservation of any local environmental features and local
habitats.
Contractors refuse shall not be deposited indiscriminately and arrangements shall be made
for all waste and general refuse such as bags, packing cases, surplus concrete, waste
timber and tins to be transported to an authorised tip. No refuse is to be deposited into
trenches or other excavations before backfilling. Local facilities for recycling of wastes shall
be investigated and adopted wherever possible.
The public highways leading to the Site, and internal access roads, which are used for
access shall be kept clean and free from spoil and rubbish at all times.
Site personnel shall be prohibited from urinating or defecating on Site except in properly
constructed toilets provided by the Contractor
If the Contractor fails to keep the Site clean then the Engineer will instruct a third party to
carry out the work and the costs shall be recovered from the Contractor through the
Contract.
Vol 3, Section3
Page 3B-1 of 20
Specifications
No caravans or huts are to be brought onto the Site for use as sleeping accommodation
unless prior approval is obtained from the Engineer.
B1.6
Demolition, Damage and Making Good

Care shall be taken when demolishing or cutting away existing work or dismantling existing
plant such that no adjacent work is unnecessarily damaged. Any work so damaged shall be
made good. For major structures in excess of 50 cubic metres the Contractor shall put
forward detailed proposals for demolition, dismantling, and temporary supports.
All materials arising from demolition work, except as otherwise provided for in this clause,
shall be disposed of by the Contractor as surplus material.
Any mechanical and electrical equipment, pipes, fittings and valves retrieved from
demolished or dismantled structures and pipelines shall, if required by the Employer, be
delivered to and stacked at one of the Employers depots to the instructions of the
Engineer. Pipes, fittings and valves not required by the Employer shall be disposed of as
surplus material.
Unless otherwise specified, underground structures and chambers shall be demolished to a
depth of one metre below finished ground level, cleared out and filled with approved clean
material
Where existing sewers and conduits are connected to the new systems, the length of pipe
which is not incorporated into the new system, shall be abandoned.
Buried pipelines to be abandoned shall be sealed with a mass concrete plug to a minimum
depth of 1,000 mm at either end and at any intermediate manholes.
Manholes and abandoned pipelines shall be demolished to a depth of 500 mm below final
ground level and the void filled with hard core or other approved fill material and surface
reinstated to a finish similar to that of the surrounding area.
Exposed raw faces of existing concrete or blockwork which will not have new work built on
to them shall be made good with cement rendering or new blockwork as applicable.
All trees and shrubs shall be protected, if necessary with fencing, unless written permission
is given to fell or lop.
Where any building, land, hedge, wall, fence or other existing feature is disturbed or
damaged in any way the permanent reinstatement shall be made with materials similar,
and not inferior, to those in the undamaged portion.
B1.7
Location of Existing Pipelines, Services, Manholes and Chambers

The exact positions of existing pipelines, services, manholes and chambers shall be agreed
with the Engineer, after trial excavations if necessary have been made to locate existing
services and other buried features.
B1.8
Not used
B1.9
Site Drainage
At all stages of the work the Site shall be properly drained so that standing pools of water
are not allowed to form.
Vol 3, Section3
Page 3B-2 of 20
Specifications
Drainage works shall be in accordance with all relevant laws and regulations and the
Contractor will be responsible for consultation and liaison with all relevant authorities. All
proposals for drainage works shall be approved by the Engineer, but such approval will not
absolve the Contractor from his complete responsibility for the Works in this regard.
Silt traps shall be provided as required on any permanent or temporary drains which may
be required for the removal of water during the construction period. All drains shall be
maintained clear of silt until completion of the Contract. Any silting of drains, whether
within the Site or not, which arises from the failure to observe this clause shall be
removed.
B1.10
Billposting and Advertising

Billposting or advertising of any kind shall not be permitted on the Works without the
written consent of the Engineer.
B2
OTHER UTILITIES
B2.1
Existing Services
As the STP site is located on a recently dredged island there should be no existing services
present. However, the Contractors attention is drawn to the Code of Practice for Service
Installation prepared by the Ministry of Works, Power & Water. In collaboration with the
Engineer and before any work commences outside the STP site, the Contractor shall
contact the local officials of each of the service authorities and shall maintain close liaison
with them throughout the construction. The Contractor shall establish in advance the
positions of all main services liable to interference by the construction and shall mark the
position physically on the ground. The Contractor shall be in possession of a cable locator
for this purpose.
Apart from verifying positions to prevent damage, scrutiny is needed to identify those main
services which might conflict with the Permanent Works where this is not indicated on the
Drawings. Early scrutiny of these services is essential to enable any such diversions to be
made in advance of the construction.
Notwithstanding the scrutiny referred to above the Contractor shall take all reasonable
precautions to prevent damage to existing buried main services and connections to
buildings.
The Contractor should note in particular that the Electricity Directorate will not permit work
in close proximity to high voltage cables (11kV and above) during periods of high demand
(which are normally from about mid May to mid September) other than in exceptional
circumstances.
The Contractor shall provide adequate temporary support to all existing services and
connections that are exposed or partially exposed or otherwise weakened by the
excavation. Should any damage occur he shall immediately notify the Engineer and service
authority and afford every facility for the immediate repair of the affected service.
The Contractor shall carefully preserve and replace all marker tapes and tiles affected by
his excavations.
In addition to the precautions to be taken with buried services the Contractor shall ensure
that his plant and equipment do not damage pipeline or pipe supports above ground or
any overhead electricity or telephone cables. He shall also take all precautions to prevent
his plant from operating too closely to overhead high tension cables, and he shall, in
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Specifications
conjunction with the Engineer and Electricity Directorate establish all necessary precautions
for crossing under such cables.
The Contractor shall afford the Engineer and the relevant service authorities such
assistance as they may require in the preparation of records of existing and diverted
services.
Existing services on the site of the STP are generally the property of the Employer. Similar
procedures shall, however, be followed to also ensure the protection of these services.
B2.2
Electricity, Water Supply and Telecommunications

Electricity, water supplies and telecommunications shall be provided to the Site for both
temporary and permanent requirements.
1.
Water Supply
The Contractor shall provide adequate supplies of water for drinking and for all other
purposes where required.
Arrangements for temporary supplies shall be made with the Water Supply
Directorate P.O. Box 326, Manama.
2.
Electricity Supply
The Contractor shall make arrangements for the supply of electricity to his own
offices, the offices of the Engineer and for use in the Works whether by means of
site generators or by connection to the public supply.
In the latter case
arrangements shall be made with the Electricity Directorate, P.O. Box 2, Manama.
Where a permanent supply will ultimately be provided the Contractor shall not
assume that this is available during the construction of the Works.
3.
Telephones
Where appropriate, the Contractor shall arrange with Bahrain Telecommunications
Company, P.O. Box 14, Manama for his telephone connections. He shall also
arrange for the telephone connections for the Engineer as required by Section A.
B3
SITE SAFETY AND WELFARE
B3.1

The Contractor shall be responsible for the health, safety and welfare of all persons
working on or visiting the Site. He shall obtain copies of the Ministerial Orders current at
the date of Tender and shall comply with these and with any legislation enacted during the
Contract Period that affects working conditions, safety, health or welfare of his employees
or those of the Engineer or Employer.
The Contractors attention is drawn to the guidance manuals on health and safety referred
to in the Schedule of Approved Standard and Guidance Publications in Section S to which
reference should be made. The Contractor shall submit his Health and Safety Manual at the
commencement of the works to demonstrate how he intends to comply with current Health
& Safety legislation and manage the health, safety and welfare of all staff engaged on the
works site.
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Specifications
The Contractor shall submit to the Engineer method statements for all safety proposals in
advance of the commencement of work, approval of which by the Engineer shall not relieve
the Contractor of his obligations to comply with all Decrees, Statutes, Ordinances,
Regulations or bye-laws. He shall make available for inspection by the Engineer all
registers, reports and certificates which the Contractor is required to keep or issue in
respect of safety matters and accidents.
Contractor shall ensure that all personnel engaged on this Contract, including his subcontactors, are aware and adhere to the safety requirements relating to the Contract and
associated site works and shall only employ personnel who have undergone recognised
training and experienced in the works to be undertaken. Experienced personnel shall
supervise any unskilled labour or trainees during the works.
The Contractor shall note that any site personnel found to be working in breach of the
safety requirements or procedures shall be first warned to correct their working methods or
procedures, if repeated breaches occur, the personnel shall be removed from site.
The Contractor shall ensure his personnel comply with any existing regulations in force at
the STP.
B3.2
Permits to Work
All site works shall be covered by a Permit to work, issued by the Engineer. The Contractor
shall not commence site works unless a valid Permit to work has been issued by the
Engineer for the site works to be undertaken.
The Contractor shall provide detailed method statements as required by the Engineer to
complete permit authorisation. These method statements shall identify the working
methods, risks and precautions necessary to complete the works.
Permits to works will be issued to the Contractor as detailed below: i)
Upon handover of the site or working area by the Employer to the Contractor.
ii)
Works requiring access into confined spaces
iii)
Works associated with existing or live electrical equipment.
iv)
Works requiring excavation.
v)
Pumping operations.
vi)
Hot works.
vii)
Operation and use of mobile or static cranes
All Permits shall be time limited and issued in accordance with the Employers procedures.
Blanket permits shall not be issued for the works under any circumstances.
The Contractor shall adhere to the requirements of the Permit, including methods of works
agreed whilst the Permit to work is in operation.
B3.3
Site Hazards
Once the construction programme has been established and detailed planning for the
works commenced, the Contractor will arrange for a HAZCON study to be conducted for
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Specifications
each of the major elements of work. The HAZCON will be attended by the Client, Engineer
and essential Contractor staff.
Hazards on the Site include:
B3.4
i)
Underground pipes and cables.
ii)
Overhead cables.
iii)
Flammable materials.
iv)
Mechanical plant and equipment.
v)
Operational staff and their Contractors and Vehicles.
vi)
Confined spaces.
vii)
Sewage and Sewage products, and the risk of leptospiral jaundice from contact
therewith.
viii)
Live electrical equipment or services.
ix)
Deep existing tanks, chambers and manholes
Precautions Against Leptospiral Jaundice

The Contractor shall ensure all personnel engaged in the site works are aware of the risks
and precautions against Leptospiral Jaundice. The following provides guidance on working
in sewage-contaminated sites:
i)
After working in contact with sewage, or anything which might have been
contaminated by it, wash your hands and forearms thoroughly with soap and water.
ii)
If clothes or boots are contaminated with sewage, wash thoroughly after handling
them.
iii)
It is particularly important to do this before taking any food or drink.
iv)
Wet protective clothing should be dried as soon as possible.
v)
Infection may enter through breaks in the skin so thorough first aid treatment of all
wounds is important.
vi)
Take particular care to wash thoroughly any cut, scratch or abrasion of the skin as
soon as possible whether the injury was caused at work or not.
vii)
Apply an antiseptic to the wound with a clean piece of cloth or cotton wool and
protect it with a strip of gauze completely covered with adhesive plaster.
viii)
Keep the wound covered until it is quite healed. Antiseptic gauze and impermeable
plaster are available at place of work.
ix)
If you suffer any cut, scratch or abrasions of the skin, it must be covered with a
waterproof plaster before entering the place of work.
x)
Avoid rubbing your nose or mouth with hands during work.
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xi)
Specifications
Every accident at work, however trivial, must be reported.
The Contractor shall ensure all personnel, including subcontractors are advised of the risks
and precautions relating to Leptospiral Jaundice and shall display the above guidance on
site in the appropriate languages of his personnel.
B3.5
Excavations
Excavations shall be adequately supported against collapse.
The Contractor shall provide protective safety barriers and appropriate bunting for the
protection of the general public and the Employers operations staff working on the existing
STP.
The Contractor shall also provide suitable and safe bridging over trenches and excavations
where required for pedestrian and vehicular access.
B3.6
Work in Public Highways

Before work commences, adequate advance warning signs, clearly signposted diversions
for traffic and pedestrians and traffic controls shall be provided to the approval and
requirements of the Traffic Directorate, the Ministry of Works, Power and Water and the
Engineer. The Contractor shall provide and maintain night lights and shall ensure their
operation during hours of darkness by night watchmen and/or night patrols.
B3.7
Protective Clothing and Safety Equipment

The Contractor shall provide all safety and protective clothing necessary for his staff and if
necessary his subcontractors, to carryout the works. All safety and protective clothing shall
be maintained in good condition and replaced when required.
All site personnel shall be provided with the following minimum safety and protective
clothing:
i)
Safety helmet.
ii)
Overalls.
iii)
Gloves.
iv)
Safety shoes.
v)
Goggles (if undertaking cutting or grinding works).
vi)
Face masks (if undertaking activities which produce dust or vapours).
vii)
High visibility jackets or waistcoats when working in or adjacent to roads or public

thoroughfares.
All safety equipment such as harnesses, breathing apparatus, ventilation equipment, gas
detectors and any other equipment deemed necessary by the Engineer for the protection
of the Contractors staff shall be provided by the Contractor and maintained in good order.
B3.8
Welfare Facilities and Site Cleanliness

The Contractor shall provide and maintain in proper order suitable messing, sanitary
conveniences and washroom facilities, for use by all persons connected with the
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Specifications
construction of the Works. The welfare facilities shall be provided within 1 week of
commencement of the works on site and shall remain in place until handover of the works.
The Contractor as a minimum shall keep on site one full stocked first aid kit and adequate
potable water for drinking and washing for use of the site personnel.
Rubbish, surplus packaging and materials not required for the works shall be removed
from the Site on a weekly basis and the Contractor shall ensure that the site is kept in a
clean and tidy condition.
B3.9
Use of Equipment
All manufacturers instructions and recommendations for the use, application, erection, or
construction of any material or item of equipment or plant shall be followed precisely.
Care shall be taken to protect all employees when using power tools or materials which will
produce a fine dust and in particular all asbestos based products. Precautions may include:
B3.10
(a)
Operator to stand upwind of the operation and wear an approved respirator and
goggles.
(b)
Overalls to be worn consisting of 60% polyester fibre and 40% cotton, to be worn
whenever possible.
Testing of Contractor's Lifting Equipment

Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle used in
constructing the Works shall be thoroughly examined by a competent person at least once
every 6 months, be test loaded to 150% of the safe working load and then tagged with the
safe working load and date of successful testing.
All parts and working gear, whether fixed or movable, including the anchoring and fixing
appliances of every crane and lifting machine shall be of good construction, sound
material, adequate strength and be properly maintained. All parts and gear shall be
examined by a competent person at least once every twelve months.
An up to date register of all such equipment and examinations shall be maintained and
shall at all times be available for inspection by the Engineer.
B3.11
Dangers of Working in Confined Spaces

Attention is drawn to the dangers of working in confined spaces. In addition to shafts,
tunnels, closed tanks, etc., any confined space with limited ventilation which is also
connected with water in or from a closed conduit or borehole, or is below ground level,
should be treated as a potentially hazardous location where dangerous gases may be
present and prior to entry adequate safety precautions must be taken in accordance with
current good practice.
Reference shall be made to the relevant guidance publications listed in the Schedule of
Approved Standards and Guidance Publications in the document .
B3.12
Dangers of Working in Sewers and at Sewage Treatment Works

1.
All personnel working on the Site shall be made aware of the dangers of working in
live sewers and at sewage treatment works; in particular the risks of physical injury,
of bacterial infection from contact with sewage, of exposure to dangerous gases;
and of explosion of sewage gases.
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2.
3.
Specifications
Safeguards must be taken in accordance with current good practice and attention is
drawn to guidance publications listed in the Schedule of Approved Standards e.g.
National Joint Health and Safety Committee for the Water Service. Health and Safety
Guidelines:
No. 2 - Safe Working in Sewers and at Sewage Works
No. 3 - Respiratory Protective Equipment.
The Contractor shall not permit any employees to enter live chambers without the
express permission of the Engineer in writing.
Permission will only be given on the standard form Authority to work within a live
Sewer, copies of which may be obtained from the Engineer.
4.
The following equipment shall be available at point of entry for personnel entering
sewage manholes, pumping stations or other structures into which sewage or
sewage gas can enter:
(a)
Oxygen deficiency and flammable gas and hydrogen sulphide gas detectors.
(b)
Rope, safety harness, helmet and safety lamp for each person entering the
sewer;
(c)
Two sets of compressed air breathing apparatus including 1800 litre capacity
cylinders, at least 70 linear metres of high quality rubber hose all for 45
minutes of man working time;
(d)
One set of emergency escape breathing apparatus with minimum 800 litre
capacity cylinders in sling harness and face mask with gas tight seal. Air
supply operation to commence automatically when the face mask is fitted and
breathing begins.
5.
Naked lights shall not be used in the vicinity of the structure. No smoking shall be
permitted.
6.
At least two people shall remain close to the point of entry who shall have noted
beforehand the nearest telephone and telephone number of the nearest hospital,
and shall be thoroughly familiar with the use of emergency breathing apparatus and
other safety equipment and procedures.
7.
Ventilation shall be provided by removing manhole covers to upstream and

downstream manholes at least 15 minutes before the structure is entered or such
other method as is appropriate for the structure including, where necessary, forced
ventilation.
8.
The atmosphere shall be tested at points of entry and exit and continuously
monitored while personnel are present. If dangerous gases are present, either (a)
breathing apparatus shall be worn or (b) ventilation shall be continued and the
atmosphere retested until such time as no dangerous gases are detected.
9.
Entry shall be authorised by a responsible person. The Contractor shall supply a list
of the names of such persons to the Engineer before any work in live sewers etc., is
carried out.
10.
All electrical equipment, e.g. power drills, shall be intrinsically safe (i.e. nonsparking).
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11.
B3.13
Specifications
All equipment shall be inspected and tested daily and all air cylinders for breathing
apparatus shall be filled with air from compressors manufactured for that specific
purpose and housed and used in accordance with the manufacturers instructions.
Emergency Arrangements
A current list of names, addresses and telephone numbers of the Contractor's staff
responsible for responding / organising emergency works outside of normal working hours
shall be provided to the Engineer and maintained as necessary.
B3.14
Contractors Plant and Equipment

The Contractor shall at all times be responsible for the adequacy, efficiency and sufficiency
of his and his sub-contractors plant and equipment which shall be of such type and size,
and used in such manner, as the Engineer shall approve.
Details of the plant proposed shall be submitted for the approval of the Engineer, which if
granted will not relieve the Contractor of any of his responsibilities, nor shall reasonable
refusal to approve entitle the Contractor to extra payment.
If circumstances arise which in the Engineers opinion make it desirable that the use of
plant or equipment be changed or suspended, the Contractor shall make such changes at
his own cost. In particular the exhausts of diesel engined plant shall be modified if
necessary to prevent nuisance from smoke and noise. The Contractor shall also ensure
minimum pollution of working areas with fuel oils.
The Engineer shall be entitled to withhold or withdraw his authority for the use of plant or
equipment which is too noisy in the circumstances, or which may endanger members of
the public, passing vehicles, or adjacent roads, services and structures.
B3.15
Accident Reporting
The Contractor shall notify the Engineer in the event of any/all accidents that occur on site,
with 24 hours. Each notification shall include the cause of the accident, personnel
involved; injuries sustained (if any) and proposed measures/methods to prevent reoccurrence.
The Contractor shall notify the Engineer and Divisional Head Occupational Health and
Safety in the event of any/all accidents the occur on site which involve lost time, medical
treatment etc, within 2 hours of the accident occurring. The Divisional Head Occupational
Health and Safety contact details will be provided at the Contract award meeting
All accidents notifiable to the Divisional Head Occupational Health and Safety shall be
formally reported to the Engineer and Divisional Head Occupational Health and Safety, in
the form of an accident investigation report. This accident report shall be submitted within
7 days of the accident.
B3.16
Electrical Safety
All temporary electrical installations required during the works, including generator
supplies, shall conform to the Safety Regulations stipulated by Ministry of Labour and Social
Affairs Ministerial Order No.33-1997 Precautions for protection of workers during work
from hazards of electricity and the current edition of the Ministry of Water and Electricity
Regulations for Electrical Installations. All equipment and cabling shall be in good
condition and electrically safe. The installation and equipment shall be tested at regular
intervals with copies of test/inspection certificates issued to the Engineer.
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Specifications
Any electrical supply derived from the public supply system shall have at its origin a
suitably rated earth leakage circuit breaker in addition to overload and short circuit
protection devices. The supply shall be distributed to the site from a metal clad MCB
distribution board. Each outgoing circuit shall be provided with a suitably rated MCB with
neutral and earth connections.
The Contractor shall install an earth connection independent to the public supply earth for
his temporary electrical installation. This earth shall be in the form of diameter copper
clad earth electrodes driven into the earth, to achieve an earth resistance of not more than
2 ohms.
All site temporary distribution or sub-distribution cabling and cabling to fixed
equipment/installations shall be carried out using suitably sized multi-core armoured cables
with correct glanding arrangements into equipment. The contractor shall not rely upon the
cable armouring to provide the earth continuity conductor; one core of the cable shall be
connected to earth. The cables shall be routed as to prevent or reduce potential damage
from the construction works or equipment.
Sub-distribution boards shall be provided to enable portable equipment to be plugged-in
locally near the work area. The sub-distribution boards shall be metal clad MCB
distribution boards, fitted with suitably rated MCBs, with socket outlets provided for
connection of portable equipment. The preferred type of socket outlet and plug is to
BS4343 design. The use of plug adaptors is prohibited.
Final circuit cabling to portable equipment shall be carried out in suitably rated multi-core
rubber sheathed flexible cables. All connections shall be made through proprietary plugs
and socket outlets only. One core of all flexible cables shall be connected to earth.
Jointing or splicing of cables is strictly prohibited.
All electrical equipment and services shall be weather proof to IP54 or provided with
suitable weatherproof enclosures. Where equipment is exposed to direct sun light suitable
enclosures shall be provided to shade the equipment or services.
B3.17
Chemical Hazards
All chemicals brought onto site shall be stored within the manufactures containers and shall
be fitted with secure lids. The containers shall clearly indicate the contents and quantities
within the container for identification purposes. Chemicals may be in the form of solvents,
resins, alkalides or acids including paints and adhesives.
The Contractor shall issue to the Engineer for approval and retain on site the manufactures
or suppliers chemical hazard data sheet. The chemical hazard data sheet shall be issued to
the Engineer prior to any deliveries to site. The Contractor shall remove chemicals that are
delivered without approval of the Engineer.
The Contractor shall limit the storage of chemical on site that are required for that days
use. Additional requirements or stocks shall be held off site at the Contractors stores until
required.
The Contractor shall remove from site all unused chemicals or empty containers prior to
handover of the works. All unused chemicals shall be disposed of in accordance with the
manufactures instructions and in compliance with the current environmental legislation.
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Specifications
B4
PROCEDURES AND PRACTICE
B4.1
Neither the Employer nor the Engineer accept responsibility for any omissions from or for
correctness of the representation on the drawings of existing features.
B4.2
Continuous Working
If, in the opinion of the Engineer, it is necessary for the safety of the Works or for any
other reason the Works, or portion thereof, shall be carried out continuously by day and
night.
B4.3
Interface with Other Contractors

The construction of the STP and associated infrastructure will be carried out concurrently
with other works on the AMAS islands including earthworks, roads, bridges, utilities,
buildings and housing. This will generate large volumes of construction traffic and possible
intermittent access restrictions. The Employers proposed access arrangements to and
around the islands are indicated on the Drawings.
The STP Contract has a number of specific interfaces with other contracts:
At the Terminal Lift Pumping Station; interface between the TLPS inlet and the
incoming tunnelled deep gravity sewer (DGS) pipe. The interface point with the
DGS will be immediately outside the station inlet within the TLPS excavation shaft.
The TLPS excavation shaft will also be the reception pit for the DGS tunnelling
equipment.
This work will require close coordination with the Contractor
constructing the DGS.
At the plant boundary; interface between the TSE irrigation pipeline from the TSE
Pumping Station and the primary TSE distribution pipeline.
Close the TLPS; interface between the STP access road and the AMAS spine road.
Interfaces are indicated on the Drawings

Close coordination will also be required with the bridge contractors constructing the bridges
over the main channel along which the new STP outfall will run.
B4.4
Abatement of Noise
The Contractor shall make every effort to keep the nuisance caused by noise to a minimum
and consideration must be given to using the quietest plant available (Refer to Clause
B3.14). If instructed by the Engineer, the Contractor shall use electric dewatering/overpumping pumps (with the generator, if required, located remotely to reduce the noise).
The cost of providing such electric pumps is to be allowed for in the rates of work.
The Contractor shall comply with all relevant regulations, decrees, and statutory
requirements relating to restrictions placed on noise from construction work.
Blasting shall not be used unless otherwise approved by the Engineer. All pneumatic
breakers shall be fitted with mufflers. Noise mitigation measures, agreed by the Engineer,
shall be provided for diesel plant when instructed by the Engineer.
Methods of working shall be devised and arranged to minimise noise impacts, and
experienced personnel with suitable training shall be employed to ensure that these
methods are implemented.
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Specifications
Particulars of all constructional plant which is likely to cause excessive noise shall be
submitted to the Engineer. The particulars shall be submitted before the plant is used on
site. Unless otherwise permitted by the Engineer, trials of the plant shall be carried out to
demonstrate that the plant can be operated which will minimise noise during the works.
The trials shall be carried out in the presence of the Engineer. The plant shall not be used
on site until agreed by the Engineer.
The noise level of any construction work other than percussive piling, during the period
0700 to 1900 hours on any day not being a general holiday, including Fridays, measured at
site boundary, shall not exceed an equivalent sound level (LEQ) of 75 dB(A).
The Contractor shall, prior to commencement of the relevant construction work, carry out
baseline monitoring to determine baseline noise levels at the nearest properties along the
pipeline route. Baseline monitoring shall be carried out for at least one week, and at
locations and to a schedule to be submitted to, and agreed by, the Engineer.
Impact noise monitoring shall be carried out at all the agreed locations whenever
construction work is being carried out. The measurements will be determined by the
Engineer to measure the maximum noise impact during the period. Measurements will not
be taken if the Contractor is not working during these periods. Monitoring will be
undertaken according to the following schedule:
1.
At least one LEQ measurement between 0700 and 1900 Saturday to Thursday, three
times each week; and
2.
As determined by the Engineer from time to time and when any powered mechanical
equipment is operating.
Whenever complaints are received, or if the maximum allowable levels are exceeded,
immediate action shall be taken by the Contractor in accordance with an action plan to be
submitted to, and as agreed by, the Engineer.
A weekly report of all noise monitoring data shall be prepared by the Contractor and
submitted to the Engineer, including at least the following:
1.
Copy of all data;
2.
Highlighting of any failures to comply with the criteria set out herewith;
3.
Implementation of the action plan when the levels are exceeded
4.
Identification of reasons for non-compliance
5.
Identification of additional mitigation measures take as a result of 2. Above; and
If monitoring of the noise level shows, in the opinion of the Engineer, an excessive noise
level, the Contractor shall take all necessary measures to ensure that the actions of the
Contractor are not contributing to the excess. The measures shall include, but not be
limited to, the following:
1.
Checking all constructional plant;
2.
Maintenance or replacement of any constructional plant contributing to the excess;
3.
Installation of constructional plant soundproofing,
constructional plant, or erection of sound barriers; and
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provision
of
alternative
4.
Specifications
Review and modification of all working methods and scheduling of activities.
The Contractor shall inform the Engineer of all measures taken, and shall submit to the
Engineer a written report and proposal for action, whenever monitoring shows that an
excessive noise level is arising.
If the proposed remedial measures include the use of additional or alternative
constructional plant, such plant shall not be used on the works until agreed by the
Engineer.
It proposed remedial measures include maintenance or modification of
previously agreed plant, such plant shall not be used on the works until the proposed
maintenance or modification has been completed and the adequacy of the maintenance or
modification has been demonstrated and agreed by the Engineer as being satisfactory.
If approved remedial measures are not being implemented and serious impacts persist, the
Contractor shall cease related parts of the work until the measures are implemented.
Nuisance caused by noise shall be kept to a minimum with consideration given to the use
of the quietest equipment available. All pneumatic breakers shall be fitted with mufflers.
Equipment should not normally be operated during the night, weekends or public holidays
except for pumps dealing with sewage flow or dewatering excavations which are to be
sited to cause the minimum inconvenience to the public.
B4.5
Pollution
All necessary precautions shall be taken to prevent the pollution or siltation of surface
water drains and ground surface by poisonous, noxious or polluting matter arising from his
operations.
B4.6
Protection of Work
The Contractor shall, at his own expense, case up and suitably protect all work liable to
injury, either by the weather or by the method adopted for execution of the Works.
Precautions especially required for the protection of new concrete and brickwork are
specified elsewhere.
No other work requiring the use of cement or lime shall be carried out when the shade
temperature is above 40C (104F) nor shall any materials that have been exposed to the
direct rays of the sun during hot weather be used until, in the opinion of the Engineer,
sufficient time under favourable conditions has elapsed for the materials to reach a suitable
temperature for incorporation in the Works.
The Contractor shall provide a sufficient number of maximum and minimum thermometers
so that the Engineer may observe the shade temperature at each place of mixing, placing
and building.
B5
MATERIALS AND WORKMANSHIP
B5.1
Local and Environmental Requirements

All materials and manufactured items shall be suitable for the climatic and environmental
conditions in Bahrain described in this specification.
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Specifications
The environmental conditions may be different in different parts of the Works and
materials shall be selected and manufactured items designed accordingly to withstand the
relevant corrosive elements. In particular:
(i)
all products or materials in contact with sewage or a sewage environment shall be

non-biodegradable.
(ii)
all products or materials in contact with potable water shall not constitute a toxic
hazard, shall not support microbial growth, shall not cause taste or odour
cloudiness or discolouration of the water, and shall be approved by a recognised
certifying authority as being suitable for use in potable water supply systems.
All local customs, laws and regulations relating to the supply or source of materials shall be
complied with.
B5.2
Quality of Manufacture and Standards

All materials and manufactured items supplied for incorporation in the permanent works
shall be new, of high quality and of sound workmanship. They shall be purchased only
from approved suppliers who shall be capable of demonstrating the suitability of their
products by reference to similar works or certified test results.
Materials and manufactured items shall normally be certified as complying with relevant
specifications of a recognised national or international standards organisation which shall
be subject to the approval of the Engineer.
Except where otherwise indicated in the Contract, the edition of an approved standard
shall be that current 42 days prior to the date for the return of tenders.
The Schedule of Approved Standards and Guidance Publications in Section S lists approved
standards as a quality guide for the materials and articles to be provided. This schedule in
no way prejudices the approval of any other equivalent or superior national or international
standards. Also included in this schedule are publications for guidance on procedure and
practice.
Where the requirements of this specification and an approved standard differ, the more
stringent requirement shall apply. Should the requirements of this specification and an
approved standard be incompatible, the requirements of this Specification shall take
precedence.
Copies of the appropriate edition of any national or international Standards in English
which may be called for as being required in the execution of the Contract shall be
provided for the sole use of the Engineer. These may include alternative Standards to
those to which the materials are manufactured for use as a comparative quality guide. The
Standards will remain the property of the Contractor and will be returned to him at the end
of the Contract.
Any reference to a Manufacturer/product is to be taken as indicative of quality only.
B5.3
Approval of Suppliers, Manufacturers, Materials and Manufactured Items

Prior to the placing of any order for materials or manufactured items, the approval
procedure described under this clause shall be followed. All requests for Approval shall be
submitted in triplicate. The information shall be clearly and neatly presented in a standard
format to be agreed with the Engineer (a sample approval sheet is attached at the end of
his Clause). All submissions shall have a document number and revision reference in
accordance with the Contractors quality assurance system. No orders shall be placed until
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Specifications
one copy of the final Request for Approval has been returned duly signed and dated by the
Engineer or his representative.
Generally a two stage approval procedure shall be followed as described below. The first
stage requires the Contractor to demonstrate that his proposed supplier/manufacturer has
the necessary experience, competency and reputation in the field of the proposed supply.
The second stage follows approval of the supplier and comprises a full technical submittal.
1.
Approval of Supplier/Manufacturer
The Contractor shall submit to the Engineer full details of his proposed
supplier/manufacturer. The submission shall include:
Name and address of proposed supplier or manufacturer
Background and history to demonstrate compliance with the specified

requirement for experience, competency and reputation in the field of the
proposed equipment supply.
Reference numbers and title of relevant specifications of a recognised national

or international standards organisation with which the materials or
manufactured items will comply together with copies of the specifications in
English where required by the Engineer.
Manufacturers literature and data sheets for articles and fabricated items.
Details of reference sites.
Contact details for referees.
Any other information called for in particular clauses of the Specification
Period for approval is 14 days subject to submitted information being of a

satisfactory standard.
For minor items of supply the approval of
Supplier/Manufacturer stage may be waived at the discretion of the Engineer.
2.
Full Technical Submission

Following approval of the supplier/manufacturer, a full technical submission shall be
made as described elsewhere under this clause.
Evidence (by copy of letter of enquiry or otherwise) that the attention of the
proposed supplier or manufacturer has been drawn to the particular climatic
and environmental conditions in Bahrain.
Samples of materials representing the quality of the bulk of such materials the
Contractor proposes to use.
Sufficient information to demonstrate that the materials or manufactured

items are suitable and comply with the Specification including reference to all
relevant Specification Clauses.
Detailed design calculations and design, fabrication and installation drawings
Any other information called for in particular clauses of the Specification.
Vol 3, Section3
Page 3B-16 of 20
Specifications
Provided the information requested is satisfactory, the Engineers approval will be

given within a period of 21 days. Where additional information or clarification is
required, the 21 day approval period will commence on receipt of the satisfactory
additional information.
Prior to despatch to Site or to a designated place of storage the following shall be
provided:
i)
Facilities for inspection and testing at suppliers' pits or quarries, manufacturers

works or at approved independent testing centres as appropriate. Inspection and/or
witness testing may be carried out by the Engineer or the Engineer Representative
or other appointed Inspector.
ii)
Details of the suppliers or the manufacturers quality control test procedures.
iii)
The carrying out of tests as stated in the current quoted or appropriate British
Standard or other national standard as appropriate, and such other tests as are
necessary in the opinion of the Engineer, to determine that the Works comply with
the Specification either under test conditions at the manufacturers works, on site or
elsewhere under normal working conditions. Where tests and inspection have been
completed to the Engineers satisfaction and when the test certificates, etc., have
been checked the Engineer will confirm acceptance in writing and the items
concerned shall not be delivered or incorporated in the Works until this acceptance
has been received.
iv)
Four copies of all test certificates where appropriate to be supplied to the Inspecting
Engineer within two weeks of any witnessed tests.
v)
Shipping and consignment identification details to be submitted to the Engineer.
vi)
Where witness tests are not required the test certificates and/or certificates of
compliance with the appropriate standard are to be forwarded to the Inspecting
Engineer within two weeks after instructions to waive witness tests have been
received.
vii)
Each certificate shall give sufficient information to enable the Engineer to identify the
material or equipment to which it refers prior to the issuing of his release order.
viii) No inspection or passing by the Engineer, or the Inspecting Engineer of the Work, or
manufactured item, or materials covered by this Contract, whether carried out or

supplied by the Contractor, shall release him from any of his obligations under the
Contract.
ix)
The Engineer reserves the right to require the Contractor to meet any extra costs
which are occasioned by failure of the Contractor to comply with the above testing
and inspection requirements including the provision of test certificates, curves, etc.,
or, which in the opinion of the Engineer, are due to insufficient care having been
taken by the Contractor or his Sub-Contractor before presenting the item for
inspection or test. If unauthorised delivery has taken place the Contractor shall if
required by the Engineer return the item to the manufacturer for inspection and/or
witness testing by the Inspecting Engineer at the Contractors expense.
Samples of all building and civil works materials shall be supplied to the Engineer for
approval. Where appropriate, sample panels of built materials shall be constructed.
Vol 3, Section3
Page 3B-17 of 20
B5.4
Specifications
Approval of Construction Methods

For all elements of the Works, fully detailed method statements describing proposed
construction techniques and programme for execution shall be submitted to the Engineer
in duplicate. These shall be supported, where applicable, by calculations for temporary
works for supporting excavated faces and shuttering of concrete.
Written approval shall be obtained before any work is commenced.
Approval of the proposed construction techniques and methods shall not relieve the
Contractor of his contractual responsibilities for the care of the Works or of his liabilities for
accidents or damage.
Vol 3, Section3
Page 3B-18 of 20
Specifications
B6
DESIGN
B6.1
Planning Permission and Building Permit

Planning permission will be confirmed by the Contractor with the Ministry at the outset of
the project
The Contractor shall consult the Ministry of Industry regarding building permits when
sufficient details are available for the Ministry to assess whether a permit is required.
B6.2
Design Life - General

The design life for the permanent Works shall be as follows unless otherwise stated
Civil structures, pipelines and buildings
50 years
Mechanical and Electrical Plant
15 years
Instrumentation and Control Systems
7 years
Analytical and Process Instruments
7 years
The design shall take into account the most extreme conditions that will occur during
construction and the life of the works, including inter alia, highest and lowest water levels
and water pressure, construction methods, climatic conditions
B6.3
Pipelines
Pipework and pipelines shall be designed for all foreseeable load cases including the
following:
B6.4
a)
maximum working pressures on completed pipelines;
b)
field test pressure on completed parts of the pipeline and the whole of the pipeline
(field test pressures);
c)
required hydrostatic test pressure on individual pipes and fitting at the place of
manufacture (works hydrostatic test pressures).
Structures
Structures shall be designed to resist water loading due to external water level
corresponding to ground level. Uplift forces on structures, tanks and pipes shall be
calculated assuming they are empty.
B6.5
Chambers
Unless otherwise stated, general chambers shall have anodised aluminium open grid or
chequer plate covers. Covers shall be fixed in frames recessed into the top of the chamber
walls. Chambers that require man entrance (generally greater than 900 mm deep) shall
be provided with minimum access area through the cover of 800 mm x 600 mm. Ladders
shall be installed in all chambers over 1.5 m deep. Where vertical ladders are installed in
chambers over 2.5 m deep they shall be provided with hoop safety cages.
All chambers shall have a nominal floor slope to a sump.
Vol 3, Section3
Page 3B-18 of 20
B6.6
Specifications

Any structures containing any liquids or excluding any liquids shall be designed to the
appropriate standard for liquid retaining structures.
Structures that are to be water tested before back filling shall be designed accordingly.
B6.7
Sound Insulation
Noise levels at the Site boundary generated by the operational plant shall not exceed 45
dBA during daylight hours and 40 dBA at night. The Contractor will be required to produce
calculations to show that noise levels generated at the Site boundary will satisfy these
conditions. In addition the noise level within any working area shall not exceed 80 dBA at
any time.
B6.8
Calculations and Drawings for Approval

The Contractor shall submit to the Engineer for his approval all Working Drawings and
calculations including details for the construction and completion of the Works.
Submissions shall be numbered using an agreed referencing system.
The Contractor shall prepare the complete working drawings, all design calculations and
details of construction of the works and other apparatus and all other parts as may be
required to give full information to the Engineer regarding the proposed design. Three
copies shall be submitted for approval by the Engineer.
B6.8.1
Civil and Building Works

The requirements for civil and building shall comprise the following:
Pipelines:
Hydraulic calculations, including determination of test pressures.
Site plan and general arrangement drawings.
Pipeline profiles.
Drawings and schedules showing all pipework, fittings, chamber and trench details and
thrust block arrangements.
Reinforcement drawings and calculations for thrust blocks to pipework and chambers.
Drawings, calculations and method statements for all road crossings and connections to
existing pipework.
Civil, Building and Structural works:
General arrangement and foundation drawings, complete with dimensions, for all
buildings, tanks, plant and associated equipment.
Structural calculations and drawings including foundation design.
Reinforced concrete details, structural steelwork and masonry drawings.
Reinforcement drawings and calculations for insitu and precast concrete.
Vol 3, Section3
Page 3B-19 of 20
Specifications
Fabrication drawings for any structural steelwork/metalwork

Architectural and building works drawings including masonry, cladding, roofing, etc, and all
specified fixtures and finishes both externally and internally.
Details of protective coating design.
Road construction drawings including kerbing and drainage details.
Landscaping, land drainage, sub and top soiling and all ancillary works.
Vol 3, Section3
Page 3B-20 of 20
Specifications
TABLE OF CONTENTS
Page No.
SECTION C - EARTHWORKS
C1
C2
C3
EXCAVATION
C1.1
Pre-Construction and Land Drainage Records
C1.2
Trial Excavations
C1.3
Topsoil and Surfacing Materials
C1.4
Handling Excavated Material
C1.5
Formation
C1.6
Rock and Hard Materials
C1.7
Use of Explosives
C1.8
Hand Excavation
C1.9
Support and Protection of Excavations
C1.10
Control of Water
FILL
C2.1
Definitions
C2.1.1
General Backfill
C2.1.2
Class 2 Fill
C2.1.3
Class 3 Fill
C2.1.4
Hardcore
C2.1.5
Lean Concrete for Backfill
C2.1.6
Topsoil
C2.2
Backfilling Excavations - General Requirements
C2.3
Placing of General Backfill
C2.4
Placing of Class 2 and Class 3 Fill
C2.5
Testing of Backfill
C2.6
Geotextile Filter Fabrics
REINSTATEMENT AND EMBANKMENT PROTECTION
C3.1
Reinstatement of Unpaved Land
C3.2
Reinstatement of Paved Roads
C3.3
Stone Pitching and Stone Revetment
Vol 3, Section 3
Page i of i
Specifications
C1
EXCAVATION
(Note: Additional specifications for earthworks required for road construction are given in
Section J).
C1.1
Pre-Construction and Land Drainage Records

Before an excavation is commenced the Contractor shall, if directed by the Engineer, assist
in the preparation of a record of the state of the surface which shall detail ground levels,
all features that may require reinstatement, and as much information as possible about
surface and underground drainage. Where necessary it shall include photographs
illustrating existing damage to adjacent building etc., or other conditions which may prove
contentious at the time of reinstatement. The Contractor shall liaise with the Engineer,
and where appropriate with owners and occupiers, in preparing this record.
The record shall if necessary be updated with details of any further subsoil drainage or
other underground features that are uncovered as work proceeds.
C1.2
Trial Excavations
Prior to all machine excavation the Contractor shall excavate by hand pilot trenches to
locate services in and around the area of the proposed Works.
The Engineer may order the Contractor to carry out additional trial excavations to reveal
existing buried services as referred to in Clause B2 or for other reasons. The trial
excavations shall normally be carried out by hand unless otherwise agreed with the
Engineer.
The Contractor shall submit to the Engineer a written report or sketch drawing of the data
obtained from each trial excavation in a form to be agreed with the Engineer indicating
the type of service, its condition and depth below ground level, and any relevant factors
and shall not backfill the excavation until the report or sketch has been supplied and the
Engineer has given his agreement.
C1.3
Topsoil and Surfacing Materials

Turf, topsoil, paving and other surfacing materials shall be stripped separately from the
subsoil and stored separately for re-use or disposal, as directed by the Engineer.
Excavations for structures shall be over areas designated by or agreed with the Engineer.
For trenches, excavation shall be for the width of the trench, and turf and topsoil shall also
be removed for the additional width agreed with the Engineer as required by the
Contractor for the passage of vehicles etc., and for storage of subsoil.
C1.4
Handling Excavated Material

Unless otherwise specified in the Contract the excavated material required for backfilling
shall be stockpiled on site or stored locally.
The Contractor shall dispose of surplus excavated material only to tips approved by the
Municipality, and proof of authorised use of these tips shall be submitted to the Engineer.
All excavated material shall be deposited so that it will cause as little damage and
inconvenience as possible. It shall not be stored on footpaths or carriageways and shall
always be kept at a safe distance from the top of the trench. Any spillage of spoil etc., on
Vol 3, Section3
Page C-1 of 9
Specifications
highways attributable to transport operated by, or on hire to, the Contractor or any of his
sub-contractors shall be removed so as to restore road surfaces, verges, etc., to a clean
and safe condition.
Where different classes of material are excavated they shall be handled separately and the
most suitable retained for backfilling. Where natural subsoil drainage depends on the
relative positions of pervious or impervious strata, special care shall be taken to separate
these materials and replace them in their natural positions.
C1.5
Formation
The Contractor shall carry out his operations in such a way as to avoid damage to the
formation of excavations. This shall normally include bottoming-up by hand excavation
immediately before pipelaying or placing concrete. Where in the opinion of the Engineer
the required bearing capacity will not be obtained at formation level, or if the formation is
damaged, it shall be further excavated and refilled with concrete, or compacted Class 2 fill
material (refer to Clause C2.2), as instructed by the Engineer. No Permanent Works of
any kind shall be constructed on an excavated surface until the formation has been
approved.
C1.6
Rock and Hard Materials

For the purpose of this Contract rock is defined as natural material that is so hard that, in
the opinion of the Engineer, it cannot be removed by the ordinary methods of hand or
machine excavation without undue difficulty, or without preliminary work to break or
loosen the material by use of rippers, pneumatic tools, or similar procedures.
Hard material is similarly defined as artificial material such as blockwork, brickwork or
concrete that, in the opinion of the Engineer, is so hard that it cannot be removed by the
ordinary methods of hand or machine excavation without undue difficulty or without
preliminary work to break or loosen the material.
C1.7
Use of Explosives
The use of explosive for any purpose whatsoever during the Contract is prohibited.
C1.8
Hand Excavation
Where ordered or necessary for reasons of limited access, proximity to other services, or
any other reason, excavation shall be carried out by hand. The Engineer may forbid the
use of machine excavators or other plant at any time.
C1.9
Support and Protection of Excavations

Excavations shall be adequately supported at all times to the satisfaction of the Engineer,
to prevent any ground movement which could diminish the width of the trench, cause
injury or delay or endanger adjacent services, structures or road surfaces.
Supports shall be properly maintained until the Permanent Work is sufficiently advanced to
permit their removal and shall be left in if specified or instructed by the Engineer.
Trench supports shall be so arranged to permit withdrawal during the placing of the pipe
bedding so as to prevent voids.
Battered sides to trenches or other excavations will only be permitted if they can be
constructed within the limits of the Site, without damage or interference to existing
Vol 3, Section3
Page C-2 of 9
Specifications
services, properties or structures, and without undue interference with pedestrians and
traffic. Side slopes shall be sufficiently flat to ensure stability of the ground.
Excavations shall be provided with adequate protective safety barriers and appropriate
warning signs, lighting and bunting.
C1.10
Control of Water
All excavations shall be kept free from water. In this respect the Contractors attention is
drawn to the very high water table throughout much of Bahrain and the relatively high
permeability of much of the strata. Reference should be made to the ground investigation
data (refer to Volume 6).
The Contractor shall submit detailed proposals for dewatering the excavations to the
Engineer for his approval.
Dewatering methods may include cofferdams, temporary drains, intercepting ditches, cutoff drains, sub-drains, sumps, wells, pumps, well-points or other dewatering equipment
and shall include all other materials and equipment necessary to keep surface water and
groundwater out of the excavations. The water table shall be maintained at least 300mm
below formation level continuously until construction therein has been completed to
ensure that no damage occurs due to flotation, hydrostatic uplift or other causes.
If excavations should flood then there is a danger that partly completed process units,
pipelines and structures may float. Any damage or expense arising from the Contractors
failure to heed this warning shall be the Contractors liability.
All necessary precautions shall be taken to prevent any adjacent ground from being
adversely affected by loss of fines through any dewatering process. Silt traps shall be
provided on pumped ground water discharges where directed by the Engineer.
Ground water systems shall be designed and controlled to ensure that any induced ground
subsidence does not adversely affect adjacent services or structures.
Unless otherwise agreed by the Engineer, all well points, sub-drains, sumps and similar
temporary works shall be kept clear of the Permanent Works and when they cease to be
used shall be finally filled with compacted load bearing fill material, grout, or sealed with
concrete at intervals to the level of the underside of the Permanent Works. Particular care
shall be taken to avoid undermining any part of the new or existing works due to the
method adopted for the removal and disposal of water.
Method Statements shall include proposals for dewatering systems and disposal of the
water arising from them.
No pipes or culverts in the new or existing works shall be used for the removal and
disposal of water without permission in writing from the Engineer. The Contractor shall
also obtain the written permission of the Ministry of Works, Power and Water or other
public authorities (using the appropriate permit application form) and owners before
connecting temporary drainage to existing drains, sewers and watercourses. Should such
permission be given, the Contractor shall be responsible for cleaning out and removing all
silt, etc., and for making good any damage whatsoever resulting from such use.
The Contractor should note that such approval may not be given and shall allow for the
provision of an alternative disposal system in his Tender.
Vol 3, Section3
Page C-3 of 9
Specifications
The Contractor shall not allow water arising from his works to discharge on to areas of
open ground.
Groundwater may be discharged to sea. If the Contractor proposes to use an existing
water course or drainage channel he shall ensure that the water course is not blocked by
development downstream and that it will carry the disposal water without causing damage
or flooding to property.
C2
FILL
C2.1
Definitions
(Note: Class 1 fill material is not included in this Specification).
C2.1.1
General Backfill
Selected site excavated material free from particles greater than 150mm nominal size,
roots and other vegetable matter, and capable of being compacted to the specified
requirements. (Refer to Clause C2.3).
Where necessary, excavated material shall be sieved or sorted to remove large stones,
rocks, or other particles which, in the opinion of the Engineer, may impede compaction.
C2.1.2
Class 2 Fill
Class 2 fill shall be good hard well graded material screened and crushed as necessary to
lie within the grading envelope given in the table below when tested in accordance with
BS 1377 Test 7. The material shall have a CBR greater than 30% when tested in
accordance with Clause B5.1.4 of BS 1377 at the density specified in Clause C2.4 of this
Specification.
The liquid limit shall not be more than 25% and the plasticity index shall not exceed 6%.
The total soluble salts shall not exceed 2%.
Grading envelope for Class 2 Fill
Sieve Size
75.0
37.5
10.0
5.0
600
75
C2.1.3
% by Mass Passing
mm
mm
mm
mm
microns
microns
85
45
20
8
0
100
-
100
100
65
45
20
Class 3 Fill
Class 3 fill shall be clean, hard, granular material free from clay and deleterious
substances. The total soluble salts shall not exceed 2% and the grading of the fill shall be
within the grading envelope given in following table when tested in accordance with BS
1377 Test 7.
Vol 3, Section3
Page C-4 of 9
Specifications
Where the percentage passing the 75 micron sieve is greater than 8%, the plasticity index
shall not exceed 20% when tested in accordance with BS 1377.
Grading envelope for Class 3 Fill
Sieve Size
% by Mass Passing
100 mm
5 mm
75 microns
C2.1.4
100
0 - 50
0 - 20
Hardcore
Hardcore shall consist of broken stone or other suitable hard material. It shall be free
from clay, dust or other deleterious matter, shall not contain pieces exceeding 100mm and
not more than 5% shall pass through a 20mm sieve. The fill shall not be susceptible to
breakdown under moist conditions. The total soluble salts shall not exceed 2% and the
total sulphate content (as SO 3 ) shall not exceed 1%.
C2.1.5
Lean Concrete for Backfill

Aggregate for lean concrete shall consist of an all-in aggregate, having a maximum
nominal size not exceeding 20mm. Aggregate quality and cleanliness shall comply with
the relevant requirements of Clause C1.5 and the overall grading of the aggregate shall lie
within the limits shown in following table.
Grading of Aggregate for Lean Concrete
Percentage by mass
passing BS sieve
Nominal maximum
size 20mm
Sieve
size
mm
20.0
10.0
5.0
microns
600
300
75
45 - 100
35 - 100
25 - 100
8 - 65
5 - 40
0 - 10
The ratio of cement to aggregate by mass shall be sufficient to produce an average 7 day
strength of 3.5 N/mm2 for each batch of five test specimens.
The moisture content of the mixed material, when determined by the vibrating hammer
method test in BS 1924, shall be within the range of optimum to optimum plus 2%.
C2.1.6
Topsoil
Only such soil which, in a loosened state, besides the normal inorganic components also
contains mineral elements in adequate quantity to serve as a nutrient medium for
vegetation when watered, will be taken as topsoil.
Vol 3, Section3
Page C-5 of 9
C2.2
Specifications
Backfilling Excavations - General Requirements

Backfilling around structures and in pipe trenches from 300mm above the crown of the
pipe shall normally be carried out as detailed below:Backfilling shall be carried out using general backfill (see C1. C2.1.1), unless otherwise
directed by the Engineer. Where the Engineer designates the excavated site material as
unsuitable, a Class 3 fill shall be imported and used for backfilling in lieu of the excavated
material.
Except where directed by the Engineer, excavations in classified major roads shall be
backfilled with dry lean concrete placed in layers not exceeding 150mm thick and
mechanically compacted to refusal.
Elsewhere, Class 2 fill or concrete shall only be used where directed by the Engineer.
C2.3
Placing of General Backfill

Soils shall be placed and compacted in layers not greater than 150mm thick such that
throughout each layer placed the dry density is not less than 95% of the maximum dry
density determined in the standard vibrating hammer test (for granular soils) or standard
4.5kg rammer compaction test (for cohesive soils) as detailed in BS 1377.
The placement moisture content shall be adjusted and maintained close to the optimum
moisture content as determined in the appropriate standard compaction test so that the
specified degree of compaction may be readily achieved.
C2.4
Placing of Class 2 and Class 3 Fill

Class 2 and Class 3 fill shall be placed and compacted in layers not greater than 150mm
thick such that throughout each layer placed the dry density is not less than 95% of the
maximum dry density determined in the standard vibrating hammer compaction test. The
placement moisture content shall be adjusted and maintained close to the optimum
percentage determined in the vibrating hammer compaction test so that the specified
degree of compaction may be readily achieved.
C2.5
Testing of Backfill
The Contractor shall provide testing apparatus and carry out tests as is necessary for the
monitoring of backfilled soil properties. He shall maintain a daily log of tests carried out,
and provide the Engineer with a copy of the log to be countersigned by the Engineer.
Tests to determine the dry density/moisture content relationship and insitu density and
moisture content shall be carried out as directed on site by the Engineer. The frequency
of testing will depend on the consistency of material and test results but unless otherwise
instructed or agreed shall be as follows:
dry density/moisture content
relationship
- one test per 150m

of trench
dry density and moisture

content of compacted soil
- 10 tests per 150m

of trench
- for other earthworks, 1 test per 500 m3 per
day with minimum 1 per day.
Vol 3, Section3
Page C-6 of 9
Specifications
Prior to the commencement of excavation, the Contractor shall submit to the Engineer for
approval a method statement for testing backfill. This statement shall include details of:
C2.6
(i)
the methods and equipment proposed for measuring dry density/moisture content
relationship, moisture content and insitu density (including sources of pouring sand
where required for the sand replacement method).
(ii)
the name and address of any proposed independent testing laboratory.
Geotextile Filter Fabrics

The required physical, mechanical, chemical and hydraulic properties for filter fabrics will,
if applicable, be specified in Particular Requirements Specification.
The material will be supplied in rolls to widths to suit the work. After excavation and
trimming to the required profile the filter fabric shall be unrolled over the prepared
formation care being taken in the case of trenches to ensure that the material is dressed
well into the sides and bottom of the trench so that subsequent placement of the filter or
fill material does not impose a strain on the fabric or cause it either to tear or to pull away
from the trench side leaving voids. Joints or laps between successive sheets shall be
formed in accordance with the manufacturers instructions.
No vehicles will be allowed to run directly over filter fabrics.
Any damaged sections shall be cut out and removed and, after restoration of the surface
to its required formation, replaced with new fabric overlapping the undisturbed and
undamaged sections by a minimum margin of 500mm at any point.
C3
REINSTATEMENT AND EMBANKMENT PROTECTION
C3.1
Reinstatement of Unpaved Land

In general the reinstatement of stripped areas of unpaved land shall restore the ground to
a condition not inferior to that which existed before the site was occupied. All initial
reinstatement shall be complete within 7 days of completion of backfilling.
The compacted backfill shall be taken up to a level which allows for settlement. In
cultivated areas and parks the surface to be topsoiled shall then be loosened to a depth of
200mm and topsoil replaced on it to the specified depth without compaction. The
Contractor shall import additional topsoil required to make up any deficiency.
Areas where grass is to be sown shall be worked to a fine tilth, levelled, graded and rolled
with a light roller. The seed shall be sown evenly at the specified rate of application in the
proper season and in suitable weather conditions, and the areas again rolled. Restoration
and re-seeding of any areas where the new grass is unsatisfactory or inadequate shall be
carried out by the Contractor as instructed. Newly sown grass shall be regularly watered
and shall receive at least one cutting.
Alternative methods of planting may be required by the Engineer and may include the
planting at 225mm centres of Bermuda or similar tropical grass tufts.
C3.2
Reinstatement of Paved Roads

For the purpose of this Specification all public asphalted roads will be considered as P.W.A.
Highways.
Vol 3, Section3
Page C-7 of 9
Specifications
In general the final reinstatement of public roads will be carried out by the Roads
Department of the Ministry of Works and Agriculture, but the Contractor may be instructed
to carry out some of this final reinstatement in accordance with the specifications issued
by the Ministry of Works and Agriculture current at the time.
Initial asphalt reinstatement shall be placed without delay following completion of
backfilling to any excavation where it is proposed to re-open that part of the road to
traffic. Initial asphalt reinstatement may only be delayed where the work dictates that
traffic should still be generally excluded from the particular section.
Prior to surface reinstatement the edges of the existing surfacing shall be cut back to give
a regular shaped, straight sided area free of deformed or cracked surfacing and at least
150mm outside the edge of the excavation. The surfacing shall be cut cleanly by
pneumatic or hydraulic breaker or by saw to give a vertical edge.
The formation shall be finished 450mm below existing road level and Class 2 sub-base
shall be spread, graded, watered and compacted in accordance with Clause C2.4. The
finished surface shall be treated with a prime coat of road oil sprayed at a rate of 0.8 sq.
m per litre and exposed faces of existing asphalt shall be painted with hot bitumen. A
layer of asphaltic wearing course to the required thickness is to be laid such that the top
surface provides a smooth transition between the existing wearing course on each side of
the trench. The initial reinstatement shall be maintained to ensure a satisfactory surface
until final reinstatement is carried out or until the issue of the Maintenance Certificate as
appropriate. In the event of settlement of initial reinstatement which in the opinion of the
Engineer or Traffic Directorate represents a hazard to pedestrians or traffic, the Contractor
shall break out the asphalt, re-compact the sub-base to the required specification and reasphalt.
Asphalt paving shall be laid to the thickness given in the following table:
Thickness of Initial Asphalt Road Reinstatement
Original Road Thickness
Initial Reinstatement
less than 50 mm
50 - 75 mm
over 75 mm
50 mm
Original thickness
75 mm
Asphalt shall normally be mix type L20 and shall only be obtained from suppliers holding
current compliance certificates issued by the Ministry of Works, Power and Water. If mix
type L20 is not available, mix type W20 or L10 shall be used as directed by the Engineer.
Before commencing reinstatement of paved road, the Contractor shall agree his method in
writing with the Engineer.
C3.3
Stone Pitching and Stone Revetment

Stone for pitching or for revetment shall be hard durable natural stone of minimum
nominal dimension 200mm but in no case shall any stone be less than 0.01 m3 in volume
or 25kg in weight. Stones shall be of suitable shape and rounded boulders shall not be
used on prepared ground surfaces having slopes steeper than 1 in 2. Flat or needle
shaped stones will not be accepted unless the thickness of each individual piece is greater
than one third of its length.
Vol 3, Section3
Page C-8 of 9
Specifications
The sides or bed of the watercourse or embankment shall first be carefully trimmed to the
required profile. Stones shall be placed by hand, dumping of stone directly onto the
prepared bed or embankment will not be permitted. For pitching, stone shall be hand
placed on a 75mm thick graded sand/gravel bed laid over an approved UV resistant filter
cloth of minimum weight 280g/sq.m. For revetment, stone shall be hand placed and
embedded a minimum of 75mm in Grade 40/20 concrete 125mm thick.
Stones in pitching or revetment shall be fitted closely together to leave the minimum of
interstices and these shall not be filled. Courses shall be laid to break joint with their
longitudinal axes horizontal and at 90 to the embankment or bed face. The final
appearance shall be neat and tidy and the local irregularities in the finished surface shall
not vary from the designed plane of the slope by more than 50mm over a surface distance
of 300m.
The minimum weight of stone is based on the volume stated above and a minimum
density of local stone of not less than 2500 kg/cu.m.
Vol 3, Section3
Page C-9 of 9
Specifications
TABLE OF CONTENTS
Page No.
SECTION D - CONCRETE
D1
CONCRETE MATERIALS AND THEIR HANDLING

1
D1.1 Concrete Materials - General Requirements
1
D1.2 Water for Concreting
1
D1.3 Cement
2
D1.3.1 Materials
2
D1.3.2 Packaging and Delivery
3
D1.4 Storage and Usage of Cement
3
D1.4.1 Storage
3
D1.4.2 Usage
4
D1.5 Aggregates
4
D1.5.1 Aggregate Sources
4
D1.5.2 Aggregate Sampling and Testing
5
D1.5.3 Fine Aggregates
7
D1.5.4 Coarse Aggregate
7
D1.5.5 Aggregates for Heavy Duty Concrete Floor Finishes (Granolithic Concrete) 8
D1.5.6 Aggregate Grading
8
D1.6 Storage and Handling of Aggregates
12
D1.7 Steel Reinforcement
12
D1.8 Storage, Cleaning and Protection of Steel Reinforcement
14
D1.9 Concrete Admixtures
16
D1.10 Curing Compounds
19
D2
CONCRETE MIXES
D2.1 Definitions
D2.2 General
D2.3 Ready Mixed Concrete
D2.4 Mix Design Constraints
21
21
24
25
25
0.35 25
D2.5 Design Mixes
D2.5.1 General
D2.5.2 Design Mixes for New Batching Installations
D2.5.3 Design Mixes from a Continuing Source
D.5.4 Method Statements
D2.6 Prescribed Mixes for Minor Works
D2.7 Concrete Quality Control
D2.7.1 General Requirements
D2.7.2 Test Cubes
Vol 3, Section 3
Page i of ii
26
26
27
27
Error! Bookmark not defined.
28
28
28
29
AL MADINA AL SHAMILYA STP
Specifications
D2.7.3 Workability
D2.7.4 Density
D2.7.5 Temperature
D2.7.6 Climatic Conditions
D2.7.7 Compliance Requirements
D2.7.7.1 Non-compliance
29
30
30
30
30
31
D3
FORMWORK AND CONCRETING PRACTICE

D3.1 Blinding Concrete (Sealing Coat)
D3.2 Formwork
D3.3 Tolerances and Finishes for Concrete Surfaces
D3.3.1 Tolerances for Exposed Surfaces
D3.3.2 Tolerances for Unexposed Surfaces
D3.3.3 Surface Finishes
D3.4 Bending, Placing and Fixing of Reinforcement
D3.5 Formation of Holes for Fixing
D3.6 Batching, Transporting and Placing of Concrete
D3.7 Batching of Admixtures
D3.8 High Temperature Concreting
D3.9 Curing and Protection of Concrete
D3.9.1 Exposed Surfaces
D3.9.2 Formed Surfaces
D3.9.3 Tanked Surfaces
D3.9.4 Damaged Concrete
D3.10 Striking Formwork
D3.11 Re-use Formwork
D3.12 Heavy Duty Concrete (Granolithic) Screeds to Benching and Channels
D3.13 Cracks in Concrete Structures
32
32
32
33
33
34
34
34
35
35
37
37
38
38
38
39
39
39
40
40
40
D4
JOINTS IN CONCRETE STRUCTURES

D4.1 Classifications
D4.4.1 Movement Joints
D4.1.2 Construction Joints
D4.2 Size and Sequence of Concrete Pours
D4.3 Water Bars
D4.4 Bond Breakers
D4.5 Expansion Joint Fillers
D4.6 Joint Sealing
D4.7 Joint Bond Breaking for Contraction Joints and Sliding Joints
D4.8 Bond Breaking Compound for Dowel Bars
D4.9 Dowel Bars
41
41
41
41
41
42
42
43
43
44
44
44
D5
PRECAST CONCRETE
45
Vol 3, Section 3
Page ii of iii
D5.1
D5.2
D5.3
D5.4
D5.5
D6
Specifications
Precast Concrete Production

Bedding Precast Concrete Units
Chamber Rings and Cover Slabs
Precast Concrete Paving Slabs
Precast Concrete Kerbs
TESTING OF WATER RETAINING CONCRETE STRUCTURES
Vol 3, Section 3
Page iii of iii
45
46
46
46
46
47
Specifications
D1
CONCRETE MATERIALS AND THEIR HANDLING

Where ready-mixed concrete is proposed, the Contractor shall use concrete from an
approved supplier and source, with the written permission of the Engineer. Ready-mixed
concrete and all its constituent materials shall conform to this Specification.
D1.1
Concrete Materials - General Requirements

In addition to the detailed requirements specified in this Section, materials for concreting
shall contain no harmful substances that will affect the strength and durability of the
concrete.
D1.2
Water for Concreting

The Contractor shall arrange for an adequate supply of water, complying the with quality
limitations of this clause, and BS 3148 wherever it is required on the Works for :(i) washing of aggregates
(ii) the production of concrete
(iii) curing of concrete
All such water for concreting shall be obtained from an approved source.
Samples of water not less than 5 litres shall be taken in the presence of the Engineer,
sealed and sent for testing at an approved, independent, laboratory both prior to the
approval of any water source and periodically during the continuance of its use. No
source of water shall be used until the required tests have demonstrated its suitability for
concreting.
Tests shall include :1.
Chemical analysis to determine the concentrations of sulphate and chloride.
2.
Physical analysis to determine pH, suspended solids, colour, smell and opacity.
3. Comparative tests for initial setting times and compressive strengths of cement
pastes prepared with water from the proposed source and with distilled water.
Any one of the following conditions shall make the proposed source of water unsuitable
for concreting :
(a) Sulphate measured as sulphur trioxide in excess of 1 000 mg/l.
(b) Chloride content in excess of 500 mg/l chloride ion.
(c)
Alkali carbonates and bicarbonates in excess of 1 00 mg/l.
(d) pH values outside the range 6.5 to 8.0.

(e) Suspended solids in excess of 2 000 mg/l.
(f)
Total dissolved solids in excess of 2 000 mg/l.
(g) Presence of organic substances indicated by colour or odour.
Vol 3, Section3
Page D-1 of 47
Specifications
(h) In comparative tests with distilled water, variations in initial setting times in excess of
30 minutes or reductions of compressive strength in excess of 10 per cent.
In addition to the above, water for concrete shall be included in the assessment of total
chloride and sulphate contents in a proposed concrete mix.
D1.3
Cement
D1.3.1
Materials
Cement shall be Portland cement complying as required with one of the following
standards :
(i)
Ordinary Portland cement complying with BS12 except that the proportion of C 3 A
by weight shall be not less than 8% nor greater than 13%.
(ii)
Moderately sulphate resisting Portland cement complying with BS12 except that the
proportion of C 3 A by weight shall be greater than 3.5% but less than 8%.
(iii)
Sulphate resisting Portland cement complying with BS 4027.
Unless otherwise approved by the Engineer all cements shall comply with the following
requirements :
(a)
The heat of hydration shall not exceed 325 kJ/kg at 7 days when tested in
accordance with ASTM C-186.
(b)
The specific surface shall not be greater than 325 m2/kg when tested in accordance
with BS 4550.
(c)
The temperature of cement shall not exceed 75C at the time of incorporation into a
concrete mix.
(d)
The cement shall be low alkali having a total acid soluble alkali content (Na 2
0+0.685K 2 0) of not more than 0.6% as determined in accordance with BS 4550.
Extra rapid hardening, rapid hardening, super-sulphated, high alumina cements, and
cements containing calcium chloride shall not be used.
Suitable type of cement shall be used in conformity with the relevant applicable standards.
The choice of cement type to be used for underground structures shall depend on the
classifications of soils for chemicals aggressive to concrete. The tenderer shall verify the
characteristics of different types of Portland cement and blended cements and consider in
his offer the usage of OPC/SRPC/MSRPC/Blended cement with mineral additions may be
required for underground /above ground structures. For above ground structures normal
OPC made to BS 12 shall be used
The Contractor shall be responsible for satisfying himself that the performance
characteristics of cement are not such as to necessitate excessive cement contents or be
likely to cause or accentuate any undesirable properties in the fresh or hardened concrete,
notwithstanding apparent compliance with this Specification.
Samples of cement shall be taken in accordance with BS 4550 on the request and in the
presence of the Engineer for testing in an approved independent laboratory. The Engineer
shall have access to the cement store at all reasonable hours.
Vol 3, Section3
Page D-2 of 47
D1.3.2
Specifications
Packaging and Delivery

Cement shall be delivered to site in consignments of sufficient quantity to ensure that
there is no suspension or interruption to the work of concreting at any time.
Unless approval is given in writing for the handling of cement in bulks cement shall be
packaged by the manufacturer in bags which are so designed as to prevent any
contamination and to minimise the adverse effects of moisture and high humidity during
transportation and storage. The Contractor shall supply to the Engineer two unused
sample bags for approval and retention.
The bags shall be marked with the manufacturers name, the brand name (if appropriate),
the name of the producing works, the cement type, the Standard to which it was made,
and the date of manufacture, or date code.
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.
The Contractor shall obtain and provide to the Engineer a certificate for each consignment
of cement which shall include the following information :(a) The manufacturers bulk average test results for the manufacturing batch including
chemical composition and physical properties determined in accordance with the approved
relevant specification for the cement.
(b) The date of manufacture, the date of original loading and the date of intended
delivery to site.
D1.4
Storage and Usage of Cement
D1.4.1
Storage
Cement shall be stored immediately upon receipt at site.
The Contractor shall provide a method statement for the storage of cement, in the terms
of B5.5 which shall be approved and implemented before any cement is delivered to site.
Bags shall be stacked close together to reduce circulation of air but shall not be stacked
against outside walls.
Each consignment and type of cement shall be stored separately for ease of access,
identification, inspection and sampling.
If bagged cement is stored in silos it shall be charged into the silos through a 6mm mesh
screen which is welded or bolted to and covers the entire feed area of the silo charging
hopper.
Cement stored in silos shall be adequately protected against rain, humidity and dewfall,
and all silo charging and discharging points shall be properly sealed. Silo aeration
equipment shall, if necessary, incorporate de-humidifiers.
Sufficient stocks shall be maintained on site to ensure the proper progress of the Works
and at least sufficient cement for one weeks consumption shall be left in store and the
stockholdings shall be to the approval of the Engineer.
Vol 3, Section3
Page D-3 of 47
D1.4.2
Specifications
Usage
Consignments shall be used in the order in which they were delivered.
Differing types or brands shall not be mixed together for use in the Works.
Cement shall not be used after 6 months from its manufacture date or after it has been
held in store for more than 3 months, unless it is retested and satisfies the relevant
standard. A re-test certificate will only be valid for a further period of 6 months.
All cement shall be used within 12 months of date of manufacture.
Cement which the Engineer considers to have deteriorated in any way shall not be used
and shall be removed from site without delay.
No cement from any consignment shall be used in Permanent Works without the approval
of the Engineer.
The type of cement required for each structure will normally be stipulated elsewhere in the
Contract Documents. Where no such stipulation exists, and unless otherwise directed by
the Engineer, cement shall be used as follows :
D1.5
(1)
Ordinary Portland cement for reinforced concrete above ground level.
(2)
Sulphate resisting Portland cement for reinforced concrete below ground level and
for mass concrete.
(3)
Moderately sulphate resisting Portland cement where directed by the Engineer,

typically where there is considered to be a risk of both chloride and sulphate attack.
Aggregates
Unless otherwise specified aggregates shall comply with BS 882 or ASTM C.33.
D1.5.1
Aggregate Sources
Primary and secondary sources of both coarse and fine aggregate shall be proposed
In assessing the Contractors request for approval to a proposed source of aggregate in
the terms of Clause B5.3 the Engineer may require to:
(i)
Accompany the Contractor to the source for examination of the types of deposit and
the methods of extraction, stockpiling, loading and quality control.
(ii)
Supervise the sampling of aggregates both at the point of production and at the
stockpiles in accordance with BS 812.
(iii)
Inspect physical, chemical and petrological analyses of the samples carried out by
an approved independent laboratory.
The limits for deleterious substances and physical property requirements are listed in
Table D1.
The Contractor is advised that natural Bahrain aggregates are normally contaminated by
layers and pockets of gypsum and have high salt contents particularly in zones within the
range of capillary moisture. Sources of rock for crushed aggregate are likely to show
potential alkali aggregate reactivity when the derived coarse aggregate is used in concrete
Vol 3, Section3
Page D-4 of 47
Specifications
manufacture. Selective quarrying together with careful processing involving the use of
multiple scalping and vigorous washing will be required to produce aggregates of an
acceptable quality. Aggregates are imported from the United Arab Emirates which have
non-alkali reactive properties generally superior to those of local sources in Bahrain,
therefore the use of local aggregates for structural concrete will not usually be permitted.
The information given in this paragraph is provided for the assistance of the Contractor
but in no way relieves the Contractor of his responsibility to supply materials in compliance
with this Specification and may not be used as the basis of any contractual claim.
D1.5.2
Aggregate Sampling and Testing

When an aggregate source has been approved, representative samples shall be taken of
each aggregate type and retained on site for reference purposes by both the Engineer and
the Contractor.
Fresh samples shall be taken in accordance with BS 812 and be analysed regularly
throughout the Contract Period to demonstrate consistency of quality and of grading. The
frequency of such sampling will be dependent on the continued adequacy of the samples
as demonstrated by the results of the analyses, but shall not be less than once per week.
Aggregates shall be hard, strong and durable and shall contain no harmful material that
will adversely affect the strength and durability of the concrete or attack steel
reinforcement.
Aggregates shall not be composed of or contain any inclusions of materials likely to cause
staining or otherwise to disfigure finished concrete surfaces.
Vol 3, Section3
Page D-5 of 47
Specifications
TABLE D1
Limits of Deleterious Substances and Physical Property
Requirements of Aggregates for Concrete
Maximum Allowable % by Weight
Property
Aggregate Type
Fine
Coarse
3 (a)
1 (b)
1 (b)
Flakiness index (determined in

accordance with BS 812).
Not applicable
30 (c)
Elongation index.
Not applicable
30 (c)
2.5
2.5 (b)
0.4 (e)
0.4 (e)
Total acid soluble chloride ion

measured in 10% nitric acid solution.
0.06 (e)
0.03 (e)
Five cycles of soundness as specified

in ASTM C88 with magnesium
sulphate
15 (d)
18 (d)
Not applicable
80kN
Not applicable
Materials finer than 75 micron sieve

(determined in accordance with
BS 812, decantation method).
Clay lumps and friable particles
(determined in accordance with
ASTM C142).
Water absorption (determined in

accordance with BS 812).
Total acid soluble sulphate as
sulphur trioxide (SO 3 ) measured
in 10% hydrochloric acid solution.
10% fines value not less than figure

indicated using the standard 10mm
to 14mm test fraction.
Hollow shells (likely to form voids)
retained on 2.4mm sieve and
determined visually.
NOTES
(a)
In the case of concrete not subject to abrasion this percentage may be increased to
5 for crushed stone sand.
(b)
This figure is for each fraction of the nominal sizes aggregate.
(c)
This figure is for the predominant size fraction of each nominal sized aggregate.
Vol 3, Section3
Page D-6 of 47
Specifications
(d)
Maximum allowable loss unless otherwise approved.
(e)
These maximum limits must not be individually exceeded and must be reduced if
any of the following overriding limitations for the total mix are exceeded :-
The total sulphate content (as SO 3 ) of any mix, including any present in the
other materials, shall not exceed 4% by weight of cement in the mix.
The total chloride content (as chloride ion) of any mix, including any chloride
present in the other materials, shall not exceed 0.6% by weight of cement in the
mix for mass concrete, 0.3% for reinforced concrete made with ordinary and
moderately sulphate resisting Portland cement, and 0.2% for reinforced concrete
made with sulphate resisting Portland cement.
The properties of the aggregates shall be such that the drying shrinkage when prepared
and tested in an approved laboratory shall not exceed 0.05% unless the Engineer relaxes
this requirement to suit practical supply constraints. It should be noted that this test
involves a testing period of about eight weeks.
The Contractor shall produce evidence that aggregate sources do not contain material that
is potentially reactive to alkalis. (This requirement may be waived by the Engineer where
the source is well established and the aggregate is well proven in Bahrain).
D1.5.3
Fine Aggregates
Except where otherwise approved on the basis of evidence of acceptable performance in
concrete, the grading of a fine aggregate, or of a combined fine aggregate, shall comply
with the limits in BS 882.
Fine aggregates shall be natural sand, manufactured crushed rock sand, or a combination
of both. The Contractor shall note that the term manufactured crushed rock sand does
not include crushed rock fines which are by-products of coarse aggregate production. A
combination of natural sand and manufactured crushed rock sand will only be permitted
where the two materials are separately batched and where each material separately
complies with the requirements of this Specification. In addition the evidence of full scale
comparative site trials shall clearly demonstrate that a combined fine aggregate provides
improved concrete in relation to the use of either material as a sole fine aggregate.
The organic content of fine aggregate shall be determined in accordance with ASTM C40.
The Engineer will decide on the basis of trial mixes whether a failure to meet the limits
suggested in ASTM C40 is sufficient grounds to reject the sample.
D1.5.4
Coarse Aggregate
Coarse aggregates shall be either crushed gravel or crushed rock which shall be prepared
as single sized aggregates and blended at the time of mixing to produce the required
nominal grading.
Where an aggregate comprises a mixture of natural and crushed material the proportion
of natural (uncrushed) particles shall not vary by more that + 10% from the proportion
contained in the aggregates used in those full scale site trial mixes which are subsequently
approved.
Vol 3, Section3
Page D-7 of 47
D1.5.5
Specifications
Aggregates for Heavy Duty Concrete Floor Finishes (Granolithic Concrete)

Aggregates for heavy duty floor finishes (granolithic concrete) shall comply with the
requirements of BS 882 except as modified by Clauses D1.5 to D1.5.4 and other
requirements of this Specification. They shall be suitable for a wearing finish and selected
for hardness, surface texture and particle shape. The aggregates shall consist of crushed
rock with a 10% fines value of not less than 150kN. They shall not contain deleterious
substances such as clay, flaky, elongated or laminated particles, inorganic impurities, iron
pyrites or soluble salts.
D1.5.6
Aggregate Grading
All aggregates shall be produced to the grading limits in BS 882. These are reproduced in
Tables D2, D3 and D4 for convenience.
Grading shall be consistent for all deliveries and the proportion of coarse and fine
aggregate shall be selected to comply with the requirements of Clause D2 (Concrete
Mixes).
For concrete Grades C45/20 and C40/20 the coarse aggregate shall be graded from 20mm
to 5mm and be produced by a combination of single size grading.
For blinding grade and mass concrete the coarse aggregate may be either an all-in
grading or a combination of single size grading.
For heavy duty concrete floor finish the aggregate shall be produced by combining coarse
and fine grading or by using an all-in grading.
Vol 3, Section3
Page D-8 of 47
Specifications
TABLE D2
Grading of single sized aggregates
Percentage by mass passing BS sieve
for nominal sizes
(1)
Sieve
size
(mm)
40mm
20mm
14mm
10mm
5mm
(1)
50.0
100
37.5
85-100
100
20.0
0-25
85-100
100
14.0
85-100
100
10.0
0-5
0-25
0-50
85-100
100
5.0
0-5
0-10
0-25
45-100
2.36
0-5
0-30
Used mainly in precast concrete.
Vol 3, Section3
Page D-9 of 47
Specifications
TABLE D3
Grading of Aggregate for Concrete
Coarse (1)
Aggregate
Fine Aggregate (2,4)

Overall
Limits
All in
(3)
Sieve
Size
(mm)
Nominal
size
20mm - 5mm
Additional Limits for grading
37.5
100
100
20.0
90-100
95-100
14.0
10.0
30-60
100
5.0
0-10
89-100
35-55
2.36
60-100
60-100
65-100
80-100
1.18
30-100
30-90
45-100
70-100
microns
600
15-100
15-54
25-80
55-100
10-35
300
5-70
5-40
5-48
5-70
150
0-15(5)
Nominal
size
20mm
0-8(6)
Notes
(1) From BS 882 Table 4
(4) In addition to complying with the overall limit, not more than 1 in 10 consecutive
samples shall have a grading outside of any one of gradings, C, M or F.
(5) Increased to 20% for crushed rock fines except when they are used for heavy duty
floor finishes.
(6) Increased to 10% for crushed rock fines.
Vol 3, Section3
Page D-10 of 47
Specifications
TABLE D4
Grading of Aggregates for Heavy Duty Concrete Floor Finishes
(Granolithic Concrete)
Sieve
Size
(mm)
Coarse (1)
Aggregate
10mm single
nominal size
Fine Aggregate (2,4)

Overall
Limits
All in
(3)
M
10mm nominal
size
14.00
100
100
10.00
85-100
100
95-100
5.00
0-25
89-100
30-65
2.36
0-5
60-100
60-100
65-100
20-50
1.18
30-100
30-90
45-100
15-40
microns
600
15-100
15-54
25-80
10-30
300
5-70
5-40
5-48
5-15
150
0-15
0-8
Notes
(1)
From BS 882 Table 4
(2)
From BS 882 Table 5
(3)
From BS 882 Table 6
(4)
In addition to complying with the overall limits, not more than 1 in 10 consecutive
samples shall have a grading outside of either grading C or M.
Vol 3, Section3
Page D-11 of 47
D1.6
Specifications
Storage and Handling of Aggregates

All aggregates shall be processed, transported, stockpiled, handled and batched such that
they are not contaminated or otherwise affected adversely in either physical or chemical
respects.
Dense concrete or bituminous slabs shall be laid to cover all aggregate stockpile areas and
shall extend to cover all surrounding areas where aggregates are likely to be discharged or
handled. These areas shall be sloped to provide free drainage and kept swept clean to
ensure that the aggregates are not contaminated by the adjacent ground through
trafficking or otherwise and shall be sufficiently strong to withstand all trafficking for the
duration of use.
Shade shall be provided where required by the Engineer to keep the temperature of the
aggregate down to a level suitable for concreting, see Clause D3.8. The Engineer may
also require the aggregate to be cooled by spraying with mixing quality water in which
case the Contractor shall ensure that the contaminant levels are not thereby increased.
Windbreaks shall be provided where aggregates might suffer excessive contamination by
windblown materials.
Adequate stocks of tested and approved aggregates shall be maintained on site or at the
source of supply to maintain continuity of work.
The general or localised 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.
Any aggregates which have suffered segregation or contamination or which otherwise do
not comply with the requirements of this Specification shall be rejected and removed from
site. The Contractor may submit re-processed aggregates for approval.
The Contractor may be required to carry out supplementary processing and/or effective
washing of aggregate on site if:
D1.7
(i)
The aggregate producers methods do not satisfy the Engineer that the end
products will consistently comply with the requirements of this Specification, or
(ii)
The aggregate suffers unacceptable changes either during handling, transportation

or storage.
Steel Reinforcement
This work shall consist of furnishing, fabricating and placing steel reinforcement bars of
the grade, type, quality, size, shape and quantity designated, all in accordance with these
Specifications.
All reinforcement bars shall be of a deformed type in accordance with BS 4449, except
that plain bars may be used where specifically required. Plain bars shall be in accordance
with BS 4449.
All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars, Grade 460 Type 2 (ribbed bars), unless otherwise
specified by the Engineer.
Vol 3, Section3
Page D-12 of 47
Specifications
Table D5 - High Yield Steel Reinforcement Bars Compliance Requirements

Test Method BS 4449: 1988, Grade 460
Property
Bar Diameter
6mm
8mm
10mm
12mm
16mm
20mm
25mm
32mm
40mm
50mm
Yield
Stress
(N/mm2)
Tensile Stress
(N/mm2)
Elongation, %
(gauge length)
Bend Test
Rebend test
Mass per metre (kg)

Minimum
Nominal
0.202
0.222
0.369
0.396
0.576
0.616
0.848
0.888
1.508
1.579
2.355
2.466
3.681
3.854
6.029
6.313
9.420
9.864
14.719
15.413
Characteristic = 460
Absolute minimum = 428
Either:
a) at least 10% greater
than the actual yield
stress, or
b) between 5 and 10%
greater than the actual
yield stress, provided
the actual yield stress
is not less than the
value determined
using the formula
A(2.1 B) where
A = 460
B = ratio of measured
tensile strength to
actual yield stress
12 minimum (5 x nominal
size of test piece)
180o on former of three
times the nominal size of
the bar
45o on former of five
times the nominal size of
the bar. 23o return bend
Maximum
0.242
0.421
0.656
0.928
1.650
2.577
4.027
6.597
10.308
16.107
Test Results
Chemical
Analysis
Carbon %
0.25 max
Phosphorous %
0.050 max
Sulphur %
0.050 max
Mild steel where specified or called for shall be either deformed or plain bars complying
with BS 4449 or any equivalent National Standard as directed and approved by the
Engineer.
Tying wire shall be No.18 gauge stainless steel wire or the equivalent BS specification for
tying wire.
Vol 3, Section3
Page D-13 of 47
Specifications
Welded wire fabric shall be used as reinforcement for concrete where shown on the
Drawings and as directed. Welded wire fabric shall conform to the requirements of BS
4483- Table 1.
Testing of Reinforced Steel
A. Testing shall be carried out on steel bars in accordance with BS 4449 unless
otherwise specified here in and shall submit a compliance statement in
accordance with the summary sheet attached.
B. The following tests shall be carried out for each delivery of reinforcement.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cross-sectional area and mass

Deformation/bond characteristics of deformed bars
Tensile test
Yield stress
Elongation
Bend test
Re-bend test
Chemical composition
Carbon equivalent value
C. Testing frequency shall be in accordance with BS 4449.

D. Test results for each bar size shall be submitted to the Engineer three (3)
weeks before concrete work commences on site.
E. Further tests may be called for when the source of supply of reinforcement
changes in which case the cost of such extra testing will be borne by the
Contractor.
F. When any test results do not confirm to the relevant standard, the
reinforcement steel shall be removed from the site and all costs resulting
therefrom shall be borne by the Contractor.
D1.8
Storage, Cleaning and Protection of Steel Reinforcement

All reinforcement storage shall be on wooden supports on a dense, impervious concrete or
bituminous slab specially placed for the purpose. The slab or slabs shall be free from
dust, sand, soil or other materials which may encroach on the area by reason of wind,
vehicular or foot traffic or otherwise. These requirements shall apply equally to
reinforcement bending and cleaning areas and to any prefabricated reinforcement storage
areas. The concrete or bituminous slabs shall be constructed and fully completed before
any reinforcement is delivered to the site.
Prior to fixing and when not being handled all reinforcement shall be protected from the
corrosive effects of windblown dust and dewfall by close wrapping with impervious
sheeting or other approved method, and from any other detrimental effects.
At the time of fixing, reinforcement shall be free from loose mill scale or rust scale, and
shall not be contaminated by grease, dirt, oil, paint, soil, sulphates, chlorides or any other
agency which may impair the bond or initiate or accentuate any reinforcement corrosion.
This may be achieved by grit/sand blasting or other approved methods. Whatever method
the Contractor proposes to use must be demonstrated as being capable of producing the
reinforcement to the above standard.
Before ordering reinforcing steel, the Contractor shall prepare bar bending schedules and
submit them to the Engineer for his approval. Bar schedules shall show the weight of each
Vol 3, Section3
Page D-14 of 47
Specifications
bar, the total weight of each bar size and the total weight of bars, and bending diagrams
for bars in accordance with BS 4466.
The Contractor shall also provide and submit to the Engineer for approval any working
drawings additional to the Construction/ Shop Drawings which may be found necessary for
the production of bar bending schedules or for the completion of the Works.
The Engineers approval of the Contractors working drawings and bar bending schedules
shall in no way relieve the Contractor of responsibility for the correctness of such drawings
or schedules.
Steel reinforcement shall be bent accurately to the shapes and dimensions shown on the
approved bar bending lists or drawings. Bars shall be bent round mandrels of the requisite
diameter.
Steel reinforcement shall be cut and bent in accordance with BS 4466. Cutting or bending
by the application of heat is not permitted. Where fabric reinforcement is required to be
bent it shall be done cold, either using a bending machine or swage blocks and hooks.
Fabric reinforcement shall be cut to cover the areas detailed plus the following laps:
a. Rectangular mesh: 450 mm for longitudinal members; 75 mm for transverse
members.
b. Square mesh: 300 mm in each direction.
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.
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.
Links, hoops, stirrups are generally to be bent round pins of the same diameter as the
bars they are to embrace. Where however, such bars are less in diameter than twice the
diameter of the link, the radius of the bend shall be equal to the diameter of the link.
The number, size, form and position of all reinforcement shall, unless otherwise directed
or authorised by the Engineer, be strictly in accordance with the approved Construction/
shop Drawings. Nothing shall be allowed to interfere with the disposition of the reinforcing
bars. Lapping of the bars other than the lap splices shown on the Drawings should be
avoided. The Engineer may approve certain lap lengths under special conditions. All lap
lengths should comply strictly with the BS/ASTM specifications, namely Article 1.5.6.
Clause "c".
All intersecting bars shall be bound together with stainless steel wire with the ends of the
wire turned into the main body of the concrete.
Concrete cover blocks shall, unless otherwise directed, be used between the
reinforcement and the bottom and sides of the forms to ensure correct placing and cover
of the bars. The strength of such concrete cover blocks shall be not less than that of the
main concrete.
The reinforcement shall be assembled as dimensioned on the Drawings within tolerances
appropriate to the structure. It shall be firmly held in position by wire ties and concrete
blocks or other approved spacers designed to maintain the correct clear cover of concrete
Vol 3, Section3
Page D-15 of 47
Specifications
over steel reinforcement. They shall be as small as possible consistent with their
purpose, and of a shape acceptable to the Engineer. Minimum cover to reinforcement
shall be as specified. The position of spacers and their method of use shall be approved
by the Engineer. No concrete or reinforcement shall be cut in any way except by
permission in writing from the Engineer.
Concrete cover blocks shall be manufactured to the same specification as the surrounding
concrete, refer to Clause A2.7. When tested in accordance with the approved standard
the water absorption shall not exceed 2% for samples up to the age of one month at the
time of test. Wire cast in the block for the purpose of tying it to uncoated reinforcement
shall be of stainless steel or epoxy coated wire and shall be rust and contaminant free.
Spacers shall be of rust-proof material and shall not produce staining, or otherwise be
detrimental to the concrete or steel.
Nothing shall be allowed to interfere with the disposition of any member of the
reinforcement and the Contractor shall take special precautions that it is not only
correctly placed, but remains undisturbed during the placing and setting of the concrete,
and that it has not been contaminated with release agent or any other substance which
will prevent the best possible bonding of steel and concrete.
With the approval of the Engineer mild steel reinforcement may be temporarily bent aside
at construction joints. This shall be done with care to a minimum internal bending radius
of 4 bar diameters and to avoid damage to the concrete during bending and restraightening. The bending of high yield bars and fabric reinforcement at construction
joints is not permitted.
The greatest care shall be taken to prevent any displacement or bending of the members
of the reinforcement adjusted and temporarily fixed in position before commencement of
the concreting. Reinforcement temporarily left projecting from the concrete at construction
of other joints shall be adequately protected against displacement both during concreting
and afterwards and shall not be bent out of position unless agreed by the Engineer's
Representative. During the concreting competent steel fixer shall be in attendance to
re-set any reinforcement inadvertently displaced.
The Contractor shall in all cases request the approval of the reinforcement by the
Engineer's Representative in sufficient time to allow an inspection to be made and shall
not commence concreting until such approval is obtained. The period between the
Contractor's request for approval and his intention to commence concreting shall not be
less than one clear normal working day and the Engineer's Representative may require a
longer period if, in his opinion, the reinforcement is of such complexity as to require it.
Such approval shall not absolve the Contractor of his responsibilities under the Contract
Concrete shall be placed not more than three days after commencement of fixing
reinforcement which shall be covered at night and whenever it is not being worked upon.
Where fixed reinforcement cannot be concreted for extended periods it shall be protected
from windblown dust and dewfall by means of close wrapped polythene sheets or other
approved methods.
D1.9
Concrete Admixtures
Concrete admixtures and cements containing additives shall not be used unless specified
or approved by the Engineer in writing.
Vol 3, Section3
Page D-16 of 47
Specifications
Where not specified, approval will not be given unless the Contractor can demonstrate
that there is a clear technical advantage resulting from their use which cannot be obtained
by reasonable variation of the constituents of the concrete mix.
Admixtures shall comply with one of the following standards, unless otherwise approved
by the Engineer.
a)
ASTM C494, ASTM C260, ASTM C1017: as applicable

The Contractor shall provide at least the following technical data for each type of
admixture.
1.
2.
3.
4.
5.
6.
7.
Solid content
Specific gravity
The typical dosage and the effects of under dosage and over dosage.
The generic type(s) of the main active constituent(s) in the admixture
Whether or not the admixture contains chloride
Whether or not the admixture leads to the entrainment of air when used at
the proposed dosage.
Where more than one admixture is used simultaneously in the same
concrete, details shall be provided on their interaction and compatibility.
When admixtures are used in the Works very strict control is to be maintained to ensure
that the correct quantity of admixture is used at all times. The equipment to be used for
dispensing and the method of incorporating the admixture in the concrete shall be to the
approval of the Engineer. Dispensing equipment for admixtures shall be of an approved
type. It shall be capable of controlling the measurement of varying quantities of
admixture by amounts not exceeding +5% of the required quantity. The equipment shall
contain a fail safe device and a calibrated sight glass for visual checking of the measured
quantity. Ability to draw-off liquid from the sight glass shall be provided. The equipment
shall be regularly serviced and cleaned and to assist in this, the equipment shall be fitted
with a flushing device. The range over which the equipment will operate within the
required accuracy shall be clearly marked on the equipment
Where approved or specified air entrainment agents, admixtures, waterproof powder or
microsilica shall be used as a means of:
b)
Increased workability of the concrete without increasing water/cement contents

Controlled and limited retardation of setting
Increasing concrete durability
Reducing bleeding and associated settlement and cracking
Increasing water proof properties
Reducing heat of hydration
Reducing water permeability
Hydrophobic Pore Blocking Admixture
Where directed by the Engineer a hydrophobic pore blocking admixture based on

Ammonium Stearates and Hydrocarbon Resin shall be used at no additional cost to
the Employer.
a) Admixture is to be added at a rate recommended by the manufacturer at the
time of mixing.
b) Manufacturers representative is to be present for all additions of the
hydrophobic pore blocking compound to ensure correct dosage rates are
used.
Vol 3, Section3
Page D-17 of 47
Specifications
c)
For self compacting concrete, hyperplasticisers and viscosity enhancing

agents shall be used to provide necessary workability.
d)
Viscosity Enhancing Admixture

The viscosity enhancing admixture having high workability and viscosity shall be used
for making self compacting concrete that can become compact without vibration even
with strongly reinforced structures. It shall be chloride free and compatible with all
type of cement.
e)
Corrosion Inhibiting Admixture

1.
2.
3.
4.
The corrosion-inhibiting admixture shall be added in an aqueous solution form at

batching plant and shall be specially formulated for Gulf area of hot weather.
The manufacturers of this product shall be ISO 9001 and ISO 14001 certified.
With the above certificates the manufacturer/supplier shall submit documented
case histories.
The corrosion inhibiting admixture product, when used in accordance with the
manufacturers recommendations, shall impart changes to three important
properties of concrete compared to similar concrete without the product. The
changes are increased corrosion resistance (durability); no adverse effects on
physical properties of concrete and effective even where corrosion is active.
Corrosion inhibitor when used in accordance with the manufacturers
recommendation, shall form a suitable alternative for compliance with design to
the relevant sections of BS 1881, ASTM C1202-91, ASTM G109. The corrosion
inhibitor shall comply with international standards such as ANSI / NSF standard
61 certification confirming the products compatibility with potable water.
The corrosion inhibitor shall be incorporated into the mixing water for the
purpose of determining the water cement ratio of the concrete. The corrosion
inhibitor shall be added to all reinforced concrete works (piles, substructures &
superstructures)
In order not to effect the W/C ratio, the corrosion inhibitor dosage shall not
exceed 1.0 lit/m3. The addition shall be made at the concrete plant.
f)
High Performance Concrete Superplasticiser based on modified

Polycarboxylic Ether
A high performance superplasticiser based on sulphonated melamine and
naphthalene formaldehyde condensates at the time of mixing shall be used for ready
mixed concrete for precast units. Normal dosage shall be as recommended by the
product manufacturer.
g)
Anti-Washout Admixture
Anti-washout liquid admixture specially developed for concrete placed under water
shall be used for all underwater concrete. It shall have superior resistance to
washout of cement and fines. The minimum dosage use shall be as recommended
by the product manufacturer.
Samples of proposed admixtures shall, if required, be submitted to an approved
testing authority by the Contractor in order to ascertain its suitability for use in the
Works. The test shall be carried out for the properties specified in Table D6.
The cost of such admixtures or water proof powder or microsilica and polypropylene
fibres shall be included in the cost of concrete and no extra payment shall be made if
they are used. The proportions of cement, fine aggregate and water shall be
Vol 3, Section3
Page D-18 of 47
Specifications
determined by the Contractor before concreting commences and submitted together

with mix design test results that are required by the Engineer for approval and the
Contractor shall not commence concreting before such approval is given nor shall he
alter or vary in any way the proportion of mix unless he submits fresh test results
and mix proportions to the Engineer for approval.
Mix design of all classes of concrete shall be verified by approved laboratory prior to
approval by the Engineer. The approval by the Engineer of such mix designs does
not in any way absolve the Contractor of any of the requirements of the
Specifications.
If two or more admixtures are to be used simultaneously in the same mix, they shall
not be pre-blended before use and the required data shall be provided to asses their
interaction to ensure compatibility.
Table D6 Testing Admixtures
D1.10
S.N
o.
Uniformity Test
1.
Colour
Test
Method
&
Requirements as per
ASTM C494
2.
Settlement
3.
Specific gravity
4.
5.
6.
7.
Solid content
pH
Ash content
Chloride content
Manufacturers
value 10%
Ditto 5%
8.
9.
Chlorine content
Alkali content
10.
Infra-red Spectrum
11.
Air void characteristics
Essentially similar to
manufacturers
reference
BSEN
480-11
as
described
in
the
standard
stated
Test
method
&
Requirements as per BSEN
934
Similar to manufacturers
description
Not to exceed manufacturers
limit
Manufacturers stated value
0.03
Ditto 5%
Ditto 1
BSEN 480 Part10

<0.1%
or
less
than
manufacturers stated value
<0.1% or Ditto
BSEN 480-12
Manufacturers stated value
Essentially
similar
to
manufacturers reference
BSEN 480-11 as described in
the standard
Curing Compounds
Liquid curing compounds for use on concrete shall comply with the following:
(i)
Only products which have been proved to be effective through extensive use shall
be proposed and manufacturers literature shall include the recent test certificates
illustrating effective quality control and high curing efficiencies.
(ii)
All materials shall be supplied in the containers marked by the manufacturer with
his name, date of manufacture, shelf life, pot life and instructions for handling and
application.
Vol 3, Section3
Page D-19 of 47
Specifications
(iii)
The liquid shall contain a white or silver colour pigment in sufficient quantity to give
a uniform colour when applied to the concrete surface.
(iv)
The liquid shall be of such chemical composition and consistency that it can be
applied by an approved mechanical sprayer in fine spray to produce an even,
uniform, impervious, continuous film within one hour of application which will not
crack, peel or disintegrate within three weeks of application.
The compound shall not be poisonous, odorous or explosive and shall not react
chemically with cement.
(v)
curing compounds shall not be applied to surfaces to which further concrete or a

surface finish is subsequently to be bonded.
Vol 3, Section3
Page D-20 of 47
D2
CONCRETE MIXES
D2.1
Definitions
Specifications
The following definitions are used in this Specification:

1. Design Mix
A mix in which the Engineer specifies the strength required to ensure durability and sets
the limits for aggregate size, cement content and water cement ratio. The Contractor or
ready-mix manufacturer is responsible for the selection of the mix proportions.
2. Prescribed Mix
A mix for which the Engineer specifies the proportions by weight and accepts the
resultant strengths, provided the Contractor has produced a properly mixed concrete
containing the constituents in the specified proportions.
3. Minimum Cement Content
The lowest permitted mean mass of cement present in one cubic metre of fully
compacted concrete.
4. Free Water / Cement Ratio
The ratio by mass of free water to cement where free water is the water in the concrete
mix in excess of that absorbed by the aggregates which is available for the hydration of
the cement and for workability of the fresh concrete.
5. Moisture Content of the Aggregate
This is the mass of free water in the aggregate expressed as a percentage of the mass of
saturated surface dry aggregate and does not include any absorbed moisture.
6. Density of Fresh Concrete
Mass of a quantity of compacted fresh concrete divided by its volume expressed in
Kg/m3.
7. Characteristic Strength
The value of compressive cubes strength below which 5% of all possible strength
measurements of the specified concrete are expected to fall.
8. Governing Strength
The value of average 28 days concrete cube compressive strength obtained from the
approved trial mix
9. Mean Strength
The mean strength of all the cubes tested.
10. Working Margin
The difference between the characteristic strength and the mean strength.
11. Certified Average Alkali Content
Certified Average Alkali Content means the average of 25 consecutive determination of
equivalent alkali content carried out on samples each of which is representative of a days
production.
12. Declared mean alkali content means the alkali content expressed as the sodium
oxide(Na2O) equivalent, which is not exceeded without prior notice from the cement or
additive manufacturer.
13. Guaranteed alkali content means the alkali limit expressed as the sodium
oxide(Na2O) equivalent which the constituent material supplier guarantees will not be
exceeded by any test result on any spot sample.
14. Cementitious Materials shall mean cement or cement plus GGBS, or cement plus
GGBS plus Microsilica or cement plus water proof powder.
15. Admixtures shall mean a material other than water, aggregate, cementitious materials
or fiber reinforcement, used as an ingredient of concrete or mortar.
16. Hot weather shall mean when the shade temperature is above 40oC on a rising
thermometer or 43oC on a falling thermometer.
17. Coarse Aggregate shall be considered as that size predominately passing a 28mm
sieve and predominately retained on a 5mm sieve.
18. Fine Aggregate shall be considered as that size predominately passing a 5mm sieve
and predominately retained on a 0.075mm size.
Vol 3, Section3
Page D-21 of 47
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Specifications
OPC shall mean ordinary portland cement.

SRPC shall mean sulphate resisting Portland Cement
MSRPC shall mean moderate sulphate resisting portland cement.
GGBS shall mean ground granulated blastfurnace slag.
MS shall mean Microsilica.
Gap-graded aggregate shall mean graded aggregates without one or more of the
intermediate sizes.
Single-sized Aggregates shall mean aggregates containing a major proportion of
particles of one size.
Target Mean Strength shall mean the specified strength plus the margin.
Acceptable or Accepted shall mean acceptable or accepted by the Engineer.
Approval or approved shall mean approval from the Engineer or approved by the
Engineer.
All-in aggregate shall mean the materials composed of a mixture of coarse aggregate
and fine aggregate.
Glossary
Air entrainment
Autogenous healing
Bleeding
Blended cement
The intentional incorporation into a concrete mix by means of

an admixture, of minute discrete bubbles of air typically less
than 0.3mm (300 microns).
The natural sealing of a crack in concrete by siltation together
with further hydration of cement or by the deposition of
calcium hydroxide with consequent conversion to calcium
carbonate.
The phenomenon of water migrating to the surface of fresh
concrete due to settlement of particulate materials.
See Composite cement.
Cohesiveness
The degree to which fresh concrete resists segregation.
Cold joint
Cold weather
concreting
Compressive
Strength Class
Compactibility
Cement content
Composite cement
Combination
Consistence
Core
Creep
Curing
Curing Initial
Vol 3, Section3
Plane of weakness caused by interruptions to placing which

results from new concrete being cast against unprepared
stiffened concrete.
Cold weather placing and finishing concrete when air
temperatures are below 5C or when freezing is likely to occur
soon after concreting
Classification comprising the type of concrete, the minimum
characteristic 150mm cube strength and the 150mm dia x 300
mm cylinder strength.
The ease with which the entrapped air in concrete can be
expelled.
Mass of cement contained in a cubic metre of fresh, fully
compacted concrete expressed in Kg/m3.
A cement or combination containing two or more main
constituents, one of which is Portland cement, mixed at a
cement works or at a ready-mix plant or on site.
Restricted range of Portland cement and additions which
having been combined in the concrete mix.
The resistance to flow of fresh concrete
The innermost part of a (thick) concrete section which is
generally unaffected by external ambient temperatures.
The continuing deformation of concrete under sustained
stress.
The action of preventing or minimizing the loss of moisture
from fresh concrete and maintaining a satisfactory
temperature so that desired properties may develop.
Deliberate action taken between placement and final finishing
Page D-22 of 47
Specifications
Curing final
Evaporation
Reducer
Design Chemical
Class (D,C Class)
Drying shrinkage
Early age thermal

contraction
Finishing
Fresh concrete
Hardened concrete
Heat of hydration
Hot weather
concreting
Joint construction
Joint movement
:
:
Laitance
Matrix
Minimum cover
Mobility
Nominal cover
:
:
:
Placing
Plastic concrete
Plastic settlement
cracks
Plastic shrinkage
cracks
Restraint
:
:
Re-tempering
Rheological
Segregation
:
:
Vol 3, Section3
:
:
of concrete to reduce the loss of moisture from the surface of

the concrete.
Deliberate action taken between the final finishing and
termination of curing.
A material that generates a continuous thin film when spread
over water on the surface of fresh concrete and thus retards
the evaporation of bleed water.
Designations used to describe a concrete quality capable of
resisting the selected aggressive chemical environment for the
concrete
The long-term reduction in size of a concrete element caused
by the loss of water upon drying.
The reduction in length of a concrete element caused by its
cooling from the elevated temperatures developed during
hydration of the cement.
Mechanical operations carried out on the surface of placed
concrete to achieve the required texture, appearance and
serviceability.
Concrete which has insufficient reaction between the cement
and water to exhibit significant mechanical properties.
Concrete which exhibits mechanical properties as a result of
the reaction of cement and water
Heat generated by the chemical reaction of cement and
water.
Placing and finishing concrete when the shade temperature is
above 40oC on a rising thermometer or 43oC on a falling
thermometer and the combination of temperature and
humidity is such that the quality of fresh or hardened concrete
may be impaired unless preventive measures are taken.
A monolithic joint with no provision for movement.
A joint formed or induced to allow movement to occur with
one or more degrees of freedom
A layer of cement and fine sand with excess water content on
top of concrete
The part of concrete which is composed of cement paste and
sand.
Cover to reinforcement assumed for the purpose of durability
The ease with which fresh concrete can be made to flow.
Cover to reinforcement shown on the drawings comprising the
minimum cover plus a tolerance c to accommodate fixing
precision.
All operations necessary for introducing the fresh concrete
into form work or other enclosures.
See fresh concrete
Cracks which form due to differential settlement of concrete
while still in a fresh (plastic) state.
Cracks which form because of excessive loss of moisture from
concrete while still in a fresh (plastic) state
Anything (internal or external) which prevents the free
movement of concrete
Addition of water and remixing of concrete to increase its
workability
Pertaining to the flow of concrete
Loss of uniformity of fresh concrete mix due to separation of
Page D-23 of 47
D2.2
Specifications
one or more of the constituents of the mix.

Sedimentation or the act of the heavy solid particles settling in
fresh concrete.
See Cohesiveness.
Time beyond which reworking of concrete would be
detrimental.
Settlement
Stability
Stiffening time
:
:
Tensile strain
capacity
Transporting
The tensile strain at which a concrete will crack.
The conveying of fresh concrete from the point of discharge

from the mixer to the point of discharge into the form work or
other enclosure
Warping
Consistency
The distortion of a slab caused by temperature or moisture

gradients across the depth of section.
The rheological properties of fresh concrete influencing the
ease with which it can be placed, compacted and finished
General
Except where otherwise required by BS 5337 or as otherwise specified herein, concrete
shall comply with the recommendations contained in BS 8110 or such modifications as
may be agreed with the Engineer.
All below ground concrete structures are to be tanked as a protection from the aggressive
groundwater both below the ground water table and in the capillary zone above.
The concrete mix for water retaining structures shall be designed to achieve the structural
performance level to HIGH as given in the table 5 of BRE Special Digest No.1 part 3:
2003 and Table A-3 of BS8500-1:2002.It shall also be watertight as described in BS 8007.
Concrete to be used in aggressive ground shall be designed as recommended in Part 2 of
BRE Digest No.1Part 2 and 3 and for precast products it shall be as specified in Part 4 of
BRE Digest No.1.
The choice of cement to be used for underground structures shall depend on the sulphate
and chloride concentrations in ground water and the soil. The tenderer shall consider in
his offer the sampling and testing of soil and ground water in accordance with BS 5930.
The concrete mix is to be designed after assessing the classification of aggressive ground
conditions at site. (Refer BRE special DigestNo.1and CIRIA guide recommendation). The
chemical classification of the site is to be decided after considering step No.1 to 5
specified in BRE Digest No.1:2003 Part I cl:6.
The choice of constituent materials of concrete and its limitations given in BS 8007:1987
BRE Digest No.1 and BS 8500:2002 are to be taken into consideration to satisfy the
structural performance level of buried concrete (Ref. Section 6 of BS 8007 and BRE
Digest No.1:2003 part 1-4).
The qualities of concrete that are required to resist chemical attack shall be as
recommended in CL 4 to 6 of BRE Digest No.1:2003 Part 2.
Usage of fibrillated polypropylene fibres in concrete may reduce the rate and amount of
bleeding as well as the effect of plastic settlement cracks in concrete. Therefore where
approved/ or use by the Engineer fibrous concrete shall be designed as stated in the mix
design specification.
Controlled Permeability formwork(CPF) on structural concrete shall be used
a) To prevent loss of fines from concrete during Vibration.
b) To evacuate the excessive air from concrete, avoid air voids on concrete surface and
improve the surface quality (Ref. CIRIA guide CL 15.5.4 and 17.6.3)
c) To substitute an insulation layer on external concrete surface to control the in situ
concrete temperature gradient and concrete surface temperature.
Vol 3, Section3
Page D-24 of 47
Specifications
d) To increase the concrete surface and wear resistance.

e) To decrease the ratio of chloride penetration, water penetration and carbonation
effect.
f) For textured surface finish to avoid sand blasting before painting and to acquire an
ideal substrate base.
g) To reduce bacterial and algae growth due to dense surface without cracks and blow
holes.
Unless otherwise indicated on the Drawings all concrete shall be Grade C45/20.
All concrete below ground will be protected in accordance with Section G.
Whether ready mixed or site batched, designed or prescribed, all concrete shall be dense,
durable and in accordance with either Table D7 or D8.
D2.3
Ready Mixed Concrete

The Contractor may use ready-mixed concrete from an approved source with the written
authorisation of the Engineer. Ready-mixed concrete and all constituent materials shall
conform to this Specification.
D2.4
Mix Design Constraints

All design mixes shall comply with the following constraints.
TABLE D7
Concrete Design Mixes
Grade
C60/20*
Nominal Max.
Aggregate
Size
(mm)
20
Cement
Content
Kg/m3 of
Finished
Concrete
Max Free
Water
Cement
Ratio
Characteristic
Cube Strength
N/mm2
28 days
Min.
Max.
400
500
0.35
C45/20
20
370
500
0.42
45
C40//20
20
350
500
0.45
40
Blinding
20
220
500
Heavy duty
10
420
500
0.42
floor finish
Note:* Self compacting concrete for insitu piling works and concrete having congested
reinforcement
Characteristic strengths are basic mix strengths and do not allow for any reduction in
strength due to the use of air entrainment agents. Air entrainment agents will be used
only where specified.
Vol 3, Section3
Page D-25 of 47
Specifications
Air entrainment agents or other admixtures will not normally be approved for concrete
having a water cement ratio exceeding 0.18.
Only air entrainment agents based on vinsol resins will be approved.
Where air entrainment is specified, the average air content by volume of fresh concrete
(measured in accordance with BS 1881) shall be 5% for 20mm nominal maximum
aggregate size. This will produce concrete having a strength approximately 70% that of
non-air entrained concrete.
If bleeding occurs in any trial mix it shall be assessed in accordance with ASTM C232 and
where necessary the mix design or sand grading shall be adjusted to prevent recurrence.
The mix proportions shall be adjusted to achieve the maximum density from the available
materials. Unless otherwise agreed by the Engineer, the saturated surface dry density of
fully compacted cubes shall be not less than 2350 Kg/m3 for those concrete for which air
entrainment has not been specified. As a guide the Contractor should note that for nonair entrained concrete, Ras Al Khaimah aggregates and dredged sand normally achieve
densities greater than 2450 Kg/m3, and local Bahrain aggregates and dredged sand
normally achieve densities greater than 2390 Kg/m3.
In-situ concrete shall be well compacted to a minimum of 98% of the density of the
relevant cube strength.
In general the actual cement content will need to be higher than the minimum value
specified to ensure adequate workability and compliance with the maximum water /
cement ratio.
Mean strengths may exceed those required to achieve the characteristic strength in order
to comply with the maximum water / cement ratio.
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 0.05%. It should be
noted that the above involves a testing period of about eight weeks.
Unless an alternative method statement is approved the workability of the concrete shall
be measured by means of the slump test. The Contractor shall provide the apparatus as
detailed in BS 1881 : Part 102.
Under no circumstances shall a slump test be used as a means of monitoring water
content and it shall be noted that for any concrete mix the slump will reduce with
increasing temperature.
Concrete mixes shall be designed such that the minimum workability at the time of placing
is adequate to allow the concrete to be placed and compacted as specified. The
workability at the time of placing shall be in the range 50mm to 100mm. In those
situations where vibration of the concrete is difficult, the Engineer will not unreasonably
withhold permission to use self-compacting concrete incorporating approved hyperplasticiser and viscosity enhancing agents.
D2.5
Design Mixes
D2.5.1
General
For guidance the Contractors attention is drawn to the CIRIA Guide to Concrete
Construction in the Gulf Region.
Vol 3, Section3
Page D-26 of 47
Specifications
Where directed by the Engineer concrete mix designs which include an admixture shall
have trial mixes prepared and tested both with and without the admixture to give a clear
indication of its effects on the physical characteristics of the mix.
The workability of the mix shall be the minimum necessary to allow satisfactory placing
and compaction. (Refer to Clause D2.4).
D2.5.2
Design Mixes for New Batching Installations

A potential mix design shall first be subjected to preliminary testing on one batch. If this
preliminary batch achieves cube strengths which exceed the characteristic strength by an
acceptable margin (an assessment based on 7 day strengths may be accepted) at the
specified free water cement ratio and produces concrete of the required workability and
even consistency the mix may be prepared for trial mix analysis. If the batch fails the
Contractor shall experiment with the mix proportions and submit another design.
Trial batches shall be prepared under strictly monitored conditions in the presence of the
Engineer. Materials shall be typical of the proposed supply and special care must be taken
to record aggregate moisture contents and to determine the required free water content.
Preferably full scale production equipment should be used - if circumstances make this
impractical the batches may be mixed in a laboratory.
Three separate trial batches shall be made using the proposed design mix. The
temperature, workability and the fresh concrete density of the trial batches shall be
determined and six cubes made from each batch, three cubes for testing at 28 days and a
further three cubes for testing at 7 days as a quality control guide.
Cubes for testing shall be submitted to an approved testing facility six days after they have
been made.
The proposed mix design will be accepted provided:
D2.5.3
i)
The plastic properties are compatible with the requirements of the Contract having
due regard to bleed capacity and minimum workability necessary to allow placing
and compaction as specified with the equipment proposed in any situation.
ii)
The specified free water/cement ratio is not exceeded.
iii)
The mean strength of the nine cubes exceeds the specified characteristic strength
by not less than 10N/sq.mm.
Design Mixes from a Continuing Source

For mixes proposed from a continuing source for which the necessary test results are
available and for a batching installation which has been operated for a sufficient period to
produce the required cube results the following procedure shall be adopted.
The means strength calculated from n cube results from separate batches of concrete
shall exceed the specified characteristic strength by a margin equal to:
1.64 x SD (0.86 + 2 n)
Where:
SD is the standard deviation from n results but not less than 3N/sq.mm.
n is the number of results not less than 10 and not greater than 100
Vol 3, Section3
Page D-27 of 47
Specifications
When n exceeds 100, the margin shall be calculated as :

1.64 x SD
Where SD is as defined above.
Previous production data for use in the above criteria shall be 28 day cube test results
from separate batches of concrete sampled at random over an immediately prior period
exceeding one month and not exceeding one year using materials and plant which are
proposed for the Works.
For new proposals to use a continuing source, such as a ready mix concrete supplier, a
trial batch shall be prepared and tested to demonstrate compliance with the strength and
workability requirements of this Specification.
D2.6
Prescribed Mixes for Minor Works

Prescribed mixes shall only be used with the Engineers agreement and where isolated
quantities of less than one cubic metre are required. They shall comply with Table D8 and
be either site batched or supplied dry in bags ready for mixing with a set volume of water.
Concrete shall not be hand mixed.
TABLE D8
Prescribed Concrete Mixes
Grade
Nominal Max.
Aggregate
Size
mm
Fine
Aggregate
Content
Kg/m3
Coarse
Aggregate
Content
Kg/m3
Cement
Content
20
650
1150
450
C30/20P
Weight requirements given are per cubic metre of compacted concrete.

grading shall comply with Table D3
D2.7
Concrete Quality Control
D2.7.1
Kg/m3
Aggregate
A Materials Approval Statement shall be submitted for the proposed methods of

controlling and recording the quality of concrete and shall include the following:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Cube strengths
Workability (Slump)
Density of fresh concrete
Density of hardened concrete
Temperature of mix during placing
Climatic conditions during placing
Vol 3, Section3
Page D-28 of 47
Specifications
This information shall be recorded on a standard from, which must be submitted to the
Engineer for approval.
The Engineer will record the ease of placement, and the subsequent condition of the
concrete after stripping of formwork. If the quality is unsatisfactory the concrete shall be
repaired or replaced and the mix design or method of placing altered to prevent any
recurrence of the problem.
D2.7.2
Test Cubes
Testing Plan A shall be the method used except where the Engineer directs the use of
Testing Plan B.
(i)
Testing Plan A
A single sample shall be obtained from one randomly selected batch of concrete
representing an average volume of not more than 20 m3 except that at least one
sample shall be taken on each day for each grade used.
From each sample a total of four cubes shall be made of which two are for testing
at 7 days as a quality guide and two are for testing at 28 days.
(ii)
Testing Plan B
Testing Plan B shall be used when directed by the Engineer and is for testing single
batches of concrete and for those occasions where the Engineer requires assurance
that concrete placed in a particular part of the Works is of adequate quality.
A single representative sample shall be taken from each batch of concrete.
Two cubes shall be made from the sample for testing at 28 days. Additional cubes
shall be made from the same samples for testing at an earlier age as ordered by, or
agreed with, the Engineer.
The rate of sampling may be varied by the Engineer to suit particular circumstances.
Sampling and making of cubes shall be carried out in accordance with BS 1881.
The samples shall, where practicable, be taken at the point of discharge.
The Contractor is responsible for initial curing of the cubes to the requirements of BS
1881. As soon as is practicable between 3 and 6 days after the cubes have been made, all
the cubes shall be submitted to the Ministry of Works, Power and Water.
D2.7.3
Workability
The workability of the concrete, both at the batching plant and the point of placement,
shall be measured by means of slump tests.
The mix design shall be adjusted, if necessary, within the approved design limits until the
workability of the concrete is suitable for that particular category of concrete and is
accepted by the Engineer.
Vol 3, Section3
Page D-29 of 47
D2.7.4
Specifications
Density
The density of the fresh concrete shall be recorded by the Contractor. The average
density of the two cubes crushed at 28 days will be used to determine the average cube
density.
D2.7.5
Temperature
The temperature of the concrete shall be measured and recorded by the Contractor at the
batching plant and at the point of placement, (Clause D3.8 refers). A thermometer
complying with the requirements of BS 1704 or other approved temperature measuring
devices shall be used.
D2.7.6
Climatic Conditions
Maximum, minimum and wet bulb shade temperatures shall be recorded daily by the
Contractor.
D2.7.7
Compliance Requirements
Compliance with characteristic requirements shall be based on the compressive strength of
the cubes crushed at 28 days.
For test plan A (see Clause D2.7.2): the average strength of the two 28 day cubes made
from each sample shall be called a test result. If the test results from any four
consecutive test results and any individual test result provide the strength margins
indicated in the table D9 the concrete shall be deemed to comply with the characteristic
strength requirements. In the case of small or new works where there are less than four
test results, the first two or first three test results and any individual test result shall be
considered.
TABLE D9
Concrete Strength Compliance Requirements
Test Result
The average test result

shall exceed the specified
characteristic strength
by at least:
Any individual test result

shall not be less than the
specified characteristic
strength minus:
First 2
1 N/mm2
3 N/mm2
First 3
2 N/mm2
3 N/mm2
any consecutive 4
3 N/mm2
3 N/mm2
Vol 3, Section3
Page D-30 of 47
Specifications
If the range of individual cube strengths made from one sample exceeds 15% of their
mean, then the method of making and curing the cubes shall be reviewed. If the range of
individual cube strengths made from one sample exceeds 20% the result shall be
considered unacceptable.
The 7 day cube strengths shall be used as a quality guide only and may not be
extrapolated to represent 28 day cube strengths for compliance purposes. Comparison
with 7 day cube strength from the trial mixes will give an indication of the quality of a
sample.
If due to exceptional circumstances concrete is placed at a mix temperature of more
than 30 C the Contractor may, notwithstanding compliance of the concrete with the
strength requirements, be required to carry out field tests and/or further laboratory tests
to allow the Engineer to determine any structural implications.
For test plan B (see Clause D2.7.2) compliance with the characteristic strength will be
assumed only if both the following conditions are met:
(i)
The average strength determined from any sample exceeds the specified
characteristic strength by 3N/sq.mm.
(ii)
The strength determined from any single result is not less than specified
characteristic strength minus 3N//sq.mm.
D2.7.7.1 Non-compliance
If cubes fail to comply with the foregoing requirements or if a series of cube results
suggests an inconsistency in batching or quality of materials the Engineer may require the
associated concrete to be cut out from the works and replaced and may also withdraw his
approval of the design(s) of the concrete mix(es) or of the batching equipment. The
Contractor may be instructed to carry out field tests and/or further laboratory tests to
allow the Engineer to determine any structural implications.
Vol 3, Section3
Page D-31 of 47
Specifications
D3
FORMWORK AND CONCRETING PRACTICE
D3.1
Blinding Concrete (Sealing Coat)

Immediately following the hand excavation to formation level for floors or foundations
where shown on the Drawings or as ordered by the Engineer a sealing coat of blinding
concrete shall be placed on the surface of the formation and carefully spade finished to an
even surface. Utmost care shall be taken to preserve the natural water content of the
ground below formation level as far as possible. Should the ground be exposed to the
weather by delay on the part of the Contractor in placing the blinding and become wetter
or drier than its natural state the Contractor shall excavate such ground as may be
affected and replace it with concrete of the same grade as the blinding.
Floors of foundations shall be laid on the blinding as soon as may be practicable, this
being especially important during hot weather. If required by the Engineer the blinding
shall be kept thoroughly damp by watering.
D3.2
Formwork
Formwork is defined as the casing into which concrete is poured and its supporting
falsework.
It shall be designed and constructed so that the concrete can be efficiently placed and
compacted without displacing or deforming the reinforcement.
It shall be firmly
supported, braced, guyed or tied back so that is stable against vertical and horizontal
forces. It shall be capable of adjustment and sufficiently strong not to distort significantly
by the pressure of the concrete or by other loads and influences. Ties shall be of types
that do not produce holes completely through the concrete and any permanently
embedded metallic parts shall not be nearer the finished surface than the cover to the
reinforcement.
Cover blocks and spacers shall be designed to maintain the correct clear cover of concrete
over steel reinforcement. They shall be as small as possible consistent with their purpose,
and of a shape acceptable to the Engineer. Minimum cover to reinforcement shall be
50mm unless otherwise detailed.
Concrete cover blocks shall be manufactured to the same specification as the surrounding
concrete. When tested in accordance with BS 1881 Part 122 the water absorption shall
not exceed 2% for samples up to the age of one month at the time of test. Wire cast in
the block for the purpose of tying it to the reinforcement shall be of annealed soft iron
and shall be rust and contaminant free.
Spacers shall be of rust-proof material and shall not produce staining, or otherwise be
detrimental to the concrete or steel.
Joints in the formwork shall be close fitting to prevent leakage. Temporary openings shall
be provided, if necessary, for cleaning and inspection. The arrangement shall allow for
removal of formwork from the sides of members without disturbing soffit formwork.
Rough-faced formwork (Grade II) may be used only for surfaces which are normally never
exposed to view. Where such surfaces are to be tanked, by covering with paint or
sheeting, the formwork shall be capable of achieving a finish suitable for the proposed
tanking.
Excavation support timbering may not be used as formwork.
Vol 3, Section3
Page D-32 of 47
Specifications
Fair faced formwork (Grade I) shall be used for surfaces of concrete which will be exposed
to view or to liquids. It shall be constructed from material of sufficiently high quality to
produce a smooth concrete surfaces of uniform texture and appearance without visible
imprint of grain or steppings or ridges. Where lined the same type of lining shall be used
throughout any one structure.
If the use of metal faced formwork is proposed details shall be submitted to the Engineer
for approval prior to use. Metal forms shall be insulated to prevent excessive temperature
fluctuations at the concrete surface.
If movement or deflection of the formwork or loss of liquid occurs, and if the Engineer so
directs, the Contractor shall cut out and replace the concrete supported by such formwork
at his own expense.
Formwork shall be used for upper inclined surfaces of concrete where the slope is greater
than 30 to the horizontal.
Formwork shall be designed so that splays, fillets, chamfers and projections are cast as
the work proceeds. The Drawings, particularly those prepared to small scales, may not
detail chamfers but unless specifically deleted all external angles on exposed concrete
shall have a 25mm by 25mm chamfer.
Before placing the concrete all extraneous matter shall be removed from the interior of
formwork. All faces of formwork against which concrete is to be placed shall be carefully
cleaned and treated with an approved non-staining chemical release agent to prevent
adhesion of the concrete. Care shall be taken to ensure that the reinforcement is kept
free from the release agent and that any excess is removed from the forms and that wind
blown dust does not adhere to any surface.
The surface temperature of the reinforcement and formwork shall not exceed the
temperature of the concrete at the time of placing.
The Contractor shall provide facilities for examination of the formwork after its erection
and before concrete is placed and shall give 24 hours notice to enable the Engineer to
examine the formwork if he so wishes. The Contractor shall place concrete only after
obtaining approval from the Engineer but this shall in no way relieve the Contractor of any
of his responsibilities under the Contract.
D3.3
Tolerances and Finishes for Concrete Surfaces

Unless tolerances for particular surfaces are specifically shown on the Drawings they shall
be as follows :-
D3.3.1
Tolerances for Exposed Surfaces

(Note: For the purpose of this clause, exposed surfaces includes those with RTR or PVC
liners).
(i)
Floor and Roof Slabs

The level of the surface at any point shall be within plus or minus 5mm of the level
derived from the Drawings. There shall be no abrupt irregularities.
(ii)
Walls
The position of the face at any point shall be within 10mm of its position derived
from the Drawings. There shall be no irregularity exceeding 3mm in a 3m template.
Vol 3, Section3
Page D-33 of 47
Specifications
The level at any point on the top of the wall shall be within plus or minus 3mm of
the value derived from the Drawings.
(iii)
Beams and Columns

The position of each face at any point shall be within 3mm of its position derived
from the Drawings.
(iv)
Measuring flumes
Any point on the invert of the flume channel shall be within plus or minus 2mm of
the level derived from the Drawings. The width of the throat at any cross section
shall be within plus or minus 2mm of the required width and the surfaces shall be
smooth.
(v)
Weirs
Any point on a weir shall be within plus or minus 2mm or the level derived from the
Drawings and the surfaces shall be smooth.
D3.3.2
Tolerances for Unexposed Surfaces

Tolerances are not specified but thicknesses shall subject to Engineers approval.
D3.3.3
Surface Finishes
Exposed concrete finishes shall comply with the following:
(i)
General
There shall be no abrupt irregularities or visible surface imperfections.
(ii)
Concrete roads
Surfaces shall have a brushed or tamped finish with float finished edges.
(iii)
External walkways
Surfaces shall be float finished and then except for margins at exposed edges,
slightly roughened by brushing to produce an even textured surface.
(iv)
Concrete floors and tops of walls

Surfaces shall be steel float finished to be uniform and smooth.
The surfaces of walls and other exposed surfaces cast against formwork that will be
exposed to view or to liquids shall be rubbed down smooth in an approved manner within
three days after formwork has been removed. After inspection by the Engineer any holes
shall be filled with matching cement mortar.
D3.4
Bending, Placing and Fixing of Reinforcement

Unless otherwise specified laps, hooks and bends shall be to the dimensions detailed in BS
4466.
The Contractors attention is drawn to the following general requirements:
(i)
Lapped joints shall not be less than forty times the diameter of the bar unless
approved by the Engineer in writing on the basis of design calculations submitted by
the Contractor
Vol 3, Section3
Page D-34 of 47
Specifications
(ii)
Hooks shall be semi-circular with a straight end length of at least four bar diameters
beyond the curve.
(iii)
Internal bend diameters shall be at least four bar diameters for mild steel and six
bar diameters for high yield steel.
All bending shall be done before the reinforcement is placed in position and no heating or
welding will be allowed. Where fabric reinforcement is required to be bent, it shall be
done cold, either using a bending machine or swage blocks and hooks.
Fabric
reinforcement shall be cut to cover the areas detailed plus the following laps:
(a)
Rectangular mesh
(b)
Square mesh
- 450mm for longitudinal members

- 75 mm for transverse members
- 300mm in each direction
The reinforcement shall be assembled as dimensioned on the Drawings within tolerances

appropriate to the structure. It shall be firmly held in position by wire ties and concrete
blocks, or other approved spacers. Minimum cover to reinforcement shall be as per Clause
A2.7 unless otherwise detailed. The position of spacers and their method of use shall be
approved by the Engineer. No concrete or reinforcement shall be cut in any way except
by permission in writing from the Engineer.
Nothing shall be allowed to interfere with the disposition of any member of the
reinforcement and the Contractor shall take special precautions that it is not only correctly
placed, but remains undisturbed during the placing and setting of the concrete, and that it
has not been contaminated with release agent or any other substance which will prevent
the perfect bonding of steel and concrete.
With the approval of the Engineer mild steel reinforcement may be temporarily bent aside
at construction joints. This shall be done with care to a minimum internal bending radius
of 4 bar diameters and to avoid damage to the concrete during bending and re-shaping.
The bending of high yield bars and fabric reinforcement at construction joints if not
permitted.
D3.5
Formation of Holes for Fixing

Where the Contract includes the formation of holes and pockets for the later building in of
holding down bolts, other fixing devices, services and structural steelwork, boxes for the
formation of such holes shall be adequately supported and preferably fixed rigidly to the
main formwork.
All holes shall be formed in positions to be detailed for the various items of machinery.
Where a group of holes has to be formed for a number of bolts for fixing one item, the
formers shall be securely fixed together before the concrete is poured around them. The
boxes shall be suitably protected to avoid extraneous matter falling onto them.
Refer also to Clause H2.2 (Fixing Metalwork and Machinery).
D3.6
Batching, Transporting and Placing of Concrete

All concrete used on the Works shall be made at batching plants where quality can be
monitored and controlled.
Measurement of all the aggregates and cement shall be by weight. Allowance shall be
made for the water content or absorption of the aggregates as appropriate.
Vol 3, Section3
Page D-35 of 47
Specifications
For this purpose the Contractor shall determine the moisture content of aggregates at
least twice a day during continuous concrete production using an approved method.
The quantity of water added to the mix shall normally be the target value determined from
the trial mixes. If however, the moisture content of the aggregate varies from that of the
trial mix aggregate, the quantity of water must be varied to maintain the true water
content.
The quantity of water for each batch shall be accurately measured by means of a
calibrated device. Concrete shall be mixed with a machine of a type and size complying
with BS 1305 and shall be used within 80-100% of its rated capacity unless otherwise
approved.
All plant and equipment used in mixing concrete shall be maintained in good working
order and shall be kept clean and free of hard or partially set concrete.
Each consignment of concrete dispatched from the batching plant to site must be
conveyed in truck mixers or agitators and must be accompanied by a delivery certificate in
duplicate stating:
(i)
Grade of concrete and design slump
(ii)
Origin
(iii)
Time and date of mixing
(iv)
Temperature of mixing
(v)
Additives (if any)
(vi)
Cement type, cement content and water / cement ratio
(vii)
Mix code number
Each certificate must be countersigned by the Engineer or a member of his staff and one
copy retained on site, prior to incorporation of the concrete into the Works. Such
signature shall not constitute acceptance of the concrete.
The following additional information shall be recorded by the Contractor and shall be
supplied by him to the Engineer within 24 hours:
(a)
Position in the structure where the concrete was placed.
(b)
Time of placing.
(c)
Whether test cubes were taken on delivery.
(d)
Slump on delivery.
(e)
Mix and ambient temperatures.
Concrete shall be conveyed to the place of final deposit as rapidly as possible after mixing,
by methods which will prevent the segregation, loss or contamination of any of the
ingredients. No additional water shall be added after the concrete has been discharged
from the mixing plant, and the concrete shall be placed and compacted not more than two
hours after mixing.
Vol 3, Section3
Page D-36 of 47
Specifications
Detailed method statements shall be supplied for the batching of concrete and for the
methods of placement for each structure or type of structure including any proposals for
the use of spouts, chutes or pumps as a means of transporting concrete.
The concreting of a section of the work shall be continuous until it is completed and shall
be carried out as quickly as possible.
The concrete shall be deposited in regular courses and spread out in layers of not more
than 500mm thickness and compacted with immersion vibrators used by properly trained
and supervised operators. Concrete shall not be dropped into place from a height
exceeding 2 metres. Vibrators shall penetrate the full depth of the layer of concrete and
where the underlying layer is of fresh concrete shall enter and re-vibrate that layer to
achieve effective knitting together. Vibrators shall not be allowed to remain in contact
with the reinforcement or formwork. Over and under vibration shall be avoided and
vibrators shall be withdrawn slowly to prevent void formation. Care shall be taken to
compact the concrete fully around reinforcement but without causing displacement of the
bars. Hand compaction will not be permitted.
Sufficient vibrators shall be provided at each pour location to ensure that the concrete is
fully compacted without delay.
At least one reserve vibrator and power source shall be provided on site and not less than
one reserve for every two in use at one time. Immediately before the mixing and pouring
of concrete each day the necessary vibrators shall be started and tested to the satisfaction
of the Engineer. Undue difficulty in starting a vibrator shall be sufficient grounds for
rejection.
External vibrators shall not be used without written approval.
Concrete floors and inverts shall be cast in one layer except where otherwise specified or
when written approval has been obtained to an alternative construction method.
Care shall be taken to prevent men engaged in placing concrete from introducing foreign
matter into the concrete from their footwear or in any other way and where concrete is
placed directly against the surfaces of excavations any softened material shall first be
removed.
D3.7
Batching of Admixtures
Where air entrainment agents or other admixtures are specified or approved they shall be
added at the mixer. Unless alternative methods to the recommendations of the admixture
supplier are approved the admixture shall be batched in solution in a portion of the mixing
water by means of a mechanical batcher which is capable of dispensing the agent in
quantities varying by not more than 5 per cent from the quantities required and in such a
manner as to ensure uniform distribution of the agent throughout the batch during the
time of mixing.
The capability of the apparatus to achieve the required dosing and mixing requirement
shall be demonstrated to the Engineer and the apparatus shall be checked each day
before concrete mixing commences.
D3.8
High Temperature Concreting

Concrete shall not be placed when the shade temperature exceeds 40C.
The temperature of batched concrete at time of placing shall not exceed 30C.
Vol 3, Section3
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Specifications
The recommendation in standard publications (see Section S) on hot weather concreting

practice shall be followed.
Measures shall be taken to provide cool concrete and cool concreting conditions in order
to reduce workability loss, premature drying of concrete and the development of high
temperatures and temperature gradients in placed concrete.
Proposed measures must be described in method statements and may include:
D3.9
(i)
Painting white or silver all storage vessels, hoppers, pipes, walls or roofs which
contain or convey aggregates, cement or mixing water.
(ii)
Shading and/or watering of aggregates.
(iii)
Removal of aggregates from stockpiles by techniques designed to avoid the direct

use of surface aggregate.
(iv)
Use of iced mixing water or crushed ice.
(v)
Shading of concrete during and after placement.
(vi)
Provision of wind breaks.
(vii)
Night working.
Curing and Protection of Concrete

Method statements for the curing of concrete shall comply with the following minimum
requirements and shall propose effective means of preventing premature drying and the
resulting effects of plastic shrinkage.
D3.9.1
Exposed Surfaces
Exposed surfaces of concrete shall be completely covered with polythene sheeting within
20 minutes of placing and compaction and within two or three hours this shall quickly be
replaced by wet hessian covered with polythene. Polythene sheeting may be temporarily
removed for surface finishing where required.
The hessian shall be kept damp continuously using water of the quality specified for
concreting for a period of at least seven days or such longer period as the Engineer may
direct.
When air temperatures exceed 30C in any part of the day or when lower temperatures in
combination with high wind speeds are likely to lead to premature drying, the surface shall
be sprayed with an approved curing compound after removal of hessian and polythene.
Curing compounds may be applied earlier to supplement use of wet hessian and
polythene. (Refer to Clause D1.10).
In addition to the above measures, shading from direct sunlight and wind breaks may be
proposed or may be required by the Engineer to give added protection.
D3.9.2
Formed Surfaces
Formed surfaces shall be completely covered by wet hessian and polythene within half an
hour of stripping the formwork and shall then be treated in accordance with Clause
D3.9.1.
Vol 3, Section3
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Specifications
Formwork shall be shaded and/or wetted to prevent high temperatures accelerating cure.
For formed surfaces which are to be exposed, effective approved measures shall be taken
to prevent concrete surfaces from drying out and to ensure adequate curing whilst rubbing
down is taking place and before application of any approved curing membranes or other
curing methods.
D3.9.3
Tanked Surfaces
External surfaces which are to be tanked with bituminous paints or bituminous membranes
as specified in Section G may, for small structures, and with the written agreement of the
Engineer, have these products applied in lieu of the above curing methods but shading or
wetting may be required to control surface temperatures, particularly if the products are
dark in colour.
D3.9.4
Damaged Concrete
Measures shall be taken to prevent damage to concrete either in mass or on the surface
during the period of setting and thereafter by shock, vibration, water or any other agent
and no loads shall be placed on any structure without the prior permission of the
Engineer.
Any concrete which is damaged or deemed unsatisfactory due to inadequacies of
constituents or any mixing, transporting, placing or curing methods shall be broken out
and replaced.
D3.10
Striking Formwork
Formwork shall not be struck until the structure has attained sufficient strength to carry its
own weight, plus any constructional or other loads likely to come upon it, without
excessive deformation. Also the concrete shall have matured sufficiently to resist physical
damage. Formwork shall be struck in such a manner that no damage shall result to the
concrete.
Formwork shall not be struck except with the Engineers permission. The work of striking
or removing such moulds, shuttering or centring shall be conducted only under the direct
supervision of a competent foreman.
The method statements for each structure shall include proposals for the methods and
times for the striking of shutters. Table D11 is included showing the minimum intervals of
time between the placing of concrete and the striking of shuttering at 16C and above but
these periods may be varied by the Engineer if environmental conditions make this
permissible or desirable. Striking times shall not be less than 24 hours.
Method statements may include proposals for different periods by reference to recognised
standard publications on concreting practice. Where it is proposed to remove soffit
shuttering in advance of props the method statement shall clearly indicate the sequence
and means of dismantling the soffit shuttering with a view to maintaining adequate
support.
The Contractor shall be responsible for any injury to the work and any consequential
damage caused by or arising out of the removal of the formwork. Any advice, permission
or approval given by the Engineer relative to the removal and striking of the formwork
shall not relieve the Contractor from the responsibility here defined.
Vol 3, Section3
Page D-39 of 47
Specifications
TABLE D11
Minimum Formwork Striking Times
Type of Formwork
Beam sides, walls, columns and

foundations
D3.11
Ordinary and Sulphate

Resisting Portland Cement
Concretes (surface temperature
16C and above)
24 hours
Soffits to slabs (props left under)
4 days
Soffits to beams (props left under)
9 days
Props to slabs
10 days
Props to beams
14 days
Re-use Formwork
Care should be taken, when re-using formwork, that its surface shall be smooth and clean
and that it shall be free from warping, twisting or other deformations. Any formwork
which has, in the opinion of the Engineer, deteriorated sufficiently to render it unsuitable
for the work shall be rejected and must be removed from the Site within 48 hours or must
be broken up at once, new formwork being provided at the Contractors expense.
D3.12
Heavy Duty Concrete (Granolithic) Screeds to Benching and Channels

Heavy duty concrete screeds should preferably be placed and compacted within three
hours of casting the base in which case the base concrete shall be left rough and the
screed shall be spread and consolidated on to the whole of each bay or structure.
Where this cannot be achieved the base concrete shall be cast with a rough surface.
Weak surface laitance and any other contaminating material must be completely removed
and the coarse aggregate cleanly exposed. This surface shall be thoroughly cleaned and
then soaked overnight, any surplus water being removed. The surface shall then be
brushed with a 1:1 sand/cement grout and the heavy duty concrete screed applied.
The concrete shall be compacted and screeded to levels or falls with a screeding board
and wood float. Further trowelling shall be done with a steel trowel after about two
hours. The thickness of a surfacing where it is inclined at 45 or greater to the horizontal
shall not exceed a nominal 15mm and if this is inadequate to complete the work the
surface shall be left rough and keyed with a trowel. A further surfacing coat shall be
applied within 24 hours.
D3.13
Cracks in Concrete Structures

The filling of cracks will not be permitted unless approval is given by the Engineer in
writing.
Vol 3, Section3
Page D-40 of 47
Specifications
D4
JOINTS IN CONCRETE STRUCTURES
D4.1
Classifications
There are two classifications of joints in structural concrete.
D4.4.1
Movement Joints
Movement joints are provided for expansion, contraction or flexibility. They are detailed in
this Specification and on the Drawings. Where the positions of movement joints are not
shown on the drawings, they shall be designed by the Contractor in accordance with the
requirements of the Specification. All movement joints are required to be leak-proof.
Expansion and contraction joints shall be formed as detailed in this Specification and on
the Drawings. The Contractor shall ensure that there is no adhesion between the two
concrete faces of the joint and that debris does not enter the joints.
A bond breaker shall be incorporated into all expansion and contraction joints to prevent
adhesion between the joint sealant and the filler in the case of expansion joints, and the
base concrete in contraction joints.
All jointing materials used in a particular joint shall be chemically compatible with each
other and with their contact environment.
D4.1.2
Construction Joints
Construction joints are provided for convenience of construction and, in some instances, to
assist in the control of shrinkage cracking. Where the positions of construction joints are
not shown on the Drawings they may be proposed by the Contractor to suit his methods
of working.
Construction joints are required to give monolithic construction and to be leak-proof.
Method statements for the detailed design of construction joints shall generally comply
with the following guidelines.
Where practicable wooden battens of trapezoidal pattern shall be inserted in the face of
the unfinished concrete at a construction joint, and later withdrawn, to form a continuous
dovetail key. The surface of the previously poured concrete at construction joints must be
clean and dry and all laitance and scum must be removed to show the tips of the coarse
aggregate before the adjacent concrete is placed; where practicable the aggregate
exposure is to be done by bush hammering, wire brushing or water jetting while the
concrete is still green. Any defective concrete shall be removed before the adjacent
concrete is cast. At horizontal construction joints the first layer of new concrete shall not
exceed 150mm in depth and particular care shall be taken to prevent loss of fines from
the bottom of the new lift.
Where, in the opinion of the Engineer, the placing of concrete is interrupted long enough
for the concrete to have hardened beyond acceptable workability limits, the surface of the
unfinished concrete shall be treated as though it were a construction joint.
D4.2
Size and Sequence of Concrete Pours

The Contractor shall include in his method statement for each structure his detailed
proposals for the sequence of placing concrete and for the positions of vertical and
horizontal construction joints not shown on the Drawings.
Vol 3, Section3
Page D-41 of 47
D4.3
Specifications
Water Bars
Water bars shall be manufactured of extruded PVC or of nitrile rubber. They shall be of
the types and general shapes indicated on the Drawings. They shall be obtained from
experienced manufacturers and shall be to the latest shapes and forms generally adopted
in the industry. Water bars shall comply with Table D12.
TABLE D12
Waterbar Characteristics at 25C
Property
Rubber
(BS 903)
PVC
(BS 2782)
Density
1100 kg/m3 (+ 5%)
1300 kg/m3 (+ 5%)
Hardness
60-65 I.R.H.D.
70-75 I.R.H.D.
Softness Number
42-52
Tensile Strength
not less than 20 N/mm2
not less than 15 N/mm2
Elongation at Break Point
not less than 450%
not less than 285%
Water Absorption
(48 hrs immersion)
not exceeding 5%
not exceeding 0.7%
Web Thickness
10mm
10mm
Centre Bulb Dimension
18mm
18mm
Rubber and PVC waterstops shall be suitable for storage, handling, installation and service
within a range of 15C to 50C.
Care shall be taken to prevent damage to water bars. Water bars shall normally include
eyelets for fixing and shall not be nailed unless they incorporate a reinforced outer nailing
flange.
Water bars shall not be displaced during the placing of concrete which shall be fully
compacted around them.
Jointing of water bars shall normally be carried out by clamping and welding or adhesion
and shall be in accordance with the recommendations of the manufacturer.
Water bars shall be arranged so that there is a minimum distance of 25mm from the water
bar to the reinforcement.
D4.4
Bond Breakers
Bond breakers shall be polyethylene tape, closed cell expanded polyethylene foam in flat
strip or solid circular core section, or another approved material which is suitable for
preventing short or long term adhesion between the sealant and the base material of the
sealant groove.
Vol 3, Section3
Page D-42 of 47
D4.5
Specifications
Expansion Joint Fillers

Unless otherwise shown on the Drawings joint fillers will be resin bonded cork to ASTM
D1752-67 with the following minimum characteristics:
D4.6
Density
200 kg/m3
Maximum load to compress to

50% of original thickness
0.55 N/mm2
Recovery after compression
95%
Joint Sealing
Sealant slots to expansion, contraction and, where included, construction joints shall be
carefully constructed to the dimensions detailed on the Drawings, or, subject to approval
of the Engineer, to the manufacturers recommendations.
The Contractor shall take care to avoid spalling of concrete on the edges of slots. Slots to
expansion joints may be formed by installing joint filler to the concrete surface and then
using a special cutter to remove filler to the required depth. Alternatively, and for
contraction joints, slots may be formed by pre-formed PVC or timber formers with sloping
sides to assist removal.
Before placing sealants, the slots must be thoroughly cleaned and all laitance and oil
removed by an abrasive method. Immediately prior to sealing the slots, all loose surface
debris, sand and dust must be blown out using compressed air, and the slots must be dry
and free from collected rainwater etc. to ensure maximum adhesion.
Bitumenised foamed polyurethane sealing strip shall be 9mm thick uncompressed. It shall
compress to 25% of its original thickness under a load of 0.045 N/mm2.
Hot poured joint sealants shall comply with the requirements of BS 2499 for Ordinary Type
Al sealant.
Cold poured polymer based joint sealants shall comply with the requirements of BS 5212
for Normal Type N sealant.
Two part polysulphide based sealants shall comply with the relevant requirements of BS
4254. Pouring grade shall be applied to horizontal upward facing joints and gungrade to
joints or any other aspect or inclination. Other two-part polymer-based sealants of gun or
trowel grade shall comply with the physical and test requirements of BS 4254.
Sealants must in all cases be carefully selected as appropriate for their climatic and
environmental exposure and must, where appropriate, be resistant to bio-degradation.
The Contractor must supply to the Engineer copies of written recommendation(s) and
guarantee(s) from the manufacturer as to the suitability of the product(s) for each
individual structure and for the methods of installation.
Primers for use with joint sealants shall be compatible with, and obtained from the same
manufacturer as, the adjacent sealant. Primers shall have no harmful effects on concrete.
Where required by the Engineer masking tape shall be applied to protect the concrete
surface on either side of the joint priming and sealing operations. Such masking tape
must be carefully stripped away after joint sealing to leave neat edges to the seal.
Vol 3, Section3
Page D-43 of 47
D4.7
Specifications
Joint Bond Breaking for Contraction Joints and Sliding Joints

Contraction joints to be sealed with polysulphide based sealants shall not have concrete
faces painted with bituminous products due to reactivity. In such cases bond breaking
shall be achieved by polyethylene tape or a plastic slip membrane.
Sliding joints shall be formed with two layers of any approved plastic slip membrane 1mm
thick.
D4.8
Bond Breaking Compound for Dowel Bars

Bond breaking compound for dowel bars shall consist of a bitumen paint containing 66 per
cent of 200 pen bitumen, blended hot with 14 per cent light creosote oil with the addition,
when cold, of 20 per cent solvent naphtha. It shall in no way retard or otherwise affect
the setting of concrete.
D4.9
Dowel Bars
Dowel bars for expansion joints in concrete shall consist of mild steel complying with the
relevant requirements of BS 4449.
Dowel bars shall be straight, free from burred edges or other irregularities, and shall have
their sliding ends sawn. The sliding half of each dowel bar shall be painted with a thin
coat of bond breaking compound, and the end of this half shall be provided with a close
fitting plastic or waterproof cardboard cap at least 100mm long, the end 20mm of which
shall be filled with a disc of joint filler or a pad of cotton waste.
Vol 3, Section3
Page D-44 of 47
Specifications
D5
PRECAST CONCRETE
D5.1
Precast Concrete Production

Details of the design of all precast units shall be submitted to the Engineer for his approval
before manufacture.
Precast copings shall be to BS 5642; precast concrete flags shall be to BS 368 and shall be
hydraulically pressed; precast concrete kerbs and edgings shall be to BS 340.
Precast concrete gullies shall comply with the relevant requirements of BS 5911: part 2.
Precast concrete units, unless otherwise specified or ordered shall be constructed from
Grade C45/20 concrete but the coarse aggregate shall be 10mm to 5mm.
Precast units shall be either:
(i)
Cast in vibrated moulds.
(ii)
Formed in hydraulically compressed moulds.
(iii)
Cast in a spun process.
(iv)
Cast in open moulds with approved compaction techniques.
In every process, the formwork shall be of adequate quality to produce a completely

smooth finish.
Curing methods shall be as specified in Clause D3.9.
Units shall not be transported until they have matured under suitable conditions for a
period of not less than 14 days.
The units shall be so handled, stacked, stored and transported that they are not subjected
to undue stress or damaged in any way and large units shall have suitable lifting holes or
hooks incorporated into their design. No unit shall be built into the work until it has
matured for 28 days.
Units may be rejected if they have any of the following defects:
(a)
(b)
(c)
(d)
(e)
(f)
Broken edges
Cracks (other than hair cracks)
Repairs
Misplaced reinforcement
Honeycombing or air holes
Finishes dimensions different from those specified or shown on the Drawings.
The Engineer may order extra precast units to be manufactured for testing to destruction.
These units will be paid for if the tests show that they comply with the Specification.
Vol 3, Section3
Page D-45 of 47
D5.2
Specifications
Bedding Precast Concrete Units

Precast concrete units, except where otherwise specified, shall be bedded and jointed in
1:3 cement mortar, each unit being firmly pressed into position and the joints flush
pointed as the work proceeds.
Where units are to be subjected to internal or external water pressure, mortar joints shall
be completely watertight.
D5.3
Chamber Rings and Cover Slabs

Precast concrete chamber and shaft sections and cover slabs shall all be to BS 5911:Part 2
and be constructed to the dimensions on the Drawings.
Details of the design of all chamber cover slabs shall be submitted to the Engineer for his
approval before manufacture.
They shall be suitably protected internally and externally in accordance with Section G.
Cover slabs shall be arranged so that they are supported ion the surround concrete and
not on the chamber or shaft sections.
The slabs shall be designed to support their own weight, imposed dead loads from any
shafts, backfill and access covers and live loads based on individual wheel loads of 112kN.
D5.4

Precast concrete paving slabs shall be to BS 368 and shall be laid on 1:3 lime mortar using
five pats not less than 150mm dia for each slab. They shall be laid at a level not
exceeding 4mm above the top of the kerb or concrete edging. The joints shall be
thoroughly cleaned out and grouted with cement mortar well brushed in and flushed off.
No cracked or broken slabs shall be used.
D5.5
Precast Concrete Kerbs

Precast concrete kerbs and edgings shall be to BS 340 and shall be hydraulically pressed.
Kerbs shall be bedded true to line and level in cement mortar on a 150mm thick
foundation of concrete Grade C15/20 and backed with concrete of the same grade. The
foundation shall be laid before the approved sub-base is laid.
Vol 3, Section3
Page D-46 of 47
D6
Specifications
TESTING OF WATER RETAINING CONCRETE STRUCTURES

This test shall, where practicable, be carried out before any backfilling and before the
application of any external concrete protection has taken place.
On completion of a water retaining structure, it shall be cleansed and made ready for
testing for water tightness. The structure shall be filled with water at an approved rate.
After allowing a period for absorption e.g. 3 days, the depth of water shall be recorded
and the water allowed to stand for a period of 7 days during which the total permissible
drop, after allowing for evaporation and rainfall, shall not exceed 1/500th of the average
water depth of the full structure or 10mm whichever is the lesser. The Contractor, where
required by the Engineer, shall provide a test tank for assessing the influence of
evaporation and rainfall.
Notwithstanding the satisfactory completion of the test, any seepage visible on the outside
faces of the structure shall, where practicable, be carried out from the face that is to be
subjected to water pressure under operating conditions. Method statements for all repairs
shall be submitted to the Engineer for approval.
In the event of any water-retaining structures failing to pass the test, the Contractor shall
make good and re-test at his own expense.
Vol 3, Section3
Page D-47 of 47
Specifications
TABLE OF CONTENTS
Page No.
SECTION E - PIPELINES AND PIPEWORK
E1
E2
PIPE AND PIPELINE MATERIALS
E1.1
E1.2
Definitions
E1.3
Pipes and Pipeline Components for Water Supply
E1.4
Classification of Pressure Pipes
E1.5
Pipe Classification & Pressure Rating
E1.6
Dimensional Requirements
E1.7
Marking of Pipes and Fittings
E1.8
Group A (Rigid) Pipes
E1.9
Concrete Pipes and Fittings
E1.10
Clayware Pipes and Fittings
E1.11
Pitch Fibre Pipes and Fittings
E1.12
Cast (Grey) Iron Pipes and Fittings
E1.13
Crushing Strengths for Group A (Rigid) Pipes
E1.14
Stiffness for Group B (Flexible) Pipes
10
E1.15
Thermoplastic Pipes
11
E1.16
Glass Reinforced Plastic (GRP) Pipes
12
E1.16.1
Definitions and Requirements
12
E1.16.2
GRP Pipe and Fittings for use in Gravity and Pressure flowsystems conveying
Sanitary Sewage
14
E1.16.3
Compulsory Requirements Particular to Sewer Pipes, Couplers and Joints
17
E1.16.4
Type Tests for GRP Pipes and Joints
19
E1.16.5
GRP Pipe and Fittings for Pumping Stations and Valve Chambers
26
E1.16.6
GRP Pipes and Fittings for Irrigation and Potable Water Distribution and
Transmission
27
E1.17
Ductile Iron Pipes
35
E1.18
Steel Pipes
38
E1.19
Stainless Steel Pipe
43
E1.20
Carbon Steel Pipe
51
E1.21
Mechanical Joints - General
56
E1.22
Flanged Joints for Iron and Steel Pipework
56
E1.23
Flange Gaskets
56
E1.24
Flexible Mechanical Couplings and Flange Adapters
56
E1.25
Flexible Joints - Sleeve and Integral Socket Types
57
E1.26
Elastomeric Joint Sealing Rings
58
E1.27
Lubricants for Joint Assembly
58
E1.28
Granular Materials for Pipe Bedding and Surrounds
58
E1.29
Selected Excavated Material for Pipe Bedding and Surrounds
60
E1.30
Maintenance of Quality
60
TYPE TESTING, ROUTINE TESTING, AND VISUAL INSPECTION OF PIPES
Vol 3, Section 3
Page i of iii
62
E3
E4
Specifications
E2.1
62
E2.2
Visual Inspection Requirements for Group A (Rigid) Pipe & Pipeline Components63
E2.3
Not Used
64
E2.4
Type and Routine Tests for Metal Pipes
64
E2.5
Visual Inspection Requirements for Metal Pipes
65
E2.6
Type and Routine Tests for Thermoplastic and RTR/GRP Pipes
66
E2.7
Visual Inspection Requirements for Thermoplastic and RTR/GRP Pipes and

Pipeline Components
71
E2.8
Holiday Detection Test
72
PIPELINE CONSTRUCTION
74
E3.1
74
Storage and Handling of Pipes
Glass Reinforced Plastic Pipes (GRP)
74
Thermoplastic Pipes (uPVC)
75
E3.2
Trench Widths for Pipelines - General Requirements
75
E3.3
Trench Widths for Flexible Pipes - Additional Requirements
76
E3.4
Pipelaying - General
77
E3.5
Not Used
78
E3.6
Welded Joints for Thermoplastic Pipes
78
E3.7
Pipelines with Concrete Beds and Surrounds
80
E3.8
Pipelines with Granular Beds or Surrounds
81
E3.9
Compaction of Granular Pipe Surrounds
82
E3.10
Pipelines Bedded on Trench Bottom
83
E3.11
Stanks to Pipelines with Granular Bedding
83
E3.12
Backfilling of Pipe Trenches
84
E3.13
Deformation Measurements on Flexible Pipes
84
E3.14
Thrust and Anchor Blocks in Pressure Pipelines
86
E3.15
Pipes Protruding from Structures
87
E3.16
Plastic Pressure Pipes Encased in Concrete
88
E3.17
Marker Posts for Water Mains and other Pressure Pipelines
88
E3.18
Cutting Pipes
88
E3.19
Flanged and Flexible Mechanical Joints
89
E3.20
Pipework within Structures - General Requirements
89
STRUCTURAL DESIGN OF PIPELINES
90
E4.1
General
90
E4.2
Polyethylene Pipes
90
E4.3 & E4.4 Not Used
90
E4.5
Steel Pipes
90
E4.6
Ductile Iron Pipes
91
E4.7 to E4.9 Not Used
92
E4.10
Design Requirements
92
E4.11
Loading Criteria
92
E4.12
Environmental Criteria
92
E4.13
Loading Combinations to be Considered
92
E4.14
Approved Calculation Procedures
93
Vol 3, Section 3
Page ii of iii
E4.15
E5
Additional Structural Design Requirements
93
NON DISRUPTIVE METHOD (NDM) FOR PIPELINE CONSTRUCTION
94
E5.1
Scope of Work
94
E5.2
Related Work
94
E5.3
Design
94
E5.4
Submittals
94
E5.5
Quality Assurance
95
E5.6
Delivery Storage and Handling
95
E5.7
Site Investigation
95
E5.8
Health and Safety
96
E5.9
Skilled Operators and Supervision
96
E5.10
Pipe Materials
97
E5.11
Joint Packing
98
E5.12
Lubricant
98
E5.13
Joint Sealant
100
E5.14
Grout
100
E5.15
Thrust and Reception Pits
100
E5.16
Pipe Installation within Sleeves
102
E5.17
Microtunnelling
102
E5.18
Line and Level
103
E5.19
Thrust System
104
E5.20
Lubrication Holes
104
E5.21
Grouting
104
E5.22
Records
104
E5.23
Testing
105
E5.24
Monitoring Ground Surface Movement
105
E5.25
Tunnelling-General Requirements
106
E5.25.1 General
106
E5.25.2 Submissions
107
E5.25.3 Safety
107
E5.25.4 Control of Water
108
E5.25.5 Testing and Records
109
E5.26
E6
Specifications
Undertaking
110
INSPECTION AND TESTING OF PIPELINES
111
E6.1
Cleaning and Inspection of Pipelines
111
E6.2
Testing of Pipelines - General Requirements
111
E6.3
Testing of Non-Pressure Pipelines
111
E6.4
Testing of Pressure Pipelines
112
Vol 3, Section 3
Page iii of iii
Specifications

E1
PIPE AND PIPELINE MATERIALS
E1.1
Pipes, fittings, specials and joints shall be manufactured to the approved national or
international Standard and to the additional requirements of this Specification.
All materials and workmanship shall be subject to the general requirements of Section B,
of this Specification.
Protective coatings and/or linings to be applied at the factory of the pipe manufacturer, or
his sub-contractor, are generally specified in this section of the Specification. Coatings and
linings to be applied on Site, or highly specialised factory coatings, are specified in
Section G, or elsewhere in this Specification.
All pipes in any particular length of pipeline shall be from a single manufacturing source
and of uniform type and size.
E1.2
Definitions
For the purposes of this Specification, the following definitions shall apply:
E1.3
"Pipes"
straight pipes with either plain ends or with an integral joint at

one or both ends.
"Fittings"
all bends, branches, tees and similar items which are made to the
requirements and dimensions in Standard Specifications or are
included in manufacturers' standard ranges.
"Specials"
any pipework item which is not covered by Standard Specifications, or is not normally in manufacturers' standard ranges of
items, or has any special features which render it different from
the standard pipes and fittings.
"Joints"
any joint assembly or components to connect items of pipework

together.
Pipes and Pipeline Components for Water Supply

Pipes and pipeline components, including their protective coatings and joint materials, that
will or may come into contact with potable water shall not constitute a toxic hazard, shall
not support microbial growth, shall not cause taste or odour, cloudiness or discolouration
of the water, and shall be approved by a recognised certifying authority as being suitable
for use in potable water supply systems.
E1.4
Classification of Pressure Pipes

Pressure pipelines shall be those pipelines through which fluid is pumped or which at any
point operate under an internal pressure in excess of 3.0 metres head of water.
Pressure pipes shall generally be designated according to their pressure rating. However
since national and international standards, procedures and conventions do not all follow
the same practice, the pressure ratings established under approved manufacturing
standards will not necessarily be accepted as the basis for classification. The pressure
Vol 3, Section3
Page E-4 of 115
Specifications
ratings which will be adopted for use with this specification will be calculated using the
material strengths, allowances and factors of safety indicated in the appropriate pipe
material clauses of this specification.
E1.5
Pipe Classification & Pressure Rating

For structural purposes pipes shall be classified into two groups:
Group A
Rigid pipes, which fail ultimately by fracturing, before sustaining

unacceptable deformations. Rigid pipe materials include:
Abbreviation
Material
Conc
PSC
Clay
AC
Concrete (except PTC)

Prestressed concrete
Clayware
Asbestos cement
Group B Flexible pipes, which can deform to unacceptable extents without fracture
occurring. Flexible pipe materials include:
Abbreviation
Material
PE
uPVC
ABS
RTR (GRP)
Polyethylene
Unplasticised polyvinyl chloride
Acrylonitrile butadiene styrene
Reinforced thermosetting resin/glass reinforced
plastic.
Steel
Ductile iron
Pretensioned concrete
ST
DI
PTC
Notes: (a)
ST, DI and PTC pipes often have sufficient strength to support loadings
without assistance from the bedding and trench sides but for structural
purposes are considered to be flexible.
(b)
Polyethylene, uPVC and ABS are further classified as 'thermoplastic'

materials.
Group A pipes shall be designated according to their crushing strengths (see Clause E1.13)
and Group B pipes according to their stiffness (see Clause E1.14).
Gravity pipes shall be supplied to the following classes:
RTR/ GRP (P)
For sewer application 5000 N/m2 stiffness class

made to BS 5480 /ASTM D 3262 : 2004.
for storm water application 5000 N/m2 stiffness class
made to BS 5480 / ASTM D 3517:2004
uPVC
Concrete
encased
microtunnelling pipe
Vol 3, Section3
GRP
for sewer or storm water application 4KN/m2

stiffness class made to BSEN 1401 1: 1998
strength class 90 made to BS 5911:120
Page E-5 of 115
Ductile Iron
Specifications
Pipe & Fittings made to BS 548 for sewer (G)

application
Pressure pipes shall be supplied to the following rated pressure classifications: Asbestos Cement
Class 18 (18 bar Test Pressure & 9 bar rated

working Pressure Class) for storm water applications
made to ISO 160/BS512
RTR/ GRP (P)
a) 12 bar rated working Pressure class for sewer

made in accordance with BS
5480/ASTM D 3754.
b)12 bar rated pressure class pipe for water or TSE
made in accordance with BS 5480/ASTM D 3517.
uPVC (P)
a)16 bar (16 bar rated pressure class PVC pipes

used
to
allow
for
temperature
derating )for pipes upto and including 160mm ,
made to BSEN 1452 2: 2000
b)12.5 bar (rated pressure class pipes used to allow
for temperature derating) above 160mm , made to
BSEN 1452 2: 2000
HDPE (P)
16 bar rated Pressure Class made to ISO: 4427:1996
Stainless steel Gr.316L: Sch40
Pressure class pipes made to PN 16 rated

ASTM
A167,
A240,
A269,
A774, A778
Carbon Steel Pipe (P)
Galvanized steel (P)
Ductile Iron (P)
A182,
A304,
A193,
A312,
A
194,A234,
A325,
A403,
PN 16 Rated Pressure Class made to ASTM A36,

ASTM A106, A197, A53, A234
PN 16 Rated Pressure Class made to ASTM A120,
ASTM A197
PN 16 Rated Pressure Class made to BS 545 for
water application
Selected pipe material should be suitable for its application. Suggested pipe schedule for
sewage treatment plant site is given in Table E1. Contractor should take Engineers
approval before ordering the pipe material.
TABLE E1
SCHEDULE OF PIPE APPLICATION SYSTEM
Sr.
Applications
Type of Pipe
1
2
Liquid stream Interconnecting pipe

Sludge stream pipe
Scum Line
GRP
GRP (sludge consistency <3%), SS
316L (sludge consistency >3%)
GRP
Vol 3, Section3
Page E-6 of 115
Specifications
Sr.
Applications
Type of Pipe
4
5
Grit Line
Chemical line
6
7
8
9
10
11
12
13
14
15
16
17
Air Line
Fuel Line (Diesel)
Chlorination
Potable water line
TSE Pressure line
Internal Sewage Line
Internal Drainage Line
Fire fighting
Irrigation line
Pump House internal piping
Cable ducting
Ventilation and ducts
SS 316L
SS316 for Polymer, uPVC for Ferric
chloride
SS316L
Carbon Steel
Seamless Carbon Steel
GRP/ HDPE
GRP
uPVC (<315mm), GRP (>315mm)
GRP
GRP
GRP/ SS
uPVC
Diameter Range (mm)

Abbreviations:
1.
GRP: Glass Reinforced Plastic
80 4,000
2.
A.C:
Asbestos Cement
80 1,800
3.
C.S:
Carbon Steel
25 400
4.
S.S:
Stainless Steel
25 400
5.
uPVC: Unplasticized Polyvinyl Chloride 12 500
6.
HDPE: High Density Polyethylene
32 630
7.
MDPE: Medium Density Polyethylene
20 300
8.
LDPE: Low Density Polyethylene
12 150
9.
PP R: Polypropylene Random
20 110 (for sanitory application)
10.
G:I:
Galvanized Iron
12 160 mm
11.
CU:
Copper
15 54 mm
E1.6
Dimensional Requirements
Unless otherwise indicated in this Section of the Specification, and apart from special
lengths of pipe required for flexibility adjacent to structures, pipes may be supplied in any
standard lengths allowed in the approved Standard. The tolerance allowed on special
lengths shall be +25mm, unless otherwise detailed.
Unless otherwise specified a manufacturing tolerance of +2 per cent shall be allowed on
the nominal internal diameter of the pipe.
The dimensions and tolerances applying to the jointing surfaces, and sealing rings or
gaskets, of pipes, fittings and special shall be such as to ensure that the required sealing
performance of the joints is maintained under service conditions, and will not be impaired
by normal installation practices.
E1.7
Marking of Pipes and Fittings

Each pipe, special and fitting shall be clearly and indelibly marked at the place of
manufacture with:
(i)
The name or distinctive mark of the manufacturer.
(ii)
The date of manufacture.
(iii)
The class or pressure rating.
Vol 3, Section3
Page E-7 of 115
Specifications
(iv)
The nominal diameter.
(v)
The manufacturing standard to which it has been produced.
(vi)
For rigid pipes - crushing strength (in kN/m or strength class).
(vii)
For flexible pipes - stiffness (in N/m2).
(viii
The angle of bends or branches.
(ix)
The name of the Employer and the Project or Contract.
(x)
where appropriate the pipework item reference number.
E1.8
Group A (Rigid) Pipes
E1.9
Concrete Pipes and Fittings

Precast concrete pipes and fitting with flexible joints shall comply with the relevant
provisions of BS 5911 Part 1. Ogee jointed concrete pipes bends and junctions for
drainage shall comply with BS 5911 Part 3.
Additionally, pipes and fittings shall comply with the following requirements as
appropriate:
(i)
Cement shall be sulphate resisting Portland cement unless otherwise specified.
(ii)
Concrete shall be dense, homogeneous and without honeycombing or other

discontinuities.
(iii)
Admixtures shall not be used without the written permission of the Engineer.
The Contractor shall ensure that, in addition to complying with any strength requirements
detailed in the Contract, pipes supplied for installation by pipe jacking techniques can
withstand the thrusting forces to which they will be subjected during installation, without
cracking or spalling. A certificate confirming that the pipes are suitable for jacking and
indicating allowable distributed jacking forces shall be supplied. The characteristic
strength of concrete used in the manufacture of pipes for jacking shall be not less than 65
N/sq.mm.
E1.10
Clayware Pipes and Fittings

Flexibly joined clay pipes and fittings for drains and sewers shall comply with the relevant
provisions of BS EN 295. The remaining types of clay pipes, fittings, joints and ducts shall
conform to BS 65 1st November 1991.
Pipes and fittings shall be fully vitrified and unless specifically designated on the Drawings
may be glazed or unglazed. Any glazing shall be ceramic type applied prior to firing. Salt
glazes are not acceptable. Joints shall be an approved flexible type with elastomeric
sealing rings and may be either spigot and socket or of the separate push-on sleeve type.
Proprietary joints may only be used with the Engineers approval.
Fully vitrified clay pipe is defined as the complete fusion of silica and clay that is achieved
by firing at sufficient temperature and time. In addition to compliance with BS EN 295,
sections of the pipe shall be examined under low-power magnification, and shall not
exhibit non-fused, loose or flaky particles.
Vol 3, Section3
Page E-8 of 115
Specifications
Pipe strengths shall not be less than 22 kN/m for DN 100 & 150, class 120 for all larger
sizes. All pipes used for the specified strength tests shall be thoroughly saturated, by
immersion in water or other approved method, prior to testing.
The minimum period of immersion in water shall be:
Wall Thickness
Minimum Preconditioning Time (Hours)

Unglazed, Glazed only
on interior or exterior
surfaces, salt glazed
E1.11
Ceramic glazed
(mm)
(hr)
(hr)
up to 20
18
42
>20< 35
42
66
>35
66
90
Pitch Fibre Pipes and Fittings

Pitch fibre pipes and fittings shall conform to BS 2760.
E1.12
Cast (Grey) Iron Pipes and Fittings

Cast grey iron pipes and fittings shall conform to BS 4622. Unless otherwise detailed, grey
iron pipes shall be of the spigot and socket type with elastomeric sealing rings.
Pressure pipes shall be rated for 10 bar working pressure unless a higher working pressure
is specified elsewhere for pipeline duty.
Fittings and specials shall be of the same (or higher) pressure rating as the pipeline of
which they are part.
Puddle flanges shall be cast integrally with the pipelines unless otherwise agreed by the
Engineer.
E1.13
Crushing Strengths for Group A (Rigid) Pipes

In addition to the requirements of the approved national standard, concrete, clayware and
pitch fibre pipes shall be supplied to the minimum proof crushing strengths (crushing load
per metre divided by the nominal diameter) shown in Table E1.
Vol 3, Section3
Page E-9 of 115
Specifications
TABLE E1
Minimum Proof Crushing Strengths for Rigid Pipes
Nominal
Diameter
Minimum Proof Crushing Strength (kN/m)
(mm)
Class L
Class M
Class H
100
12.5
16
22
150
14
17.5
22
200
15
20
25
225
16
20
30
250
17.5
24
35
300
25
25
40
400
27
35
45
450
27
35
45
500
32
38
48
600
32
45
56
700
36
52
62
800
40
55
65
900
45
65
75
1000
50
75
90
1000
52
80
105
1200
55
85
110
1500
65
105
130
1800
85
125
160
The ultimate load at which pipe failure occurs in the three edge crushing strength test
shall be not less than 125% of the minimum proof crushing strength specified above.
E1.14
Stiffness for Group B (Flexible) Pipes

Pipes for non-pressure purposes shall have minimum specific tangential initial stiffness, at
the ambient temperature stated in Clause A2.2 or at 20C where no such temperature is
stated, in accordance with one of the following classes:
Class
Class
Class
Class
L1
L2
M
H
1,250N/m2
2,500N/m2
5,000N/m2
10,000N/m2
The initial stiffness of pipes having diameter of 500mm or more, shall not exceed the
minimum stiffness value of the next higher class.
Stiffness shall be calculated as EI/D3, where E is the modulus of elasticity of the pipe wall
material in ring bending, I the moment of inertia per unit length of pipe wall in ring
bending and D the mean diameter of the pipe.
Vol 3, Section3
Page E-10 of 115
Specifications
Pipes for pressure pipelines shall have stiffnesses at least corresponding to Class L1.
E1.15
Thermoplastic Pipes
(i)
Thermoplastic pipe materials include polyethylene, uPVC, ABS, PP and PB.
The only additives which may be used during pipe manufacture are those which are
necessary for the manufacture of the basic polymer feedstock and for its satisfactory
further processing to produce a finished product complying with the Specification. All
additives shall be thoroughly dispersed throughout the material. Thermoplastic
components shall be stabilised against ultra-violet light degradation. The material
shall be thoroughly and consistently fused throughout the component.
Unless otherwise specified, polyethylene, polypropylene and polybutylene pipes shall
be jointed by fusion welding in accordance with Clause E3.6, and uPVC and ABS
pipes shall be jointed using integral sockets and spigots, in accordance with
Clause E1.25.
Solvent-welded joints shall not be used except where shown on the drawings or
agreed by the Engineer.
Compliance with the appropriate stiffness class of Clause E1.14 shall be verified by
parallel plate loading tests in accordance with Clause E2.4, carried out at the
ambient temperature stipulated in Section A, or at 20oC where no such temperature
is stipulated.
The hoop tensile strength of the material shall be obtained by stress rupture testing
in accordance with Clause E2.4 and the estimated minimum hoop tensile strength at
50 years, obtained by extrapolation of the test results shall be in accordance with
the following table:
Minimum 50 Year Hoop Tensile Strength for Thermoplastic Group B Pipes
Material
PVC-U
Hydrostatic
Design
Stress
@ 20C
(MPa)
Temperature Derating Factors
25C
30C
35C
40C
12.5
1.0
0.88
0.78
0.70
PE/MRS 100
6.3
0.9
0.81
0.72
0.62
PE/MRS 80
6.3
0.9
0.81
0.72
0.62
PE/MRS 63
5.0
0.9
0.81
0.72
0.62
PE/MRS 40
2.5
0.82
0.65
0.47
0.30
PE/MRS 32
2.0
0.82
0.65
0.47
0.30
The pressure ratings of the pipes, as defined in Clause E1.4, shall be obtained by
using the hydrostatic design stress from the above table, and applying the derating
factor appropriate to the design temperature as specified in the particular
specification.
Vol 3, Section3
Page E-11 of 115
Specifications
The finish of pipes shall comply with the requirements of Clause E1.4.
(ii)
Polyethylene Plastics
Copolymerisation with small quantities of propylene is permitted. The specific
gravities of polyethylene plastics shall be in the following ranges: low density 0.710
to 0.925, medium density 0.926 to 0.950, high density 0.951 and over.
Polyethylene pipes shall be jointed by fusion welding in accordance with Clause
E3.6, unless otherwise specified.
(iii)
uPVC Plastics
PVC material shall be unplasticised and of an impact resistant or high impact grade.
High molecular orientation uPVC may be used. The material shall have a fracture
toughness of not less than 3.25 MN/m3/2.
PVC pipes shall be provided with socket and spigot joints, sealed by elastomeric
sealing rings, unless otherwise specified.
(iv)
ABS Plastics
ABS plastics may be either copolymers of, or blends of homopolymers of, the
constituent monomers. The maximum content of acrylonitrile shall be 15%, of
butadiene shall be 6% and of styrene (or substituted styrene) shall be 15%. The
total content of the three basic monomeric constituents shall be not less than 95%
and the specific gravity shall be in the range 0.990 to 1.200.
ABS pipes shall be provided with socket and spigot joints, sealed with elastomeric
sealing rings, unless otherwise specified.
E1.16
Glass Reinforced Plastic (GRP) Pipes
E1.16.1
Definitions and Requirements

The following definitions are used in this specification.
GRP Pipe: A tubular product containing glass-fiber reinforcements embedded in or
surrounded by cured thermosetting resin with or without aggregate.
Aggregate: Siliceous sand conforming to ASTM C33, except the gradation requirement
need not apply.
E-glass: Low Alkali content glass fiber.
ECR-Glass: Form of glass fiber specially developed for acid resistance.
C-Glass: Alkali -Lime glass with added boron used for surface layer reinforcement. (Good
chemical resistance).
Reinforcement: Glass fibers used to provide strength and stiffness to a composite
material.
Resin: A polymer that has high molecular weight with no definite melting point used as a
basic material for plastics.
Vol 3, Section3
Page E-12 of 115
Orthophthalic resin:
temperature resistance.
Specifications
A general purpose polyester resin of limited chemical and
Polyester resin: Type of thermo-set resin with two or more ester group.
Thermo-set Resin: Resin which hardens irreversibly by use of additives.
Once cured, a thermo-set resin cannot be re-melted and insoluble.
Epoxy resin: A polymer containing two or more three membered rings, each consisting
of one Oxygen and two Carbon atoms. The polymer is cured by cross-linkings with amine
or anhydride hardner, with or without heat, catalysts or both.
Vinylester resin:
High performance corrosion-resistant epoxy based resin.
Lining: Integral internal reinforced lining of a GRP pipe, normally of high resin content
consisting of a 'barrier layer' and a 'surface layer'.
Roving: A collection of parallel glass strands or filaments with binder.
Chopped fiber: Continuous fibers cut into short lengths (3-50mm).
Resin-rich Lining:
A corrosion resistant lining containing approximately 65-80% of resin
by weight applied to the interior surface of GRP pipe to protect the structural wall from
corrosion.
Laminate:
A composite of cured resin and reinforcement.
Filament winding: General term for pipe manufacturing method using continuous
rovings as the reinforcement.
Helical winding: Filament winding manufacturing method where continuous rovings are
applied at 60 - 70 degree to axis of pipe mould.
Barrier-Layer: The resin -rich anti penetrant layer forming part of the internal corrosion
resistant pipe lining applied behind the interior liner of pipe.
Inner surface layer: Resin-rich layer forming part of the internal corrosion resistant pipe
lining.
Exterior surface layer: A filled or unfilled resin-rich layer (reinforced or non
reinforced) applied to the exterior surface of the pipe wall.
Barcol hardness: Measure of surface resin hardness, used to check the degree of cure.
Cure: Conversion of liquid resin into solid.
Air inhibition: Failure of surface layer of resin cure because of contact with atmosphere.
Stress: The force per unit cross section area.
Vol 3, Section3
Page E-13 of 115
Specifications
Strain: Dimentional change per unit of length resulted from applied force or load
measured in ( mm/mm).
Strain corrosion: Brittle failure mode caused by exposure of a strained laminate to a
corrosive environment.
Stiffness:
The resistance of a pipe to circumferential deflection in response to
external loading applied along one diametrical plane.
Pressure class: Maximum sustained pressure for which the pipe is designed.
Pipe stiffness: A measure of the force required to deflect the diameter of a pipe ring a
unit amount.
Stiffness class: The nominal stiffness of a specified pipe.
Creep: Deformation or strain that occurs over time when a material under sustained
stress. GRP is subject to creep at all temperatures when subjected to stress.
Hydrostatic Design Basis (HDB): The long -term hydrostatic hoop strength of a specific
fibre glass pipe material as determined by hydrostatic pressure test and the data
extrapolated to 50 years to use the data in pipe design calculation.
Long-term strain corrosion (SCV): The long-term strain corrosion strength of a specific
fibre glass pipe in acidic & under strained condition determined by deflection test and the
data extrapolated to 50 years to use in pipe design calculation.
Long-term Stiffness (Creep): The long term stiffness retention and creep factor of a
GRP pipe(under wet condition) determined by constant failure strain (deflection) test and
the test data analysed and extrapolated to 50 years.
Long-term Ring bending strain: The long term bending strength (in normal water
under immersed condition) of a GRP pipe determined by constant failure strain (deflection
test) and the test data analysed and extrapolated to 50 years strain to use the data in pipe
design calculation.
Design factor (FS): A number equal or greater than 1.0 which takes into consideration
the variables and degree of safety involved in a design. Test data are divided by the
design factor to obtain design allowable values. Also called safety factor.
E1.16.2
GRP Pipe and Fittings for use in Gravity and Pressure flowsystems conveying
Sanitary Sewage
Pipe manufacturers must be members of, or affiliated with, a quality control or certification
authority relevant to the pipes or fittings proposed for incorporation in the works. ISO
9001 certification is required for pipe/fittings manufacturers.
The following specifications are referenced as applicable:
REFERENCE
BS 5480: 1990
Vol 3, Section3
DESCRIPTION
British standard specification for glass reinforced plastic
(GRP) pipes, joints, and fittings for use for water supply or
Page E-14 of 115
Specifications
sewerage.
ASTM D3262:2004
Specification for fibreglass sewer pipes for use in

gravity flow systems for conveying sanitary sewage
ASTM D3754:2004
Specification for fibreglass sewer and industrial

pressure pipes for use in pressure systems for conveying
sanitary sewerage and industrial wastes
ASTM D3517:2004
Specification for fibreglass pressure pipes for

conveying water system.
AWWA C950:2001
Standard for fibreglass pressure pipes
AWWA M45
Fibreglass pipe design manual
The GRP pipes & fittings shall be certified in accordance to BS 5480, ASTM
D-3262 & D 3754 (Certificate to be submitted for Engineers approval). Certification must
include the diameters of pipe to be supplied. Evidence of diameter range is necessary.
GRP Pipe and fittings shall be manufactured in accordance with BS 5480 and ASTM D-3262
for gravity application and BS 5480 and ASTM D-3754 for pressure application. GRP pipe
and fittings shall be at least adequate to achieve a minimum working life of 50 years under
all applicable loading, local environmental and installation conditions.
The pipes and fittings shall be designed to withstand up to 5% long term deflection in the
installed conditions.
Both gravity & Pressure Pipes shall have a 50 years strain corrosion design performance as
per the latest editions of ASTM D3262/ASTM D 3754, AWWA C 950 for sewer pipes, but
the mean value of the regression line at 50 years shall not be less than 1 % strain.
Evidence of third party approved regression test date must be submitted.
The GRP pipes used for gravity applications shall comply with the minimum requirements
for 6 Bar pressure pipes as the pipe lines may be intended to operate under surcharged
conditions and not as gravity pipe lines.
The pipe shall also comply with the additional requirements to suit the prevailing Local
temperature and corrosive environment conditions specified.
Materials Specification
Resin
The resin used for the internal liner of the pipes and fittings shall be of an epoxy based
vinylester resin complying with BS 5480 and shall have a minimum elongation to break of
5% when fully cured.
The resin in the structural wall of the pipes and fittings shall be of unsaturated Isophtalic
polyester type incorporating styrene as the monomer and meeting the requirements of BS
3532 Type B. The use of vinylester resin in the structural layer is also permitted.
* No pigments in the liner or structure shall be added.
Glass
The internal and external layer shall be of "C" glass veil produced from a chemically
resistant glass durable in both acid and alkaline environment and shall have a surface
treatment compatible with the resin. All fiber reinforcement used shall be of high acid
resistant type "ECR/Advantex" ' comply with BS 5480 and shall have a surface treatment
Vol 3, Section3
Page E-15 of 115
Specifications
compatible with the resin. The reinforcements shall generally comply with the standards
listed below as appropriate.
BS 3691 "Glass fiber roving for the reinforcement of polyester resin systems".
BS 3496 "Glass fiber chopped strand mat for the reinforcement of polyester resin
systems".
BS 3396 "Woven glass fiber fabrics for plastic reinforcement".
BS 3749 "Woven glass fiber roving fabrics for the reinforcement of polyester resin
systems".
Glass rovings used in the structural wall shall not exceed 2400 Tex.
Aggregates and Fillers
Aggregates if used, shall be minimum 98% pure Silica Sand as defined in BS 5480:1990
and AWWA C950 and shall contain no impurities. The aggregates shall only be used in the
stiffening layer of the pipe wall, where it is designed as part of the composite structure.
The final product shall meet the requirements of the specifications.

Silica sand aggregates as defined in BS 5480 shall contain no impurities. Fillers as defined
in BS 5480 shall not be used. The silica sand content in the pipe wall shall not exceed
50%.
The resin shall be cured to reach hardness not less than 90% of the resin manufacturer's
recommended hardness.
A manufacturer's tolerance of 1 % shall be allowed on the nominal diameter of the pipe.
The pipes shall be supplied in standard lengths of 3, 6, 10 or 12 metres with a tolerance of
25 mm. The deviation from straightness of the bore of the pipe shall not exceed 0.3% of
the effective length or 15.00 mm whichever is smaller and shall apply when measured on
site. Up to 10% of the pipes will be allowed in random lengths.
The ellipticity of any pipe when measured resting freely on the ground shall not be more
than 2% of the mean diameter at any point. No pipe known to have undergone a
deflection greater than 7% shall be incorporated into the Works.
The Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes to be used in
Pumping Station and valve chambers and for Irrigation &Water application the stiffness
shall be minimum 10,000 N/m2 and pipes for use in microtunnelling or similar jacking
operations the stiffness shall be minimum 50,000 N/m2 unless surrounded in concrete.
GRP Pipes shall also be used inplace of A.C. Pipes wherever applicable in storm water
drainage and Irrigation Pipes. The pipe laying procedures & the deflection checks at Site
etc. shall be the same as for sewer pipe. Pipe installation & Pipe surround material shall be
the same as specified for GRP Pipes & Fittings. The minimum / maximum burial depth shall
be as recommended by the Pipe manufacturer. Supporting design calculation shall be
provided to the Engineer to satisfy the installation condition.
The specific tangential initial stiffness shall be demonstrated by application of the following
equation:
Stiffness of the pipe
= is defined as EI/D3
(STIS)
Where: E
Vol 3, Section3
bending modulus of pipe wall circumferentially
Page E-16 of 115
E1.16.3
Specifications
(in N/m2).
second moment of area of pipe wall per Unit length
(in m4/m)
mean diameter of the pipe in metres
Compulsory Requirements Particular to Sewer Pipes, Couplers and Joints

The Inner Layer
All pipes and fittings shall have a resin- rich liner internal to protect the glass in structural
laminate from long term degradation having a minimum thickness of 1.5mm and maximum
thickness of 2.5mm consisting of an inner most 0.25mm surface layer reinforced with
chemical resistant "C" glass impregnated with 90% resin. The remainder of the 1.25 mm
backup barrier layer shall consist of acid resistant (ECR/ ADVANTEX) chopped glass
strands or powder bound chop strand mat and having a glass content between 25 and
30% by weight. The lining materials selected should provide a good impact and corrosion
resistance.
The Structural Layer

The structural wall of the pipe shall be reinforced with closely spaced continuous
fiber glass (ECR/ADVANTEX) filament winding, chopped roving, Silica Sand all impregnated
with Isophtalic polyester resin. No dark pigments or resin fillers such as Calcium Carbonate
shall be used in the pipes or fittings. Fine Silica Sand. Containing no impurities and
complying with the requirements of BS 5480 may be added in a core layer sandwich,
between the pipe structural layers.
The Exterior Layer

The exterior resin rich layer of the pipe shall have a maximum thickness of
1 mm reinforced with corrosion resistant glass (ECR/ ADVANTEX) and "C" glass veil
impregnated with isophthalic resin/vinyl ester resin. For protection against ultra violet light
degradation a translucent "uv" inhibitor should be included in the resin mix.
A black colouring pigment to suit the service identification of Storm water drain pipe shall
be added on external resin rich layer.
Fittings
All fittings such as bends, tees, junctions, reducers and the like shall conform to BS 5480:
1990. The construction of bends shall be swept or mitered. The laminated joints used in
the fabrication of fittings shall meet or exceed the required design requirements of the
piping system. All hand laminations or windings shall utilize only one type of resin
throughout.
Flanges
GRP flanges shall be flat faced and drilled to BS 4504 PN 10 or PN 16 drilling pattern.
Flanges shall be filament wound up to 1800mm and may be contact moulded for larger
sizes. GRP flange gasket shall be of a design, material and thickness as recommended by
the GRP fitting manufacturer. The use of epoxy resin in a flange manufacture is permitted.
Joints (For buried pipes)

Except where otherwise detailed on the drawings, all pipes and joints shall be of flexible
type. Joints shall be of loose GRP machine made coupling having two rubber rings gaskets.
All joints shall be capable of withstanding the various tests specified for the appropriate
class of pipe.
Joints shall withstand while maintaining the specified test pressure at a deflection of not
less than the values specified in the BS5480: 1990/ ASTM D3262/ ASTM D4161.
Vol 3, Section3
Page E-17 of 115
Specifications
Pipes used for adjustment and short length shall be ordered from the manufacturer.
Cutting and rejoining is only allowed when butt joints are used or a calibration machine is
available and approved by the manufacturer. No cutting on site is allowed without
manufacturers recommendation. The Rubber rings shall be kitemarked meeting the
requirements of the appropriate parts of BS EN 681-1 and be of the EPDM formulation.
Joint Lubricants
For lubricants, use only a vegetable based soap available from the pipe manufacturer.
Never use petroleum product or automotive oils to lubricate the joint, as they will damage
the rubber rings.
Pipes shall have a resistance to longitudinal tensile force per unit circumference as under:
Nominal Diameter (mm)
InitialUltimate Resistance (N/mm)
Up to 700
100
700 to 1,000
120
1, 000 to 1, 600
160
1,600 to 2,400
250
2,400 to 4,000
300
and when subjected to a parallel plate loading test shall show no evidence of crazing or
cracking and no structural failure with the deflection levels specified in AWWA C 950-Table
9. The deflection criteria presented are based on a Maximum installed long term deflection
of 5%. If the pipe sample fails to meet either or both requirements, the long term
allowable deflection must be reduced proportionally for the pipes represented by the
sample.
The jointing system shall be an approved coupling system. Where the system involves
separate reinforced plastic couplings of sockets formed by a lay-up process subsequent to
pipe production, the resins used shall be clear and non-pigmented to permit visual
examination within the laminate.
Where GRP laminate is cut, exposed ends shall be sealed with a suitable resin and
approved prior to incorporation into the Works. Where such cutting and sealing takes place
at site the resins used and the methods of storage, mixing, application and curing shall be
strictly to the manufacturer's recommendation. Before any such work takes place the
manufacturer's representative shall visit the site to demonstrate and give clear procedural
advice to the Contractor in the presence of the Engineer.
GRP pipe and fittings shall be as uniform as commercially practicable in colour, opacity,
density, and other physical properties.
GRP pipe and fittings shall be smooth and both the internal and external surfaces shall be
clean and free from delaminations, cracks, bubbles, pinholes, pits, blisters, foreign
inclusions and resin-starved areas that due to their nature, degree or extent detrimentally
affect the strength and serviceability of the pipe.
Unless authorized by the Engineer, repair will not be permitted on any pipes with defects,
as listed below and such pipes shall not be incorporated into the works:(1)
A scratch of greater depth than 0.30 mm.
(2)
Cracks of any type on the inside of the pipe.
(3)
Cracks on the outside, longer than 200 mm circumferentially or 6mm
longitudinally.
(4)
Delaminations.
(5)
Damaged ends including bubbles, cracks, voids, exposed reinforcement or
extraneous matter.
Vol 3, Section3
Page E-18 of 115
(6)
Internal protruding fibres.
(7)
(8)
More than 25% of the external area with protrusions of any sort.
Air voids and blisters exceeding 5 mm diameter or 1 mm in depth, greater in area
than 0.50% of internal or 1.00% of external surfaces.
Pitting to more than 5% of the internal or 10% of the external surface area and
individual pits more than 1 mm diameter or 0.5 mm in depth.
Wrinkles more than 3% of the surface area and individual wrinkles more than 2
mm deep
(9)
(10)
E1.16.4
Specifications
Type Tests for GRP Pipes and Joints

Type tests shall be carried out on locally produced representative pipe products in
accordance with Table E.1 to pre-qualify the products and to verify the design input data
given in the design calculations. The tests will be witnessed by a Ministry of Housing
approved, NAMAS accredited, independent third party materials testing laboratory.
Table E.1: Pre-qualification Tests
Qualification or Type Tests
1)
Long term
(10,000
hrs)
Chemical test ( strain corrosion
resistance)
Test Method
BS 5480
OR
ASTM D3681
Minimum Requirements
Extrapolated predicted failure
strain at 50 yrs. shall not be
less than 1%.
ASTM D2992 /
OR
BS 5480
BS 5480 Appendix L
Hydrostatic strain at 50 yrs.

shall not be less than 0.66%
5)
Long term hydrostatic or

pressure design basis 10,000
hrs test. (for Pressure Pipe)
Long term specific ring stiffness
(creep factor) under ring
deflection (10,000 hrs test)
Long term ring bending strain
(sb)
Impact resistance
6)
Joint water tightness.
ASTM 4161/BS 5480
7)
UV exposure on GRP Pipe (1

Year).
8)
Short time Hydraulic failure

pressure of pipes and fittings
(After the first production).
Manufacturers
Recommended
test
Method.
ASTM D 1598 / D
1599
2)
3)
4)
Note:
ASTM D 5365
BS 5480 Appendix J
50 years-extrapolated stiffness
value shall not be lower than
70% of the initial stiffness.
50 years strain shall not be less
than 1.35%.
As
specified
in
relevant
standard.
Requirements as specified in
relevant standard.
Not
to
show
surface
Deterioration due to UV effect.
(a) Withstand 3.5 times the
rated working pressure with
no sign of leakage or weep.
(b) Determine the failure
pressure by pipe bursting.
(1) The above tests are to be repeated on locally made pipes when the material
type & compositions are changed during the production from the original type
test of the product.
Quality control tests on raw materials and final products shall be carried out as listed
below:
A. Quality Control Tests & Records
The manufacturer shall have maintained a record of all quality control tests for a period of
not less than 2 years and if requested, shall submit the data to the Engineer.
Vol 3, Section3
Page E-19 of 115
Specifications
1. General Requirements
The pipe manufacturer must demonstrate the capability to produce pipes of consistent
properties and quality meeting the requirements of these specifications. A detailed quality
control/quality assurance program must be implemented at the manufacturing facilities
and all necessary test equipment to be operated by skilled technicians. Calibration of test
equipment shall be performed at least once a year. Details of the pipe manufacturers
QC/QA program, testing equipment, testing program shall be presented to the Engineer
for review and approval prior to commencement of pipe manufacture. The manufacturer's
quality control scheme shall be certified by a recognized independent authority to meet the
requirements of ISO 9001.
2. Reconfirmation of Strain Corrosion Regression Line
When a GRP piping product has an existing strain corrosion regression line, any change in
material, manufacturing process, construction or liner will necessitate a Screening
evaluation as described in CL 10.2, 10.3, 10.4, 10.6 & 11 of ASTM D3681:96. The pipe
samples for screening test shall be selected by the Engineers representatives from locally
produced pipes only.
Table E.2:
Minimum Design Parameters, Installation Conditions and the
Mandatory Requirements for Sanitary Sewer Pipe Intended to Carry Septic
Sewage
Details
Requirements
Minimum working pressure class of

pipe for gravity applications.
..
6 Bar
Ground
water
(assumed)
level
..
Minimum
surface.
Minimum working Pressure class

pipe
Category
for
Pressure
applications.
..
12 Bar
Service operating temperature
..
50 Degree C
table
Installation depth ('H' Min.& 'H'

Max.)
metre
below
Not less than 1.5 M

Not less than 10 M
Stiffness Class Pipe (for gravity &

pressure)
..
Minimum 5000 N/M2
50 Years extrapolated
stiffness retention value
(end stiffness) of pipe..
..
(a) Not less than 3500 N/M2 for

5000 STIS class pipe
(b) Not less than 7000 N/M2
for 10,000 STIS class pipe.
50 Years extrapolated strain value

established by long-term strain
corrosion type test conducted on
local made pipe (G & P) and
witnessed
by
3rd
party
independent lab.
..
Minimum 1 %
safety factor = 1.5
Vol 3, Section3
Page E-20 of 115
ground
Specifications
Required minimum strain value by

1000 hrs control test on local made
production pipe.
..
Strain percentage achieved shall not be

lower than the type test result of GRP.
50 Yrs extrapolated 'HDB'

value
established by long term type test
conducted on local made pipe (G&
P) and witnessed by 3 rd party
independent lab.
..
Minimum 0.66% safety factor = 1.8
Permitted maximum long-term

deflection at 50 years service life
of pipe.
..
Not greater than 5%
Shape factor input data (Df) for

pipe design.
..
Back fill modulus E'b for pipe zone

embedment.
..
Live load assumption to use in pipe

design.
..
Impact factor to use in pipe

design..
Water hammer calculation
..
Minimum 4.5 as given in A WW A

M45 manual.
for pipe zone embedment material as
gravel with compaction moderate to
light.
Minimum 20.7 Mpa as given in
AWWA M45.manual..Crushed rock as
pipe zone embedment with moderate
proctor
Four-lane road with truck centered in
each 3.7Mwide lane as given in
AWW A M45 manual.
As per A WW A M45 manual
recommendation.
Ditto
..
B. M aterials in P ipe Lam inate Structure

(A)
(B)
Type of glass throughout the pipe wall

Type of resin to be used in structural wall.
:
:
(C)
Type of resin to be used on resin-rich liner

internal & external of pipe wall.
(D)
Aggregate & fillers
ECR/ Advantex only

Isophthalic polyester Resin type
B
having
minimum
3.0%
elongation property.
Epoxy based vinyl ester resin
having minimum 5% resin
elongation property.
Silica sand SiO2 > 98%
(E)
'C' Glass (for the internal liner and liner

external of pipe)
Chemical resistant ECR Type only.
C. Corrosion Resistant Lining I nside the P ipe W all

(a) Surface layer internal
..
(b) Barrier layer behind the surface

layer of pipe.
..
Vol 3, Section3
Nominal thickness 0.25mm

Glass content upto 10%.
Minimum thickness 1.25mm
Maximum thickness 2.25mm
Epoxy based V.E.Resin 60- 80%
ECR / Advantex Glass 20-40%
Page E-21 of 115
Specifications
(c) Overall liner thickness internal
..
Minimum 1.5mm
Maximum 2.5 mm
(d) Overall liner thickness external
..
Minimum 0.5mm
Maximum 1.00 mm
(e) Glass fiber reinforcement & sand

content minimum/max limitations
..
(a) Hoop glass % minimum 55%

in structural layer(s) of pipe wall.
(b) Chopped rovings in pipe wall
minimum 7%.
(c)Sand content in gravity pipe wall shall
not be greater than 50% and 30% in
pressure pipe.
The manufacturer shall carry out the quality control test listed below using the pipe
production sample selected and witnessed by the Engineer at the frequency stated. The
manufacturer shall maintain records of all tests and inspections and two copies of all test
certificates and reports shall be forwarded to the Engineer.
Raw Materials
Checks shall be made on all raw materials to ensure that they comply with the
manufacturers stated values. All deliveries of resin shall be checked for consistency of
Viscosity and reactivity. Any resin deviation from the manufacturers published figures shall
not be used. Glass samples shall be checked for yield/tex, moisture and size content. All
deliveries of aggregate shall be checked for consistency of grading, moisture content and
purity. The pipe manufacturer should provide a copy of the materials certificate of analysis
for the material supplied together with in-house Q.C. test reports stating that the material
used in the pipe wall construction is conforming in all respects to the relevant specification.
Table E.3: Quality Control Tests on Final Product
1.
2.
Pipes & Fittings
Test Method
Minimum
Hydrostatic Pressure
Test
(Pressure
&
Gravity)
(1) 100% of pipes and
couplers.
(2) 1% of the pipes and
couplers
Stiffness (for Gravity &
Pressure) 1 in every 100
pipes
manufactured
(minimum).
BS 5480 / ASTM
D 3262 / ASTM
3754 / AWWA
C 950
(1) 2 x Rated working pressure

for 5 minutes.
(a) At 5% deflection.
ASTM D2412 / BS
5480
ASTM D3262 /
D3754
a) 5000 / 10000 N / m2
(minimum).
b) No liner crack
(b) At level A (12% /

9%)
Deflection. For 5000
/ 10000 STIS pipe.
(c) At level B (20% /
15% )
Deflection for 5000 /
10000 STIS pipe.
Vol 3, Section3
Page E-22 of 115
Requirements
(2) 2 x Rated working pressure

for 4 hours.
c) No structural failure
Specifications
(d) After level A.

3
4.
Wall Thickness
(On
100%
Pipes,
Couplers and Fittings)
Hardness
(On 100% of pipes,
Couplers and fittings)
using Barcol impressor
934 1, on liner.
5.
Loss on Ignition
every 100 pipes)
6.
7.
8.
(1 in
BS
4549:PI
Appendix A or
ASTM D2583.
ASTM D2584
+ / -5% of manufactures
specified resin / glass sand ratio.
Hoop Tensile Strength

1 in 100 pipes.
ASTM D2290 / BS
5480
Longitudinal
Tensile
Strength
(1 in 100 pipes) in axial
direction.
Fittings
(a) Visual inspection
(b) Dimension
(c) Pressure tests
BS 5480 : 1990
Appendix A
Requirements specified in table

10 of ASTM D 3754 as
appropriate for the pressure
class or AWWA C950 Table 10.
BS 5480 : 1990 Table 2 / Table
13 of ASTM D3754.
(d) Barcol hardness

(Resin cure)
9.
ASTM D3567
d) Continue to deflect to the

point of liner cracking and
record.
Manufactures minimum quoted
thickness given in the calculation
for the pipe design.
Minimum 90% of the hardness
value declared by the resin
manufacturer but not less than
33 barcol readings using barcol
impressor 934 1.
ASTM D2563
ASTM D3567
BS 5480 / AWWA
C 950
ASTM D2583
Chemical Control Tests

(100 & 1000 hours tests)
on
samples
of
manufactured
pipes
during pipes supply for
each contract.
ASTM D3681
ASTM D3262
BS 5480
(a) Every items

(b) Every items
(c) 1 in 10flanged items 2 x WP
for 60s.
(d) Every item minimum.
Barcol reading 33.
Strain level shall be above 1%.
Evidence from the manufacturer shall be provided of the satisfactory completion of

the Strain Corrosion Control test on samples of pipe representative of those to be
supplied together with an assurance that the test result are in full compliance with
the requirements stated in Table above.
D. Visual I nspection
Each pipe and fittings shall be subjected to a complete schedule of inspection before
shipment and after offloading at site. All pipes and fittings shall be commercially free of
defects such as delaminations, bubbles, exposed or protruding fibre, cracks, air voids, pits,
or resin-starved areas that due to their nature, degree of extent detrimentally affects the
strength and serviceability of the pipe. The maximum allowable visual defects of GRP pipe
laminate parts shall be classified to type and level as given in ASTM D2563: Table 1. The
acceptable quality level for the pipes internal and external shall be the level 2 as specified
in CL. 3.3 of the above standard. Visual inspection report of the pipes, couplers and fittings
in accordance with the above standard are to be provided by the manufacturer. Joints
surface shall be free of dent and other surface irregularities that will affect the integrity of
the joints. Any repairs at site if approved by the Engineer shall be carried out by qualified
and skilled staff of the pipe manufacturer.
Vol 3, Section3
Page E-23 of 115
Specifications
E. Design Calculations
The manufacturer shall design the pipes for a life of not less than 50 years and shall
submit calculations for initial and long term deflection with truck loads, buckling, vacuum,
pressure, class, and strain in accordance AWWA M45. (Chapter V)
For the purpose of design calculations only the bedding and back fill for pipes shall be
considered as crushed stones/gravel with slight compaction and the modulus of soil
reaction value shall be 20.7 Mpa as given in Table 5.5 of AWAWA M45. The maximum
calculated long term deflection shall not exceed 5%. Copies of the design calculations shall
be submitted to the Engineer for review and approval at the time of material submission.
F. Shape Factor
The shape factor input data to be used in the design calculation shall be based on dumped
gravel with slight compaction and its appropriate value shall choose as given in Table 5.1
of AWWA M45 Manual.
G. Safety Factor
The following safety factor shall apply:

AWWA M 45 Design Procedure
Pressure Rating > = 1.8
Ring Bending Strain or stress > = 1.5
Combined Strain or stress > = 1.5 and 1.8
Buckling> = 2.5
H. I nspection and Testing

1.
The manufacturer shall take adequate measures in the production of products

covered by this specification to assure compliance with the requirements herein. An
inspection and testing plan should be forwarded to the Engineer for approval prior to
start of manufacturer.
2.
Production and testing notice: When plant inspection is required by the Engineer the
manufacturer shall provide adequate advance notice of when and where production
and testing of ordered products will commence.
3.
The Engineer shall have free access with reasonable advance notice to the
manufacturer's plant areas that are necessary to assure that the products comply
with all requirements herein.
I . W orkm anship
GRP Pipes, fittings and joints shall be free from delaminations, bubbles and pinholes, pits,
blisters, dry spots, pimples, resin pockets, deep scratches, wormholes and deep wrinkles.
All GRP Fittings shall be fabricated in the factory to ensure quality control (under no
circumstances fabrication of fittings be allowed on site by the contractor). Complex fittings
arrangements may be pre-assembled by the pipe manufacturer on the factory such that
the field joints are kept to a minimum.
J. M arking
Each pipe and fittings shall be legibly marked with the following information:
Manufacturers name or trademark
Manufacturing date and the applicable standard
Manufacturing number
Nominal diameter in mm
Operating pressure in bar
Pipe stiffness class
Nominal laying length (for pipe only)
Vol 3, Section3
Page E-24 of 115
Specifications
Manufacturer's inspection mark

Contract name and number
Identificationmark & the colour distinguishing the gravity & pressure pipe.
K . Subm ittal/ Draw ings
The following information shall be submitted to the engineer by the manufacturer.

(1) Resin, Glass reinforcement, aggregate, joint and gasket data, with material
manufacturers certificate of analysis.
(2) Pipe supply specifications & installation manuals.
(3) GRP manufacturers Pre-qualification
(4) GRP Manufacturers Quality Control and Assurance Manual.
(5) GRP pipe data sheet in the standard format shown below.
In addition to the above information, the following information shall be submitted during
the mobilisation period.
1)
2)
3)
4)
5)
6)
7)
Detailed Manufacturing process for pipe, joints and fittings.

Detailed drawing of pipe end and couplers including pipe spigot OD, home line length,
allowable tolerance, and allowable gap between pipes.
Complete design calculations and design requirements including pressure class from
HDB, working pressure and surge pressure using pressure class, calculation of
allowable deflection from ring bending, external loads, WC & WL based on Burrial
depth, predicted deflection, buckling etc.
Quality procedure
Type test results and reports specified
Safety factor
Proposed inspection and testing programme.
Prior to start production the manufacturer shall submit to the Engineer dimensional
drawings of each fittings required for approval. The Engineer may require design
calculations, and samples for approval at no extra cost.
GRP PIPE DATA SHEET (FOR EACH DIAMETER / PRESSURE/SERVICE)
(TO BE PROVIDED TO THE ENGINEER PRIOR TO START OF PIPE MANUFACTURING)
Design parameters
Service (sewer/storm water)
Nominal Diameter (DN)
Pipe Manufacturing process
Installation service (minimum/maximum depth adopted)
Rated working pressure (PN)
Joint type
Maximum allowable vacuum
Factory hydrotest pressure
Length of each pipe
:
:
:
:
:
:
:
:
:
:
Pipe Wall Structure

Nominal Wall Thickness
a)
Liner thickness
b)
Structure Wall thickness
c)
Outer Layer thickness Resin /glass type
Vol 3, Section3
Page E-25 of 115
:
:
:
:
Units
Specifications
Mechanical Properties
Design specific Tangential initial stiffness (STIS)
Design initial Longitudinal tensile strength
Design initial hoop tensile strength
Internal Pressure & External Load
Flexural Modulus
Allowance design stress
:
:
:
:
:
:
Calculation Method
Internal Pressure & External Load
E1.16.5
GRP Pipe and Fittings for Pumping Stations and Valve Chambers
The design of GRP pipe and fittings for pumping stations and valve chambers shall
incorporate all the requirements of these specifications except for the following over-riding
or supplemental stipulations.
GRP pipe and fittings inside pumping stations and chambers shall be designed for use
above ground with no thrust blocks and shall have sufficient axial strength to resist end
thrust, temperature and bending stresses.
GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m2 and a minimum
wall thickness of 10 mm.
The design working pressure for pipes and fittings shall be minimum 12 bar unless
otherwise specified and the service temperature shall be 50C. A minimum surge
allowance of 40% above the working pressure shall be included in the design of pipes and
fittings. Copies of the design calculations shall be submitted to the Engineer for approval.
The basis of design shall be checked by conducting 'type' tests on representative
sample(s) of manufactured materials, in accordance with the requirements of BS 5480 or
ASTM D-2992.
The wall of the pipes and fittings shall be made up of:
1.
A resin-rich inner liner of 1.5 mm minimum thickness, consisting of C glass veil, and
'ECR/ADVANTEX' glass and impregnated with vinylester or epoxy resin.
2.
The structural layer consisting of ECR/ADVANTEX glass reinforcements impregnated

with vinylester or epoxy resin. Silica sand shall not be used.
3.
An exterior resin-rich layer of 1.0 mm minimum thickness, reinforced with a C glass

veil and impregnated with vinylester or epoxy resin.
No dark pigments, sand or aggregate fillers shall be used for pipes and fittings. Ultra
Violet stabilizers shall be incorporated in the pipe and fitting construction.
GRP pipe and fittings for pumping station and valve chamber pipework shall have a
suitably designed restrained joint capable of withstanding the design operating
pressure with no leaks and without the use of thrust blocks.
The acceptable jointing system shall be GRP flanges. GRP flanges shall be machine
filament wound using 'ECR/ADVANTEX' glass fibre reinforcements and vinylester or
epoxy resin. Hand layed up flanges shall not be permitted. Flanges shall be drilled to
BS 4504 (metric units) type PN 10.
Vol 3, Section3
Page E-26 of 115
Specifications
A. Factory Testing
The following tests shall be carried out on manufactured GRP pipe and fittings at the
intervals specified. Test methods shall be in accordance with BS 5480 or ASTM equivalent.
Witnessing of factory testing by the Engineers Representative will be required prior to
delivery of the material. Copies of the Manufacturer's test reports shall be submitted to the
Engineer after each consignment of pipe or fittings delivered to the site.
All GRP standard pipe and pipe used for fitting fabrication shall be factory pressure tested
to 24 bar for pressure pipes and 12 bar for non-pressure pipes.
The following tests shall be conducted on all GRP pipe and fittings:
-
Dimension measurements (Wall thickness, Diameter, Length)

Visual inspection
Barcol Hardness (Resin Cure)
Stiffness and resistance to structural damage as per Tensile strength by strip for GRP pipes
as per BS 5480: App: #, 1990.
Mechanical property testing shall be conducted on 1% of GRP pipe and fittings produced.
Other tests for quality assurance shall be carried out on representative sample(s) as
required by BS 5480 or ASTM equivalent.
Initial longitudinal unit tensile strength by a tensile strip test as per BS5480 Appx A.
Initial specific stiffness under ring deflection BS 5480 Appx H.
B. I nstallation
GRP pipe and fittings shall be installed in accordance with the manufacturer's written
instruction. A field representative of the manufacturer shall be made available as and
when required during the installation of the GRP pipe and fittings. All flanges shall be
tightened in accordance with the Manufacturer's written instructions using a torque
wrench.
E1.16.6
GRP Pipes and Fittings for Irrigation and Potable Water Distribution and
Transmission
A. Scope
This specification covers the minimum requirements for the GRP piping for aboveground
and underground installations, intended to be used for potable and raw water applications.
The Manufacturer's design shall satisfy the minimum requirements set herein. This
specification includes the minimum requirements for design, manufacture, workmanship,
testing, inspection and installation of standard GRP pipe systems.
B. M anufacturers P re-Qualification
All Pipes and fittings shall be certified in accordance with BS5480 / ASTM D3517. For the
diameters intended for the supply, evidence of the certified range to be submitted.
GRP pipe and fittings shall be manufactured by an established pipe Manufacturer in a

purpose-built facility for the production of such materials. The Manufacturer shall have an
approved Quality Management System complying with ISO 9001 for all activities being
undertaken during pipe design, manufacture and supply.
Manufacturer's Scope of Work
The GRP pipe system Manufacturer will be responsible for the following:
Vol 3, Section3
Page E-27 of 115
Specifications
a)
Manufacture and Supply of the GRP pipe, fittings, flanges, saddles for instrumentation
tapping and pipe closing (make-up) pieces. Manufacturer to also supply the gaskets
for use in flange connections and provide general recommendations on associated
equipment such as valves, expansion bellows, nuts and bolts and other accessories.
b)
Design of the GRP pipe system including Stress Analysis (Surge and Flexibility),
Support Location / Function Analysis and the Conceptual Support Design for the given
design and routing for all above ground applications. These Engineering / Design
analysis are to be implemented by the pipe manufacturer.
c)
Inspection and testing at the Manufacturer's works in accordance with specified

requirements herein.
d)
Marking of pipe for identification shall be as per specification
e)
Provision of a Site Staff (s) to assist during pipe installation.
Applicable Codes and Standards

The following internationally accepted standards are the minimum requirements for the
manufacture of GRP Pipe Systems and should be referenced throughout the Project
Specification where appropriate.
AWWA C950
Glass Fiber Reinforced Thermosetting Resin Pressure (Latest

Edition)
AWWA M45
Fiberglass Pipe Design
BS 5480
Glass Fiber Reinforced Plastic GRP pipes and Fittings for use for
Water Supply or Sewerage
ASTM D3517
Specification for Glass Fiber Reinforced Thermosetting Resin

Pressure Pipe for conveying water system
C. P roduct Description
1. General
Pipe shall be designed and manufactured by the glass filament winding process as
described by AWWA M45, ASTM D3517 and BS 5480. Accepted manufacturing processes
are the continuous filament winding or the helical filament winding process. The filament
wound pipe shall be made using a straight steel mandrel.
The pipe shall be constructed so as to include internal and external corrosion barriers of a
composition suitable to resist the corrosive effects of the contained and surrounding
environments.
The inside diameter (ID) of the finished pipe is fixed by the mandrel outside diameter. The
outside diameter (OD) of the finished pipe is determined by the amount of material that is
wound on the mandrel.
The pipe shall be produced in one continuous piece with no joints.
The resins to be used shall be:
Vol 3, Section3
Page E-28 of 115
Specifications
Polyester: Isophthalic Acid Grade (at least equal to the requirements of BS 3532
Type B).
a. Liner
Pipe and Fittings shall have a smooth resin rich internal liner of 1 mm thickness with a
resin to glass ratio of 70 : 30. This liner will be reinforced with "C" Glass.
No dark pigment or resin fillers, such as calcium carbonate shall be used.
b. Structural Wall
The structural wall of the pipe shall be reinforced with closely spaced continuous fiberglass
filament winding, chopped roving, all impregnated in thermosetting resin. No dark
pigments or resin fillers such as calcium carbonate shall be used.
c. External Layer
A resin-rich post-coat, identically constructed as the inner liner, must be
applied to the external surfaces of all of the GRP pipes. All external surfaces shall be able
to resist the anticipated corrosion imposed by the service and ambient conditions.
Approximate thickness of the external surface, shall be 0.5 mm.
No dark pigments or resin fillers such as calcium carbonate shall be used.
d. Reinforcing ribs
Where stiffener ribs are used to structurally reinforce the pipe wall, they must be protected
in the same manner as specified for the external surface, above.
2. Raw Materials
All materials and the manner and degree to which they are used during the construction of
all components required for the GRP pipe system described by this specification shall be
selected so they will resist the corrosive effects of both the contained and surrounding
environments.
All structural materials shall be new and free from all deleterious defects and imperfections
and only be used for production after having been controlled and approved by the
Manufacturer's Quality Department.
Testing and controlling shall be done according to the relevant methods
Glass Reinforcements shall be compatible with the impregnating resin used and should be
suitable for the service intended.
Resins used shall be a commercial high grade thermosetting isophtalic, resin as specified
No dark pigments shall be used in the GRP pipe or joints. No additives shall be used except
when required for viscosity control.
Pipes used for Potable Water Service: All GRP pipes and fittings conveying potable water
shall be certified and listed for potable water use by the Water Regulations Advisory
Scheme "WRAS" United Kingdom, in accordance with BS 6920.
Vol 3, Section3
Page E-29 of 115
Specifications
D. Requirem ents
1.
Wall Thickness
The wall thickness required for each size/pressure class shall be established by the
manufacturer to meet the design requirements but in no case shall the wall thickness be
less than (0.010 x DN); where DN is the nominal pipe inside diameter. For ribbed pipe, the
minimum shell wall thickness shall be (0.005 x DN); where DN is the nominal pipe inside
diameter. The pipe working pressure class shall be based on the Hydrostatic design basis
(HDB) of the pipe with a design (service) factor of 0.5.
2.
Length
GRP pipe shall be manufactured in standard laying lengths of not greater than 12 meters.
Random short lengths, if supplied, shall not exceed 5% of the quantity supplied of each
size. The tolerance on the Manufacturer's declared laying length shall not exceed 25 mm.
3.
Diameters
Pipe shall be manufactured in standard metric sizes based on the pipe nominal diameter in
sizes 25 mm and larger. The actual inside diameter shall not vary from the nominal inside
diameter by, more than 1 % or 4 mm whichever is greater.
4.
Stiffness
The pipe stiffness shall be determined by the Manufacturer to meet the design
requirement with particular regard to installation method, burial depths, deflection limits,
buckling and vacuum requirements, in accordance with AWWA M45. The pipe initial
specific stiffness (EI/D3) shall, in no case, be less than 10,000 N/m2, when tested in
accordance with ASTM D2412 or BS 5480.
5.
Beam Strength
GRP pipe shall meet the minimum longitudinal tensile strength requirements specified in
AWWA C950 for the appropriate operating pressure class.
The above requirements are intended to provide adequate strength for normal handling
and under ground conditions. Pipe intended to withstand the end load resulting from
internal pressure at changes of direction or the beam load resulting from above ground
installation shall require higher longitudinal strengths and a suitably designed, fully
restrained, jointing system.
6.
GRP pipe systems shall meet the minimum hoop tensile strength requirements specified in
AWWA C950 standard for the appropriate operating pressure class. However, the
structural wall hoop tensile stress for pressure pipe shall not be less than 12 kN/m2 when
tested in accordance with A WW A C950 or BS 5480.
7.
Hardness - Barcol (ASTM D 2583)
The laminated surface shall have Barcol hardness of at least 90% of resin manufacturer's
minimum specified hardness for the cured resin.
Vol 3, Section3
Page E-30 of 115
8.
Joints
a)
Flexible Joints
Specifications
Standard buried pipe with unrestrained joints shall be filament wound GRP coupling,
with confined rubber ring gaskets. Rubber rings shall be of natural rubber conforming
to BSEN 6811 or ASTM F 477 for seawater service, and synthetic rubber for other
services. Neoprene rubber shall be used for oil contaminated services. Joints shall
allow for at least 0.75 deviation while remaining watertight at 1.5 times the pipe
operating pressure. The rubber rings shall be the sole element depended upon for
water tightness. This system will require thrust blocks at changes in direction to
accommodate thrust loads,
b)
Rigid Joints
Flanges: GRP flanges where used shall be machine filament wound upto 1800mm.
Contact moulded flanges may be used for sizes 2000mm and larger. Flanges shall be
manufactured with epoxy or Vinylester resin. Flanges shall be flat faced with full or '0'
Ring type gaskets. Gasket material and design shall be as per the Manufacturer's
recommendations. The pipe Manufacturer shall provide the torqueing sequence and
maximum tightening torque as appropriate for each flange size and design and should
at least be present in a supervisory role during the torqueing of all flange
connections. Washers shall be used under all nuts and bolts heads with special
spacers to be used at flange to valve connections as required.
Flange drilling and rating shall be as specified on the drawings. Flanged joints shall be
tensile resistant for above ground service.
c)
Reinforced Overlay Joints (butt & wrap)

Butt & Wrap joint where used only for site modification or repair shall consist of
layers of Glass fiber reinforcement impregnated with resin. The wall thickness, tensile
and axial strength of the reinforced overlay shall meet or exceed the design strength
of the adjoining pipe sections.
Butt & Wrap joints on site shall be performed only by or under the supervision of the
pipe Manufacturer.
All of the joint types shall be designed to remain watertight when tested after
installation to 1.5 times the pipe line pressure for a minimum of one (1) hour.
9.
Workmanship
GRP pipe, fittings and joints shall be free from de-laminations, cracks, bubbles, pinholes,
pits, blisters, foreign inclusions and resin-starved areas that due to their nature, degree or
extent detrimentally affect the strength and serviceability of the pipe. No glass fiber
reinforcements shall penetrate the interior surface of the pipe wall.
Joint sealing surfaces shall be free of dents, gouges, de-laminations, or other surface
irregularities that will affect the integrity of the joints.
GRP pipe, fittings and joints shall be as uniform as commercially practicable in
colour, capacity, density and other physical properties.
Vol 3, Section3
Page E-31 of 115
10.
Specifications
Fittings
GRP fittings such as bends, tees, junctions and reducers shall be equal or superior in
performance to the GRP pipe of the same diameter and pressure. All fittings shall have a
smooth internal surface with similar wall construction.
Standard fittings shall be filament wound or mode by mitered construction from filament
wound GRP pipes.
For GRP fittings, the deviation from the stated value of the angle of change of direction of
a bend, tee, junction etc. shall not exceed 1 degree.
The tolerance on the Manufacturer's declared length of fitting shall be 10 mm taken from
the point of intersection to the end of the fitting or 10 mm on a straight fittings.
All GRP fittings shall be fabricated in the factory, by the pipe manufacturer, to ensure
Quality Control (Under no circumstance shall fabrication of fittings be allowed on site by
Contractor). Complex fittings arrangements may be pre-assembled by the pipe
Manufacturer in the factory such that field joints are kept to a minimum.
E. Design P aram eters

Pipe shall meet the following minimum design requirements:
Operating Pressure (Pw)
Minimum 12 bar or as specified
Surge Pressure (Ps)
40% of Pw' unless otherwise

specified.
As specified.
1 .0 m or as shown on drawings
for buried pipe.
2.0% Min
Vacuum (Pv)
Minimum Earth Cover
Initial Installed Deflection for buried pipe
Long term Installed Deflection for Buried Pipe
5.0% Max. (3.0% max for ribbed

pipe and 5% for solid wall pipe).
Service temperature
Safety Factors
Pressure Rating
Ring Bending Strain (stress)
Combined Strain (stress) Buckling
As specified
> = 1.8
> = 1.5
> = 1.5
> = 2.5
The Contractor shall be responsible for implementing / installing the correct design for
each GRP pipe system.
Buried GRP pipe design shall be established in accordance with A WW A M45. Support
requirements for complex above ground piping systems shall be based on computer
flexibility analysis (static and dynamic) of the piping systems. Pipe manufacturers Design
calculations shall be submitted to the Engineer for review and approval.
F. I nspection & Testing
The Manufacturer shall take adequate measures in the production of the products covered
by this specification to assure compliance with the requirements herein. An Inspection and
Testing plan (ITP) should be forwarded to the Engineer for approval. Plant inspection by
the Contractors or Engineers qualified personnel or the omission of such inspections shall
Vol 3, Section3
Page E-32 of 115
Specifications
not relieve the Manufacturer of the responsibility to furnish products complying with the
requirements of the minimum manufacturing requirements given herein.
Production and Testing Notice - When plant inspection is required by the Contractor or
Client the Manufacturer shall provide adequate advance notice of when and where
production and testing of ordered products will commence.
The Contractor and / or Client Inspector (s) shall have free access with reasonable
advance notice to the Manufacturer's plant areas that are necessary to assure that
products comply with all requirements herein.
As a minimum the following tests shall be performed at the indicated intervals unless
otherwise agreed-upon, and shall form a part of the Manufacturers overall quality control
program.
The following test shall be conducted on every pipe;
-
Visual Inspection
Dimension Measurements
Resin cure (Barcol Hardness)
The following tests shall be conducted on pipe samples at a frequency of not less than one
per 50 pipes (one lot) of the same Diameter and Pressure.
-
Stiffness
Longitudinal Tensile Strength
Loss on ignition (composition)
However, this sampling is not applicable for GRP pipe manufactured thru helical winding
process. The determination of strength properties may be treated as qualification testing,
provided the manufacturer declares the winding angle and submits qualification test
reports duly authenticated by third party.
Pipe hydrostatic pressure test shall be carried out on 100% of Pipes.
Test methods shall be in accordance with AWWA C950 and BS 5480.
Copies of all test reports shall be submitted to the Client for each lot delivered to Site.
G. M arking
Each pipe and fitting shall be indelibly marked with the following information.
-
Vol 3, Section3
Manufacturers Name or trademark

Manufacturing date
Manufacturing number
Nominal diameter in mm
Operating pressure in bar
Nominal laying length in meter (for pipe only)
Manufacturers Inspection mark
Applicable standard complying the product.
Page E-33 of 115
Specifications
H. Subm ittals
The following information shall be submitted by the manufacturer.

1.
2.
3.
4.
5.
6.
7.
Pipe Data Sheet (s)

Detailed Resin Data
Detailed Glass Reinforcement Data
Detailed Pipe Aggregate Data
Detailed Joint & Gasket Data
GRP Pipe Manufacturer's Pre-Qualification
Manufacturer's ISO 9001 Certification
In addition to the above information, the following shall be submitted during the
mobilization period:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Detailed manufacturing process for pipe, joints and fittings.

Detailed drawings for pipe ends, joints and fittings.
Complete pipe design calculations for each Diameter/Pressure.
Friction loss factors of pipes and fittings
Manufacturers Quality Control and Assurance Manual.
Proposed Inspection and Testing Program (ITP).
Pipe Manufacturers written handling, storage and installation instructions.
Proposed Hydrotest method statement
Proposed pipe transport procedures.
Qualification (Type) Test results and report for:
- Long term stiffness (Aging factors); for buried pipe only
- Long term hydrostatic Design Basis (HDB); for pressure pipe only
I . I nstallation (General Requirem ents)

-
The Contractor shall submit the pipe Manufacturer's Installation Manual and
associated Data for engineers review. A site meeting to include the engineer, the
Contractor and Manufacturer is to occur within two weeks from Contract Award to
clarify any outstanding issues / questions on the given installation procedures.
GRP pipe shall be handled, stored, transported and installed in strict accordance to
the Manufacturer written instructions.
The pipe installation procedures and practices chosen shall meet the design
requirements specified.
No stacking of pipe larger than 1.8 m in diameter shall be allowed on site or during
transport.
Reinforced concrete thrust blocks shall be used at all changes in direction, size
reduction / expansion, and other thrust locations under ground for unrestrained
pressure systems. Thrust blocks shall encase the entire GRP fitting at the directional
change and should be constructed to fully absorb all thrust loads. Thrust block sizes
may be reduced or eliminated by using an axially restrained piping system utilising
high axial strength GRP pipe and fittings and a suitable restrained pipe joint design.
Pipe deflection readings shall be taken and recorded on all buried pipe at three meter
intervals. Initial deflections shall not show a reduction in internal vertical.
The Contractor shall employ on a full-time basis the services of field representatives
from the pipe manufacturer throughout the pipe off loading, storage, installation and
testing period.
For standard buried unrestrained pipeline sections, a flexibly jointed short pipe shall
be incorporated outside rigid structures to provide pipeline flexibility against
differential settlement. A minimum of two (2) flexible joints on either side of a rigid
structure is required. The length of the short pipe shall be in accordance with the
Vol 3, Section3
Page E-34 of 115
Specifications
manufacturers recommendation.
J. Onshore Buoyancy Considerations
Where the pipe is to be installed on-shore within water table level, proper considerations
have to be taken to prevent pipe flotation. In general, a minimum soil cover equal to one
pipe diameter should be kept above the, pipe crown to prevent flotation.
GRP PIPE DATA SHEET (FOR EACH DIAMETER/PRESSURE/SERVICE)
(TO BE PROVIDED PRIOR TO START OF PIPE MANUFACTURING)
Design Parameters
Units
Nominal Diameter
mm
Pipe Manufacturing Process

Service
:
:
Rated Working Pressure

Joint Type
Maximum Allowable Vacuum
:
:
:
Barg
Laying Length
Nominal Wall Thickness

Inner Layer
Thickness
Resin Type
Glass Type
:
:
:
:
mm
mm
Structural Wall
:
:
:
mm
:
:
:
mm
Pa
Barg
Pipe Wall structure
Outer Liner
Thickness
Resin Type
Glass Type
Thickness
Resin Type
Glass Type
Mechanical Properties
Design Specific Tangential Initial Stiffness
E1.17
Design Initial Longitudinal Tensile Strength :
MPa
Design Initial Hoop Tensile Strength
Mpa
Ductile Iron Pipes

Ductile iron pipes shall comply with the following requirements:
(i)
Materials:
Ductile iron pipes shall be manufactured from cast spheroidal graphite iron, having
mechanical properties not less than the values in the following table:
Vol 3, Section3
Page E-35 of 115
Specifications
CentrifugallyCas
t
Not CentrifugallyCast
Tensile Strength (MPa)
420
400
0.2% proof stress (MPa)
300
300
Modulus of rupture (MPa)
550
500
10
Elongation at break (%)

(units up to DN 1000)
Elongation at break (%)
(units over DN 1000)
Note: DN = Nominal Internal Diameter in Millimetres

(ii)
Manufacture:
Straight Pipes shall be manufactured by centrifugal casting, and bends and fittings
shall be cast in sand or metal moulds.
Wall thickness of pipes and fittings shall be calculated from the formula:
Thickness = K(0.5 +0.001 DN)
- in which, unless otherwise specified, the value of K shall be as follows:
For centrifugally cast pipes,
For bends and tapers,
For tees and branches,
(iii)
K=9
K = 12
K = 14
Joints:
Unless otherwise specified, pipes and fittings shall be provided with push fit
integrally cast socket and spigot joints, capable of accepting the following angular
deviations and axial movements, at the specified pressure rating, without leakage:
Nominal Diameter
(mm)
(iv)
up to 300
300600
700- 1200
1400-2000
Deflection Angle
5o
4o
2 o
1 o
Axial Movement (mm)
25
40
50
60
Dimensions:
Unless otherwise specified, socket and spigot pipes having diameters up to and
including 600 millimetres may be supplied with individual lengths of from 4 to 6
metres, and pipes having larger diameters with individual lengths of from 5.5 to 8
metres.
The tolerances on finished internal diameter of pipes shall be as follows:
Diameter up to and including 250mm, + or - 5mm
Diameter exceeding 250mm, +0.02DN and -0.005DN
Vol 3, Section3
Page E-36 of 115
Specifications
The tolerance on wall thickness shall be calculated from the following formula:
Tolerance = -(1.3 + 0.001DN)
In no case shall the wall thickness be less than 4.8 millimetres.
The barrels of nominally straight pipes shall not show curvature or other departure
from straightness, greater than the values given in, and determined in accordance
with the following procedure:
A true straight edge shall be placed against the outside of the pipe barrel, along a
side showing concave curvature, so as to contact the barrel at points separated by
at least two thirds of the length of the barrel. The maximum radial distance
between any other point on the pipe barrel, and the straight edge, shall not
exceed 0.125% of the length of the pipe.
(v)
Performance:
The superficial hardness of the iron in finished pipes shall not exceed 230 Brinell,
and that of the iron in fittings shall not exceed 250 Brinell.
The performance of pipes shall be verified by the testing of random samples,
selected in accordance with Clause E2.1, and subjected to the tests specified in
Clause E2.4.
(vi)
Corrosion protection:
All pipes of sizes up to and including DN800 shall be coated externally with
metallic zinc. The Zinc coating shall contain not less than 99.9% zinc, and shall be
applied at a rate of not less than 130 grams per square metre of surface.
Pipes of sizes greater than DN800 shall be coated externally, either with metallic
zinc, as above, or with zinc rich paint, containing not less than 85% zinc, so that
the mass of zinc is not less than 150 grams per square metre. Unless otherwise
specified, the internal surfaces of the barrels of pipes and fittings shall be lined
with cement mortar. The thickness of the lining of units of various diameters shall
comply with the following:
Nominal Size of Unit,
mm dia
Minimum average
thickness, mm
Minimum individual
thickness value, mm
80 - 300
3.0
2.5
350 - 600
4.5
3.5
700 - 1200
5.5
4.5
1300 - 2000
8.0
6.5
over 2000
12.0
10.0
All surfaces of pipes and fittings, other than mortar lined surfaces, shall be coated
with bitumen, to a minimum average thickness of 70 microns, and with an
absolute minimum thickness at any individual point, of 50 microns.
Where pipes and fittings are required to be protected additionally with
polyethylene sheet wrapping, this may, unless otherwise instructed, be applied
either in the factory, or on Site. Factory applied polyethylene wrapping shall
comply with the following requirements:
Vol 3, Section3
Page E-37 of 115
Specifications
Polyethylene sheet wrapping may be unbonded, or bonded to the pipe surface. If

unbonded, it shall be closely wrapped around the pipe barrel, and secured along
the seam so as to provide a tensile strength across the seam not less than that of
the material itself. If bonded, the peel strength shall be not less than 20 newtons
per centimetre of strip width.
The thickness of the material shall be between 0.2 and 0.25 millimetres, if the
tensile strength is in excess of 15MPa, and at least 1.8 millimetres if the tensile
strength is less than 15MPa, or is unspecified.
The wrapping shall be free from "holidays" when spark tested at 25kV.
E1.18
Steel Pipes
General
Unless fabrication on Site has been specifically approved in writing, steel pipes and fittings
shall be factory made. Site fabrication of specials will be permitted, subject to the detailed
provisions of this clause. Factory welding of longitudinal and spiral seams shall be by an
automatic submerged arc welding process, except for smaller diameter pipes as detailed
under 'Manufacture' in this clause. The ends of pipes, fittings and specials shall be fully
prepared for jointing by the specified method, prior to delivery to Site.
Internal and external corrosion protection systems shall normally be applied at the factory,
and pipes and fittings shall be supplied to the Site with adequate quantities of materials to
permit the completion of the protection systems at welded joints on Site.
Materials
Steel shall be manufactured by an open hearth, electric or basic oxygen process. For
welded pipes, Grades 32 and 36 steel may be supplied rimmed, otherwise all steel shall be
fully or semi-killed.
Unless otherwise specified, steel shall comply with the chemical composition, and
mechanical properties, for the appropriate grade, as follows:
Maximum Content of Non-Ferrous Elements %
Minimum
Yield
Stress
Minimum
Elongation
Grade
Si
Mn
MPa
32
0.16
0.70
0.05
0.05
195
25
36
0.17
0.35
0.80
0.05
0.05
215
24
40
0.25
0.35
1.20
0.05
0.05
227.5
22
43
0.25
0.50
1.50
0.04
0.04
270
20
50
0.20
0.50
1.60
0.04
0.04
345
18
Full details of chemical composition and recommended welding procedures shall be

provided.
Manufacture
Seamless manufacture will not be permitted for Light Duty Class L pipes of any diameter
nor for any class of pipe exceeding 50mm nominal bore.
Vol 3, Section3
Page E-38 of 115
Specifications
Butt welding may be used for longitudinal seams in pipes up to and including 100mm
nominal diameter, manufactured from rolled steel strip having a thickness not exceeding
5.4mm.
Electric resistance and induction welding may be used for longitudinal seams in pipes up to
and including 500mm nominal diameter, manufactured from rolled steel strip having a
thickness not exceeding 10mm.
Submerged arc welding, using an automatic process, may be used for longitudinal or spiral
seam welds for pipes of nominal diameters exceeding 100mm, using sheet steel having a
thickness not exceeding 32mm. There shall be at least two weld runs, one of which shall
be on the inside of the pipe.
Heat treatment shall be applied to all cold finished pipes, and to the weld zones of electric
resistance or inducation welded pipes with diameters of 200mm or more. Sheet and plate
steel shall be shaped by rolling or pressing only.
Special fittings may be fabricated on Site using, to the greatest possible extent,
components cut from factory made and tested pipes. Fabrication shall use qualified
welders and procedures, following the steel supplier's recommendations.
All units, whether factory or Site fabricated, shall have a workmanlike finish, free from
visual defects, and shall pass all specified tests. Butt welded, electric resistance and
induction welded units shall not include welds used for joining lengths of strip steel.
Dimensions
Steel pipes with nominal diameters up to and including 150mm shall have average wall
thicknesses not less than those given in the following table for the appropriate class.
Individual thickness measurements less than the tabulated values will be accepted if within
the stated tolerance.
Nominal Diameter
Mm
6
8
10
15
20
25
32
40
50
65
80
100
125
150
Tolerance
Thickness mm
Light Duty
Class L
1.8
1.8
1.8
2.0
2.3
2.65
2.65
2.90
2.90
3.25
3.25
3.65
4.5
4.5
-8%
Medium Duty
Class M
2.0
2.35
2.35
2.65
2.65
3.25
3.25
3.25
3.65
3.65
4.05
4.5
4.85
4.85
-10%
Heavy Duty
Class H
2.65
2.9
2.9
3.25
3.25
4.05
4.05
4.05
4.5
4.5
4.85
5.4
5.4
5.4
-12.5%
Steel pipes with nominal diameters greater than 150 and not exceeding 480mm shall have
average wall thicknesses not less than those given in the following table for the
Vol 3, Section3
Page E-39 of 115
Specifications
appropriate class. Individual thickness measurements shall be not more than 15% above
or 12.5% below the tabulated value.
Nominal
Diameter mm
Thickness mm
Schedule 20
Schedule 30
Schedule 40
Schedule 60
200
6.35
7.04
8.18
10.31
250
6.35
7.80
9.27
12.70
300
6.35
8.38
10.31
14.27
350
7.92
9.52
11.13
15.09
400
7.92
9.52
12.70
16.64
450
7.92
11.13
14.27
19.05
Note: Schedule numbers are as used in API 5L

Steel pipes with nominal diameters greater than 480mm, unless otherwise specified, shall
have minimum wall thicknesses such that the ratio of internal pipe diameter to minimum
wall thickness does not exceed the value given in the following table for the appropriate
steel grade and pipe pressure rating.
Steel
Grade
Diameter: Thickness Ratio for Stated Pressure Rating
6 bar
10 bar
16 bar
25 bar
40 bar
32
130
130
122
78
48
36
130
130
130
86
53
40
130
130
130
91
56
43
130
130
130
108
67
50
130
130
130
130
86
Steel pipes with nominal diameters up to and including 150mm shall be supplied in lengths
of between 4 and 7 metres. Pipes of larger diameters shall have individual lengths of
between 6 and 10 metres.
Jointing Provisions
Steel pipes with nominal diameters up to and including 150mm shall be threaded at both
ends and provided with a detachable screwed coupling attached to one end. Couplings
shall have a minimum length of 44% of the pipe diameter, plus 30mm, and shall have
parallel threads. Pipe ends shall be provided with taper threads. Couplings shall be made
from similar material to that of the pipes.
Steel pipes with nominal diameters exceeding 150mm, and not exceeding 650mm shall be
provided with sleeve or socket type joints providing a double seal. The inner seal shall be
provided by a rubber 0-ring, positively located by a groove in a raised portion of the pipe
spigot end, and the outer seal by an externally Site welded joint between the end of the
Vol 3, Section3
Page E-40 of 115
Specifications
pipe socket and the periphery of a steel flange to be located at least 250mm back from
the rubber 0-ring on the pipe spigot end.
Steel pipes of diameters exceeding 650mm shall be provided with ends bevelled for butt
welding, or with sleeved, collared or shaped ends providing socket and spigot assembly.
Pipes for jointing by the latter method shall be suitable for the making of internal and
external welds on Site, and shall be drilled, and fitted with a nipple to permit air testing
between the internal and external welds.
Pipes for butt welding shall have their ends square to the axis of the pipe within 1.5
millimetre, or 1 millimetre per 300 millimetres of pipe outside diameter, whichever is the
greater.
Corrosion Protection
Unless otherwise specified, steel pipes shall be provided with internal and external
corrosion protection systems as follows.
Pipes and fittings up to and including 150mm nominal diameter shall be hot dip
galvanised. Prior to galvanising, units shall be thoroughly descaled and cleaned.
Galvanising shall be carried out by dipping in a bath containing not less than 98.5% by
weight of molten zinc.
The whole surface of the unit coated with uniformly adherent zinc, capable of passing an
approved copper sulphate solution immersion test. Galvanising shall be carried out prior to
threading of jointing surfaces.
Pipes and fittings of nominal diameters greater than 150mm shall be protected externally
by reinforced bitumen enamel wrapping, or coal tar enamel wrapping, and internally by
cement mortar lining. Where in contact with sewage, the cement mortar lining shall have
an additional coating of bitumen.
Surfaces to be protected shall be thoroughly cleaned to remove all scale, rust, grease or
other extraneous matter, by acid pickling, abrasive, mechanical or flame descaling.
Reinforced bitumen or coal tar enamel wrapping shall comprise hot applied, mineral filled,
bitumen, or coal tar, giving a minimum finished thickness of 3mm. Reinforcement shall
comprise an inner layer of 40 grams/square metre glass tissue, spirally wound with
overlap, separated from the pipe surface by at least 1mm thickness of enamel, and an
outer sheathing of bitumen or coal tar impregnated, longitudinally reinforced, glass fabric
spirally wound onto the pipe with overlap, and separated by at least 1mm of enamel from
the inner glass reinforcement.
Cement mortar lining shall be a centrifugally applied mortar containing not less than
1000kg per cubic metre of Portland or Sulphate Resisting cement, and suitably graded
silica sand. The water cement ratio shall be between 0.30 and 0.45:1 by mass. The
minimum thickness of lining shall be 6mm for pipes up to and including 325mm diameter,
7mm for pipes exceeding 325 and not exceeding 610mm diameter, 9mm for pipes
exceeding 610mm and not exceeding 1220mm diameter, and 12mm for pipes exceeding
1220mm diameter. The lining thickness shall not exceed the specified value by more than
3mm.
Where coatings other than those described above are specified, the requirements are
given in Section G, or elsewhere in this Specification.
Vol 3, Section3
Page E-41 of 115
Specifications
Factory Testing
Tensile tests on the steel used for pipe manufacture shall show compliance with the yield
strength and elongation properties specified for the appropriate grade of steel.
Tensile tests on samples cut to include a weld shall show strengths not less than specified
for the base metal.
Bend tests shall be carried out on complete tubes of nominal bore up to and including
50mm. Ungalvanised tubes shall be bent through 180 degrees around a former having a
radius equal to six times the pipe outside diameter without signs of fracture or failure.
Galvanised tubes shall be bent through 90 degrees around a former having a radius of
eight times the pipe outside diameter, without signs of fracture or failure of the steel.
Destructive weld tests shall be carried out on samples obtained from each batch of pipes.
A batch shall be defined as the number of pipes manufactured during a single run. When
more than one hundred pipes are manufactured during a single run sampling shall be at
the rate of one pipe per hundred, or part thereof.
Pipes of nominal diameter exceeding 50mm and not exceeding 150mm shall have test
rings not less than 38mm cut from them and flattened between parallel plates. Any weld
in the sample shall be positioned at the point of maximum bending, and shall show no sign
of fracturing until the distance between the plates is less than 75% of the original outside
pipe diameter. No sign of fracture in the base metal shall occur until the distance between
the plates is less than 60% of the original outside diameter.
Pipes greater than 150mm nominal diameter shall have samples cut from their ends and
subjected to a weld bend test, by bending the sample through 180 degrees around a
former having a radius equal to twice the pipe wall thickness. After bending, the sample
shall show no crack in the weld metal, or between weld metal and base metal, with a
dimension exceeding 3mm. Alternatively, if cracking or fracture does occur, the sample
shall be opened and the fracture surfaces examined. The sample will be regarded as
having passed the test if the fracture surfaces show no gas pockets or slag inclusions
having any dimension exceeding 2mm.
In the event that any test piece should fail any of the specified tests, then two further
tests pieces shall be taken from the same pipe, and subjected to the same test. If both
these additional test pieces pass the required test, then the pipe and the batch of 100
pipes which it represents will be regarded as having satisfied the requirements of the
Specification in respect of the particular test. If either of the additional test pieces fails the
test, then the pipe and the batch which it represents, will be rejected. The manufacturer
will, however, retain the option of testing all the remaining pipes in the batch, at his own
expense, and each pipe which then passes all the specified tests will be regarded as
acceptable.
In addition to the destructive tests specified above, all welded steel pipes shall be subject
to non-destructive testing of the welds, as follows:
Within an axial distance of 200mm of the pipe ends all welds shall be subject to
radiographic examination. The acceptance limits for slag inclusions and gas pockets shall
be as agreed with the Engineer.
The remainder of all welds shall be subject to either radiographic or ultrasonic
examination. Acceptance criteria for the assessment of imperfections identified by either
method shall be as agreed with the Engineers Representative.
Every complete pipe shall be hydrostatically tested to a pressure corresponding to a
circumferential tensile stress in the pipe wall equal to 75% of the specified yield strength
Vol 3, Section3
Page E-42 of 115
Specifications
of the steel. The test pressure shall be held for sufficient time to permit inspection of all
weld seams, which shall show no signs of leakage.
Galvanised coatings of small diameter pipes shall be tested by dipping sample lengths of
pipe in a copper sulphate solution containing 33 grams of crystalline copper sulphate per
100ml of distilled water. Samples shall have a length of 200mm for diameters up to and
including 32mm, 150mm for diameters exceeding 32mm and not exceeding 65mm, and
100mm for diameters exceeding 65mm, and shall be prepared by dipping in a 2% solution
of sulphuric acid for 15 seconds, and then rinsing and drying. The sample shall then be
tested by dipping four times for a duration of one minute in the copper sulphate solution
at a temperature between 15 and 20 degrees centigrade. Between dips the sample shall
be rinsed, cleaned and dried.
After the dips, the sample shall show no red deposit of metallic copper on the base metal,
after rinsing and wiping dry, other than within 25mm of the ends. If any such red deposit
of copper remains after rinsing and wiping, and it can be removed by rubbing, peeling or
scrubbing after immersion in 1:10 hydrochloric acid solution for 15 seconds, then the
sample will be regarded as having passed the test if continuous zinc coating is found
beneath the removed copper.
Bituminous and coal tar based coatings shall be tested for continuity of coverage by the
use of holiday detectors. All pinholes or other discontinuities shall be made good. Adhesion
of coatings shall be checked by cutting through the coating and peeling off a 50mm wide
strip. Inspection during and after peeling shall show adhesion between coating and pipe to
have been obtained over the whole area.
E1.19
Stainless Steel Pipe

General
A.
Scope:
1 Stainless steel pipe, fittings and appurtenances.
B.
Reference standards:
1.
AWWA MIL 11 : Steel Pipe A Guide for Design and Installation
2.
AWWA C200, C203
3.
ANSI B1.1, B 36.19, B 18.2
4.
ASTM A167, A182, A193, A194, A234, A240, A269, A304, A312, A325,
403,A 774,A 778.
5.
AWS D1.1
C.
Source
1.
2.
3.
4.
D.
Quality Control
Shop test fabricated pipe, fittings and specials after fabrication.
Hydrostatically test fabricated pipe
Test all welds of fittings and specials which are assembled from
Hydrostatically tested fabricated pipe by non destructive means such as
dye-penetration test.
Follow requirements of AWWA C200.
Quality Control:
1.
All welders certified per AWS D1.1.
Submittals
Shop drawings and product data
1.
Detailed drawings showing fabrication and weld locations; and the
2.
Complete data of material proposed.
Vol 3, Section3
Page E-43 of 115
3.
4.
5.
6.
Test Reports:
1.
2.
Specifications
Do not manufacture until approved.

Show where each numbered pipe, fitting or special is to be installed.
Numbers correspond to those tagged on pipe.
Prepare drawings to scale.
Submit certified copies of shop test on fabricated pipe, fittings and
specials.
Reports of field tests.
Product Delivery, Storage and Handling

A.
B.
C.
Handling and storage:

1.
Ensure undamaged condition.
2.
Follow AWWA C203, Section 2.14.
3.
Use wide canvas slings and wide padded skids.
4.
Do not use bare cables, chains, hooks metal bars, or narrow skids.
5.
Do not store directly on ground, provide proper blocking.
Shipment:
1.
Support on padded saddles not less then 300 mm.
2.
Laterally support pipe ends, fittings, and specials to maintain shape.
3.
Separate materials so they are protected from contact damage
4.
Securely fasten load to prevent movement in transit.
Delivery:
1.
Reject products with dents, kinks, abrupt changes of curvature or other
damage.
2.
Reject any products dropped from truck or crane.
3.
Replace or recondition rejected items at contractors expense.
4.
Reconditioning subject to Engineers approval.
Material
A.
Pipe:
1.
2.
3.
B.
Low Pressure Air (LPA) service:

a. ASTM A778.
b. Plate: ASTM A240, Type 316L.
c. Diameters and wall thickness: ANSI B36.19.
d. Min. Wall thickness:
Sch.10 (interior or exposed)
Sch.40 (buried)
liquid service per these Specification documents:
a. ASTM A312, welded
b. Diameters and wall thickness : ANSI B36.19
c. Grade : Type 316L
d. Min. Wall thickness : Sch.40
High Pressure Air service:
a. ASTM A269
b. Grade : Type 316L
c. Min. Wall thickness : 0.5mm
Fittings and Specials:

1. Low Pressure Air (LPA) Service:
a. ASTM A774.
b. Plate: Same as for Pipe.
c. Diameter and wall thickness: ANSI B36.19.
d. Diameter: ANSI B 16.9 , ASTM A234
Vol 3, Section3
Page E-44 of 115
Specifications
e. Wall thickness: Same as Pipe

2. Liquid Service:
a.
ASTM A403, WP-W
b.
Grade: Type 316L
c.
Dimensions : ANSI B 16.9
d.
Rating: Standard weight, Class D, High Pressure, Class E.
e. Use class E flanges for all service categories with test pressures in
excess of 15 Bar, as defined in these Specification documents.
3. High Pressure Air:
a. Type : Compression
b. Grade : Type 316L
C.
Flanged Joints:
1. Flanges:
a. Face ring type on pipe
b. Stub end on fittings.
c. Material same as for pipe.
d. Backing flanges standard (150 lb.) or high pressure (300 lb), flat face,
stainless steel to match pipe.
e. Forged stainless steel, ASTM A182, Grade 316L, or slip-on raised face
machined when mating with flat faced flange in submerged service
and designated hazardous environment.
2. Flange bolting:
a. Material : Type 316L
b. Type: Bolt and nut: bolt-stud and 2 nuts permitted for 25 mm and
larger.
c. Bolts and bolts-studs:
1. Length: Ends project 6 mm to 12 mm beyond nuts.
2. Ends: Chamfered or rounded.
3. Threading: ANSI B1.1 Coarse thread series class 2A fit. Bolt studs
may be threaded full length. Studs for tapped holes.
4. ASTM A193, Grade B8M hex head bolts.
d. Nuts:
1. Dimensions : ANSI B18.2, heavy, semi- finished Pattern
2. Threading: ANSI B 1.1, coarse thread series, class 1 B fit.
3. ASTM A 194, Grade 8M hex head nuts.
3. Mechanical Couplings
1. Couplings:
a. Insulating: Dresser Style 39 Rockwell 416W or equal.
b. Reducing: Dresser Style 62, Rockwell 415, or equal.
c. Transition coupling: Dresser 62, Rockwell 413, or equal.
d. Others: Dresser Style 38, Rockwell 411 flexible Coupling, or
equal.
e. Flange coupling adapters:
1. 150 mm through 300 mm Rockwell 2912, Dresser 127, or
equal.
2. 350 mm: Rockwell 913, Dresser128.
3. Provide anchor studs at locations indicated or as directed by
Engineer.
f. Grooved end, conforming to ASTM A743.
1. Style 77S Victaulic, flexible, or equal
2. Style 07 Victualic, rigid, or equal.
Vol 3, Section3
Page E-45 of 115
Specifications
3. Material: 316L S.S.

4. Gasket Type: EPDM
4. Joint harness:
a.
Bolts: ASTM A193, Grade B7, or Ryerson Stress-Proof, minimum

yield point 690 N/mm2.
1. Threading : ANSI B1.1, Class 2A fit, coarse thread series for
25mm and smaller and 8 thread series for 30 mm and larger,
2. Ends: Chamfered or rounded.
b.
Nuts: Hexagonal, ASTM A 194, Grade 2H, or better.

1. Threading: As specified for bolts except Class 2B fit.
2. Dimensions: ANSI B 18.2, heavy, semi-finished pattern.
c.
Washers: Hardened steel, ASTM A 325.
5. Gaskets:
a. EPDM
D. Expansion Joints:
1.
Flanged with stainless steel bellows.
2.
Flexonics Free Flexing Expansion Joint or equal.
E. Small branch connections:

1.
2.
Pipe nipples: Seamless type 316L stainless steel pipe, ASTM A240 standard
weight (Schedule 40).
Thread lubricant: Teflon tape.
F.. Wall sleeves:

Stainless steel, ASTM A304, Schedule 40S.
Water stop material: ASTM A167, Type 304L.
Fabrication and Manufacture
A. Basis of design: Pipe, fittings and specials.
1. Use fabricated or seamless pipe conforming to ASTM A 778 or ASTM A312 as
specified.
2. Use fittings and specials fabricated from hydrostatically tested pipe or welded
seamless pipe conforming to ASTM A774 or ASTM A403 as specified.
3. Provide special sizes, dimensions and shapes per drawings.
4. Specified pipe size indicates the nominal inside diameter where 300 mm or
smaller, and the actual outside diameter where 350 mm or larger.
5. Strength design criteria:
a.
Reinforce or increase shell thickness to maintain combined stress due to
internal pressure and bending below 50% of yield strength.
b.
Internal pressure is the specified test pressure.
c.
For pipes with no specified test pressure, base design on an internal
pressure of 14 Bar.
d.
Dead load is equal to pipe full of water.
Vol 3, Section3
Page E-46 of 115
e.
Specifications
Where pipe is installed in trench; design sheet thickness for external load
of 5000 kg per lineal meter.
B. Ends of Sections:
1.
2.
3.
Use outside bevelled for field butt welding.

Make welded bell and spigot per AWWA C200.
For bell and spigot with rubber gasket.
a.
Provide gasket for watertight joint under all service conditions, including
expansion, contraction and earth settlement.
b.
Groove spigot ends to retain gasket.
c.
Make pipe ends self centering.
4.
For mechanical couplings:

a.
b.
c.
d.
make plain type ends per AWWA C200.

Grind welds flush on ends without pipe stops to permit slipping the
coupling in at least one direction to clear pipe joint.
Make outside diameter and out-of-round tolerances within limits per
manufacturers recommendation.
Grooving shall confirm to rigid grooving dimensions.
5. Length tolerance:
1. Make space between pipe ends at least 12 mm or the length
recommended by the manufacturer.
6. Special sections:
1.
Provide with ends as required and fabricate to shape, size and

dimensions indicated on Drawings.
6. Small branch connections:

1.
Use welded fittings and threaded outlets for connections 60mm

and smaller.
2.
Use 25 mm outlet and reducers for connections known to be less

than 25 mm.
Use pipe nipples or fittings welded to pipe shell and reinforced as
required for connections 75mm through 300mm. Locate
connections to avoid interference with joints, supports, or other
details.
3.
7. Field joints:
1.
2.
3.
Provide flanged, welded and compression sleeve coupled joints

in exposed locations as shown on Drawings.
Additional field welded and mechanically coupled joints may be
provided to facilitate installation. Keep additional field joints to
minimum.
Location of additional field joints subject to Engineers approval
8. Flanged Joints:
1.
2.
Vol 3, Section3
Finish flange faces to a Flat to a plane surface within a 0.25 mm

maximum tolerance.
Maximum tolerance of 0.40 mm/m of flange diameter for flange
faces from the normal with respect to axis of pipe.
Page E-47 of 115
Specifications
3.
4.
5.
Test flanges for true plane after welding and reface if

necessary.
Coordinate flange dimensions and drillings between piping,
valves and equipment.
Blind flanges:
a. Conform in diameter, drilling and thickness with flanges
to which they attach.
b. Reinforce as required.
9. Mechanical Couplings:
1.
Couplings:
a.
b.
c.
2.
Middle ring length not less than 175 mm.

Omit pipe stop from inner surface of middle rings where
couplings are used for closures or where union
connections are requires.
Clean couplings and shop prime with manufacturers
standard rust inhibitive primer.
Joint harnesses.
a. Provide joint harnesses on all couplings under pressure.
b. Design harnesses per Section 19.8, Table 19.7, of AWWA
M11, Steel Pipe Manual except.
Lug plate thickness increased 1/3.
Fabricate lugs from 3 pieces of plate; single bent plate
not
acceptable.
c. Shop weld lugs to pipe; except where drawings require a
sleeve be welded to the pipe and lugs welded to the
sleeve.
d. Place harness lugs and use bolts of sufficient length so
coupling can be slipped clear of joint in at least 1
direction.
e. Use at least two bolts per harness.
f. Double nut bolts.
g. Design bolts based on 276 n/mm2 max stress at
hydrostatic test pressure after installation.
h. Design harness on couplings not subject to hydrostatic
test on basis of 10 Bar hydraulic pressure and above
requirements.
3.
Flanged coupling adapters:

a. Use per coupling manufacturers recommendations.
b. After pipe placement determine location and drill anchor
stud holes if required by Engineer.
c. Hole diameter: Not mote than 3 mm larger than
diameter of
stud projection.
d. Use only at direction and approval of Engineer.
10.
Size grooved coupling joints for proper installation on ends provided.
11.
Shop welded joints:

1.
2.
Vol 3, Section3
Make sound and free from embedded scale and slag.

Ensure tensile strength across weld is not less than that of the
Page E-48 of 115
Specifications
3.
4.
12.
thinner of connected sections.

Make watertight.
Use butt welds for all joints in line pipe assemblies and in
fabrication of fittings and other specials.
Pipe supports, anchors blocking and hangers:

1.
2.
3.
4.
13.
Per requirements of pipe support specification and drawings

Install complete with concrete bases, anchor bolts and nuts,
plates, rods, and other accessories.
Modifications for fit subject to Engineers approval.
Shop weld lugs required for lateral or longitudinal anchorage.
Type of protective coatings: All pipe, fittings, specials and wall fittings:
Exterior exposed: Standard No. 4 polish finish.
Buried: Same as steel pipe, E1.18, p.E-42
Installation
A.
General:
1. Install as shown on Drawings.
2. All piping beneath concrete slabs and footings to be concrete encased.
3. Buried piping shall be installed in trench in accordance with Section 02700.
B.
Flanged joints:
1. Take care in bolting to avoid restraint on opposite end that would prevent
uniform pressure application on gasket.
2. Ensure that stresses are not transmitted to equipment flanges by connecting
piping.
3. Gradually tighten bolts, in turn, at uniform rate.
4. Permanently support pipe at equipment to obtain accurate matching of bolt
holes and uniform contact over surface of flange, before installing bolts.
5. Ensure pump connection piping is free to move longitudinally while bolts are
tightened.
6. Level, align and wedge equipment into position to fit connecting piping.
7. Do not grout equipment until connecting piping properly aligned.
8. Test pump connections by loosening flange bolts. There should be no
movement of piping relative to equipment or opening of equipment
connection joints.
C.
Field welded joints.

By certified welders
Furnish test specimens as required by Engineer.
D.
Grooved coupling joints:

1. Arrange piping so the clear space between pipe ends inside each grooved
coupling is not more than 1 times, or less than times the maximum
recommended by manufacturer.
2. Couplings shall not be used to connect valves, equipment, or structures.
3. Grooved flanges shall not be used without prior written approval of the
Engineer.
E.
Coupling:
1. Remove dirt or foreign material from pipe ends and couplings.
2. Keep gaskets clean.
3. Use wrenches recommended by coupling manufacturer.
Vol 3, Section3
Page E-49 of 115
4.
Specifications
Tighten all bolts the same amount with parts square and symmetrical.
F.
Anchorage: whether indicated on Drawings or not.

1. Anchor or harness piping with mechanically couplings or similar joints to
prevent separation of joints in all exposed locations where coupling is subject
to internal pressure.
G.
Closures:
1. Make length adjustments as necessary by making cuts or by use of wrapper
plates.
2. Make wrapper plates the same thickness and material as pipe, full-fillet
double welded, and lapped no less than 65 mm. Make the lap no less than 75
mm between pipe ends.
3. Make closures after backfilling as near a practical and after pipe temperature
has had time to stabilize.
4. Make closures in early morning when air and pipe are coolest.
H.
Mitre cutting:
1. For bends up to 4- degrees, mitre by cutting one end.
2. For bends up to 22- degrees, mitre by cutting two adjacent ends.
3. For bends greater than 22- degrees, use fabricated bends.
I. Alignment:
Make horizontal and vertical deviation not more than 150 mm from lines shown on
Drawings, at any point.
No tolerance at manholes, valves or connections to existing pipelines.
J. Insulation of dissimilar piping material:
Electrically insulate connections between stainless steel and ductile iron, steel,
copper and other dissimilar piping materials for corrosion protection.
Make connections using non-conductive gaskets and bolt spacers/sleeves.
Use One piece sleeves and washers for bolt isolation.
K.Provide expansion joint for Low Pressure Air (LPA) pipe at maximum 30 meter
intervals.
Cleaning
A.
Remove dirt, rocks, debris and other foreign material from all pipelines.
For low pressure air remove all material greater than 1 micron in diameter.
Keep interior of pipe and fittings thoroughly clean before installation and until
work is accepted.
Take precautions to prevent entrance of foreign material during jointing, lining
repair and inspection operation.
B.
C.
Field Quality Control

Leaks:
1.
2.
3.
4.
5.
6.
7.
Vol 3, Section3
Make all joints and seams watertight and airtight whether tested or not.
Inspect all exposed shop and field welded seams.
Mark leaks clearly.
Do not remove marks until leak corrected.
Repair welded joints by grinding or chipping out defective parts and
rewelding.
Do not hammer welds.
Repair leaks discovered within 1 year after Taking- Over of Works at
Contractors expense.
Page E-50 of 115
E1.20
Specifications
Carbon Steel Pipe

This Section includes the specification of carbon steel pipe and applicable fittings identified in
the Pipe Schedule and within these Specifications documents
Quality Assurance
A. Reference Standards
American Society for Testing and Materials:
a.
ASTM A53 - Specification for Pipe, Steel, Black and Hot-Dipped, ZincCoatedWelded and Seamless
b.
ASTM A 47 - Ferritic Malleable Iron Castings
c.
ASTM A 105 - Standard Specification for Forgings, Carbon Steel, for
Piping Components.
d.
ASTM A 106 - Standard Specification for Seamless Carbon Steel Pipe
for High-Temperature Service.
e.
ASTM A 181 - Standard Specification for Forgings, Carbon Steel, for
General Purpose Piping.
f.
ASTM A 183 - Standard Specification for Carbon Steel Track Bolts and
Nuts
g.
ASTM A 193 - Standard Specification for Alloy-Steel and Stainless
Steel Bolting Materials for High-Temperature Service.
h.
ASTM A 194 - Standard Specification for Carbon and Alloy Steel Nuts
for Bolts for High-Pressure and High-Temperature Service.
i.
ASTM A 197 - Standard Specification for Cupola Malleable Iron.
J.
ASTM A 307 - Standard Specification for Carbon Steel Externally
Threaded Standard Fasteners.
k.
ASTM A 536 - Standard Specification for Ductile Iron Castings. I.
ASTM A 563 - Standard Specification for Carbon and Alloy Steel Nuts
2.
American Society of Mechanical Engineers

a.
ASME-17 Boiler and Pressure Vessel Code, Section Ix Welding and
Brazing Qualifications.
3.
American
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
National Standards Institute

ANSI B21 Pipe Threads.
ANSI B16.3 Malleable Iron Threaded Fittings.
ANSI B16.5 Pipe Flanges and Flanged Fittings.
ANSI B16.9 Factory-Made Wrought Steel Butt Welding Fittings.
ANSI B 16.11 Forged Fittings, Socket-welding and Threaded.
ANSI B16.25 Butt- welding Ends.
ANSI B16.39 Malleable Iron Threaded Pipe Unions.
ANSI B31.1 Power Piping.
ANSI B31.2 Fuel Gas Piping.
ANSI B31.3 Chemical Plant and Refinery Piping.
ANSI B36.1 0 Wrought Steel and Iron Pipe
4. American Water Works Association

a.
AWWA C207-78 Steel Pipe Flanges for Water Works Service - Size 4 in
through 144 in.
b.
AWWA C209-84-Cold Applied Tape Coatings for the Exterior of Special
Sections, Connections, and Fittings for Steel Water Pipelines
5. Chlorine Institute
a.
Comply with Chlorine Institute recommendations for all chlorine
pipelines operating under pressure.
Vol 3, Section3
Page E-51 of 115
B. Source
1.
2.
3.
Specifications
Quality Control:
All products shall be new.
Shop test pipe, in accordance with ASTM A312.
Hydrostatically test fabricated pipe.
C. Quality Control:
1. All welders certified per ASME-17, Section IX.
Pipe:
A. Pipe, 50 mm and smaller
1.
2.
3.
4.
Material: Carbon Steel, ASTM A 106.

Type: Seamless.
Grade: B.
Wall Thickness: Schedule 80, ANSI B36.10.
B Pipe, 65mm and larger

1. Material: Carbon Steel, ASTM A53.
2. Type: Seamless or Electric Resistance Welded. Use only Seamless piping for
chlorine gas
3. Grade: B, Type S.
4. Wall Thickness: Schedule 40. Use Schedule 80 for Chlorine pipelines operating
under pressure.
C. Joints
1. Pipe. 50mm and smaller
a.
Threaded: ANSI B2.1.
2. Pipe, 65mm and larger
a.
Flanged: ANSI B16.5, Class 150, and ASTM 105
b.
Butt-welded.
D. Fittings
1.
50mm and smaller

a.
Joint: Threaded.
b.
Rating: Class 150 for Malleable Iron; Class 125 for Cast Iron. Use
1364 kg CWP forged steel fittings for chlorine gas (pressure).
c.
Material: Malleable iron ASTM A 197 or cast iron ASTM A 126.
d.
Dimensions: ANSI B16.3
2. 65mm and
a.
b.
c.
d.
e.
larger
Joint: Butt-welded.
Rating: Standard weight, Class D, High Pressure, Class E
Material: Carbon steel, ASTM A234, Grade WPB.
Dimensions: ANSI B16.9.
Use Class E Flanges for all service categories with test pressures in
excess of 15 Bar.
3. 65mm and larger

a.
Joint: Grooved End.
b.
Material: Malleable iron ASTM A47 or ductile iron ASTM A536.
c.
Grooved or shouldered ends to accept mechanical couplings without
field preparation.
Vol 3, Section3
Page E-52 of 115
d.
Specifications
Manufacturer: Victualic, Gustin-Bacon, or equal.
4. Unions, 50mm and smaller

a.
Rating: Class 150 or equivalent to fittings
b.
Material: Malleable iron, black, ASTM A 197, brass to iron seat. Use
Ammonia type union with lead washers for chlorine gas (pressure).
c.
E.
Flanges
1. Type: Weld-neck or slip-on.
a.
Material: Forged carbon steel, ASTM A 105.
b.
Raised-face.
c.
Rated: Standard Weight, Class D 1.03 N/mm2 (150 psi), High Pressure
Class E,1.9 N/mm2 (275 psi)
d.
Dimensioned: ANSI B16.5.
e.
Use Class E Flanges for all service categories with test of 15 Bar.
2.
When mating with a cast iron flat faced flange, machine off steel flange raised
face or provide suitable spacer plate designed for full contact with the flat
faced flange.
3.
Grooved end pipe adapter flange:

a.
Material:
1.
2.
b.
Malleable iron, ASTM A47, or

Ductile Iron, ASTM A536.
Rated: Standard Weight, ANSI Class125, High Pressure,ANSI Class 300.
F.
Grooved- end Couplings

1.
Type : Rigid
2.
Material:
a.
Malleable iron, ASTM A47, or
b.
Ductile Iron, ASTM A536
3.
Rated: Standard Weight, ANSI Class 125, High Pressure, ANSI Class 300.
G.
Gaskets
1.
Flanged Joints:
a. Material: Cloth insert rubber
b. Thickness: 3.2 mm
2.
Grooved end Joints:
Material: EPDM or Chlorinated butyl; ASTM D2000.
Dimensions: AWWA C606.
Galvanised Steel Pipe

A.
Pipe.
1.
2.
3.
Vol 3, Section3
Material: Galvanized Carbon Steel, ASTM A120.

Type: Welded or Seamless.
Wall Thickness: Schedule 40.
Page E-53 of 115
B.
Joints
1.
C.
Specifications
Threaded: ASTM A 120
Fittings
1.
2.
3.
Joint: Threaded
Material: Malleable iron ASTM A47 Galvanizing to ASTM A 153
Dimensions: ANSI B16.3
Couplings
A.
Screwed Coupling
1.
2.
Material Malleable iron, ASTM A197 or A47.

B. Grooved-end Pipe Couplings

1.
Material:
a.
Malleable iron, ASTM A47, Federal Specification QQ-1-666C, Grade 11.
b.
Ductile iron, ASTM A536.
Bolting
A. Class 150 and 300 Raised-Face Flanges.
1.
Bolts: Carbon Steel, ASTM A307, Grade A, hex head.
2.
Nuts: Carbon Steel, ASTM A563, Grade A, hex head.
B. Grooved-end Joints.
1.
Bolts: Heat-treated carbon steel, ASTM A 183.
2.
Nuts: Heat-treated carbon steel, ASTM A 183.
3.
Tensile strength: 758 N/mm2, minimum.
C. Insulating Flanges (steel).
1. 3.2 mm undersize bolting material.
2. Bolts: ASTM A 193, Grade B7 Alloy stud.
3. Nuts: Carbon Steel, heavy hex, ASTM A 194, Grade 2H.
Thread Lubricant
Teflon Tape.
Welding
A. General: In accordance with the latest editions of API 1104, ASME-17 and
ANSI 831.1 and 831.3.
B. Performance Qualifications:
1.
Vol 3, Section3
Qualify all welders and welding operators before performing welding under
this section. Perform welder qualification tests in accordance with Article
III of ASME17.2. Qualify welders and operators in the performance of
making groove welds in carbon steel pipe.
Page E-54 of 115
Specifications
C Identification of Welds: Mark each weld with a symbol identifying the person who made
the weld.
D. Procedure:
1.
2.
3.
No welding shall be performed if there is any rain, high wind or other

inclement weather in contact with the weld area or if the ambient
temperature is below Design Operating Conditions.
If the ambient temperature is less than Design Operating Conditions, local
preheating to a temperature warm to the hand is required.
Tack weld piping into position.
a.
b.
c.
Remove tack welds if not made by a qualified welder using the same
procedure as for the completed weld.
If not removed, make tack weld with an electrode the same as, or
equivalent to, the electrode to be used for the first weld pass.
Remove cracked tack welds.
4.
Clean each layer of deposited weld metal with a power-driven wire brush,
prior to depositing each subsequent layer of weld metal, including the final
pass.
5.
Chip or grind out surface defects which will affect the soundness of the weld.
6. Weld Passes:
a. 150mm and Larger Pipe: Minimum of three weld passes using the
specified covered electrode.
b. 100mm and Under Pipe: Minimum of a full root and second pass.
7.
8.
Welds: Free of cracks, incomplete penetration, weld undercutting, excessive

weld reinforcement, porosity, slag inclusions, and other defects in excess of
the limits prescribed in Chapter V of ANSI 831.3.
Branch Connections: Fit and groove-weld in accordance with the details
described and shown in Chapter V of ANSI 831.3.
Fabrication
A.
End Preparation:
1.
Machine shaping of pipe ends is the preferred method.
2.
Oxygen or arc cutting is acceptable only if the cut is made smooth and true with
all slag removed either by chipping or grinding.
3.
Bevelled Ends for Butt Welding: Meet the requirements of ANSI B16.25.
B. Cleaning: Clean surfaces free of paint, oil, rust, scale, slag, or detrimental to welding.
C. Alignment and Spacing:
1.
2.
Align ends to be joined within existing commercial tolerances on diameters,

wall thicknesses, and out-of-roundness.
Root Opening of the Joint: As stated in the welding procedure specification as
specified in Article II of ASME-17.
Flanged Joints
A. Take care in bolting to avoid restraint on opposite end that would prevent uniform pressure
application on gasket.
Vol 3, Section3
Page E-55 of 115
Specifications
B. Pipe or fitting free to move in any direction while bolting.

C. Gradually tighten bolts, in turn, at uniform rate. Follow manufacturer's recommendations.
D. Ensure that stresses are not transmitted to equipment or valve flanges by connecting
piping.
E. Permanently support pipe to equipment to obtain accurate matching of bolt holes and
uniform contact over surface of flange, before installing bolts.
E1.21
Mechanical Joints - General

Other than in cases where welding is used, or where detachable mechanical couplings
(Clause E1.24) are used, all pipes shall be provided with a complete mechanical jointing
system by the pipe manufacturer. All components of the jointing system shall be mutually
compatible, and shall be capable of providing a lasting watertight seal under the specified
operating conditions, and in the specified tests. The design and assembly of the joint shall
be such that the stresses developed in the pipes, and joint components, do not cause
harm.
Unless otherwise specified, pipes shall be provided with an appropriate mechanical jointing
system as specified.
E1.22
Flanged Joints for Iron and Steel Pipework

Flanges for grey and ductile iron pipes and fittings shall have at least a 16 bar pressure
rating and be drilled accordingly.
Where an item to which a flange is to be jointed is drilled differently then the flange shall
have a thickness appropriate to a 16 bar pressure rating but shall be drilled to suit.
E1.23
Flange Gaskets
Gaskets for use on water supply pipelines shall be manufactured from ethylene propylene
rubber (EPDM or EPM) and shall comply with the requirements of Clause E1.3.
Gaskets shall be 3.2mm thick and dimensioned to the full face of the flange to suit the
flange bolting.
The rubber hardness (measured in International Rubber Hardness Degrees - IRHD) shall
be in the range 66 to 75.
Gaskets shall be stored in a clean, cool condition out of direct sunlight and without being
deformed.
E1.24
Flexible Mechanical Couplings and Flange Adapters

Flexible mechanical couplings and flange adaptors shall be of an approved type and design
and shall be compatible in all respects with the pipes or fittings to which they are
connected. They shall be designed to withstand the maximum hydraulic works test
pressure specified for the pipeline.
Couplings shall consist of a central sleeve and two end rings retaining elastomeric sealing
rings; the end rings shall be tightened by an adequate symmetrical bolting system or, for
sizes up to 60mm outside diameter only, screw threaded to the central sleeve.
Unless otherwise specified, central sleeves of couplings shall be provided without integral
registers or locating plugs.
All nuts, bolts, and washers shall be galvanised unless otherwise specified.
Vol 3, Section3
Page E-56 of 115
Specifications
Anchored, harnessed or other special couplings or flange adapters shall be provided as

detailed on the drawings, or otherwise indicated
Couplings shall be capable of accepting the minimum angular and axial movements shown
in the following table whilst subjected to the internal Site test pressure without leakage,
without direct contact between pipe and coupling at any point, and without inducing
stresses or strains in the pipe that exceeds safe working limits:
Deflection Criteria for Couplings and Flange Adaptors
Nominal Diameter
Up to
600
601750
751900
9011200
12011800
greater than
1800
Deflection Angle
6o
5o
4o
3o
2o
1o
Axial Movement (mm)
The minimum deflection angles and axial movements accepted by flange adapters shall be
fifty per cent of the values specified above for couplings.
Axial movement shall be achieved by deformation of the elastomeric sealing ring.
Protective coatings shall be as specified elsewhere and applied in accordance with the
requirements of Section G of this Specification. If not specified elsewhere, couplings and
flange adapters shall be shop painted with one coat of red pigmented chlorinated rubber
primer paint for protection in transit.
E1.25
Flexible Joints - Sleeve and Integral Socket Types

This clause applies to sleeve-type joints and integral spigot and socket joints with or
without a detachable mechanical (bolted) gland ring assembly.
Unless specified elsewhere for particular pipe materials, or pipeline duties the completed
joints shall be capable of accepting the following ranges of deflection and load whilst
subjected to the internal Site test pressure without leakage, without direct contact
between socket (or sleeve) and spigot, and without inducing stresses or strains in the pipe
that exceed safe working limits:
Angular Deflection: (all materials)
Nominal Pipe Diameter
(mm)
Minimum Angle
(degrees)
up to 200
3.0
201 to 500
1.5
501 to 1350
1.0
greater than 1350
0.5
Axial Movement:
Not less than 10mm or the following proportions of the length of the longest pipe or rigidly
jointed pipeline unit at any joint:
Vol 3, Section3
Page E-57 of 115
Specifications
Pressure Pipelines
Non-Pressure
Pipelines
Steel, ductile and grey iron, asbestos

cement, cement and concrete
0.2%
0.1%
Polyethylene
2.3%
1.0%
uPVC and RTR
0.7%
0.3%
ABS
1.2%
0.5%
Shear:
Joints for rigid pipes shall be capable of accepting a shear load equivalent to 20N per mm
of pipe diameter.
Joints for flexible pipes shall be capable of accepting a shear load induced by a 5%
elliptical deflection of the spigot end forming part of the joint.
If the approved Standard does not include a shear test for the jointing system, the test
shall be as instructed by the Engineer.
E1.26
Elastomeric Joint Sealing Rings

Elastomeric sealing rings for water supply pipelines shall be manufactured from ethylene
propylene rubber (EPDM or EPM) and shall comply with the requirements of Clause E1.3.
Sealing rings for use on sewage pipelines may alternatively be manufactured from styrene
butadiene rubber (SBR).
All sealing rings shall have physical and chemical properties, including hardness (measured
in International Rubber Hardness Degrees - IRHD), compatible with the pipe material.
Sealing rings shall be stored in a clean, cool condition out of direct sunlight and without
being deformed.
Rings for use with thermoplastic pipes shall contain no component which can react with
the material of the pipes.
E1.27
Lubricants for Joint Assembly

Lubricants for the assembly of pipeline joints shall be inert so as not to damage the pipes
or joint components and, for water supply pipelines, shall comply with the requirements of
Clause E1.3. Lubricants other than those recommended by the pipe or joint supplier shall
not be used without the Engineer's approval.
E1.28
Granular Materials for Pipe Bedding and Surrounds

Granular material for pipe bedding and surrounds shall be sand, gravel or crushed rock as
indicated in the following table. Selected excavated material (see Clause E1.29) may be
used only in the cases indicated.
Vol 3, Section3
Page E-58 of 115
Specifications
Suitability of Bedding Materials for Various Group A and B Pipeline Installations

Pipe
Material
Group
Installation
Characteristics
Suitability of Bedding Material
Gravel or
Crushed
Rock
Sand
Selected
Excavated
Granular bedding
BB
Yes
Yes
No
Granular surround
SO
Yes
No
No
SO
Yes
No
No
SO
Yes
Yes
No
SO
Yes
Yes
Yes
Non-pressure pipes
under 50000N/sq.m
stiffness and
pressure pipes under
5000 N/sq.m
stiffness
Non pressure pipes
over 50 000 N/sq.m
and under 100 000
N/sq.m stiffness and
pressure pipes over
5000 N/sq.m and
under 100 000
N/sq.m stiffness
Non-pressure pipes
over 100 000 N/sq.m
stiffness and
pressure pipes over
10 000 N/sq,m
stiffness
Bed
Type*
As depicted on the Drawings
Material for gravel beds shall be free- draining, hard, clean, chemically stable natural
gravel, crushed stone or crushed slag, graded in accordance with the following table:
Granular Material Gradings for Pipe Bedding and Surround
Percentage by Mass Passing
Test Sieve
For Pipes of
Diameter
400mm and
above
For Pipes of
Diameter 600mm
and below
63 mm
37.5 mm
100
Vol 3, Section3
Page E-59 of 115
Specifications
20 mm
85-100
14 mm
100
10 mm
0-50
85-100
5 mm
0-10
0-25
2.36 mm
0-5
The material for sand beds shall contain not less than 90% passing a 5mm sieve and not
more than 10% passing a 0.2mm sieve, and shall have a compaction fraction value not
exceeding 0.2 when determined in accordance with the following test:
A sample of the material proposed for use shall be submitted to the Engineer for his
testing and written approval well in advance of the time when it will be needed on Site; in
the event that the sample material is not satisfactory, the Contractor shall adjust the
proportions of the constituents of the material, or obtain alternative materials, until a
satisfactory material is obtained, and this shall be used in all relevant parts of the Works
unless the Engineer gives written approval for an alternative material. The Engineer may
from time to time require the Contractor to submit further samples for routine testing and
the Contractor shall have available on the Site at all times throughout pipelaying the
apparatus necessary to carry out the tests required.
Pipe bedding material to concrete pipes shall not contain more than 0.3 per cent sulphate,
expressed as sulphur trioxide.
For all thermoplastic and polythene wrapped DI pipes only rounded aggregates will be
permitted but for all other pipe materials crushed aggregates may also be used.
Beds and surrounds for small diameter service pipelines of 100mm diameter and less
which are for pipe protection only and are not required for structural support shall be
approved sands free from particles larger than 5mm.
A sample of the material proposed for use shall be submitted to the Engineers for his
testing and written approval well in advance of the time when it will be needed on Site; in
the event that the sample material is not satisfactory, the Contractor shall adjust the
proportions of the constituents of the material, or obtain alternative materials, until a
satisfactory material is obtained, and this shall be used in all relevant parts of the Works
unless the Engineer gives written approval for an alternative material. The Engineer may
from time to time require the Contractor to submit further samples for routine testing, and
the Contractor shall have available on the Site at all times throughout pipelaying the
apparatus necessary to carry out the tests required.
E1.29
Selected Excavated Material for Pipe Bedding and Surrounds

This material shall be a consistent quality, well graded, inert and free from roots or other
vegetable matter, building rubbish or debris, any clay lumps or stones retained on a 25mm
mesh sieve, minerals that may be dissolved in groundwater or other deleterious materials.
E1.30
Maintenance of Quality
The requirements of the Specification relating to the quality, performance and finish of pipes
and pipeline components, will apply to their condition as installed. The certification or
approval of items at the manufacturers works, at a stockyard, or at any other temporary
location, will in no way relieve the Contractor of his responsibilities for the condition of the
items when installed.
Vol 3, Section3
Page E-60 of 115
Specifications
Any damage, or circumstances capable of giving rise to damage, shall be reported

immediately to the Engineer, who will give instructions regarding the testing and/or repair of
the suspect items.
Any protective lining, coating or wrapping damaged during construction shall be repaired as
soon as is practicable after the damage occurs in order to limit the extent of any resulting
corrosion. Any such damage which cannot, in the opinion of the Engineer, be satisfactorily
repaired in-situ shall render the item or items concerned liable to rejection and they shall be
replaced by the Contractor at his own expense.
Where pipes and pipeline components have been purchased separately by the Employer, and
are handed over to the Contractor for installation, the Contractor shall, before moving or
using any of the items, visually inspect them, and immediately notify the Engineer of any
damage, deterioration, or suspicious circumstances. Failure to do this will result in the
Contractor being held responsible for any damage coming to light after he has taken over the
materials.
Unless otherwise instructed by the Engineer, the Contractor will not be required to carry out
tests, or examinations other than visual, at the time of taking over, and will not be held
responsible for any not visually apparent defects originating prior to the time of taking over.
The Contractor will, however, be responsible for insuring the items against all normal risks,
from the time of taking them over.
Vol 3, Section3
Page E-61 of 115
Specifications
E2
TYPE TESTING, ROUTINE TESTING, AND VISUAL INSPECTION OF PIPES
E2.1
Pipes shall be subjected to "Type" and "Routine" testing in accordance with the
frequencies stipulated below and in the following clauses. This requirement is additional to
any further requirements of the approved Standard to which the pipes are manufactured.
where specified test requirements differ from those given in the approved Standard, the
more stringent requirement shall apply.
Pipes to be coated at the place of manufacture shall have all hydraulic and pressure
testing completed prior to application of the coating.
Test certificates for all pipes shall be submitted to the Engineer for approval.
The Engineer or his appointed Inspecting Engineer may require to witness any of the
stages of manufacture or any of the tests and free access shall be provided by the
manufacturer during all working hours for such purposes. Adequate notice of the time and
place of all prescribed testing shall be given.
(i)
"Type" Tests are required to prove the design of a component or assembly and
shall be carried out whenever there is a change of design, of type of material or
method of manufacture. The number of tests performed shall be sufficient to
demonstrate consistent performance within the prescribed range. For long term
tests and/or provided consistency of material quality and dimensions of
construction can be demonstrated, certified manufacturer's test results may be
accepted.
(ii)
"Routine" Tests are required as a means of quality control to demonstrate

consistency and adequacy of materials and production techniques. Testing shall be
carried out at the sampling frequency described below in which the number of
units in a batch shall be taken as the number of joints, and batches shall be
distinguished by diameter and manufacturing group.
(a)
For all pipes:

No. of Units in
Batch
up to 50
51 to 150
151 to 250
251 to 500
501 to 1000
over 1000
No. of Units in
First Sample
No. of Units in
Second
Sample
2
4%
3%
2%
1.5%
1%
5
8
10
14
20
2%
Limiting
Failures for
Acceptance
of Second
Sample
1
2
2
3
4
20% of sample
Samples shall be selected on a random basis.

Any failure in the first sample shall necessitate the testing of a separate
second sample. Provided the number of failures in the second sample is
less than or equal to the limiting number quoted, then the batch will be
accepted, excluding those sample pipes which have failed.
Vol 3, Section3
Page E-62 of 115
Specifications
If a batch fails the manufacturer may request either:
(b)
(1)
Having the batch passed for a lower pipe class if a lower class is
required and if the sample test results permit acceptance for that
class in which case the pipe shall be marked as "derated to Class
...".
(2)
The testing of all pipes in the batch for those tests which have
failed the sampling criteria to enable pipes to be passed
individually. In such a case the manufacturer will accept all costs
of the Employers Representatives Inspector.
For Pressure Pipes:

In addition to the prescribed sample testing, the internal pressure test
only shall be carried out on every pipe and joint to be supplied and pipes
and/or joints will be accepted or rejected individually. Satisfactory
pressure test certificates shall be provided for every pressure pipe and
joint supplied.
In addition to the prescribed testing, pipes shall be subjected to visual inspection

at the place of manufacture and at Site and may be rejected if pipes are
incorrectly marked or have defects outside the ranges permitted.
E2.2
Visual Inspection Requirements for Group A (Rigid) Pipe & Pipeline Components
All pipes and pipeline components will be subject to visual inspection at any time and, if
found unsatisfactory may be rejected or, where permitted, repaired. Cutting of pipes to
permit use of undamaged or unaffected sections may be permitted provided the distance
from the unacceptable defect to the cut is not less than one metre.
TABLE D5
Visual Inspection Requirements for Group A (Rigid) Pipes
Condition
Requirements
Concrete
Vitrified Clay
Ellipticity
+ 3% on mean dia for

diameters up to 500.
+ 1% on mean dia for
diameters over 500
+ 2% on mean diameter.
Variation in
wall thickness
+ 5% of mean thickness
at any pipe cross section.
y+ 5% of mean thickness at
any pipe cross section
Cracks
Unreinforced pipes shall

contain no cracks.
There shall be no cracks

running in a longitudinal
direction, and no cracks of
length 25mm running in a
circumferential direction.
Vol 3, Section3
Page E-63 of 115
Specifications
Condition
Requirements
Concrete
Vitrified Clay
Voids, chips and

cavities.
There shall be no honey combing or open texture.
There shall be no broken

blisters and no chips or other
cavities measuring more than
25mm in a longitudinal or
50mm in a circumferential
direction or 0.25 times the
pipe wall thickness in depth.
Protruberances
There shall be no
protruding aggregates.
There shall be no
protruberances of any sort
extending more than 2mm
from the normal surface.
There shall be no blisters of

diameter 50mm or height
2mm
There shall be no
protuberances extending
more than 2mm from the
normal internal surface.
Other
Where glazing is specified not

more than 5% of the surface
area (excluding pipe ends)
shall be free from glaze.
E2.3
Not Used
E2.4
Type and Routine Tests for Metal Pipes

The tests required in respect of steel and ductile iron pipes are indicated in the following
table:
Steel
Ductile
Iron
Burst pressure
Joint watertightness
Yes
Yes
Yes
Chemical analysis
Yes
Tensile test
Yes
Yes
Modulus of rupture
Yes
Charpy impact
Yes
Flattening test
Yes
Yes
Type Tests
Deflection test (for mortar lined pipes)

Routine Tests
Vol 3, Section3
Page E-64 of 115
Specifications
Ductile
Iron
Steel
Weld bend test
Yes
Brinell hardness
Yes
Hydrostative test
Yes
Yes
Weld inspection
Yes
Note:
Additional tests for small diameter steel pipes are specified

in Clause E1.18.
The flattening, and weld bend tests for steel pipes are
alternatived tests, and it will not normally be required to
perform both tests.
E2.5
Visual Inspection Requirements for Metal Pipes

All steel, ductile iron, and grey iron pipes and pipeline components will be subject to visual
inspection at any time, and, if found unsatisfactory shall be rejected, or, where permitted,
repaired. Cutting of pipes to permit use of undamaged or unaffected sections may be
permitted provided the distance from any unacceptable defect to the cut is not less than
one metre.
Condition
Steel
Requirements Ductile
Iron
Elipticity
+ or - 1%
+ or - 1%
Dents and Buckles
None
None
Laces and Laps
None exceeding 30% wall

thickness
Cracks and Tears
None deeper than one third wall

thickness or one eighth wall thickness
over a length of one quarter pipe
diameter. Defects deeper than one
eighth wall thickness, but not
exceeding above criteria, shall be
made good by welding.
None
Pits and Voids
Ditto
None
Mortar Lining
The maximum crack width, or radial displacement, in all types of iron

and steel pipe shall not exceed the following values:
Pipe Diameter (mm)
Maximum Dimension (mm)
80
0.8
100-600
1.2
700-1200
1.5
over 1200
Vol 3, Section3
Page E-65 of 115
2.0
E2.6
Specifications
Type and Routine Tests for Thermoplastic and RTR/GRP Pipes

The tests required in respect of pipes manufactured from thermoplastic and RTR materials
are indicated in following table:
Type and Routine Tests for Thermoplastic and RTR Pipes
PE
ABS
PVC
RTR/
GRP
Type Tests
Deflection
Stress rupture (pressure pipes)
Strain corrosion
Environmental stress cracking
Creep
Joint watertightness
Yes
Yes
Yes
Yes
-
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Routine Tests
Stiffness
Heater reversion
Watertightness (gravity pipes)
Pressure (pressure pipes)
Water bath
Acetone immersion
Barcol hardness
Fracture toughness
Yes
Yes
Yes
Yes
Yes
-
Yes
Yes
Yes
Yes
Yes (1)
Yes
Yes
Yes
Yes
Yes
-
Note: (1) PVC only

(i)
Deflection Test:
Short sections of sample pipe shall be vertically compressed between rigid parallel
flat plates for periods of one minute, and the pipe inspected for damage at various
deflections. Deflection shall be measured as percentage shortening of the vertical
diameter.
For thermoplastic pipes, the test deflections are as follows:
Minimum Crack and Failure Deflections for Thermoplastic Pipes
Pipe SDR
(1)
10
20
30
40
50
60 or more
Vol 3, Section3
% Deflection
No Crazing
or
Cracking
No Failure
of Wall
1.75
3.50
5.25
7.00
8.75
10.00
20
20
20
20
20
20
Page E-66 of 115
Specifications
Note: SDR (standard dimension rates) is included as the mean pipe diameter
measured at the midpoint of the wall divided by the wall thickness
In addition the deflections at which crazing and/or cracking of the inner
and outer surfaces of the pipe first occur shall be noted, and also the
deflection at which failure occurs. The pipe deflection shall be
progressively increased to the extent which is necessary to enable these
points to be established. For the purpose of this test wall failure shall be
defined as the formation of any discontinuity extending throughout the
thickness of the pipe wall.
(ii)
Stress Rupture Test:

Two representative pipes for each combination of class and pipe diameter shall be
tested for each material. The tests shall consist of maintaining the sample pipe at
constant temperature and effective internal pressure for a specific period as
indicated below:
(a)
For thermoplastic pipes:
Stress Rupture Tests for Thermoplastic Pipes

Test 1
Stress
Mpa
Test 2
Time &
Temperature
Stress
MPa
Time &
Temperature
Test 3
Stress
MPa
Time &
Temperature
PVC-U
42.0
1 hour
@ 20C
35.0
100 hours
@ 20C
12.5
1000 hours
@ 60C
PE/MRS
100
12.4
100 hours
@ 20C
5.5
165 hours
@ 80C
5.0
1000 hours
@ 80C
PE/MRS
80
10.0
100 hours
@ 20C
4.6
165 hours
@ 80C
4.0
1000 hours
@ 80C
PE/MRS
63
8.0
100 hours
@ 20C
3.5
165 hours
@ 80C
3.2
1000 hours
@ 80C
PE/MRS
40
7.0
100 hours
@ 20C
2.5
165 hours
@ 80C
2.0
1000 hours
@ 80C
PE/MRS
32
6.5
100 hours
@ 20C
2.0
165 hours
@ 80C
1.5
1000 hours
@ 80C
Note: The effective internal pressure for each test shall be that pressure which produces
a stress in the pipe wall of magnitude not less than the indicated value.
(b) For thermosetting pipes (RTR/GRP) the test pressures shall be related to
thepressure rating (PR) of the pipe as follows:
Vol 3, Section3
Page E-67 of 115
Specifications
Test No.
Temperature
Pressure
Duration
20
C
6 x PR
1 hour
80
C
4 x PR
1 hour
80
C
2.7 x PR
170 hours
80
C
2.3 x PR
1000 hours
No pipe shall fail in a time less than that stated for the particular test.
Stress rupture testing carried out at temperatures, pressures and
durations other than those indicated may be accepted as indicating
compliance provided that at least two samples for each combination of
class, diameter and material have been tested for a duration of not less
than 1000 hours and that the test data indicates a regression not inferior
to that indicated by the tabulated requirements.
(iii)
Strain Corrosion Test:

A programme of strain corrosion testing shall be carried out for each design of
RTR pipe. Provided that the materials employed in the pipe construction, the gelcoat thickness, the laminate design, and all other relevant aspects, remain
effectively similar then tests will not be required for all pipe diameters.
For each design a minimum of 18 samples shall be tested by measuring the time
to failure at various levels of pipe wall bending strain in the presence of 0.1
normal sulphuric acid.
The sample pipe rings shall be strained, by vertical deflection, to various levels
such that the number of failures occurring within various periods shall comply with
the following:
Time to Failure
(Hours)
No. of Failure
Points
10 to 1000
At least 4
1000 to 6000
At least 3
More than 6000
At least 3
More than 10000
At least 1
The performance of the samples tested shall be such as to indicate a minimum

time to failure at 0.9% strain of 50 years. In addition, the tests shall indicate that
the pipe can sustain the strains associated with the deflections stipulated in
Clause D3.1.16 for at least 50 years, if these strains exceed 0.9%.
Any of the following shall constitute failure of the sample:
fracture of the pipe wall;
passage of liquid through the pipe wall;
evidence of delamination;
lifting and cracking of resin surface;
blistering of more than 25% of the wetted surface area.
Vol 3, Section3
Page E-68 of 115
(iv)
Specifications
Environmental Stress Cracking Resistance Tests of Polyethylene:

The resistance of polyethylene materials to environmental stress cracking shall be
tested by measuring the time to failure of notched specimens subjected to flexural
stress and immersed in an appropriate surfactant which is not absorbed by the
material.
(v)
Flexural Creep Test:

For each thermoplastic material, or for each laminate design of RTR, three sample
pipe sections shall be tested as follows:
The samples shall be subjected to a parallel-plate or two-edge line loading, applied
uniformly along the length of the sample, such as to produce an immediate
deflection of 1% of the pipe diameter. For each sample the deflection shall then be
remeasured after elapsed times of 0.1 hours and 100 hours under continuous
constant load.
For each sample the ratio which the deflection at 100 hours bears to the deflection
at 0.1 hours shall be calculated. The resulting ratios shall not exceed the values
shown in the following table.
Creep Deflection Tests for Thermoplastic Pipes
Average Creep
Deflection Ratio of
Three Samples
Maximum Creep
Deflection Ratio of
Any One Sample
Polyethylene
2.5
3.0
PVC and ABS
1.75
2.0
RTR/GRP
1.4
1.5
Pipe Material
The tests shall be carried out at a temperature of 20oC + 1oC, and the samples
shall have a length of 1/5 pipe diameter, or 300mm for pipe diameters less than
1 500mm.
(vi)
Stiffness Test:
Pipe stiffness shall be determined by parallel plate loading on sample pipe sections
having lengths of 1/5 pipe diameter or 300mm for pipe diameters less than 1
500mm, at a temperature of 20oC + 1oC.
The total load on the sample shall be measured at deflections of 3% and 5%.
The pipe stiffness shall be calculated as EI/D3 = K x load/deflection where the
load is measured in newtons per linear metre and the deflection in metres. K shall
have a value of 0.01935 at 3% deflection and 0.0199 at 5% deflection.
(vii)
Heat Reversion Test:

Heat reversion testing of thermoplastic pipes shall be carried out at the rate of one
sample pipe per production machine per 8 hours operation.
The tests shall be carried out by measuring the change in dimension, parallel to
the pipe axis, between two points in the pipe barrel after the pipe as been heated
Vol 3, Section3
Page E-69 of 115
Specifications
to, and maintained at, a temperature of 120oC for a period of 30 minutes and then
allowed to return to room temperature.
The change in length shall not exceed 2% for polypropylene plastics, and 5% for
other thermoplastics.
(viii)
Watertightness Testing:
Pipes for non pressure applications shall be subject to watertightness testing at
the place of manufacture. Wherever possible the testing of pipes and joints shall
be carried out simultaneously.
Sample pipes shall be subjected to an internal hydrostatic pressure of 1 bar, and
shall withstand this pressure for a period of one minute without distress and
without the appearance of water on the outside of the pipe.
(ix)
Internal Pressure Testing:

In addition to the internal hydrostatic pressure tests carried out in accordance with
the stress-rupture test requirements, pipes for pressure applications shall be
subjected to following internal pressure testing at the place of manufacture.
Wherever possible the testing of pipes and joints shall be carried out
simultaneously.
The sample pipes shall be subjected to an internal hydraulic pressure equal to the
pressure rating of the pipe, and shall withstand this pressure for a period of 30
minutes without distress and without the appearance of water on the outside of
the pipe.
(x)
Water-bath Test for Polyethylene Pipes:

Polyethylene pipes shall be tested to ensure that oxidation of the material has not
occurred during extrusion or otherwise during manufacture.
Testing shall consist of cutting a sample ring from the pipe, the ring being a
complete cylindrical section of pipe having a length of approximately 50mm, and
immersing this sample in water at a temperature of 80oC (+2o) for a period of 24
hours. The sample shall then be removed from the water-bath and allowed to dry
in air without wiping or other intervention. The appearance of any form of coating
on the surface of the pipe shall constitute failure of the test.
(xi)
Acetone Immersion Test for uPVC Pipes:

Suitably sized samples shall be cut from uPVC pipes such that a substantial
proportion of the surface area of the sample is comprised of material from the
interior of the pipe wall. The sample shall then be immersed in acetone completely
free from water in a sealed container for 30 minutes at 20oC + 3oC. At the end of
this period there shall have occurred no flaking, delamination or disintegration.
Swelling of the sample, provided it is not associated with other deterioration, shall
not constitute failure.
(xii)
Barcol Hardness Test of Reinforced Thermosetting Resin:

Barcol hardness shall be measured by means of an indentor consisting of a
hardened steel truncated cone having an angle of 26o with a flat tip of diameter
0.157mm. Hardness tests shall be carried out on the cured pipe at the rate of at
least two tests per curing operation; thus the testing rate may only be less than
two tests per pipe if two or more similar pipes are simultaneously cured under
Vol 3, Section3
Page E-70 of 115
Specifications
identical conditions. The two test measurements shall be conducted one on the
outside surface and one on the inside surface of the pipe. The pipe surface shall
be adequately supported during testing so as to prevent flexure of the specimen.
Measurements shall not be taken within 10mm of the ends of the pipe or within
5mm of previous test compressions.
E2.7
Visual Inspection Requirements for Thermoplastic and RTR/GRP Pipes and

Pipeline Components
All thermoplastic and RTR/GRP pipes and pipeline components will be subject to visual
inspection at any time and, if found unsatisfactory shall be rejected or, where permitted,
repaired. Cutting of pipes to permit use of undamaged or unaffected sections may be
permitted provided the distance from the unacceptable defect to the cut is not less than
one metre.
These visual inspection requirements also apply to RTR/GRP joints and fittings which have
otherwise been manufactured in accordance with Section H of this Specification.
Visual Inspection Requirements for Thermoplastic and RTR/GRP Pipes
Condition
Requirements
Thermoplastics
Thermosets
Elipticity
+1% on mean diameter
+1% on mean diameter
Eccentricity
Pipe wall thickness measured at

any point must be such that the
Standard Dimension Ratio
calculated on that thickness is
within the stipulated range.
Pipe wall thickness must be within

+10% of design value at any point
and within +5% when the average
thickness is measured along any
single straight axial line the length
of the pipe.
Surface Finish
There shall be no crazing, flaking

or indication of disintegration.
There shall be no crazing of

external gel-coats or resin-rich
layers.
There shall be no evidence of

extrusion dye-marks or spiderlines.
Resin-dry areas not exceeding 6mm

dia externally may be accepted if
made good.
Scratches
None on internal surface.

External surfaces shall be free
from longitudinal scratches and
from circumferential scratches
longer than 5% of the pipe wall
thickness.
Scratches not exceeding 0.3mm

deep may be accepted without
repair. Scratches exceeding 0.3mm
deep but not exceeding 1mm deep
may be accepted if satisfactorily
made good.
Cracks
All pipes shall be completely free

from cracks.
Longitudinal cracks:
There shall be none on internal
surfaces. External cracks may be
accepted after repair if less than
200mm long.
Circumferential cracks:
No cracks shall be of sufficient
depth to expose glass fibres. Cracks
not exceeding 200mm length may
Vol 3, Section3
Page E-71 of 115
Specifications
Requirements
Condition
Thermoplastics
Thermosets
be accepted after repair.
"Star cracks" may be accepted after
repair if all cracks are contained
within a circle of 100mm diameter.
E2.8
Voids
No visible voids will be accepted.
Voids (or blisters) may be accepted

after repair if not greater than 2mm
diameter and 1mm depth provided
that not more than 0.5% of surface
area of pipe is affected.
Protuberances
Ridges or ripples shall not

exceed 0.5mm in height.
There shall be no protruding fibres

from the internal surface of the
pipe. Wrinkles, ridges and nipples
shall not exceed 3mm in height.
Inclusions
There shall be visible inclusions

of extraneous matter.
There shall be no visible inclusions

of extraneous matter other than
permitted fillers or aggregates.
Delamination
Not applicable.
There shall be no visible

delamination.
Holiday Detection Test

Coatings and linings which are required in the Specification to be subject to holiday
detection testing, shall be tested in accordance with the following procedure:
Factory applied coatings shall be tested at works. Site applied coatings and areas of
factory applied coatings which have been completed or repaired on Site or which may, in
the opinion of the Employers Representative, have suffered damage or have deteriorated
in any way which warrants a retest shall be tested on Site.
Unless otherwise permitted in writing by the Employers Representative, all coatings which
are to be tested in accordance with this clause (in whole or in part) shall be tested in the
presence of the Employers Representative or his appointed representative.
The apparatus for testing pipeline coatings shall consist of:
(i)
a low amperage, adjustable voltage, full wave rectified direct current output
detector;
(ii)
an exploring electrode of the wire brush, coil spring, conductive rubber or silicon
electrode, or other approved type capable of being moved in a controlled manner
across the surface of the coating under test;
(iii)
an audible alarm signal which shall be activated whenever the exploring electrode
passes over a defect in the pipeline coating under test;
(iv)
(v)
Vol 3, Section3
a "ground wire" to provide a low resistance connection between the apparatus

and the coating substrate;
a kilovoltmeter capable of detecting a single pulse and holding the reading for
sufficient time for the meter circuits and alarm to indicate the fault.
Page E-72 of 115
Specifications
The apparatus shall have a power rating of no more than 20 watts and an output voltage
variable up to 20 kilovolts.
The operating voltage of the equipment shall be selected to suit the type and thickness of
the coating to be tested and shall be determined from either:
(i)
the dielectric breakdown voltage per millimetre of coating thickness quoted by the
manufacturer;
The operating voltage for test purposes shall be the product of the above voltage
and the minimum allowable thickness of the coating in millimetres;
or:
(ii)
by using the apparatus to apply a steadily increasing voltage to an approved

sample area of the coating (the sample area shall be free of holidays and other
weaknesses) until sparking occurs due to breakdown of the coating. The voltage
shall then be steadily reduced until sparking ceases;
The operating voltage for test purposes shall be mid-way between the above two
voltage limits.
If the second method is used and the sample area forms part of the coating of an item to
be incorporated into the Works, the sample area shall be repaired to the satisfaction of the
Employers Representative upon completion of the test to determine the operating voltage.
Holiday detection testing shall only be carried out when:
(a)
the surface of the coating to be tested is completely dry;
(b)
the ambient air temperature exceeds 4oC;
(c)
the relative humidity of the ambient air is less than 85%.
Each coating to be tested for holidays shall be thoroughly and completely explored. The
electrode shall, insofar as is practicable, remain in contact with the coating surface
throughout the test and shall travel steadily across the surface at a speed within the
limitations recommended by the manufacturer of the testing apparatus or, in the absence
of such recommendation, at no more than 0.3 metres per second. All flaws, pinholes,
holidays and other defects discovered by the test shall be marked and shall be recorded
and reported to the Employers Representative or his representative.
Repairs to coatings shall be carried out only with specific permission from theEmployers
Representative and to his entire satisfaction. Items with coatings which include flaws,
pinholes, holidays or other defects shall not be incorporated into the works. Coatings
which are repaired as aforesaid shall be retested as described above.
All retesting and repairs to coatings shall be carried out at the Contractor's expense.
Vol 3, Section3
Page E-73 of 115
Specifications
E3
PIPELINE CONSTRUCTION
E3.1
Storage and Handling of Pipes

Method Statements must be approved for the transportation, handling and storage of
pipes before any pipes are delivered to site.
All pipes shall be handled and stored in compliance with the manufacturer's
recommendations subject to the following limitations: Pipes shall be transported, handled and stored with such packing and in such a manner
that damage does not occur and that contact is avoided with sharp edges which may
cause damage. During transit, pipes and fittings shall be well secured and adequately
supported along their length.
At every point of loading or unloading, all pipes or castings must be handled by approved
lifting tackle unless specified elsewhere. Unloading by rolling down planks or any other
form of inclined ramp will not be allowed. Pipes shall not be tipped or dropped.
Pliable straps, slings or rope shall be used to lift pipes, and steel cables or chains will not
be used without written permission.
Nesting of pipes for transportation will be permitted provided method statements
demonstrate that effective precautions will be taken to protect inner surfaces from
damage.
All pipes and fittings shall be thoroughly inspected on arrival at site after off-loading and
prior to installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other
damages, proposals for repairs shall be submitted in writing for the Engineer's approval. If
in the Engineer's opinion the nature of any damage is such that the condition of a pipe has
been impaired and cannot be repaired, the pipe concerned shall not be incorporated in the
Works.
Suitably smooth and level storage areas shall be provided at or near the site and made
secure to prevent unauthorised access.
Pipes of different sizes and thickness shall be stocked separately.
Glass Reinforced Plastic Pipes (GRP)
When pipes are transported or stacked they shall be supported on cradles at least 100 mm
wide, conforming to the shape of the pipe placed at not more than 3 metres centres. Pipes
must on no account be stacked directly on the ground but if individual pipes are placed on
the ground prior to laying care shall be taken to remove all rocks and any potentially
damaging debris.
The number of layers in a stack shall not exceed the following:
Internal Diameter
of Pipe (mm)
Up to 500
500 to 700
Vol 3, Section3
Maximum Number
of Layers
5
3
Page E-74 of 115
Specifications
The end pipes in each row shall be strapped to the battens. Pipes shall not rest on their
sockets.
Thermoplastic Pipes (uPVC)
Pipes and fittings of plastic materials smaller than 300 mm diameter may be handled
manually and those equal or larger than 300 mm diameter shall be lifted using a single
fabric or large diameter rope sling. There shall be enough slack in the sling to keep the
hook at least 600 mm over the pipe. Use of wire rope chains and fork lifts shall not be
permitted.
Care shall be taken to prevent distortion of the pipes during transportation, handling and
storage. They shall be stacked either on bearing timbers on a level surface staked to
prevent movement, or in suitable racks. Not more than two layers shall rest on the bottom
layer, and for spigot and socket pipes, sockets shall be at alternate ends so that no
pressure comes on a socket. Bearing timbers shall be spaced at not more than 1 metre
and shall be wide enough to prevent denting of the pipe wall. Sharp edges (e.g. of metal)
shall be avoided. Similar care shall be taken with pipes in transit.
Where shaped battens are used, they shall be at least 100 mm wide and not more than
1.5 meters apart. The end pipes in each row shall be strapped to the battens. The pipe
shall not be stacked any higher than five (5) layers.
All thermoplastic pipes shall be shaded/protected from direct sunlight during handling,
transportation, storage and laying.
The Contractor shall ensure that thermoplastic pipes do not come into contact with
bituminous or other hydrocarbon based materials..
E3.2
Trench Widths for Pipelines - General Requirements

The Contractor will be responsible for selection of actual trench width. In so selecting, the
Contractor shall take proper account of the needs to:
(i)
provide sufficient width to permit safe working and proper pipelaying procedures;
(ii)
minimise disruption of vehicular, pedestrian or other traffic;
(iii)
minimise the risk of damage to adjacent buildings, services or other installations;
(iv)
minimise possible loss of crops or other surface vegetation or amenity.
When no limitations on trench width are stipulated, the trench widths defined below shall
be used for measurement purposes.
For single pipelines, the nominal trench width shall be defined as 1.5 times the nominal
pipe diameter plus 300mm subject to a minimum trench width of 750mm.
For two or more pipes in the same trench, the nominal trench width shall be defined
as the sum of the nominal pipe diameters plus 450mm between the pipes plus 450mm.
The pipe bedding provided shall completely fill the whole width of the trench excavated,
and any additional material necessary to fill regions of overexcavation shall be provided
entirely at the Contractor's expense.
Where the actual trench width exceeds a specified maximum, then unless otherwise
agreed by the Employers Representative the volume produced by the additional width
Vol 3, Section3
Page E-75 of 115
Specifications
between the trench bottom and a plane 1000mm above the crown of the pipe shall be
filled with concrete at the Contractor's expense (minimum Grade blinding).
E3.3
Trench Widths for Flexible Pipes - Additional Requirements

Because flexible pipes (Group B) rely in part on the surrounding soil to resist the
development of excessive deflections it may be necessary, where trenches pass through
soft ground, to increase the trench width and replace the soft native soil with imported
material, or to introduce other measures to limit the pipe deflection. All such measures
shall be carried out according to the Employers Representatives instructions issued as
work proceeds.
In order that delays to construction arising from the above considerations may be
minimised the Contractor may be required to carry out in-situ measurements to establish
the deformation modulus of the native soil at the installation level of the pipe. Such
measurements shall normally be made using a Static Cone Penetrometer in advance of the
trench excavation. Where such penetrometer tests indicate a modulus of less than 9kg per
sq.cm for the native soil then one of the following forms of construction shall be employed
as instructed by the Engineer:
(i)
concrete haunching shall be provided between the pipe and the trench walls;
(ii)
trench sheeting shall be left in below a level of 300mm above the top of the pipe, or
such higher level as theEmployers Representativemay direct;
(iii)
precast concrete (or other approved material) slabs, having a height of 500mm or
one pipe diameter, whichever is greater, shall be placed vertically in the granular
bedding material at the sides of the pipe midway between the sides of the pipe
and of the trench;
(iv)
as an alternative to any of the above measures where considerations of available

space, practicality and economics permit, the trench width may be increased to at
least the minimum value obtained from the following table.
Trench Width Criteria for Flexible Pipes
Static Cone Penetrometer
Modulus (kg/cm)
Minimum Trench Width
less than 9
less than 8
less than 7
less than 6
less than 5
less than 4
2.5 x Pipe Diameter

3 x Pipe Diameter
3.5 x Pipe Diameter
4 x Pipe Diameter
4.5 x Pipe Diameter
5 x Pipe Diameter
Notes:
(a)
Where the static cone penetrometer test value is less than 3kg/cm2 a
construction method other than wide trench will normally be required.
(b)
For pipelines of small diameter (less than 100mm) little or no increase in

trench width, beyond the minimum required for safe construction, may be
necessary in order to obtain the required structural width.
Vol 3, Section3
Page E-76 of 115
E3.4
Specifications
Pipelaying - General
Pipes shall be laid and jointed in accordance with all relevant recommendations of the
manufacturer. Any variations between the manufacturer's recommendations and this
specification shall be notified to the Engineer and installation of pipes shall not commence
until the conflict has been resolved. All pipelaying shall be performed by experienced and
competent pipelayers.
The joints and interiors of all pipes and fittings shall, if necessary, be carefully cleaned
before installation and any damage to coatings shall be rectified. Particular care shall be
taken to prevent sewage or polluted water of any kind from coming into contact with pipes
for water supply. Whenever pipelaying is interrupted for any reason, the open end of the
pipeline shall be sealed with a suitable expanding stopper.
The line of the pipe shall be set out and agreed with the Engineer well in advance of the
excavation. Surface stripping, excavation, pipelaying, backfilling and reinstatement shall
follow each other without undue delay or distance between them.
Pipes shall be laid to true inverts and, except when using rigid joints, each pipe shall be
separately set by laser or boned between sighting rails. Any pipe which is outside the
permissible tolerances shall be unjointed and removed; the bedding shall be adjusted, and
the pipe relayed and rechecked for line and level. After the laying of a length of a pipeline
but before preliminary testing, the crown of the pipeline shall be checked for level and
alignment and any necessary adjustment shall be carried out by unjointing and removing
the pipes concerned, adjusting the bedding, relaying the pipes and rechecking for line and
level. The permissible tolerances for pipelines in trench and heading shall be 6mm in level
and 25mm in line between manholes or changes in direction or gradient. In addition,
where a gravity pipeline is shown on the drawings as being straight between manholes it
will not be accepted unless a light can be sighted through the length concerned.
Pipelines shall not be laid to a curved alignment, achieved either by angular deflection at
the joints or by curvature of flexible pipe except where expressly indicated on the
drawings, specified or instructed by the Engineer.
For pipeline jointing systems incorporating flexible jointing rings, pipes shall be laid with a
gap between the end of the spigot and the base of the socket, or between spigots. This
gap shall be not less than 6mm or greater than one third of the axial deflection test
dimension specified for the pipe joint and it shall be achieved by positive means, such as
marking the outside of the pipe or using removable metal or hardwood feelers. After the
joint has been made and the preliminary testing completed, the annular gap at a socket or
collar outside the flexible jointing ring shall be closed with fine grained clayey soil or cotton
waste to prevent the entry of granular material.
Where flexibly jointed pipes are laid to curves the angular displacement at any joint as laid
shall not exceed three quarters of the maximum allowed by the manufacturer.
Pressure pipelines shall be secured at all changes in direction by concrete anchor blocks.
All bends and junctions on gravity pipelines shall be made inside a chamber unless
otherwise specified.
For pipelines laid in headings the individual pipes shall not exceed 2.5m in length, where
the heading is to be backfilled manually, and the heading shall be driven complete from
shaft to shaft before pipelaying is commenced.
Vol 3, Section3
Page E-77 of 115
Specifications
E3.5
Not Used
E3.6

The most widely used forms of welding for polyethylene (and other polyolefin) pipes, are
butt fusion, and, increasingly, electrofusion sleeve jointing.
Butt fusion, which, for obvious reasons, is normally the only acceptable method where
polyethylene pipes are to be inserted into old pipelines as liners, requires careful control to
maintain quality. Electrofusion sleeve jointing, on the other hand, is a largely automated
process, and therefore more likely to be consistent in quality where control and
supervision are suspect or difficult.
(i)
Solvent welded joints for uPVC and ABS pipes will not be permitted unless
specifically ordered or permitted in writing by the Engineer.
Thermal fusion welded joints for PE, PP and PB pipes shall comply with the
following requirements:
The type of welded joint and all plant, personnel, materials and procedures shall
be in accordance with the pipe manufacturer's recommendations. Pipe
manufacturers will be required to provide suitably qualified technical
representatives on Site to assist in such matters as the establishment of
procedures, training of welders and the resolution of technical problems.
Subject to the above, the following table indicates the acceptability of various
jointing systems relying wholly, or in part, on thermal fusion welding.
Type of Welded Joint
Acceptability for Various Pipe Diameters

Less than 750mm
dia
750mm dia and over
No
No
Socket and spigot with

sealing ring and external
extrusion weld
Yes (1) (2)
No
Heated tool socket fusion
Yes
Socket and spigot with

internal and external
welds
No
Electrofusion of spigot and

socket or sleeve joints
Yes
Yes
Butt fusion
Yes
Yes
Friction Welding
Notes:
(1)
Vol 3, Section3
Acceptable for non-pressure pipelines only.
Page E-78 of 115
No
(Filter rod welding)
Yes
(Extrusion welding)
(2)
Specifications
Sealing rings may be omitted for joints between small diameter lateral
sewers or house connections and main sewers (or compatible plastic
manholes).
Welding shall be carried out in such a manner that the weld can sustain any
stresses arising from subsequent laying operations without damage or loss of
efficiency.
Any evidence of oxidation of the weld material or pipe material will constitute
cause for rejection of the joint.
Welds must be continuous across the whole available weld surface. Where butt
fusion welding is employed accurate alignment around the full circumference shall
be ensured by the use of positive mechanical support around the whole of the
circumferences of both pipe ends.
The completed welded joint shall be free from projections into the bore of the pipe
except in the base of butt fusion welds where weld "beads" not exceeding 2mm
projection will not be required to be removed unless specifically ordered by the
Engineer.
Joints on pressure pipelines shall provide a weld factor of not less than 1.0 and on
non-pressure pipelines of not less than 0.7.
(ii)
Testing of Welded Joints

The ability of each type of welded joint proposed for use in construction to provide
the specified weld factor shall be proved by a Type Test carried out at the pipe
manufacturer's works (or other agreed location). The type test shall consist of
making three representative welded joints, each of which shall be formed between
two sections of pipe having lengths of at least two pipe diameters. Each of the
three assembled samples shall then be subjected to a tensile test by clamping
around the full circumference at each ends, and loading until failure occurs.
Where welded joints are proposed for pressure pipelines, a further type test shall
be performed to prove the ability of the weld to withstand the internal pressure.
The test shall consist of taking three representative sections of pipe containing a
welded joint, and subjecting each to the 170 hour duration stress-rupture test
specified for the appropriate pipe material. The welded joint shall withstand the
specified test pressure for at least 170 hours without sign of distress.
The tensile and stress-rupture type tests will be regarded as satisfactory if all
three samples for each test meet the specified requirements. If two samples pass
the test and the third fails then one further sample shall be taken and tested. If
this sample meets the specified requirements then the whole test shall be
regarded as satisfactory, if this sample fails to meet the specified requirements
then the whole test shall be regarded as having been failed. Where the whole test
has failed to meet the above requirements, the method of welding will not be
accepted for use without modification. A suitably modified, or alternative, method
or procedure shall then be proposed, and shall be subjected to the appropriate
type tests.
Site tests of welded joints shall be made according to the following procedures:
Vol 3, Section3
(a)
All joints will be subject to inspection for lack of continuity, oxidisation of

materials, excessive projections or other faults.
(b)
All joints will be subject to the specified pressure tests for the pipeline.
Page E-79 of 115
(c)
Specifications
Periodically the Engineer will order selected joints to be removed from the
pipeline by cutting the pipe not less than 300mm on each side of the joint.
Tensile test samples shall then be cut from the removed section of pipe
and shall be tested to show compliance with the specified weld factor. The
normal rate of carrying out such tests shall be 2% of the joints made by
each method being employed. In the event of any such sample failing to
meet the specified weld factor, then the subsequent rate of testing for
that type of joint shall be increased to 10%, until such time as 20
successive joints have been successfully tested, when the testing rate
shall revert to 2%.
In the event of two successive tests on a particular type of welded joint
failing to provide the specified weld factor then approval of the method of
jointing employed will be withdrawn until the appropriate type test
procedures have been repeated and satisfied.
In addition, if two successive tests of joints made by a particular individual
welder should fail to meet the specified weld factor, then approval of the
employment of the welder concerned on permanent work will be
withdrawn. Any such welders from whom approval has been withdrawn
will not be permitted to be re-employed on permanent work until they
have completed a representative sample weld in the presence of the
Engineer and the sample weld has then been satisfactorily tested.
E3.7
Pipelines with Concrete Beds and Surrounds

Concreting shall be carried out in accordance with Section D of this Specification.
Where pipes are laid with a plain concrete cradle, a reinforced concrete cradle, or a full
concrete surround, any vertical faces, or faces sloping more steeply than 1 vertical to 2
horizontally, shall be properly shuttered, (unless, with the approval of the Engineer, they
are cast directly in contact with the side of the trench). A transverse expansion/movement
joint shall be provided at each pipe joint of compressible expansion joint filler shaped
exactly to the shape of the pipe and the full extent of the concrete. Unless detailed
otherwise on the drawings the thickness of this expansion/movement joint shall be a
minimum of 25mm except in the case of full concrete surrounds, where the minimum
thickness shall be as follows:
Pipes up to 300mm nominal diameter
25mm
Pipes 301 - 600mm nominal diameter
50mm
Pipes 601 - 1200mm nominal diameter
75mm
Pipes greater than 1200mm nominal diameter
100mm or as otherwise specified
For spigot and socket type pipes, the expansion joint in the concrete shall be aligned with
the face of the socket, and for asbestos cement sleeve type joints, with the face of one
end of the sleeve. For flexible detachable/sleeve type joints, the expansion joint filler
material shall be positioned on one side of the coupling but the filler and concrete bed or
surround shall only be placed after the application of the specified corrosion prevention
system has been applied to the pipe ends and joint. No steel reinforcement shall pass
through the concrete expansion joint.
At the Contractor's option he may use rectangular concrete blocks (two per pipe) made of
Grade C45/20 concrete, cast at least 7 days before use, together with pairs of approved
hardwood folding wedges of the same width as the blocks in order to align and support
the pipe before concreting. The blocks and wedges shall be of sufficient size and suitably
Vol 3, Section3
Page E-80 of 115
Specifications
founded on the bottom of the trench to support the pipe adequately without settlement or
movement at any stage. The blocks and wedges should be placed near the ends of each
pipe length and should be left undisturbed during jointing of subsequent pipes and during
construction, although the wedges should be removed during placing of the concrete.
Alternatively the pipe may be bedded direct onto the concrete cradle or base of the
surround, provided care is taken to ensure uniform support along the length of the pipe
and that the alignment of the pipe is correct; the bedding-down of the pipe must be done
whilst the concrete is fresh and workable.
The concrete shall be placed carefully and uniformly (to ensure that the pipeline is not
displaced), and shall be properly compacted by mechanical vibration, with particular
attention to ensuring that no cavities are left underneath the pipe. The whole of the
concrete for each length of pipe shall be placed in the same concreting operation and
suitable measures shall be adopted to ensure that the pipeline is not displaced by
differential side pressure or by flotation.
All shuttering used for forming the concrete bedding shall be removed, unless the written
approval of the Engineer is given to leave it in place for safety or similar reasons.
The bedding and surround shall be completed by the careful placing of selected excavated
material in layers not exceeding 150mm thick, thoroughly compacted on both sides of the
pipeline to a level at least 300mm above the crown of the pipes. As this material is placed
and compacted in the trench, the supports to the sides of the trench shall be concurrently
partly withdrawn so that there are no voids or uncompacted zones.
Except where instructed by the Engineer, no traffic load may be imposed upon the trench
within 72 hours of the placing of the concrete cradle or surround.
If the Contractor wishes to use any other method of laying pipes in concrete cradle or
surround, he must submit his proposals in writing to and obtain the approval in writing
from the Engineer well in advance of the date when he wishes to perform the work.
E3.8
Pipelines with Granular Beds or Surrounds

Where pipes are laid with a granular bed or surround the appropriate granular bedding
material shall be placed in the trench bottom, carefully so as to avoid segregation, and
spread and thoroughly compacted by approved mechanical means in successive uniform
layers each not exceeding 150mm compacted thickness to produce a uniform bed true to
gradient. Where plate vibrators are used, there shall be a minimum of one pass for gravels
and two passes for sands. Hand tamping or punning will only be permitted where
insufficient space is available to allow the use of mechanical plant. The minimum thickness
of compacted granular material over even bottoms and peaks of irregular bottoms shall be
as follows:
150mm (minimum 100mm under sockets) for pipes not exceeding 300mm nominal
diameter;
200mm (minimum 100mm under sockets) for pipes greater than 300mm nominal
diameter.
The pipes shall then be bedded evenly on the bed with great care being taken to ensure
uniform support for the entire length of the pipe.
Pockets in the bedding shall be formed at each pipe joint to permit jointing to be carried
out without the sleeve or socket of the pipe joint bearing on the bedding material and
without bedding material entering the joint.
Vol 3, Section3
Page E-81 of 115
Specifications
After the pipeline alignment and joints have been inspected and approved by the
Engineer, after satisfactory completion of the preliminary air testing of the pipeline and
where appropriate after the sealing of the annular gap at each pipe joint to prevent entry
of stones, each joint pocket shall be carefully filled with granular material and thoroughly
compacted up to the same level as the top of the bedding. Granular bedding material of
the same type shall be placed on both sides of the pipeline in successive uniform layers
not exceeding 150mm thick and compacted as specified, care being taken to ensure that
no cavities remain under the pipe, and that the pipes are not displaced by differential
pressure from either side.
When placing surround material the Contractor shall take care not to displace or damage
the pipes - tipping surround material from ground level directly onto the pipes shall not be
permitted.
Unless otherwise detailed on the drawings, for pipes with a full granular surround the
granular material shall extend up to a minimum height of 300mm over the crown of the
pipes. For rigid pipes with granular bedding, unless otherwise detailed, the granular
material shall extend up to the springing level of the pipe, and the surround shall be
completed by the careful placing of selected excavated material in layers not exceeding
150mm thick, thoroughly compacted on both sides of the pipeline to a level at least
300mm above the crown of the pipes.
If the Contractor wishes to use any other method of laying pipes in granular bedding or
surround he must submit his proposals in writing to and obtain the approval in writing
from the Engineer well in advance of the date when he wishes to perform the work.
E3.9
Compaction of Granular Pipe Surrounds

Granular surround material shall be carefully laid and compacted below and at the sides of
pipes in accordance with one of the procedures shown in the following table:
Granular Surrounds - Compaction Requirements
Surround Material
(Clause E1.28)
Maximum
Layer
Thickness mm
Alternative Methods
(Number of Passes of Compaction Plant)
Hand
Rammer
Vibrating
Plate
100kg Power
Rammer
(Group A
pipes only)
Gravel
200
Sand
150
In no circumstances will the use of heavy power rammers be permitted in the vicinity of
Group B, flexible pipes.
In all cases, special attention shall be given to ensuring that bedding material is fully
brought into contact with the haunches of the pipes. This shall be achieved by carefully
shovel slicing the material beneath the pipe's horizontal diameter or by other approved
methods.
Great care shall be taken not to damage or displace the pipes while compaction of the
surround is carried out.
Vol 3, Section3
Page E-82 of 115
Specifications
As bedding and surround material is placed and compacted in the trench, the supports to
the sides of the trench shall be concurrently partly withdrawn so that there are no voids or
uncompacted zones in the bedding and surround.
Once the surround material has been brought up to the level of the crown of the pipe,
compaction equipment shall only be used for the portions of the subsequently placed
surround material at the sides of the trench. The portion of surround material immediately
above the pipe shall be lightly compacted by foot only.
E3.10
Pipelines Bedded on Trench Bottom

Where pipes are to be bedded directly on the trench bottom the formation shall be
trimmed to provide even bedding for the pipeline and to be free of extraneous matter that
may damage the pipe or its coating.
A recess shall be formed by hand excavation at each joint to permit making the joint and
to prevent loads from bearing at this point.
After the pipeline alignment and joints have been inspected and approved by the
Engineer, after satisfactory completion of the preliminary air test and where appropriate
after the sealing of the annular gap at each pipe joint, the recesses shall be carefully
packed with selected fine material.
The bedding and surround shall be completed by the careful placing of selected excavated
material in layers not exceeding 150mm thick, thoroughly compacted on both sides of the
pipeline to a level at least 300mm above the crown of the pipes. As this material is placed
and compacted in the trench, the supports to the sides of the trench shall be concurrently
partly withdrawn so that there are no voids or uncompacted zones.
E3.11
Stanks to Pipelines with Granular Bedding

Where pipes are laid with granular bedding or back fill a stank (which is an impermeable
barrier designed to prevent groundwater flow along the trench) shall be provided across
the full width of the trench and for the complete depth of the bedding and fill at intervals
not exceeding 50m and generally midway between manholes or thrust blocks.
Stanks shall also be provided at any points where pipe trenches pass through or into
impermeable strata or strata whose permeability is lower than that of the adjacent ground
so as to form a restriction to the flow of groundwater. In these cases, the stank shall be so
formed as to restore the continuity of the impermeable, or low permeability, stratum
where it has been intersected by the trench excavation.
Stanks may be dispensed with where the pipeline will always be above groundwater level.
The frequency of stanks may need to be increased, or other measures undertaken, in
locations where the groundwater is already highly mobile.
The stank shall consist of either:
(i)
a 300mm long plug of clay, clayey soil or other approved impermeable soil, or of a
mixture of sand and bitumen, consolidated in an approved manner;
or
(ii)
a layer of plastic sheeting, minimum thickness 1mm, cut to fit around the pipe
across the full width of the trench and laid on the granular bedding or fill material at
the natural repose angle.
All methods must form an impermeable barrier.

Vol 3, Section3
Page E-83 of 115
Specifications
Bitumen shall not be used for trenches containing thermoplastic pipes.

E3.12
Backfilling of Pipe Trenches

After completion of placement and compaction of the surrounds to the pipelines backfilling
shall proceed using selected excavated materials in accordance with the specifications for
earthworks, (Section C).
The use of power rammers will not be permitted over any pipe until the depth of fill above
the crown of the pipe is at least 500mm.
E3.13
Deformation Measurements on Flexible Pipes

Deformations of the cross sections of buried pipes shall be measured in accordance with,
and shall conform to the limits specified in, this clause, for the following categories of
pipes:
(a)
all thermoplastics pipes;
(b)
reinforced thermosetting resin pipes having initial stiffnesses less than 100,000
Newtons per square metre;
(c)
ductile iron pipes having a standard dimension ratio greater than 60. Thus, class
K9 ductile iron pipes of DN600 and smaller, will not be subject to this clause;
(d)
steel pipes having a standard dimension ratio greater than 65.
The procedures for measuring deformation, and the acceptance criteria, depend on
whether the pipes have a nominal diameter greater than 600 millimetres or not.
(i)
Pipes of DN600 and less:

The deformation of pipes of DN600 and less will be checked by passing a mandrel
throughout the length of the pipeline. The mandrel shall have a cylindrical cross
section, of diameter not smaller than 1 millimetre less than the minimum
acceptable pipe diameter, calculated by applying the deflection limits given in the
following table to the reference diameter of the pipe. The reference diameter of
the pipes shall be calculated according to the following formula:
Reference diameter = (External circumference of pipe -2T)
3.14159
where T is the wall thickness of the pipes.
Deflection Limits for Flexible Pipes DN600 and smaller
Maximum Limits for Flexible Pipes
DN600 and Smaller
Type of Pipe
UPVC,
Vol 3, Section3
Pipe
Acceptance
(See Note
1)
Bedding
Acceptance
(See Note
2)
Installation
Acceptance
(See Note
3)
2.25
3.75
5.00
7.00
1.0
1.5
2.0
2.5
1.0
2.0
2.5
3.0
SDR less than 16

SDR 16 to 25.9
SDR 26 to 34.9
SDR 35 and over
Page E-84 of 115
Specifications
Maximum Limits for Flexible Pipes

DN600 and Smaller
Pipe
Acceptance
(See Note
1)
Bedding
Acceptance
(See Note
2)
Installation
Acceptance
(See Note
3)
PE, SDR 10 and over
7.00
2.5
3.0
PP, SDR 15 and over
7.00
2.5
3.0
RTR/GRP
SDR 30 to 40.9
SDR 41 to 49.9
SDR 50 and over
5.00
6.00
7.00
1.5
2.0
2.5
2.0
2.5
3.0
Steel
CM lined
Bitumen lined
See Note 4
5.00
2.0
3.0
2.5
4.0
Type of Pipe
Notes:
(ii)
(1)
Pipes whose deflection at any time has exceeded this value will not be
accepted for incorporation into the work.
(2)
To be measured after placing of the surround material, and after

withdrawal of trench sheeting to above the crown of the pipe, but before
backfilling. For non-pressure pipes, the permissible percentage deflection
will be accepted only as an elongation of the vertical diameter, and no
reduction will be acceptable at this stage. For pressure pipes, the permissible deflection will be acceptable as either an increase or decrease of the
vertical diameter.
(3)
To be measured not less than two weeks after completion of backfilling. If

the deflection of non-pressure pipes exceeds the permissible value within
less than two weeks of the completion of backfilling, the installation will
be rejected without additional measurement after two weeks. If the
deflection of pressure pipes exceeds the permissible value at any time
prior to pressure testing, but does not also exceed the "pipe acceptance"
value, then the installation acceptance criteria may also be regarded as
having been satisfied if the deflection measured not less than two weeks
after pressure testing of the pipeline is less than the permissible value.
This latter provision will only apply, however, if pressure testing is carried
out within 6 months of the completion of backfilling.
(4)
Pipes will be accepted provided their deflection has at no time exceeded

5%, and also provided they have not sustained bends, buckles or damage
to the mortar lining in excess of the limits stipulated in Clause E2.5.
(5)
'SDR'is the Standard Dimension Ratio which is defined as the ratio of pipe
diameter (measured at midpoint of wall) to pipe wall thickness.
Pipes larger than DN600:

For pipelines of more than 600mm diameter, internal measurements of deflection
shall be made in the vertical and horizontal planes and readings shall be recorded
at each pipe joint, at the midpoint of each pipe length, at any point where the
limiting deflections appear to be exceeded and at any other point directed by the
Engineer.
Vol 3, Section3
Page E-85 of 115
Specifications
The deformations of the pipe cross section, at every point measured, shall be
within the limits indicated in the following table. Attention is drawn to the fact
that, for pipes in this size range, not only must the separate measurements of
vertical and horizontal diameters, at any one cross section, comply with a more
stringent limit but
Deflection Limits for Flexible Pipes Larger than DN600
(Notes as for previous table)
Maximum Limits for Flexible Pies DN600
and Smaller
Pipe
Acceptance
(See Note 1)
Bedding
Acceptance
(See Note
2)
Installation
Acceptance
(See Note
3)
PE, SDR 10 and over
1.75
0.625
0.750
RTR/GRP SDR 30 to 40.9

SDR 41 to 49.9
SDR 50 to 64.9
SDR 65 to 89.9
SDR 90 and over
1.25
1.50
1.75
2.00
2.25
0.375
0.500
0.625
0.750
0.875
0.500
0.625
0.750
0.875
1.000
See Note 4
1.25
0.50
0.75
0.625
1.00
0.500
0.625
0.750
0.000
0.500
0.625
0.750
0.875
1.000
Type of Pipe
Steel
CM lined
Bitumen lined
DI
SDR 55 yo 69.9
SDR 70 to 89.9
SDR 90 and over
Individual measurements of either the vertical or horizontal diameter may show

deflections, by comparison with the reference diameter, of FOUR TIMES the value
listed above.
E3.14
Thrust and Anchor Blocks in Pressure Pipelines

Underground pressure pipelines shall be provided with thrust and anchor blocks where
necessary or instructed by the Engineer. Thrust blocks will normally be required at bends,
tee branches, angle branches, tapers, stop ends and similar fittings; anchor blocks will
normally be required on pipelines laid to gradients steeper than 1:20 as follows:
up to 1:15
anchor block every third pipe;
up to 1:10
anchor block every second pipe;
greater than 1:10
anchor block every pipe.
Concrete shall extend to undisturbed ground on thrust faces of thrust blocks and on both
side faces of anchor blocks; any additional costs arising from over excavation shall be
borne entirely by the Contractor.
Additional requirements for both location and details of thrust and anchor blocks may be
instructed as work proceeds to suit the actual Site conditions encountered.
Vol 3, Section3
Page E-86 of 115
E3.15
Specifications
Pipes Protruding from Structures

(i)
Where pipes are built into structures the joint between the pipe and the structure
shall be watertight.
The Contractor's attention is drawn to the importance of providing flexibility in
pipelines protruding from structures so that differential settlement between a
structure and pipeline will not lead to pipe failure. The Contractor will be
responsible for ensuring that pipes, joints and supports are provided and placed in
accordance with the Specification and drawings.
Unless otherwise detailed on the drawings, pipelines (other than those constructed
from PE,PP and PB) at or below ground level protruding from a structure shall
have two flexible joints adjacent to the structure located according to the pipeline
material and diameter as shown in the following table:
Location of Pipe Joints at Structures for Different Pipe Materials

DISTANCE FROM
STRUCTURE TO FIRST
JOINT
Pipe Dia.
(mm)
Rigid Pipes
DI and Steel
Pipes
uPVC, ABS
and RTR
Pipes
*
Note:
DISTANCE BETWEEN FIRST

AND SECOND JOINTS
up
to
225
226450
451900
901
and
over
up to
225
226450
451900
901
and
over
Max.
200
1D
1D
1D
450
750
1300
2500
Min.
300
600
1000
2000
Max.
400
2D
2D
2D
1500
2500
5000
8000
Min.
1000
1500
3000
5000
Max.
200
1D
1D
1D
3D
3D
3D
3D
Min.
2D
2D
2D
2D
Unless specifically detailed on the drawings, the first joint shall be constructed as
close to the face of the structure as is practicable.
For key to pipe groups, see Clause E1.5.
If during construction a void arises below a built-in pipe protruding from a
structure, the Contractor shall clear the void of all extraneous and uncompacted
materials and then fill it with Grade C20 concrete in the form of a cradle under the
protruding pipe. This cradle must not extend beyond the first flexible joint. If the
void extends beyond the first flexible joint the formation of the pipeline beyond
that joint shall be restored with compacted structural fill material.
(ii)
Requirements for Concrete, Clay, AC, PF, CI (grey) Pipelines

Where additional support to the length of pipe between the structure and first
joint is necessary, details will be shown on the drawings or issued as work
proceeds.
Vol 3, Section3
Page E-87 of 115
(iii)
Specifications
Requirements for uPVC, ABS, RTR Pipelines

Where a flexible pipe passes through a rigid concrete face to a structure, the pipe
shall be protected from stress concentration and possible fracture of the pipe at
the concrete face as follows. A 10mm thick neoprene or other approved synthetic
rubber strip shall be wrapped around and cemented to the pipe and, where the
neoprene strip is exposed to liquid, a sealant groove shall be formed and filled
with an appropriate, approved sealant. The precise configuration is detailed on the
drawings. Care shall be taken to ensure that the neoprene strip is not displaced
during concreting.
(iv)
Requirements for Steel and Ductile Iron Pipelines

Except where otherwise detailed, the two flexible joints shall not be provided for
steel and ductile iron pipelines less than 75mm in diameter.
E3.16
Plastic Pressure Pipes Encased in Concrete

Where plastic (including RTR/GRP) pressure pipes are encased in concrete, for instance
where they pass through anchor or thrust blocks, they shall be wrapped with an approved
compressible material such as building felt of minimum thickness 2mm.
E3.17
Marker Posts for Water Mains and other Pressure Pipelines

Precast concrete marker posts of approved type shall be installed at all changes of
direction, valves, air valves, washout and hydrant positions, road crossings, land
boundaries and otherwise at approximately 150-200m intervals as directed by the
Engineer.
Marker posts shall be installed in a foundation block of Grade C45/20 concrete (0.1 m3
concrete per post).
The type, depth, location and diameter of the main or fittings shall be detailed in Arabic
and English to an approved design on an approved type of indicator plate, which shall be
attached to the indicator post.
Details of indicator posts and plates are to be found in Section 7.3 of the Code of Practice
for Service Installation prepared by the Ministry of Works, Power and Water.
E3.18
Cutting Pipes
Where pipes are required to be cut for any reason the cutting shall be done by the
Contractor in accordance with the recommendations of the manufacturer and in a manner
approved by the Engineer. Care shall be taken not to damage either section of the cut
pipe, and the Contractor shall be responsible for the accuracy of the measurement of the
cut pipe as well as the actual cutting.
The Contractor shall take all necessary safety precautions. In particular, all personnel
involved in cutting or turning asbestos cement pipes must be warned that inhalation of
asbestos cement dust is dangerous to health. When cutting or turning pipes by any
process which creates dust, all personnel shall be provided with, and instructed to wear or
use appropriate clothing and equipment including where necessary suitable face masks or
respirators.
Vol 3, Section3
Page E-88 of 115
E3.19
Specifications
Flanged and Flexible Mechanical Joints

Flanged joints shall be made with great care, and with special attention to the accurate
alignment of pipes and flanges. Jointing materials shall be cleaned before assembly and
bolts shall be tightened up in sequence, diametrically opposed bolts being tightened a
small amount in turn. Any specified torque limitations shall be strictly adhered to.
Proprietary flexible mechanical joints shall be assembled in accordance with the
manufacturer's instructions.
E3.20
Pipework within Structures - General Requirements

Pipework shall be supplied complete with all joint rings, gaskets, washers to each side of a
bolted joint, nuts, bolts, grease and any other components necessary for the complete
installation.
The layout and design of the pipework shall be such as to facilitate its erection and the
dismantling of any section for maintenance of associated plant by inclusion of approved
mechanical couplings or flange adaptors.
Where a common delivery pipe is used, individual pump delivery branches shall be jointed
to it in a horizontal plane and angled to minimise turbulence in the flow.
Adequate supporting and anchoring arrangements for all pipes shall be included which
may take the form of straps, stays, tie bars, concrete cradles and puddle flanges.
Steel and cast grey and ductile iron pipes shall be provided with puddle flanges where
they pass through the walls of underground or water retaining structures. Where thrusts
will be transmitted from the pipework to the wall, the puddle flanges shall be integrally
cast in the case of cast iron pipes or welded in the case of steel pipes.
All pipes connected to pressure vessels, pumps and similar equipment shall have flanged
connections.
All pipes shall be checked for alignment and mating of flanges and connections before
being secured. Pipes shall not be sprung into position.
Vol 3, Section3
Page E-89 of 115
Specifications
E4
STRUCTURAL DESIGN OF PIPELINES
E4.1
General
All pipelines to be constructed or installed as part of this contract shall be satisfactorily
structurally designed so as to facilitate their construction, and to ensure a service life of
not less than 50 years.
Full structural design calculations shall be submitted for approval in respect of all pipelines
of size DN100 or larger. For pipelines of smaller size, the Contractor shall submit details of
the type of pipes proposed, and of the installation details, and the Engineer will then
decide whether design calculations are also required.
The design calculations and/or installation details described in this Clause are to be
accompanied by construction method statements, which must be fully compatible with the
design, and must show how the assumptions of the design will be fulfilled on Site.
The structural design must verify that the criteria set out below, or such additional criteria
or more stringent criteria, as may be stipulated by the pipe or coupling manufacturer, are
satisfied.
E4.2
Polyethylene Pipes
(a)
Criteria to be satisfied by both non-pressure and pressure pipelines:

Long-term deflection:
Buckling stability:
Not more than 6% of reduction in vertical diameter.

The factor of safety against buckling collapse shall not be
less than the following:
1.5
2.0
2.5
3.0
(b)
for pipes with less than 1.5m cover, calculated

without soil support.
for pipes embedded in gravel.
for pipes embedded in sand.
for pipes embedded in other soils.
Criteria to be satisfied by pressure pipelines only:

The combined stress due to ring bending (external loads) and hoop tension
(internal water pressure) shall not exceed the following values:
Material Grade
Combined Stress
PE/MRS
PE/MRS
PE/MRS
PE/MRS
PE/MRS
7.0
6.3
5.0
3.2
2.5
100
80
63
40
32
Mpa
Mpa
Mpa
Mpa
Mpa
E4.3 & E4.4 Not Used

E4.5
Steel Pipes
(a)

Long-term deflection:
Vol 3, Section3
The long-term deflection, measured as reduction of the

vertical diameter shall not exceed the following:
Page E-90 of 115
Specifications
2% for pipes with cement mortar lining and cement

mortar (or concrete) coating.
3% for pipes with cement mortar lining, and polymeric,
bitumen, coal-tar or similar coating.
5% for pipes with polymeric or bitumen lining and
coating.
Buckling stability:
The factor of safety against buckling collapse shall be not

less than the following:
1.5 for pipes with less than 1.5m cover, calculated
without soil support.
2.0 for pipes embedded in gravel.
2.5 for pipes embedded in sand.
E4.6
Ductile Iron Pipes

(a)

Long-term deflection
The long-term deflection, measured as reduction of the

vertical diameter, shall not exceed the following:
Pipe Size (DN)
Class K7
Class K9
100
1.6
1.00
150
2.1
1.45
200
2.4
1.85
250
2.7
2.20
300
3.0
2.45
350
3.1
2.65
400
3.2
2.90
450
3.3
3.05
500
3.4
3.25
600
3.6
3.50
700
3.8
3.75
4.0
4.00
800 and over

Bending Stress:
(b)
Criteria to be satisfied by pressure pipelines only:

Hoop tensile stress:
Vol 3, Section3
The bending stress in the ductile iron pipe walls shall not
exceed the guaranteed minimum bending strength
divided by 1.5.
The hoop tensile stress caused by internal water pressure

shall not exceed 140 Mpa.
Page E-91 of 115
Specifications
E4.7 to E4.9 Not Used

E4.10
Design Requirements
The structural design calculations to be submitted by the Contractor to verify that the
above criteria, as appropriate for the pipe material, will be satisfied, shall take account of
the following:
E4.11
(a)
The loading and environmental criteria specified in this clause, elsewhere in the
specification, or stated by the contractor in respect to temporary construction
loadings.
(b)
The depths of cover at which the pipelines will be installed.
(c)
The detailed method of construction which will be employed by the Contractor for
the installation of the pipeline.
(d)
Any temporary loadings to which the pipeline will be subjected by the contractors
operations on Site.
Loading Criteria
Backfill density: Unless otherwise specified or indicated, the backfill density shall be taken
as 20kN per cubic metre.
Backfill loading: The design backfill loading (as vertical pressure, or load per unit length of
pipeline) shall be not less than that resulting from an average
vertical pressure, acting on the full width of the pipe, equal to the
product of the backfill density and the depth from ground level to
the top of the pipe.
Where the pipe: soil stiffness ratio is such as to cause a
concentration of load (pressure) then the increased value shall be
used in design. Where pipelines are installed in sufficiently narrow
trenches, the backfill loading may be reduced to take account of
the silo-effect, provided that in no case is it reduced below the
value obtained as the product of soil density and depth of cover.
Surcharge loading:
E4.12
The design shall include for the effect of surcharge pressures due
to a single wheel load of 100kN, applied with an impact factor of
1.5.
Environmental Criteria
Temperature:
Ground Conditions:
E4.13
See environmental and climatic data

See Site investigation information
Loading Combinations to be Considered

The pipeline structural design shall satisfy the criteria specified above for each of the
following loading combinations relevant to the pipe material.
(a)
Pressure pipelines:
PE, PVC and RTR/GRP pipes:
Vol 3, Section3
Page E-92 of 115
Specifications
Each of the following simultaneous loadings shall be considered:

(i)
(ii)
(iii)
Backfill load, vehicle surcharge, working pressure.

Backfill load, minimum negative surge pressure (for buckling)
Backfill load, maximum positive surge pressure.
Steel pipes
Simultaneous action of backfill loading and minimum negative surge pressure (for
buckling).
E4.14
Approved Calculation Procedures

The following design codes are approved in respect of their calculation procedures, though
not necessarily in respect of the loadings which they include. (The actual loadings used in
the design calculations for this contract shall be not less than those specified in this
Clause).
Pipe Material
Design Code
PE and PVC
Pipe Materials Selection Manual, WRc, 1988
Steel
American Water Works Association, M11, 1986

Pipe Materials Selection Manual, WRc, 1988
Ductile Iron
American Water Works Association, C150, 1981

International Standards Organisation, CD 1083 (Third Edition,
1994)
Ductile Iron Pipelines, Embedment Design, Stanton, 1979
Pipeline structural design in accordance with other codes or procedures may be permitted,
but only if a full English language version of the code has been submitted to the Engineer
and approved in advance.
E4.15
Additional Structural Design Requirements

The pipeline structural designs shall not be limited to coverage of the requirements
referred to above, or in the approved codes, but shall also include the following:
(a)
Provisions to resist the thrusts generated at changes of direction or cross-Section

Gn pressure pipelines, and to avoid joint dislocation, excessive pipeline movement,
overstressing or overstraining of pipes, or other harmful effects.
(b)
Provision of pipeline foundations which will ensure that the pipeline remains within
the specified tolerances on level for the design lifetime.
(c)
Provision of arrangements to accommodate differential settlements at any point

along the pipelines, including their approach to structures, such that the pipes will
not be overstressed or overstrained, and so that the movements at pipe joints will
not exceed their stated or specified capabilities.
(a)
Provision of anchorages to pipelines constructed in ground sloping as per Clause

E3.14, p E-88.
Vol 3, Section3
Page E-93 of 115
Specifications
E5
NON DISRUPTIVE METHOD (NDM) FOR PIPELINE CONSTRUCTION
E5.1
Scope of Work
Furnish all labour, materials and equipment and perform all the work necessary to design
and construct pipelines crossing under paved roads using non-disruptive methods, as
specified herein and indicated on the drawings.
Construction shall be by using trenchless techniques that are appropriate for the intended
installation and which can be demonstrated to the satisfaction of the Engineer to meet the
contents of these specifications.
Where a pipeline is to be constructed by microtunnelling, the Contractor shall confine his
surface operations to working shafts and the area immediately adjacent to such shafts.
Such working area shall be kept to the minimum practicable for the proper construction of
the works.
The Contractor shall propose the location of all working shafts, having due regard to
existing services, minimising disruption to traffic and pedestrian movements and achieving
the required system layouts, as shown on the Drawings. Locations shall be approved by
the Engineer prior to the commencement of construction.
The Contractor shall obtain approval of his method statement from concerned Authorities.
Where the Drawings show that a range of pipe diameters are to be constructed, the
Contractor may propose to the Engineer for his approval that certain sections are
constructed within larger diameter pipes and the annular space grouted. The difference
between the external face of the inner pipe and the internal face of the outer pipe shall
not be less than 150mm and not more than 250mm.
E5.2
E5.3
Related Work
Earthworks
Section C
Concrete Works
Section D
Design
The Contractor shall be responsible for the design of the pipes used for the non-disruptive
method including all joints, for the design of the thrust and reception pits including support
and thrust wall and for the design of the jacking system in general. His design shall have
the Engineers approval.
E5.4
Submittals
In addition to the applicable requirements of this Specification, the following shall be
submitted by the Contractor and approved by the Engineer prior to commencement of any
works:
1.
Programme of work with resource and equipment allocations.
2.
Additional Soil Investigations.
3.
Design Calculations for the non-disruptive method:
Vol 3, Section3
Page E-94 of 115
a)
Specifications
Pipes including jacking and friction forces in the axial direction and earth,
traffic and surcharge loadings in the vertical direction and the pipes resistance
to these loads.
Also, allowable deflections at joints to limit damage to the joint from eccentric
loading under thrust and sealing limits.
b)
Thrust and reception pits to resist external soil and water pressures and
stresses resulting from jacking machine. Drawings showing on plan and
sections the method of supporting excavations and equipment layout shall be
included.
All calculations shall be certified / signed by a qualified Engineer.
E5.5
4.
Materials Specifications and product data.
5.
Method Statements which shall include :

a)
List of equipment and resources.
b)
Detailed step by step procedure describing how work will be carried out
including clear definition of responsibilities and authority.
c)
Support of existing services and adjacent structures.
d)
Safety arrangements for compliance with safety requirements.
e)
Arrangements for dealing with groundwater taking due regard to controlling

the loss of material and preventing settlement around pits, pit / pipe interface
and tunnel face.
f)
Dealing with different ground conditions.
g)
Locking pipe in position during insertion of next pipe.
h)
Sealing thrust and reception pits during exiting and entering of pipe.
i)
Control of overbreak.
j)
Grout mix design and method of grouting.
k)
Handling and fixing, of the inner pipe in the case of microtunnelling with
larger diameter pipes.
Quality Assurance
The non-disruptive method of pipeline installation shall be executed by firms having a
record of at least five years of successful, trouble free execution of similar works.
E5.6
Delivery Storage and Handling

All materials shall be properly protected so that no damage or deterioration shall occur
during a prolonged delay.
E5.7
Site Investigation
Soil conditions and ground conditions shall constitute the Contractors risk.
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Specifications
After award of the Contract, the Contractor shall be responsible for carrying out all
geotechnical site investigations, including ground water level monitoring, which he
considers necessary but as a minimum at the proposed access pit locations, and central
median. The Contractors site investigation programme shall be submitted to the Engineer
for review. The results of such investigations shall be submitted to the Engineer and shall
include recommendations for pipelaying, excavation support and soil stabilisation if
required.
The Contractor shall be responsible for obtaining existing utility information and executing
trial pits to locate and confirm services at pit locations, etc., as required.
E5.8
Health and Safety

The Contractor shall adopt safe working practices for tunnelling in accordance with BS
6164.
Only authorised personnel shall be allowed access to the site.
The Contractor shall provide a Safety Officer, suitably experienced in tunnelling operations
and with adequate authority to control and implement safe working practices.
The Contractor shall make suitable arrangements for accommodating his personnel at the
site including the following as a minimum :
1.
Air-conditioned mobile office at the thrust pit with space, desk and chair for one
inspector.
2.
Telephone service.
3.
Telecommunication between the control room and the work crews.
4.
Cool air-conditioning in summer for work crews engaged in operations at the thrust
and the reception pits.
5.
Approved gas detectors.
6.
First aid kit.
7.
One vehicle.
8.
Emergency escape or BA sets.
The excavated pits shall have a separate cage type ladder bay complete with ladder in
addition to any other bay or bays required for the construction of the works.
The pits shall be fenced off on all sides with close steel panels at least 1.8m in height and
equipped with safety warning lights. The panels (maximum space between 100mm) shall
be joined by steel rods supported on concrete blocks.
Adequate lighting and ventilation shall be provided to the pits and electricity shall be
supplied at no greater than 110/220 volts.
E5.9
Skilled Operators and Supervision

All operators in the employment of the Contractor shall be skilled and experienced in their
respective trades and in particular shall be fully skilled in shaft sinking and tunnelling
microtunnelling.
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Specifications
The operators who will perform the Work shall have a minimum of 1 year experience in
the performance of tunnelling/ microtunnelling subject to performance with 3 months
probation.
Curriculum Vitae of key personnel and operators shall be submitted for approval.
Interviews may be undertaken at the discretion of the Engineer/Department.
E5.10
Pipe Materials
Pipe materials shall comply with the specifications.
Microtunnel pipes shall be designed to withstand the maximum axial thrust with a factor of
safety of 4 based on the full effective area and the ultimate compressive strength of the
pipe material. For reinforced concrete pipes the full effective area at the joint shall be
used.
Where GRP or similar materials pipes with concrete surround are proposed
for
microtunnelling, the concrete shall be regarded as sacrificial. The concrete surround shall
be designed to withstand the maximum jacking force.
Joints in pipes used in microtunnelling shall be designed to avoid projections which could
obstruct the travel of the pipe and they shall be watertight under axial loading and at the
permissible deflection of the pipes. Quality control tests at the factory should include
subjecting the pipe joints, at a maximum permissible deflection, to an external hydrostatic
pressure of 2 bars.
The Contractors submittals shall describe the measures to be taken to avoid the
development and transfer of grout shrinkage or expansion stresses to the pipe and to
avoid any adverse chemical reaction between the pipe and concrete, grout or other
materials comprising the pipeline.
The pipe manufacturer has to guarantee that this pipe and its material are suitable for its
intended use.
Standard pipes shall be a minimum in length subject to the installation method used.
Where required, pipes shall incorporate lubricant injection holes spaced equally around the
circumference. Concrete pipes with a liner shall only be permitted to have lubricant
injection holes in the concrete. Lubrication holes shall be clear of joints and shall be
plugged on completion of the work. The liner shall be made good and continuous. Pipes
may incorporate lifting holes and fixing holes for securing temporary apparatus. All such
holes shall be threaded to enable plugs to be screwed into the sockets to withstand any
external water pressures.
Joints which shall be used in conjunction with a resilient packing, shall be capable of
accepting repeated annular deflections of up to 10 without :
i)
damage to pipe or loss of structural strength.
ii)
the ingress or egress of water or lubricant under the maximum operational or test
pressures.
iii)
the ingress of soil / groundwater onto the bearing surfaces.
The joint design for concrete pipes shall be such that the areas available for transmitting
the maximum permitted thrust force will be sufficient to ensure that with an annular
deflection of 1 and with resilient packing material in place the maximum pressure applied
to the joint bearing surface will not exceed 23.5 N/mm2 for drives up to 100 metres in
length and 21.0 N/mm2 for drives in excess of 100 metres and up to 150 metres in length.
Vol 3, Section3
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Specifications
Unless independently authenticated test results acceptable to the Engineer are available,
two consecutive axial loading tests incorporating a 1 angular deflection with the
application of double the maximum permissible thrust force (or, if greater, of the greatest
thrust force that the proposed thrust equipment can apply) shall have been successfully
conducted without any visible crushing, cracking or spalling of the pipe being evident,
before any pipes will be accepted for use. The tests shall be extended to record the
loading at which any visible signs of failure become evident, and shall be carried out in an
approved manner to simulate actual working conditions. Pipes which have been submitted
to the proof load test will not be permitted in the Works.
Where the Contractor elects to construct certain sections within larger diameter pipes and
grout the annular space, the external pipe may be of steel with full circumferential weld.
The steel pipe and the grout shall be regarded as sacrificial and the inner pipe shall be
designed as a stand alone pipe, capable of withstanding installation and grouting forces
and soil, traffic and groundwater loads subject to the method.
Where the Contractor elects to construct sections not within larger diameter pipes, pipe
installation shall continue until at least one additional length of pipe beyond the limit of
construction is exposed. Where the pipe has failed, a second pipe shall be jacked through
and inspected. The condition of the exposed pipe and its exterior coating shall be
inspected by the Engineer. Where in the opinion of the Engineer the pipe or coating has
been damaged during installation, the Contractor shall submit a proposal, for review by
the Engineer, for demonstrating the adequacy of the pipeline installed.
The external coating to reinforced concrete pipes shall be pure epoxy 500 microns
minimum thickness.
E5.11
Joint Packing
The material used for joint packing shall have under dry conditions when subjected to the
maximum permitted bearing pressure :
i)
a restoration after 1 hour of at least 65% of the original thickness, and
ii)
a compression of at least 50% of the original thickness.
Independently authenticated test results to demonstrate that the packing complies with
the Specification shall be submitted and shall include a graph of the stress / strain
relationship over the range of conditions which will be encountered during the Works.
The material used for packing shall withstand all imposed loadings applied during the
installation of all pipes for each completed length without showing signs of deterioration or
distress. The packing material is to be cut to dimensions that ensure the full bearing width
of the joint is protected. The initial thickness of the packing shall be such that the final
joint gaps achieved upon completion of the pipeline are a nominal 8mm in width.
Packing shall not be fixed over the full face of the pipe but stopped approximately 1cm
from free edges. The joint gap shall have a tolerance of between 6mm and 15mm
depending on jacking forces.
Outside gaps in the joints between pipes shall be sealed.
E5.12
Lubricant
Lubricant shall always be used when microtunnelling.
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Specifications
The material used for lubrication shall be a polymer or bentonite based slurry approved by
the Engineer. It shall be stored and mixed in a manner recommended by the supplier and
tested prior to use.
Lubricant injection overpressure shall be avoided. It shall be sufficient to fill the annular
overbore voids around the outside of the pipe to avoid collapse and upward migration of
the void prior to permanent grouting.
A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
powder showing the properties of each consignment delivered to the Site. This certificate
shall be made available to the Engineer on request. The properties to be given by the
manufacturer are the apparent viscosity range (in pascal seconds) and the gel strength
range (in pascals) for solids in water.
Bentonite shall be mixed thoroughly with clean fresh water to make a slurry 24 hours
before its usage. The temperature of this water used in mixing the bentonite suspension,
and of the suspension when supplied to the drilling machine, shall be not lower than 50C.
Where saline or chemically contaminated groundwater exists, special precautions shall be
taken to modify the bentonite suspension or prehydrate the bentonite in fresh water so as
to render it suitable in all respects for the intended purpose.
Control tests shall be carried out on the bentonite suspension, using suitable apparatus.
The density of freshly mixed bentonite suspension shall be measured daily as a check on
the quality of the suspension being formed. The measuring device shall be calibrated to
read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH
value shall be applied to bentonite supplied to the pipe bore. For average soil conditions
the results shall Generally be within the ranges in the following Table.
Tests on Bentonite
Property to be measured
Range of results at
200C
Test method
Density
Less than 1.10 g/ml
Mud density balance
Viscosity
30 - 90s
Marsh cone method
or
less than 0.020 Pa-s
Fann viscometer *
Shear Strength
1.4 - 10 Pa
Shearometer
(10 minute gel strength)
or
pH
4 - 40 Pa
Fann viscometer
9.5 - 12
pH indicator paper strips

electrical pH meter
Where the Fann viscometer is specified, the fluid sample should be screened by a
number 52 sieve (300 gm) before testing.
The frequency of testing bentonite slurry and the method and procedure of sampling shall
be proposed by the Contractor for approval before the commencement of work. The
frequency may subsequently be varied as required, depending on the consistency of the
results obtained, subject to approval.
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Specifications
The tests shall be carried out until a consistent working pattern has been established,
account being taken of the mixing process, any blending, of freshly mixed bentonite
suspension and previously used bentonite suspension, and any process which may be used
to remove impurities from previously used bentonite suspension. When the results show
consistent behaviour, the tests for shear strength and pH value may be discontinued, and
tests to determine density and viscosity shall be carried out as agreed with the Engineer.
In the event of a change in the established working pattern, tests for shear strength and
pH value shall be reintroduced for a period if required.
E5.13
Joint Sealant
The joint sealant shall be an elastomeric ring complying with BS 2494:1990.
E5.14
Grout
As Slurry replacement:
The grout shall consist of Portland cement and water as determined by geotechnical data
and directed by the Engineer. Its normal strength shall be at least 20 N/mm2.
Admixtures shall be used only if tests have shown to the satisfaction of the Engineer that
their use improves the properties of the grout, e.g. by increasing workability or slightly
expanding the grout.
As Annular Space Filling:
A low strength, non shrink grout or foam concrete shall be used and placed at low
pressures. The density of the mix shall be in the range 900 - 1200 kg/m3 and the free
water/cement water not greater than 0.6.
The carrier pipe and joints shall be protected from the possible adverse physical or
chemical-effect of grout. Compressible material shall be wrapped around pipe.
The internal pipe shall be filled with water to avoid floatation forces, hydration
temperatures and to resist forces during grouting. A 5m high free vented standpipe
should be used.
A free venting standpipe of not less than 100mm dia. shall be installed on the grout
injection feed to restrict grouting pressures to a maximum of 1 bar.
E5.15
Thrust and Reception Pits

The dimensions of thrust and reception pits shall be limited to the minimum required to
construct the Works.
Thrust and reception pits shall be constructed within a sheet pile cofferdam or caisson if
the ground conditions dictate. The pit bottom shall be sealed with concrete. Entry and
exit sealing rings shall be provided.
The Contractor shall determine the excavated dimensions of the drive and reception shafts
as required to suit the site conditions. Minimum shaft dimensions shall be used at all
locations where utilities, roads or trees exist adjacent to the required shaft locations.
Excavations shall be supported according to type of pit as specified below :
Type A
Thrust and reception pits in all types of soils except rock, with high groundwater table and
with the excavation secured by precast reinforced concrete caisson.
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Specifications
The caisson bottom shall be sealed with a concrete plug which shall be placed underwater
and designed to resist water uplift as well as forces from the jacking equipment to be
installed in the pit. All the joints between caisson rings shall be sealed with the joint
sealant and the caisson grouted from outside in order to make in water tight. A reinforced
concrete wall shall be provided in the thrust pit to resist the jacking force. A properly
braced concrete wall shall be provided in the thrust and reception pits in order to install
the entry and the exit rings.
Type B
Same as Type A but the excavation is secured by inter-locked steel sheet piles. The
sheet piles shall be braced by suitable steel framing welded to the sheet piles. No struts
shall be used for bracing. The first set of bracing shall be at 0.5m from the ground
surface.
Type C
Same as Type A but in dry conditions.
Type D
Same as Type B but in dry conditions.
Type E
Same as Type A except that the pit is partially in soil and partially in rock. The portion in
soil is secured by caisson as in Type A where as the portion in the rock can be
unsupported. Special precautions shall be taken to seal the interface between the caisson
and the rock so that it is water and soil tight.
Type F
Same as Type E except that excavation in soil is secured by sheet piles instead of a
caisson.
Type G
Same as Type E but in dry conditions.
Type H
Same as Type F but in dry conditions.
Type I
The thrust and reception pits are in rock in an area of high groundwater table. The
excavation can be unsupported. A reinforced concrete wall shall be provided in the thrust
pit to resist the jacking force. Properly braced concrete walls shall be provided in the
thrust and reception pits in order to install the entry and exit rings.
Type J
Same as Type I except in dry conditions.
The pits shall be completely dry prior to commencing and throughout tunnelling works.
Dealing with groundwater where required shall be conducted in a slow manner. Standby
facilities shall be provided.
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Specifications
The thrust wall shall be perpendicular to the proposed line of thrust. The thrust wall shall
be sufficient to accept repeatedly the maximum permitted thrust force without undue
movement. It will not be permissible to thrust directly off any permanent part of any shaft,
chamber or pumping station unless this is specifically designed to withstand the thrust
reaction.
Thrust wall shall not be joined to the jacking rig base concrete.
Where it is proposed to use a tail tunnel as the reaction surface the maximum permitted
thrust force shall not exceed the lesser of the following :
i)
The maximum permissible thrust force.
ii)
a)
50% of the sum of the maximum forces recorded at the rigs used to construct
the tail tunnel, or
b)
if the overbreak to the tail tunnel has been grouted up, 100% of the sum of
the maximum forces recorded at the rigs used to construct the tail tunnel.
Any tail tunnel which has been used as a reaction surface shall pass the specified
watertightness test at a time not less than 14 days after the load has been removed.
The design of the thrust wall and any other associated Temporary Works shall be such as
to prevent damage to any part of the Permanent Works or any immediately adjacent
service or structure.
Any void between the soil face used to provide a reaction to the thrust force and the thrust
wall shall be filled completely with grout.
The Contractor shall take any measures necessary to prevent damage or deterioration of
the soil reaction face during the construction of the Temporary and Permanent Works from
whatever possible cause, such as ingress of water, softening, corrosive soil or loss of fines
from a granular soil.
E5.16
Pipe Installation within Sleeves

Pipe sections shall be placed and joined individually within the sleeve or mounted on guide
rails or trolleys in such a manner as to transmit the pulling / pushing forces through the
carriage and not through the pipe.
E5.17
Microtunnelling
Unless otherwise agreed, the method to be employed for microtunnelling shall be
mechanical earth-pressure counter balance tunnelling system incorporating, a polymer or
bentonite based slurry system. The use of water alone shall not be permitted.
The horizontal drive rate shall be maintained equal to the excavation rate throughout the
operation.
During all stages of the setting up, microtunnelling operation and dismantling both
subsidence and heave shall be prevented.
The microtunnelling system shall be manufactured and operated having regard to the
provisions of BS 5228:Parts 1 and 2 and BS 6164.
The slurry system shall have a dual purpose of removing excavated soil and balancing
groundwater and face pressures. The slurry / excavated soil mixture shall be properly
Vol 3, Section3
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Specifications
removed from the excavation, and removed from the site to a suitable location. Stock
piling on site shall be avoided.
Presure gauges shall be provided in the control room to measure the slurry and suction
pressures.
Face support shall be provided by full earth pressure balance.
The tunnelling machine shall be steerable, incorporating hydraulic rams to move the
articulated head. The line and level control shall be achieved by a laser beam transmitted
from the jacking shaft to a target mounted in the tunnelling machine.
The design of the tunnelling machine shall ensure no rotation or rolling during installation.
The tunnelling operation shall be run continuously between thrust and reception pits.
During short stoppages needed for pipe jointing, the slurry pressures / face pressures shall
be maintained.
Tailings removal and cutting face shall not be operated when the pipe thrust is not being
carried out.
A remote control tunnelling machine shall be used and it shall include a closed circuit
television camera which transmits a picture of the laser beam on the target together with
other machine information (such as jacking force, face pressure, length, roll, pitch,
steering attitude, temperature valves open or closed) to a microprocessor console on the
surface from where the system is operated.
The tunnelling machine shall be capable of operating under groundwater conditions as
necessary. The hydrostatic balance shall be not less than 3m head of water.
E5.18
Line and Level

A laser guidance system shall be used for the control of tunnel alignment. The laser shall
be mounted independently of the thrust wall or machine jacking rig or anything else that
may move during jacking. The shield / tunnel machine shall be fitted with a calibrated
laser target, robustly constructed and rigidly secured to the shield / tunnel machine.
Manual checking of line and level shall carried out by conventional theodolite and level
techniques.
The setting of the laser and target and the alignment of the tunnel relative to the laser
beam shall be accurate and checked constantly.
The lateral deviation of any part of the pipeline should not be more than 50mm from that
detailed in the Contract.
The level of any part of the pipeline shall not deviate by more than 20mm from that
detailed in the Contract.
The maximum lipping between the edges of adjacent pipes shall not be more than 5mm.
If the deviation exceeds the specified tolerance, work shall cease immediately and the
Engineer informed forthwith. The Contractor shall submit proposals to rectify the deviation
and work shall only recommence on the written instruction of the Engineer.
Vol 3, Section3
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E5.19
Specifications
Thrust System
The rig shall distribute the thrust to the pipes via a thrust ring and packing. The jacks
shall apply the thrust to the thrust ring by means of a symmetrical distribution. Interjack
stations shall be used where frictional resistance or other causes would otherwise result in
unacceptable thrust forces.
If used, spacer blocks shall be true and free from any distortions.
All thrust rings shall be true and free from any distortions and sufficiently stiff so as to
transfer the load from the jacks uniformly to the packing.
Other than at the shield, each group of jacks shall be interconnected to ensure that an
evenly distributed load is applied to the thrust ring. Each jack shall incorporate a load cell.
At the rig and at intermediate stations automatic thrust recording equipment monitoring
load cells incorporated in each jack is to be provided together with a pressure metering
device. Other continuous records including cutter torque, rate of progress, slurry progress,
pitch, roll, slurry flow, earth face pressure, etc. shall be provided.
Copies of these records clearly stating the units measured shall be submitted daily to the
Engineer.
The thrust force shall not exceed the maximum permissible thrust force as determined by
the Contractor, based on calculations submitted by the Contractor and approved by the
Engineer and on consideration of the behaviour of the pipe joint at the maximum
permitted angular deflection of 0.5 with the maximum permissible bearing stress in
conjunction with the stress / strain relationship obtained from the packing compression
tests.
E5.20
Lubrication Holes
Where lubrication holes are required, these shall be threaded to enable plugs to be
screwed into the socket and withstand the external pressure. Non-return valves shall be
fitted where opening a hole would permit ground loss. Lubrication holes shall be plugged
watertight on completion, lining or coating shall be made good. The pressure of the
lubricant shall be maintained until it is replaced by grout.
E5.21
Grouting
Upon completion of a section, if grouting is required or specified, the grout shall be
pumped through all lubrication holes. The pressure and quantity of grout injected shall be
calculated by the Contractor and approved by the Engineer. Grouting shall commence at
the lower holes and shall be carried out systematically working from one end of the
pipejack to the other. Where injection holes can be opened without loss of ground, grout
shall be pumped through the lower injection holes until it emerges from the upper holes.
Grouting progress shall be continuously monitored to ensure no over pressurisation.
E5.22
Records
The Contractor shall maintain and submit to the Engineer after each shift a log which
records:
Identification number of pipes installed during shift and name of operator Strata
encountered.
Position and orientation of the lead ten pipes.
Vol 3, Section3
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E5.23
Specifications
Forces used on both main and intejack rams during driving of each pipe.
Line and level.
Roll of pipe jacking shield.
Maximum rate of advance.
Thrust from ground on face of machine.
Volume of lubricant used, location of injection and pressure at point of injection.
Gas readings at the excavating face (oxygen, methane and hydrogen sulphide)
Volumes of material removed.
Volumes of grout used, the points of injection and pressure at the points of
injection.
Cutter torque.
Slurry flow and pressure.
Supply pressure.
Pitch of TBM.
Gas readings in thrust pit.
Level records of around surface or road pavement.
Accident and stoppage, if any, with full explanation.
Testing
Upon completion of the permanent construction of the tunnel, an infiltration test shall be
conducted to verify that the joints are water tight. The infiltration test shall be carried out
after dewatering has stopped and the groundwater has attained normal levels. In the
case of lined concrete pipes the leakage tests shall be carried out after installation and
before the liners of the successive pipes are joined and sealed. After joining and sealing of
the liners, there shall be no evidence of a build-up of groundwater pressure at the joints of
the concrete pipe.
Man-entry pipelines shall be visually inspected only. Any leaks will be repaired / stopped.
Infiltration or pipe deflection is not permitted in sections of pipelines underneath roads,
paved areas and services.
In the event of the Works failing the test, for whatever reason, the Contractor shall at no
extra cost to the Employer, take such remedial action as is necessary, subject to the
Engineers approval of any methods proposed. The Works shall then be re-tested until
such time as the Works pass the test.
E5.24
Monitoring Ground Surface Movement

The Contractor shall continuously monitor the ground surface, adjacent structures, and
buried utilities and shall control activities such as excavation, tunnelling and dewatering to
prevent movement and / or damage to existing structures.
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Specifications
Settlement shall be held to within the following limits :

1.
Ground or roadway surface above the pipe centreline : 5mm
2.
Front face of adjacent structures : 3mm
Settlement points shall be installed and monitored prior to any excavation associated with
the pipeline to be constructed by microtunnelling.
The Contractor shall determine the optimum location for settlement points to monitor
existing structures to approval of the Engineer.
The Contractor shall provide settlement points on the road surface and within existing
structures. Settlement points along the road surface shall be located along the pipe
centreline and on lines parallel to the centreline at 2 metres and 4 metres away from the
pipe centreline on each side. The distance between settlement points along the same line
shall be 5 metres. Settlement points on existing structures shall be located approximately
0.5 metres above the ground surface. Location of settlement points in the vicinity of the
shafts will be agreed with or at the direction of the Engineer.
The Contractor shall monitor all settlement points with reference to benchmarks located
outside the area of influence of the works. Monitoring shall demonstrate repeatedly to
3mm.
The Contractor shall obtain the elevations of settlement points as described below:
1.
For settlement points within 20 metres of the heading, after each advance of 5
metres.
2.
For settlement points greater than 20 metres but less than 100 metres away from
the heading, daily.
The settlement point elevations shall be reported to the Engineer within 24 hours during
the course of construction of the pipeline and related shafts.
Should settlement occur greater than the specified limits, at any location affected by the
works, the Engineer may require modification of the method or sequence of the work or a
shutdown of the work to make appropriate changes in the construction operation.
Changes required to keep settlement within the specified acceptable limits shall be made
solely at the Contractors expense.
Upon completion of the pipeline, the Contractor shall continue to monitor the settlement
point elevations regularly during the maintenance period and report to the Engineer on a
monthly basis. If the specified limits are exceeded then the Contractor should report
immediately and submit a proposal to rectify the road surface and prevent further
settlement.
E5.25
Tunnelling-General Requirements
E5.25.1
General
(1)
The Contractor shall be responsible for all methods of working in underground

works, including the design, provision and erection of all things necessary to
safeguard the Works and the workmen. In particular, the Contractor shall be
responsible for the support of all excavation in underground works during
construction, which shall include making good after falls.
Vol 3, Section3
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E5.25.2
Specifications
(2)
All procedures necessary to safeguard the Works and workmen, except for any
emergency measures that may have to be taken by the Contractor to ensure safety,
shall be subject to the prior consent of the Engineer, but such approval shall not
relieve the Contractor of any of his responsibilities.
(3)
Except where otherwise required, tunnels in soft ground shall be straight or, in order
to accomplish changes in alignment, shall lie on horizontal and vertical circular
curves of minimum 50m radius. Curves may be omitted where a change in
alignment occurs at a shaft.
Submissions
For each pipeline the Contractor shall submit to the Engineer for his approval the
following:
E5.25.3
(a)
particular site investigation;
(b)
calculations of design and tunnel linings;
(c)
method description including drainage, excavation, ventilation and illumination;
(d)
specifications of materials and equipment to be used;
(e)
pipe calculations and loading tests results;
(f)
design and calculations of Temporary Works for tunnelling shafts and receiving pits,
shoring and drainage;
(g)
safety measures.
Safety
(1)
The Contractor shall comply with the safety requirements specified in this
Specification.
(2)
All tunnelling works shall be carried out in accordance with BS6164 Code of Practice
for Safety in Tunnelling in the Construction Industry and other relevant construction
and safety standards and regulations. The Contractor shall be fully conversant and
comply with the relevant sections of all safety regulations relating to underground
works enforceable by law.
(3)
The Contractor shall be responsible for the safety of all his employees and other
persons entering or in the Works and shall, at his own cost, and with the approval of
the Engineer, take all measures necessary to ensure their safety. In particular such
measures shall include the following:
(a)
Provision of proper safety and emergency regulations and fire, gas and
electric shock precautions.
(b)
Provision of a first aid box and rescue facilities at each tunnel portal or shaft.
(c)
Provision of a first aid post. The first aid post shall be in telephone
communication with portals and shafts in their areas and shall have a
telephone on the public network.
(d)
Safe storage, handling and use of gases, fuels and other dangerous goods.
(e)
Safe supporting of all excavations.
Vol 3, Section3
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E5.25.4
Specifications
(f)
Provision of efficient safety helmets for all personnel including authorized

visitors to the site; provision where necessary of safety harnesses for
personnel including the Engineer and his staff.
(g)
Control of water, including the provision of

generating plant.
(h)
Provision of lighting to provide adequate illumination of the Works, including

spares and standby equipment.
(I)
Provision and maintenance of safe, sound mechanical cranes, hoists and

conveying facilities for the transport of materials, each item of plant having an
up to date test certificate.
(j)
Provision and maintenance of safe, sound ropes, slings, blocks and other
lifting tackle, each appliance having an up to date test certificate.
(k)
Provision of temporary ladders to all shafts, with landings at intervals not

exceeding 3m. Protection shall be so provided that neither persons using the
ladders nor the ladders and their supports are subject to danger or risk of
damage by the passage of skips and/or materials in the shaft.
(l)
Provision and maintenance of safe, sound hoists and cages for conveying
personnel where necessary, each item having an up to date test certificate.
(m)
Provision of competent operators for control of all lifting and hoisting

equipment, with at least one banksman, the operators of shaft hoisting gear
being in telephone communication with the bottom of the shaft.
(n)
Provision and maintenance of all temporary electrical installations to the

standards prescribed in BS 6164.
(o)
Provision of notices, minimum 1.5m by 1.0m in size written in bold letters to

be erected on existing footpaths where appropriate and at points of access
likely to be used by the public to warn them of the existence of the Works.
These notices shall be in addition to any statutory requirements demanded of
the Contractor.
ample standby pumping and
(4)
The Contractor shall submit for the approval of the Engineer detailed proposals of
safety and emergency regulations. After approval, copies of the safety regulations
shall be produced by the Contractor and distributed to all of his employees and staff
and to the Engineer and his staff. Notices shall be displayed at all portals and
shafts detailing emergency and rescue procedures.
(5)
The Contractor shall ensure that all personnel are conversant with regulations.
Control of Water
(1)
The Contractor shall be responsible for the control of water in underground works
and shall keep these works well drained until the issue of the last Certificate of
Completion in respect of underground works or until the written approval of the
Engineer.
(2)
The Contractor shall ensure that all watercourses, whether they be natural or manmade, shall be trained away from shafts and tunnel entrances so that the Works are
protected from flooding.
Vol 3, Section3
Page E-108 of 115
E5.25.5
Specifications
(3)
Where the levels of workings are such that drainage or accumulations of water do
not flow away or cannot be piped away by natural gravitational means to existing
points outside the underground workings, the Contractor shall install and operate all
necessary pumping plant, pipework, tanks etc. including stage pumping where
appropriate, and shall eject all accumulations of water from the underground
workings. The Contractor shall, in locations agreed by the Engineer, provide and
install meters or other approved means of flow measurement in all incoming and
outgoing water pipes for monitoring the natural ingress of water.
(4)
Standby pumping plant with alternative motive power shall be provided by the
Contractor.
(5)
The Contractor shall at all times be aware of the possibility of sudden inrushes of
water if the excavation taps an underground source of water and shall take all
necessary precautions to ensure the safety of all men working in the tunnel and to
prevent delay in tunnel driving due to damage to plant. The precautions to be
taken shall include pilot drilling ahead of the face at all places where there is reason
to expect significant inflows of water, or there is a risk of interception known or
suspected fault zones or similar hazards. When excavation is by drilling the pilot
hole shall be drilled to at least twice the distance of the anticipated pull. The
number of pilot holes and their positions shall be governed by the type of ground
and available site investigation data. Radial pilot holes shall be utilized where
necessary. The Contractor shall be deemed to have allowed for the effects of pilot
holes on adjacent works and structures.
(6)
The Contractor shall ensure that all watercourses whether they be natural or manmade shall be trained away from shafts and portals so that the Works are protected
from flooding. Where in the opinion of the Engineer there is a danger of flooding,
he may order work to be discontinued and labour removed either until such danger
had passed, or until the Contractor completes additional protective measures to the
satisfaction of the Engineer.
(7)
Measures shall be taken by the Contractor, to the satisfaction of the Engineer, to

prevent pollution of existing watercourses by impurities in water discharges from
tunnels and shafts.
(8)
Water shall be kept clear of concreting work by grouting or by piping it away from
behind the shutter. Water shall not be allowed to run over or through freshly placed
concrete.
Testing and Records

(1)
Notwithstanding which method of excavation is used, the Contractor shall keep a log
in which shall be recorded the results of all examinations of the ground immediately
after excavation. The log for each heading shall be available for inspection by the
Engineer at a days notice at his office and on demand at the tunnel site. A copy of
the log shall be provided for the Engineers retention.
(2)
Entries in the log shall give the precise locations of all visually distinguishable
geological features. The log shall show the precise length and chainage excavated
in each shift. The chainage shall be marked at 10m intervals by approved
temporary marks concreted in place and maintained.
(3)
Records shall be kept of progress, ground conditions and where appropriate of the
line, level, plumb, square and roll of the shield and the lining and of the wedge ram
thrust at every tenth ring or such other interval as the Engineer may direct and a
copy sent daily to the Engineer.
Vol 3, Section3
Page E-109 of 115
E5.26
Specifications
(4)
Where appropriate records shall also be kept of the type and amount of grout
injected in each section of shaft or tunnel and a copy supplied to the Engineer daily.
(5)
Inspection and watertightness tests of completed tunnelling shall be performed in

accordance with the requirements of this specification.
Undertaking
The Contractor shall enclose with his request for approval (Notice of Intent) to carry out
the works from the concerned Authorities, an undertaking in the form of Exhibit I formally
executed by the Contractor, bearing the corporate seal and signed by the Contractors duly
authorised signatory.
EXHIBIT 1
UNDERTAKING
We undertake to inform the
in the event of collapse or settlement of a
road when we are carrying out excavation in, under or near to it. We hereby undertake to carry out
the required reinstatement works exactly in accordance with
specifications and to pay all compensations / entitlements for any accidents that may occur due to
this road collapse or settlement.
This is our undertaking in this respect.
CONTRACTOR
CORPORATE NAME
CHIEF EXECUTIVE OFFICER
Corporate Seal
Insert name of concerned Authority
Vol 3, Section3
Page E-110 of 115
Specifications
E6
INSPECTION AND TESTING OF PIPELINES
E6.1
Cleaning and Inspection of Pipelines

For the purposes of cleaning and inspection, the term "pipelines" includes those laid in
heading or by pipe-jacking techniques.
During and after construction the Contractor shall take all reasonable measures, including
the provision of plugs where appropriate, to prevent the ingress of deleterious matter into
pipelines.
After completion of manholes, chambers and similar features, the interior of pipelines shall
be cleaned of silt and debris by approved methods for inspection by the Engineer as
described below. In the case of pipelines laid in trench, this shall be carried out after
trench backfilling but before surface reinstatement.
Pipelines of 600 mm nominal internal diameter and smaller shall have a loose plug passed
through them to show that they are clear of obstruction. This shall be in the form of a
sphere or cylinder 25 mm smaller than the actual internal diameter of the pipeline.
Pipelines greater than 600 mm nominal internal diameter will after cleaning be inspected
from the inside and the Contractor shall provide a suitable trolley, ventilation and safety
equipment, and any other plant and labour necessary for this purpose.
Pipelines will be inspected again before commissioning or taking-over (whichever is
sooner) and if required by the Engineer shall be cleaned again in whole or in part.
E6.2
Testing of Pipelines - General Requirements

For the purposes of inspection and testing, the term "pipelines" includes those laid in
heading or by pipe-jacking techniques.
All pipelines and pipework shall be tested by the Contractor for watertightness and
stability. All tests shall be carried out in the presence of the Engineer and the Contractor
shall notify the Engineer or his Representative at least one full working day in advance of
his intention to carry out any test.
The Contractor shall provide all necessary plant and equipment, including struts and thrust
blocks, as may be necessary for effectively testing the pipelines to the specified pressures,
and shall be responsible for the supply and later disposal of all water necessary for testing
purposes.
The Contractor shall be responsible for sealing pipelines at the appropriate test pressures
and any difficulties encountered for whatever reason shall be overcome at the Contractor's
expense.
Should any inspection be unsatisfactory or any test fail the Contractor shall at his own
expense replace defective pipes, leaking joints or otherwise re-execute defective work
following which cleaning and testing will be repeated until the Engineer certifies the
pipeline as satisfactory.
E6.3
Testing of Non-Pressure Pipelines

Non-pressure pipelines of 750 mm and smaller nominal internal diameter laid in trench
shall be given a preliminary test when the pipeline is bedded and jointed but before
backfilling, and a final test after backfilling. Pipelines laid in heading or by pipejacking shall
be given a final test after completion of pipeline construction.
Vol 3, Section3
Page E-111 of 115
Specifications
Unless otherwise instructed, pipelines shall be tested in sections between

manholes/chambers/pumping station wet wells. In addition pipelines shown as straight
lines on the drawings shall be subjected to a light test as detailed in the pipelaying
specification, and all pipelines other than those with ogee joints shall be subjected to an
infiltration test.
Preliminary and final tests will not normally be applied to pipelines greater than 750 mm
nominal internal diameter and acceptance of these pipelines will be dependent on
satisfactory infiltration testing and visual inspection of the pipes and joints.
(i)
Preliminary Test
Air shall be pumped into the pipeline to a pressure of 100 mm head of water and
the pressure shall not fall to less than 75 mm during a period of 5 minutes.
Adequate precautions shall be taken to ensure that the accuracy of the test is not
impaired by fluctuations in the temperature of the air inside the pipeline. If
necessary, the hours during which testing is carried out shall be restricted as
directed by the Engineer's Representative.
(ii)
Final Test
The part of the pipeline under test shall be filled with fresh water to give an
effective minimum internal water pressure of 1.2 m at the highest point and a
maximum of 6m at the lowest point. Due allowance shall be made for any external
groundwater pressure. After standing for 30 minutes the water shall be topped
up if necessary and in the following 60 minutes the loss of water shall not exceed
0.25 litres per metre of diameter per metre of length of pipeline under test. In
addition there shall be no identifiable leak at any point in the pipeline.
This test will not be required where, in the opinion of the Engineer, it is not
appropriate due to the presence of a high groundwater table.
(iii)
Infiltration Test
After completion of backfilling and restoration of normal sub-soil conditions all
pipelines and their associated manholes shall be examined for infiltration.
There shall be no discernible inflow of water at any point and there shall be no flow
of water at any manhole or pipeline outlet.
E6.4
Testing of Pressure Pipelines

Unless otherwise specified, site testing for pressure pipelines shall be to 1.5 times their
maximum working pressure.
(i)
Preliminary Test
Pressure pipelines laid in trench shall be given a preliminary test after pipelaying
and bedding but before backfilling as follows:
Pipelines of 675 mm or more internal diameter shall have each joint individually
water tested by means of an approved joint testing apparatus at a pressure of
100 kN per square metre. The test will not be considered satisfactory if the loss of
pressure during a test period of 30 minutes exceeds 10 kN per square metre as
indicated by an approved pressure gauge having a range of 0-150 kN per square
metre.
Vol 3, Section3
Page E-112 of 115
Specifications
Pipelines of lesser diameter shall be air tested in convenient lengths as short as is

practicable. Air shall be pumped into the pipeline by suitable means until a
pressure of 300 mm head of water is indicated on a water manometer and the
test will not be considered satisfactory if the air pressure falls to less than 275 mm
during a period of 5 minutes. Adequate precautions shall be taken to ensure that
the accuracy of the test is not impaired by fluctuations in the temperature of the
air inside the pipeline. If necessary, the hours during which testing is carried out
shall be restricted as directed by the Engineer.
(ii)
Final Test
After they have been cleaned and inspected all pressure pipelines shall be given a
final test using fresh water as described below. In the case of pipelines laid in trench
this shall be carried our after trench backfilling.
Pipelines shall be tested in convenient lengths of up to 400 m by filling with water
under pressure. In addition to tests on separate sections, the whole pipeline shall
be tested by the same procedure as described below for individual sections. The
section under test shall be filled with water so that all air is expelled. In the case of
absorbent pipe materials or linings such as cement lined ductile iron, the pipeline
may be left to stand for a suitable period, normally 24 hours, at a pressure less than
the test pressure. The pressure in the pipeline shall then be steadily raised to the
specified test pressure in accordance with the pipe manufacturers recommendations
and maintained at that level for a period of one hour. The pump shall then be
disconnected, and no further water shall be permitted to enter the pipeline for a test
period of a further one hour.
At the end of this period the original pressure shall be restored by pumping and the
loss measured by drawing off water from the pipeline until the pressure as at the
end of the test is again reached. The loss of water shall not exceed 2 litres per
metre nominal diameter per kilometre length per metre pressure head (average
head applied to the section) per 24 hours. In addition, there shall be no visible leak
or pipeline movement at any point in the pipeline.
Care must be taken where appropriate to isolate air valves and other fittings, not
to apply a higher pressure than specified at any point in the pipelines, and to
ensure that the pipelines are adequately anchored before any test is carried out.
Testing against valves which are themselves connected to an existing public water
supply is prohibited because of the danger of contamination. Testing against other
closed valves (including air valves) not so connected may be attempted if the
Contractor so wishes but at his own risk, provided that the valves are of adequate
pressure rating and are anchored against thrust and on condition that any
consequent damage is rectified by the Contractor as his own expense.
After testing, suitable plugs shall be provided and maintained in all open ends of the
pipelines in order to exclude silt or any other deleterious matter until the pipelines are
commissioned.
Vol 3, Section3
Page E-113 of 115
Specifications
TABLE OF CONTENTS
Page No.
SECTION F - BRICKWORK AND BLOCKWORK
F1
GENERAL
F2
DESIGN
F3
MATERIALS
F3.1
Clay Engineering Bricks
F3.2
Concrete Blocks
F4
F3.2.1
Cement
F3.2.2
Aggregates
F3.2.3
Sand for Mortar
F3.2.4
Lime for Mortar
F3.2.5
Water
F3.2.6
Plasticisers for Mortar
F3.2.7
Pigments
F3.2.8
Concrete Block Manufacture
CONSTRUCTION
F4.1
Brickwork and Blockwork General
F4.2
Clay Engineering Brickwork
F4.3
Jointing and Pointing
F4.4
Mortars Generally
F4.5
External Rendering
Vol 3, Section 3
Page i of i
Specifications

F1
GENERAL
This section gives the general requirements for brickwork and blockwork. Further details
of the requirements for brickwork and blockwork in buildings are given in Section L of the
General Technical Specification.
F2
DESIGN
Brickwork and blockwork shall be designed to BS 5628 or other approved design code with
reinforcement designed and fixed accordingly.
Jointing arrangements shall be in
accordance with the guidance given in BS 6093. Design calculations shall be submitted to
the Engineer for approval and no laying of brickwork and blockwork shall commence
before the designed is approved.
Building designs shall be in accordance with local building regulations and Ministry
standards.
F3
MATERIALS
F3.1
Clay Engineering Bricks

Bricks for all sewerage and drainage work shall be clay engineering bricks to BS 3921, Class
A or Class B as detailed. Special purpose bricks (e.g. bull nosed, coping or radial bricks for
circular work) shall be to the shapes and dimensions specified in BS 4729. Faces of
engineering bricks to be exposed to the weather shall not be wire cut. Bricks for oversail
corbelling shall be solid.
Before any bricks are ordered samples shall be submitted to the Engineer for approval.
F3.2
Concrete Blocks
F3.2.1
Cement
Cement for concrete blocks required for work below ground level shall be sulphate resisting
Portland cement complying with BS 4027.
Cement shall be low alkali having a total acid soluble alkali content (Na20 + 0.685K20) of
less than 0.6 percent when tested in accordance with BS 4550.
Cement for mortars shall be compatible with the cements specified for concrete blocks.
F3.2.2
Aggregates
Aggregates used for the manufacture of concrete blocks shall comply with the requirements
for aggregates for concrete stated in Clause D1.4. The grading shall comply with Table 4 of
BS 882 for 10mm nominal size of single-sized aggregates as follows:
Vol 3, Section 3
Page F-1 of 6
F3.2.3
Specifications
Sieve Size
(mm)
Percentage by mass passing

BS sieve
14
10.0
5.0
2.36
100
85 - 100
0 - 20
0-5
Sand for Mortar

Sand for mortar for brickwork, blockwork and general purposes shall comply with Table I of
BS 1200, as follows:
Sieve Size
(mm)
Percentage By Mass Passing

BS sieve
5.00
2.36
1.18
microns
600
300
150
75
100
90 - 100
70 - 100
40
5
0
0
100
70
15
5*
* May be increased to 10% for crushed stone sands.

The clay/silt content when determined in accordance with BS 812 shall not exceed 3 percent.
The chloride and sulphate contents for sands and mortar shall not exceed the limits given for
aggregates for concrete stated in Clause D1.4 and sands shall not contain harmful matter
such as iron pyrites, salts or laminated material such as mica, shale or organic or other
impurities in sufficient quantity to adversely affect the hardening strength or durability of the
mortar.
F3.2.4
Lime for Mortar

Lime for mortar shall be non-hydraulic (calcium) or semi-hydraulic (calcium and magnesium)
and shall comply with BS 890.
F3.2.5
Water
Water for block making or mortar shall be as specified for concrete in Clause D1.2.
F3.2.6
Plasticisers for Mortar

Mortar plasticisers shall comply with the requirements of BS 4887.
F3.2.7
Pigments
Pigments for use in blocks or mortar shall comply with BS 1014. The pigment content shall
not exceed the weight of cement by more than 10 percent and if carbon black is used the
proportion shall be not more than 3 percent by weight of cement.
Vol 3, Section 3
Page F-2 of 6
F3.2.8
Specifications
Concrete Block Manufacture

Concrete blocks shall be manufactured generally in accordance with BS 6073 and shall be
solid, hollow or cellular and to the dimensions as shown on the Drawings. For hollow blocks
the hollow area shall not exceed 50 percent of the overall plan area of the block.
The minimum compressive strength when sampled and tested in accordance with BS 6073
shall be not less than 7N/sq.mm.
Where blocks of moderately sulphate resisting Portland cements and sulphate resisting
cements are required on the same site the Engineer may require the latter to be pigmented
in accordance with Clause F1.7 if, in his opinion, the two categories of blocks might
otherwise be confused on site.
Vol 3, Section 3
Page F-3 of 6
Specifications
F4
CONSTRUCTION
F4.1
Brickwork and Blockwork General

Bricks and blocks shall be carefully handled during unloading, properly stacked on clean
level hard-standing, and adequately protected from inclement weather. Broken bricks and
blocks shall be removed from the site.
During hot and dry weather, bricks and blocks shall be wetted before laying as necessary
and the tops of walls shall be wetted to reduce excessive suction before any work
commences. Completed work shall be protected to avoid excessive drying out.
No brickwork or blockwork shall be carried out when the shade temperature is greater
than 35C.
Bricks and blocks in each course shall break joint correctly with the course underneath.
The courses shall be laid parallel with joints of uniform thickness and shall be kept straight
or regularly curved as required. Vertical joints shall be in alignment as required by the
bond and shall, unless otherwise shown on the drawings, have an average thickness of
8mm. Bricks forming reveals and internal and external angles shall be selected for
squareness and built plumb. Bricks with single frogs shall be laid frog upwards. All joints
shall be bedded solid in mortar as the work proceeds.
Walls shall rise uniformly; corners and other advanced work shall be raked back and not
raised above the general level more than 1 metre. No brickwork shall be carried up higher
than 1.5 metres in one day. For brickwork, oversail corbelling shall not exceed 30 mm on
each course.
All faces of blockwork shall be kept clean and no rubbing down will be permitted.
Exposed faces of finished brickwork and blockwork and joints shall be protected in
accordance with Clause G4
F4.2
Clay Engineering Brickwork

Unless otherwise specified or ordered all engineering brickwork shall be built in alternate
header and stretcher courses
In all engineering brickwork the overall dimensions of four bricks laid in mortar shall not
exceed by more than 25mm overall dimensions of the same bricks laid dry.
F4.3
Jointing and Pointing

Bricks and blocks shall be laid in mortar properly bedded and jointed and all joints filled
with mortar on every course. Unless otherwise stated all joints are to be finished flush
pointed.
Where walls are to receive rendering joints are to be raked out not exceeding 5 mm deep.
F4.4
Mortars Generally
Mixing of mortar will normally be carried out with a machine driven roller pan mixer of
approved type and size. Mortar which has begun to set shall not be revived or re-used.
Proportions of Mortar:
Cement Mortar
Vol 3, Section 3
1 part cement
3 parts sand
Page F-4 of 6
Cement/Lime Mortar
Specifications
1 part cement
1 part lime
6 parts sand
Unless otherwise specified cement mortar shall be used for brickwork and blockwork below
ground level and cement/lime mortar shall be used for work above ground level.
F4.5
External Rendering
The following applies to below ground external rendering. Refer to Section L for building
wall rendering.
Where external renders are detailed on the drawings they shall be applied to various
backgrounds as follows:
Concrete, Concrete Blocks and Bricks and Engineering Bricks:
The render shall be three coat work comprising of a stipple coat, undercoat and finishing
coat giving a maximum thickness of 15mm. The mix shall be in the proportions shown on
the schedule of mixes.
(i)
The stipple coat shall consist of 1:1 cement/sand mixed with 50% water/50%
PVA bonding agent to form a thick slurry. The mixture shall be vigorously brushed
onto the background and stippled to give a close textured key. The resulting finish
shall be kept damp to prevent rapid drying out and allowed to harden for seven
days minimum before subsequent coats are applied.
Prior to rendering, surfaces are to be damped sufficiently to ensure uniform
absorption.
(ii)
The undercoat shall be level, true and of nominal thickness 9 mm but always of
sufficient thickness to prevent the joints in the background showing through.
A key for the final coat shall be provided by combing the undercoat prior to setting
with wavy lines 20 mm apart and 5 mm deep.
In hot weather the undercoat shall be protected to avoid rapid drying out and if
necessary polythene sheet shall be held against the surface to prevent
evaporation and retained in place for 3 - 4 days to achieve satisfactory curing.
This shall be followed by a further period to allow the surface to dry out before
the final coat is applied.
(iii)
Vol 3, Section 3
Before application of the final coat the surface shall be damped down to control
and provide an even suction. The final coat shall be applied approximately 6 mm
thick and to achieve the overall thickness of the render required. The surface shall
be worked to a level and smooth finish with a wooden float. The whole shall be
protected from rapid drying out and surface kept damp to obtain even drying.
Page F-5 of 6
Specifications
Schedule of Mixes to External Render

Mix Type
Cement:Lime:Sand
Vol 3, Section 3
Concrete, Concrete Blocks, Concrete Bricks,

Engineering Bricks
Undercoat
Finish
1::4
1:1:5
Page F-6 of 6
Specifications
TABLE OF CONTENTS
Page No.
SECTION G - CORROSION PROTECTION AND SURFACE COATINGS
G.1
MATERIALS
G.1.1
Corrosive Environment and Corrosion Protection System
G.1.2
Paint
G.1.3
Impervious Tanking Membrane
G.1.4
PVC Sheet Lining Materials
G.1.5
Glass Reinforced Plastic Liners
G.1.6
In-situ GRP Laminations
G.1.7
Epoxy Mortar for Stormwater Manholes
G.1.8
Rubberised Bitumen Emulsion
G.1.9
Waterproof Paper
G.1.10 Protective Materials for Wrapping Pipeline Components
G.1.11 High Density Polyethylene Protection Sheet
G.1.12 Protective Coating with Cementitious Water Proof Coating
G.1.13 Approved Paint Suppliers
G.1.14 In-situ GRP Lamination with Grit bonding on final finish coat
1
1
1
2
2
2
5
16
17
17
17
17
18
18
19
G.2
INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE
G.2.1
General
G.2.2
Water Proof Membranes/Liners/Roof Waterproofing and Protective
Coatings
G.2.3
GRP Prefabricated benching unit for Sewer Inspection Chambers
G.2.4
Cutting and Sealing of Reinforced Liners
G.2.5
Protective Coatings to Concrete Works
20
20
20
31
31
31
G.3
COATING SYSTEM FOR FERROUS, NON FERROUS METALS AND PLASTICS
G.3.1
General
G.3.2
Products
G.3.3
Execution
G.3.4
Testing and Inspection
40
40
47
48
51
Vol 3, Section 3
Page i of i
Specifications

G.1
MATERIALS
G.1.1 Corrosive Environment and Corrosion Protection System

Systems and surface coatings for protection against corrosion and for decorative purposes
shall in all cases be suitable for-exposure to their contact with environmental conditions which
may include any or all of the following:
1. The average climatic conditions detailed in Section A of the Specification, with particular
emphasis, where appropriate, on the consequential effects of UV light, temperature
variations, high surface temperatures and high humidity.
Under certain combinations of the climatic conditions considerable condensation may take
place.
A considerable amount of salt is contained in the atmosphere, which together with the
extremely high ambient humidity, can produce severe corrosion problems.
Distribution of rainfall is irregular, and the precipitation amounts are normally of no
significance, but attention should be paid to the fact that sudden heavy rainfalls over a
very short period of time can occur.
2. Septic sewage with a pH value of less than 1.
3. Sulfuric acid solution in sewage slimes in concentrations up to 15 % by weight.
4. Hydrogen sulphide and other gases (Ammonia, methane and carbon dioxide) emanating
from sewage, septic sewage and sewage sludges.
5. Saline groundwater with high chloride or sulphate contents both below the water table
and in soil zones above the water table where capillary action and the presence of oxygen
may cause extremely severe conditions.
6. Wind blown chlorides
7. Wind blown abrasive sands
For raw and treated potable water schemes the protective systems and coatings shall be
approved by a recognised certifying authority as being suitable for water systems without
imparting odour or taste, nor causing discolouration, and all materials shall be non-toxic and
non carcinogenic.
The Contractor shall ensure that suppliers and manufacturers of materials for protective
systems are made aware of the above conditions and the conditions described elsewhere in
the Specification
G.1.2 Paint
Protective and decorative paint systems including primers and undercoats shall be obtained
ready mixed for use. All containers of paints and other coating systems shall show date of
Vol 3, Section3
Page G-1 of 68
Specifications
manufacture, shelf life and pot life where applicable. Paint shall be applied as per Clauses in
section G.2.
The Contractor shall only be allowed to use paints which are delivered to the site in sealed
cans or drums bearing the name of the manufacturer and properly labeled.
Tints and shades of final coats shall be advised by the Engineer or his Representative.
G.1.3 Impervious Tanking Membrane
Membrane used for tanking to concrete structures shall be impervious, self-adhesive and
covered with a release agent.
G.1.4 PVC Sheet Lining Materials
PVC sheet materials to be used for lining concrete structures and pipelines internally shall be
manufactured from polyvinyl chloride, plasticisers and pigments to make permanently flexible
sheets.
The colour of the sheet shall be approved on site.
The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed by extrusion to
have on one side locking keys or ribs of either 'T' or diamond section at centers not greater
than 75 mm. It shall be capable of forming a continuous 100% effective seal with the use of
welding strips or other approved method and shall be supplied with all materials and tools for
making the joints.
The tensile strength of the material shall be not less than 17000 kN/m2.
All weld strips, patches and other sheets used in the permanent fixing of the ribbed sheet
shall be of a material having the same composition as the ribbed sheet.
G.1.5 Glass Reinforced Plastic Liners
Glass Reinforced plastic liners to be used for lining pumping stations and manholes shall be
manufactured to the dimensions given on the Drawings, within the following tolerances :
(1) The work size, which is defined as internal diameter as specified by the manufacturer,
shall be declared and shall not differ from the normal diameter by more than 1%.
A manufacturing tolerance on the work size of 10 mm will be allowed provided that a
tight fit is achieved between the liner and the slab liner.
(2) Liners shall be supplied in lengths to suit requirements with a resin rich finish to internal
surfaces.
(3) Maximum thickness shall be 7 mm for sewerage work and 5 mm where approved for
drainage work. Liners larger than 2000 mm in diameter shall have a minimum wall
thickness of 9 mm.
(4) The out of squareness shall not be greater than 10 mm.
(5) The deviation from straightness of the bore of the liner shall not exceed 20 mm.
Although the liners are not designed to be structural, they shall have a sufficient stiffness to
withstand:
a. Buckling or distortion in transit or storage.
b. A hydrostatic head of 8 metres without distortion damage, leakage or permeation.
Vol 3, Section3
Page G-2 of 68
c.
Specifications
Grouting pressures.
Prior to grouting of the manhole liner at least 24 hours shall be allowed for temperature
equalization between the manhole structure and the reinforced plastic liner.
The manufacturer shall provide shop drawings of the proposed top slab liners prior to
manufacture for approval.
The manufacturer shall stipulate the maximum deflection of the slab liner permitted without
causing surface cracking to the gel coat. The Contractor must take care not to exceed this
limit, and any surface cracking that occurs will be repaired.
The construction methods employed shall be so as to ensure that a completely water and gas
tight seal is made preventing any exposure of the concrete surround to the corrosive liquids
and gases present, in the sewage.
In particular:
Glass Reinforced plastic liners shall be handled in the same manner as glass reinforced plastic
pipes. In addition, extra care shall be taken to avoid damage to the liners which are not
designed to carry loads.
The manufacturer shall visit the site to demonstrate to the Contractor in the presence of the
Engineer's Representative the methods of handling and lifting, including formation of the
joints between the chamber liner.
The Contractor is reminded that these liners are not designed to withstand pressure exerted
by the concrete during construction.
The design of GRP liners to provide a permanent internal shutter, to the concrete structures
shall be the responsibility of the liner manufacturer. The design should however incorporate
all the requirements of these Specification.
The liner shall be designed to provide protection for concrete for 50 years from the corrosive
effects of raw sewage in temperature up to 50C. The GRP liners shall be machine made
filament wound and of similar material (except sand filler) construction and manufacturing
process as for the GRP pipe.
Chemical Requirements
The liner design shall qualify the chemical requirements specified in ASTM D3753.
1. Testing shall be performed in accordance with the chemical test method.
2. The log percentage property retention versus log of time data graph should be
extrapolated by a linear plot beyond the 12 months result to 10,000 hours. The
extrapolated data must assure retention of at least 50% of the initial properties.
Chemical Test Method
Testing procedures for measuring chemical resistance shall conform to ASTM C581 with the
exceptions as noted below:
1. Test Laminate Construction: The basic test coupon shall be cut from a laminate made
in a manner consistent in every way with manhole construction.
2. Test Intervals: Coupons shall be drawn and tested after 1 month, 3 months, 6 months,
and 12 months immersion in each test medium. It may be advisable to include extra
Vol 3, Section3
Page G-3 of 68
Specifications
coupons at the time of the initial immersion in the event it is necessary to extend the test
interval beyond 1 year to 10,000 hours.
3. Test Media: The test media shall represent as completely as equal to the actual
environment in the manhole service. In that respect, test medium shall be the material as
specified for chemical resistance for sewer manholes.
4. Test Temperature: The test temperature of test medium used in corrosion resistance
verification of manhole containing that medium (normally this shall be 50C).
5. Interpretation of Results: Laminate properties to be determined initially and after
each test period are flexural strength, flexural modulus (both as per ASTM D790) and the
Barcol hardness as per ASTM D2583) of both interior and exterior lamination. The
laminate should be fully cured before initial properties are obtained. Any effect up on the
immersion medium or laminate observed during visual inspection shall be noted. The log
percentage retention after immersion testing (verses initial) is to be plotted against the
log of immersion time in hours.
Quality Control Testing
The following test shall be carried out as detailed below:
1. Composition Test: A loss on ignition test shall be carried out once every 100m of shaft
produced. Conduct the test as per ASTM D2584 and determine the glass/resin ratio.
Controls on glass and resin content must be maintained for all manufacturing process and
for each portion of manhole fabrication. Record shall be maintained of these control
checks.
2. Barcol Hardness: Each manhole component part shall be tested in accordance with
ASTM D2583, standard method of test for Indentation Hardness of plastics by means of a
Barcol Impressor. The minimum acceptable value of cure shall not be less than 90
percent of the resin manufacturers minimum value for the cured resin.
3. Thickness: Wall thickness of each manhole component part shall be checked with a
micrometer caliper gauge, or other suitable instrument to establish the actual thickness.
4. Appearance (Interior and Exterior Surfaces): The following defects are not
permitted.
(a) Crazing (b) Delamination (c) Blisters (d) Fiber show (e) Surface pits and voids directly
beneath the surface of the laminate and on the surfaces (f) Dry spots (g) Pimples (h) Pit
or pinhole (i) Resin pocket (j) Deep scratches (k) Impact cracks (l) Fish eye (m) Worm
holes (n) Deep wrinkles.
Certification
When requested, a certification shall be made on the basis of acceptance. This shall consist of
manufacturers test report accompanied by copy of test results, that the GRP liner has been
sampled, tested and inspected, in accordance with the previsions of this specification and
meets all requirements. Each certification shall be signed by the manufacturer.
Cutting and Sealing of Reinforced Liners
Where the Contractor is required for any reason to cut reinforced plastic liners, he shall seal
the exposed ends with an approved resin before incorporating the cut reinforced plastic in the
work. No cut reinforced plastic shall be used until the resin has cured.
The resin shall be as recommended by the manufacturer of the reinforced plastic item and
shall be pigmented so that the areas where it has been applied are easily identifiable.
It shall be delivered to site in sealed containers bearing the name of the manufacturer and
properly labelled as to its content and shelf life.
Vol 3, Section3
Page G-4 of 68
Specifications
For flexible pipe materials a rubber protection strip shall be inserted between the pipe barrel
and the steel band.
G.1.6 In-situ GRP Laminations
General
This Clause shall cover all in-situ GRP lamination work to be carried out under the Contract as
corrosion protection. It shall include site work related to jointing of prefabricated reinforced
plastic components eg. manhole liners, GRP pipe sleeves, lamination work to benchings and
channels, sealing of pipe entries, lamination work to internal concrete faces of major concrete
structures, pumping stations, valve chambers, air valves and washout chambers etc as shown
in the approved drawings.
Vol 3, Section3
Page G-5 of 68
Specifications
Table G1- PROPOSED CORROSION PROTECTION SYSTEM WITH 7mm THICK IN SITU GRP LAMINATION ON MAJOR CONCRETE
STRUCTURES INTERNAL
Unit Process
Fluid Type
Covered
Corrossive environment
Proposed Corrosion
Protection System
TLPS Wet Well
Septic sewage
Yes
Very high H2S levels, high corrosion risk
System A
Tanker Reception Sump
Septic sewage
Yes
System A
Inlet Works (Screen Channels)
Septic sewage
Yes
System A
Aerated Grit Channels
Septic sewage
Yes
System A
Flow Splitter Chamber
Septic sewage
Yes
System A
Digested Sludge Sump & Pump

House
Digested sludge
Yes
System A
Ferric bund area
Ferric Chloride
No
PH=1, very acidic
System A
Liquor Return Sump & Pump House
Filter dirty backwash,

permeate from GBT,
Belt press/centrifuge &
site drainage
Yes
PH = 1, very acidic, pH = very alkaline
System A
Diesel Storage Tank Bund
Diesel /oil
No
Vol 3, Section3
Page G-6 of 68
System A
Specifications
Site Operatives for GRP Work

The In-situ GRP lamination work shall be carried out only by the Client approved laminators.
All lamination work must be carried out by skilled operators under the supervision of a worker
with a minimum of 10 years experience in in-situ lamination.
The Contractor shall only employ personnel who have received suitable training and possess
relevant experience in the execution of any in-situ GRP work, including lamination work and
the cutting, sealing and jointing of reinforced plastic. Site operatives for employment on this
work shall be certified in writing by the supplier or Contractor as trained to a satisfactory
standard in application techniques.
Such personnel will be subject to approval by the Engineer prior to the commencement of
such work. Approval will include site trials to demonstrate competence to undertake the work.
GRP Applicators Special Requirements
1. The company doing the GRP lamination work should have:
a. a Safety Manual For Guide to Making a Laminate, Planning and Maintaining the Work
area
b. an automatic master and batch mixer with agitator
c. a mobile storage (fire-proof) vehicle with steel container having AC, exhaust fan inside for
storing the resin and glass and the master batch resin mixer.
d. automatic resin discharge pump system and spray facilities to feed the resin from master
batch mixer into the laminated work area to achieve a uniform resin mixing and
dispensing during lamination period.
e. in-situ testing apparatus to carry out the following quality control tests.
1.
2.
3.
4.
5.
Barcol impressor Nr. 934-1 with sufficient numbers of calibrating shim.

Digital elcometer thickness gauge with calibration shim
Pull off adhesion tester with sufficient numbers of dolly.
Holiday detection spark tester recommended by the resin manufacturer
Relevant hammer for hammer test
f. Safety arrangements to keep inflammable catalysts with fire hydrant in working condition.
g. services of an efficient technician at site to mix the resin in desired proportion to suit the
variable working temperature condition at site.
h. AC room facilities for bulk storage of resin drums and glass mat rolls in an isolated place.
i. first aid facilities and the services of a safety engineer at site.
j. Sufficient numbers of powerful exhaust fan at working area to clear out the styrene gas.
k. Breathable air inlet facilities for the workers at site
l. Safety harness for each labourer working on site.
Method Statement
All in-situ lamination must be carried out in accordance with an approved detailed method
statement. This shall include details of all materials to be used together with the
manufacturers names, addresses and specification sheets. Particular details of procedures
relative to separate categories of work as given above shall be itemised separately.
If materials are to be stored on site then details shall be provided of the store in which the
materials are to be kept, the environmental controls which will be used to ensure materials
are stored in accordance with manufacturers recommendations and the control and security
arrangements necessary to prevent unauthorised tampering with materials.
Vol 3, Section3
Page G-7 of 68
Specifications
If materials are to be brought to site on a daily basis from the suppliers central store in site
containers then details shall be provided of the type, size and identification markings on each
container to be used for this purpose. The Contractor shall indicate the controls to be set-up
to ensure that different resins and materials are clearly identifiable at site. The method
statement shall include forms to be submitted to the Engineer which will be necessary to
record the decanting of materials from manufacturers containers to site.
Materials in GRP Lamination
Table G2 Materials in GRP Lamination
a.
Type of resin to prime the concrete
surface
b. Type of glass (csm) throughout the
lamination
:
:
c.
Type of C glass tissue for final layer
d.
Recommended catalysts to prepare resin

at site
Type of resin throughout the lamination
e.
Epoxy based vinyl ester resin having

minimum 8% elongation property
Powder bound ECR/Advantex fiber glass
csm having excellent corrosion resistance
to acids
C glass of ECR type having excellent
corrosion resistant to acids
1. BUTANOX LPT
2. MEKP LA 3
Epoxy based vinyl ester
Table G3-Typical Room Temperature Clear Casting properties of VE Resin

Tests
Tensile Strength MPa
Tensile elongation at
yield%
Tensile modulus GPa
Flexural strength MPa
Flexural modulus GPa
Compressive Strength
MPa
Compressive Modulus
GPa
Compressive
deformation at yield%
Specific Gravity
Average coefficient of
expansion between 25
and 100C X10-6 cm
cmC
Izod impact J/m
Heat distortion temp
C
Barcol Hardness
Epoxy Resin
81
5
3.3
124
3.1
114
2.4
6
1.12
Epoxy Resin Primer

70
8
Method of Analysis
ASTM D-638
,, D-638
3.1
135
3.2
86
,,
,,
,,
,,
D-638
D-790
D-790
D-695
2.2
,,
D-695
,,
D-695
,,
,,
D-256
D-648
1.13
65
22
70
250
102
35
80
40
Table G4- Typical Properties of Liquid Resins

Property
Epoxy Resin
Epoxy Resin Primer
Styrene Level %
45
40
Brook field Viscosity
MPa at 25C
500
350
Flash point C Tag
open cup
34
32
Vol 3, Section3
Page G-8 of 68
Barcol impresser
model 934 - 1
Property
Specific Gravity
uncured at 25C
Acid number
maximum
Storage stability
(months)
Specifications
Epoxy Resin
Epoxy Resin Primer
1.04
1.04
8.5
10
Table G5- Physical Properties of ECR / Advantex Glass Fibres

Property
Density
Refractive index
Thermal linear
expansion 0 - 300C
Softening point
Annealing point
Strain point
Test Method
ASTM D1505
Oil Immersion
ASTM D696
Unit
g/cc
ppm/C
ECR/Advantex
2.62
1.560-1.562
6
ASTM C338
Parallel Plate
Viscometry
Parallel Plate
Viscometry
916
736
691
Table G6- ECR/Advantex Single Filament Tensile Properties

Property
Tensile Strength
@23C
Elastic Modulus
Elongation at the
Breaking Load
Test Method
ASTM D2101
Sonic Method
ASTM D2101
Unit
MPa
Kpsi
GPa
MPsi
ECR/Advantex
3100-3800
450-550
80-81
11.6 11.8
4.6
The method statement shall also provide details of the material build up or lay up. It shall
state the number and type of layers of glass fibre reinforcement together with the resin used
to impregnate it. Proposed lay up shall be not less than the requirements detailed in this
Clause.
The method statement shall also detail the Contractors safety proposals with respect to this
work to demonstrate compliance with his obligations under the Contract, for each type of
work location.
Surface preparation
The concrete surface must be fully cured and older than 4 weeks.
Before commencing work surfaces must be cleaned down, suitably prepared and allowed to
dry. Under no circumstances must the laminate be applied in dirty, damp or wet conditions.
Once dry, no water should be allowed into the structure except that required for safety
reasons.
Concrete surfaces must be clean, sound, dry and dust free. Any surface laitance, loose or
unsound concrete etc shall be removed. Surfaces must be entirely free of oil, grease, paint,
detergents, rust, biological or other surface contaminants. Surfaces shall preferably be
prepared by high pressure water jetting, pneumatic scabbling, grinding or steel grit blasting,
followed by thorough brushing with a clean paint brush (used only for this purpose) or by
washing to remove dust and remaining particles and to provide an exposed aggregate finish
Vol 3, Section3
Page G-9 of 68
Specifications
to ensure a mechanical key to the laminate. Diesel, oil and grease contaminants shall be
removed and rinsed thoroughly with water by steam cleaning, detergent scrubbing or the use
of proprietary degreaser. Effectiveness of decontamination may, on the instructions of the
Engineer, require to be assessed by a pull-off test. The hardened condition of the concrete
substrate is to be subjected to hammer test by tapping on concrete and make sure any
hollow sound is not produced. The defective concrete is to be removed and make good and
allow the surface to dry condition.
Prior to application, all active hydrostatic leaks must be stopped by the use of an appropriate
approved material specifically formulated to stop the ingress of water.
Where the laminate will be in contact with the surface or edges of uPVC pipes or existing GRP
laminates, liners, pipe or fittings the contact surface shall first be roughened by grinding or
wire brushing. The contact surface for benching lamination extending within GRP pipes shall
be accurately feather ground from 0 to 7 mm over a length of 150 mm. All dust shall be
removed as above.
Grinding shall be carried out to limits neatly defined by masking tape or other approved
means. Measures shall be taken to prevent damage to surfaces outside such limits by the
use of appropriate masking devices etc.
On concrete surfaces of major structures, base slab wall and roof slab: After completed two layers of GRP lamination work, SS 316 grade HILTI nails are to be shot
into the concrete by the help of a shotgun at 60 cm intervals to achieve a proper key in
interlock between the concrete surface and the GRP lamination work. Further layers of
lamination work shall be continued after the nail fixing.
Particular care is needed in preparation to ensure that the correct laminate thickness will be
maintained over nosings to the arris between horizontal and vertical parts of the benching,
including removal of concrete as necessary.
Following after obtaining engineers approval for the GRP materials a trial lamination work to
a size of 1.2M x 1.2M shall be carried out on concrete surfaces of any one of the structures
and conduct the followings Pre qualification test. These trials shall be carried out using the
approved type of materials, mixing procedures and applications as will be used on the
Contract.
Table G7- Trial Sample and Pre qualification Test on GRP Lamination Work
Sr.
Test
1. 100 days acid immersion
test @10% concentrated
sulphuric acid at 50C
2. Flexural strength of GRP
laminate sample
3. Tensile strength of GRP
laminate sample
4. Pull off adhesion strength
of lamination
5. Resin / Glass ratio
6. Resin cure
Test method
ASTM C581
7. Thickness of Lamination
8. Holiday Detection Test
Digital Elcometer
105 DC high voltage 0-
Vol 3, Section3
ASTM D790
Minimum Test Requirements

Test sample shall not show any
defects as mentioned in relevant
standard
193 MPa
ASTM D639
138 MPa
ASTM D 4541
Pulling strength shall be greater

than concrete
60:40
Minimum : 33 Barcol reading in
accordance with the manufacturers
test procedure specified.
Not less than the specified thickness
Air bubble / voids free surface on
ASTM D 2584
Barcol Impressor
934-1
Page G-10 of 68
Sr.
Test
9. Surface Quality
10 Acetone Sensitivity test
11 Hollow sound detection
Specifications
Test method
10 to 20 kV Holiday
Detector
ASTM D 2563
Resin manufacturers
recommended test
Hammer test

final lamination
Quality level 2 as specified in
relevant standard
Tack free surface on GRP
lamination
No hollow sound on completed
lamination work.
Note:
1. All relevant samples of GRP lamination test coupons are to be taken from the test patch
area and identified by the Engineer.
2. The tests are to be witnessed by the Engineer.
3. Testing apparatus required for in-situ tests is to be provided by the GRP applicator.
The acid immersion test will take 100 days duration and hence the applicator shall provide a
guarantee for the work until they get the relevant test results for the GRP lamination work.
The lamination work shall start at site on written confirmation with the guarantee.
Table G8- Minimum Quality Control Test on Final GRP Lamination work
Sr.
Test
1. Barcol Hardness
Test method
Resin manufacturers
recommended test
method
2. Thickness
Digital elcometer
3. Alarm type Spark test
As stated in Spark tester

catalogue
4. Pull off adhesion test

5. Resin glass ratio
Pull off test in

accordance with ASTM
D4541
ASTM D 2584
6. Visual inspection
ADTM D 2563

Average 33 reading on Barcol
Impressor @ 100% of laminate
area in accordance with test
procedure specified
Min. 3 tests on each structure and
shall achieve the minimum
thickness specified.
Full surface area of each structure.
Locate the defects if any & repair
in good condition
Minimum one test on each major
structure. Pull off strength shall be
greater than the concrete strength
One test on a sample taken from
any one of the structure. The
proportion shall be 5% of the
specified value
100% of the GRP laminated area.
Required Level-2 as specified in the
standard.
Test Procedure for Barcol Hardness Test Recommended by the Resin Manufacturer
Use Barcol impresser apparatus Nr. 934-1

Take 10 12 readings on test patch area
Reject the highest and lowest readings
Take the average of the remaining 10 readings to get the Barcol hardness value
Final approval for the GRP lamination work will be given by the Engineer only after comply
with the pre-qualification test specified.
Final approval for GRP work to proceed on site shall be subject to satisfactory compliance test
results observed at site.
Vol 3, Section3
Page G-11 of 68
Specifications
Site Lamination
The following details of lamination apply to all work required under the Contract.
Application shall be carried out in the cooler times of the day ie. early morning or late
evening. Application shall not be carried out to surfaces exposed to direct sunlight and high
surface temperatures. Shade structures shall be provided as necessary. Application shall not
be carried out in conditions of windblown dust and sand or during periods of high humidity.
Before entering any chamber or standing on any surface which is to receive lamination
workers shall check their footwear to ensure that it is clean and will not transfer
contamination. Care shall be taken when passing materials down into chambers etc. to avoid
entry of contaminating materials.
Upon completion of mixing, materials shall be used immediately. During lamination, work
must cease immediately if the resin starts to gel and the work completed to that point shall
be allowed to cure before restarting.
No standing on or application of pressure to uncured laminates will be permitted as this will
result in squeezing out of resin producing defective areas of laminate where the glass has not
been fully wetted out.
All surfaces to receive lamination shall be prepared as detailed above. Lamination shall not be
carried out to concrete surfaces until they have cured for at least the minimum number of
days recommended by the resin manufacturer since casting of the concrete.
All lamination to surfaces of prefabricated components shall be gradually feathered away to a
defined limit using masking tape or similar so that the final appearance is neat without a
sudden change in thickness or of appearance to the completed job.
Lamination Build-up
A Primer coat of 75 to 125 micron catalysed vinyl ester resin shall be painted over the area to
be laminated. Whilst still wet one layer of ECR/Advantex glass shall be applied over the area.
Where it is necessary to make a joint in the reinforcement then the reinforcement must
overlap by a minimum of 25 mm. The reinforcement shall then be rolled with a metal roller
and then wet out with further resin until fully wet. It shall then be carefully finally rolled with
a metal roller to remove all air and consolidate the laminate.
Successive layers of ECR/Advantex glass shall be added and fully wetted-out with epoxy
based vinyl ester resin. Between applying each layer the laminate shall be fully rolled using
the metal roller to ensure that all the air is removed from all the layers.
Joints in reinforcement layers shall not lie directly above joints in layers below.
This layer shall be allowed to fully cure. When fully dry the whole surface shall be lightly
abraded using a grinder with a 120 grit disc.
A coat of vinyl ester resin shall be applied over the area. Whilst still wet one layer of
ECR/Advantex glass chopped strand mat shall be applied. Further layers of ECR/ Advantex
glass chopped strand mat shall be applied and fully wet out with epoxy based vinyl-ester resin
and rolled with a metal roller.
The final two layers of 'c' glass tissue shall then be applied and wet out with vinyl-ester resin.
These layers shall not be rolled with a metal roller.
Vol 3, Section3
Page G-12 of 68
Specifications
When the last layer has dried it shall be lightly sanded using 120 grade wet and dry abrasive
paper to remove any lumps or loose fibres. Any resin runs shall also be removed making sure
not to de-laminate the previous layers.
A final layer of epoxy based vinyl ester resin incorporating a sealing agent (paraffin wax) to
ensure final and full cure shall then be applied over the whole laminate and allowed to dry.
In situ GRP lamination to concrete surfaces shall have the following composition, as a
minimum requirement.
Final finished GRP
surface
---------------------------
Minimum 7 mm thick
GRP Laminated
Composite
-------------------------============
====
xxxxxxxxxxxxx
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
Concrete surface
-----------------------
Finished GRP Surface with Paraffinated

vinyl-ester resin flowcoat
2 x ECR, C glass tissue impregnated with
Epoxy based vinyl ester resin
300 g/m2 ECR glass CSM impregnated
with Epoxy based vinyl ester resin
Vinyl ester Resin Prime Surface coat
In situ GRP lamination to the internal faces of brickwork corebelling shall have a lesser
composition as a minimum requirement as follows.
Final finished GRP
Finished GRP Surface with Paraffinated
surface
------------------------- vinyl ester resin flowcoat
--------------------------============
2 x ECR, C glass tissue CSM
impregnated with Epoxy based vinyl ester
resin
Minimum 3 mm thick
xxxxxxxxxxxxxxxxxx 300 g/m2 ECR glass CSM impregnated
GRP Laminated
Composite
------------------------- Vinyl ester Resin Prime Surface coat
Concrete surface
Surface coat
Pipe Entries
The position of the centre of the required hole shall be accurately marked. This includes holes
to liners only where a box-out has been provided through the structural wall. The
prefabricated component and/or concrete wall shall be neatly cut by means of a hole saw or
diamond drill coring machine. The radius of the hole shall be not less than the outer pipe
radius plus 5 mm nor more than the outer pipe radius plus 15 mm.
The surface of the liner shall be abraded to a distance of 100 mm from the cut hole. The pipe
to be fitted shall have its end and final 75 mm of barrel prepared to receive lamination.
The pipe shall be-fitted and securely fixed in position in accordance with an approved Method
Vol 3, Section3
Page G-13 of 68
Specifications
Statement. It shall protrude at least 50 mm and not more than 100 mm past the face of the
liner. The annular gap shall be filled with vinyl ester putty which shall be neatly trimmed and
allowed to cure.
Lamination shall then be carried out to seal the pipe entry to the liner using ECR' glass buildup to a minimum of 7 mm thickness but using vinyl ester resin only throughout. Lamination
shall be turned over the pipe end.
These requirements apply to all pipe entries including house connections, cable ducts, air
release pipe work from pump casings, sump pump discharges, penstock spindle sleeves, etc.
These requirements apply to pipes built through both walls above benching level and to pipes
through walls into the benching. Sealing requirements where the pipes penetrate the main
structural wall are identical in both cases irrespective of whether the pipe will later be covered
by benching concrete.
Should the material of the pipe built through the walls into the benching be incompatible with
in situ GRP lamination materials then the joint between the pipe and liner shall incorporate a
prefabricated GRP pipe sleeve which shall be bonded to the pipe outer diameter with a
solvent free epoxy adhesive putty. In-situ GRP benching lamination shall be bonded to the
inner faces of the GRP pipe sleeve in accordance with the above.
Cutting and Sealing of Reinforced Plastic
Where the manufacturer or Contractor is required for any reason to cut or drill prefabricated
reinforced plastic (GRP), including pipes, he shall completely seal the exposed ends and edges
with a coat of approved vinyl ester resin, before incorporating the cut reinforced plastic into
the Works. No cut reinforced plastic shall be used until the sealing resin has fully cured.
Resin used for sealing shall be delivered to site in sealed containers bearing the name of the
manufacturer and properly labelled as to its contents, storage requirements and shelf life.
Safety Precautions
Proper ventilation and/or breathing apparatus shall be provided and all necessary precautions
shall be taken to ensure the safety of workers when in situ GRP lamination materials are
being used.
Applicators shall also be made aware of the health risks involved in working with these
materials. Skin and eye contact should be prevented by the use of plastic or rubber gloves,
barrier creams, eye protection and protective clothing. Smoking will not be permitted.
Nothing in this Clause shall be deemed to limit the Contractor's more general obligations
under the Contract.
In-Situ GRP Lamination Requirements
Following Lamination Procedures and tests are to be conducted by the G.R.P applicator.
1. To reduce air bubbles in the laminate relevant catalysts recommended by the resin
manufacturers only to be used. Catalyst manufacturer's technical catalogue to be
provided along with the material submission.
2. Samples of all materials to be used on sites are to be provided prior to start of lamination
work on site.
Vol 3, Section3
Page G-14 of 68
Specifications
3. Resin and glass mat brought to the site are to be supplied in manufacturers sealed
drums, in packets with manufacturing date, compliance certificate and the allowable pot
life.
4. Details of each constituent material and proof of supply through out the work period on
site from the manufacturer is to be provided. Also provide test certificates from the
relevant material manufacturers for the materials used on site.
5. The lamination work is to be guaranteed for material and workmanship for a period of 10
years from completion by the applicator and countersigned by the manufacturer.
6. A Trial lamination is to be carried out in the presence of Engineer's Representatives using
proposed materials and the procedure, as specified, on a concrete surface and arrange to
conduct an initial pull off test, barcol hardness, thickness and resin/glass ratio tests.
7. Lining of a concrete surface is to be carried out as per the manufacturers recommended
procedure.
8. Care must be exercised to ensure the correct balance of catalyst and accelerator for
optimum curing. Checking for complete cure to be carried out as per the procedure
recommended by the manufacturer.
9. The resin/glass ratio in the laminate, type of resin and glass and the sequence of layers
proposed are to be reported.
10. Final laminate thickness, loss on ignition, pull off adhesion, hardness tests etc are to be
conducted to prove compliance of the laminate with the contract requirement and
specification.
11. 100 days acid immersion test in 10 percent concentrated sulphuric acid solution at 50
degree centigrade using final laminate samples selected by the Consultant is to be carried
out. In-situ tests on the resin will be conducted during lamination work.
12. 2 layers of 'c' glass tissue of ECR type to be used on the final laminate.
13. Final wax topcoat resin formulation to be as per the procedure recommended by the
manufacturer.
14. Provide full details of safety measures that will be instituted during lamination works for
separate approval before starting any in-situ work. A full time supervisor from the
applicator's side must be on site.
15. Provide technical catalogue for all the type of resin, glass and surface tissue proposed.
16. Minimum thickness of lamination shall be 7 mm and use only ECR glass epoxy based vinyl
ester resin approved by the Engineer.
17. No hollow sound on final laminate will be permitted.
18. Lamination work is to be carried out in layer by layer and not to apply more than 3 layers
in a day and allow the styrene gas to come out and enough curing time for curing each
layer.
19. Final approval shall be given following the acceptance of quality of the finished works.
Vol 3, Section3
Page G-15 of 68
Specifications
Material samples, safety procedures, material details, guarantee letter, name of skilled
workers and supervisors etc. are to be provided prior to starting the lamination work on site.
G.1.7 Epoxy Mortar for Stormwater Manholes
Where indicated on the drawings or specified to use epoxy mortar for benching and channels
in any manhole or any other structure such as chambers, pump station wet-well, etc., they
shall be formed to have a min. of 10 mm thickness of an approved epoxy-resin mortar system.
The epoxy mortar system shall be a trowellable, two component epoxy resin system
consisting of a prefilled base and unfilled reactor which when mixed shall produce a high
strength, impermeable and chemically resistant mortar.
The epoxy mortar system shall have excellent chemical resistance to sodium chloride and
sulphuric acid (shall pass the relevant chemical resistance test), and shall have high impact
resistance. Typical properties are given in the following table:
Table G9- Properties of Two Component Epoxy Mortar
Property
Test Method
Limit
Sag at 10 mm thickness
None
Working Time
ASTM C308
> 90 min. at 25C
Full Cure at 25C
3 to 7 days
Setting Time at 25C
30 to 45 min.
Water Absorption
ASTM C413
< 0.07 %
BS 6319:Part 2
> 40 N/mm2 at 25C,

7 days cure
Flexural Strength
BS 6319:Part 3
> 3 N/mm2 at 25C,
Tensile Strength
BS 6319:Part 7
7 days cure
> 8 N/mm2
Bond Strength
BS 6319:Part 4
> 30 N/mm2
Density
BS 6319:Part 1
1750 kg/m3
When placed on a concrete substrate the epoxy mortar system shall have an adhesive
strength of not less than the internal cohesive strength of concrete.
To achieve the necessary adhesion to the substrate an epoxy primer compatible for use with
the mortar and the substrate shall be applied.
The epoxy mortar, or the primer where required, shall be suitable for application onto a
substrate with a moisture content of 4% or less as measured by the "wet-check" Moisture
Meter or other instruments approved by the Engineer.
The pot-life of the mixed mortar shall not be less than one hour at the temperature at the
place of application at the time of mixing. The Engineer may restrict application to such time
as the ambient temperature is sufficiently low for the specified pot-life to be ensured.
There shall be strict control of surface cleanliness between primer and epoxy mortar and
between coats of the same. Vacuum removal of dust and sand shall be employed and water
soluble contamination shall be removed as specified above. Where dirt or dust has become
trapped in the primed surface it shall be removed with suitable abrasive paper. The surface
Vol 3, Section3
Page G-16 of 68
Specifications
being primed shall be free of visible moisture throughout these operations.

The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all curing
temperatures likely to be encountered and these shall be adopted with a maximum tolerance
of +4 hours. Where this is exceeded the surfaces to be re-coated shall be suitably abraded to
remove gloss.
Mixing of the components shall be strictly in accordance with the Manufacturer's
recommendations and care shall be taken to avoid the entrainment of air in the mixes.
Wet thickness gauge shall be used by the mortar applicators continually to check that
sufficient mortar is being applied to achieve the required dry thickness.
G.1.8 Rubberised Bitumen Emulsion
The bitumen emulsion shall be a cold applied thixotropic coating incorporating a liquid latex in
the bitumen emulsion conforming to BS 8102. The latex content will be a minimum 10% on
the dried film and the solid content Min. 60%.
The coating shall be applied in two coats with a priming coat which will be made by diluting
the bitumen emulsion with max. 10% clean potable water or as manufacturers
recommendations.
Two undiluted coats of the bitumen paint shall be applied @ 1.1 lit/m2 in two coats. The total
dry film thickness of the coating shall be Min. 0.50 mm.
The second coat will be applied at right angles of the first coat and only after the coat has
dried completely.
For concrete haunching at manhole and chamber covers and for 300 mm height of concrete
of structures above ground level, two coats of rubberised bituminous emulsion system shall
be applied. The second coat shall not be the same colour as with the first.
The brush applied bituminous emulsion shall be used on location as given in the approved
drawings. The surface shall first be wire brushed and all dust and loose scale removed. Both
methods of protection shall totally enclose the substructure within a water proof membrane of
either polyethylene sheet or a waterproof building paper as applicable to the limits shown on
the drawings.
G.1.9 Waterproof Paper
Waterproof building paper shall be to the approved standard. For road works it shall be
Class B.
G.1.10 Protective Materials for Wrapping Pipeline Components
The protective materials for wrapping pipeline components shall comprise a rust inhibiting
compound for the bolts, a mastic or comparable filler which will not harden for moulding over
the assembly, and a waterproof tape for wrapping.
G.1.11 High Density Polyethylene Protection Sheet
The polyethylene sheet shall be of 1000 gauge (heavy duty) minimum thickness 250 microns.
Vol 3, Section3
Page G-17 of 68
Specifications
G.1.12 Protective Coating with Cementitious Water Proof Coating

Concrete surface shall be protected with an approved elastomeric cementitious waterproof
coating as follows:
On the concrete blinding below perimeter and dividing wall base slabs.
The materials are required to provide excellent waterproofing and crack-bridging properties,
whilst providing protection against water abrasion.
The system shall be a high performance, elastomeric, cementitious coating system specifically
formulated to provide excellent resistance against aggressive elements whilst retaining its
chemical and physical properties through long term water immersion.
The coating shall exhibit the following typical properties.
Table G10- Typical Properties of Coatings
% Elongation
Minimum 120%
Water vapour diffusion resistance
SD 0.11 m @ 200 microns dft
Resistance to positive water pressure
7 bar DIN BSEN 12390
Resistance to negative water pressure
3 bar DittoReduction in chloride ion penetration
>99% (no penetration after 10 months continuous
testing)
Dynamic crack accommodation
1.8 mm
Abrasive resistance
Wear index
The mixing and application of the elastomeric cementitious coating shall be strictly in
accordance with the manufacturer's instructions.
In preparation for the fairing coat and protective coating all existing surfaces shall be free
from existing coatings, 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 sweep blasting.
Blow holes, prepared surface cracks and areas of substantial pitting shall' then be filled with a
proprietary polymer modified cementitious fairing coat as recommended by the coating
manufacturer.
The protective coating system shall be spray applied by a specialised applicator approved and
recommended by the coating manufacturer.
Where required by the Engineer, trial areas not exposed in the finished work shall first be
treated using the selected materials. These trial areas shall be carried out using the type of
materials, mixing procedures and applications as will be used on the contract. These shall be
approved by the Engineer before the Contractor commences with the general work. .
G.1.13 Approved Paint Suppliers
All paint suppliers shall be subject to approval. Suppliers shall demonstrate that their paint
systems have been successfully used in sewage environments similar to conditions
experienced and / or anticipated in Bahrain.
Vol 3, Section3
Page G-18 of 68
Specifications
G.1.14 In-situ GRP Lamination with Grit bonding on final finish coat
This clause will cover all in-situ GRP Lamination work as specified in G.1.6 and an additional
resin coat to be applied as final finish top coat sprinkled with non-metallic mineral abrasive
grit or sand to achieve a non-slip, non-abrasive surface finish.
Vol 3, Section3
Page G-19 of 68
G.2
Specifications
INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE
G.2.1 General
Concrete structures shall be protected both internally and externally by the methods detailed.
G.2.2 Water Proof Membranes/Liners/Roof Waterproofing and Protective Coatings
All the protection systems shall be applied strictly in accordance with the manufacturers
instructions, two copies of which shall be included with the Contractors application for the
approval of the material, and when approved will be deemed to be part of this specification
unless stated otherwise.
The permissible rate of permeation of all protection systems shall not exceed 0.0027 per inch
(ASTM, 1 per inch = 1 gram of water per hour per square foot (0.0929 m2) per mil (0.00254
mm) of thickness for a 1 inch (25.4 mm) difference in Hg vapour pressure on each side of a
membrane.
Coating shall not be applied at expansion, contraction or construction joints which incorporate
a sealant.
External and Internal Exposed Surfaces Where exposed surfaces of concrete structures are not protected by reinforced plastic liners,
the following systems given in the Schedule of Tanking Membranes and Protective Coating or
as indicated on the drawings, where applicable, shall be applied.
Table G11- Schedule of External Tanking Membrane on Concrete Surfaces of under
ground Structures up to the Existing Finished Ground Level
System
Description & Generic Type of Material
T1
Single coat solvented bitumen primer as recommended by the tanking membrane
manufacturer
T2
Pre-fabricated self-adhesive SBS modified bitumen membrane 1.5 mm thick
sandwiched between two layers of silicon film having the specified properties
T3
Impervious self adhesive bituminous water proofing membrane 2 mm thick
tropical grade, non-perforated, cross laminated white polythene sheet top film
with high impact and puncture and UV resistance having the specified properties.
T4
Self-adhesive type 6 mm thick Asphaltic protection board impregnated with tough
layer fibre glass reinforcement inside to use under all raft foundation floor slab on
top of blinding layer.
T5
Self-adhesive type 3 mm thick bituminous protection board with UV resistant, 400
gm/m2 polyester fabric layer external having specified properties.
T6
Termination end details of self-adhesive membrane 2 mm thick + 3mm thick selfadhesive protection board as shown in the approved drawing
T7
Termination end details of composite 1.5 mm thick SBS modified membrane +
2mm thick cross laminated membrane + 6 mm thick self adhesive protection
board as shown in the approved drawing
T8
Termination details of membrane over protruded built in pipes from the structure
as shown in the approved drawing.
T9
Termination details of membrane at internal and external corners as shown in the
drawing
T10
Termination details of bitumen emulsion + P.E. sheet as shown in the drawing.
Or alternatively
T11
3 mm thick two component spray in place flexible 100% solid content
Thermoplastic (Tpu) Polyurathene / Polyurea Coating System
Note:
The Contractor can choose either the tanking membrane system T1 T10 or the
3mm thick polyurea coating without any extra cost variation.
Vol 3, Section3
Page G-20 of 68
Specifications
External Buried Surfaces

The external surfaces of major and minor concrete substructures shall be protected or
tanked by the following methods which will be indicated on the approved Drawings.
a)
External Waterproofing for Major Buried Structures

Water proofing for major structures shall be a three layer application.
Prime the concrete surface with solvent based bitumen primer as
recommended by the membrane manufacturer.
The first layer shall be a 1.5 mm thick prefabricated layer of SBS modified
bitumen sandwiched between two layers of silicon film. The layer shall have
1200 % elongation. The overlaps should be 15cm and should have 100%
bitumen to bitumen adhesion to ensure a seamless layer of rubberized
bitumen. The layer should have no reinforcements or top films which would
affect the elongation and overlap adhesion.
The second layer shall be 2 mm thick an impervious bituminous
waterproofing membrane.
The membrane shall be tropical grade, non- perforated cross-laminated top film
with high strength, puncture and impact resistance and shall be chemically
resistant for protection against aggressive soils and contaminated ground water.
The membrane shall be white in colour to reduce the effect of UV and for easy
identification of damages if any on the membrane.
The cross laminated self-adhesive membrane shall comply with the following:
Table G12 Properties of Self-adhesive Membrane
Properties
Test Method
Typical Results
Tensile strength of membrane
ASTM D 638
Longitudinal
3.8 N/mm width
Transverse
3.8 N/mm width
Top Surface High Density Cross Laminated PE Film White
Tensile strength (Film)
ASTM D 882
Longitudinal
38 N/mm2
Transverse
38 N/mm2
Elongation of membrane
ASTM D 638
Longitudinal
230%
Transverse
180%
Tear Resistance (film)
Longitudinal
Transverse
ASTM D 1004
Puncture Resistance
ASTM E154
220N /60mm deflection
Adhesion to primed substrate

-Ditto- self
Water absorption
After 24 hours
After 35 days
ASTM D 1000
2 N/mm width
2.4 N/mm width
280N/mm thickness
280N/mm thickness
ASTM D 570
0.14%
0.95%
Crack bridging ability

Water resistance of
Membrane
Cross laminated Film (solvent
extracted from membrane)
Self-adhesive softening point
Vol 3, Section3
Page G-21 of 68
Min 1 mm
BSEN 12390
5 bar pressure
No penetration
5 bar pressure
ASTM D 36
No penetration
102C
Specifications
The membrane shall be laid on the twin stick surface of the SBS bitumen layer with
the sticky side downwards and laid strictly in accordance with the manufacturers
instructions. The minimum overlap should be 150 mm side and end. The top silicon
release film of the twin stick membrane to be removed before the application of the
subsequent layer.
The corners and pipe joints shall be sealed with a 1.5 mm thick two side adhesive
bitumen tape. The tape shall comprise of a non-reinforced SBS modified bitumen
layer sandwiched between two layers of plastic release film. The bitumen tape
should have a minimum ultimate elongation of 1200%. The tape should be a
minimum of 300 mm width. The silicon release film on the top side should be
removed at the time of laying the waterproofing membrane. In the event adhesive
side of the tape gets contaminated with dust or other debris, the tape should be
removed with a heated scraper. The surface should then be primed again and the
tape re-applied. If the contamination is very minor and localised, the tape can be
repaired with heating it up with a hot air gun. A 40 mm x 40 mm corner fillet with
polysulphide sealant shall be made for all corners around the pipes to allow
movement.
Protection Board (6 mm & 3 mm thick)
The membrane has to be protected as the third layer with a 6 mm thick self-adhesive
asphaltic protection board impregnated with a tough layer of fibre glass and to be
used under all the raft foundation and 3 mm thick protection board for walls and sides
of raft foundation. The board should be weather, water and rot proof and should be
completely devoid of organic material. The edges of the protection board to be sealed
with a 50 mm self adhesive bitumen strips in order to avoid any back fill material from
entering into the system. The protection board shall comply with the following
properties.
Table G13- Properties of Protection Board
Property
Test Method
Thickness
Chisel test
BS 1142
Heat resistance
Ueatc
Typical Results
6 mm & 3 mm
pass
Min 80C
All products in the waterproofing system to be sourced from the same manufacturer
who operates a certified ISO quality system. The membrane shall be applied strictly in
accordance with the manufacturers method statements.
Termination of the system shall be done at a height of 100 mm from the ground level.
A 40mm x 40mm groove to be cut and the membrane neatly tucked into the groove.
The groove to be sealed with a polysulphide sealant. The self-adhesive protection
board should extend at least 50 mm above the groove and be sealed to the substrate
with an epoxy adhesive or a suitable system recommended by the membrane
manufacturer and approved by the Engineer. The cost of membrane is inclusive of
fixing and termination with approved sealant.
(b) External Waterproofing for Minor Buried Structures such as Manholes,
Inspection Chambers etc.
The external surfaces of minor concrete substructures shall be protected or tanked by
the following method. The water proofing system shall be two layer application. The
1st layer waterproofing membrane shall be a 2 mm thick bitumen cross laminated self
Vol 3, Section3
Page G-22 of 68
Specifications
adhesive membrane and the 2nd layer shall be with a 3 mm thick self adhesive
membrane protection board with a tough geo-textile surfacing. The membranes shall
comply with the technical specifications as given in Clause 7.2.2.1 (a).
The surface on which the waterproofing membrane is to be applied shall be smooth
and free of any sharp edges or protrusions. The surface should be primed with an
approved primer recommended by the membrane manufacturer.
Once the primer is completely cured, the membrane shall be laid on the surface. The
silicon release film is peeled off the sticky side and the membrane is to be carefully
laid on the surface. Care should be taken to minimize the entrapped air. The
minimum overlap should be 100 mm at side and end and minimum 200 mm at the
corners.
The corners and pipe joints shall be sealed with a 1.5 mm thick two side adhesive
bitumen tape. The tape shall comprise of a non-reinforced SBS modified bitumen
layer sandwiched between two layers of plastic release film. The bitumen tape should
have a minimum ultimate elongation of 1500%. The tape shall be of minimum 300
mm width. The silicon release film on the top side shall be removed at the time of
laying the waterproofing membrane. In the event adhesive side of the tape gets
contaminated with dust or other debris, the tape should be removed with a heated
scraper. The surface shall then be primed again and the tape re-applied. If the
contamination is very minor and localised, the tape can be repaired with heating it up
with a hot air gun.
Protection Board (3 mm thick)
The membrane shall be protected with a self-adhesive protection membrane board
with a tough, UV resistant, polyester surface. Staggered overlaps to be ensured while
application of protection membranes. The protection membrane shall comply with the
following properties.
Table G14 Protection Membrane Properties
Property
Test Method
Thickness
Puncture resistance
ASTM E 154
Tear resistance
ASTM D 5147
Min: top surfacing weight of fabric
Elongation of compound
ASTM D 638
Typical Results
3 mm
1500 N
500 N
350 gm / m2
1500%
Any punctures on the membrane shall be repaired with an additional patch which
would extend at least 5 cm from the edges of the damage. The waterproofing
membrane shall be protected immediately with the protection membrane to avoid any
damages to the system because of ongoing site activities.
The end termination of the composite system shall be as shown in the approved
drawings or as recommended by the membrane manufacturer and approved by the
Engineer.
(c ) Brush Applied Bituminous Emulsion
The bitumen emulsion shall be cold applied thixotropic coating conforming to ASTM D
1227 Type III Class 1. The coating shall have a solid content of Min 50%. The
coating shall be applied in two coats with a priming coat which will be made by
diluting the bitumen emulsion with max 20% clean potable water or as per
manufacturers recommendations. Two undiluted coats of the bitumen paint shall be
Vol 3, Section3
Page G-23 of 68
Specifications
applied @ 1.1 lit /m2 in two coats. The total Dry Film Thickness of the coating shall be
a minimum 0.5 mm.
The second coat shall be applied at right angles of the first coat and only after the
coat has dried completely.
The above coating system shall be protected with 1000 gauge polyethylene sheet or
building paper as specified for each specific location and use.
Vol 3, Section3
Page G-24 of 68
Specifications
Table G15
Application Procedure for Impervious Bituminous Tanking Membrane System (Clause G.2.2 (1) (a) & (b) on Concrete Surfaces &
Structures (External) up to the Ground Level (For Major Structures)
Item
Description and/or
Location of work
Application /
location
1.
Buried concrete external

surface in contact with soil
and groundwater for
major structures; blinding
under the raft foundation
Blinding layer
under raft
foundation
(a) under the
blinding
(b) over the
blinding
2.
Ditto Raft Foundation

sides and tank walls and
roof slab in contact with
ground soil / water
Vol 3, Section3
(a) Raft
foundation
base slab sides
and tank walls
Surface
preparatio
n
Levelled
formation
Sweep blast
Shop
/ site
Sweep blast
Type of Coat
No. of
coats
Description & generic type of

material
Thickness
Microns
PE sheet 1000 gauge as specified
250
Primer
System T1
Membrane
System T2
One
layer
One
coat
One
layer
Rubberised bitumen emulsion
50
1.5 mm
thick
Membrane
System T3
One
layer
Membrane
System T4
Primer
System T1
One
layer
One
coat
Self-adhesive type SBS modified

Bitumen non-reinforced membrane
as specified
Self-adhesive Bituminous membrane
cross laminated with white PE at top
as specified
Self-adhesive type Bituminous
Protection board.
Solvented Bituminous Primer.
Membrane
System T2
One
layer
1.5 mm
thick
By hand
application
System T3
One
layer
2 mm
thick
System T5
One
layer
Self adhesive type SBS modified

bitumen membrane (non reinforced)
as specified.
Self adhesive type bituminous
membrane cross laminated with
white PE at top as specified.
protection board with UV & puncture
resistant fabric layer on top.
Fix in
staggered
joints
Fix in
staggered
joints.
1000 gauge
Polyethylene
sheet
2 mm
thick
6 mm
thick
50
Remarks
To be placed
on the
formation
By brush
application
By hand
application
By Hand in
staggered
Joints
-DittoBy brush
application
Page G-25 of 68
3 mm
thick
Specifications
Table G15 (Continued)

Item
Description and/or
Location of work
Application
/ location
3.
Ditto for Minor

Structures like manholes,
chambers, strip footing
and its blinding layers.
Concrete
blinding
(a) under the
blinding
(b) over the
blinding
4.
Ditto for wall, roof slab,

the buildings strip footing,
and on chambers below
ground
Vol 3, Section3
Manhole wall,
roof slab
Surface
preparati
on
Levelled
formation
Sweep blast
Sho
p/
site
Sweep
Blast
Type of
Coat
1000 gauge
Polyethylene
sheet
No.
of
coats
Primer
System T1
Membrane
System T3
One
layer
One
coat
One
layer
Membrane
System T5
One
layer
Primer
System T1
One
coat
Membrane
System T3
One
layer
System T5
One
layer
Description & generic type of

material
Thickness
Micron
s
Remarks
To be placed
on the
formation
By brush
application
By hand
application
PE sheet 1000 gauge as specified

Solvented bitumen primer as
specified
Self-adhesive Bituminous membrane
cross laminated with white P.E. at
top as specified
Self-adhesive type bituminous
protection board with polyester
fabric at top as specified
Solvented Bituminous Primer as
specified
250
50

membrane with cross laminated at
top with white PE as specified
protection board with polyester
fabric at top as specified
2 mm
thick
By hand
application
3 mm
thick
Fix in
staggered
joints
2 mm
thick
3 mm
thick
50
Fix in
staggered
joints
By brush
application
Page G-26 of 68
Specifications
Table G16 [System I, J, K, L, M & N]

TANKING MEMBRANE AND PROTECTIVE COATING TO CONCRETE Clause G.2.5 (1) [B & C] SCHEDULE OF IN-SITU BITUMINOUS
MEMBRANE/GRP/ COATING SYSTEM (FOR MINOR STRUCTURES)
STRUCTURE
INTERNAL
EXTERNAL
FLOOR
WALL
CEILING
Base Slab/Strip footing
Base slab sides,
/foundation
Wall and Top of
Cover Slab
1. Sewer Manholes (Internal)
In-situ GRP Lamination
Pre Fabricated GRP Liners
7mm thick system
Pre Fabricated GRP

slab Liners
System I
System J
System J
5 mm Prefabricated
GRP Benching Unit or
in-situ GRP lamination
System N
300 micron thick Epoxy

Coating
300 micron thick

Epoxy Coating
System L
System L
3. Building Strip footing, compound wall

foundation etc.
N/A
N/A
N/A
4. Storm water MHs, chambers & Similar
Epoxy Resin mortar as

specified in CL 7.1.7
300 micron thick Epoxy

coating system
300 micron thick

Epoxy coating
System K
System L
System L
5. Anchor blocks Protection slab,

concrete surround, & other similar
burried concrete
N/A
N/A
N/A
6. Above ground structures like Panel

plinth (Exposed Surfaces)
System D as specified
System D as specified
N/A
2. Sewer Inspection Chambers (Internal)
Vol 3, Section3
Page G-27 of 68
P.E sheet under the blinding
*System T1 +
*Rubberised Bitumen
emulsion over the blinding +
*System T1 +
*System T3 +
*System T5
System M
Rubberised bitumen
emulsion +
1000guagePolyethylene sheet
*System T3 +
*System T1 +
*System T3 +
*System T5
*System T5
For each structure
Rubberised emulsion +
P.E Sheet
System M
-
Same system given for sewer

manholes & chambers as
above
Same system given for

sewer manholes &
chamber as above
P.E. sheet at formation

2 Coats Rubberised
Bitumen emulsion over
concrete
1 Layer P.E. sheet on top

System M
Same as item 1 above
Ditto
Specifications
(d) Alternative Proposal for Membrane Protection

3 mm thick two component spray in place flexible 100% solid content thermoplastic (Tpu)
polyurethane /Polyurea Coating System.
Table G17- Physical Data of Coating System
Physical Properties
Density (kg/m3)
Permeability (more than 1 mm)
Hardness (Shore A)
Abrasion Resistance (Taber)
Tensile Strength (kg/cm2)
Elongation (%)
Adhesion
Tear Resistance (N)
Colour
ASTM Test
D - 1622
D - 2240
D - 4060
D - 2370
D - 2370
D - 4541
Absolute
Load
FED STD
595B
Value
1121.3 (kg/m3)
0.000 (metric/m2)
98
0.001/1000 Cycles
126.67
82.24% @ yield
77 (kg cm2)
123.56 (N)
Black or other
Table G18- Resin Liquid Chemical Properties @24C

Properties
Viscosity (cps)
Specific Gravity (gr/cc)
ASTM Test Method

D - 1638
Component A
Component B
D - 1638
Component A
Component B
Mixing Ratio (A:B) by

volume
Value
600 + 100
1100 + 100
1.15
1.08
50:50
A Trial sample of the Tpu coating is to be applied on any one of the concrete structures
external surfaces and the relevant sample is to be subjected to 100 days acid immersion test
in 10% concentrated sulphuric acid @ 50C. This coating will be acceptable only, if the
chemical resistance of the coating fully comply with the specification. The test shall be
conducted in accordance ASTM C 581.
(e) Waterproofing on Tanks Buildings Roof where thermal insulation is required.
The roofing system shall incorporate the materials and methodology specified in Building
Works - Section L.
(f) Roof Water proofing on tanks where slope is required to drain rain water
The roof water proofing system proposed shall include the following materials and works to
be supplied and installed by an approved manufacturer
1. Materials
1st Layer
Vol 3, Section3
Sprayed high density polyurethane foam waterproofing

Grade: Spray
Average thickness: 20 mm
Core Density: 55 kg/m3
Page G-28 of 68
Specifications
Comp. Strength: 2.5 kg/cm2

Tensile Strength: 3 kg/cm2
Closed cells: 98%
Standards: BS 5241 Part 1
2nd Layer
Liquid Elastomeric UV coating

Grade: Spray
Density: 1.2 gm/cc
pH: 8-8.5
Solid content: 60%
Elongation: 300%
Standards: BS476-3
3rd Layer
Filter Membrane
Grade: Filter Membrane
Mass: 120 gm/m2
Thickness: 1.5 mm
Elongation: 50%
Colour: White
4th Layer
Shotcrete (Recommended fall 1:200) to a minimum thickness

of 40mm.
Grade: Pouring
Mix Class: 350 OPC
Slump: 100 25mm
Density: 2.5 Kg/litre
5th Layer
Cementitious Waterproof coating as specified

Grade: Brush / Spray
Density: 1.8 gm/cc
Elongation: 120%
Water Penetration: Nil
Standards: BS 1881 Part 5
Construction Joints:
Filler Board
Grade: Impregnated Filler Board
Thickness: 12 mm
Density: 220 kg/m3
Standards: BS 1142
Construction Joints:
Poly sulphide Sealant

Grade: Pouring
Solid Content: 100%
Temperature Resistance: 20C to 120C
Elongation: 400% (at break)
Standards: BS 6920-88
2. Installation
a. Roof slab shall be inspected by a roofing specialist from the manufacturer and
confirm acceptance of the roof for application of the waterproofing system.
Surfaces to receive membrane roofing shall be free of projections, voids,
depressions, scale, efflorescence, loose material, laitance, oil, grease
Vol 3, Section3
Page G-29 of 68
Specifications
and other foreign contaminants.

Before start the work, inspect all surfaces to receive membrane and report in
writing to the Engineer any surfaces that are not suitable for
correct application of the membrane.
For surfaces which are unsuitable to receive membrane, the Contractor shall
see that same are corrected by the respective trade prior to application of his
work.
Relevant shop drawing shall be submitted to the Engineer prior to start of the
work.
b. Clean the roof using compressed air to make sure substrate is free of dust and
debris.
c.
Supply and spray polyurethane foam insulation complying with BS 5241 Part 1
at an average thickness of 45mm of density 40-50 Kg/m3 over the entire roof
area including the upstand to a height of max. 200 mm.
d. Supply and spray liquid elastomeric UV protection coating over the entire foam
area and allow to dry for 48 hours.
e. Flood test the roof for a minimum period of 24 hours with 25 mm head of water
as specified in Cl.9.3 of BS 8007: 1987. Any area where leaks occur shall be
drained, thoroughly dried, repaired and then retested. Installation of insulation
board, separation layer and concrete, which are applied over the waterproofing,
shall not start until such time as the membrane is leak free and has been
accepted by the Engineer.
f.
Supply and lay filter membrane protection layer over the entire roof area.
g. Supply and fix expansion joint filler boards in slope and in panels
h. Supply and lay protective concrete screed in panels and cure as per standard
procedures
i.
j.
k.
l.
Supply and apply PVA bonding agent to all corners and upstands in 1:3
Proportion.
Prepare angle fillet all around parapet and upstands using sand cement mortar.
Supply and apply polysulphide sealant to all construction joints including backing
rod.
Supply and spray apply cementitious water proof coating over the entire roof
area including upstands and allow to dry for 48 hours.
m. Final inspection shall be carried out by the manufacturer

n. Roof water proofing system shall be carried out only by Clients approved
applicator.
3. Inspection
Inspection will be carried out as per Clients approved inspection plan.
4. Guarantee
Vol 3, Section3
Page G-30 of 68
Specifications
a. Guarantee stating that the water roofing system installed will be waterproof and free
from defects for a period not less than 25 years from the date of Taking Over of the
Works.
b. In the event any leaks occur within the period stipulated, the Contractor shall at the
convenience of the Employer, effect all repairs and replacements necessary to
remedy defects all to the complete satisfaction of the Engineer at no additional cost
to the client.
G.2.3 GRP Prefabricated benching unit for Sewer Inspection Chambers
GRP prefabricated benching units shall be manufactured to the same process as specified in
G.1.6 for in-situ lamination but the work shall be carried out in manufacturers yard with a
wall thickness of 5 mm.
G.2.4 Cutting and Sealing of Reinforced Liners
Where the Contractor is required for any reason to cut reinforced plastic liners, he shall seal
the exposed ends with an approved resin before incorporating the cut reinforced plastic in the
work. No cut reinforced plastic shall be used until the resin has cured.
The resin shall be as recommended by the manufacturer of the reinforced plastic item and
shall be pigmented so that the areas where it has been applied are easily identifiable.
It shall be delivered to site in sealed containers bearing the name of the manufacturer and
properly labelled as to its content and shelf life.
For flexible pipe materials a rubber protection strip shall be inserted between the pipe barrel
and the steel band.
G.2.5 Protective Coatings to Concrete Works
Protective Coating on Concrete ( Internal & External)
The coating system and the surface preparation shall be to the approved standard and
shall conform to the schedule of surface preparation and protection systems given below
for concrete work.
The coating system proposed shall be applied by Client approved specialist applicator.
Table G19- Surface Preparation on Concrete

Syste
Description
Surface Preparation
m
a)
Sweep Blasting
The surface shall be sweep blasted with non-metallic mineral
abrasive to achieve a minimum surface roughness of 100
micron on concrete or as recommended by the paint
manufacturer.
b)
Surface Cleaning
The concrete surface shall be cleaned to remove dirt, oil,
dust, laitance and all other surface contaminations.
c)
Epoxy binder / sealer One coat 100 micron D.F.T two component polyamide epoxy
based transparent sealer coat shall be applied by spray
application to seal the porous concrete substrate if any.
Vol 3, Section3
Page G-31 of 68
d)
Filler
Specifications
One coat of alkali resistant acrylic based filler 100 micron

DFT shall be applied by steel trowel or hand application to fill
the surface voids or as recommended by the paint
manufacturer.
1. Application of Field Coatings:

a. Coating shall be applied with spraying equipment recommended by the
Manufacturer.
1. Areas inaccessible to spray coating or rolling shall be coated by brushing or
other suitable means.
o. Give special attention to ensure that edges, corners, crevices, welds, bolts, and
other areas, as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.
p. Protective coating materials shall be applied in strict accordance with the
manufacturers printed instructions.
q. Prime coat shall be applied to clean surfaces:
1. Within a 4-hour period of the cleaning.
2. Prior to deterioration or oxidation of the surface.
3. In accordance with the manufacturers recommendations.
r.
Coatings shall be applied in dry and dust-free environment.

1. No coating shall be applied during following conditions:
a.
2.
3.
f.
from
When the surrounding air temperature, measured in the shade, is

below 17 C
b.
To wet or damp surfaces.
c.
In rain, fog or mist or when the relative humidity exceeds 85%.
d.
When it is expected that the relative humidity will exceed 85% or that
the air temperature will drop below 5C within 18 hours after the
application of the coating or paint.
e.
Dew or moisture condensation shall be anticipated.
f.
The cement laitance is removed with non-metallic mineral abrasive
blasting
g.
Minimum specified surface roughness is achieved.
h.
Specified primer /sealer coat is applied.
i.
Filling the surface voids/cracks/and imperfections with approved epoxy
filler.
If the above conditions are prevalent, coating shall be delayed until surfaces are
dry.
The days coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying
time prior to the formation of moisture.
Care shall be exercised to avoid lapping, coating on adjacent surfaces.

1.
2.
3.
4.
Vol 3, Section3
Coatings shall be sharply cut to lines.

Finished coated surfaces shall be free from defects or blemishes.
Drop cloths shall be used to protect floors, fixtures, and equipment.
Care shall be exercised to prevent paint from being spattered onto surfaces
Page G-32 of 68
5.
6.
g.
which such paint cannot be removed.

Surfaces from which paint cannot be removed shall be painted or repainted as
required to produce a finish satisfactory to the Engineer.
Apply second coat at right angles to first coat, ensuring pinholes are covered.
Surfaces inaccessible after assembly shall be coated before erection.
h.
Touch-up of surfaces shall be performed after installation.
i.
Surfaces to be coated shall be clean and dry at the time of application.
j.
Time of Coating:
a. Manufacturers recommended recoat time shall be complied with.
b. Sufficient time shall be allowed to elapse between successive coats to permit
satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.
c. No additional coating of any structure, equipment, or either item designated to be
painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment,
or other item.
k.
Thickness of Coating:
a.
[A]
Specifications
Dry film thickness specified shall be achieved for each coat.
l.
Clean up
1.
Concrete surfaces shall be visually inspected to ensure proper and complete
coverage has been attained.
2.
Upon completion of the work, staging, scaffolding, and containers shall be
removed from the site or destroyed in an approved manner.
3.
Coating spots, oil, or stains upon adjacent surfaces shall be removed.
m.
Protective coating properties tests are to be conducted on the final coated surface and
shall comply with the requirements specified in Table G21.
Schedule of Concrete Protection System

For Major Structures Internal:
System -
7mm thick in-situ GRP lamination as specified in CL G.1.6.
System-
A-1
7 mm thick in-situ GRP lamination with grit bonding on top of final

finish coat as specified in CL.G.1.14.
System -
1mm thick heavy duty glass flake vinyl ester resin based coating 250
micron each. Total D.F.T 4 x 250 microns + Approved Primer
recommended by the paint manufacturer.
System -
1mm thick Polysulphide modified Epoxy resin coating system

designed for superior adhesion, corrosion Protection, Chemical
resistance & waterproof coating 250 micron for each coat. Total
D.F.T (4 x 250 micron) = 1 mm + approved primer recommended
by the paint manufacturer.
System -
0.5 mm thick solvent free 100% solid content polyamine based

Epoxy + Polyurethane resin coating.
Vol 3, Section3
Page G-33 of 68
Specifications
Epoxy = 300 microns thick

Polyurethane = 200 microns thick
Total DFT = 500 microns + Approved Primer recommended by the
paint manufacturer.
System -
Aggregate dressed (3 component) heavy duty, hard wearing,

solvent less Epoxy, anti slip deck coating minimum D.F.T = 3 mm.
+75 micron high build epoxy finish top coat with anti-fungi and
antibacterial agents.
System -
Fibre reinforced acid resistant, mineral based alkaline silicate mortar

minimum 6 mm thick with finish top coat for hard floor coating.
System -
Double sided PVC lined membrane as specified in Section 4

Mechanical Specification.
For Major Structures External Surfaces above Ground Exposed to Sunlight

System -
[B]
[C]
[D]
Alkali Resistant Acrylic based anticarbonation coating + Sealer coat

+ filler Coat
Epoxy binder / Sealer Coat 100 microns thick.
Alkali Resistant Acrylic based filler 100 microns thick.
Alkali Resistant acrylic based anticarbonation coating 100 x 3
coats = 300 microns thick.
For minor Structures (Internal Surfaces)

System -
7mm thick in-situ GRP lamination over granolithic benching for

sewer MHs as specified in CL G.1.6.
System -
7mm thick Prefabricated GRP liner as specified in CL G.1.5 for sewer

manholes.
System -
Two component Epoxy mortar 10mm thick over granolithic benching

of storm water MHs as specified in CL G.1.7
System -
Solvent free 100% solid content Polyamine based pure Epoxy 300
micron thick + primer, for storm water MHs and Inspection
chambers (sewer) etc.
For Minor Structures (External surfaces)

System -
System -
Rubberised bitumen emulsion + P.E sheet on top as specified in

G.1.8.
5 mm thick GRP pre fabricated benching or in-situ lamination over
benching of inspection chambers (sewer) as specified in Clause
G.2.3.
Roof Water Proofing System on Roof Top Exposed To Sunlight

System -
RWP - 1
Roof Water Proofing Systems on Roof top of Residential Buildings

& Pump Rooms as specified in Building Specification.
System -
RWP - 2
1.5 mm thick Protective coating with Acrylic modified elastomeric
Vol 3, Section3
Page G-34 of 68
Specifications
cementitious coating on Sloping Roof Top where Insulation is

not required
Table: G20- Schedule of Concrete Protection Details
S.N.
EXTERNAL PROTECTION FOR ALL MAJOR STRUCTURES

Particular
Protection Protection details
System
1
a.
b.
Below Ground Level

Below Blinding
Above Blinding (raft)
c.
Walls outer surface
Above Ground Level
A.N.
1
a.
P.E
System
T1,T2,T3 &
T4
System
T1,T2,T3 &
T5
System H
INTERNAL PROTECTION AND ROOFING DETAILS

Unit Details
Protection Protection details
System
Tanker Reception
Tanker Discharge Sump, Spill
System A
GRP Liner (7mm thick) as specified in CL G.1.6
Collection channel, Pump Sump
2
a.
Coarse and Screen Channels

Walls, Floors (top of benching if
System A
any), columns, beams and roof slab
(internal)
3
a.
b.
Ferric Storage system

Ferric storage and dosing area bund System A
Ferric chemical unloading area
System
A-1
Aerated Grit Channels
Channel between coarse and fine
System A
screen and aerated grit channels
Feed channels, grit channels, Scum System A
channels and outlet channel
4
a.
b.
Bio-reactor
5.1
Flow Splitting Cham ber
a.
Floor, walls, ceiling
5.2
Anaerobic/Anoxic/ Aeration,
Membrane tank & RAS Sump
Floors, Walls & Ceiling, inlet/ outlet
channels
a.
1000 gauge PE Sheet (250 micron thick)

Approved bituminous primer + 2 layers
bituminous membrane 1.5 mm and 2mm thick
each & 6 mm thick protection board as specified.
Approved bituminous primer + 2 layers
bituminous membrane 1.5 mm and 2mm thick
each with 3 mm thick protection board on top as
specified.
Approved sealer coat and filler coat and Alkali
resistant acrylic based anticarbonation coating
(300 micron) thick
Vol 3, Section3
GRP Liner (7mm thick) as specified in Cl.G.1.6
GRP Liner (7mm thick) as specified in CL.G.1.6

Grit bonded GRP liner (7mm thick) as specified
in Cl.G.1.14
System B
Approved primer recommended by the Paint

manufacturer +1 mm thick heavy duty glass
flake vinyl ester resin based coating
System B

Page G-35 of 68
Specifications

b.
Membrane Tank pipe gallery floor
System E
c.
Membrane Tank pipe gallery walls
System L
b.
Valve Chamber (RAS/SAS)
System L
6
a.
CCT and TSE Storage Tank

Floors, Walls, Columns, ceiling
System L
b.
Inspection Manholes
System L
7
a.
TSE Pump House

Wet Well
System L
b.
Valve Chamber
System L
Chemical Storage & Dosing
3 mm thick heavy duty (3 component) non-slip

epoxy abrasion resistant deck coating + high
build 75 micron finish coat on top with anti
fungi and anti bacterial agents.
Approved primer recommended by the paint
manufacturer +300 micron epoxy paint

(polyamine based)
manufacturer +300 micron pure epoxy paint
(polyamine based)

(polyamine based)
P olym er Storage and Dosing

a.
Polymer storage and dosing area

bund
Aerobic Digesters
a.
Walls and Floors (top of benching if System B

any)
b.
Walkways
10
Digested Sludge Pump and

Sump
a.
b.
Walls, floors, ceiling

Valve Chamber
11
Liquor Return Sump and Pump

House
Wet Well Walls, Floors and Ceiling
Dry Well/ Valve chamber floor and
Roof top
a.
b.
12
System A
GRP Liner (7mm thick)as specified in CL G.1.6
System E

3mm thick, heavy duty, non slip abrasion
resistant deck coating + high build 75 micron
finish coat on top with anti-fungi and anti
bacterial agents.
System A
GRP Liner (7mm thick)as specified in CL G.1.6
System L

manufacturer + 300 micron pure epoxy paint
(Polyamine based)
System A
GRP Liner (7mm thick)
System L

manufacturer + 300 micron pure epoxy paint
(Polyamine based)
Diesel Storage
Vol 3, Section3
Page G-36 of 68
Specifications
Diesel Tank Concrete Bund
System A
GRP Liner (7mm thick)
Concrete protection of any major and minor units not including under Table G20 shall be provided to
suit the purpose as specified in this section.
Table G21- Test on Protective Coating of Concrete
Sr.
Properties
Test Method
Minimum Requirements
Dry film thickness
BS 3900
Specified thickness for each coat
Discontinuity (holiday) detection
National Association of
Corrosion Engineers
standard recommended
practice
100% pin hole free
Pull of adhesion strength
ASTM D4541/ISO 4624
3.00 N/mm2 for epoxy coating

2.00 N/mm2 for anti carbonation
coating
Notes: (1)
(2)
Freedom from pinhole shall be established by the use of a spark tester.

Coating system should be resistant to:
(a)
Sulphate and chloride ion penetration
(b)
CO 2 diffusion
(c)
Bacterial and fungus growth
(d)
Atmospheric temperature resistant
(e)
Acids and alkalis of PH2 -14
(f)
To accommodate shrinkage cracks appearing on concrete substrate.
TABLE G22- BUILDING FINISHES DETAILS

Sr.
1
Building
Type
MCC Room,
Transformer
room, RMU/
Battery Room
Flooring
Blower
Houses
3mm thick
heavy duty
non slip (3
component)
epoxy abrasion
resistant deck
coating +
finish coat with
anti-fungi and
anti-bacterial
Vol 3, Section3
Walls (internal)
Power floated Plaster and plastic

concrete
paint with anti- fungi
structural slab and anti- bacterial
agent
Primer - 1 coat
No Coating On Intermediate coat - 1
Finish coat - 1
Floors
Plaster and plastic

paint with anti fungi
and anti bacterial
agent
Primer - 1 coat
Intermediate coat - 1
Finish coat - 1
Page G-37 of 68
Walls (external)
Ceiling
Skirting
Cement plastered
or fair- faced
concrete and
weather shield
(water resistant, UV
resistant, Crack
Bridging and flame
retardant) acrylic
emulsion coating
Primer -1 coat
Paint - 2 coats
-----do-----
Plaster and
plastic paint
with anti- fungi
and antibacterial agent
Prime - 1 coat
Intermediate
coat - 1
Finish coat - 1
100mm
high
ceramic
skirting
with
chamfere
d/
rounded
edge
-----do-----
N/A
Sr.
Building
Type
Flooring
Specifications
Walls (internal)
Walls (external)
Ceiling
Skirting
agents
Ventilation
fan Room
TSE Pumping
Station- Dry
Well
(concrete
walls/floor/ro
of)
Residual
Chlorination
Building
(delivery and
storage area)
Residual
Chlorination
Building
(chlorinator,
motive water
and
compressor
room)
Vol 3, Section3
3mm thick
heavy duty
non slip (3
component)
epoxy abrasion
resistant deck
coating +
finish coat with
anti-fungi and
anti-bacterial
agents
6mm (min)
thick fibre
reinforced
alkaline silicate
mineral based
mortar flooring
with paint
manufacturers
recommended
finish coat
(System F)
6mm (min)
thick fibre
reinforced acid
resistant
alkaline silicate
mineral based
mortar flooring
with paint
manufacturers
recommended
finish coat
(System F)
3mm thick
heavy duty
non slip (3
component)
epoxy abrasion
resistant deck
coating +
finish coat with
anti-fungi and
anti-bacterial
agents
Plaster and plastic

and anti- bacterial
agent
Primer - 1 coat
Intermediate coat - 1
Finish coat - 1
-----do-----
-----do-----
--
Cement plastered or
fair- faced concrete
and epoxy, primer
+ two coats paint
-----do-----
-----do-----
--
Cement plastered or
and epoxy, primer +
two coats paint
-----do-----
-----do-----
--
Cement plastered or
and epoxy, primer +
two coats paint
-----do-----
-----do-----
--
Page G-38 of 68
Sr.
7
10
11
Building
Type
Sludge
Dewatering
and Drying
Flooring
Specifications
Walls (internal)
Walls (external)
Ceiling
Skirting
3mm thick
Cement plastered or
-----do---------do----heavy duty
non slip (3
and epoxy, primer +
component)
two coats paint
epoxy abrasion
resistant deck
coating +
finish coat with
anti-fungi and
anti-bacterial
agents
Polymer
3mm thick
Cement plastered or
-----do---------do----preparation heavy duty
and dosing
non slip (3
and epoxy, primer +
room
component)
two coats paint
epoxy abrasion
(including
resistant deck
polymer
coating +
storage
finish coat with
room)
anti-fungi and
anti-bacterial
agents
Emergency 3mm thick
Plaster and plastic
-----do---------do----Generator
heavy duty
Building
non slip (3
and anti- bacterial
component)
agent
epoxy abrasion Primer - 1 coat
resistant deck Intermediate coat - 1
Finish coat - 1
coating +
finish coat with
anti-fungi and
anti-bacterial
agents
Diesel Pump 3mm thick
Plaster and plastic
-----do---------do----Room
heavy duty
non slip (3
and anti- bacterial
component)
agent
epoxy abrasion Primer - 1 coat
resistant deck Intermediate coat - 1
Finish coat - 1
coating +
finish coat with
anti-fungi and
anti-bacterial
agents
Building Roof min 50mm thick light weight concrete (for slope) + bituminous waterproofing
Top Water
membrane + 50mm thick extruded polystyrene insulation board + geotextile
Proofing
protection layer + 400x400x 40mm white aggregate concrete tiles.
Details
Vol 3, Section3
Page G-39 of 68
--
--
--
--
G.3
Specifications
COATING SYSTEM FOR FERROUS, NON FERROUS METALS AND PLASTICS
G.3.1 General
DESCRIPTION
A.
Provide all labour, materials, equipment, services and accessories necessary to
furnish and install the coating system work of this Section, complete and functional as
indicated in Contract Documents and as specified herein.
1.
Coatings for all ferrous, Non-ferrous surfaces, interior and exterior.
2.
Submerged ferrous metal surfaces.
3.
Structural and miscellaneous steel including tanks, hoppers and similar
equipment.
4.
Equipment furnished without factory finished surfaces.
5.
Exposed galvanized metal except handrails, grating, piping and checkered
plate.
SUBMITTALS.
A.
Manufacturers Data
1.
Manufacturers current printed product description, materials safety and
technical data sheets for coating systems.
2.
Detailed mixing, thinning and application instructions, minimum and
maximum application temperature, curing and drying times between
coatings.
3.
Instructions for surface preparation requirements, number and types of coats

required for each surface.
4.
5.
Colour charts for each coating system.

Certifications from manufacturer verifying factory applied prime coatings are
compatible with the specified finish coatings.
6.
Detailed maintenance manual including the following information:

a.
Product name and number.
b.
Name, address and telephone number of manufacturer and local

distributor.
7.
c.
Detailed procedures for routine maintenance and cleaning.
d.
Detailed procedures for light repairs such as scratches and staining.
Abrasive:
a.
Certified information of:

1. Particle size distribution.
2. Dust generation at proposed operating pressure and distance.
3. pH value.
4. Soluble chloride content.
5. Analysis for free silica.
6. Trace toxic contaminants.
B.
Sample Panels
1.
Apply a complete coating system to a panel of the same material as that on
Vol 3, Section3
Page G-40 of 68
Specifications
C.
which the coating will be applied and submit for approval for each colour
specified.
2.
Approved sample panels will be used for quality control in applying coating
systems.
Certificates of Compliance.
D.
Inspection Reports.
E.
Test Reports.
DELIVERY, STORAGE AND HANDLING

A
Delivery
1.
Deliver materials in original, unopened packages and containers bearing
manufacturer's name and label including the following information:
a.
B.
Name or title of material.
b.
Manufacturer's stock number and date of manufacture.
c.
Manufacturer's name.
d.
Contents by volume for major pigment and vehicle constituents.
e.
Thinning instructions where recommended.
f.
Application instructions.
g.
Colour code and name.
Storage
1.
Store materials on site in a suitable location, protected from exposure to
extreme weather.
2.
Keep area clean and accessible.
3.
Restrict storage of coating materials and related equipment.
4.
Keep temperature of storage area between 18C and 32C.
5.
Comply with Local Laws and Regulations.
6.
Cloth and Cotton wastes that might constitute of fire hazard shall be placed in
closed metal containers or destroyed at the end of each workday.
7.
Provide approved fire extinguishers in material storage area.
QUALITY ASSURANCE
A.
Applicator Qualifications
1.
Submit name and experience record of manufacturers recommended coating
applicator.
2.
Include list of utility or industrial installations painted, responsible officials,
architects, or engineers concerned with the project and the approximate
contract price.
B.
Inspect surface and correct defects prior to application of each coat.
C.
The protective coating systems specification, report on paint work progress and the
final report on corrosion protection should be provided by the applicator in the
formats (A), (B) and (C) given in this clause.
Vol 3, Section3
Page G-41 of 68
Specifications
Form A Form for a Protective Paint System Specification for New Work
(To be filled in for each constituent element of the structure by the applicator)
Project:
Name of Client:
Project:
Protective paint system:
Location:
ISO 12944-5 paint system No.
Constituent element:
Environment:
Drawing No. / area:
Required durability:
Position No.:
Sheet No:
Shop Application
Surface Preparation Grade:
Type of Prefabrication Primer (if used):
Area:..m2
Paint manufacturer:
Protective Paint System
Nominal dry
Overcoating interval
Drying time
at .C (h)
film thickness
m
Minimum (h)
Maximum (h)
st
1 Coat
2nd Coat
3rd Coat
4th Coat
Total:
Site Application
Surface Preparation Grade:
Touch up:
Complete:
Area: ..m2
Paint Manufacturer:
Protective Paint System
Nominal dry
Overcoating interval
at .C (h)
film thickness
m
Minimum (h)
st
1 Coat
2nd Coat
3rd Coat
4th Coat
Total:
Vol 3, Section3
Drying time
Page G-42 of 68
Maximum (h)
Specifications
Form B Form for a Report on Paint Work Progress and Application Conditions
(To be filled in by the coating applicator during the progress of work)
Project:
Drawing No:
Location:
Corrosion Protection Plan No:
Constituent Element:
Position No:
Inspected by:
Comments:
Area:
1
Date
Time
10
Type of work
Method
General
Temp
Temp
Rel.
Dew
(i.e. surface
used
weather
Air
Structural /
air
point
preparation,
conditio
Constituent
humidity
application of
ns
element C
priming coats,
11
12
13
Blast
Paint
Colour
Remarks (eg.
Signature/
cleaning
batch
ISO standard,
initials
abrasive
no.
surface
(material
prepar,
no.)
grade,
irregularities
intermediate
coats, top
coats)
_______________
__________________
_______________
(Place)
Vol 3, Section3
(Date)
___________________________
________________________
___
(1st Signature)
Page G-43 of 68
(2nd Signature)
(3rd Signature)
14
Specifications
Form C Form for Final Report on Corrosion Protection Work

(To be filled in by the applicator after the completion of the paint works)
Name of structure:
Project No:
Drawing No:
Protective paint system:

ISO 12944-5 paint system No. (if applicable)
1st Coat
2nd Coat
3rd Coat
4th Coat
Paint work contractor:

New work
Rust grade of steel surface (ISO 8501-1)
.A
.B
.C
.D
Milling imperfections found
Sharp edges and burrs removed
Welding residues, including weld spatter, not

removed
Specified surface preparation grade (ISO 8501 1 or ISO 8501-2):

Blast-cleaning
Sa2
Sa 2
Sa 3
PSa 2
PSa 2
PSa 3
Flame cleaning
FI
Hand and power tool
St2
St3
Cleaning
PSt2
PSt3
Machine abrading
Pma
Specified surface profile (ISO 8503-1):

Comparator G
Fine
Medium
Coarse
Comparator S
Fine
Medium
Coarse
Vol 3, Section3
Page G-44 of 68
5th Coat
Vol 3, Section3
Specifications
Page G-45 of 68
Specifications
ENVIRONMENTAL CONDITIONS
A.
Unless otherwise recommended by coating manufacturer, the ambient temperature shall

be between 7C and 35C when applying coatings other than water-thinned epoxy.
D.
Water-thinned coatings shall be applied only when ambient temperature is between

10C and 32C.
C.
Epoxy coatings will be applied only within the minimum and maximum temperatures
recommended by the coating manufacturer.
D.
Coatings, except water-thinned types shall be applied only to' surfaces that are
completely free of moisture as determined by sight or touch.
Vol 3, Section3
Page G-46 of 68
E.
Specifications
Do not apply to surfaces which have visible frost or ice.
G.3.2 Products
MANUFACTURER
A.
Products and manufacturers specified hereinafter are specified for the purpose of
establishing minimum quality standards.
Products equal in quality to, or better than those specified will be considered acceptable.
Decision of acceptability will rest with the Engineer.
Paint shall be from the approved suppliers list.
GENERAL
A.
No substitutions shall be considered that decrease:
1. Film thickness.
2. Number of coats.
3. Surface preparation.
4. Performance criteria of the generic type of coating specified.
B.
Furnish coatings and coating products under this Section from a single manufacturer
unless otherwise specified.
C.
Compatibility
1.
Compatible materials shall be used as primer and finish coats of systems.
3.
Compatible barrier coats may be used between factory-applied prime coats, or
finish coats on existing surfaces to be refinished and subsequent field coats with
the Engineer's approval.
D.
Colours
1.
Colours shall be as scheduled or selected by the Engineer.
2.
Prime and intermediate coats shall be tinted as approved by the Engineer to
facilitate inspection of coverage for each coat
HAZARDOUS MATERIALS RESTRICTIONS

A.
Paints and painting practices shall comply with all applicable state and local
requirements
limiting the emission of volatile organic compounds.
MATERIALS
A.
Abrasive
1.
Chose particle size, shape, and specific gravity to produce desired surface
profile for coating adhesion recommended by coating manufacturer.
a.
If not listed in manufacturer's literature, provide for a 50 to 75 microns
average profile.
2.
pH value
:
Not less than 4 nor greater than 10 when
mixed in neutral water
Vol 3, Section3
Page G-47 of 68
3.
4.
5.
B.
Specifications
Soluble Chloride
Free Silica
Trace Toxic Contaminants
:
:
:
None.
To meet government regulations
To meet government regulations
Colours as selected by Engineer from manufacturer's standards.
G.3.3 Execution
WORKMANSHIP
A.
Paint and coatings shall be applied so as to produce an even film of specified
thickness.
B.
Edges, corners, crevices and joints shall receive special attention to ensure that they
have been thoroughly cleaned and that they receive an adequate thickness of paint.
C.
Finished surfaces shall be free from runs, drips. ridges, waves. laps. brush marks and
variations in colour, texture and finish.
D.
Coverage shall be complete so that the addition of another coat of paint would not
increase the coverage.
E.
Adjacent surfaces shall be protected by the use of drop cloths or other approved
precautionary measures.
ITEMS NOT TO BE COATED
A.
Hardware, hardware accessories, nameplate data tags, machined surfaces and similar
items shall not be coated.
Such items in contact with coated surfaces shall be removed or masked prior to the
commencement of the surface preparation and painting operations.
B.
Following completion of coating of each piece, removed items shall be reinstalled.
C.
Removal and installation shall be done by workmen skilled in the trades involved.
PREPARATION
A.
Surfaces to receive paint and protective coatings shall be cleaned as specified prior to
application of coating materials.
B.
C.
D.
Examine surfaces to be finished and correct surface defects before application of any
coating material.
Beginning the work of this section without reporting unsuitable conditions to the
Engineer constitutes acceptance of conditions.
Marred or abraded areas on shop-primed 'and factory-finished surfaces shall receive
touch-up restoration prior to any other coating applications.
SANDBLASTING
A.
All sandblasting shall be done in strict accordance with the referenced specifications
of the Steel Structures Painting Council.
B.
When items to be shop primed or shop primed and finish coated in the shop, surface
preparation shall be as specified in this Section.
C.
The Engineer shall have the right to witness, inspect and reject any sandblasting done
in the shop.
D.
When sandblasting is done in the field, care shall be taken to prevent damage to
structures and equipment.
1.
Vol 3, Section3
Pumps, motors and other equipment shall be shielded, covered or otherwise
Page G-48 of 68
2.
E.
protected to prevent the entrance of sand.

No sandblasting may begin before the Engineer inspects and approves the
protective measures.
Following surface preparations for metal surfaces to be painted or given protective

coatings shall form part of this Section:
1.
White Metal Blast Cleaning (For very corrosive atmosphere).

a.
2.
3.
Blast cleaning of all except tightly adhering residues of mill scale rust
and coatings, exposing numerous evenly distributed flecks of
underlying metal.
Solvent Cleaning
a.
Removal of oil, grease, dirt, soil, salts and other contaminants by

cleaning with solvent, vapour alkali, emulsion or steam.
Surface preparations shall be done to the satisfaction of the Engineer.

1.
G.
Blast cleaning until at least 67 percent of each element of surface area is

free of all visible residues.
Brush- off Blast Cleaning

a.
5.
Blast Cleaning nearly to White Metal Cleanliness, until at least 95

percent of each element of surface area is free of all visible residues.
Commercial Blast
a.
4.
Removal of all visible rust, will scale, paint and foreign matter by blast
cleaning by wheel or nozzle (dry) using sand, grit or shot.
Near-White Blast Cleaning (For high humidity, chemical atmosphere, marine

or other corrosive environment).
a.
F.
Specifications
No painting or protective coating shall be applied before the Engineer has

inspected and approved the preparation.
After sandblasting, dust and spent sand shall be removed from the surfaces by brushing
or vacuum cleaning.
APPLICATION OF PROTECTIVE COATINGS

A.
Shop Coating
1.
2.
Vol 3, Section3
Fabricated metalwork and equipment which requires coating may be shop

primed with specified primer.
Any such work delivered to the job site with any other shop coat shall have this
coating removed and the specified coating applied in the field. Manufactured
equipment with approved corrosion-resistant factory finishes and galvanized
finishes shall be exempt from this requirement of stripping.
Page G-49 of 68
B.
Specifications
Field Coating
1.
Except where in conflict with the manufacturer's printed instructions or where

otherwise specified herein, use choice of brush, roller, spray or airless spray
application.
a.
b.
2.
3.
4.
5.
6.
Any spray painting must first have the approval of the Engineer.
Areas inaccessible to spray coating or rolling shall be coated by brushing
or other suitable means.
Give special attention to ensure that edges, comers, crevices, welds, bolts and
other areas as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.
All protective coating materials shall be applied in strict accordance with the
manufacturer's printed instructions.
Prime coat shall be applied to clean surfaces within a 4-hour period of the
cleaning and prior to deterioration or oxidation of the surface and in accordance
with the manufacturer's recommendations.
Coatings shall be applied in dry and dust-free environment:
No coating or paint shall be applied during following conditions:
a.
When the surrounding air temperature, measured in the shade is below

15C.
b.
To wet or damp surfaces.
c.
In rain, fog or mist, or when the relative humidity exceeds 85%.
d.
When it is expected that the relative humidity will exceed 85% or that the
air temperature will drop below 5C within 18 hours after the application
of the coating or paint.
e.
Dew or moisture condensation shall be anticipated.
7.
If above conditions are prevalent, painting shall be delayed until surfaces are dry.
8.
The day's coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time
prior to the formation of moisture.
Care shall be exercised to avoid lapping paint on adjacent surfaces:
9.
a.
b.
c.
d.
e.
f.
Coatings shall be sharply cut to lines.

Finished coated surfaces shall be 'free from defects or blemishes.
Drop cloths shall be used to protect floors, fixtures, and equipment.
Care shall be exercised to prevent paint from being spattered onto
surfaces from which such paint cannot be removed.
Surfaces from which paint cannot be removed shall be painted or
repainted as required to produce a finish satisfactory to the Engineer.
Whenever two coats of a dark coloured paint are specified, the first coat
shall contain sufficient powdered Aluminium to act as an indicator of
proper coverage, or the second coating shall be of a contrasting colour.
Vol 3, Section3
Page G-50 of 68
10.
Surfaces inaccessible after assembly shall be coated before erection:

a.
b.
C.
No structural friction connections, high-strength bolts and nuts shall be

painted before erection.
Areas damaged during erection shall be hand or power-tool cleaned and
recoated with prime coat.
11.
Touch up of surfaces shall be performed after installation.
12.
All surfaces to be coated shall be clean and dry at the time of application.
Time of Coating
1.
Manufacturer's recommended recoat time shall be complied with.

a.
b.
2.
D.
Specifications
Sufficient time shall be allowed to elapse between successive coats to

permit satisfactory recoating, but once commenced, the entire coating
operation shall be completed without delay.
No additional coating of any structure, equipment or other item
designated to be painted shall be undertaken without specific permission
of the Engineer until the previous coating has been completed for the
entire structure, piece of equipment or other item.
Piping shall not be finish coated until it has been pressure tested and approved.
Thickness of Coating
1.
Dry film thickness specified shall be achieved and verified for each coat.
G.3.4 Testing and Inspection

A.
Inspection Devices
1.
Provide, until final acceptance of coating and' painting, inspection devices in good
working condition for detection of holidays and measurement of DFT of coatings
and paints. .
2.
Furnish U.S. Department of Commerce, National Bureau of Standards or

equivalent certified thickness calibration plates to test accuracy of DFT gauge and
certified instrumentation to test accuracy.
Dry film thickness gauges shall be made available for the Engineer's use until final
acceptance of application.
Holiday detection devices shall be operated in the presence of the Engineer.
Inspection devices shall be operated in accordance with the manufacturer's
instructions and when directed by the Engineer's representative.
3.
B.
Conduct DFT measurements and electrical inspection of the coated surfaces.
C.
Recoat and repair as necessary for compliance with the specifications.
Vol 3, Section3
Page G-51 of 68
D.
Specifications
After repaired and recoated ferrous metals areas have cured, final inspection tests
shall be conducted by the Engineer.
1.
Coating thickness specified in mils on ferrous substrates shall be measured

with a non destructive magnetic or digital type dry-film thickness gauge
2.
Discontinuities, voids and pinholes in the coatings will be determined with
non-destructive type electrical holiday detector.

3.
Epoxy coatings and thin film coatings shall be checked for discontinuities and
voids with a low-voltage detector of the wet-sponge type,
4.
Use a non-suding type wetting agent, which shall be added to the water prior to
wetting the sponge.
5.
A high-voltage, low-current, spark type detector shall be used for electrical
inspection of coal tar enamel only.
6.
Tape-type coatings shall be inspected for holidays using a device designed for
use in detecting such flaws.
7.
Pinholes shall be marked, repaired in accordance with the manufacturer's printed
recommendations and retested.
8.
No pinholes or other irregularities will be permitted.
9.
Coatings not in compliance with the specifications will not be acceptable and
shall be replaced and re-inspected at Contractor's expense until the requirements
of the specifications are met.
All gauges and detectors shall be provided with calibration by the Contractor facilities subject to
the approval of the Engineer.
Paint Properties tests are to be conducted on final coated surface and shall comply with the
following test.
Test on protective coating to metal works shall be as given in Table G23
Table G23 -TEST ON PROTECTIVE COATINGS OF METAL WORKS
Properties
Test Method
Minimum Test
Requirements
1.
Dry film thickness
BS 3900
2.
Pull of adhesion
strength
Discontinuity
(Holiday detection)
ASTM D 4541 / ISO 4624
Specified thickness for each

coat
6N/mm2
3.
4.
Abrasion resistance
5.
Coating resistance
to cracking (bend
test)
National Association of corrosion

Engineering standard recommended
practice
ASTM D 4060
BS 3900 : PG8 RG5
100% pin hole free

0.22gm weight loss in 1000
cycles
PermeabilityNil
Visible defects - Nil
CLEANUP
A.
Upon completion of the work staging, scaffolding and containers shall be removed
Vol 3, Section3
Page G-52 of 68
from
Specifications
the site or destroyed in an approved manner.

B.
Paint spots, oil or stains upon adjacent surfaces shall be removed.
PAINT AND COATING SCHEDULE

A.
General
1.
The schedule here-in shall indicate the surface preparation and practice coating
system to be used.
2.
The list shall not be construed as a complete list of surfaces to be coated, but
3.
4.
B.
rather as a guide as to the application of the various coating systems.

All surfaces shall be painted except those specifically deleted herein.
Where reference is made to ferrous metal in this schedule, it shall not include
stainless steel or galvanized metals except as specified in paragraph C - Paint
Schedule.
Painting Systems
1.
a.
On ferrous metal subject to corrosive moisture or atmosphere and

condensation. Typical examples include the screening facility and grit
dewatering facility.
b.
Surface Preparation:
1. All metal surfaces shall be sandblasted near White Blast Cleaning
using proper abrasive size to achieve 35 to 40 micron anchor
pattern.
2. Weld surface, edges and sharp corners shall be ground to a curve
and all weld splatter removed.
c.
Coating:
1.
Shall be applied by airless spray or by brush for small areas.
2.
Coating Thickness:
Minimum Dry Film

Thickness
50 microns
Primer
Intermediate Coat
Finish Coat
d.
Vol 3, Section3
Component
or
as specified in Table 7-25
200 microns or
50 microns
or
Time Between Coatings:

1.
A minimum of 12 hours time is required before additional coats
are applied to the prime coat.
2.
Two hours for the intermediate coat
3.
Two hours for the finish coat
Page G-53 of 68
2.
Specifications
a.
On ferrous metals subject to normal indoor or outdoor exposure, except

as specified for buildings and not subject to chemical attack.
b.
1.
All surfaces shall be free of dirt, dust, grease or other foreign

matter before coating.
Surfaces shall be cleaned and, Brush off Blast Cleaning.
Weld surfaces and rough edges shall be ground and weld
splatter removed.
2.
3.
c.
Coating:
1.
2.
3.
Application shall be in strict conformance with the

manufacturer's recommendations.
All sharp edges, nuts, bolts or other items difficult to coat shall
receive a brush-applied coat of the specified coating prior to
application each coat.
Coating Thickness:
Minimum Dry
Film Thickness
d.
a.
b.
Primer
Intermediate Coat
50 micro
or as specified in Table 7 25
200 microns or as specified in Table 7 25
Finish Coat
50 microns or as specified in Table 7 - 25
Time Between Coatings

1.
3.
Component
As stated in B1 (d) above
On ferrous metals submerged or intermittently submerged in water or

corrosive liquid. Typical examples include the primary settling tanks and
aeration tanks.
1.
c.
All metal surfaces shall be sandblasted with near White Blast

Cleaning using proper abrasive to achieve 50 to 75 microns anchor
pattern.
2.
Weld surface, edges and sharp comers shall be ground to a curve
and all weld splatter removed and welds neutralized with thinner.
Coating:
1.
Vol 3, Section3
Application shall be in strict conformance with the manufacturer's

recommendations.
Page G-54 of 68
Specifications
2.
3.
All sharp edges, nuts, bolts or other items difficult to coat shall
receive a brush-applied coat of the specified coating prior to
application of each coat.
Coating Thickness:
Minimum Dry Film
Thickness
Primer
Finish Coat
d.
Component
50 microns
or as specified in Table 7 25
250 microns or as specified in Table 7 - 25
Time between Coatings:

3. As stated in B1 (d) above
4.
a.
For exterior galvanized steel including the operating platform, handrail,

piping etc.
b.
1.
2.
c.
Coating:
1.
d.
Given in schedule of protection system for metal surface.
Time Between Coatings:

1.
C.
Galvanized surfaces shall be washed with solvent thinner as

recommended by the paint manufacturer.
Use power tool cleaning to remove insoluble contaminants.
As stated in B1 (d) above
Paint Schedule
1.
General
a.
The coating system to be used is specified here-in the schedule of

protection system for metal surface.
b.
All surfaces shall be painted except those specified in paragraph 1.01.
c. The Engineer shall select the colours.

2.
Process Piping Colour Code

a.
3.
As specified in Mechanical Identification".
Equipment Colour Code

a. All plant and equipment shall be painted to the colours
detailed below or equivalent RAL colours unless otherwise
instructed by the Engineer.
Vol 3, Section3
Page G-55 of 68
Specifications
Item
D.
BS 4800
Colour Description
Base-plates and mounting stools

handrails, walkways & steel supporting
structures
}
}
}
00 A 05
Light Grey
Screw pumps
Non Potable Water Tanks
}
}
00 E 53
Black
Light Green
Coupling & Fly wheels

Drive Shafting
Valve hand-wheels
Lifting equipment, including rails
beams, Bogies, gantry girders crab,
block and control cabin
}
}
}
}
}
}
04 E 53
Red
Pumps
Gearboxes
}
}
08 E 51
Mid Yellow
Transformers
Control, switchgear, distribution &
mimic panels
}
}
}
18 E 51
Sky Blue
Motors
Alternators
All other exposed metalwork
}
}
}
Shafts and coupling guards

Aluminium or GRP hand railing
}
}
18 E 53
Mid Blue
Self Colour
General Coating System

1.
The following list shall indicate the coating system.
2.
Piping shall be defined as all pipe, valves, fittings, supports, operating systems
3.
and guides.
Mechanical equipment shall include all drives, motor control panels, and all other
electrical equipment requiring a protective coating.
The colours of other surface shall be selected by the Engineer.

Item
System
aPump Station Wet Wells and Sewage and

.Sludge Treatment Equipment:
As specified in
schedule of
protective
coating on
metal works
All exposed mechanical equipment
Vol 3, Section3
All submerged mechanical equipment and

piping
b
Pump Station Dry Wells and Motor Rooms:
.
All mechanical equipment and piping
Page G-56 of 68
Colour
*
..
Black
..
Specifications
c
Offices/Store/Workshops:
.
..
All exposed metal
..
..
d
Miscellaneous:
.
All miscellaneous interior exposed metal
surfaces
All miscellaneous exterior exposed
..
metal surfaces
All submerged metal surfaces
..
Black
*
5.
Colour per equipment or pipe color code schedules.

All structural steel shall be hot-dip Galvanised in accordance with BS729 and to be
painted as per the schedule of protection system after applied paint manufacturers
particulars recommended wash primer.
SCHEDULE OF SURFACE PREPARATIONS ON FERROUS & NONFERROUS METALS &

PLASTICS
System
Description
Surface Preparation
(a)
Degreasing
Shop cleaning to remove group 1

contaminants in accordance with the
approved standard.
(b)
Blast Cleaning
The surface shall be shot or grit blasted

to remove all rust, mill scale, in accordance
with the approved standard first quality
finish for steel, second quality finish for
cast iron. Blasting materials shall be free of
deleterious substances.
(c)
Fettling
The surface shall be cleaned to remove

all scale, rust, etc., by hand cleaning using
a powered wire brush or other approved
method.
(d)
Site cleaning
Immediately before site painting all dirt,

oil or grease shall be removed from the
surface with white spirit or other approved
solvent.
(e)
Wire wool or
Abrasive cloth
On site preparation to provide key for

primers and undercoats.
(f)
Polish and /or

Anodise
Shop treatment for aluminium.
Sweep Blast
Site preparation for galvanized areas.
(g)
Vol 3, Section3
Page G-57 of 68
(h)
Specifications
Spot Blast cleaning
Welded spot shall be spot blast cleaned

to Sa 2 to remove the accumulated dirt &
welding resounds.
(i)
Pickling (stainless steel)
The passive layer on the welded parts of

stainless steel shall be removed &
restored by pickling prickling the metal in a
tank and then treating it with passivating
solution.
(j)
Electro Chemical Polishing

(Stainless steel)
Electrolyte bath to produce a

homogeneously polished surface with a dirt
repelling effect.
SCHEDULE OF PROTECTIVE COATINGS ON FERROUS & NONFERROUS METALS

System
Description
P1
Zinc metallisation or zinc spray to the approved standard.

Or thicker metallic zinc coating
P2
Sealer primer to follow hot dip galvanising.
P3
Etch primer or wash Primer to follow zinc spray.
P4
Micaceous Iron Oxide Paint containing not less than 80% iron oxide
and not more than 5% anti-settling agent.
P5
Alkyd Resin base undercoat
P6
Alkyd Resin base gloss finish paint
P7
Zinc Chromate primer with 85% zinc on dry film
P8
Epoxy or Polyester prefabrication primer
P9
Epoxy Zinc phosphate submersible primer
P10
High build Polyamine based Epoxy or Polyester airless spray coating
P11
Approved nylon, PVC or other synthetic dip or spray applied coating.
P12
Hand wrapping with hydrocarbon paste, mastic, Denso PVC tape and
Insulation
P13
Polyurethane tie coat for non ferrous substrate
P14
Polyurethane based coating for ferrous and non-ferrous metal
P15
Acrylic urethane based finish coat
P16
High alumina fibre cement mortar lining to specified thickness.
P17
Air drying modified polysiloxane resin based coating to withstand 250C.

temperature
Vol 3, Section3
Page G-58 of 68
Specifications
P18
Fusion bonded Epoxy
P19
High build Epoxy aluminium primer/build coat.
P20
Vinyl ester based primer
P21
Glass flake vinyl ester
P22
Zinc Phosphate Primer Epoxy for ferrous substrate
P23
Modified Epoxy
P24
Epoxy high build MIO (for Galvanized)
P25
Special Red oxide Primer for non-ferrous areas.
P26
Polyethylene Sleeve / Thermal Insulation
P27
Anti Slip Deck Coat (3mm thick)
P28
Sprayed aluminium
P29
High build Epoxy for Potable water resistant
Notes: (1)
For manufactured items all cutting and drilling shall be completed before application
of any of the surface treatment specified.
(2)
All paint systems shall achieve a minimum dry film thickness (dft) of 300 and a maximum
of 500 micron unless otherwise stated separately. The number of coatings to achieve this
thickness may vary according to method and time of application.
(3)
Epoxy/polyester coatings must be applied by airless spray of electrostatic charging of

particles and stoving.
(4)
Freedom from pin holes shall be established by a spark tester or such other means
recommended by the coating applicators/manufacturer. Such equipment shall be
provided and maintained by the contractor and be available at all times for the sole use
of the engineer.
(5)
Hot dip Galvanizing shall be as specified.
Vol 3, Section3
Page G-59 of 68
Table G24-
SCHEDULE OF PROTECTION SYSTEMS ON FERROUS & NON- FERROUS METALS

[A]
No.
1.
Specifications
Substrate
INTERNAL SURFACES
Environment
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Mild Steel
Ditto
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Ditto
Ditto
Ditto
Mild Steel
Ditto
Ditto
(b) Partially
submerged in
sewage or in
contact with
sewage
vapours
Pipes &
fittings
Preparation
in Shop
Vol 3, Section3
(a) Fully
submerged in
Sewage or in
contact with
Sewage
vapours
Typical
Application
Ditto
(a) & (b)
Shop Coatings
1st,2nd,3rd,4th,5th
P1, P16, P10,

P10
Shop coating thickness

in microns
Preparation
on Site
1st
100
2nd
4mm*
3rd
100
4th
100
5th
(d) & (e)
Site Coating
System
1st
P10
2nd
P10
P10
P10
3rd
Total
Coating
thickness
including
Primer
microns
4300
Ditto
P1,P9,P10,P10
100
50
100
100
"
Ditto
P1,P9,P10,P10
100
50
100
100
"
Ditto
P1,P9,P10,P10
100
50
100
100
"
P10
P10
P10
P10
350
P1,P16,P10,P15
100
4mm*
150
50
"
P10
P15
4300
P1,P3, P10,P15
100
50
150
50
"
P10
P15
350
P1,P3, P10,P15
P1,P3, P10,P15
100
100
50
50
150
150
50
50
"
"
P10
P10
P15
P15
350
350
Pipes &
Fittings
Page G-60 of 68
350
350
No.
2.
Substrate
Specifications
Environment
Typical
Application
(c) Submerged
Potable
/effluent
water
Shop Coatings
1st,2nd,3rd,4th,5th

in microns
(a) & (b)
P1,P16,P10,P10
100
4mm*
100
100
"
4300
P1,P9,P29,P29
50
50
125
125
"
350
P1,P9,P29,P29
P1,P9,P29,P29
50
50
50
50
125
125
125
125
"
350
350
(a) & (b)
P22,P16,P10
50
4mm*
125
P22,P29,P29
50
125
125
P22,P29,P29
P22,P29,P29
50
50
125
125
125
125
P22,P16,P10,P2
9
100
4mm*
100
P9,P29,P29
50
125
P9,P29,P29
P9,P29,P29
50
50
125
125
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Ditto
Ditto
Ditto
Mild Steel
Ditto
Ditto
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Ditto
Ditto
Ditto
Mild Steel
Ditto
Ditto
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Ditto
Ditto
Ditto
Mild Steel
Ditto
Ditto
Stainless Steel
GR:
316L/GR304
(d) Exposed to
ambient
conditions
(e) Buried under

the ground
Vol 3, Section3
Exposed to
ambient
conditions
Buried under
the ground
Pipes &
Fitting
Preparation
in Shop
Pipes &
fitting
Pipes &
Fittings
Hot
water
pipes
(a) & (b)
No Coating
Internal
No Coating
Internal
Page G-61 of 68
Preparation
on Site
"
Site Coating
System
Total
Coating
thickness
including
Primer
P10
P10
4175
P29
P29
300
"
"
P29
P29
P29
P29
300
300
(d) & (e)
P29
4300
125
Ditto
P29
300
125
125
Ditto
Ditto
P29
P29
300
300
100
Specifications
No.
Substrate
Environment
Typical
Application
3.
Galvanised Metals
(a) Exposed to
ambient
conditions
Ductile Iron
Ditto
Cast Iron
Carbon Steel
Ditto
Ditto
Mild Steel
Galvanised
Iron
Ditto
Ditto
(b) Buried under
Ground
Ductile Iron
Cast Iron
Carbon Steel
Ditto
Ditto
Ditto
Mild Steel
Galvanised
Iron
Thermo Plastics &
Thermo Set
Plastics in
uPVC/GRP/
GRE
Ditto
Ditto
4.
Shop Coatings
1st,2nd,3rd,4th,5th

in microns
P3,P22,P16,
P10, P15
P3,P22,P24,P15
10
50
10
P3,P22,P24,P15
P3,P22,P24,P15
Pipes &
fittings
150
50
4m
m*
150
10
10
50
50
150
150
100
100
P3,P22,P24,P15
10
50
150
100
P3,P22,P23,P23
P3,P22,P23,P23
10
10
75
75
125
125
100
100
P3,P22,P23,P23
P3,P22,P23,P23
10
10
75
75
125
125
100
100
P3,P22,P23,P23
No Coating
required Internal
10
75
125
100
* 4 mm thick cement mortar lining
Vol 3, Section3
Preparation
on Site
Site Coating
System
Total
Coating
thickness
including
Primer
(g)
P15
4310
"
"
P15
310
P15
P15
310
310
P15
310
P23
P23
310
310
"
P23
P23
310
310
"
P23
310
Pipes &
fittings
Preparation
in Shop
Page G-62 of 68
100
100
"
"
"
"
"
Table G25-
SCHEDULE OF PROTECTION SYSTEMS ON FERROUS, NON- FERROUS METALS & PLASTICS

[B]
No.
1.
Substrate
Ferrous Metals
Ductile Iron
Specifications
EXTERNAL SURFACES
Environment
(a) Fully
submerged in
sewage or in
contact with
sewage
vapours
Typical Application
Mechanical
Equipment
Pipe work **
Preparation in
Shop
Shop Coatings
1st,2nd,3rd,4th,5t
h
Preparation on site Shop

coating thickness
Unit (microns)
1st
2nd
3rd
4th
Preparation on Site
Site Coating System

1st
2nd
3rd
Total
Coating
thickness
(a) (b) & h
P20,P21,P21
50
750
750
(d)
(e)
(g)
P20
P21
1550micro
ns
(a) (b) & h
P20,P21,P21
50
750
750
(d)
(e)
(g)
P20
P21
1550micro
ns
1550micro
ns
1550micro
ns
1550micro
ns
Carbon Steel
Ditto
P20,P21,P21
50
750
750
(d)
(e)
(g)
P20
P21
Structural
Steel
Mild Steel
Ditto
P20,P21,P21
50
750
750
(d)
(e)
(g)
P20
P21
Cast Iron
Ditto
P20,P21,P21
50
750
750
(d)
(e)
(g)
P20
P21
Ditto
P22,P4,P15,
P15
75
125
50
50
(d)
(e)
(g)
P4
P15
300
microns
P22,P4,P15,
P15
P22,P4,P15,
P15
75
125
50
50
(d)
(e)
(g)
P4
P15
75
125
50
50
(d)
(e)
(g)
P4
P15
300
microns
300
microns
(d)
(e)
(g)
P14
P14
(d)
(e)
(g)
P4
P15
(b) Exposed to
Ambient
Conditions
Vol 3, Section3
*Mechanical
equipments
** Pipe works
(a) (b) & h

"
Valves
"
Gratings
"
P22,P14,P14
75
250
250
Handrails
"
P22,P4,P15,P1
5
75
125
50
Page G-63 of 68
50
575
microns
300microns
No.
*
**
Substrate
Environment
Specifications
Typical Application

Preparation on Site
coating thickness
h
Unit (microns)
Mechanical equipment shall include all drives, motor control Panel and all other electrical equipment requiring a Protective Coating.
Pipe work shall include all Pipes, Valves, fittings, supports operating system and guides
M.S.Pipe
"
P7,P3,P5,P6
100 10
100 100
(e)
(g)
Protection
Barrier
Plat forms
"
P22,P14,P14
75
250
250
(d)
(e)
(g)
2.
Ditto
Ditto
Galvanised Metals
(c) Buried under

the ground
Fully submerged
in effluent
/Potable water
(a) Exposed to
ambient
conditions
MH & PSTN
Covers
Pipe work to
with stand
temperature
up to 250C
Pipe works
"
Mechanical
equipment
Pipe works
Galvanised
steel gratings
G.I
multispan covers
G.I Panel
support
frames
Galvanised
electric
light poles
G. I. Pipes
Vol 3, Section3
Preparation in
Shop
Shop Coatings
1st,2nd,3rd,4th,5t
75
200
200
"
P9,P10,P10,
P15
P7,P17,P17
25
75
"
P22,P23,P23
75
(a) (b) & h
P9,P29,P29
Ditto
P5
P6
310microns
P14
P14
P10
P15
575
microns
525microns
(e)
50
(d)
(e)
125
125
(d)
(e)
(g)
P23
P23
125
125
125
(d)
(e)
(g)
P29
P29
P9,P29,P29
125
125
125
(d)
(e)
(g)
P29
P29
(g)
P3,P24,P14,
P14
10
100
250
250
(d)
(e)
(g)
P14
P14
(g)
P3,P24,P24,
P14
P3,P24,P5,24
P15
10
100
250
250
(d)
(e)
(g)
P14
P14
10
100
100
100
P15
P15
P3,P24,P24,P1
5,
P15 (clear)
P3,P24,P24,
P15,P15
10
100
100
50,
50
(d)
(e)
(g)
P15
P15
310 micron
10
100
100
50,
50
(d)
(e)
(g)
P12
P12
Insula
tion
310
microns
(g)
(g)
Page G-64 of 68
(g)
Total
Coating
thickness
(d)
(g)
50
Site Coating System
P17
150
microns
P12
325
microns
375
microns
375
microns
610
microns
610
microns
310
microns
No.
4.
Substrate
Non- Ferrous
metal.
Stainless steel GR
316L/304
Ditto
Environment
Specifications
Typical Application
(b) Buried under

the ground
G. I. pipes
(a) Fully
submerged in
sewage or in
contact with
sewage
vapours
Pipe works
(b) Exposed to
ambient
conditions
Pipe works
carrying hot
water up to
50C
Ditto above
50C to 120C
Ditto
Ditto
5.
Aluminium
Shop Coatings
1st,2nd,3rd,4th,5t
h
P3,P24,P23,
P23
Preparation on Site
(d)
(e)
(g)
Site Coating System

P23
P23
50
500
500
(e)
(g)
P21
P21
"
P25,P15,P15
50
50
100
(e)
(g)
P15
P15
"
P25,P28
50
100
(e)
(g)
Covers &
platforms
Handrails
"
P25,P14,P14
50
250
250
(e)
(g)
P14
P14
"
"
No coating
external &
internal
(Natural
Finish)
P25,P29,P29
50
125
125
(e)
(g)
P29
P29
"
P25,P29,P29
50
125
125
"
"
P29
P29
"
P25,P23,P23
50
125
125
"
"
P23
P23
(g) & (f)
P25,P15,P15
50
50
50
(d)
(e)
P15
P15
Mechanical
equipment
Pipe works
(d) Buried under

the ground
Pipe works
Exposed to
ambient
conditions
covers
(e) & g ,
(h) (i)(j)

coating thickness
Unit (microns)
10
100
100 100
P25,P21,P21
(c) Fully
submersed in
effluent/Pota
ble water
Vol 3, Section3
Preparation in
Shop
Page G-65 of 68
Total
Coating
thickness
310
microns
1050
microns
P12
Insul
ation
200
microns
P12
Insul
ation
150
microns
550
microns
300
microns
300
microns
300
microns
P12
Insul
ation
150
microns
No.
6.
Substrate
Thermo Plastics
UPVC/P.P/
HDPE
Environment
(a) Exposed to
ambient
conditions
Specifications
Typical Application
pipe works
Preparation in
Shop
(d) & (e)
(b) Buried under

the ground
7
Thermo Setting
Plastics
(GRP/GRE)
(a) Exposed to
ambient
conditions

coating thickness
Unit (microns)
Preparation on Site
Site Coating System
P25,P15,P15
50
50
50
(d)
(e)
P15
P15
150
microns
Total
Coating
thickness
No Coating
Required
Odour Control
GRP Duct
Pipes & fittings
(d) & (e)
P25,P15,P15
50
50
50
(d)
(e)
P15
P15
150
microns
GRP Pipes and

fittings for
water
distribution
Type A
covers on
Odour Control
units
(d) & (e)
P25,P15,P15
50
50
50
(d)
(e)
P15
P15
150
microns
(d) & (e)
Type B cover
on Odour
Control Unit
(d) & (e)
Cover
manufacturers
recommended
protective
coating system
resistant to
corrosion &
U.V
Cover
manufacturers
recommended
protective
coating system
resistant to
corrosion , Non
slip and U.V
resistant
GRP
"
GRP
(b) GRP Dome

shaped
smooth finish
non
pedestrian
trafficable
covers
GRP
GRP Non Slip

pedestrian
trafficable
covers
Vol 3, Section3
Shop Coatings
1st,2nd,3rd,4th,5t
Page G-66 of 68
No.
Substrate
GRP
GRP
GRE
Environment
GRP Non Slip
Pedestrian
trafficable
covers with
chequer plate
wearing
surface
GRP Chemical
Storage tanks
/ GRP potable
water storage
tanks
(c) Potable Water
Pipes
exposed to
ambient
conditions for
fire fighting
Specifications
Typical Application
Preparation in
Shop
Shop Coatings
1st,2nd,3rd,4th,5t
h

coating thickness
Unit (microns)
Preparation on Site
Site Coating System
Total
Coating
thickness
Type C
covers on
odour Control
Units
(d) & (e)
Cover
manufacturers
recommended
protective
coating
Tanks external
& related
fittings
(d) & (e)
P25,P15,P15
50
50
50
(d)
(e)
P15
P15
150
microns
Tanks pipes &

Fittings
external
surfaces
(d) & (e)
P25,P15,P15
P25,P15,P15
50
50
50
50
50
50
(d)
(d)
(e)
(e)
P15
P15
P15
P15
150microns
150microns
Note: (1) Final Coat protective coating on exposed surfaces of all GRP, GRE items Multi Colour Shades for beautification purposes will be selected by Dubai Municipality Architect /
Engineer at site.
(2) All structural steel items are to be hot dip galvanised to a minimum thickness of 140 microns.
(3) Colour shades of the metal works should match with relevant structures concrete paint system or as decided by the Engineer/Architect.
(4) All buried ferrous and non ferrous metal painted pipes & fittings shall be protected further with any one of the Protection wrapping system specified in CL.7.2.5.4 on top of
Protective Coating
specified.
(5) All S.S bolts, nuts & washers are to be removed from the fittings before to apply paints and rectified after painting.
(6) All S.S bolted fitting, buried under the ground shall be protected with approved insulation system specified.
Vol 3, Section3
Page G-67 of 68
Specifications
G.3.5 Protective Wrapping Tapes and Sleeve on Buried Pipes and Fittings
Buried ferrous and stainless steel pipelines, joints, valves and other fittings shall be protected
either by wrapping with adhesive tape, synthetic resin or plastic tape or plastic sleeves. When
applying wrapping tape an overlap of at least half the width of the tape for pipes up to 300 mm
dia is required.
Adhesive Tape
Adhesive tape shall be either a synthetic fibre or glass cloth impregnated with a mixture of
petroleum jelly and neutral mineral filler. When used for above ground pipes these tapes shall
be protected by a bituminous tape.
Synthetic Resin or Plastic Tape
Synthetic Resin or Plastic Tape shall be PVC or black polyethylene strips 250 micron thick with
fabric core coated one side with a compact adhesive normally of synthetic rubber base.
Two-Pack Taping
Two-pack taping system shall be woven glass tape or sheet form impregnated with a two pack
solventless composition of polyester or epoxy. The surface to be protected should first be
cleaned and primed to receive the with two pack epoxy. It should then be wrapped with glass
cloth in tape form with polyester or epoxy. A thin coat of impregnating tape and then reinforcing
substrate are applied. Several layers are be built up and the final layer shall be trowelled
smooth. The coating should set to a hard glass like protective coating which is impermeable to
water
G.3.6 Plastic Sleeves
Plastic sleeve shall be a black colour high density polyethylene 250 micron thick which shall be
used as a protective sleeve on pipes. The sleeving is to be applied at the time of laying the pipe
and joints are taped with adhesive tape.
G.3.7 Hot Dip Galvanising
Hot dip galvanised coating on iron and steel articles shall be carried out in accordance with the
requirements of BS 729:1971. The minimum average coating thickness shall be 140 microns
(equivalent to 720-1000g/m2).The coating operation shall consist of dipping the steel parts into a
molten Zinc bath at a temperature of 450C. After completion of the dipping further treatment
comprising of degreasing, pickling, rinsing, fluxing and drying shall be carried out separately.
G.3.8 Water Level Marking Paint
The paint shall be a thermoplastic non-toxic WRAS APPROVED product suitable for application
by brush or airless spray, day light reflecting type acrylic paint with fluorescent pigments which
give intense colour impression and high visibility. Suitable colour shades shall be as approved
by the Engineer.
Vol 3, Section3
Page G-68 of 68
Specifications
CONTENTS
Page No.
SECTION H - FITTINGS AND FABRICATED ITEMS

H1
MATERIALS
H1.1
Aluminium Alloys
H1.2
Steel
H1.3
Stainless Steel
H1.4
RTR (Reinforced Thermosetting Resin)
H1.4.1
General RTR Requirements
H1.4.2
Manufacturing Standards
H1.4.3
Resins
H1.4.4
Curing
H1.4.5
Reinforcement
H1.4.6
Structural Design
H1.4.7
Moulds
H1.4.8
Fabrication
H1.4.9
Samples
H1.4.10
Tolerances for Moulded RTR
H1.4.11
Quality Control and Testing
H1.4.12
Visual Inspection
H1.4.13
Trial Erection
H1.5
RTR Liners for Pumping Stations and Manholes
H1.6
RTR Sealing Plates to Access Covers
H1.7
Valves and Penstocks - General Requirements
H1.8
Gate Valves for Water Supply
H1.9
Gate Valves for Sewage and Related Fluids
H1.10
Non Return Valves
10
H1.11
Valves for Gas Pipelines
10
H1.12
Cast Iron Butterfly (Disc) Valves
10
H1.13
Cast Iron Penstocks
11
H1.14
Plastic Composite Penstocks
11
H1.15
Cast Iron Flap Valves
11
H1.16
Plastic Flap Valves
12
H1.18
Underground Fire Hydrants
12
H1.19
Marking of Valves, Penstocks, and Hydrants
13
H1.20
Hydraulic or Pneumatic Actuators for Valves and Penstocks
13
H1.21
Electric Actuators for Valves and Penstocks
13
H1.22
Access Covers and Frames and Surface Boxes
14
H1.23
Access Gratings and Frames
14
H1.24
Ladders
15
H1.25
Staircases
15
H1.26
Open Mesh and Chequer Plate Flooring
16
H1.27
Hand railing
16
Vol 3, Section3
Page i of ii
H2
Specifications
H1.27.1
General
16
H1.27.2
Aluminium Alloy Hand railing
16
H1.27.3
RTR Hand railing
17
H1.28
Safety Chains, Safety Ropes and Fittings
17
H1.29
Nuts, Bolts, Screws, Washers and Grommets
17
H1.30
Fixing Bolts and Building-in Material
18
H1.31
Step Irons
18
H1.32
Hand Blocks
18
H1.33
Weirs
18
H1.34 Glass Reinforced, Hot Pressed, Sheet Moulding Compound Potable

Water Tank
18
H1.35
GRP Baffles
23
H1.35
Glass Reinforced Plastic Tanks for Chemical Storage
23
INSTALLATION
29
H2.1
Installation of Access Covers and Surface Boxes
29
H2.2
Fixing Metalwork and Machinery
29
H2.3
Installation of RTR Manhole and Pumping Station Liners
30
H2.4
Cutting and Sealing of RTR (Reinforced Thermosetting Resin)
30
H2.5
Installation of Lifting Equipment
30
H2.6
Fixing of Weir Plates
31
Vol 3, Section3
Page ii of ii
Specifications
SECTION H - FITTINGS AND FABRICATED ITEMS

H1
MATERIALS
H1.1
Aluminium Alloys
Aluminium alloys shall be selected as having properties appropriate to the duty of the unit,
the method of fabrication and the environmental conditions.
Unless otherwise specified or detailed, alloys of the following ISO designations shall be
used (ref. BS EN485 and 573):
For Castings
For Wrought Items
A1 Si7 Mg
Al Mg 4.5 Mn
or
or
A1 Si12
Al Si1 Mg Mn
Alternative alloys may be proposed by the Contractor if the manufacturer considers its
properties more appropriate to the application or the environmental or physical conditions.
Construction in aluminium shall be to the recommendations of BS 8118.
H1.2
Steel
Steelwork shall comply with the approved international standard (refer to Section S and
unless otherwise specified by reference to Section G shall be supplied by the
manufacturer with a zinc dipped coating.
H1.3
Stainless Steel
Unless otherwise specified or approved by the Engineer all supply items specified and
manufactured in stainless steel shall be to BS 970 as follows:
Percentage Chemical Composition
Fabrication
Technique:
Welded
Cold Fabrication
Classification:
316S12
316S16
Carbon
Silicon
Manganese
Nickel
Chromium
Molybdenum
Sulphur
Phosphorous
% min.
0.2
0.5
11.0
16.5
2.25
-
% max.
0.03
1.0
2.0
14.0
18.5
3.0
0.03
0.045
% min.
0.2
0.5
10.0
16.5
2.25
-
% max.
0.07
1.0
2.0
13.0
18.5
3.0
0.03
0.045
Alternative higher grade stainless steel may be proposed by the Contractor if the
manufacturer considers its properties more appropriate to the environmental or physical
conditions.
Vol 3, Section3
Page H-1 of 31
Specifications
H1.4
RTR (Reinforced Thermosetting Resin)
H1.4.1
General RTR Requirements

This clause applies to all RTR items except machine made pipes, the requirements for
which are stated in Section E of this Specification.
RTR (Reinforced Thermosetting Resin) shall be as follows:
H1.4.2
Manufacturing Standards
The specification for design, materials, construction, inspection and testing of RTR
laminates shall conform to the appropriate sections of the BS 4994.
H1.4.3
H1.4.4
Resins
(a)
Isophthalic, Terephthalic and Bisphenol Polyester resins complying with BS 3532

or Vinyl Ester resins may be used. The resins used shall have a minimum strain to
failure of fully cured cast resin of 3% and a minimum heat distortion temperature
of 65C.
(b)
Pigments or fire retardant resins (or fillers) shall only be used when specified or
ordered in writing.
(c)
Additives shall not be included in the resins unless they are required for viscosity
control.
(d)
Due attention must be paid to preclude the possibility of air inhibition occurring on
the laminate surfaces. The inclusion of paraffin wax or similar additives must be in
accordance with the resin supplier's recommendations.
(e)
Where protection against Ultra Violet light degradation is provided, it shall be

achieved by including a translucent UV inhibitor in the outer layers of the
laminate.
Curing
Curing systems shall be in accordance with the resin manufacturer's recommendations.
The manufacturer of the laminate shall demonstrate that the laminate has been
adequately cured prior to its acceptance at the laminator's works.
H1.4.5
Reinforcement
(a)
E type glass chopped strand mat reinforcement shall be to BS 3496 and shall be
of 1st grade quality to a maximum unit weight of 600 gm/m2.
(b)
E type glass woven roving fabrics shall be to BS 3749 and shall be to a maximum
unit weight of 800 gm/m2.
(c)
C type glass veil (or synthetic fabric veil where approved by the Engineer) shall
be used to reinforce all internal and external surface resin layers on laminates.
(d)
Use of high acid resistant glass fibre reinforcement will also be permitted.
Vol 3, Section3
Page H-2 of 31
H1.4.6
Specifications
Structural Design
(a)
The laminate shall be designed to withstand all the loadings normally carried by
the laminates during service and any abnormal loads arising during handling and
erection of the finished item.
Full details of the proposed laminate construction shall be submitted to the
(b)
Under the worst combination of loading conditions, a maximum design strain of

0.2% shall be permitted in the laminate.
(c)
Except where otherwise specified for particular fabricated items, a minimum

laminate thickness of 4 mm shall be maintained at all points including the facings
over and under stiffener sections.
(d)
Stiffener sections may be used to increase the rigidity of a structure. The

minimum glass reinforcement content shall be 1.8 kg/m2 in these areas. Stiffener
sections may be manufactured from the following materials.
(1)
Polyurethane Foam
(2)
Marine Plywood
(3)
Other material agreed to in writing by the Engineer.
Stiffener sections shall not be made from steel or other metal sections unless
written consent has been previously obtained from the Engineer.
H1.4.7
Moulds
Moulds shall be of adequate rigidity to retain dimensional stability and permit a high level
of laminate consolidation. The mould surfaces shall be of a quality which will ensure
maintenance of the previously approved surface finish throughout the full extent of the
Contract.
H1.4.8
Fabrication
Manufacture shall be by approved mechanical methods or by hand lay-up processes. If
deposition of resin by gun is used, this must be carried out by airless spray technique.
(a)
Unless otherwise specified all laminate surfaces which may be exposed to

chemical attack shall include a corrosion resistant finish which shall comprise a veil
reinforced surface layer and a backing layer and shall have a minimum overall
thickness of 1.5 mm. A veil reinforced surface layer shall be provided on all other
surfaces.
Veil reinforced surface layers shall be approximately 90% resin by weight and
between 0.25 mm and 0.50 mm thick.
Backing layers shall normally be reinforced with chopped strand mat and shall
have a resin content of between 65% and 75% by weight.
(b)
Vol 3, Section3
Where un-reinforced gel coats to moulded surfaces are specified they shall have a
maximum nominal thickness of 0.5 mm and shall be of a suitably resilient gel coat
system.
Page H-3 of 31
Specifications
Where un-reinforced gel coats to non-moulded surfaces (top coats) are specified
they shall be fully brushed out to remove resin rich areas. The top coat shall not
exceed 0.3 mm in thickness.
H1.4.9
(c)
Chopped strand mat layers in the structural laminate shall have a resin content of
between 55% and 70% by weight.
(d)
Woven roving glass fabric layers in the structural laminate shall have a resin
content of between 40% and 50% by weight.
(e)
Where edges of laminates are cut or exposed they shall be sealed with a
continuous layer of fully cured resin. The resin shall be the same as or superior to
the resin used for the structural laminate.
(f)
Where protective bisphenol or vinyl ester internal linings are used in conjunction
with isophthalic or terephthalic structural laminates, these linings shall be allowed
to harden sufficiently before the structural laminate is applied to prevent
movement of the lining layers.
Samples
(a)
A sample measuring 500 mm square and typical of each different laminate

proposed shall be submitted for approval together with a detailed descriptive
specification at least 4 weeks prior to the commencement of manufacture.
(b)
Production samples measuring 300 mm square and typical of each different

section of laminate shall be submitted to the Engineer or his duly authorised
Inspecting Engineer throughout the period of manufacture for the purpose of
testing. The rate of sampling shall be one sample per 20 square metres of
production laminate unless otherwise agreed by the Engineer.
(c)
Samples of liquid and cast resin together with reinforcements and surfacing veils
(or fabrics) required to manufacture the samples indicated in (b) above shall also
be made available to the Engineer on request.
Vol 3, Section3
Page H-4 of 31
H1.4.10
Specifications
Tolerances for Moulded RTR

Tolerances in thickness shall be in accordance with the following table (ref. BS 4549 Part
1):
Nominal Thickness
mm
H1.4.11
Open Mould
mm
Closed Mould
mm
Up to but not including 1.5
+0.50
-0.25
+0.20
Matched Metal
Mouldings
mm
+0.18
1.5 to but not including 3
+0.75
+0.30
+0.20
3 to but not including 6
+1.1
+0.50
+0.30
+1.5
+0.75
+0.40
+2.0
+1.4
+0.50
25 and over
+3.0
+1.9
+0.65
Quality Control and Testing

Testing, inspection and quality control shall be carried out generally in accordance with BS
2782. In particular:
(a)
(1)
The laminate shall be fully cured and shall show full resistance to a
commercial acetone sensitivity test.
(2)
The laminate shall give Barcol Hardness of at least 90% of the resin
manufacturers recommendations. The measurement of hardness by
means of a Barcol Impressor shall be carried out in accordance with the
approved Standard.
(b)
Resin burn off tests shall be performed on cut-outs for man-ways or other
apertures. Where no such cut-out exists the Engineer reserves the right to have
50 mm diameter cut-outs for checks to be made on local glass reinforcement
content; the laminate shall then be repaired by the manufacturer. The tests shall
be conducted in accordance with the BS 2782 Part 10 Method 1002, except that
the result shall define glass content.
(c)
Where directed by the Engineer the following strengths of the laminate shall be
determined:
Vol 3, Section3
(1)
Ultimate tensile unit strength, lap shear strength and extensibility in

accordance with Appendix C6 BS 4994
(2)
Flexural strength in accordance with BS 2782 Part 10 Method 1005.
(3)
Where a laminate has been designed to take bolts in the make up of the
structure, tests for bolt bearing strength shall be performed in accordance
with BS 4549 Part I Appendix C.
(4)
Where a laminate is to be used in conjunction with electrical control

equipment, electrical strength and insulation resistance tests in accordance
with BS 2782 Part 2 may be called for.
Page H-5 of 31
(e)
Specifications
Additional tests may be called for at the discretion of the Engineer.
All the tests referenced in (a) to (f) above shall be witnessed unless waived in writing by
the Engineer.
Test Certificates shall be obtained from the resin supplier for the following properties of
the resin when cured as proposed for the laminate manufacturing procedure:
H1.4.12
(i)
Heat distortion temperature.
(ii)
Barcol hardness.
(iii)
Extension to failure of fully cured un-reinforced resin.
(iv)
From the glass reinforcement manufacturer for all the different grades and types
of glass employed in the fabrication of the laminate.
Visual Inspection
All RTR items will be subject to visual inspection at any time and shall meet the following
requirements. For the purpose of this sub-clause, a corrosion resistant surface is one
with a corrosion resistant lining as described in H1.4.8 (a).
(a)
Surface finish
There shall be no crazing of gel coats or resin rich layers.
Resin dry areas not exceeding 6mm diameter on moulded and corrosion resistant
surfaces may be accepted if made good. Not more than 0.5% of the surface area
shall be so affected.
There shall be no resin dry areas on other surfaces after repair.
(b)
Scratches
Scratches not exceeding 0.2 mm deep to moulded and corrosion resistant surfaces
may be accepted without repair provided that no glass fibres are exposed.
Scratches exceeding 0.2 mm deep but not exceeding 0.5 mm deep may be
accepted if satisfactorily made good. The total extent of scratching shall not
exceed 200 mm length per m2 surface area. Alternatively, where small scratches
are grouped together, the affected area shall not exceed 1% of the surface area.
Scratches to other surfaces may be repaired provided that the structural integrity
of the laminate is not impaired.
(c)
Cracks
For moulded and corrosion resistant surfaces there shall be no cracks of depth
greater than 0.5 mm or of sufficient depth to expose glass fibres. Cracks up to
0.5 mm depth not exposing glass fibres and not exceeding 200 mm in length may
be accepted after repair but such cracks shall not be present to an extent greater
than 1 crack per 5 m2 of surface area.
Cracks not exceeding 200 mm in length to other surfaces may be repaired
provided that the structural integrity of the laminate is not impaired.
Vol 3, Section3
Page H-6 of 31
Specifications
Star cracks may be accepted after repair if the cracks are contained within a
circle of 100 mm diameter and a maximum of 0.2% of the area of any one
moulding is affected.
(d)
Voids
Voids (or blisters) at moulded and corrosion resistant surfaces may be repaired if
not greater than 2 mm diameter and 1 mm depth provided that the voids occur in
discrete clusters and the sum of the areas of discrete clusters does not exceed
0.5% of the total moulding area.
Voids to other surfaces may be repaired if they do not extend to more than 20%
of the laminate thickness and not more than 3% of the surface area is affected.
(e)
Protuberances
There shall be no fibres protruding from the surface of laminates. Wrinkles and
undulations shall be gradual and the surface shall be continuous at such locations.
Such defects shall be not greater than 3 mm in depth or a quarter of the laminate
depth whichever is the smaller. Such defects shall not appear extensively on single
mouldings and shall not be repeated through a production run.
(f)
Inclusions
There shall be no visible inclusions of extraneous matter other than permitted
fillers and aggregates.
(g)
Delamination
There shall be no visible delamination.
H1.4.13
Trial Erection
A sufficient proportion of the fabricated sections of the structure must be trial assembled
to demonstrate the correctness of fit of the various sections.
H1.5
RTR Liners for Pumping Stations and Manholes

RTR (reinforced thermosetting resin) liners for Pumping Stations and Manholes shall be
manufactured to the dimensions given on the drawings, within the following tolerances:
(i)
A manufacturing tolerance of 10 mm on the nominal diameter will be allowed

provided that a tight fit is achieved between the liner and the slab liner.
(ii)
Liners shall be supplied in lengths to suit requirements.
(iii)
Minimum thickness shall be 6.5 mm.
(iv)
The out of squareness shall not be greater than 10 mm.
(v)
The deviation from straightness of the bore of the liner shall not exceed 20 mm.
Although the liners are not designed to be structural, they shall have a sufficient stiffness
to withstand:
(i)
Vol 3, Section3
Buckling or distortion in transit, storage or handling.
Page H-7 of 31
(ii)
Specifications
A hydrostatic head of 8 metres without distortion damage, leakage or permeation

when installed.
All liners shall be clearly and indelibly labelled on both inside and outside surfaces showing
(i)
Name of manufacturer
(ii)
Date of manufacture
(iii)
Nominal internal diameter
(iv)
Minimum thickness
The manufacturer shall provide shop drawings of proposed roof and reducing slab liners
prior to manufacture for approval.
The manufacturer shall stipulate the maximum deflection of the slab liner that can be
permitted without causing surface cracking to the gel coat and the Contractor shall take
care not to exceed this limit.
H1.6
RTR Sealing Plates to Access Covers

RTR (reinforced thermosetting resin) sealing plates to access covers shall be designed to
be gas-tight when bolted in the frames. They shall have a minimum thickness of 4.5 mm
and shall be capable of withstanding a static load of 150 kg applied centrally over a 150
mm square surface area with a deflection measured at the centre not exceeding 25 mm.
H1.7
Valves and Penstocks - General Requirements

Valves shall be classified according to their pressure rating (maximum working pressure at
20oC) expressed in bars.
Unless otherwise specified, all valves and penstocks shall be anti-clockwise opening and
operated by hand wheel; the maximum effort required, applied at the circumference of the
hand wheel, to operate the valves against the maximum unbalanced head shall not exceed
250 N. Unless otherwise detailed or approved all hand wheels shall be made of cast iron
and shall have the words open and close in English and in Arabic with arrows
indicating the direction of rotation cast on.
Where Operation by Tee Key is specified the valve or penstock shall be supplied with a
suitable yoke with a squared cast iron cap of standard size keyed to the valve spindle.
Tee keys shall be galvanised and shall be sufficiently strong to withstand all operational
loads without deformation.
Valves and penstocks of all types shall be capable of withstanding corrosion in the ambient
conditions and any parts manufactured from a material which is not itself corrosionresistant must be protected. Paint systems shall be as specified in Section G (Corrosion
Protection and Surface Coatings) or as specified elsewhere for individual valves or
penstocks. For sewage applications, nylon or other thermoplastic materials susceptible to
attack from hydrogen sulphide shall not be used without the Engineer's approval.
Works tests on valves greater than 300 mm nominal diameter will normally be witnessed.
Works tests on other items will not normally be witnessed except where so specified or
required by the Engineer.
Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected with grease. The initial charges of oil, grease and similar materials necessary
Vol 3, Section3
Page H-8 of 31
Specifications
for the correct setting to work and operation of valves and penstocks shall be provided by
the Contractor.
Packing must be sufficient to ensure the complete protection of fittings during transit and
storage.
H1.8

Gate valves shall be generally to BS 5150 or BS 5163 and unless higher pressure ratings
are specified elsewhere, gate valves shall have a pressure rating of 10 bars. Flanges shall
have a pressure rating of 16 bars and shall be drilled accordingly.
Unless detailed otherwise, valve bodies shall be of cast iron, gates shall be of wedge
pattern, and gate and body mating faces shall be of gunmetal. Stems shall be of stainless
steel, aluminium bronze or high tensile brass and shall be non-rising unless otherwise
detailed. Stem nuts shall be of aluminium bronze, high tensile brass, or gunmetal.
Where resilient seal valves are detailed, the Specification shall be as above for metal faced
valves except that the gate shall be of cast iron covered with a suitable resilient facing
material.
Valves greater than 300 mm in diameter which are to be actuator operated or fixed in a
horizontal position shall be fitted with machined gunmetal shoes on the wedge working in
machined gunmetal channels in the body.
Valves greater than 300 mm in diameter shall be fitted with drain plugs.
Indicators, hand wheels, caps for key operation, extension spindles, capstan headstocks,
locking devices and other detailed requirements shall be provided as specified or shown on
the drawings.
All valves shall be open end tested by an approved method and shall be watertight at the
appropriate test pressure.
H1.9
Gate Valves for Sewage and Related Fluids

Gate valves shall be generally to BS 5150 or BS 5163 and unless higher pressure ratings
are specified elsewhere, gate valves shall have a pressure rating of 10 bars. Flanges shall
have a pressure rating of 16 bars and shall be drilled accordingly.
Valve bodies shall be of cast iron, gates shall be of wedge pattern, and gate and body
mating faces shall be of gunmetal or aluminium bronze. Stems shall be of stainless steel,
aluminium bronze, high tensile brass or gunmetal and shall be non-rising unless otherwise
detailed. Stem nuts shall be of aluminium bronze, high tensile brass, or gunmetal. Valves
shall not be fitted with resilient seals without the Engineer's written approval.
Valves greater than 300 mm in diameter which are to be actuator operated or fixed in a
horizontal position shall be fitted with machined gunmetal shoes on the wedge working in
machined gunmetal channels in the body.
Indicators, hand wheels, caps for key operation, extension spindles, capstan headstocks,
locking devices and other detailed requirements shall be provided as specified or shown on
the drawings.
Valves greater than 300 mm in diameter shall be fitted with drain plugs.
All valves shall be open end tested by an approved method and shall be watertight at
the appropriate test pressure.
Vol 3, Section3
Page H-9 of 31
H1.10
Specifications
Non Return Valves

Non-return valves shall be to BS 5153 and shall be of the single door swing check type.
They shall have a pressure rating of 10 bars. Flanges shall be to BS 4504 with a pressure
rating of 16 bars and shall be drilled accordingly.
Valves shall be copper alloy faced and resilient seated. All valves shall be clearway, and
lugs provided on screwed seats etc. for assembly shall be removed. Valves shall, unless
otherwise specified, be capable of passing solids not exceeding 90 millimetres.
Valves shall be provided with a removable cover on top of the body casing, to enable the
hinge and door to be inspected or removed.
The door opening shall be restricted to a maximum of 70 degrees at the hinge, measured
from a plane passing through the hinge at right angles to the axis of flow. Valves shall be
provided with extended spindles to the doors fitted with lever arms suitable for balance
weights.
When specified, limit switches shall be provided, operated by external cams rigidly
attached to the door spindles. The limit switch shall operate when the valve door has
moved through approximately 10 degrees. The switch shall provide one normally open
and one normally closed electrically separated contacts of the make before break type.
H1.11
Valves for Gas Pipelines

Valves for gas pipelines shall be to the appropriate approved Standard.
Unless otherwise specified or detailed, valves shall be suitable for 100oC operating
temperature and shall have a pressure rating of not less than twice the specified
maximum operating pressure of the pipeline (subject to a minimum rating of 4 bars).
When subjected to an approved hydrostatic test at the required pressure rating the valves
shall not leak.
H1.12
Cast Iron Butterfly (Disc) Valves

Butterfly (disc) valves shall be generally to BS EN 593. Bodies shall be of cast grey or
ductile iron, discs shall be of cast grey or ductile iron, stainless steel or gunmetal, and
shafts and internal fastenings shall be of stainless steel.
For valves greater than 300 mm in diameter, bearings shall be of the sealed, selflubricating type and disc seals shall be renewable.
Unless detailed otherwise:
(i)
Disc seals shall be of the resilient type.
(ii)
body.
Valves greater than 600 mm in diameter shall have support feet cast onto the
(iii)
Valves shall be provided with hand wheel and worm reduction gearing in a fully
enclosed cast iron gearbox.
(iv)
Valves shall be Tight Shut Off (TSO) : when tested as required by BS EN 593
there shall be no visible leakage at the appropriate test pressure.
(v)
Valves shall have a pressure rating of 10 bars. Flanges shall have a pressure
rating of 16 bars and shall be drilled accordingly.
Vol 3, Section3
Page H-10 of 31
H1.13
Specifications
Cast Iron Penstocks

Penstock gates, frames, brackets and pillars shall be of close grained cast iron. Mating
surfaces of gates and frames shall be of non-ferrous metal (excluding aluminium)
accurately machined to ensure a watertight fit in the closed position.
Adjustable wedges with non-ferrous faces shall be fitted to all penstocks having a
waterway area exceeding 0.3 m2.
Unless otherwise detailed, operation shall be by means of rising phosphor bronze or
stainless steel screwed spindles working in gun metal nuts for clockwise closing.
Extension spindles, where required, may be of galvanised mild steel unless otherwise
detailed and shall be connected to the screwed spindle with a suitable muff coupling.
Universal joints shall be provided at cranks.
Rising spindles to be installed in the open air shall be protected with a suitable corrosionresistant and weatherproof metal or plastic cover.
H1.14
Plastic Composite Penstocks

Penstock frames, brackets and pillars shall be manufactured from stainless steel, protected
mild steel or protected cast iron as appropriate.
Penstock gates shall be faced in an approved plastic material capable of withstanding
corrosion from the anticipated conditions. They shall be reinforced and designed to
withstand deflections capable of damaging bonds or seals between the component
elements of the gate when subjected to the maximum head specified.
Mating surfaces of gates and frames shall be of an approved plastic material and shall be
accurately machined or moulded to ensure a water-tight fit when in the closed position.
Adjustable wedges of corrosion resistant material shall be fitted to all penstocks which
have a waterway area exceeding 0.3 m2.
Unless otherwise detailed, operation shall be by means of rising phosphor bronze or
stainless steel spindles working in gunmetal nuts for clockwise closing.
Extension spindles, where required, shall be of stainless steel unless otherwise detailed
and shall be connected to the screwed spindle with a suitable muff coupling. Universal
joints shall be provided at cranks.
Rising spindles to be installed in the open air shall be protected with a suitable corrosionresistant and weatherproof plastic cover.
H1.15
Cast Iron Flap Valves

Flaps and frames shall be of close grained cast iron. Mating surfaces of flaps and frames
shall be of non-ferrous metal (excluding aluminium) machined to ensure a watertight fit in
the closed position.
Hinge pins shall be of phosphor bronze or stainless steel; all flaps shall be double hung
and seated off the vertical.
Hinge pins and mating surfaces shall be greased during assembly and shall be smeared
with grease before packing and again after installation.
Vol 3, Section3
Page H-11 of 31
H1.16
Specifications
Plastic Flap Valves

Plastic flap valves shall be manufactured from an approved plastic mated with stainless
steel or coated mild steel frames where appropriate. The flap shall be weighted to assist
closing and shall be suitably braced and reinforced.
Hinge pins and fasteners shall be of stainless steel and all flaps shall be double hung (or
equivalent) and seated off the vertical.
Mating surfaces shall be accurately moulded or machined to ensure a water-tight fit in the
closed position.
H1.17
Air Relief Valves

Except where detailed otherwise, air relief valves shall be the double orifice type,
integrating small and large orifice operation into a single unit assembly with a single
pipeline connection.
All valves shall be designed to prevent pneumatic closure and to ensure closure when all
air has been released.
All valves shall be supplied with an isolating valve or valves including bevel gearing where
necessary, and, where required, a short length of double flanged pipe to increase the
height of the valve above the pipeline.
Valves for sewage and effluent systems shall be designed to prevent blockage by solids
and shall incorporate a large volume auxiliary float chamber to isolate the air valve seat
and orifice from the fluid. Float elevators and guide rods of such valves shall be of
stainless steel.
Valves for potable water pipelines shall be insect and vermin proof at the outlet vents
leading to the atmosphere.
Unless other pressures are specified elsewhere, air relief valves shall have a minimum
pressure rating of 10 bars. Flanges shall have a pressure rating of 16 bars and shall be
drilled accordingly.
H1.18
Underground Fire Hydrants

Underground fire hydrants and their surface boxes shall conform to an approved Standard
and, if installed for fire-fighting purposes, to the requirements of the appropriate local
authority responsible for fire fighting.
Gate valves shall be as specified elsewhere.
Screw down hydrants shall have stainless steel, high tensile brass or aluminium bronze
spindles and gunmetal, high tensile brass, aluminium bronze or die-cast brass spindle nuts
and body seatings. Screw-down valve seats shall be of the resilient type.
Valve bodies and duckfoot bends shall be of cast grey or ductile iron.
Stem caps shall be of cast iron and suitable for tee key operation.
Screwed outlets shall be of gunmetal, die-cast brass or high-tensile brass and shall be
supplied with a plastic cap connected with a galvanised chain or other approved flexible
device.
Vol 3, Section3
Page H-12 of 31
Specifications
Hydrants shall have a pressure rating of 16 bar unless otherwise detailed and shall show
no visible leakage when pressure tested in accordance with the approved Standard.
H1.19
Marking of Valves, Penstocks, and Hydrants

Valves, penstocks, hydrants and similar items shall be marked as follows:
(i)
(ii)
H1.20
Embossed or stamped on the main body or frame casting:

(a)
the name or distinctive mark of the manufacturer;
(b)
the Standard to which the item has been manufactured;
(c)
the pressure class where appropriate;
(d)
the nominal size;
(e)
for uni-directional valves, an arrow indicating the direction of flow.
Labelled or painted conspicuously on the main body of the item and on the
outside of packing cases:
(a)
the weight of the item in tonnes or kilograms;
(b)
the item reference number given in the contract documents or drawings;
(c)
the name of the Employer and the project or contract name or number.
Hydraulic or Pneumatic Actuators for Valves and Penstocks

Unless otherwise specified, all hydraulic or pneumatic valve and penstock actuators shall
consist of a double acting piston and cylinder suitable for operation with oil or compressed
air as specified and shall be suitable for remote automatic/manual control.
For valve operation, the cylinders shall be directly mounted on the valve bonnet with a
suitable distance piece. For penstock operation, the cylinders shall be mounted on the
operating platform with extension spindles where necessary.
Graduated indicator plates showing the degree of opening shall be fitted to the cylinders.
Actuators shall be fitted with limit switches where specified.
Actuators shall be supplied complete with all necessary ancillary equipment including small
bore pipe work, manually operated multi-valves, stop cocks, pressure gauges and
hydraulic or pneumatic units.
H1.21
Electric Actuators for Valves and Penstocks

Electric motor operated actuators for valves and penstocks shall have totally enclosed
drive units and reduction gearing and hand operating gear the use of which automatically
disengages the electric motor. Limit switches and torque limiting devices shall be provided
to prevent over-running.
Each drive unit shall, unless otherwise specified, be complete with starter, anticondensation heater, local operating buttons, local and remote selector switch and circuits
for remote indication of gate open or closed all housed within a weatherproof enclosure
with a weatherproof terminal box with provision for cable glands for the incoming
electricity supply, remote indicating lights and control signals.
Vol 3, Section3
Page H-13 of 31
Specifications
Where remote control is specified 24V dc interposing relays shall be provided.

H1.22
Access Covers and Frames and Surface Boxes

(i)
Unless otherwise specified or approved by the Engineer, access covers and frames
shall be of cast iron to BS 497 Part 1 and shall be to the dimensions shown on the
Drawings. Covers and frames having minimum clear openings outside the ranges
of BS 497 Part 1 shall nevertheless comply with the provisions of that Standard
where applicable.
Covers and frames shall be heavy duty (BS 497 Grade A) or medium duty (BS 497)
Grade B, class 1) as detailed. If not so detailed, covers and frames in major roads
shall be heavy duty and elsewhere shall be medium duty.
Covers shall have keyways closed on the underside with no projections above
cover level and positioned such that each cover balances and can be lifted in a
horizontal plane. Double triangular covers shall have two keyways on each half
cover.
Frames shall incorporate recesses for prising bars.
All surfaces of covers and frames shall be protected in accordance with system 1
of Schedule No. G3 except for access covers having machine faced seatings where
such faces shall not be protected. Any transit damage to the approved coating
system shall be made good prior to installation
H1.23
(ii)
Covers with a stipulated minimum clear opening of 600 x 600mm or less shall,
unless detailed as non-rocking, be seated in a sealing groove and shall be sand
and gas tight. Non-rocking covers shall be as specified in paragraph (iii) below.
(iii)
Covers with a stipulated minimum clear opening of 675 x 675mm shall be heavy
duty, non-ventilating and shall, with their frames, incorporate non-rock triangular
point suspension (machine faced seatings are not acceptable). Seating points
shall bear sloping faces to minimise the risk of sand and grit lodging on them.
Frames shall incorporate a lip formed accurately near the bottom of the frame to
accept an RTR sand and gas tight sealing plate as specified in Clause H1.6 which
shall be supplied with the cover and frame.
(iv)
Multiple covers and frames for pumping stations and large chambers shall be
heavy duty, non-rocking and shall be sand and gas tight. Where multiple
triangular covers are detailed they shall incorporate non-rock triangular point
suspension and not machined seatings. Ductile iron covers and frames may be
used for pumping stations.
(v)
Surface boxes shall also be of cast grey unless otherwise specified or approved by
the Engineer
(vi)
Surfaces boxes and covers to manholes and chambers shall have cast on letters in
English and Arabic as specified or instructed by Engineer to indicate the function
of the fitting or structure. Covers and Frames shall be clearly marked with the
country of manufacture and the name of the manufacturer.
Access Gratings and Frames

Access gratings and frames shall be used on stormwater drain chambers where indicated
on the Drawings or as instructed by the Engineer.
Vol 3, Section3
Page H-14 of 31
Specifications
Stormwater chamber access gratings and frames shall be minimum 550 dia. clear opening,
lift-out non-rocking, cast grey or ductile iron in accordance with BS EN 124, Grade A, class
1.
All gratings and frames shall be fitted with GRP sealing plates to prevent the ingress of
sand during the dry season and shall be protected in accordance with system 1 of
Schedule No. G3.
H1.24
Ladders
Ladders shall be RTR, aluminium alloy or mild steel and comply with BS 5395. Material of
ladders shall be selected in line with area of application considering local environment
conditions and should be approved from the Engineer.
Unless a higher grade of protection is detailed, all mild steel ladders ladder components
shall be zinc dipped after fabrication and painted. Stringers shall be 65mm by 12mm strip
and spaced 375mm apart. The rungs shall be 25mm reduced to 20mm dia. at the ends
and riveted over. They shall be spaced at 225mm centres. Ladders shall be provided with
welded-on fixing brackets or the ends of the stringers shall be turned over to form fixings
as shown on the Drawings. Where extended stringers are required they shall not be less
than 1100mm high. Safety hoops shall be provided where indicated to the dimensions
shown for circular pattern as Figure 3 of BS 5395.
Aluminium ladders shall be fabricated from Grade 6082 aluminium complying with BS
1474. After fabrication they shall be anodised in accordance with BS EN 12373 Grade AA
25 unless specified otherwise.
Aluminium alloy ladders shall have 25 mm diameter solid rungs passing through and fillet
welded at 225 mm centres to 75 mm by 38 mm channel stringers spaced 380 mm apart.
Aluminium angle cleats shall be welded to the top and bottom of each stringer and drilled
for a 20 mm diameter fixing bolt. All aluminium surfaces in contact with concrete shall be
protected by a suitable insulating spacer.
RTR ladders shall be dimensionally similar to mild steel ladders for rung widths and
spacings. The treads of rungs shall have a non-slip finish.
Fixing bolts, washers and nuts for all ladders shall be of stainless steel. For steel and
aluminium ladders suitable non-conducting spacers shall be used to separate the metal
surfaces of the ladder from the structure to which it is attached.
H1.25
Staircases
Fabricated staircases shall be mild steel, aluminium alloy or RTR as detailed and comply
with BS 5395. Material of fabricated staircase shall be selected in line with area of
application considering local environment conditions and should be approved from the
Engineer.
Unless a higher grade of protection is detailed, all mild steel staircase components, shall
be zinc dipped after fabrication and painted.
Aluminium alloy staircases shall be structural marine quality aluminium grade 6082 to BS
1474. After fabrication they shall be anodised in accordance with BS EN 12373 Grade AA
25 unless specified otherwise.
When staircases are constructed from a combination of materials (e.g. mild steel structural
members and aluminium treads and guard rails), suitable non-conducting spacers shall be
used at all connections.
Vol 3, Section3
Page H-15 of 31
H1.26
Specifications
Open Mesh and Chequer Plate Flooring

Open mesh and chequer plate flooring shall be of aluminium alloy or RTR (reinforced
thermosetting resin) as detailed.
The flooring shall be designed in accordance with BS5395: Part 2 and BS 4592: Part 1
generally for general duty (regular 2-way pedestrian traffic). Deflection shall not exceed
1/200 x span for metal flooring or 1/100 x span for RTR flooring.
Flooring shall be supplied in easily handled panels and each panel shall not normally
exceed 25kg. Where removal of panels will not be required for any operation and
maintenance requirements, or permanent lifting equipment is available, this may be
increased to 40kg subject to the Engineers approval.
All flooring shall generally be supported on curbing cast into the top of the supporting
walls. The curbing shall be sized to suit the flooring so that the upper surface of the
flooring is flush with the top edge of the curbing. Flooring shall be clipped or bolted down
and adjacent panels clipped, or stitch bolted, together. The flooring shall be fixed so as to
produce a finished appearance that is straight, level and true to dimensions.
All flooring shall have a non slip surface.
H1.27
Hand railing
H1.27.1
General
Hand railing shall be of aluminium alloy or RTR (reinforced thermosetting resin). Material
of hand railing shall be selected in line with area of application considering local
environment conditions and should be approved from the Engineer.
Hand railing shall be designed in accordance with BS6180 and BS 5395. Stanchions shall
be designed to withstand a horizontal load generally in accordance with general duty
(regular 2-way pedestrian traffic) but heavy duty may be required in critical areas. The
recommendations of Appendix B of BS6180 shall be followed if there is a possibility of
vehicular impact.
Toe plates shall be provided to all handrail other than on the sloping section of stairs or
where there is an existing concrete upstand. Toe plates shall be a minimum of 100mm
high above floor level and any gap between the toe plate and the floor level shall be less
than 15mm. The plates shall be fixed at each stanchion and factory assembled corner
pieces used.
Hand railing shall generally be provided1100mm high with a knee rail at 550mm. Further
details are shown on the Drawings. Hand railing shall be fixed so as to produce a finished
appearance that is straight, level and true to the required dimensions.
The Contractor shall submit full dimensioned illustrations of the details of the handrails,
including joints and samples, for the Engineers approval prior to manufacture.
The Engineer may require tests on handrail assemblies to confirm suitability.
H1.27.2
Aluminium Alloy Hand railing

Unless otherwise specified or ordered, aluminium Hard railing shall be fabricated from
extruded aluminium tube to BS EN 515, 573 and 755 Grade 6082 (structural marine
quality) or equivalent and shall be anodised to BS EN 12373 Grade AA 25.
Vol 3, Section3
Page H-16 of 31
Specifications
Stanchions shall be formed from nominal 57mm O.D. x min. 6,35mm thick wall tube for
the lower section and 57mm O.D. x min. 3.25mm thick wall tube for the upper section.
Stanchions shall have torpedo sections at the top and centre to connect the handrail with
approved clamping device. Stanchions shall be fixed to concrete using grade 316 stainless
steel resin anchor bolts, washers and nuts. Nylon washers shall isolate the bolts from the
stanchion. Where possible stanchions shall be side palm mounted.
Handrail joints shall be of the concentric internal expanding type and concealed, wherever
possible, within the stanchion. Where handrail joints have to be made outside the
stanchion, the exposed connection shall accurately fit together to form a hairline joint.
All bolts, washers and nuts for fixing hand rails and standards to structures shall be of
stainless steel with suitable non-conducting spacers to separate the metal surfaces from
the structure.
H1.27.3
RTR Hand railing

RTR guard railing shall be to the general dimensions shown on the Drawings. Handrails
and standards shall be of tubular or box section as required and the Contractor shall
submit details and samples of the rails, standards and fixings he proposes to use together
with the manufacturers specification literature for the Engineers approval. This must
state the maximum spacing of stanchions recommended to accommodate a horizontal
loading of 740N/m without undue deflection.
H1.28
Safety Chains, Safety Ropes and Fittings

Safety chains to hand railing shall be supplied by the hand railing manufacturer to the
dimensions shown on the approved drawings. The safety chain shall be 316L stainless
steel.
Except where otherwise detailed on the approved drawings, safety chains or ropes shall be
fitted in manholes across the entries to all sewers exceeding 700 mm diameter and shall
be manufactured of polypropylene or other material capable of withstanding continuous
exposure to severe corrosive conditions occurring in sewers carrying septic sewage and
groundwater. Fittings shall be of 316L stainless steel.
All safety chains shall be capable of withstanding an impact loading equivalent to 1950
Nm/sec.
H1.29
Nuts, Bolts, Screws, Washers and Grommets

Nuts, bolts, screws, washers generally shall be stainless unless otherwise specified.
Grommets shall be synthetic rubber to BS 1767 or similar approved type.
Stainless steel items shall be made from steel classification 316S16 as defined in Section
H1 of this Specification.
Nuts, bolts and screws shall have coarse metric threads.
Bolting for pipes and fittings shall comply with the approved standard. Spheroidal graphite
iron bolts for use with ductile iron pipes and fittings shall have a tensile strength of
500 N/mm2.
Bolt lengths shall be sufficient to ensure that nuts are full-threaded when tightened in their
final position.
At least two washers shall be provided with each nut and bolt set.
Vol 3, Section3
Page H-17 of 31
H1.30
Specifications
Fixing Bolts and Building-in Material

Fixing bolts, nuts and washers shall be of stainless steel Grade 316S16 as defined in
Section H1 of this specification. The bolts may be rag bolts, expansion bolts, or resin
bonded bolts. The Engineer may require tests to confirm suitability.
When the bolts, nuts and washers are used for fixing aluminium items they shall be
insulated from the aluminium by a non-metallic sleeve and under washer.
The building-in material for use with rag bolts shall be a proprietary epoxy non-shrink
grout or a proprietary non-shrink mortar or caulking compound.
H1.31
Step Irons
Step irons for chambers shall be either zinc dipped (but not painted) malleable iron
complying with the relevant requirements of BS 1247 or of stainless steel as detailed.
Unless otherwise detailed stainless steel step irons shall be fabricated from 25mm solid bar
twice bent to form a U shaped rung with 375mm tread width and two legs 350mm long
the ends of the bars being ragged for building 175mm into the concrete wall. The tread of
the rung and at least the first 125mm of the adjoining legs shall be stamped or ribbed to
provide a non-slip surface.
H1.32
Hand Blocks
Hand blocks shall be provided with lifting and operating chains of the dimensions detailed
and shall be of the specified capacities which shall unless otherwise approved be clearly
inscribed on the block. Each block shall be works tested to 150% of the working load and
a confirmatory manufacturer's test certificate shall be provided.
H1.33
Weirs
All type of weirs (sharp crested rectangular, V-notch etc) shall be of stainless steel plate of
minimum 6mm thickness.
H1.34
Glass Reinforced, Hot Pressed, Sheet Moulding Compound Potable Water Tank
SCOPE
This specification shall apply to the tanks assembled by the Hot pressed Sheet Moulding
Compound (SMC) panels, manufactured from fibre-glass reinforced polyester compound,
filler, unsaturated polyester resin, pressurised and moulded by hydraulic process where
used for Potable water storage, Treated Effluent water storage and Irrigation water
storage.
Applicable Standards: - BS 7491
BSEN 13280
ASTM 3841
General
The Product manufacturer shall submit the relevant product catalogues/descriptive
literature stating manufacturing process, material, mill certificates of accessories, and
instructions on construction or erection manual, handling, periodic inspection and
maintenance.
The tank capacity shall be as shown in the approved drawing. The product manufacturers
Shop drawing shall indicate the capacity as given above, and the tank type, design load
Vol 3, Section3
Page H-18 of 31
Specifications
parameters, dimensions, materials, fabrication details, clearance, field jointing, tolerances,

support details, integration of piping components, anchorage, partition etc.
The panel specification sectional design according to tank size and application flexibility
shall be submitted for the approval of the Engineer. These panels shall be non- toxic,
hygienic for water storage and ultra violet protection against algae growth.
The panel thickness to be designed based on (FEM) Finite Element Method study with a
safety factor 6times the actual hydrostatic water pressure according to BS 7491 and the
relevant design calculation shall be submitted for engineers review.
Tank material shall be virgin reinforced fiber-glass mat E type comply with BS
3691/3496/3396/3749 standards, the mixed filler and unsaturated polyester resin comply
with BS 3532 Type-B & BS 5480.
The tank shall be suitable for 100% humidity and > 50C Water temperature, corrosion
proof, UV stabilized, non-toxic, non-staining, smooth inner surface & algae resistant.
The colour of tank panels & components shall be light Grey, pigmented as such to reduce
the heat absorption. The process shall be hot press using SMC material. Different process
like RTM/cold press shall not be acceptable.
The SMC Panel structure shall be double skin with foam material heat insulation type (25
mm Polyurethane, density 40 kgs/m3 with thermoplastic vacuum moulded cover for top,
side panels, and bottom).
The tank should be opaque to help reduce evaporation of disinfectant and inhibit algae
growth. Maximum measured light transmission value inside a closure cover tank shall not
exceed 0.05%.
Tank exterior frames, pipe fittings, fasteners, supports, etc. shall be protected against
weather conditions.
Interior strengthening reinforcing steel shall be with stainless steel pipe section min dia 32
mm grade 444 (carbon content < 0.025).
Tank shall be erected above ground with General arrangements shown in the approved
drawing and a clear access of not less than 1m all around.
Flexible connectors shall be used to avoid stress & vibration transfer to the water tanks.
Manufacturers instructions and guidelines concerning storage of tank parts and
accessories general site conditions of tank location, erection method, usage and operation
of the water tanks shall be strictly observed.
The water level indicator shall be as recommended by tank manufacturer.
Manufacturers representative certified and experienced bodies shall fix the tank.
The manufacturer must be a member of, or affiliated with quality control or certification
authority, relevant to GRP tanks & fittings proposed for incorporation in the works. ISO
9001 certification is required for the tank manufacturer.
Construction
The tank body shall be configured to quadrilateral panel assembling type and secure
assemblage space and maintenance space around the tank. The Wall Panel configuration
Vol 3, Section3
Page H-19 of 31
Specifications
shall be as follows: 1 x 1.5m and 1 x 2 m panels shall be used at the top part, while 1x1 m
panels shall be used at the lower part of the wall.
Example:
2.5m High tank: 1 x 1 (bottom) + 1 x 1.5 (top)
4.0m High tank: 1 x 1 (bottom), 2 nos + 1 x 2 (top)
External and internal reinforcing parts section shall be capable to withstand the expected
load such as water pressure, wind load, live load, etc..
Tank roof panel top supporting metal reinforcements shall be installed outside to avoid the
chlorine gas corrosion.
Internal / external Reinforcing parts: Internal Reinforcement shall be used at the lower
part of the tank (MATERIAL SUS 444, NO WELDING, SECTION PIPE DIA 32 MM MIN),
while the upper part (Large panels 1.5 M, 2 M) must be externally reinforced with top
external stays, vertical external frame and bottom external bracket due to the following
reason: Chlorine from disinfectant generates rust on upper part of internal reinforcement
material (SS) which are not under water, say 1.5 m section below the ceiling.
Tank accessories, structural reinforcing / frames, fasteners, & components shall be as
given below.
GRP HOT PRESSED SECTIONAL (PANEL) WATER TANKS
Sr.
No.
1.
2.
3.
PHYSICAL
CHARACTERISTICS
SPECIFIC GRAVITY
TENSILE
STRENGTH
(Longitudinal transversal)
FLEXURAL STRENGTH
4.
IMPACT STRENGTH
5.
6.
7.
8.
9.
10.
11.
12.
13.
WATER ABSORPTION
GLASS CONTENT
LIGHT TRANSMISSION
COEFFICIENT OF THERMAL
EXPANSION
THERMAL CONDUCTIVITY
BARCOL HARDNESS
CAVITY
TOXICITY
MICRO- BIOLOGICAL GROWTH
14.
15.
ULTRA VIOLET RESISTANCE

OPACITY
STANDARD
VALUES
ASTM D 792
ASTM D 638;BS 2782;
ASTM D 2841
ASTM D 790; BS 2782;
ASTM D 3841; BS 5734
ASTM D 256;BS 2782;
BS5734
ASTM D 570; BS 7491
ASTM D 2584; BS 2782
1.8
(1000 Kg/cm2 15%)
ASTM D 696
(1900 Kg/ cm2 15%)

(59 kgf.cm/cm2)
Not greater than 0.10%
More than 30%
< 0.05%
1.7 x 105 /C
BS 6920
BS 6920
0.15 kcal/m/hr/C
>40
Less than 1%
Nil
Nil
BS 2782 / BSEN 578
Stabilised / resistant
0.02
ASTM D 2583; BS 2782
Contents of the panel tank

COMPONENTS
Tank Panel
Material
Nuts, Bolts, Washers
Sealant / Gasket
External Reinforcement
Internal Reinforcement
External Ladder
Internal Ladder
Vol 3, Section3
STANDARD ITEMS
Hot pressed SMC- grey colour
SMC Suitable for storing drinking water
S/S grade 316L in contact with liquid water
PVC foam
Structural steel hot dipped galvanised
S/S grade 444 angle stays, tie angles or tie rods
Stainless steel 316 grade L
Stainless steel grade 444
Page H-20 of 31
Specifications
COMPONENTS
Roof Support
Level Indicator (optional)
Steel Skid
STANDARD ITEMS
75mm diameter Pipes S.S grade 444
Mechanical float switch/clear tube/or painting
Hot dip galvanised & epoxy coated structural steel
channels
Smooth internal and external finish
S/S 316L rods diameter 12 mm
Water temperature up to 50C
Finishing
Tie Rods
Resistance
Properties of Insulation (Polyurethane)

Density
Thermal Conductivity
Closed cells
Operation Temperature
Insulation Thickness
Light transmission
38 to 40 Kg/m3
0.018 to 0.020 kcal/m/hr/C
90 to 95 %
+ 80 C
25 mm
0.00%
Panel Tank Accessories

Accessories / Fasteners
External
Base frame, Wall panel
joints, (Frames, Flanges bars,
and Roof stays)
External Ladder
Roof access Manholes, Min.
900 mm dia, clear opening.
Equipped with locking device.
Bolts, nuts, washers
Fittings
Ventilation hole,
Internal
Corner frames, stays, Tie
rods etc.
Roof support (pipe 75mm )
Ladder
Bolts, nuts, washers
Material
Corrosion Protection
Structural
Steel
channel sections
Hot dip galvanised and epoxy &

Polyurethane coated.
Stainless steel grade

316L
GRP , SMC
SS 316L
Copper alloy / PVC
ABS Material with PE
Screen
Specified Coating & Insulation

UV protection
Stainless Steel G:444
Stainless steel G:444

Hinge :
Stainless steel grade 316L
Quality Control
The manufacturer / Supplier shall take necessary measures to satisfy the client that water
tank supplied for use within its domain meets the requirements detailed. This shall be
repeatedly done every five years or as and when called by the owner during guarantee
period.
Tanks shall be erected, tested and commissioned for use by the manufacturer/ Local Agent
under the supervision of engineers representatives.
The manufacturer / local agent shall carry out periodic inspection of tank algae growth and
remedial measures.
Whenever composition or manufacturing process of particular component part is changed or
modified, the affected component part shall have to be tested in the presence of Engineer.
Vol 3, Section3
Page H-21 of 31
Specifications
All testing and inspection costs shall be borne by the contractor.

The GRP hot pressed water tank shall comply the requirements of British Standard BS 7491 /
ASTM D3841.
The tank operating atmospheric pressure shall be tested under tank full condition for water
tightness and structural soundness. Water tank shall be subject to a standing leak test for 24
hours, during which time all joints shall be carefully examined. Noticed defects shall be
rectified immediately and the test to be repeated.
In house QA/QC records: (mill certificate for SS 444 accessories and SMC) shall be provided
along with tank supply to the site.
Upon the completion of the erection, tank shall be cleaned and disinfected by the contractor,
as per the manufacturers guideline.
Inlet, Outlet & Over Flow Pipes
UPVC material (socket / flange type). Overflow pipe shall be placed in same level of inlet pipe.
Outlet pipes shall be kept level at least 10cm above the tank bottom.
Drain Pipe
Drainpipe shall be fixed at bottom most level of the tank.
Approval of Local / International Health Authorities
The tank manufactured shall be certified by International Authority to meet the requirements
of BS 6920 for products approved for potable water usage. The following certificates to be
provided for engineers review and approval.
WRAS (UK) approval up to 50C

FDA (USA) approval for SMC material
Potable water tank must comply with BS 7491 requirements. The following test reports by
Independent Authority is to be provided by the manufacturer for Engineers review, during
submittal stage:
Permanent compressive strain test.

Sunlight transmission test
Physical properties test (tensile, Bending, Elastic modulus, Barcol hardness, Water
absorption)
Leakage test
Deflection test
Metal toxicity test of Stainless steel in contact with water.
Test of Sealing gasket in accordance with Japanese Food Sanitation Law
Opacity Test to BS EN578 : 1994
Testing of GRP for use in contact with water intended for human consumption.
A guarantee of fitness for storing, effluent water shall be obtained from concerned local
government agencies (Municipality & Town planning / Environment & Health Section), and a
copy provided to the Engineer. Certificate should cover accessories and component parts of
the Water tank in question.
Guarantee Certificates
Vol 3, Section3
Page H-22 of 31
Specifications
Manufacturer, importer or supplier of the water tank shall provide a certificate of guarantee,
against manufacturing and erection defects covering a period of minimum ten (10) years from
the date of erection. During the guarantee period, tank component parts and accessories
found deteriorated, defective shall be replaced by the manufacturer at his cost.
H1.35
GRP Baffles
Material
1. Fibreglass reinforced polyester resin composite laminate shall exhibit the following
minimum properties:
Property
Test Method
Minimum
Requirement
Impact Notched , Izod

Heat Distortion
Water Absorption after
24 hours
Tensile Strength
Thermal Expansion
Flexural Strength
Flexural Modulus
Barcol Hardness
ASTM D 256
ASTM D 384
ASTM D 570
13.5 Nm
79C
Max 0.20%
ASTM
ASTM
ASTM
ASTM
ASTM
62 MPa
10.5 x 10-6 mm/mm/F
110 Mpa
6 Gpa
40
D
D
D
D
D
638
696
790
790
2583
2. ECR glass fibre and vinyl ester Epoxy resin shall be used in full laminate.
3. Perform hardness tests on the resin-rich surfaces of the test samples.
4. Prepare test coupons in accordance with appropriate ASTM test method.
5. The manufacturer shall maintain a continuous quality control program and upon request
shall furnish certified test results of the physical properties.
6. Laminate shall be 75 mm thick and shall contain a gel-coat on each surface a minimum of
20 mils thick.
Components
1. The Baffle System component shall be as shown in the Drawing.
Each segment shall be moulded using gel-coated exterior surfaces, vinyl resin and fibreglass
reinforcement (ECR C glass).
H1.35
Glass Reinforced Plastic Tanks for Chemical Storage

Scope of Work
Furnish all labour, materials, equipment, and incidentals required to install, field test,
complete and make ready for service vertical, flat bottom, seamless, fibreglass tanks for
chemical storage and make-up, as shown on the Drawings and as specified herein.
Related Work
A. Field painting external as specified in protective coating schedule
Or pigmented coating recommended by the manufacturer.
Vol 3, Section3
Page H-23 of 31
Specifications
B. Chemical feed pumps are as shown in the drawing.

C. Instrumentation is as shown in the drawing.
D. Piping, valves and appurtenances and pipe hangers and supports are shown in the
drawings.
E. Process mixers are as shown in the drawing.
F. The chemical compatibility of the liner internal proposed shall be based on the
process fluid storing inside.
G. The size and capacity of the tank shall be as shown in the drawing.
H. The geometry and supports of the tank shall be as shown in the drawing.
Submittals
A. Submit to the Engineer the shop drawings showing details of construction and erection as
follows:
1. The type and category of tanks shall be related to the three categories given in Table 2 of
BS4994: 1987 to suit the various chemicals storing inside.
2. The chemicals storing inside the tanks are Ferric chloride, caustic & Polymer.
3. Dimensions of tank, fittings and attachments.
4. Wall thickness (shell, head and base).
5. Location of fittings, attachments and joints.
6. Width and thickness of joint overlays.
7. Resin used and complete description of chemical resistance for all materials that will come
in contact with material stored.
8. Weight of tanks and fittings.
9. Statement that fabrication is in accordance with these Specifications.
10. Complete structural calculations for each tank, including all accessories and tank
supported appurtenances to be furnished by others.
11. Description of fabrication method.
12. Laminate samples.
13. Description of hold-downs.
14. Description of nozzles showing details of construction and attachment to tank.
15. Instructions for handling, storage and installation of tanks.
16. Installation list of tanks with similar applications.
B. Samples
Representative laminate samples of both the filament wound cylindrical shell and the heads
shall be furnished. These samples shall be from plant production and shall be representative
of actual construction, workmanship, appearance and surface hardness of tanks to be
furnished. The Engineer may reject any tank which does not meet the standard of the
representative samples.
C. In the event that it is impossible to conform with certain details of the specifications due
to different manufacturing techniques, describe completely all non-conforming aspects.
D. Drawings shall be approved by the Engineer prior to start of fabrication. Approval of
Drawings by the Engineer shall not release the Contractor of responsibility of compliance with
specifications. All proposed changes in specifications shall be stated in writing. No fabrication
may start prior to approval of proposed changes by the Engineer.
E. Submit shop inspection and test records as specified herein.
Reference Standards
A. American Society for Testing and Materials (ASTM).
1. ASTM D3299- Standard Specifications for Filament-Wound Glass-Fibre
Vol 3, Section3
Page H-24 of 31
Specifications
Reinforced Thermo set Resin Chemical-Resistant Tanks.

2. BS 4994:1987 Design and construction of vessels and tanks in reinforced
plastics.
3. BS 476-7.
4. ASTM C 581
5. ASTM C 582
6. ASTM D 4097
B. Occupational Safety and Health Administration (OSHA).
Quality Assurance
A. Tanks shall be constructed by a single manufacturer that has at least 10 years prior
experience in construction of fibreglass tanks for similar applications.
B. Should equipment which differs from these Specifications or as shown on the Drawings be
offered and determined equal to that specified and shown, such equipment shall be
acceptable only on the basis that any revisions to the design and/or construction of the
structure, piping, appurtenant equipment, etc., required to accommodate such a substitution
shall be made at no additional cost to the client and be as approved by the Engineer.
System Description
A. The tanks shall be constructed of fibreglass reinforced polyester with chemical resistant
backing layer internal and shall be vertical, cylindrical, flat bottom, furnished with all
accessories as specified herein.
B. Tank accessories and fittings shall be of the sizes and arrangement as detailed on the
Drawings.
Delivery, Storage and Handling
A. The Contractor shall require the manufacturer to assume responsibility for packaging to
prevent damage to the tanks during normal transit and handling.
B. Flange faces shall be protected from damage. All openings are to be securely
covered
to prevent entrance of dirt, water and debris.
C. Tanks shall be mounted on skids or protective framework so constructed as to provide for
easy handling for fork truck or similar device and be provided with lifting lugs, cleats, etc. to
permit handling by crane, nozzles manholes, or other fittings shall not be used for lifting.
D. Tanks shipped horizontally shall be supported by cradles supporting 120 degrees
of the tank circumference.
E. Instructions shall be provided for unloading and installation of the tanks.
Products
General
A. The use of manufacturer's name and model or catalogue number is for the purpose
of establishing the standard of quality and general configuration desired.
B. Like items of materials, equipment shall be the end products of one manufacturer in order
to provide standardization for appearance, operation, maintenance, spare parts and
manufacturer's service.
C. Hold-down devices shall be provided by the manufacturer
Materials
A. Resins used for the tanks shall be a commercial-grade corrosion-resistant thermo set, fully
tested and acceptable for the service conditions. Resins shall not contain fillers, pigments,
Vol 3, Section3
Page H-25 of 31
Specifications
dyes, or colourants. A chemotropic agent that does not interfere with either visual inspection
of laminate quality or with corrosion resistance of laminate, may be used.
B. Clear ultraviolet absorbers shall be used in final resin coats.
GRP Tanks
The GRP tanks shall be manufactured strictly in accordance with the specified standards.
The GRP tanks shall be constructed using the filament winding process and shall be capable
of storing the chemicals specified above at service temperatures in excess of 82C. The
manufacturer shall be responsible for the design and structural integrity of the tanks. All glass
reinforcement used shall be 'ECR' type only.
The type of chemical barrier to be used shall be agreed between the manufacturer and the
Engineer prior to manufacture the tank where a thermo set lining is used it shall be as
specified in CL 7 & 8 of BS 4994: 1987.
All parts shall be designed and proportioned as to have lateral strength and stiffness, to
especially adapted for the work to be done. Ample room and facilities shall be provided for
access.
Tanks shall be non-insulated suitable for vertical installation in an enclosed thermally
controlled or outdoor environment as specified. Tanks shall be designed so that no external
bracing, ribs, hoops, or support wires are required. Top of tank must be capable of supporting
weight of maintenance personnel.
There shall be no vertical joints (in axial direction) in the cylindrical shell. The entire thickness
of the cylindrical shell (inner surface, interior layer and exterior layer) shall be built up prior to
removal of the shell from the mandrel.
The longitudinal strength of the cylindrical shell shall be at least 25 percent of the hoop
strength.
Regardless of the theoretical design requirements, the minimum total laminate thickness of
the filament wound tank shall NOT BE LESS THAN 10mm with stiffeners external. The tank
wall thickness shall be designed by the manufacturer in accordance with BS 4994/ ASTM D
3299 and relevant calculations shall be provided for engineers review.
Where a tank is intended to contain flammable fluids the external surface layers shall be
modified so as to have a surface spread of flame characteristic which at least complies with
class 1 requirements of BS 476-7.
The knuckle radius of the top and bottom heads shall be a minimum of 40-mm.
Heads may be fabricated integrally with the shell or may be fabricated separately. Heads
fabricated separately shall be moulded with an integral skirt. The minimum skirt length shall
be l00-mm. The entire head including knuckle radius and skirt shall be fabricated in one piece.
Tanks shall be completely fabricated in the shop. No field assembly is permitted.
All surfaces exposed to chemicals shall be resin rich with "c" glass and the thickness of this
inner most layer shall be a minimum of 0.5mm.
A backing layer of 2mm thick normally containing a minimum of 1.2 kg/m2 "CSM" between
25% - 33% glass content by mass with epoxy based vinyl ester resin.
Vol 3, Section3
Page H-26 of 31
Specifications
The heat distortion temperature of the fully cured resin system used for the GRP laminate
shall not be less than 20 degree C higher than the design temperature of the tank when
determined as described in BS 2782 method 121A.
The exterior layer of laminate shall consists two layers of "C" glass resin rich outer liner and
the minimum thickness shall be 1 mm.
The structural layers shall be with ECR glass and ISO resin and no sand filler Shall be
used. The laminate shall consist of Hoop glass, CSM, glass cloth & woven roving as necessary.
External ribs shall be used to meet the stiffness requirements not less than 10,000 N/ m2.
No paints or pigmented, coloured or dyed resins shall be used on the outside surface of the
tank.
The tanks shall be made with machine made shaft liner.
Tanks specified herein to require interior baffles shall be sized and oriented within the tank as
recommended by the mixer manufacturer. Tank baffles shall be of GRP attached to the tank
walls by Gusseted Brackets, at the locations recommended by the mixer manufacturer.
Accessories
(1) The fibreglass tanks shall be equipped with the accessories as shown on the
drawings.
(2)
Each tank shall have an identification label laminated to the exterior surface
which shall indicate manufacturers name, address, model number, and date of
manufacture, capacity, design temperature and the pressure rating.
Installation
The contractor shall install the tanks in accordance with the drawings and the manufacturer's
instructions.
Compliance
The manufacturer shall provide a compliance statement for the products supplied in
accordance with relevant standards given in CL 7.4.1.4.
Test Requirements
Degree of cure of the laminate by Barcol hardness in accordance with ASTM D 2584.
Chemical resistance of the resin in accordance with ASTM C581
Wall thickness in accordance with ASTM D 3567.
The glass content of the inner liner and the interior layer combined in accordance with STM D
2584.
The surface spread of flame characteristic in accordance with BS 476-7. All test result should
comply with the relevant standard requirements.
Field Testing
After installation the tank shall be field tested by filling with water. The tank & fittings shall
hold water without loss, evidence of weeping or capillary action for a period of 24 hrs prior to
acceptance.
Guarantee
The finished product shall be guaranteed for a minimum of 50 years design life.
Vol 3, Section3
Page H-27 of 31
Specifications
Inspection
Should any defects become evident during inspection, testing or within the guarantee period
the contractor shall repair or replace the tank or fitting as approved by the Engineer.
Additional Labelling
Each tank shall be labelled with the name of relevant liquid content proposed, operating and
safety instructions and other warning if necessary.
Vol 3, Section3
Page H-28 of 31
Specifications
H2
INSTALLATION
H2.1
Installation of Access Covers and Surface Boxes

Access cover and surface box frames shall be bedded on cement mortar which shall be
haunched over the base and sides. Where blockwork or brickwork is shown on the
Drawings this shall be adjusted to allow for the frames to be set to the required levels and
inclinations.
Concrete haunching to frames shall only be carried out with the cover in position.
Sealing grooves, mating surfaces and all exposed gaps between covers and frames shall
be filled or coated with a vegetable based, high melting point grease after all construction
activity has ceased.
Keyways shall be packed with cotton waste or similar approved material to prevent the
ingress of sand and stones.
Where sets of lifting keys are required they shall be delivered to the Engineer at or prior to
take over or occupation by the Employer of the relevant sections of the work.
H2.2
Fixing Metalwork and Machinery

Where expansion and resin bonded fixing bolts are to be used the fixing bolt holes shall be
as specified by the bolt manufacturers.
The holes for other fixing bolts may be dimensioned on the drawings and prepared by
boxing or drilling. If they are not so dimensioned they shall be formed by methods which
shall be agreed in advance with the Engineer.
Where a group of holes has to be formed for a number of bolts for fixing one item, the
formers shall be securely fixed together before the concrete is poured around them. The
boxes shall be suitably protected to avoid extraneous matter falling into them.
Methods to be adopted for building bolts into prepared holes shall be agreed in a Method
Statement. The methods shall take account of the materials being used and the
equipment or machinery that is to be fixed. The timing and sequence of the building-in
shall be determined by the Contractor if he, or a nominated Sub-Contractor, provides the
item to be fixed. Where the item to be fixed is provided under a separate contract the
building-in shall be carried out only when instructed by the Engineer.
Unless otherwise specified, all items to be fixed shall initially be set on adequate packers
and the bolts shall then be located in their correct positions. The building-in shall then be
carried out in the manner specified by the bolt manufacturer (for expansion bolts) or by
the supplier of the building-in material. The bolts shall not be brought into use until they
are effectively anchored and any building-in material has achieved adequate strength.
The bolts and nuts shall be tightened only by the party responsible for erection of the
item. This party may be the Contractor, a sub-contractor (nominated or otherwise) or
another Contractor.
When agreed with the Engineer the voids below or behind the item shall be filled with a
dry mix 1:3 cement/sand mortar or an approved proprietary material. This shall be done
so as to form a solid and effective bedding the extent of which will either be detailed in
the documents or agreed with the Engineer. Any shrinkage in the bedding shall be dealt
with by packing, caulking, grouting and/or tightening the fixings, as appropriate.
Vol 3, Section3
Page H-29 of 31
H2.3
Specifications
Installation of RTR Manhole and Pumping Station Liners

The construction methods employed shall be so as to ensure that a completely water and
gastight seal is made preventing any exposure of the concrete to the corrosive liquids and
gases present.
In particular:
(i)
The rebates formed in the concrete base slab and benching in which the liner is
positioned shall be tightly packed with a suitable sealant in accordance with the
recommendations of the liner manufacturer and to the approval of the Engineer.
(ii)
Any holes required in the liner for pipe work shall be carefully cut to the required
diameter, the cut edge sealed as specified, and any space between the liner and
the pipe sealed with an approved mastic sealant or as otherwise detailed on the
drawings.
(iii)
The liner and slab liner shall be bonded together with RTR to provide a totally
watertight joint.
RTR liners shall be handled in the same manner as RTR pipes. In addition, extra care shall
be taken to avoid damage to the liners which are not designed to carry loads.
The manufacturer shall visit the Site to demonstrate to the Contractor in the presence of
the Engineer the methods of handling, lifting and assembly, including formation of the
joints between the chamber liner, shaft liner and slab liner.
It is emphasised that these liners are not designed to withstand the pressure exerted by
the concrete during construction.
H2.4
Cutting and Sealing of RTR (Reinforced Thermosetting Resin)

Exposed ends of RTR which is cut, for any reason, shall be sealed with an approved resin
before incorporating the cut RTR in the work. No cut RTR shall be used until the resin has
cured.
The resin shall comply with the requirements of Clause H1.4 and shall be pigmented so
that the areas where it has been applied are easily identifiable.
The resin shall be delivered to site in sealed containers bearing the name of the
manufacturer and properly labelled as to its contents and shelf life.
H2.5
Installation of Lifting Equipment

Runway beams and rails for travelling cranes shall be set within the dimensional
tolerances permitted by the crane manufacturer.
Before lifting equipment is used it shall be tested and certified by the relevant testing
authority to lift and maintain a minimum test load of 125% of the safe working load.
During this overload test each movement in turn shall be manoeuvred and the equipment
shall sustain the load under full control.
The tests shall be carried out in the presence of the Engineer or his duly appointed
Inspecting Engineer.
Vol 3, Section3
Page H-30 of 31
H2.6
Specifications
Fixing of Weir Plates

Weir plates shall generally be fixed in accordance with the details shown on the approved
Drawings. Walls to which weir plates are to be fixed shall be finished smooth and to a
uniform profile.
The joint between the wall and the weir plate shall be free of leaks when tested as
specified for a water-retaining structure.
Vol 3, Section3
Page H-31 of 31
Specifications
TABLE OF CONTENTS
Page No.
SECTION J ROADWORKS AND LANDSCAPING
J1
J2
ROADWORKS
J1.1
Design of Roads
J1.2
Earthworks for Roads
J1.3
Finish and Protection of Sub grade
J1.4
Material and Construction of Sub-base
J1.5
Tolerances
J1.6
Asphaltic Pavements
J1.7
Weather Limitations
J1.8
Precast Concrete Kerbs and Edgings
J1.9
J1.10
Laying of Precast Concrete Kerbs and Edgings
J1.11
Laying of Precast Concrete Paving Slabs
J1.12
Testing
J1.13
Interlocking Block Paving
J1.14
Laying of Interlocking Block Paving
LANDSCAPING
J2.1
Submissions
J2.2
Materials and Workmanship
J2.3
Existing Trees
J2.4
Replacement of Existing Trees
J2.5
General Filling
J2.6
Time for Planting
J2.7
Irrigation
J2.8
Maintenance
J2.9
Replacement
J2.10
Vines and Climbers
J2.11
Shrubs
J2.12
Trees
J2.13
Agricultural Soil Top Soil
J2.14
Top Soil Additives:
J2.15
Irrigation Water
J2.16
Drainage Pipes
J2.17
Surface Preparation
J2.18
Preparation of Soil and Plant Pits
J2.19
Planting and Seeding
J2.20
Staking and Anchoring Trees
J2.21
Maintenance
J2.22
Defects Liability
Vol 3, Section3
Page i of i
Specifications
SECTION J ROADWORKS AND LANDSCAPING

J1
ROADWORKS
J1.1
Design of Roads
The Contractor shall prepare the detail design of roads, hard standings, and associated
drainage, to the approval of the Engineer, on the basis of the arrangement shown on the
Drawings to provide vehicular access to all major items of plant and equipment.
Carriageway widths and turning circles shall be as specified in the particular specification,
on the Drawings or as appropriate to the maximum size of transport envisaged for
operation of the works.
Pavement design for roads and hard standings shall generally be in accordance with The
Ministry of Housing requirements and the typical details shown on the Drawings. The
design shall be based on a design life of 60 years and traffic weight and volumes
envisaged for operation of the works.
The Contractor shall make his own assessment of the traffic and the sub grade CBR at the
site and accordingly design the thickness of the road base and surfacing.
Carriageway construction and surfacing to hard standings shall be resistant to diesel and
other chemical spillage.
J1.2
Earthworks for Roads

The earthworks for roads shall generally be in accordance with Section C of the
Specification supplemented by Clauses 612, 613 and 614 of the current version of the
Roads Directorate General Specification for Roadworks.
J1.3
Finish and Protection of Sub grade

The finished surface of the sub grade shall be approved by the Engineer before any subbase material is placed. The sub grade, once it has been finally compacted, shaped and
approved, shall be protected and kept well drained.
Plant and materials shall not be stored or stockpiled on the formation. Contractor's traffic
shall not be permitted to pass over the completed sub grade unless otherwise approved by
the Engineer. The Contractor shall, at his own expense, repair any soft spots or damage
caused to the sub grade.
J1.4
Material and Construction of Sub-base

The granular material used in the sub-base shall comply with the requirements specified in
Section C for Class 2 and Class 3 fill. All material shall be placed, spread evenly and
compacted, spreading shall be undertaken concurrently with placing. The material shall be
spread in one or more layers so that after compaction the total thickness is as required.
Compaction of the sub-base shall be to 98% of the maximum dry density in accordance
with BS 1377 and shall be completed as soon as possible after the material has been
spread. Where compacting plant is of insufficient capacity, the sub-base shall be laid in
two or more layers.
J1.5
Tolerances
Alignment, level and surface regularity tolerances shall be as specified in Section 700 of
the current version of the Roads Directorate General Specification for Roadworks.
Vol 3, Section3
Page J-1 of 9
J1.6
Specifications
Asphaltic Pavements
Asphaltic surfacing shall be accordance with Section 900 of the current version of the
Roads Directorate General Specification for Roadworks, mix references GW20, W20, B28
and L10.
Only asphalt companies currently approved by the Ministry of Housing for the supply of
the relevant material shall be used.
J1.7
Weather Limitations
Bituminous courses shall be constructed only when the base is dry and when the weather
is not rainy.
J1.8
Precast Concrete Kerbs and Edgings

Precast concrete kerbs and edgings shall comply with Clause 1001 of the current version of
the Roads Directorate General Specification for Roadworks.
J1.9

Pre-cast concrete paving slabs shall comply with Clause 1002 of the current version of the
Roads Directorate General Specification for Roadworks. Slab dimensions may be varied
from those specified to suit the required pathway widths.
J1.10
Laying of Precast Concrete Kerbs and Edgings

Precast concrete kerbs edgings shall be laid true to line and level. Any unit of kerb or
edging deviating more than 3mm in 3m shall be made good by lifting and relaying.
Where practicable kerbs shall be laid before paving.
Kerbs shall be bedded on a layer of 3:1 sand-cement mortar with grade C45/20 bedding
and backing shaped to the required cross-section as indicated on the Drawings. All
concrete shall be protected with a coating of road oil.
For radii of 1.0, 3.0 and 5.0 specially cast circular kerbs shall be used. For radii 5.0 to
12.0, half length kerbs shall be used.
Kerbs shall be jointed with cement mortar.
J1.11
Laying of Precast Concrete Paving Slabs

The formation for paving slabs shall be prepared as specified for roads, except that proofrolling will not be required. Paving slabs shall be laid to the required cross-falls using a
minimum of five pats of mortar not less than 150mm diameter to each slab.
On circular work, where the radius is 12m or less, all slabs shall be cut on both edges to
the required line.
Joints shall be uniform in width not exceeding 12mm and grouted with mortar.
J1.12
Testing
The Contractor shall carry out tests at such intervals as the Engineer may direct to
demonstrate that the materials for the granular sub-base and road-base comply with the
Specification and that the specified density for the sub-grade, sub-base and road base are
being achieved.
Vol 3, Section3
Page J-2 of 9
Specifications
The Contractor shall inspect and test each area of layer for compliance with surface level
accuracy.
J1.13
Interlocking Block Paving

Blocks shall be precast concrete, 60mm thick to BS 6717 having an interlocking pattern
and colour to the approval of the Engineer.
J1.14
Laying of Interlocking Block Paving

The formation for blockwork shall be prepared as specified for roads, except that proofrolling will not be required. Blockwork shall bedded on a minimum of 50mm of sand. All
edges of the paving shall be retained by precast concrete edgings to secure the perimeter
stones and sand levelling course.
Laying shall be in accordance with the following:
1.
Pavers shall be clean and free of foreign materials before installing.
2.
Installation should start from corner or straight edge and proceed forward over the
undisturbed sand levelling course.
3.
Paving work shall be plumb, level and true to line and grade; shall be installed to
properly coincide and align with adjacent work and elevations.
4.
Paving stones should be installed hand tight and level on the undisturbed sand
levelling bed.
5.
Concrete or masonry sand should be spread over the installed paving stones so
that it may be vibrated into the joints.
6.
A roller or plate vibrator shall be used to compact the stones and to vibrate the
sand into the stone joints
7.
Excess sand should be swept into the joints or disposed of from surface area
8.
The completed paving stone installation should be washed down and cleaned to
provide a clean finished workmanlike installation.
Vol 3, Section3
Page J-3 of 9
J2
LANDSCAPING
J2.1
Submissions
Specifications
Prior to commencement of any landscaping work, the Contractor shall submit to the
Engineer for approval his detailed proposals for the landscaping scheme including the
proposed species of grass, trees and shrubs. Hard landscaping of interlocking concrete
block pavement shall be provided between surrounding asphalted roads to access various
process units
J2.2
Materials and Workmanship

All landscaping materials and work shall be in accordance with Section 20 of the current
edition of the Ministry of Housing Standard Specification for Building works.
J2.3
Existing Trees
Existing trees shall be retained as far as possible. Any existing trees obstructing the new
works shall be carefully removed and either stored (or replanted) for use in the new
landscaping scheme.
Existing trees not affected by the new works shall be protected from damage and
disturbance resulting from the Contractors operations.
J2.4
Replacement of Existing Trees

Should any existing tree not affected by the new works be damaged or killed as a result of
the Contractors operations then it shall be replaced by the Contractor by an equivalent
mature tree of the same variety.
J2.5
General Filling
General filling shall be carried using selected excavated material as specified in Section C.
Fill shall be neatly trimmed to form a level surface and stable sloping embankments as
indicated on the drawings to suit the finished structures and roads.
J2.6
Time for Planting

In programming the planting work the Contractor shall take due regard of the accepted
seasons for planting as specified in the Section 20 of the Ministry of Housing Standard
Specification for Building Works. Should the time for completion be such that landscaping
works would be carried out at a time when planting is inadvisable then the Contractor may
apply to the Engineer for permission to postpone the planting until a more suitable time of
year.
Should this delay mean that the planting has to be carried out after the date of completion
of the Works then the Contractor shall give satisfactory undertakings to carry out the
outstanding landscaping during the Notification of Defects Period.
J2.7
Irrigation
An automatic irrigation system, utilising final treated effluent, shall be provided for the
irrigation of the landscaping throughout the whole of the plant
Vol 3, Section3
Page J-4 of 9
J2.8
Specifications
Maintenance
All new plants and grasses shall be maintained for not less than 12 months after planting.
This shall take the form of irrigation, re-staking, pruning, weeding, tilling, etc. to ensure
sufficient growth is achieved by all plants until Completion of the Works.
J2.9
Replacement
Any trees, shrubs or areas of grass which fail to show satisfactory growth or wither and die
shall be replaced by the Contractor.
The responsibility for the irrigation and maintenance of these replacement plants shall
remain with the Contractor until such time as they exhibit satisfactory growth.
J2.10
Vines and Climbers

The type of vines and climbers shall as follows or similar approved:
Blooming:
Bougainvillea Spectabilis
Green:
Ipomea purpurea
Jasminum Officinale.
Plants shall be healthy and vigorous, well branched and densely foliated when in leaf.
J2.11
Shrubs
The type of shrubs shall as follows or similar approved::
J2.12
Evergreen:
:
Dodonea Viscosa
Jasminum humile
Blooming:
Hibiscus Rosa Sinensis

Lantana Camara
Nerium Oleander
Bouganvillae Spectabilis
Trees
Trees may selected from the following or alternatives proposed to suit the concept of the
landscaping scheme and the local conditions:
evergreen ornamental trees:
Encalyptus spec
Acacia Cyanophylla
Casuarina equisetifolia
Casuarina glauca
Ficus mitida
Tamarix Apphylla
Deciduous ornamental trees:
Vacaranda Sp
Melia azedaract
Morus alba
Palm Trees:
Vol 3, Section3
Page J-5 of 9
Specifications
Phoenix dcatylifera
Oreadoxa regia
Cbamaerops humilis
Washingtonia filifera
The trees not grown in Container shall be planted immediately after delivery to the site.
The stem and 50% of the leaves should be protected against drying out with jute
bandage. Palm trees with a heights over 3m must have a root ball, with a diameter of 1m.
J2.13
Agricultural Soil Top Soil

Soil shall be obtained from sources approved by the Ministry of Agriculture and shall have
the following characteristics.
Clay max.
60%
Sand min.
40%
pH value max. 8.3.
The Contractor shall provide Soil analysis, showing the pH value, electrical conductivity, Ca
CO 3 , texture as well as the contents of nitrogen, phosphorus, potassium and magnesium.
The maximum levels of acceptance are:
Phosphorus
Magnesium
Potassium
P205
Mg
K20
10 mg/100 g soil
10 mg/100 g soil
4 mg/100 g soil
If the value of electrical conductivity is higher than 2000 micro mhos/cm, leaching of the
soil in a well drained area will be necessary with a suggested water quantity of 300 ltr/m
with a soil depths of 30 cm.
In order to get the top soil conditioned for cultivation, the soil shall be mixed with soil
improvers according to sand and soil analysis.
Soil improvers:
Organic fertilizer 5%
Peat moss
Shredded bark
Organic resin foam
Inorganic fertilizer
10%
10%
5%
200 gr/m3
A sample of agricultural soil shall be submitted for approval and all material delivered to
the site must conform to the approved sample.
J2.14
Top Soil Additives:

a.
Inorganic Fertilizer
The inorganic fertilizer shall be in compound form containing N (Nitrogen), P 2 0 5
(phosphorus) and K 2 0 (Potassium) in an adequate mix to suit the purpose. They
shall be delivered in original unopened containers and bear the manufactures
analysis.
b.
Organic Fertilizer.
Organic fertilizer shall be cow manure, sheep manure, poultry manure, compost or
sludge. They must be thoroughly pulverized, sterilized, and decomposed.
Vol 3, Section3
Page J-6 of 9
c.
Specifications
Peat moss:
Peat moss shall be of a quality acceptable for use as a soil amendment and shall
have a pH range from 3.7 to 5.
It shall be unfertilised and consists only of sphagnum.
d.
Organic Resin Foam

Organic resin foam shall be urea-formaldehyde foam formulated for horticultural
use, resistant to breakdown in the prevailing climate conditions, with an estimated
life of more than 10 years and shall be flaked up to 30mm in size with minimum
moisture absorption of 50% of volume.
J2.15
Irrigation Water
Water for irrigating plants and leaching operations should be sweet water or tertiary
treated final effluent. Water analysis showing the pH value, the hardness and the
electrical conductivity shall be provided by the Contractor for any water used for interim
irrigation.
J2.16
Drainage Pipes
Drainage pipes for plant pits and beds shall be plastic polyvinyl chloride pipes 100mm in
diameter or approved alternative.
J2.17
Surface Preparation
Areas which are to be landscaped shall be prepared as follows:
J2.18
a.
The area shall be cultivated to the full depth of agricultural soil which shall have a
minimum thickness of 450mm. Where mechanical cultivators cannot be used, the
work shall be carried out to the same depth by hand.
b.
All stones over 50mm diameter shall be removed from site to an approved tip.
c.
All rubbish, large stones and weed roots shall be collected and removed from site to
an approved tip.
d.
The area shall be graded to remove all irregularities and to produce evenly running
falls. This operation shall not reduce the approved depth of agricultural soil.
Finished levels shall be 25mm lower than all surrounding finished levels unless
otherwise specified.
e.
The Engineer shall be notified when these operations are taking place and his
approval obtained before any planting.
Preparation of Soil and Plant Pits

Soil shall be conditioned as per clause J2.13 and the recommendations of soil analysis
report. Fertiliser shall not be applied more than 24 hours prior to tilling operations.
Tillage depth shall be 300mm and water shall be added before, during and after all mixing
operations to soil. Stockpiled, windblown sand shall be cleaned of all stones, sticks, plants
and other foreign materials before being spread.
J2.19
Planting and Seeding

a.
Vines, Climbers, Shrubs and Trees.
Vol 3, Section3
Page J-7 of 9
Specifications
Planting season shall be between November and March. Plant pits shall be
excavated with sides as nearly vertical as possible. The following sizes shall be
maintained:
Vines and
Climbers:
500mm square x 700mm deep.
Shrubs:
Shrubs pits shall be 300mm greater in diameter than the spread of

roots. Depth should allow a minimum 100mm topsoil mix under
the root balls. If the shrub is less than 80cm high, the size of the
pit should be 500 square x 500mm deep.
Trees:
Tree pit shall be 600mm greater in diameter than the spread of

the roots of tree and sufficiently deep to allow for a 150mm layer
of planting soil under the root. If the tree is not higher than 2m,
the size of the pit shall be 1000 square x 1000mm deep.
Before planting container grown plants. Some of the roots shall be cut and
removed. In freeing the roots at the periphery of the soil some of the soil shall be
broken away to provide better contact between the root ball and fill soil. The hole
shall be backfilled with top soil, taking care in not leaving any air pockets. Then a
shallow basin shall be built around the tree pit so that water soaks down into the
root ball
b.
Palm Trees
Planting season for Palm trees shall be between September and March.
The size of pits for palm trees shall be as follows:
Palm tree up to 4m:
2500 x 1500 x 1500mm deep
Palm tree over 4m:
2000 square x 2000mm deep
Before starting planting all injured, dry and damaged root shall be cut off. The
leaves of palm trees shall be cut back by a quantity of 30% in one level to reduce
water requirements. After setting the palm tree the pit shall be filled with top soil.
J2.20
Staking and Anchoring Trees

Staking shall be done at the same time as planting. For vines only one stake shall be
used. For trees, two stakes are necessary. The trunk shall be tied to the stake in one
level. Trees with a height of more than 3m, or with a trunk circumference of more than
1.8m, shall be anchored using 3 stakes and guy wires.
J2.21
Maintenance
a.
The Contractor shall be responsible for the maintenance of planted areas for the
duration of the Contract and during the defects liability period.
b.
All stakes and ties must be regularly checked and repaired or replaced as necessary.
c.
Watering during the defect liability period must be undertaken daily and the
application must be sufficient to soak the soil to below root depth.
d.
The Contractor shall provide the Employer a Landscape Maintenance Manual before
the issue of the final Inspection Certificate.
Vol 3, Section3
Page J-8 of 9
J2.22
Specifications
Defects Liability
Inspection will be carried out at the end of the Defects Liability Period. Any plants and
trees found to be dead shall be replaced by the Contractor at his own expense.
Vol 3, Section3
Page J-9 of 9
Specifications
TABLE OF CONTENTS
Page No.
SECTION L BUILDING WORKS
L1
L1.0
L1.1
L1.2
L1.3
L1.4
L1.5
L1.6
L1.7
L1.8
L1.9
L1.10
L1.11
L1.12
L1.13
L1.14
L1.15
L1.16
L1.17
L1.18
L1.19
L1.20
L1.21
L1.22
L1.23
L1.23.1.
L1.23.2.
L1.23.3.
L1.23.4
L1.24
L1.25
L1.26
BUILDING WORK MATERIALS

General
Damp-Proof Courses
Damp-Proof Membranes
Metal Lathing
Mastic for Pointing
Softwood Timber for Carpentry and Joinery
Hardwood Timber for Joinery
Flush Doors
Internal Timber Door Frames
Door Seals
Ironmongery
Glass
Glazing Compounds
Windows and Doors
Roller Shutter Doors
External Doors and Frames
External Windows
Emergency Doors
Roof Lights
Signs
Wall Tiles
Concrete Blockwork
Wall ties
Movement Joints
Joint Fillers
Bond-breakers and backing strips
Primers
Joint Sealants
Cement Mortar
Mortar Plasticizers
Chemical Resistant Mortar.
L2
L2.1
L2.2
L2.3
L2.4
BUILDING WORKMANSHIP
General
Roofing General
Rainwater Outlets
Galvanized Steel Sheet
Vol 3, Section3
Page i of ii
1
1
1
1
1
1
1
1
2
2
2
2
2
2
3
4
5
5
6
6
6
6
6
7
7
7
7
8
8
8
8
9
13
13
13
13
13
Specifications
L2.5
L2.6
L2.7
L2.8
L2.9
L2.10
L2.11
L2.12
L2.13
L2.14
L2.15
L2.16
L2.17
L2.18
L2.19
L2.20
L2.21
L2.22
L2.23
L2.24
Movement Joint Sealing

Damp-Proof Courses
Openings
Frames
Cavity Walls
Tolerances
Scaffolding
Filled Blocks
Surface Finish
Joint Reinforcement
Anchors
Granolithic Flooring
Protection of Flooring
Wall-Tiling
Cement Plastering
Wall Painting
Rendering with Plain Finish
Metal Lathing, Expanded Metal and Wire Mesh
Plumbing Systems
Sanitary Systems
13
13
14
14
14
14
15
15
15
15
15
16
16
16
16
16
16
17
17
17
L3
L3.1
L3.2
L3.3
L3.4
L3.5
L3.6
L3.7
STRUCTURAL STEELWORK
General
Bolts and Nuts
Welding Consumables
Erection
Welding
Fabrication Tolerances
Dissimilar Metals
18
18
19
19
19
20
21
21
L4
L4.1
L4.2
L4.3
L4.4
L4.5
L4.6
L4.7
L4.8
STEELWORK COATING SYSTEMS

General
Coating System 1
Coating System 3
Coating System 4
Coating System 5
Coating System 6
Coating System 7
Coating System 8
23
23
24
24
25
26
26
26
27
L5
L5.1
L5.2
L5.3
METALWORK
Cleanliness
Pricing
Aluminium Windows and Doors
29
29
29
29
Vol 3, Section3
Page ii of iii
L5.4
L5.5
L5.6
L5.7
Vol 3, Section3
Specifications
Fly Screens
Louvers
Sealing Joints
Cat Ladders
32
32
32
32
Page iii of iii
Specifications
SECTION L BUILDING WORKS

L1
BUILDING WORK MATERIALS
L1.0
General
All building materials shall comply with Bahrani Building Regulations and where discrepancy
exists between quoted the quoted standards and specifications hereafter and the
regulations then the latter shall prevail.
Building works shall generally comply with the Ministry of Housing Standard Specification
for Building Works.
L1.1
Damp-Proof Courses
Flexible damp-proof course materials for walls and lintels shall meet with the following
requirements:
L1.2
Type 1:
Bituminous damp-proof course materials with asbestos base and complying

with BS. 6398.
Type 2:
Black polythene damp-proof course materials complying with BS. 6515.
Type 3:
Pitch polymer damp-proof course materials having a minimum thickness of

1.27mm and a minimum weight of 1.45 Kg/m2
Damp-Proof Membranes
The damp proof membrane on concrete floors shall be a cold applied bitumen solution
manufacture applied in two coats to give an impervious finish.
L1.3
Metal Lathing
Metal lathing shall be galvanised steel lathing having a weight of 1.60 kg/sqm. Where
necessary mesh to take render coats shall be 13 mm No.22 galvanised wire mesh.
L1.4
Mastic for Pointing

Mastic for pointing shall be approved Butyl joint sealing compound of approved colour
applied by gun in full accordance with the manufacturer's instructions.
L1.5
Softwood Timber for Carpentry and Joinery

Softwood timber for non-structural members shall be of the class suitable for the purpose
for which it is intended. The moisture content shall be less than 20% at the time of fixing
or such lesser moisture content as is necessary to ensure adequate performance for the
purpose and position of the members.
L1.6
Hardwood Timber for Joinery

Hardwood timber for joinery shall be of the Class suitable for the purpose for which it is to
be used.
Hardwood shall be F.A.S. (first and second) or equal quality of the species described.
Samples of each type of hardwood shall be submitted to the Engineer for approval before
any joiners work is commenced. Hardwood for joinery work generally shall be teak.
Vol 3, Section3
Page L-1 of 33
L1.7
Specifications
Flush Doors
Internal and external flush doors shall comply with BS 459 Part 2.
Fire check flush doors and frames shall comply with BS 459 Part 3.
L1.8
Internal Timber Door Frames

Internal timber door frames shall be in hardwood of a species approved by the Engineer.
13 mm thick plywood grounds shall be fixed in structural openings to the full thickness of
the wall with open channel exposed type galvanised mild steel. plaster stop beads set
oversailing the grounds at reveals and heads. The grounds shall be fixed to walls with
holdfasts.
Wooden door frames to single and double leaf single action doors shall be in two pieces
each overall opening 75 mm x 38 mm screwed to the S W grounds and pelleted.
Doors frames to double action swing doors shall be on grounds as for other doors but
frames shall be in one piece overall opening 130 x 38 mm face grooved with neoprene
seals.
L1.9
Door Seals
Door seals to the outer stiles, the frame and the meeting stiles of double action swing
doors shall be of the neoprene brushing type set in with aluminium screws the seals to
brush onto PVC inserts in an aluminium alloy channel section similarly fixed.
Threshold seals in neoprene to the bottom of doors shall be set in upstand type aluminium
holding channel.
All door seals shall be to the approval of the Engineer.
L1.10
Ironmongery
Generally hinges to all timber and aluminium doors shall be stainless steel washered butt
hinges and be fixed with stainless steel screws.
Unless specified elsewhere, external doors shall be fitted with 5 level mortice locks
incorporating separate dead bolts. Internal doors shall be fitted with single bolt dead locks.
All exposed parts and striking plates shall be stainless steel. Two keys shall be provided for
each lock.
All doors shall have aluminium level furniture with internal latch springs. The handle plate
shall be fixed with stainless steel screws and shall incorporate the keyhole. External doors
shall be fitted with overhead door closers to prevent slamming.
L1.11
Glass
Obscure panels to window frames shall be formed in 4 mm thick toughened opaque float
glass in approved colours.
Internal screens, doors, inspection panels and aluminium framed glass doors shall be in 4
mm thick Georgian wired plate glass, or approved equivalent.
L1.12
Glazing Compounds
Vol 3, Section3
Page L-2 of 33
Specifications
The putty and mastic for glazing is to be a type approved by the window manufacturer.
Glazing in timber doors and screen shall have both glass and beads bedded and back
puttied and the putty trimmed off flush.
Glass edges in aluminium window frames are to be filled with acrylic sealant.
Glazing is to be carried out using mastic glazing tape externally and PVC vision strip
internally.
L1.13
Windows and Doors

Windows and doors shall be of good quality and robust and shall be to the approval of the
Engineer. General details are given on the Drawings
Weather-stripping shall:
1.
be made from materials known to be compatible with aluminium
2.
not shrink or warp nor adhere to sliding surfaces or closing surfaces
3.
not promote corrosion when in contact with the aluminium alloy used, and
4.
be resistant to deterioration by weathering.
Joints in frames shall be made neatly and accurately either by welding or by mechanical
means (e.g. cleating and screwing) and may have flush stepped or lapped surfaces.
Welded joints shall be cleaned off smooth on the surfaces which are exposed when the
window or door is in the closed position or where they come into contact with glazing.
Flush joints formed by mechanical means shall be in line to within the limits permissible.
Hinges and pivots shall be either of suitable corrosion resistant materials or if not
compatible with the frame material shall be separated from the frame by materials that are
compatible with it. Hardware including its fittings shall be of suitable corrosion resistant
materials. Materials or finishes, which are not compatible with the frame materials, shall
not be used unless they are satisfactorily separated from the frame by materials that are
compatible with it. Screws (self tapping and wood) nuts bolts washers and other
fastenings shall be of stainless steel or aluminium. Stainless steel fastenings shall be grade
316S. Provision shall be made for suitable fixing devices. Where such devices are built in
and not exposed directly to the weather they may be made from steel which has been hotdip galvanised or zinc sprayed or zinc plated and passivated. Glazing beads gaskets glass
adapters and glazing compounds shall be of materials compatible with the frame material
and finished thereon.
Windows and doors shall be such that glazing or re-glazing on site is possible without the
need to remove the outer frame from the structure of the building. They shall comply with
the British Standards Institution "Severe Exposure" Quality Assurance standard.
All opening windows shall be fitted with suitable insect screens.
The Contractor shall submit details of manufacture including sections of frame members
and no orders shall be placed until such details have been approved by the Engineer.
Vol 3, Section3
Page L-3 of 33
L1.14
Specifications
Roller Shutter Doors
L1.14.1 Scope
This section comprises the minimum requirements for the design and erection of roller
shutter doors.
L1.14.2 Technical Data Requirements
The Contractor shall submit to the Engineer for approval:
Manufacturers published specifications.
Shop detail and erection drawings
Detailed painting and coating specifications and procedures.
L1.14.3 Design Requirements
All components of the doors shall be designed to withstand and remain operable under a
steady wind load due to the maximum wind speed of 45m/s. Windlocks shall be provided
to prevent slats disengaging from guides.
L1.14.4 Delivery and Storage
Doors and materials shall be delivered to the jobsite in packages or bundles which are
clearly marked, to identify fully the contents. Pre-finished materials shall be enclosed and
interleaved as required to prevent damage or defacement caused by handling or weather.
Door shall be stored off the ground, under cover, and accessible at all times for piece by
piece inspection.
L1.14..5 Materials of Construction
Door Curtain:
The door curtain shall be constructed of interlocking, roll formed steel slat of flat
configuration. Size and gauge shall be as required to provide the curtain with adequate
stiffness. Slats shall be hot-dip galvanized and painted.
Two galvanized steel angles of equal weight shall be securely fastened back to back to the
bottom of curtain for reinforcement.
Accessories:
Doors shall be equipped with the following accessories:
Loop-type rubber or neoprene astragal attached to bottom bar.
Rubber or neoprene hood baffle.
Weather seal at jambs.
Miscellaneous:
Mechanisms, box, motor covers and manual control gear shall be coated during
manufacture..
Vol 3, Section3
Page L-4 of 33
Specifications
Lintels and structural steelwork shall be coated during manufacture..

L1.14.6 Finishing
After installation all exposed elements of the roller shutter doors shall be painted.
L1.14.7 Operation
Doors shall be motorized and operated by an electric motor of sufficient power to raise the
door with a velocity of not less than 250 mm per second.
Doors shall have a standard 3 push button control station mounted on the inside wall
together with a weatherproof, key operated control station mounted on the exterior side.
Doors shall have a manual emergency stand-by system, consisting of a hand chain,
sprocket and reduction gear arranged to raise the door with a pull of approximately 150 N.
L1.15
External Doors and Frames

External doors and frames shall be of good quality, and robust.
External doors shall be so designed that they swing to the closed position unless
deliberately held open. The doors and frames shall be fitted with efficient draught
excluders.
Glazing to external doors shall be in polished plate toughened glass complying with BS 952
Table 5. Samples of toughened glass shall be submitted to the Engineer for his approval.
All external glass shall be in tinted brown to the approval of the Engineer.
L1.16
External Windows
External windows and frames shall be of good quality, and robust.
All hardware shall be supplied and fixed by the manufacturer and shall match the finish of
the surfaces of the units and shall be replaceable without removing the outer frame from
the structure. Fasteners shall be designed so that they cannot be released from the
outside by the insertion of a thin blade or other simple tool.
Windows shall meet the performance requirements of severe (a) exposure", that is a
maximum three second gust speed of 45 m/s.
All surfaces in contact with blockwork, concrete render or other alkaline materials shall be
coated with two coats of black bitumen solution or similar approved protective coating. All
unit surfaces which will be visible when the window is fixed in position shall be protected
after manufacture by low tack tape or other suitable means capable of being removed after
installation of the window to leave clean undamaged anodised surfaces.
All windows shall equal or exceed the following performance requirements:
There shall be no water leakage when tested at 330 mm water gauge and air filtration shall
be less than 12 mlh/m when tested at 40 mm water gauge.
Vol 3, Section3
Page L-5 of 33
L1.17
Specifications
Emergency Doors
Emergency doors where shown on the drawings or instructed by the Engineer shall be
fitted with approved panic bolts Part 1 to the inside of the doors and the doors shall be
designed to open outwards.
L1.18
Roof Lights
Roof lights shall be of clear plastic conforming to BS 8213, Part 1 (Cleaning and safety) and
BS CP 153, Part 2 (Durability and maintenance).
Roof lights shall be permanently fixed, and shall not be readily interfered with by
unauthorised persons. The mounting shall be to upstand kerbs cast into the roof slab.
L1.19
Signs
Room designation sign, name plates and fire exit direction signs shall be made from
engraved plastic laminate, screw fixed in required positions. All signs shall be in both Arabic
and English lettering to the approval of the Engineer.
L1.20
Wall Tiles
The tiles shall be 150 x 150mm and of the best quality ceramic tiles available. The quality
and colour shall be approved by the Engineer.
L1.21
Concrete Blockwork
Precast concrete blocks used in manholes, chambers, and structures shall be made using
sulphate resisting cement Type V.
Precast concrete blocks generally shall comply with BS 6073 Part 1
Blocks in external walls shall be min. 190 mm thick. Those in internal partition walls shall
be min. 100 mm thick. Block dimensions shall be as follows with the indicated tolwerances:
Length:
390mm (+3mm, -5mm)
Height:
190m (+3mm, -5mm)
Width:
90mm, 140mm, 190mm or 290mm.(+3mm, -2mm av. +4mm, -4mm at any

individual point)
Precast concrete blocks shall be solid, hollow or cellular complying with BS 6073. Blocks
shall have a minimum compressive strength of not less than 7.0 N/mm2 unless otherwise
noted on the drawings.
Where concrete blocks are cast on Site by the Contractor they shall be made in approved
concrete block making machines.
All casting shall be carried out with the block making machines under cover. The concrete
shall be put into the machine moulds in thin layers and properly tamped. On removal from
the machine the blocks shall be carefully cured. After placement on racks under sheds the
blocks shall be kept wet for three days. Curing shall be continued for a further five days the
blocks being kept on racks in the open under mat covers and kept wet. Further curing shall
take place by leaving the blocks under mat covers for a further seven days without wetting.
If the Contractor wishes to use steam-cured concrete blocks he shall request the approval
of the Engineer to the methods of curing proposed.
Vol 3, Section3
Page L-6 of 33
Specifications
Blocks shall be carefully packed in transport and unloaded and stacked on delivery by hand
or other approved means so as to avoid damage to surfaces. Blockwork shall be
constructed using cement sand mortar and joints shall not be less than 6 mm thick nor
more than 10 mm thick at their narrowest part.
Where appropriate, the courses shall be laid level or parallel to the axis of the Work and
with parallel neat and regular joints. Vertical joints shall be kept true and in perpendicular
alignment as appropriate.
Immediately before being laid, the blocks shall be thoroughly soaked in clean water and
before continuing partly completed work the exposed bed joint shall be likewise soaked.
The courses shall be built up uniformly and no portion of the wall during laying shall rise
more than one metre above any other portion of the wall. No bats or broken blocks shall be
allowed except where necessary for closures.
The joints shall generally be not more than 6 mm in the beds and 10 mm at the ends or
such other dimensions as may be agreed by the Engineer.
All joints shall be completely filled flush with mortar.
All blockwork shall be protected during erection from the effects of heat, sun and rain by
suitable covering. Curing finished work shall be as specified for concrete.
L1.22
Wall ties
Wall ties shall be stainless steel. Unless otherwise specified or approved by the Engineer
they shall be of the vertical-twist strip type.
Special anchor ties for connecting brickwork blockwork or masonry to dovetail slots case in
concrete shall be of similar specification and approved by the Engineer.
L1.23
Movement Joints
L1.23.1. Joint Fillers

Joint fillers shall be compressible, non-staining, resistant to damage handling and shall not
be extruded from joints when movement occurs. Joint fillers shall have the characteristics
detailed in table 5 of BS 6093 and shall be of the following types.
Type 1
Wood fibre/Bitumen
Type 2
Cork/Resin
Type 3
Bitumen/Cork
Type 4
Cellular plastic and rubber
The type and dimensions of joint fillers shall be 20mm thick Type 2 unless otherwise
specified.
L1.23.2. Bond-breakers and backing strips
Bond-breakers shall be thin one-sided self adhesive tape or closed cell foam backing strip
as specified on the drawings.
Vol 3, Section3
Page L-7 of 33
Specifications
L1.23.3. Primers
Primers shall be fully in accordance with the requirements and recommendations of the
sealant manufacturer.
L1.23.4 Joint Sealants
Joint sealants shall comply with the following:
L1.24
i)
One part polysulphide sealants shall comply with BS5215.
ii)
One part polyurethane based sealants shall be gun applied.
iii)
Silicone sealants shall comply with type A (low modulus) requirements of BS5889.
iv)
Two part polysulphide based sealants shall comply with the relevant requirements of
BS4254. Pouring grade shall be applied to horizontal upward facing joints and gun
grade to joints or any other aspect or inclination. Other two-part polymer-based
sealants of gun or trowel grade shall comply with the physical and test requirements
of BS4254.
v)
Two part polyurethane based sealants shall be non sag type and gun applied.
vi)
Sealants shall in all cases be carefully selected as appropriate for their climatic and
environmental exposure. The Contractor shall supply to the ENGINEER copies of
written recommendation(s) and guarantee(s) from the manufacturer as to suitability
of the product(s) for each individual structure and for the methods of installation.
All sealants shall be approved by the ENGINEER prior to their incorporation with the
works.
vii)
Primers for use with joint sealants shall be compatible with, and obtained from the
same manufacturer as, the adjacent sealant. Primers shall have no harmful effects
on the brickwork, blockwork or finishes.
viii)
For general usage, two part polysulphide based sealants shall be used unless
otherwise specified or approved by the Engineer
Cement Mortar
Cement mortar shall consist of cement and sand gauged by volume in wrought wooden
boxes in the proportion of 1 part of Sulphate Resisting Portland Cement to 3 parts of sand.
Mortar shall be mixed until the colour and consistency are uniform and shall be mixed only
as and when required.
L1.25
Mortar Plasticizers
Mortar Plasticizers shall not contain chlorides.
Mortar Plasticizers shall be used only with the approval of the Engineer.
Plasticizers shall be used strictly in accordance with the recommendation of the
manufacturer.
Vol 3, Section3
Page L-8 of 33
L1.26
Specifications
Chemical Resistant Mortar.
L1.26.1 General
Chemical resistant mortar shall be used in corrosive environment for internal pointing of
blockwork in underground structures and for internal rendering of concrete surfaces
including concrete blockwork where specified or where the installation of plastic lining is
impractical.
The purpose of the mortar is to resist bio-degradation in septic sewage environments which
include sulphuric acid up to 10 % concentration (w/w) and up to 35C. Chemical resistant
mortar shall be of a type and make approved by the Engineer.
This section covers the requirements for chemical-resistant resin mortars for bedding,
jointing or pointing bricks, concrete blocks or tiles, to be used as a corrosion-resistant lining
in sewers, manholes, chambers and related structures. The mortar may have to be applied
and cured in damp or wet conditions. Mortar required for pointing may have to be applied
by gun, through a small diameter nozzle reaching to the bottom of the pointing groove.
Internal concrete surfaces not protected with plastic lining shall be protected with chemical
resistant mortar at least 10 millimetres deep. The concrete surface shall be prepared to
provide a key for the mortar strictly in accordance with the mortar manufacturers
instruction. The connection between the plastic linings shall be detailed and constructed in
accordance with instructions and recommendation of both material manufacturers.
L1.26.2 Information to be submitted by the Contractor
Certificates
Where the Contractor wishes to submit results of tests previously carried out on materials
those results shall be submitted with certificates from the independent testing laboratories
used.
Sampling
The Contractor shall arrange to have samples of chemical-resistant resin mortar tested by a
laboratory approved by the Engineer and suitability for the purpose of compliance with this
Specification shall be established to the satisfaction of the Engineer before any such
product is used in the Works. Further samples shall be taken during the period of
application at the rate of one sample for every 1000 kg of mortar delivered for use and
tested by any or all of the procedures necessary to establish compliance with this
Specification, as required by the Engineer. If any sample fails to comply, application shall
cease until suitability and compliance with the Specification has been re-established to the
satisfaction of the Engineer.
Manufacturers Literature.
Any samples of chemical-resistant resin mortars submitted by the Contractor for the
approval of the Engineer, shall be accompanied by a complete set of the literature issued
by the manufacturer describing their product. In addition to the manufacturers standard
data sheets, details of other installations where the mortar has been used, and any
references as to its suitability should be included.
L1.26.3 Material and Properties
Description
Vol 3, Section3
Page L-9 of 33
Specifications
The mortar shall be an intimate mixture of liquid resinous material and a setting agent and
may contain appropriately selected filler materials. When mixed these components shall
form a mortar, with a workability suitable for the proposed method of application, that
subsequently hardens.
Composition
The liquid resin shall be any solvent-free resinous material capable of forming a chemical
resistant mortar when mixed with a suitable catalyst and if required, a filler material. The
filler material if used, shall be compatible with the liquid resin, of the chemical resistance
required and of a size that will permit the preparation of a minimum joint thickness of 3.0
mm. The mixed mortar shall not adversely affect or be affected by other construction
materials with which it will properly come into contact, including fixtures and fittings.
Colour
The colours of individual components
sufficiently different from each other
components will be apparent by visual
chemical-resistant resin mortar shall be
tiles to be pointed.
of the chemical-resistant resin mortar shall be

so that complete, homogenous mixing of the
inspection. The colour of the completely mixed
appreciably different from that of the bricks and
Packaging
The components of the chemical-resistant resin mortar shall be pre-measured and
packaged by the manufacturer in units sized to suit the method of application. All packages
shall be clearly marked as to size, contents, mixing instructions, safety precautions, storage
requirements and date of expiration of the contents.
Shelf Life
The unmixed components of the chemical-resistant resin mortar shall have a minimum
shelf life after delivery to the site of 12 months when stored at a temperature between 5oC
and 45oC.
Pot Life
Where it is proposed to apply the mortar by trowel the working time after initial mixing of
the resin, filler material and hardener shall be a minimum of 60 minutes at a temperature
of 20oC and 30 minutes at 45oC. The pot life of the mortar shall be considered exceeded
when the mortar can no longer be applied to a prepared surface without curling behind the
trowel according to ASTM C308. If it is proposed, subject to the approval of the Engineer,
to apply the mortar by some other method (e.g. by gun) the working time after mixing
shall be of a length suitable for the proposed method of application. Mortar applied at any
time during the pot life shall have the specified properties when cured.
Bond Strength
The chemical-resistant resin mortar shall form a bond with the brick, tile or concrete, or
with a cured surface of itself, with a minimum strength subject to substrate cohesive
capacity, of 3 N/mm2. This bond strength shall be achieved regardless of whether the
mortar is applied to a dry, a damp or wet surface without priming or other form of surface
preparation. The bond strength shall be tested and measured in other form of surface
preparation. The bond strength shall be tested and measured in accordance with ASTM C
321 using samples of the actual construction materials.
Vol 3, Section3
Page L-10 of 33
Specifications
The chemical-resistant resin mortar shall have a minimum compressive strength of 15
N/mm2
Tensile Strength
The chemical-resistant resin mortar shall have a minimum tensile strength of 5 N/mm2
Modulus of Elasticity
The chemical-resistant resin mortar shall have a maximum elastic modulus of 9 kN/mm2
Chemical Resistance
The cured chemical-resistant resin mortar shall be capable of resisting attack by any
constituents that may normally or occasionally be present or which may form within the
system by a combination of physical, chemical and biological reactions. In particular, the
mortar shall be capable of resisting attack from extended exposure to sulphuric acid in
concentrations up to 15%, oils, greases and petrol.. The tests shall be conducted using
petrol at 20oC. The maximum changes in weight, compressive strength and bond strength
shall be measured after 7, 28, 56 and 84 days. The results of the tests, for petrol and each
acid concentration and temperature shall be plotted on a graph, against time elapsed and
submitted for approval by the Engineer.
While discolouration and loss of gloss on the surface of these tested specimens is
acceptable, there shall be no surface cracks, etching, pitting or softening of the exposed
surface. If the test solution becomes discoloured during the test, the test shall be continued
with fresh solution and there shall be no further discolouration.
Shrinkage
The chemical-resistant resin mortar shall have a shrinkage not exceeding 0.5% when
tested after curing for 84 days at a temperature of 70oC
Absorption
The cured chemical-resistant resin mortar shall have an absorption not exceeding 3.0%
Curing
The chemical-resistant resin mortar shall achieve its service strength in a period not
exceeding 7 days at temperatures ranging from 10C to 45C in dry, damp or wet
conditions. The properties of the cured mortar shall not be impaired by curing in dry, damp
or wet conditions at any temperature ranging from 5C to 45C.
L1.26.4 Testing
The standards for testing the material described above shall not be less than as follows:
For Resistance to Chemicals:
Tested in accordance with ASTM C 267.
For Working and Setting Time:
Tested in accordance with ASTM C308.
For Bond Strength:
Tested in accordance with ASTM C321
For Absorption:
Tested in accordance with ASTM C 413.
Vol 3, Section3
Page L-11 of 33
Specifications
For Shrinkage:
For Tensile Strength:
For Modulus of Elasticity:
For Thermal Compatibility:
Testing shall be carried out to the Engineers approval before any product is used in the
Works.
Testing shall be carried out subsequently at the rate of one set of tests per 1000 kg of
mortar delivered to Site.
L1.26.5 Storage and Application
The manufacturers recommendations for storage of the components of chemical-resistant
resin mortar shall be followed. In all cases, storage shall be in a dry, cool place with
containers tightly sealed and away from open flame. Components that have exceeded their
shelf life or have become wet shall not be used.
The manufacturers recommendations for the safe use of the chemical-resistant resin
mortar shall be followed. Workers shall wear gloves when handling the product. In the
mixing and working areas there shall be no open flame and adequate ventilation shall be
provided.
The components of the chemical-resistant resin mortar are to be supplied in pre-measured
quantities. Under no circumstances shall these quantities be divided to mix smaller batches.
Mixing of the chemical-resistant resin mortar shall be in strict accordance with the
manufacturers recommendations. The temperatures of the component shall be such that
the temperature of the mixed mortar is between 150C and 400C. Mixing shall be thorough
and complete such that the mortar is a homogeneous colour and free from lumps and air
bubbles. In no case shall mixed mortar that has become unworkable be re-tempered with
resin liquid or by any other means. Once mortar has become unworkable, it shall be
discarded.
The manufacturers recommendations for surface preparation and for application and
spreading of the mortar shall be followed. The joints shall be completely raked out to a
depth of 25 mm. The surfaces to which the mortar is applied shall be free from dirt, debris,
grease, oil and other materials that would prevent the formation of a sound bond. Where
surfaces are damp or wet such special measures as are recommended by the manufacturer
for these conditions shall be adopted. The joints shall be carefully inspected by the
Contractor prior to mortar application.. A smooth, even surface shall be achieved, flush with
the surface of the blocks or tiles.
The manufacturers recommendations for curing the chemical-resistant resin mortar shall
be followed. The temperature during the curing period shall be kept within the range of 50C
to 400C. Special consideration shall be given to curing in damp or wet conditions.
Vol 3, Section3
Page L-12 of 33
L2
BUILDING WORKMANSHIP
L2.1
General
Specifications
All workmanship shall comply with Bahraini building regulations and where discrepancy
exists between quoted the quoted standards and specifications hereafter and the
regulations then the latter shall prevail.
L2.2
Roofing General
Reinforced concrete roof slabs shall be covered by an approved concrete insulating screed
with a minimum thickness of 50 mm and a three layer built-up bituminous roof sheeting.
When required, joints shall be formed in the insulating screed. A vapour barrier and
ventilation to the bituminous roof sheeting shall also be provided. If applicable, the hatch
in the roof shall be provided with an insulating sandwich panel in a thickness of 50 mm
consisting of coated polyurethane foam or similar approved. The Contractor shall submit
samples and references to the Engineer for his approval of the materials he intends to use
before ordering these materials.
L2.3
Rainwater Outlets
Rainwater roof outlets shall be fitted with circular gratings and sized for the down-pipes. A
sample of the type of rainwater outlet to be used shall be submitted to the Engineer for
approval.
L2.4
Galvanized Steel Sheet

Galvanized steel sheet for covering roof movement joints shall be 20 gauge (1.00 mm
thick).
L2.5
Movement Joint Sealing

Joints shall be clean and dry at the time of priming and sealing. All movements joints shall
be provided with a bond breaker. Primer shall be applied in accordance with the
manufacturers recommendations and the joint sealed as soon as the primer is tack dry.
Adjacent surfaces shall be marked as necessary and visible joints shall be visually
acceptable.
All workmanship shall be in accordance with the manufacturers instructions and
recommendations including backing, priming, application and curing. All jointing work shall
be executed prior to painting of adjacent surface.
Unless otherwise specified, movement joints in blockwork shall be provided at maximum 6
metre centres and shall be 20mm wide and 12mm deep.
L2.6
Damp-Proof Courses
a. Damp-proof courses shall be laid on an even mortar bed, free from any projections that
may puncture the material.
b. Damp-proof courses shall be lapped at least 150mm at joints and angles and be
bedded on and covered with a bed of mortar. At locations where a downward
movement of water is to be prevented, Type 2 materials shall be welted and Types 1
and 3 lapped and sealed in accordance with the manufacturers recommendations.
Vol 3, Section3
Page L-13 of 33
c.
Specifications
Damp-proof courses shall be continued vertically for 150mm where the wall abuts a
concrete column or wall.
d. Damp-proof membrane under the ground slab shall be sealed to the damp proof course
in every adjoining wall.
e. Damp-proof courses near ground level shall be provided at 150mm above finished
ground level or as detailed on the drawings.
L2.7
Openings
Reveal blocks shall be used by the side of openings and at the exposed wall junctions to
give a straight plane surface. Use of mortar for making the ends of blocks plane shall not
be permitted.
Openings, holes, sinkings, mortises, sleeves and any other inserts for other trades shall be
correctly located and formed as the work proceeds. No chasing of the work shall be
permitted unless approved by the Engineer. Approval for chasing will be given only when
the contractor uses tools which cleanly cut masonry and the machiners ability to cut an
acceptable chase shall be demonstrated. Before any chasing is carried out, the walls shall
be allowed to set thoroughly. No horizontal or diagonal chases shall be permitted and joint
reinforcement shall not be cut. Chases shall be repaired by using mortar or other materials
as approved by the Engineer.
L2.8
Frames
All wooden window and door frames shall have ties and lugs built in where required and on
completion the frames shall be pointed on exposed sides with gun grade mastic tested to
B.S 3712 or other sealant approved by the Engineer. Where the frames are built in they
shall be bedded in the same mortar as that used for the walling.
L2.9
Cavity Walls
Cavity walls shall consist of a cavity separating an outer and inner skin, each of which may
be either brickwork, blockwork or stone. The two skins shall be tied together with ties
which are properly bedded in the mortar beds and joints and are at staggered centres,
900mm horizontally and 400mm vertically. Ties shall be carefully laid such that they do not
fall towards the inner part of the wall.
All cavity walls shall be closed at jambs and openings. A damp-proof course shall be built
into the closure to form a moisture barrier. The cavity shall be kept free from mortar,
rubbish and other deleterious matter which may facilitate the passage of moisture to the
inner skin.
Cavity tray damp-proof courses shall be provided where lintels, sills or any other solid
object bridges the cavity. The cavity tray shall be installed such that a slope is provided
towards the outer skin and weep holes shall be provided at 800 mm centres to allow any
water accumulating in the cavity to escape from the building. Plastic or cotton insect
screen cloth shall be provided on the cavity side of the weep holes.
L2.10
Tolerances
Permissible deviations in level from the specified dimensions, shall be not more than
3mm/m height in level for the brickwork or 5mm/m height for blockwork. Permissible
deviation in plumb shall be not more than 2mm/m height and not more than 5mm per
storey.
Vol 3, Section3
Page L-14 of 33
L2.11
Specifications
Scaffolding
Scaffolding shall be totally independent of all masonry work. No supports shall be allowed
to pass through the walling unless otherwise agreed by Engineer.
L2.12
Filled Blocks
All hollow blocks at the following locations shall be filled with concrete having a
compressive strength at 28 days of not less than 40 N/mm2
i)
At sides of openings
ii) At intersections and junctions between concrete columns and or concrete walls where
wall ties are used.
iii) Under sills.
iv) In blocks supporting in-situ concrete.
v) In the bottom course of a block wall
L2.13
Surface Finish
All masonry which is to receive plaster, stucco or similar finish shall have a sufficient
wrought keyed surface. The joints and beds shall be raked out to a depth not exceeding
5mm by using a raking key with shoulders to prevent deeper raking. The raking shall be
carried out as the work proceeds.
When not treated with paint, all fair faced Calcium Silicate brickwork and blockwork shall be
treated with an approved water repellent conforming to B.S. 6477, Grade 4, immediately
after each section of work is completed.
All exposed masonry shall present a consistent visual appearance comparable to an
approved sample panel.
L2.14
Joint Reinforcement
Joint reinforcement, where required shall be fully embedded in the mortar.
The
reinforcement shall be laid with minimum lap of 150mm at overlap locations and junctions
and shall have a minimum 25mm cover when bedded in the wall.
L2.15
Anchors
Where masonry walls abut concrete walls or columns, anchors shall be provided at a
vertical spacing of six courses for brickwork and three courses for blockwork.
Anchors shall consist of anchor slots cast into the concrete member and dovetailed anchors
unless otherwise indicated on the drawings or approved by the Engineer. When approved
by the Engineer anchors or ties may be cast into the concrete and bent down after the
removal of formwork. All anchors shall be securely bedded into the mortar bed of the
walling and not into the bricks or blocks.
At the junctions with concrete wall and concrete and steel columns fixing shall be provided
across movement joints that will ensure lateral stability but allow movement of the wall in
the longitudinal direction.
Vol 3, Section3
Page L-15 of 33
L2.16
Specifications
Granolithic Flooring
Granolithic flooring shall have a minimum thickness of 75 mm
L2.17
Protection of Flooring
All finished surfaces shall be properly protected until completion of the Contract. Terrazzo
tile and in-situ flooring shall be protected with a layer of clean sawdust. PVC tile floors and
carpets shall be protected with polythene sheeting.
L2.18
Wall-Tiling
Walls or part of walls which have to be tiled shall be floated off with mortar consisting of
Portland Cement, shell lime or similar approved and sand in the volume ratio 1/2 : 1 : 4
before tiling. The tiles shall be fixed evenly with an approved adhesive.
The joints shall be narrow and of uniform width and shall be filled with approved white
proprietary tile grout.
Filling with grout shall be according to the manufacturer's instructions. Where necessary,
tiles shall be cut and properly fitted.
L2.19
Cement Plastering
Internal walls and ceilings shall be plastered with 1 : 4 Portland Cement-sand mortar. Total
thickness of plaster on internal walls shall be 20 mm. Before plastering is carried out, the
joints shall be raked out to a depth of at least 5 mm.
The surface of the wall shall be cleaned of all foreign matter before application.
L2.20
Wall Painting
The surface of the cement plastered walls and ceilings shall be primed and painted with a
washable and weatherproof wall paint. The paint to be used shall be the best quality
plastic emulsion paint available. The colour will be selected by the Engineer. If necessary,
walls and ceilings shall be cleaned beforehand to the satisfaction of the Engineer.
All paint shall be applied according to the manufacturers recommendations.
L2.21
Rendering with Plain Finish

Plain finished rendering shall be carried out with 1: 5 cement-sand in two or three coats.
Three coat work shall be carried out on metal lathing and on other backgrounds which the
Engineer determines by inspection to be too uneven to permit two coat work.
Rendering applied to external walls shall contain a waterproofing agent to the approval of
the Engineer.
Where rendering is to be applied to surfaces of concrete or blockwork such surfaces shall
be treated by means approved by the Engineer to provide a mechanical key for the
rendering.
Surfaces shall be cleaned of all residual mould oil dust loose particles and other deleterious
material before rendering work is begun.
Particular care shall be taken to cure newly applied rendering as specified herein for
concrete.
Vol 3, Section3
Page L-16 of 33
Specifications
The coat shall have a wood float finish to true planes and regular curves and to an even
surface. Arises shall be rounded and in true alignment and a hollow fillet shall be run at
internal angles.
L2.22
Metal Lathing, Expanded Metal and Wire Mesh

Metal lathing and all such forms of reinforcement and backings to plaster shall be in
galvanized steel. Samples of lathing etc., shall be submitted to and be approved by the
Engineer before the use in the work.
L2.23
Plumbing Systems
Hot and cold water plumbing systems shall generally conform to BS 6700 and BS 8000Part 15, or to local standards and regulations. General details are shown on the Drawings.
L2.24
Sanitary Systems
Sanitary systems shall generally conform to BS 5572 and BS 8000- Part 13, or to local
standards and regulations. General details are shown on the Drawings.
Vol 3, Section3
Page L-17 of 33
L3
STRUCTURAL STEELWORK
L3.1
General
Specifications
Hot rolled and hollow structural steel sections shall be mild steel complying with the
requirements of BS 4360 Grade 43A and 43C subject to the additional requirements of BS
449.
Where the use of proprietary designs of prefabricated building frames is proposed, the
standards to which they are manufactured shall be no less rigorous than those stated
above.
Structural steel work shall be provided and fixed complete with all plates, cleats, bolts, etc.
cut to lengths and sizes and drilled as shown on the drawings.
Steel tubes shall be seamless tubes in accordance with BS 1387 or with BS 1775.
Unless otherwise required by the Contract all forms of steel used shall be of standard
section and shall be of the exact dimensions. Should the Contractor be unable to obtain
steel to the required dimensions he shall submit alternative propose to the Engineer for his
approval. Two copies of all detailed working drawings, calculations, etc. prepared by or on
behalf of the Contractor shall be submitted to the Engineer for his approval. Any approval
by the Engineer shall in no way relieve the Contractor of his responsibilities for the work
under the Contract.
The workmanship shall be of the best quality and all persons employed in the factory or
site shall be competent and skilled in their respective trades.
The design and detailing of connections and workmanship shall be in accordance with the
drawings and BS 449 to transmit the loads specified by the Engineer.
The work shall be erected, fitted and temporarily bolted together for the approval of the
Engineer before any riveting or welding is carried out.
During erection and prior to the construction of any necessary stiffening members,
temporary bracing will be provided as necessary to ensure the stability of the framing
against wind or accidental force.
Shop and site joints will be formed by galvanized high strength friction bolts to suit the
plant, equipment and erection procedure of the steel work Contractor, due regard being
paid to efficiency, appearance and ease of maintenance. Site connections generally will be
made with black bolts, with a minimum of two bolts to any connection, except where fitted
bolts, high strength friction grip bolts, or site welding, are specifically referred to in the
Specification or on the drawings.
High strength friction grip bolts shall be tightened by a part-torque part-turn method. After
bedding down of the joints, each nut and the protruding threads of bolt shall be
permanently marked to record their relative positions. The nuts shall then be tightened to
the approval of the Engineer by the part-turn of the nut method. High strength friction grip
bolts will generally be preferred to fitted bolts. The surfaces of members joined by friction
grip bolts shall be free from oil and paint, etc. Portal frame site connection at apex and
knee where they employ HSFG Bolts in tension, such bolts shall be torqued up to their
proof load.
Plates and sections shall be true to form. Stiffeners, plates and the like shall be ground to
fit the profile of the member. Sections to be cut to 'exact' lengths shall be accurately cold
sawn or machined. Preparation of edges by flame-cutting shall, wherever practicable, be
Vol 3, Section3
Page L-18 of 33
Specifications
done by machine. Cold sawn, machine-cut and flame-cut edges shall be cleaned free of
burrs and slag and left as smooth and regular as those produced by edge planing. All holes
shall be drilled.
Not less than 28 days before the fabrication or steel work is to begin the Contractor shall
submit detailed shop drawings to the Engineer. Fabrication shall not commence until the
Contractor has received the Engineer's approval of his..... Such approval does not in any
way relieve the Contractor of his responsibilities to produce an adequate and safe scheme.
Chequer plates may be clipped to supporting members unless stated otherwise in the
Contract drawings. The surface pattern of adjacent plates shall be matched to lay in the
same direction.
Purlins shall, where possible, be fabricated to span continuous over two bays. To achieve
this purlin joints should be staggered, with suitable continuity joints for single bay length
members. PS 'Z' type purlins shall be connected with PS jointing sleeves.
Holding down bolts will be supplied as required for building into the supporting concrete
members.
L3.2
Bolts and Nuts

Steel bolts and nuts for structural steelwork shall be high strength friction grip bolts
conforming to BS 4395 or black bolts conforming to BS 4190. Washers shall conform to BS
4320 with a tolerance of 1.5mm on the diameter of the hole. When bolting to diminishing
sections tapered washers shall be used.
High strength friction grip bolts shall be used in conjunction with approved proprietary load
indicating washers.
L3.3
Welding Consumables
All welding consumables (electrodes, wire, filler rods, flux, shielding gas and the like) shall
comply with the requirements of BS 5135.
Weld electrodes for metal arc welding shall conform to BS 639 and with the requirements
of the appropriate weld procedure.
L3.4
Erection
All erection work is to be carried out in a safe manner. Sequence - The Contractor will
supply the Engineer with a schedule showing the order of erection based against a time
scale.
The Contractor shall supply temporary bracing to the building until blockwork is completely
grouted. The bracing shall remain on the structure until 10 days after the last column and
bond-beam has been completed.
Immediately upon arrival on site of the materials, the Contractor shall check through all
items and report to the Engineer any shortages (including nuts, bolts, washers, etc. or
damage to any member.
Damaged members shall be set aside and immediately repaired to a state where they
comply with the fabrication specification unless in the Engineer's opinion, they are damaged
beyond repair and have to be replace.
Vol 3, Section3
Page L-19 of 33
Specifications
All members shall be carefully handled to avoid local buckling, damage to paint, gouging
and other undesirable defects. Only competent people shall handle the materials. On no
account shall members be tipped or dropped off trucks or mishandled with forklifts.
The steel work will be stacked in areas provided clear of traffic and stacked on dunnage.
The Contractor shall supply and install adequate screens and covers for the protection of
operators and work when welding is being done out of doors during inclement weather.
This protection shall ensure that no water or other deleterious matter finds its way into the
joint during the welding operation and that the work is adequately protected from cold
draughts of air. If, in the opinion of the Engineer, the weather is entirely unsuitable, the
Contractor shall, when so instructed, cease all outdoor welding operations.
The Contractor shall supply and install scaffolding which, in the opinion of the Engineer, is
adequate and sufficiently comfortable to permit the operators to produce welding of the
required standard.
This in on way relieves the Contractor of his statutory obligations regarding scaffolding.
In the event of misfits the Contractor will immediately notify the Engineer who will
prescribe what corrective measures are to be taken.
Under no circumstances will the Contractor take it upon himself to remedy the situation by
a cutting and welding operation.
Unless shown to the contrary on the drawings, or unless prior approval to the contrary is
given by the Engineer, it is the Contractor's responsibility to ensure that all members after
erection and after application of all dead loads are level, plumb and straight.
The Contractor shall not erect steel work using HSFG bolts where the facing surfaces
contain anything between them other than clean steel or inorganic zinc silicate paint. All
bolts, nuts and washers shown on the drawings as HSFG shall comply with BS 3139 Part 1
and the assembly to follow will comply with BS3294 Part 1 Code for High Strength bolting.
All bolts shall have coronet load indicating washers fitted and nuts tightened in accordance
with the code and the manufacturer's specification. Al bolts and nuts to be cadmium plated
or equal.
These shall be tightened in sequence (where used) and tensioned with a torque wrench. Al
threads on the nut will be fully engaged.
The Contractor will responsible for touching up all damaged paint work, whether occurring
in transit or during handling and erection. Touch-up paint must be compatible with the
original galvanizing system.
L3.5
Welding
All welding carried out during fabrication or erection shall be in accordance with the
requirements of BS 5135 and as shown on the approved detail drawings. Details of the
proposed weld procedures shall be submitted to the Engineer for approval at the same time
as the detail drawings. All connections shall be welded in such a manner as to make the
finished connections neat and smooth in appearance and suitable for painting. All slag
shall be removed and all sharp projections shall be round smooth.
Before welding is commenced either in the fabrication shop or on Site, weld procedure tests
shall be carried where directed by the Engineer.
Vol 3, Section3
Page L-20 of 33
Specifications
All welders employed either in the fabrication shop or on Site shall pass qualification tests
relevant to the weld procedures in use. Welders shall have satisfactory evidence of having
been engaged in welding for at least 9 months in the preceding 12 month period. If the
work of any welders employed on the Contract is unsatisfactory, the Contractor shall carry
out such further welder qualification tests as are necessary to demonstrate that the welders
are proficient.
Welds shall be subjected to non-destructive testing by processes which may include but
shall not necessarily be limited to radiographic, ultrasonic, magnetic particle, or dye
penetrant methods, depending on the type of weld and its position in the structure. The
standards of acceptance shall be at least equivalent to BS 5500: Table 5.7, If any work
shows defects or fails to comply with the requirements of the detailed drawings or
Specification for any reason it shall be repaired or rejected, even though it may have been
carried out by qualified welders using approved procedures.
L3.6
Fabrication Tolerances
The general tolerance on all dimensions shall be + 2 mm. Holes shall be aligned such that
fasteners can be freely inserted through the members at right angles to the contact face.
Where holes in members cannot be aligned without damaging or distorting the structure or
(unless the Engineer shall permit) reaming the holes, the member or members shall be
rejected.
A structural member shall not deviate from straightness (or from the specified shape) by
more than:
1 /1,000 of the lengths between lateral restraints in the case of compression members and
beams, or
1 / 500 of the overall lengths (maximum 25 m) in the case of other members.
A structural member shall not deviate from its intended length by more than:
1 mm in the case of compression members faced at both ends for bearing, or
+ 0 to 4 mm in the case of other members.
Lengths of components shall be such that cumulative variations do not prejudice the
accurate alignment of the completed structure.
Where two steel surfaces are required to be in contact to effect a bearing or frictional
contact, the surfaces shall be prepared so that at least 90 % of the area is touching before
any clamping force is applied.
L3.7
Dissimilar Metals
Where dissimilar metals are used in close proximity to structural steel members or their
connections, contact between such metals and the steel shall be avoided unless the
Contractor can demonstrate to the satisfaction of the Engineer that contact between the
dissimilar metals will not lead to galvanic corrosion.
Contact between aluminium or aluminium alloy and galvanized mild steel will be permitted.
For fixing aluminium to steel structures, bolts, nuts, washers and screws shall be
galvanized.
Vol 3, Section3
Page L-21 of 33
Specifications
Where galvanized parts might otherwise become sacrificial anodes to the main structure, or
where the electrolytic potential difference exceeds 250 mV, the parts shall be separated by
an insulating medium of adequate strength.
Vol 3, Section3
Page L-22 of 33
Specifications
L4
STEELWORK COATING SYSTEMS
L4.1
General
The coating systems for steelwork shall be as listed below depending on the application
and as detailed in the following sections.
The Contractor shall submit his painting programme together with the manufacturer's
documentation for the Engineers approval.
The paint manufacturers instructions shall be followed closely, particularly regarding coat
thicknesses, drying time, pre-treatment, etc.
The base coat shall be applied in the shop within four hours of sandblasting. The surfaces
which shall not be affected by the welding operations shall be painted with an intermediary
coat.
For painting on site, the following shall apply.
Welding zones and zones which have been damaged shall be carefully cleaned and made
smooth as described above. After cleaning and smoothening, a base coat and an
intermediary coat shall be applied. All surfaces shall receive two coats of finishing paint.
The total thickness of paint shall be not less than 280 micron.
System No
Application
Ferrous surfaces, including items of structural steelwork subject to

atmospheric exposure and operating at up to 100 C.
Not used.
Ferrous surfaces in contact with soil or water not specified to be zinc metal
sprayed , galvanized, or mortar coated.
Ferrous surfaces within 100 mm of a site weld line, all ferrous surfaces
encased in concrete, and for temporary protection to ferrous surfaces.
Ferrous surfaces subject to atmospheric exposure, not insulated, and

subject to operating temperatures between 100 C and 500 C
Proprietary coating systems.
Internal surface of ferrous storage tanks, pipe ends receiving flange

adaptors and flexible couplings and inside surfaces of socket joints.
Galvanising
Coating thickness for liquid coatings are referred to throughout as minimum dry film
thickness (m.d.f.t.).
Vol 3, Section3
Page L-23 of 33
L4.2
Specifications
Coating System 1
Ferrous surfaces, including items of structural steelwork subject atmospheric exposure and
operating at up to 100 C
L4.3
Prior to blast cleaning, surface irregularities and surface contaminants shall be

removed.
Blast clean surfaces to visual standard of Sa 2 in accordance with SIS 05 5900
Surface amplitude of between 50 and 75 microns shall be obtained.
Method of coating application, drying/curing conditions and overcoating

sequence shall be in accordance with coating manufacturers recommendations.
Ensure surface to be coated is free from dust, grit or foreign matter immediately
prior to coating application.
Immediately prior to coating application ensure surfaces still have Sa 2 l/2

surface quality.
Coating thickness.
Primer
Undercoat
Intermediate
Finish Coat
Zinc-rich 2-pack
epoxy
High-build 2pack epoxy
High-build 2pack epoxy
Polyurethane
acrylic .
50 microns
m.d.f.t.
100 microns
m.d.f.t.
100 microns
m.d.f.t.
40 microns
m.d.f.t
Total Dry Film

Thickness
290 microns
m.d.f.t.
Coating System 3
Ferrous surfaces, except inside surfaces of water storage tanks, in contact with soil or
water, not specified to be zinc metal sprayed, galvanized, or mortar coated.
1
Prior to blast cleaning, surface irregularities and surface contaminants

shall be removed.
Blast clean surfaces to visual standard of Sa 2 in accordance with SIS 05

5900.
Method of coating application, dry/curing conditions and overcoating

sequence shall be in accordance with coating manufacturers
recommendation.
Ensure surface to be coasted is free from dust, grit or foreign matter

immediately prior to coating application.
Vol 3, Section3
Page L-24 of 33
Specifications
Immediately prior to coating application ensure surfaces still have Sa 2

surface quality.
Coating thickness.
Additional inspection requirements.
Finish Coat
Total Dry Film Thickness
Pure solvent-free polyurethane
1.5 mm m.d.f.t.
1.5 mm m.d.f.t
The coating shall be compatible with the application of cathodic protection and cathodic
disbondment test data shall be submitted by Contractor for Engineers approval. The use of
a primer to improve cathodic disbondment characteristics may be acceptable subject to
Engineers approval.
L4.4
Coating System 4
Ferrous surfaces within 100 mm of a site weld line, temporary protection for surfaces and
all ferrous surfaces encased in concrete.
1

shall be removed.
Blast clean surfaces to visual standard of Sa 2 in accordance with SIS 05

5900.
Method of coating application, dry/curing conditions and overcoating

recommendation.
Ensure surface to be coated is free from dust, grit or foreign matter

Immediately prior to coating application, ensure surfaces still have Sa 2

surface quality.
Coating thickness.
Coating
Total Dry Film Thickness
2 pack epoxy zinc phosphate primer
25 to 50 microns m.d.f.t.
Vol 3, Section3
Page L-25 of 33
L4.5
Specifications
Coating System 5
Ferrous surfaces subject to atmospheric exposure, not insulated and subject to operating
temperatures between 100 C, and 500 C.
1

shall be removed.
Blast clean surfaces to visual standards of Sa 3 in accordance with SIS 05

5900.
Method of coating application by gas flame or electric arc process using

aluminium wire.
Ensure surface to be coated is free from dust, grit or foreign matter

Immediately prior to coating application, ensure surfaces still have Sa 3

surface quality.
Coating thickness.
Apply sealing coat.
Coating
Sealer Coat
Aluminium metal spray

150 to 250 microns thick
L4.6
Aluminium silicone, minimum thickness to

achieve complete sealing and coverage
Coating System 6
Items of equipment which due to their use and/or complexity are not suitable for coating
with any of the coating systems defined elsewhere in this Specification may, on the
Engineers approval, be coated with Contractors standard heavy duty coating system(s).
In such circumstances, the Contractor shall submit full details of the proposed coating
system(s) for review and approval by the Engineer prior to ordering. The Contractors
submittal to the Engineer shall include but not necessarily be limited to the following:
L4.7
a)
Proven suitability of the coating system for an aggressive salt laden environment.
b)
Contractors procedures and specification for substrate surface preparation,

coating application and quality control.
c)
Coating manufacturers data sheets and recommendation for surface preparation

and coating application.
d)
The m.d.f.t.s for each coating application and for the total coating system.
Coating System 7
Vol 3, Section3
Page L-26 of 33
Specifications
Internal surfaces of ferrous storage tanks.

1
Prior to blast cleaning, surface irregularities and surface contaminants shall

be removed.
Blast clean surfaces to visual of Sa 2 in accordance with SIS 05 5900

1967.
Method of coating application, drying/curing conditions and overcoating

recommendations.
Ensure surface to be coated is free from dust , grit or foreign matter

Immediately prior to coating application ensure surface still has Sa 2

surface quality.
Coating thickness.
Additional inspection requirements.
Primer
Undercoat and
Intermediate
Coats
Finish Coat
2-pack epoxy zinc

phosphate
High-build 2-pack
epoxy
High-build e-pack
epoxy
25 microns m.d.f.t.
100 microns each

m.d.t.f.
100 microns m.d.f.t.
Total Dry Film

Thickness
325 microns m.d.f.t.
The Contractor shall submit to the Engineer test certificates from the proposed coating
manufacturer to demonstrate compatibility of the coating system with the substances to be
stored in the tank. Additionally, coating to be used in water storage tanks shall be
compatible with the application of cathodic protection and cathodic disbondment test data
shall be submitted by Contractor for Engineers approval.
L4.8
Coating System 8
Surfaces required to be hot dip galvanized are ladder, racks, cable trays, stair-treads,
gratings, grilles, hand railing, bolts, nuts, washers and other miscellaneous carbon steel or
low alloy steel items unless otherwise specified.
Other surfaces requiring galvanizing shall be as shown on drawings and in the
Specifications.
Galvanising shall be carried out only after completion of all welding, drilling, grinding and
other fabrication activities associated with the items to be galvanized. Steels to be
galvanized shall not be susceptible to embrittlement by the galvanising process.
Vol 3, Section3
Page L-27 of 33
Specifications
Galvanising shall be in accordance with BS 729 or equivalent. The minimum zinc coating
weight shall not be less than 610 gm/m of surface area or, for threaded fasteners only,
305 gm/m of surface area. The galvanized surfaces shall possess a uniform bright
metallic sheen free from defects.
In special cases, and at the Engineers sole discretion, threaded fasteners may be zinc
electro-plated and passivated. Steels possessing a minimum specified ultimate tensile
strength of 100 kg/mm or greater shall be heat treated prior to passivation.
Where galvanised ferrous metals are specified to be painted, the following shall be applied:
Preparations:
Degrease
Abrade or pre-treatment etching primer
Primer:
1 coat of zinc chromate primer, 2550 microns m.d.f.t.
Finishing:
2 coats alkyd gloss finish, 50 microns m.d.f.t.
Vol 3, Section3
Page L-28 of 33
L5
METALWORK
L5.1
Cleanliness
Specifications
The Contractor is advise to take particular care of the anodised aluminium surfaces by
using masking tape or other methods of protection and is warned that the Engineer may
require the removal and replacement of aluminium work which has been damaged due to
lack of adequate protection.
All materials shall be free from scale, rust damage or defects. All welding, bracing or hot
forging shall be carried out by approved processes.
All metal work shall be approved by the Engineer before starting painting works.
All steel items which are not galvanized or zinc-coated are to be primed with a coat of
approved rust proofing primer applied to all surfaces at the workshop or on site
immediately after delivery and before erection and to be touched up where necessary after
erection.
L5.2
Pricing
The cost of supplying and fixing metal work generally are to include for horizontal, raking
or vertical work, cutting members to length, for all shop and site welding, grinding, drilling,
countersinking, bolting, riveting, assembling, adjusting and fixing complete. Rates for
items manufactured in the shop shall include for preparing and submitting shop drawings
for the Supervising Officer's approval before manufacturing commences.
L5.3
Aluminium Windows and Doors

Extruded aluminium sections should be in alloy AIMgsi.5 with temper F22 (DIN
Specifications) or equivalent.
All visible surfaces of the sections shall have a powder coated finish. Samples of colour
shall be submitted for the Engineers approval before work commences.
The sections shall be powder coated to a minimum thickness of 80 microns. The supplier
must submit necessary evidence to the satisfaction of the Engineer that the thickness of
coating is not less than 15 microns. In case of doubt the Engineer reserves the right to
send sample pieces to independent testing laboratories, at the cost of the supplier. If the
testing laboratory report states that the thickness or quality of the anodisation is deficient,
the Employer may ask the supplier to treat the order as cancelled and the supplier in such
a case shall immediately indemnify the Employer of any/all losses incurred by the supplier.
Contractor shall provide 10 years warranty.
Aluminium doors and windows are to be obtained from an approved supplier and shall
include all necessary ironmongery. The doors and windows shall be constructed of
extruded powder coated aluminium sections with joints accurately machined to ensure
perfect fit and mechanically jointed.
All items shall be strengthened, tapped and modified as necessary to receive ironmongery.
Windows shall be fixed light or opening as shown on the drawings. Opening lights shall be
Vol 3, Section3
Page L-29 of 33
Specifications
hung or sliding as shown on the drawings complete with approved fly-screens. Where
opening lights are hung, solid aluminium hinges with stainless steel pins and washers shall
be used. Ironmongery shall be provided, and samples shall be submitted to the
Supervising Offices for approval. Where glazing beads are used, they shall be of matching
aluminium. Glass shall be as specified in Glazing Section of the Preambles.
All frames should be made to fit the actual openings with a 5mm clearance all round.
Discrepancies in overall width or height exceeding 5mm will not be allowed and the frames
will be rejected in such cases. Any small discrepancies shall have the gaps suitably backed
and then filled with gun-applied mastic sealant.
At all opening windows and doors and where there are louvered screen and doors, a fly
screen shall be provided to the approval of the Engineer, constructed following the
principles and specifications as described elsewhere in this Specification.
Insect screens shall be in aluminium mesh, or stainless steel 18 x 16 meshes per inch. The
gap between the insect screen and the shutter shall be covered with an adaptor PVC
section.
For reference to window types see general arrangement drawings, elevations and
quantities.
Tolerances are to be approved by the Engineer before manufacture.
All ironmongery which is to have the same finish as the frames it is on shall be approved by
the Engineer.
The Contractor shall provide shop drawings for aluminium windows and doors which shall
be submitted to the Engineer for approval. A sample of typical window is to be submitted at
actual size using the specified glass and frame colour, clearly labelled complete with
Ironmongery.
Approval by the Engineer of the shop drawings shall not relieve the Contractor of his
responsibilities under the Contract.
All assembly screws shall be in 18-8 stainless steel.
Glazing sections shall be in special heat-resisting PVC and of channel type.
glazing sections on each side of the glass will not be permitted.
Separate
Sliding Windows and Doors

Weather-stripping - high density acrylic or wool weather pile shall be used. There should
be double brushes at every contact between shutter and frame sections for complete
insulations. These should be present consistently throughout the unit between the inside
and the outside and no portions without it are permitted.
The rollers for sliding shutters for both windows as well as doors shall be of adjustable
type. The adjusting screws must be accessible in the assembled state of the shutters and a
vertical adjustment of 7mm should be possible.
Vol 3, Section3
Page L-30 of 33
Specifications
All sections for sliding windows and doors should be of tabular shape and the
sections dimensions of the sections should be not less than 60 x 40mm.
cross
The outer frame must be suitable for accommodating sliding fly screens as required.
The handle-latch set should have all visible surfaces of anodised aluminium or similar nonrusting materials to approval. The handle must have a proper grip. A small projecting
flange or a recess in the shutter sections cannot be accepted to serve as handles. The
latching mechanism should not be surface mounted but should be concealed within the
sections.
Sash rails of vertical sliding windows are to be of tabular box sections with corner joints of
outer frames and sashes interlocked, and the balance mechanism is to be an approved
proprietary product.
Side Hung Windows, Doors and Ventilators
All windows and doors should be weather-stripped with heat resistant PVC sections. The
weather fighting action should be achieved by a positive compressive action against the
PVC section and should not depend on an external contact with the PVC section. At every
contact between two weather-stripping sections should be provided for complete weather
protection.
The bottom sections for hinged doors must be capable of being adjusted vertically if
necessary. The gap between the bottom section and the floor should be covered with a
pair of special flay-type PVC sections.
The shutter sections for both windows as well as doors shall be of tabular type and shall be
of overall size as shown on drawings and door sections shall be of overall size as shown on
drawings too (including flanges).
The shutters of the windows and doors should be assembled with concealed corners of
high rigidity. Hinges should be concealed within the sections.
Hinges shall be anodised aluminium with stainless steel pins and nylon washers. Handles
shall be in anodised aluminium and mounted with self-lubricating nylon washers.
A mortice cylinder rim automatic deadlock of high quality with double pin tumbler is to be
used.
Windows shall have anodised aluminium handles and a latching mechanism securing the
shutter to the frame both at the top and bottom.
The glazing vinyl shall be in heat resisting PVC and of channel type. Individual glazing
sections on both sides of the glass will not be permitted.
Fittings were required:
(a)
Single action door closer concealed in the head bar of the outer frame and
mounted on an adjacent pivot at the threshold and deadlock fitted.
Vol 3, Section3
Page L-31 of 33
Specifications
(b)
The left hand leaf of double doors with flush bolts at head and sill with deadlock
fitted to the right hand leaf.
(c)
Escape doors to have panic bolt assembly with vertical elements concealed in the
stile and door closer as in (a).
L5.4
Fly Screens
Fly screens shall be fitted to all opening leaves of windows consisting of a separate metal
sub frame filled in with fly wire as previously described. The fly screens shall be adequately
secured with suitable slips, set screws or turn buckles and shall be removable for
maintenance purposes. Fly screens doors shall consist of similar sections to the metal
casement doors and shall be fitted with removable panels of fly wire, in manner similar to
that described for window fly screens.
L5.5
Louvers
For details of louvered windows refer to window details.
aluminium. Fly screens will be fitted externally to all louvers.
L5.6
Louvers will generally be
Sealing Joints
The Contractor shall ensure that joints are dry and remove all loose material, dust and
grease.
Joints shall be prepared in accordance with sealant manufacturer's recommendations using
recommended solvents and primers where necessary.
Adjoining surfaces which would be impossible to clean if smeared with sealant shall be
masked.
Backing strips shall be inserted in all joints to be pointed with sealant.
When using backing strips, the Contractor shall not leave gaps and shall not reduce depth
of joint for sealant to less than the minimum recommended by the manufacturer.
Cavities shall be filled and jointed with sealant in accordance with the manufacturer's
recommendations.
Sealant shall be tooled to form a smooth flat bead.
Excess sealant shall be removed from adjoining surfaces using cleaning materials
recommended by the sealant manufacturer, and shall be left clean.
L5.7
Cat Ladders
Cat ladders where noted on the drawings shall be aluminium and unless otherwise detailed
shall be constructed as follows. Stringers shall be 50mm x 6mm (2" x ") flat attached to
the structure with 75mm x 75mm x 6mm (3" x 3" x ") plates bolted to the structure so
than the clearance of the stairs from the structure is not less than 300mm (12").
Vol 3, Section3
Page L-32 of 33
Specifications
Treads shall be formed of 19mm (") tube riveted to the stringers.

Safety loops shall be fitted to cat ladders more than 2m (6'6") long and thereafter at 1m
(3'3") intervals. The width across the loop shall be 685mm (2'3") and the distance from
the centre line of the stringers to the inside of the back of the loops measured at right
angles to the stringers shall be 762mm (2'6"). The loop material shall be minimum 50mm
x 12mm (2" x ").
Vol 3, Section3
Page L-33 of 33
Specifications
TABLE OF CONTENTS
Page No.
SECTION M GRP FABRICATED COVERS FOR ODOUR CONTROL SYSTEM
M1
GENERAL DESCRIPTION
M2
REFERENCE DOCUMENTS AND STANDARD SPECIFICATIONS
M3
GENERAL
M4
GRP FLAT COVERS
M5
ACCESS HATCHES
M6
SEALING AND ASSEMBLY
M7
FIXING AND HARDWARE
M8
LIGHT
M9
FRESH AIR INLETS
M10 FOUL AIR OUTLETS
M11 FINE SCREEN CHANNEL
M12 AERATED GRIT CHANNELS
M13 FLOW SPLITTER CHAMBER
M14 ANAEROBIC AND ANOXIC TANKS
M15 SUBMITTALS
M15.1
Product Data
M15.2
Shop Drawings
M15.3
Samples
M15.4
Quality Assurance
M15.5
Warranty
M16 PRODUCTS
M16.1
General
M17 GRP DOME AND FLAT SHEET COVERS
10
M18 GRP COVERS DESCRIPTIVE REQUIREMENT
11
M19 GRP DOME AND FLAT SHEET AESTHETIC COVERS
12
M20 TECHNICAL SCHEDULE
12
M20.1
Technical Schedule Covers
12
M20.2
Technical Details
12
Vol 3, Section3
Page i of iii
Specifications
M21 GRP LAMINATION
13
M22 FEATURES
13
M22.1
Assembly
14
M22.2
Non-Return Valves
14
M22.3
Pressure Rating
14
M22.4
Structural Loading for Covers
14
M22.5
Cover Structural Supports
14
M22.6
Temperature ratings
15
M22.7
Wind Loadings
15
M22.8
Gaskets and Sealants
15
M22.9
Fixing, handles and associated fittings
15
M22.10
Access, Inspection Covers and Hatches
15
M22.11
Chemical Resistance
15
M22.12
Personnel Protection
15
M22.13
Name plates
16
M22.14
Fastenings and Miscellaneous
16
M22.15
Painting
16
M23 QUALITY CONTROL AND PERFORMANCE TESTS
16
M23.1
Quality Control tests and records (To be witnessed by the Engineer) 16
M23.2
Examination after testing
17
M23.3 Information and requirements to be agreed and to be documented prior

to Design and manufacture the covers.
18
M23.4 Requirements to be agreed and documented prior to design and
manufacturer the covers.
M23.5
19
Minimum categories & Type of Covers for Design basis consideration 20
M23.6 Design documentation and shop drawing requirements from the

manufacturers
21
M23.7
Smoke Testing
21
M23.8
Works Testing
21
M23.9
Inspection and Performance Testing
21
M23.9.1
Site Testing
21
M23.9.2
Installation of GRP Dome & Flat Covers
22
M24 PACKING AND DELIVERY
22
M24.1
Labels and Markings
22
M24.2
Packing
22
M25 DOCUMENTATION SUBMITTAL
23
M25.1
Detailed Design
23
M25.1.1
Conceptual (Preliminary) Drawings and Data
23
M25.1.2
Approved For Construction Drawings and Data
23
M26 AS CONSTRUCTED DRAWINGS
24
M27 OPERATION AND MAINTENANCE MANUAL
24
M28 TESTING AND COMMISSIONING
24
Vol 3, Section3
Page ii of iii
Specifications
M29 TRAINING
25
M30 MANUFACTURERS PRE-QUALIFICATION
25
Vol 3, Section3
Page iii of iii
Specifications
SECTION M GRP FABRICATED COVERS FOR ODOUR CONTROL SYSTEM

M1
GENERAL DESCRIPTION
The work included in this section comprises design, fabrication, supply, delivery,
installation, testing and commissioning GRP covers, for the odour control system;
furnishing all labour, equipment, appliances and materials and performing all operations
for:
1. GRP flat covers with chequer plate wearing surface.
2. GRP non-slip flat covers.
3. GRP smooth curved dome shaped covers.
The scope of works shall include for:
Covers
Access hatches on covers
Inspection hatches on covers
Fresh air inlets on covers
Foul air outlets from covers
Penstock/slidegate covers
Flanged duct connections to covers
Allowances on covers for instruments, cut around existing equipment

etc.
Supply of Pressure Relief Valves if required
Nuts, bolts and all fittings relevant to covers
Gaskets and sealant to ensure covers and interfaces can be made air tight
Site consumables
General Arrangement Drawings of Covers
Shop drawings of covers
Installation Manuals
O & M manuals
Engineering support (i.e. assistance during installation, commissioning
Delivering to site
Independent Design review
Structural design of covers
Balancing of air flows

Fresh air inlet and foul air outlet arrangement (number and location) on covers shall be
designed to provide 100% air circulation below the covers reducing risk of gas entrapped
at corners which could cause corrosion problem.
M2
REFERENCE DOCUMENTS AND STANDARD SPECIFICATIONS

- EUROCOMP Code Design of Composite Structures
- BS 4994: 1987 Design and Construction of vessels and tanks in reinforced plastics.
- DIN 18820 Part 1 - 4
- Engineers tender drawings for tank opening dimensions and interfacing tank
structures available for supporting the covers.
M3
GENERAL
GRP Covers for the sewage odour control system must have the following key attributes:
1. Shall be highly resistant to the corrosive atmosphere over a service period of at least
25 years.
2. Shall be able to free span over a range of 6 14metres, without incorporating any
metal components in the covering system, except for fasteners.
3. Shall have good seal between cover panels and to the concrete tanks
4. Shall be readily accessible / removable for maintenance of the tank and its contents
5. Shall be light weight in order to minimise the loading on the concrete walls and for
handling by service personnel in key access areas.
Vol 3, Section3
Page M-1 of 25
Specifications
6. Shall have a design basis that is well proven over time to ensure minimal damage in
the course of day to day access, traffic and prevailing environmental conditions (sun,
wind)
7. Shall be readily and economically transportable from factory to site. Each unit part
shall not be greater than 30m2 with a mass of under 350 kg.
In the design stage of a cover system, close and early co-operation between the cover
supplier and the engineer is essential.
M4
GRP FLAT COVERS

(a) Pedestrian Trafficable Type
The manufacturers design shall include, in all cases, a chequer plate pattern top
surface or sanded surface in coloured UV resistant Gelcoated resin matrix and a
structural core as required for the load rating and the span of panel.
Panels shall be monolithic GRP construction which provides both the necessary
corrosion barrier and structural contribution to the overall panel duty application.
Corrosion barrier should be in the form of a C Glass surface veil as last layer on
the face exposed to tank atmosphere. External surface exposed to open air
should be Gelcoated UV resistant smooth surface.
Loads for pedestrian/maintenance traffic are commonly 2.5 kPa live load. Loads
up to 7.0 kPa for wheeled appliances, or superimposed loads such as mechanical
items, shall be accommodated with appropriate designs where required.
Panel sizes shall be designed to be self supporting with only Gelocated GRP
composite construction without any use of metals as metals are prone for
corrosion in Sewage environments.
All handles, lifting lugs, hinges, bolts, hard ware etc shall be in 316 stainless
steel.
Joints between panels shall generally overlap to ensure a good seal.
Seals shall be compressible neoprene or equal as EPDM.
Long span trafficable covers shall incorporate GRP beams, stiffeners which
eliminate the need for separate supports attached to the concrete walls/floors.
Each plant is custom engineered and detail drawn prior to manufacture, ensuring
rapid on-site installation with minimal problems.
(b) Non - Pedestrian or Non Trafficable

Lightweight covers for non- pedestrian or non- trafficable areas may be flat or
profiled to suit.
(c) Curved (Profiled) Covers
For areas generally not requiring regular Pedestrian trafficable access, curved covers
shall generally be used.
Various profiles shall be used, depending upon the span. Maximum self-supporting
span shall be 20 meters.
The Construction shall generally be a combination of the shape contribution and thin
GRP Gelcoated laminate to provide the desired result. The external surface shall be
coloured (as approved by the Engineer) with a UV resistant gelcoat, the internal
surfaces featuring the corrosion barrier for long spans. Formed components of single
shell FRP produced in tools (mould) that are specially manufactured for this surface
or ribs may be incorporated. The structures should have proven their suitability and
must be confirmed by a static calculations.
Vol 3, Section3
Page M-2 of 25
Specifications
In all designs, the aim is to minimise areas under covers where algae growth can occur or
foreign material become impinged.
All external surfaces of the covers should be so designed to eliminate ponding of water
over the cover. All covers must be designed to be self draining for any water due to rain
or otherwise on or surfaces and drainage outlets should be left into the tanks with water
sealed U traps made of PVC or other non metallic materials.
All fittings and fixings shall be 316 stainless steel.
M5
ACCESS HATCHES
All covers require some form of access hatch for day to day plant operational purposes,
and larger hatches for major tank and contents maintenance.
Man access shall be provided by a panel section up to 1200mm x 1200 mm, which is
hinged and features a quick release locking device. Low weight limit of 15-20 kg maximum
set to enable a person to open.
All hatches shall be integrated with regard to the shape into the cover elements and shall
be fitted with particular seals.
For less frequent access, cover panels shall be removable, singly or in sets of 3 or 4 (up to
8m width).
The Hatch cover interface with hatch opening on main panel should be designed to
provide a push fit & gas tight seal with compressible Neoprene gasket mechanically locked
in to the periferry of the cover lid. The access cover latch also should be so designed that
the neoprene remains in compressed state when the latch is closed.
M6
SEALING AND ASSEMBLY

For covers to work effectively and the odour extraction facility to be able to perform its
function, covers must be fully sealed.
Seal material shall be neoprene or similar approved which is moulded shape. Compressible
extruded neoprene Gaskets with minimum 40% compression having the specified
properties shall also be used. The minimum neoprene section width should be 20mm. The
use of air curing Semi-liquid sealing materials is not acceptable, except in very small areas
where a moulded seal is not practical. All cover elements should overlap at the joints,
preferably all elements should be executed alternatively lying on top and bottom so that
every second element can be removed towards the top independently from the adjacent
element. The cover elements shall be screwed together but it shall be detachable from
outside. Laminated steel plates with incised thread shall be used for such connection. The
use of automotive set serves shall not be permitted. The element on top shall have a hole
thread insert of the element at the bottom shall be designed for M10 Screws.
M7
FIXING AND HARDWARE

All fixings shall be set into concrete with epoxy and be located outside the seal. Minimum
bolt size shall be M12 diameter unless otherwise indicated. Hinges, latches, handles, bolts
etc shall be 316 stainless steel.
Vol 3, Section3
Page M-3 of 25
M8
Specifications
LIGHT
No light shall penetrate the covers. The use of vision panels in covers is therefore not
required
M9
FRESH AIR INLETS

To obtain foul air dilution and a flow beneath the covers, fresh air inlets shall be
incorporated into the covers. These may be upstanding non return type or flush fitted
plate type, their locations shall be a matter for resolution with the process engineers.
M10
FOUL AIR OUTLETS

Foul air outlets comprising a flanged riser bonded into the cover shall be sized and
positioned. They should be included in the cover supply to ensure proper installation and
ongoing warranty of the cover unit. The number of such outlets and positions shall be
advised by the Engineer.
M11
FINE SCREEN CHANNEL

These areas are traditionally high pedestrian loading, especially around the screens.
Covers shall be non-slip plate, load bearing, in panels to about 100 kg for areas not
subject to regular access, 25-40 kg for areas requiring access via manual opening/hinged
hatches.
Flat covers spanning upto 3meters which incorporate GRP beams shall be used in lieu of
separate support beams bolted to the concrete. The minimisation of fixed beams/supports
attached to the concrete walls is required so as to maximise clear entry space once covers
are lifted.
Chequer plate finish, pedestrian trafficable covers, loading shall be 5KN/m2.
M12
AERATED GRIT CHANNELS

The aerated grit channels shall be more economically covered with curved covers. Access
to the baffles, air pipe etc to be included.
Inlet and distribution channels shall be pedestrian trafficable covers.
Foul air draw off points shall be included to suit duct design.
Covers shall be fitted with pressure relief valves. The design of Pressure Relief Valve will
be as approved by the Engineer.
M13
FLOW SPLITTER CHAMBER

This area shall utilise pedestrian trafficable flat covers as necessary. The receiving
chamber may use a curved profile with one or two flat crossover panels.
Access to the flow splitter weir shall be provided through the GRP covers (adjustment,
clean out).
Self-lifting, hinged cover panels shall be provided to enable scum removal.
M14
ANAEROBIC AND ANOXIC TANKS
Vol 3, Section3
Page M-4 of 25
Specifications
The anaerobic and anoxic tanks of the bio-reactors shall be more economically covered
with curved covers. Common feed channel shall be of pedestrian trafficable flat covers.
Access to the baffles, air pipe etc to be included.
Inlet and distribution channels shall be pedestrian trafficable covers.
Foul air draw off points shall be included to suit duct design.
Covers shall be fitted with pressure relief valves. The design of Pressure Relief Valve will
be as approved by the Engineer.
M15
SUBMITTALS
M15.1
Product Data
1. Manufactures catalog data showing:
a.
b.
c.
d.
e.
M15.2
Dimensions, spacings and construction details.

Design calculation and tables showing limits for span length and deflection
under various uniform and concentrated loads, Laminate design and
thickness & choice of construction etc. Compliance with the EUROCOMP Code
for limiting states for stresses and deflections shall be demonstrated for each
load case.
Materials of construction. Selected resin & Glass specification shall be
submitted clearly showing the maximum temperature resistance to the
sewage environment. The heat distortion temperature of the fully cured resin
system used for the reinforced laminate shall be not less than 20C higher
than the design temperature of the covers. The Glass mat used shall be ECR
type as specified in CL 7.1.6.
Manufacturers prequalification for successfully completed the covering of
sewage treatment tanks for odour control with minimum 20,000 m2 covered
area in a single plant.
100 days acid immersion test conducted in accordance with ASTM C581 @
50C in 10% concentrated sulphuric acid on GRP Cover sample coupons and
submit the test data to prove the chemical resistance.
Shop Drawings
1. Shop drawings of all GRP products shall be submitted to the Engineer for approval in
accordance with the requirements.
2. Drawings to Indicate detail fabrication and erection of each GRP fabrication.
a.
3.
M15.3
Include plans, elevations, sections and details of GRP fabrications and their
connections.
b.
Show anchorage and accessory items.
c.
Clear sections showing all interfaces with supporting tank structures shall be
included.
Copy of Euro comp code is to be provided for the Engineers reference.
Samples
1. Samples of each type of GRP product proposed shall be submitted for approval. This
shall be in the form of 300 x 300 mm specimen cut from a cover section to identify:
a.
Vol 3, Section3
Surface texture and finish for externally visible areas.

Page M-5 of 25
b.
c.
d.
e.
f.
M15.4
Specifications
Laminate build up layers with thickness of each layer including gel coat.
S.S accessories
Neoprene gasket with coverlid sample.
Samples of glass mats, and non-catalysed resin and the gel coat material
Various colour samples of covers to choose the desired colour on site.
Quality Assurance
A. Material covered by these specifications shall be furnished by a reputable and
qualified manufacturer of proven ability who has regularly engaged in the
manufacture and installations of GRP systems for atleast 10 years.
B. Manufacturers Prequalifications
1.
2.
Firms shall be experienced in successfully producing GRP fabrications similar

to that indicated for this project, with sufficient production capacity to
produce required units without causing delay in the work.
Firms shall have successfully completed covering of sewage treatment tanks
or odour control with minimum 20,000 m2 covered areas of tank in any single
plant.
C. Substitution of any component or modification of system shall be made only when

approved by the Engineer and at no additional cost to the Employer.
D. In addition to the requirements of these specifications, Contractor shall comply with
manufacturers instructions and recommendations for such work.
M15.5
Warranty
A. Manufacturer and the Contractor shall jointly guarantee the completed GRP products
installation to be free of defects in workmanship and or materials for a minimum
period of Twenty Five (25) years from the date of Taking Over of the Works.
B. Warranties and guarantees by the suppliers of various components in lieu of single
source responsibility by the GRP products manufacturer will not be accepted.
1.
2.
The manufacturer shall be solely responsible for the warranty.

In the event of a failure in the installation or a component is proven defective
in service during the warranty period, the Contractor and manufacturer shall
repair or provide a replacement without any additional cost to the Employer.
Contractor shall furnish Employer with the manufacturers guarantee and warranty
certificate for all materials and components duly registered by the manufacturer.
M16
PRODUCTS
M16.1
General
A.
GRP fabrications shall be designed, fabricated and installed to withstand the specified
structural loads without exceeding the allowable design working stress of the materials
involved, including anchors and connections.
1.
2.
Vol 3, Section3
Loads shall be applied to produce the maximum stress and deflection less
than allowable as per EUROCOMP code in each respective component of each
GRP fabrication.
Details of the secondary support system where required by the manufacturer
shall be furnished to the Engineer for approval.
Page M-6 of 25
3.
Specifications
All calculations on selection of structural sizes shall be furnished to the

B. Materials used in the manufacture of the GRP products shall be new stock of the best
quality and free from all defects and imperfections that might affect the performance of
the finished product.
C. All materials shall be of the kind and quality specified and where the quality is not
specified, it shall be the best of the respective kinds and suitable for the purpose
intended. All Glass mats used shall be ECR type powder bound and the resin used shall
be epoxy based vinylester throughout the laminate wall.
D. All GRP covers, shall be manufactured using a handlay up contact compression moulded,
Light Resin Transfer Moulded or pultrusion process utilising an Epoxy based vinyl ester
resin with flame retardant and ultra-violet (UV) inhibitor additives. All external surface
shall be Gelcoat pigmented with vinylester resin. It shall be a composite laminate
consisting of a corrosion resistant liner, barrier layer, a structural layer and an exterior
Gelcoated resin rich layer.
1.
Two layers of C glass chemical resistant ECR type surface veil shall be
applied at the inner most layers covering the interior surface and minimum
700 gm/m2 Gelocat pigmented outermost layer covering the exterior surface.
2.
GRP shapes shall achieve a flame spread class 1 in accordance with BS 476
Part 7.
3.
The Barcol hardness of the inner & outer surface shall not be less than 35
when tested with a Barcol Impresser.
E. All GRP items shall be corrosion resistant to raw sewage, sodium hydroxide, and sodium
hypochloride as well as a 5% concentration of either Sulphur dioxide or Hydrogen
sulphide, ammonia, methane and carbondioxide gases emitting from sewage.
F. After fabrication, all cut ends, holes and abrasion of compression moulded and pultruded
GRP shapes shall be sealed with a compatible resin coating to prevent intrution of
moisture or other elements.
G. GRP products exposed to weather shall contain an ultraviolet inhibitor and shall
additionally receive one mil thick U.V. coating to shield from ultra-violet light. No item of
fabrication shall be exposed to the external humid environmental without Gelcoate
surface to avoid water ingress into the laminate. If Pultruded sections are used, these
shall be fully encapsulated on compression moulded or contact moulded GRP laminates
with proper Gelocated surface exposed to atmosphere.
H. All exposed surfaces shall be smooth and true to form wherever applicable.
I.
Colour shall be as instructed by the Engineer.
J.
Contact Moulded Flat and Curved Monolithic Panels:

1. Minimum Glass content in structural layer shall be 55% with multiaxial Glass, woven
glass, CSM glass. For Resin rich corrosion barrier layer with C-Glass surface veil, the
resin content shall be minimum 90%.
2. Resin used for lamination shall be vinylester based Bisphenol A Epoxy and fire
retardency to class 1 as per BS 476 Part 1.
3. Mechanical Properties
Property
Test Method
Flexural Strength
Tensile Strength
ASTM D790
ASTM 368
Vol 3, Section3
Page M-7 of 25
Minimum
Requirement
300MPa
200 Mpa
Tensile Modulus
Flexural Modulus
Izod Impact Strength
Specifications
ASTM
ASTM
ASTM
ASTM
638
D695
D790
D256
14 GPa
150 MPa
13 GPa
12 J/cm
K. Compression Moulded Profiles:

1.
2.
3.
4.
L.
Minimum glass content shall be 55%.

Compression moulded with continuous woven strand of ECR type
reinforcing fiberglass together with vinylester formed at a minimum pressure
or 2 bars to minimize porosity.
Cure temperature shall be in excess of 93C to assure proper adhesion of
resin to glass fiber.
Mechanical Properties:
Property
Test Method
Minimum Requirement
Flexural Strength
Flexural Modulus
Izod Impact Strength
ASTM
ASTM
ASTM
ASTM
245 MPa at 65C

213 MPa at 22C
18 GPa at 65C
40 Nm at 22C
D790
D695
D790
D256
Pultruded Profiles
1.
2.
3.
Minimum glass content shall be 70% continuous.

ECR glass fiber reinforcements in continuous woven strands.
Mechanical Properties.
Property
Test Method
Tensile Strength:
Longitudinal direction
Transverse direction
ASTM D638
Compressive Strength:
ASTM D695
Flexural Strength:
ASTM D790
Shear Strength:
ASTM D2344
Tensile Modulus:
ASTM D638
Compressive Modulus:
ASTM D695
Flexural Modulus:
ASTM D790
Vol 3, Section3
Page M-8 of 25
Minimum Requirement
200 MPa
48 MPa
200 MPa
100 Mpa
200 MPa
69 MPa
30 MPa
30 MPa
17 GPa
6 GPa
17 GPa
7 GPa
11 GPa
6 GPa
Specifications
Property
Test Method
Shear Modulus:
ASTM D2344
Density
Water absorption (24 hr immersion)
Barcol hardness
Coefficient of thermal expansion
Thermal conductivity
ASTM D792
ASTM D570
ASTM D2583
ASTM D696
ASTM C177
Minimum Requirement
3 GPa
3 GPa
1.66 1.94 g/cm3
Max 0.60%
45
8 x 10-6 mm/mm/C
0.5 W/mK
M. Laminating Procedures
The laminating procedures requiring approval shall include the following.
a. General. Laminates of a basically similar construction to that proposed for the cover
wall barrel and the domed web ends of the cover to be fabricated shall be tested in
accordance with the specified standards.
b. Flange web construction. Samples of the manufacturers standards forms of such
details shall be laminated and their construction demonstrated as satisfactory by
visual inspection of the finished sample, followed by inspection of cross sections
taken through the flange/ web on two planes at right angles to each other.
For each type of construction, there shall be at least one test piece each to represent
details up to 50 mm nominal bore and of greater than 50 mm nominal bore.
c. Cover shell. Samples of the manufacturers standard forms shall be laminated and
their construction demonstrated as satisfactory by visual inspection of the finished
sample, followed by inspection of cross sections taken through the shell on two
planes at right angles to each other.
For each type of construction, there shall be at least one test piece each to represent
details up to 50mm nominal bore and of greater than 50mm nominal bore.
d. Special forms of construction. Any special form of construction shall be demonstrated
as giving satisfactory results by visual inspection of the finished sample and by
examination of sections cut through the critical areas of the construction.
e. Butt jointing. These shall be demonstrated as satisfactory by visual inspection of a
finished mock up and of three sections cut through the sample on planes normal to
that of the joints.
N. Production samples for mechanical tests on laminates
General
Samples from waste areas such as cut-outs for branch openings shall be made available
for inspection and appropriate testing, provided that they are typical of the laminate
represented.
Note: In the majority of cases such samples will not be flat and therefore there may be
difficulty in carrying out all the mechanical tests which could normally be done on a flat
sample. The properties of laminates are determined to a considerable extent by the type
of glass reinforcement, the type of resin and the glass resin ratio and what is required
from production samples is a clear indication that the properties of the laminate produced
match the properties used in design. This information may be obtained by measuring the
thickness of the laminate, burning off the resin to obtain the glass content, and examining
the glass which remains to determine the type of glass and the number of layers. If the
Vol 3, Section3
Page M-9 of 25
Specifications
lap shear strength of the laminate is also determined, there shall be enough information to
provide an adequate guide to the mechanical properties of the laminate.
As an alternative to using cut-outs for test samples, specimen laminated shall be prepared
by the operators working on the production laminate. These specimens shall be laid up at
the same time with the same materials and in the same manner as the item they
represent and cured under the same conditions as the main laminate.
Testing
The following tests shall be carried out on all samples to verify laminate construction and
determine typical properties as given in Table 7-26.
a)
b)
c)
d)
e)
f)
g)
h)
visual examination of a prepared cross section of the cut-out or prepared

samples;
thickness of the laminate
lap shear strength of laminate as specified in relevant standard.
glass content (BS 2782: Method 1002);
number of layers of glass and the type;
acetone test (see B.18) of BS 4994
Barcol hardness of the inner and outer surfaces (see B.14); of BS 4994; the
minimum requirement shall be at least 90% of the hardness value published
by the resin manufacturer for the particular system.
Glass Transition temperature in accordance with ASTM with D3418:99
When vinylester resins are used for the fabrication of covers and if following the
Barcol test there is any doubt about the state of cure of the laminate, a residual
styrene test shall be carried out. The residual styrene content of the laminate shall
not exceed 2% by mass of the resin content of the sample or a glass transition
temperature test, shall be carried out on a cut out cover production sample and the
Tg value observed shall not be lower than 80C. relevant graph showing the Tg
value achieved shall be provided for engineers verification.
The following tests shall be carried out when it is required to verify the mechanical
properties of the laminate:
1)
2)
3)
M17
ultimate tensile unit strength (see B.6); of Bs 4994

unit modulus (see B.7); BS 4994
ultimate compressive unit strength (see B.8); BS 4994
GRP DOME AND FLAT SHEET COVERS
GRP dome or flat covers shall be provided for all the relevant tanks as shown on the
Drawings.
All covers shall be self-supporting from their periphery, and shall be pre-shaped segments
or flat having various surface finish specified with gasket over lapping and screwed.
Design Requirements
1. The design life shall be 25 years. The design and installation for all GRP covers shall
incorporate provisions for thermal expansion and contraction over a range of ambient
conditions specified.
2. Design safety factor of 4 and limiting states as per EUROCOMP Code for stress and
deflection limits shall be applied to all load combinations.
3. Complete structural design calculation and shop drawings shall be submitted for
Engineers approval.
Vol 3, Section3
Page M-10 of 25
M18
Specifications
GRP COVERS DESCRIPTIVE REQUIREMENT
Type A
Cover
Self
supporting
Type B Self supporting Cover
Type C Self Supporting

Cover Trafficable
Live Load = 2.5 kN/m2

Features = Curved

Features = Non-Slip Flat Covers
Wind Load = 160 kM/h
Wind Load = 160 km/h
Internal Vacuum load: (- 0.5

kN/m2)
Internal Vacuum load: (-0.5

kN/m2)
Internal Pressure : 0.5

kN/m2
Panel Size : As designed by

the manufacturer to suit the
structure.

Features = Flat Covers
pedestrian trafficable
with chequer plate
pattern & Load bearing
anticipated Super
imposed Load from
mechanical Items = 7
kN/m2
Wind Load = 160 kM/h
Internal Vacuum load:

(-0.5 kN/m2)
Internal Pressure : 0.5 kN/m2
Internal Pressure : 0.5

kN/m2
Panel size: As designed by the

manufacturer to suit the
structure.
Panel size : As designed

by the manufacturer to
suit the structure.
Joints between Panels:

Neoprene or EPDM + S.S
Screws
Joints between Panels

Screws
Joint Between Panel

Screws
GRP Beams : If Required,

integrally moulded with
Panels
Surfaces finish external:
Coloured with U.V Resistant
GEL Coat
GRP Beams : If required,

integrally moulded with Panels

Coloured with U.V Resistant
GEL Coat
GRP Beams = If required

integrally moulded with
Panels
Coloured with U.V
Resistant GEL Coat
Support System =
Structure production
from moulds
Support System =
Structure production
from moulds
GRP Beams = If
Required
All Fitting and Fixing : SS

316L Grade
All Fitting & Fixing :

SS 316L Grade
All Fitting & Fixing :

SS 316L Grade
Access hatches required

section as shown in the
drawings
Access hatches required

section as shown in the
drawings
Access hatches
required section as
shown in the drawings
Gas tight Sealing required

with Neoprene + Sealant
Gas tight Sealing required

with Neoprene + Sealant
Fixing & Hardware

(a) To be set into concrete
with an Epoxy
outside the seal
(b) Hinges, latches,
handles, bolts etc
Vol 3, Section3
Fixing & Hardware

with an Epoxy
outside the seal
handles, bolts etc
Page M-11 of 25
Gas tight Sealing

required with Neoprene
+ Sealant
Fixing & Hardware
with an Epoxy
outside the seal
handles, bolts etc
Type A
Cover
Self
supporting
Specifications
Type B Self supporting Cover
shall be SS .316 grade
Light No Light should

penetrate through the
covers
Fresh air Inlet Required
Foul air Outlet Required
Type C Self Supporting

Cover Trafficable
Light No Light should pass

through the covers

Foul air Outlet Required
Light No Light should

pass through the covers

Foul air Outlet
Required
Lifting handles As a safety feature, all lifting handles, and fixing both shall be recessed as per
standard design.
Rain Water Outlet Appropriate rain water runoff is also to be considered, with water sealed U
trap drain to the inside of the tanks.
Note: Selection of Type A, B and C covers shall be based on specific area operation and
maintenance requirement in addition to the covers design limitations and requires prior
approval from Engineer.
M19
GRP DOME AND FLAT SHEET AESTHETIC COVERS
GRP dome or flat aesthetic covers shall be provided for all the process tanks other than
the tanks with odour control covers.
GRP dome or flat aesthetic covers shall be similar to the odour control covers however
the purpose of these covers is to enhance the plants aesthetic appearence.
Structural design of aesthetic covers shall be similar to the odour covers.
Gas tight sealing is not required for aesthetic covers.
Adequate air inlet and outlets shall be provided to maintain the atmospheric pressure
condition inside the covers.
All covers shall be self-supporting from their periphery, and shall be pre-shaped segments
or flat having various surface finish specified with gasket over lapping and screwed.
M20
TECHNICAL SCHEDULE
M20.1
Technical Schedule Covers

Individual Schedules to be completed for each set of covers offered.
M20.2
Technical Details
The Contractor shall complete this Schedule giving manufacturers name and other details
as required.
All items supplied and/or installed must comply with the requirements of the specification.
Item
Offered
1. Covers
1.1 Place of Manufacture
1.2 Manufacturer
1.3 Type
Vol 3, Section3
Page M-12 of 25
1.4
1.5
1.6
No. Off
Design Loading
Size Type A,B,C
Type
Type
Type
Type
Type
Type
1.7
Weight per cover
1.8
1.9
1.10
1.11
Maximum span
Maximum deflection (mm)
Deflection /Span ratio
Surface finish and UV
resistance
Fixing details
Colour
1.12
1.13
1.14
1.15
M21
Specifications
A
B
C
A
B
C
GRP LAMINATION
1.
Laminate Sequence
a.
b.
c.
d.
e.
f.
Interior surface shall be resin rich corrosion barrier consisting of 0.50 mm

thick with two layers of C glass veil at 10% glass content and 90% resin.
Surfacing veil shall be supported by 2.0 mm thickness barrier layer of woven
roving or chopped strand ECR glass and vinyl ester resin. (ECR glass 2040% & resin 60-80%)
Structure shall consist of alternating layers of ECR type multiaxial Glass or
woven roving and chopped strand glass saturated with approved fire
retardant Bisphenol A Vinylester resin to complete the required thickness.
Total laminate thickness shall in no case be less than the design allowable
safety factor of 4 or as per limiting states specified by EUROCOMP code for
design of Composite Structures.
Exterior surface shall be an exterior grade vinylester gel coat with ultra violet
protection, fire resistant and pigmented cosmetic coating.
No filler shall be permitted in the cover wall structure.
1.
2.
3.
g.
M22
A paraffinated wax additive shall be used in conjunction with gel coat

to eliminate the air inhibition (minimum 450 microns thick)
Colour to be yellow or white unless otherwise approved by the
Engineer.
Coloured samples to be proposed for approval.
Cut edges or drilled holes must be deburred and resin or gel coat sealed.
FEATURES
1.
GRP Covers shall incorporate the following:

a.
b.
c.
Vol 3, Section3
Fiberglass compression ring with cover. .

Integral fiberglass tension ring.
Internally moulded GRP ribs, beams and stiffeners. Any core used should be
non metallic and fully encapsulated inside GRP laminate.
Page M-13 of 25
d.
e.
f.
g.
h.
M22.1
Lifting lugs suitable for handling, installing and removing each segment are to
be embedded at balance points in each segment.
Drip lip shall be integrally moulded near the periphery of each panel segment
to prevent condensate from seeping onto tank wall exterior.
Alternatively provide separate FRP wall cover filled with an inner and other
trickling edge.
Gasketing for all joints and back flange of dome roof segments shall be
neoprene.
All assembly fastners and anchors shall be Grade 316L stainless steel.
Assembly
1.
2.
3.
4.
M22.2
Specifications
Fiberglass cutouts from dome segments shall be identified and shipped with
cover.
Cut outs shall be used by the Engineer to determine proper thickness, glass
content and laminate sequence.
Assembly of dome segments shall be such as to allow all bolting to be
performed from exterior of dome roof.
The assembled segments shall be bolted through the radial joints at a
maximum of 1.5m centres during erection to render the cover a unified dome
structure.
Non-Return Valves
Non-Return valves will be constructed from SS316 stem with fiberglass gate and SS handle
and locking mechanism.
Non-Return valves shall be located where they
can easily be operated from a
walkway/ground level. Where it is unavailable dampers may be located in overhead duct runs
provided a means of operation from ground level is developed by the contractor. Use of chains
to address this requirement shall not be acceptable.
M22.3
Pressure Rating
The covers shall be rated for a minimum pressure of 0.5kPa (g). Structural design shall also
consider loading scenarios where potential negative pressures due to blockage of the air
inflow points occurs.
M22.4
Structural Loading for Covers

Covers shall be designed with safety of all personnel during manufacture, transportation
installation, commissioning, operation and decommissioning in mind. The Subcontractor shall
demonstrate during detailed design that each aspect has been considered. The contractor
shall outline in their proposal how this shall be agreed.
M22.5
Cover Structural Supports

The contractor shall design and supply all necessary supports for the covers if necessary. Any
support under the cover shall be either SS316 or Fiberglass. The ultimate support for the
covers shall be the tank walls. Contractor shall supply reaction force details with magnitude
and directions for all reactions imposed by covers onto supporting tank structure. Cover shall
be fabricated only after approval of these reactions report by the Engineer.
Vol 3, Section3
Page M-14 of 25
M22.6
Specifications
Temperature ratings
M22.7
The ambient temperature at site may vary between 10 - 50 Degrees Celsius in the shade.
Surface temperatures are likely to exceed this and should be accounted for in the design.
The covers shall be exposed to direct sunlight. Incident solar radiation loadings shall be
determined by the contractor in accordance with geographical location.
Wind Loadings
The maximum wind velocity shall be considered based on Bahrain meteorological data.
M22.8
Gaskets and Sealants

All gaskets, regardless of where they are used, should conform to the following:
Resistant to UV
If self-adhesive strip is applied, this should maintain its adhesive properties for the design
life (25 years)
Neoprene (or equivalent) Gaskets should be easily compressible, air tight and return to
their original shape when load is removed.
Gaskets/sealant should be able to be removed and replaced it they become damaged.
Instructions for application of gaskets should be provided in the installation and
maintenance manual;
Design life of gaskets should match that of the covers (25 years) or a replacement
schedule and spares should be provided.
Any non-conformances with the above requirements shall be listed in detail in Technical
Schedule of cover.
M22.9
Fixing, handles and associated fittings
M22.10
Fixings should be suitable for under cover use (i.e. be able to withstand corrosion) and
the use of dissimilar metals which may lead to galvanic corrosion should be avoided.
Design life of all fixings should match that of the covers and ducts (25 years)
Expansion, joints, cap plates, sliding joints etc. should be constructed of materials which
do not deteriorate over time.
Access, Inspection Covers and Hatches
The contractor shall also be required to supply and install access hatches in the location as
required.
M22.11
M22.12
Chemical Resistance
The Contractor shall design for peak gaseous H2S of 200ppm and shall advise the
chemical resistance of the covers to condensate of low pH = 1.
The cover production samples shall be subjected to 100 days acid immersion test as
specified in Table 7-6 and comply the requirements specified.
The Barcol hardness at cover internal surface after the acid test shall not be less than 35.
Personnel Protection
Vol 3, Section3
Page M-15 of 25
Specifications
Equipment shall be guarded in accordance with the requirements of the Dubai Health and
Safety Regulations and Guidelines.
Guards shall be strong enough to withstand personnel and other loads during maintenance
and inspection activities.
Appropriate workplace health and safety warning signs complying with relevant Standards
shall be fastened to all equipment.
M22.13
Name plates
A nameplate manufactured from grade 316 stainless steel shall be affixed to the cover by
means of grade 316 stainless steel screws, stamped or engraved with the following
information:
Manufacturers name:
Model/type description:
Asset number:
Serial number:
Total weight:
M22.14
Fastenings and Miscellaneous
All nuts, bolts, washers and other fastening systems used for covers and ducts shall be in
grade 316 stainless steel. Any electrometric materials shall be in Nitrile rubber or EPDM, and
consistent with the operating conditions, long-term exposure to direct sunlight and the
required equipment design life. The holding down bolts shall be in stainless steel grade 316.
M22.15
Painting
Painting of components shall be in accordance with relevant systems of Standard

Specification. Manufacturers standard painting systems shall be considered suitable where
they are equal to or better than the provisions of the Standard Specifications. Brief details of
the painting system offered shall be entered into the Technical Schedules with its long
performance test data.
M23
QUALITY CONTROL AND PERFORMANCE TESTS
M23.1
Quality Control tests and records (To be witnessed by the Engineer)
Material records
Record of resin type and quantity
Record of glass type and quantity
Record of personnel on the fabrication
Record of layers and type of glass
Vol 3, Section3
Page M-16 of 25
Type A
Cover
X
X
X
X
Type B
Cover
X
X
X
X
Type C
Cover
X
X
X
X
Specifications
Record of cure system

Record of post cure (when used)
Quality Control Tests
Spark test on GRP Covers Prior to apply Gelcoat
Adequate documented information on the
mechanical properties of the particular
resin/glass laminate to be provided. If this is
not available production test samples to be
tested as required.
A production test coupon to be laminated with
the cover obtained from cut-outs. The coupons
to be tested, as follows.
Ultimate tensile unit strength (BS 2782
: method 1003)
Unit modulus (BS 2782 : method 1003)
Lap shear strength Bs 994 : 1987 B.9
Visual examination of cut-outs
Ash test on cut outs (L.O.I)
Thickness measurementa
Acetone test (polyester resin) BS4994 : 1987
(B.18)
Barcol hardness measurement BS 4994 : B14
Residual styrene (polyester resin) BS 4994 :
B17
Acid immersion test in 10% concentrated sulphate
acid @ 50C in accordance with ASTM C581.
Quality Control Records
Hardness test (Barcol)
Thickness measurement
Nameplate details
Documentation requirements
Pressure /vac/hydrostatic head
Ultimate tensile unit strength
Unit modulus
Lap shear strength
Ash test on cut-out
Independent inspection
a
To verify minimum design thickness. Particular
attention is to be paid to points of discontinuity, at
end attachments.
Note: all Q.C tests are to be conducted prior to
pigmented coating external
M23.2
Type A
Cover
X
X
Type B
Cover
X
X
Type C
Cover
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Examination after testing

On completion of load and vacuum tests the cover shall be inspected internally and externally.
Any indication of cracking, resin crazing or excessive strain shall be cause for failing the test.
The cover linings shall again be spark tested after completion of testing; any evidence of
cracks or weld defects of any necessary repairs the tests shall be repeated.
Vol 3, Section3
Page M-17 of 25
M23.3
Specifications
Information and requirements to be agreed and to be documented prior to

Design and manufacture the covers.
a)
Process conditions.
1)
2)
3)
4)
5)
b)
Site Conditions
1)
2)
3)
4)
5)
c)
Materials to be handled (names, concentrations and relative densities)

including likely impurities or contaminates.
Design pressure (or vacuum) including test requirements and design
temperature.
Operating pressure (or vacuum) and temperature.
Mode of operation
Any abrasion or erosion problems which may be encountered.
Nature of ambient atmosphere including any extremes of temperature.

Superimposed loads, e.g. wind, snow and associated pipework
Loads imposed by personnel during erection and operation
Expected loading, e.g. traffic if any
Seismic loading
Special Conditions
1)
d)
e)
f)
g)
h)
Formation of acidic droplets on interior surface of covers during condensation

of H2s gas (acid rain)
2)
Vibration due to adjacent plant
3)
Agitation details within the covered tank
4)
Danger of mechanical impact an damage
5)
Loads imposed during transport
6)
Finish, e.g. if fire-resisting
Details of any special or additional tests or inspection required and where these are
to be carried out
Exemption to apply a pigmented coating to the covers before final inspection
Facilities for testing
Name of Inspecting Authority, if applicable
Requirements for packaging, despatch and installation
Nomenclature, symbols and units
Term
Ultimate
tensile
unit
strength
(UTUS)
Definition
The
strength
of
a
reinforcement
type,
expressed as force per unit
width, per unit mass or
reinforcement
Derivation
Obtained from the
fracture load of a
laminate of known
construction, in a
tensile test
Load-limited
allowable
loading
The load permitted to be

applied to a reinforcement
type per unit width mass of
reinforcement, not taking
strain into account.
Determined
by
dividing the ultimate
tensile unit strength
by the design factor,
k
uL
N/mm per
kg/m2 glass

Determined
by
multiplying the unit
uS
N/mm per
kg/m2 glass
unit
Strain
limited
allowable
unit
Vol 3, Section3
Page M-18 of 25
Symbol
u
Unit
N/mm per
kg/m2 glass
Term
loading
Design
loading
design
loading)
unit
(layer
unit
Unit modulus
Overall
modulus
unit
Specifications
Definition
type per unit width, per unit
mass of reinforcement,
taking only strain into
account
type per unit width per unit
mass of reinforcement, for
the
cover
under
consideration.
The ratio of the load per
unit
width
to
the
corresponding direct strain,
in a loaded tensile test
specimen per unit mass of
a single glass reinforcement
type
The calculated ratio of the
load per unit width to the
corresponding direct strain
in full laminate of single or
multiple
glass
reinforcement type.
Design Strength
(laminate design
unit loading)
The load carrying capacity

of a laminate, expressed as
force per unit width.
Unit load
The force per unit width

carried by a laminate
resulting from pressure or
other loads applied to the
cover.
M23.4
Derivation
modulus, X, by the
allowable strain for
the
particular
laminate layer
Whichever is the
smaller or u S or u L at
the design strain, d
Symbol
Unit
uZ
N/mm per
kg/m2 glass
Obtained from the

measured load and
strain in a tensile test
N/mm per
kg/m2 glass
Obtained
from a
summation of the
products
of
unit
modulus and mass of
each
glass
reinforcement type in
a laminate
Obtained
by
summing the load
carrying capacities of
all the layers in the
laminate (u, m, n,
terms).
The
subscripts indicate a
main (U LAM ) or an
overlay
(U OVL )
laminate.
Obtained from the
appropriate
design
calculations for the
portion calculations
for the portion of
cover
under
consideration.
X LAM (may
be
identified
by further
subscript)
N/mm
U LAM
U OVL
N/mm
width
N/mm
width
Requirements to be agreed and documented prior to design and manufacturer

the covers.
The following items shall be agreed between the Inspecting Authority, where appropriate
and the manufacturer shall be fully documented. Both the definitive requirements specified
throughout the standard and the documented items shall be satisfied before a claim of
compliance with this standard can made and verified.
(a)
(b)
(c)
Resin system to be used shall be agreed between the engineer and the manufacturer
Use of reinforcing materials other than those complying with BS 3396,BS 3691 or
3749, as appropriate.
Mechanical properties of material as specified in the attached table
Vol 3, Section3
Page M-19 of 25
(d)
(e)
Specifications
Type of chemical barrier to be used internal & UV protection coating external

Design details
1)
2)
3)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
M23.5
Essential dimensions, including tolerances preferably on a drawing.

Design calculations with references.
Nominal thickness, including tolerances of corrosion-resistant lining gelcoat
which does not contribute to strength
4)
Form(s) of reinforcement including type, number and arrangement of
individual layers.
5)
Form(s) of local stiffening, where used.
6)
Bolting and flange materials and details if required.
7)
Gasket materials and details
8)
Details of external.
9)
Requirements for access and inspection openings
Where the design incorporates reinforcement with directional properties, the
orientation of the fibers
Supports
Any modification to the approved design
Where site fabrication is employed, the special procedures to be adopted.
Repair of laminate defects and method of repair
Arrangements for access to manufacturers premises
The provision of special test laminates and the extent of mechanical testing to be
carried out either on cut-outs or prepared laminates.
Minimum categories & Type of Covers for Design basis consideration

Type A
Cover
Contentsa
Toxic gas from sewage
Highly corrosive
Corrosive
Flammable
Chemical compatibility of GRP with process
Type B
Cover
Type C
Cover
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
T 60 C
Design pressure and/or vacuum as specified
Cover units shape & sizes
X
X
X
X
X
X
Known long-term compatibility based on service

experience
Compatibility based on related performance data
Only specimen data (dip coupons)available
Design temperature, T
Geometry and supports

Flat bottom support
Any other, e.g. legs, skirts, saddles, rings and
frames
Other criteria
If item is critical to safety
Vol 3, Section3
Page M-20 of 25
Specifications
Description of contents classification
Toxic
The contents could present a significant risk to health of persons exposed
Highly corrosive The contents could severely burn, blind, disfigure or maim an individual.
Corrosive
The contents could cause damage to the skin or eye.
Flammable
The contents have a flash point equal to or less than 55C.
M23.6
Heat distortion temperature of resin

Design documentation and shop drawing requirements from the manufacturers
Type A
Cover
Design Calculations
a)
b)
Type B
Cover
Type C
Cover
Independent approval required

Calculations to cover
1)
Hydrostatic loadings
2)
Applied pressure
3)
Applied vacuum
4)
Wind loads
5)
Lifting arrangements
6)
Supporting
7)
Seismic loading (if applicable)
Drawing requirements
Covers general arrangement
Full fabrication drawings showing method of
manufacturer
Installation procedure.
M23.7
Smoke Testing
Once installed all covers and ducts shall be smoke tested to check for leaks and to ensure
airtight seal has been accomplished. Any leaks shall be repaired or sealed and the smoke test
carried out again to prove.
M23.8
Works Testing
Load testing of covers shall be carried out for at least one type of each cover produced.
M23.9
Inspection and Performance Testing
M23.9.1 Site Testing

Pre-commissioning shall include Site Performance Proving Tests to demonstrate the
performance and mechanical integrity of the covers.
Vol 3, Section3
Page M-21 of 25
Specifications
Pre-commissioning shall not commence until all documentation (including Operation and
Maintenance Manuals) required to be supplied under the Contract have been approved by the
Contractor.
The Contractor shall provide all test instruments and tools necessary to carry out such tests.
M23.9.2 Installation of GRP Dome & Flat Covers
A.
B.
Shall be in accordance with the manufacturers installation procedure.

The cover system shall be so designed as to achieve minimum site activity. All covers
shall be factory produced. Site assembly should be limited to inter panel joints and
fixing to supporting tank structure. Only fittings shall be assembled at site. No cover
fabrication at site shall be allowed without prior approval of the Engineer in
exceptional situation.
M24
PACKING AND DELIVERY
M24.1
Labels and Markings

All items shall be individually labeled prior to packing. Labels shall include the following
information:
Contract Number
Item / Part Number
Marking
Applicable standard
Manufactures name
Design Load
Medium test pressure & working temperature
Year in which cover was completed
Resin & glass reference
The certifying work of the inspecting
authority
Where items are manufactured for specific mating component parts, they shall all bear
individual identification numbers and reference to the mating part identification numbers.
M24.2
Packing
All items shall be individually packaged for long term storage in a tropical environment,
withstand the loads imposed during transportation. Goods shall be packed in wooden
crates with weatherproofing inside to prevent damage or discolouration by exposure to the
elements and potentially a lengthy storage period. Goods received in damaged packaging
or crating may be returned to the contractor for re-manufacture and/or re-inspection and
testing at the contractors cost.
Crates shall be clearly marked in black stencilled lettering with the following information:
Consignees name and delivery address as given in the subcontract.
Consignors name and contact point.
Contract number.
Vol 3, Section3
Page M-22 of 25
M25
Specifications
DOCUMENTATION SUBMITTAL
The following information shall be supplied.
Preliminary individual dimensioned general arrangement drawings of all equipment, and

covers to be supplied under this sub-contract. These shall show all cover dimensions etc.
A priced Recommended Spares list.
Completed Technical Schedules
A detailed list of any deviations or omissions. Items not specified in this list shall be
deemed included and comply with this specification.
M25.1
Detailed Design
Drawings and data shall be submitted in stages for review as follows:
M25.1.1 Conceptual (Preliminary) Drawings and Data
General arrangement and set-out drawings for the complete facilities showing overall
dimensions, weights, hold down bolt layouts. Sufficient detail shall be shown regarding
location of hatches, duct supports etc. to allow detailed design of other interfaces (e.g.
duct support plinths) to be undertaken.
Report on reactions imposed by covers onto the supporting tank structures for
consideration by the engineers in design of tank structures.
M25.1.2 Approved For Construction Drawings and Data
Detailed covers layout drawings, equipment schedules, calculations, testing &

commissioning schedules, full load rating Equipment drawings shall show key dimensions,
plans and elevations, parts lists, materials of construction.
Structural calculations report (with proper composites laminate design with micro & macro
mechanical analysis) with material test certificates ( from National Physical Laboratory UK
or equivalent Internationally reputed laboratory) supporting the material mechanical
properties used in calculations.
All drawings shall be submitted in Auto CAD 2000.
Certified drawings of all proprietary items of mechanical equipment.
Draft maintenance procedures.
The Engineers review is only for acceptance of general conceptual design and for suitability in
terms of dimensional constraints, e.g. overall arrangement, location of access, etc. it shall not
in any way diminish the responsibility of the Contractor to comply with any of the specified
requirements included for the equipment performance. The Engineer may elect to transmit
electronic copies of accepted or commented drawings back to the Contractor or advise by
correspondence in lieu of returning hardcopy drawings.
Following receipt of accepted drawings, the Contractor shall resubmit each drawing to the
Engineer, endorsed For Construction.
Vol 3, Section3
Page M-23 of 25
M26
Specifications
AS CONSTRUCTED DRAWINGS
During all stages of the work, the subcontractor shall maintain as constructed records on
site. Records shall be available for inspection by the Engineer at any time.
Further to the requirements of the General Conditions of Contract regarding the Certificate
of Practical Completion, the contractor shall be required to provide As Constructed
Drawings.
As constructed information shall be amended on AutoCAD (R 2000) drawing files of the

contract drawings. As-constructed amendments shall be identified by clouding on the
drawings. Drafting standards shall be equal to the standard of the base drawings.
As constructed drawings shall be marked As Constructed, signed and certified by the

Contractor as being a true representation of the works as constructed.
M27
OPERATION AND MAINTENANCE MANUAL

The contractor will be required to provide operation and maintenance manuals for the
equipment provided in accordance with the Specification.
Copies of the Operation and Maintenance Manuals conforming to this Specification shall be
provided by the contractor. The draft copies shall be submitted in accordance with the
Schedule.
The airflow balancing section of the O& M manual format shall be agreed with the
Engineer prior to production. As a minimum the airflow balancing O&M shall set out:
A general description of the procedure and equipment
The purpose of each component of the equipment
Hydraulic (or other measure) of the capacity of component of the process / equipment.
Mechanical, Electrical and control components of the equipment
Operational philosophy and control of the ductwork system
Troubleshooting guides
Maintenance requirements
M28
TESTING AND COMMISSIONING

Testing and commissioning shall include, but not be restricted to:
Design acceptance operation to demonstrate that all equipment and systems e.g. can be
successfully and reliably operated under working conditions.
Satisfactory operation will be defined as meeting the following performance requirements:
Submission of final Operation and Maintenance manuals.
Vol 3, Section3
Page M-24 of 25
Specifications
Submission of any outstanding Work as Executed (WAE) records for all work under the
contract, including re-submission of any WAE drawings that may require amendment as a
result of changes during the commissioning process.
Conditions operation of the whole of the works for seven (7) consecutive days without any
faults. During this period, if any failure occurs, the 7 day test shall recommence for a
further 7 days, after the fault has been rectified.
In the event that the equipment fails to meet the guaranteed performance the Contractor
shall carry out whatever remedial and ameliorative measures are necessary to achieve the
guaranteed performance at his own cost. The certificate of practical completion will not be
issued and final payment will be withheld until such time that all performance related criteria
have been met or exceeded.
The contractor shall produce all necessary documentation records as verification that
installation testing and commissioning has been successfully completed. An up to date copy of
developing test records shall be present on site at all times during construction and
commissioning for information and review.
Should the plant fail any test, the manufacturer Contractor shall take any actions deemed
necessary to correct the failure and repeat the test.
M29
TRAINING
The Contractor shall provide a minimum of four (4) hours of competency based training and
briefing for Clients operations and plant maintenance staff. This shall be repeated in two
separate sessions to fit in with work arrangements.
The training shall be performed by experienced mechanical, personnel who are familiar with
the installation. Training shall consist of, but not necessarily be limited to, the following.
(a) Briefing on the equipment; / installation.
(b) Servicing and maintenance requirements for the equipment;
(c) Demonstration of any special servicing or maintenance procedures;
M30
MANUFACTURERS PRE-QUALIFICATION
The manufacturer shall have minimum 10years experience in manufacturing similar covers
for STP and must submit the following documentations for the Engineers review.
a)
b)
c)
d)
List of references for the last 10 years.

Certificate of completion from 5 clients.
Test reports carriedout by independent authority on preview projects done for the
last 10 years.
The design calculation adopted for the similar covers installed during the last 10
years.
Vol 3, Section3
Page M-25 of 25
Specifications
TABLE OF CONTENTS
Page No.
SECTION N PILE FOUNDATION
N1
GENERAL DESCRIPTION
N2
MATERIALS
N3
PILING METHOD
N4
CONCRETE FOR PILES
N5
REINFORCEMENT FOR PILES
N6
BORING FOR PILES
N7
PLACING CONCRETE
N8
EXTRACTION OF CASING
Vol 3, Section3
Page i of i
Specifications
SECTION N PILE FOUNDATION

N1
GENERAL DESCRIPTION
Pile foundations if required shall be based on the detailed soil investigation carried out by
Contractor. Contractor can refer the Ministry of Housings ground investigation survey
results as a reference to understand the requirement. Pile depth shall be designed
considering the existing underground aquifer at site.
All pile foundation shall be bored cast-in-place concrete, all shall be constructed as per
structural foundation requirement as per approved drawings and in compliance with BS
8004 requirements.
N2
MATERIALS
N3
PILING METHOD
N4
Concrete for piles shall be class 60 (as per Table D7 of Section D- Concrete
Works, Volume 2, Section 3- Civil Specifications) and shall be in accordance
with BS 8110 requirements.
The concrete shall have sufficient workability to enable it to be placed and compacted
by the methods used in forming the Piles.
REINFORCEMENT FOR PILES
N6
The Contractor shall supply for approval all relevant details of the method of piling
and the plant he proposes to use.
The Contractor shall inform the Engineer each day of the intended program of piling
for the following day and shall give adequate notice of his intention to work outside
normal hours and public holidays.
The Contractor shall submit to the Engineer his proposed sequence and timing for
boring piles, having regard to the avoidance of damage to adjacent piles.
CONCRETE FOR PILES
N5
The materials for the manufacture of the reinforced concrete shall be and in
accordance to with BS 8110.
The temporary casing shall be cylindrical and shall be of sufficient strength to maintain
shape and location during boring and placement of concrete. The casings shall be
sufficiently watertight to exclude ground water during placing of concrete.
In case drilling mud is required, bentonite clay shall be used for the purpose.
The reinforcement for the piles to be high tensile deformed steel bars and shall
conform to the requirement of BS 4449.
Reinforcement in the form of a cage shall be assembled with additional support such
as spreader forks and lacing, necessary to form a cage which can be lifted and placed
without permanent distortion.
BORING FOR PILES
Prior to boring the Contractor shall the casing position for each pile during and
immediately after placing the casing, and agree it with the Engineer.
Casing shall be free from significant distortion. They shall be uniform cross-section
throughout each continuous length. During concreting they shall be free from internal
Vol 3, Section3
Page N-1 of 2
N7
projections and encrusted concrete which might adversely affect the proper formation
or piles.
Where boring takes place through unstable water bearing strata, the process of
excavation and the depth of casing employed shall be such that soil from outside the
area of the pile is not drawn into the pile section and cavities are not created outside
the casing as it is advanced.
PLACING CONCRETE
N8
Specifications
The method of placing and workability of the concrete shall be such that a continuous
monolithic concrete shaft of the full cross- section is formed.
The concrete shall be placed without such interruption as would allow the previously
placed batch to have hardened. The method of placing shall be approves.
The contractor shall take all precautions n the design of the mix and placing of
concrete to avoid arching of the concrete in casing. No soil liquid or other foreign
matter which would adversely affect the performance of the piles shall be permitted
to contaminate the concrete.
Internal vibrators shall not be used to compact concrete.
EXTRACTION OF CASING
Casing shall be extracted while the concrete within them remains sufficiently workable
to ensure that the concrete is not lifted. During extraction the motion of the casing
shall be maintained in an axial direction relative to the pile.
When the casing is being extracted, a sufficient quantity of concrete shall be
maintained within it to ensure that pressure from external, drilling fluid or soil is
exceeded and that the pile is neither reduced in section nor contaminated.
The concrete level within a casing shall be topped up where necessary during the
course of casing extraction in such a way that the case of the casing is always below
the concrete surface under the casting of the piles has been completed.
Vol 3, Section3
Page N-2 of 2
Specifications
SECTION S - SCHEDULE OF APPROVED STANDARDS & GUIDANCE PUBLICATIONS

General Introduction
Except where otherwise specified, all materials and workmanship shall conform to the requirements of
the latest editions of the relevant Bahrain, European, and International Standards and Codes of
Practice and any other Standards which are referred to in the Specification.
The Standards and Codes shall be current at forty two days prior to the first date set for the delivery
of Tenders. If necessary equivalent National Standards may be substituted for the Standards referred
to in the Specification provided the Contractor shall have justified such substitution to the Engineer
and only after written approval has been received from the Engineer.
Matters not Covered by Standards
Any materials and workmanship not fully specified herein, or covered by the Standards, Codes or
Manuals, shall be of such type and quality so as to produce a first class work. In such circumstance,
the Engineer shall determine whether all or any of the materials offered or delivered to the Site are
suitable for use in the Works and the Engineers decision in this respect shall be final and conclusive.
(1)
It is a basic requirement of the Contract that all materials and articles are
manufactured/tested/supplied in accordance with recognised, approved, national or
international Standards.
(2)
The Standards quoted in this schedule will be approved against the relevant Clause and/or
item and give a guide as to quality requirements. This schedule does not prejudice the use of
alternative, equivalent or superior Standards proposed by the Contractor in accordance with
Section B of the Specification.
(3)
Reference to any Standard implies reference of all associated or related Standards referred
to within that Standard.
(4)
The schedule includes reference to publications for guidance on current practice on some
topics.
(5)
The editions of approved Standards used shall be those current 42 days prior to the date for
the return of tenders.
(6)
The Contractor may be required to supply any of the Standards or publications listed in this
schedule for the use of the Engineer (with English language translations where appropriate).
(7)
The following Standards Authorities and research bodies may be relevant to the Project and
abbreviations for standards have been used in this schedule or elsewhere in the
Specification:
ACI
American Concrete Institute
P.O.Box 4754
Redford Station
Detroit
Michigan 48219
ANSI American National Standards Institute
11 West 42nd Street
New York
New York 10036
API
American Petroleum Institute
Division of Production
Vol 3, Section3
Page S-1 of 15
Specifications
300 Corrigan Tower Building

Dallas
Texas 75201
ASTM American Society for Testing and Materials
1916 Race Street
Philadelphia
Pennsylvania 19103
AWWA American Water Works Association
6666 West Quincey Avenue
Denver
Colorado 80235
BCPA
BEC
82 New
London
British Concrete Pumping Association

Building Employer's Confederation
Cavendish Street
WIM 8AD
BRE
Building Research Establishment
Garston
Watford WD2 7JR
British Steel
British Steel Plc
Commercial Steels
Marketing Services Dept.
P.O. Box 1
Frodingham House
Scunthorpe DN16 1 BP
BS and BSI
BSI Customer Services
British Standards Institution
389 Chiswick High Road
London W4 4AL
Fax : +44 208 996 7001
C and CA
formerly : Cement and Concrete Association
now part of
British Cement Association
Wexham Springs
Slough SL3 6PL
CEN
Comit Europen de Normalisation
Rue de Stassart 36
B - 1050 Brussels
The Chlorine Institute, Inc.
2001 L Street, N.W., Suite 506
Washington, D.C. 20036
Telephone: +1 202 775-2790
Fax: +1 202 223-7225
CIRIA Construction Industry Research and Information Association
6 Storey's Gate
Westminster
London SW1P 3AU
Fax : +44 207 222 1708
Vol 3, Section3
Page S-2 of 15
Specifications
CS
The Concrete Society
Devon House
12 - 15 Dartmouth Street
London SW1H 9BL
CP
Code of Practice, BSI
DoE, BRE
Department of the Environment
Building Research Establishment
Transport and Road Research Laboratory
London
DIN
Deutsches Institut fur Normung e.v.
Beuth Verlag GmbH
Burggrafenstrasse 4-10
1000 Berlin 30
EN
Euronorm
Boulevard de l' Empereur 5
1000 Brussels
Belgium
Euro Chlor
Avenue E Van Nieuwenhuyse 4, box 2
B-1160 Brussels, Belgium
Tel + 32 2 676 7211
Fax + 32 2 676 7241
HMSO Her Majesty's Stationery Office
HMSO Publications Centre
P.O. Box 276
London SW8 5DT
MOWA
Ministry of Works and Agriculture
Government of Bahrain
HSE
Health and Safety Executive
St. Hugh's House
Stanley Precinct
Bootle
Merseyside L20 3QY
ICE
Institution of Civil Engineers
Great George Street
London SW1P 3AA
IEE
Institution of Electrical Engineers
Savoy Place
London WC2
ISO
International Standards Organisation
NACE National Association of Corrosion Engineers

P.O. Box 218340
Houston, TX 77218
United States of America
Vol 3, Section3
Page S-3 of 15
Specifications
NJHSCWS
National Joint Health and Safety Committee for the Water Service
1 Queen Anne's Gate
London SW1H 9BT
SIS
Swedish Standards Institute
Box 3295
S-10366 Stockholm 3
Sweden
SSPC Steel Structures Painting Council
United States of America
WRc
Water Research Centre (Engineering)
Frankland Road
Blagrove
P.O. Box 85
Swindon
Wiltshire SN5 8YR
Vol 3, Section3
Page S-4 of 15
Specifications
SECTION B GENERAL OBLIGATIONS

BS
BS
BS
BS
BS
BS
BS
3143
4465
5531
5973
6164
6187
7121
Safety Manual: BEF, BAS (2) Code of Practice for Service

Installation MOWA
Guide : 'Construction Safety Manual' - BEC
Safety Harnesses
BS
BS
BS
BS
EN
EN
EN
EN
354
355
358
361 to BS EN 365 inclusive
Safety in Sewers and at Sewage Works Guides: `Safety in Sewers and at Sewage Works' - ICE
`Safe Working in Sewers and
at Sewage Works'
NJHSCWS
BS EN 60079-14
BS 6959
BS EN 132 to BS EN 139 inclusive
BS EN 145 (BS 7170)
Abatement of Noise
Guide : 'Legislation and Practice on Noise Control on Construction

Sites with particular relevance to Piling' - British Steel
Fire Safety Code of Practice
Ministry of Interior , Civil Defence and Fire Service Directorate
Use of Explosives
BS 5607
Support to Excavations
BS 6031
BS 6164
BS EN 1537
Guide : 'Trenching Practice'
Report 97, CIRIA
Site Investigation
BS 5930 including
Steel Sheet Piles
Guides : 'Piling Handbook' + others referred to therein - British Steel
Steel for Wailings, Capping

and Tie Rods
Vol 3, Section3
Guide : 'The Standard Penetration Test

(SPT): Methods
BS
BS
BS
BS
BS
BS
EN 10137-1
7668
EN 10029
EN 10113
EN 10155
EN 10210
Page S-5 of 15
Specifications
Control of Water
Guide : `Control of Groundwater for Temporary Works' - Report

113, CIRIA
Ventilation
BS 5720
Methods of Testing Soils

and
Relative Density Tests:
BS 1377
Rammer and Drop Method

Sand-Cone Method
Rubber Balloon Method
Nuclear Methods
Drive-Cylinder Method
Sleeve Method
ASTM D 698
ASTM D1556
ASTM D2167
ASTM D2922
ASTM D2937
ASTM D4564
Water for Concreting
BS 3148
Cement:
OPC (high C 3 A)
SRC (medium C 3 A)
SRC (low C 3 A)
ASTM 150 Type I or BS 12

ASTM 150 Type II or BS 12
ASTM 150 Type V or BS 4027
Guide : 'Sulphate and Acid Resistance, of Concrete in the Ground - BRE Digest 363, 1991
Methods of Testing Cement
Heat of Hydration Test
Acid Soluble Alkali Test
BS EN 196
BS EN 196-7
ASTM C186
BS EN 196-2
Aggregates
ASTM C33 or BS 882
Sampling of Aggregates
BS EN 1097-3
Aggregate Tests:
Drying Shrinkage
BS 812, UK BRE Digest No. 35
Materials Finer than 75

Micron (Decantation Method)
BS 812
Clay Lumps and Friable Particles ASTM C142

Water Absorption
BS 812
Acid Soluble Sulphate
As BS 1377 but with acid solution
Acid Soluble Chloride
As BS 812 but with acid solution
Vol 3, Section3
Page S-6 of 15
Five Cycles of Soundness

Aggregate Impact Value
Specifications
ASTM C88
BS 812
Aggregate (Fine) Grading
BS 882
Method of Test for Aggregate

Organic Content
ASTM C40
Aggregates for Granolithic

Concrete
BS 882
Reinforcement:
Mild Steel and Deformed
High Yield
Cold Worked High Yield
BS 4449
BS 4449
Fabric Reinforcement
BS 4482 and BS 4483
Tying Wire
BS 1052
Epoxy Coated Steel

Reinforcement
BS ISO 14654 ASTM A775/A775M
Admixtures
BS EN 480-1 or ASTM C494
and
Air Entrainment Agents
BS 5075 or ASTM C260
Guides : Àir Entrained Concrete' CS Technical Report No. 18 `Guide to Chemical Admixtures for
Concrete' - C & CA
Curing Compounds
ASTM C171 and C309
Premixed Concrete
BS 5328
Design Constraints on Concrete

Grades and Types
BS 114
Concrete Mix Design
Guide : `Design of Normal Concrete Mixes' UK, DoE, BRE : HMSO
Structural Use of Concrete

Concrete Quality Control
BS 8110 BS 8007
BS 1881 ISO 1920
Guide : 'Testing Concrete in Structures : A guide to equipment for testing concrete in structures'.
Tech. Note 143, CIRIA
Determination of Air Content
BS 1881 Part 106
Thermometer
BS 1704
Formwork
Vol 3, Section3
Guides :
BS 5975 - Code of Practice for Falsework
Page S-7 of 15
Specifications
'Concrete Pressure on Formwork' - Report 108, CIRIA

Bending Reinforcement
BS 8666
Batching, Transporting
and Placing of Concrete
BS 1305
BS 5328
Guides :
'The Manual and Advisory Safety Code of Practice for Concrete Pumping' - BCPA
'Concreting Deep Lifts and Large Volume Pours' - Report 135, CIRIA
'Mass Concrete' - CS Digest No. 2
Guide to concrete Construction in the Middle east CIRIA
Water Bars
BS 903
BS 2571
BS 2782
Expansion Joint Filler
ASTM D1752
Joint Sealing
BS
BS
BS
BS
Dowel Bars
2499
4254
5212
6213
BS 6744
Precast Concrete
BS 5911
BS 5642
BS 7263
Precast Concrete Manhole

Segments
BS 5911 Part 200

Concrete Pipes
BS 5911
Asbestos Cement Pressure

Pipes and Joints
BS EN 512
ASTM C296
DIN 19800/1
ISO 160
Asbestos Cement Pipes for

Sewerage and Drainage
BS EN 588
ASTM C428
ISO 881
Clay ware Pipes
BS EN 295
ASTM C700
Extra Chemically Resistant

Clay ware Pipes
BS EN 295
uPVC Pressure Pipes
BS EN 1452
ASTM D2241
DIN 8061/2
ISO 2505
Vol 3, Section3
BS 8010
Page S-8 of 15
Specifications
ISO 3114
ISO 3472 - 3
uPVC Pressure Fittings
BS 4346
ISO 2035
ISO 2043 - 5
ISO 2048
uPVC Gravity Pipes and Fittings BS 4660 (up to 160 mm)

BS EN 1401
(200 mm to 630 mm)
ASTM D2729
DIN 19534
Reinforced Thermosetting Plastic
BS 5480, Pipes (RTR)

ASTM D3262
ASTM D3517
ASTM D3754
AWWA C950
Pipe Joints
Strain Corrosion Test
ASTM D4161
ASTM D3681
Resin Elongation Test
BS 4994 Method C5
Ductile Iron Pipes, Fittings

and Joints
BS EN 598
BS EN 545
ISO 2531
DIN 28600
Grey Iron Pipes, Fittings

and Joints
BS 4622
ISO R13
Flanges for CI and DI Pipework
BS EN 1515
Flange Gaskets
BS 2494 (Materials), BS EN 1514 (Dimensions)
Cast Iron Drain Pipes and Fittings
BS 437
Cast Iron Rainwater Pipes
BS 460
Cast Iron Soil, Waste and

Ventilation Pipes
BS 416
Steel Pipes
BS 534 , BS 3601
Concrete Porous Pipes for

Under Drainage
BS 5911 Part 114
Clay ware Field Drain Pipes
BS 1196
Perforated Clay Pipes

and Fittings
BS EN 295
Plastic Pipes for Use as Light

Duty Sub-Soil Drains
BS 4962
Vol 3, Section3
Page S-9 of 15
Ogee Jointed Concrete Pipes
Specifications
BS 5911 Part 10
Elastomeric Joint Sealing Rings BS 2494 , ISO 4633

Rubber Hardness (IRHD)
BS 2782-365A
ISO 48
ISO 1400
ISO 1818
Shear Test Procedure for
BS 5911 Part 100 (Concrete)
Flexible Joints
BS EN 295/BS 65 (Clay)
ASTM D3262/D3517/4161 (RPM)
ASTM D3212 (uPVC)
Thrust and Anchor Blocks in
Guide to the Design of Thrust Blocks for Buried Pressure Pipelines

- Report 128, CIRIA
Trenchless technology
Pipe Jacking
Guide : 'Inspection to Trenchless Technology' - ISTT, UK

Guide : 'Best Practice for Pipe Jacking' - Pipe Jacking
Association,UK
Pipes for Micro tunnelling
BS EN 295-7ASTM C1208
BS 5911 Part 120 (draft EN 1916)
Guide : 'Simplified Tables of External Loads on Buried Pipelines' - HMSO

Packing Rings
BS EN 120BS EN 312

Bricks General
BS EN 772
Special Bricks
(Shapes/Dimensions)
BS 4729
Calcium Silicate Bricks
BS 187
Concrete Blocks
BS EN 772
Sand for Mortar
BS 1199 and 1200
Methods of Testing Sands
BS EN 1097
Lime for Mortar
BS 890 BS 6463
Mortar Plasticizers
BS 4887
Pigments for Cement Products
BS 1014

Corrosive Environments
Vol 3, Section3
BS 8102, BS CP102
Page S-10 of 15
Specifications
Tests for Membranes:

Puncture Resistance
Tensile Strength
ASTM E154
BS 2782
Water Absorption
ASTM D570
Bituminous Emulsion
BS 434 Part 1
Waterproof Building paper
BS 1521
Protective Coatings
BS 5493
Degreasing
BS 5493, BS 7773
Blast Cleaning
Zinc Metallisation :
BS 5493,
BS 7079
ISO 8501-1
DIN 55928
SSPC-SPS (surface preparation specifications)
Hop Dip Galvanising
BS 729
ISO 1459
Zinc Spray
BS EN 22063
Extenders for Paints
BS 1795
ISO 3262
Glossary of Paint Terms

Methods of Test for Paint
BS EN 97
BS 3900
Determination of Film Thickness BS 3900 Part C5

ISO 2808
Compatibility of a Product
with the Surface to be Painted
BS 3900 Part C9
ISO 4627
Puff-off Test for Adhesion

BS EN 24624
Surface Finish of Blast-Cleaned BS 7079 (Finish First quality)
Steel for Painting
ISO 8501-1 (Finish Sa 3)
SSPC (Finish SP-5)
Metallic Zinc-rich Priming Paint BS 4652
Liquid Organic Coatings and
Finishes on Aluminium
BS 4842
CP for Protective Coating of Iron

and Steel
BS EN ISO 12944 & BS EN ISO 14713
Powder Organic Coatings
BS 6496
Vol 3, Section3
Page S-11 of 15
Specifications
and Finishes on Aluminium

Powder Organic Coatings
and Finishes on Galvanised Steel
BS 6497
Specification of Materials
paint & varnish standards)
ISO TC35
Holiday Detection
NACE Standard RP0188

NACE Standard RP0274
NACE Standard TM0384
ASTM G62
(ISO Catalogue list,
SECTION H FITTINGS AND FABRICATED ITEMS

Aluminium Alloy
BS 485 to 1301 inclusive

(alloy N8) ISO 209
(Al-Mg 4.5 Mn) BS 8118
Wrought Steel General
BS EN 10084
Weldable Structural Steel
BS
BS
BS
BS
BS
BS
Hot Rolled Sections
BS 4, BS EN 10210
Tubes
BS 6323
Hot Dip Galvanising

for Mild Steel
BS EN ISO 1461
Stainless Steel
BS EN 10084
Steel Plates etc.
BS EN 10029 & BS EN 10048

Grades 316:S12 & S16
DIN equivalent grades
Werkstoff Nos. 1.4404, 1.4435, 1.4401 & 1.4436
American Grades A151, 316 and 316L
EN 10137
7668
EN 10029
EN 10113
EN 10155
EN 10210
Reinforced Thermosetting Plastics:

Manufacturing Standard
BS 4994
Resins
BS 3532 (Class B)
È' Type Glass Chopped Strand

Mat Reinforcement
BS 3496
ISO R1888
È' Type Glass Woven Roving

Fabrics
BS 3749
Vol 3, Section3
Page S-12 of 15
Tolerances
Specifications
BS 4549 Part 1
Quality Control:
Cure - Barcol Hardness
BS 2782 Part 10 (Method 1001)
Glass Content
Flexural Strength
Ultimate Tensile Strength
BS 4994
Lap Shear Strength
BS 4994
Shear Strength of Bond
BS 4994
Peel Strength of Bond
BS 4994
Bolt Strength Test
BS 4549 Part 1 Appendix C
Electrical Properties
BS 2782 Part 2 (M. 221 & 232)
Valves - face to face and

centre to face dimensions
BS EN 558 (BS 2080) ,

ISO 5752

Flanges
BS 5163
BS EN 1515
Flanged Gate Valves for

Sewage
BS 5150 or BS 5163
Flanges
BS 4504
Access Covers and Frames,

including ventilated
BS EN 124
Underground Hydrants
BS 750
Ladders
BS EN 131 (BS 2037)

BS 4211
BS 5395
BS 1474
BS 1615
BS 729
ISO 1459
Road Gully Gratings
BS EN 124
Open Mesh and Chequer

Plate Flooring
BS 5395,
BS 4592
BS 6399
BS 1474
BS 1615
BS 729
ISO 1459
Vol 3, Section3
Page S-13 of 15
Specifications
Steel Guard railing
BS 1387
BS EN 10137
BS 7668
BS EN 10029
BS EN 10113
BS EN 10155
BS EN 10210
BS 5395
BS 6180 (Protective Barriers)
BS 729
ISO 1459
Aluminium Guard railing
BS EN 515 & BS EN 573

BS 1472
BS 1474
BS 1615
BS 4211
BS 5395
BS 6180 (Protective Barriers)
ISO 209
Steel Safety Chains
BS 3113
Polypropylene Rope
BS EN 696, BS 7648
ISO Metric Black Hexagonal

Bolts, Screws and Nuts
BS 4190
ISO 885; ISO 888
Metal Washers for General

Purposes
BS 4320, ISO R887
High Strength Friction Grip

Bolts, Nuts and Washers
BS 4395 Parts 1 and 2

ISO 225
ISO Metric Black Cup and

Countersunk Head Bolts and
Screws with Nuts
BS 4933
Hot Dip Galvanising

ISO 1459
BS EN ISO 1461
Electroplated Cadmium or
Zinc Coatings
BS EN 12329 & BS EN 12330

ISO 2081 and 2082
ISO Metric Hexagonal Bolts

Screws and Nuts
BS 3692
Bolting for Pipes and Fittings
ISO 2084
Spheroidal Graphite Iron Bolts

ISO 1083
BS EN 1563
Rag Bolts
BS 1494
Vol 3, Section3
Page S-14 of 15
Specifications
Manhole Step Irons
BS 1247
Permissible Stresses and

Design of Cranes
BS 2573
Hand Blocks
BS 3243
Chain Link Fencing and Posts
BS 1722 Part 1
Geotextile Fabric Filter Membrane
BS EN ISO 10319
Stainless Steel Clamping Systems
BS 1133 Section 15
BS 4853
Underground Services
Warning Tapes
BS 2782 Parts 3 and 6

BS 5252
SECTION L - BUILDING WORKS

Placing Damp-Proof Course
Vol 3, Section3
BS 8215
Page S-15 of 15

Specifications Fro Sewerage Plant

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AL MADINA AL SHAMALIYA

SEWAGE TREATMENT PLANT

General Table of Contents

Design Documents (DRAWINGS)

AL MADINA AL SHAMALIYA (AMAS)

AL MADINA AL SHAMALIYA STP

Objective of the Works .................................................................................................. 1

Specification Documents ............................................................................................... 1

General Information Pertaining to the Site ................................................................... 1

Architectural Design and Treatment of the works ........................................................ 6

AMAS STP Landscaping.................................................................................................. 6

DESIGN OF THE WORKS .................................................................................................... 7

Design Lives ................................................................................................................... 9

Standards and Codes ..................................................................................................... 9

Planning Permission and Building Control Permits ....................................................... 9

Contractor's Documents for Review by the Engineer .................................................. 10

Final Documents to be provided by the Contractor ..................................................... 15

Other Documents to be provided by the Contractor ................................................... 16

Quality Assurance/Quality Control System ................................................................. 17

Contractors Company Quality Assurance System....................................................... 17

Control Plans for the Works included in this Contract ................................................ 17

Quality Assurance Plan (QAP) ..................................................................................... 17

Control Plans ............................................................................................................... 18

Contractors Control and Documentation .................................................................... 18

Defects Liability Period ................................................................................................ 19

Retention of Documents .............................................................................................. 19

Post Warranty Service Agreements ............................................................................. 19

ENVIRONMENTAL MANAGEMENT SYSTEM ...................................................................... 20

CONSTRUCTION OF THE WORKS .................................................................................... 20

Construction Permits ................................................................................................... 20

AL MADINA AL SHAMALIYA STP

Interpretation of Drawings ......................................................................................... 20

Continuous Working .................................................................................................... 20

Temporary/Security Fencing of Site ............................................................................ 21

Setting Out and Checking the Works .......................................................................... 21

Interference with Land Interests ................................................................................ 22

Interference with Access to Properties ....................................................................... 22

Site Cleanliness and Environmental Protection........................................................... 22

Demolition, Damage and Making Good ....................................................................... 22

Site Drainage ............................................................................................................... 23

Monitoring of Existing Structures................................................................................ 23

Interface with Existing Structures .............................................................................. 23

Interface with Other Contractors ................................................................................ 24

Traffic Requirements ................................................................................................... 24

Maintenance of Access Roads...................................................................................... 24

Water for Testing ......................................................................................................... 24

Excavations for Water Mains and Sewers ................................................................... 24

Existing Services .......................................................................................................... 25

Electricity, Water Supply and Telecommunications .................................................... 25

Protection of Work ...................................................................................................... 26

Materials and Workmanship ........................................................................................ 26

Site Safety and Welfare ............................................................................................... 29

Site Offices, Attendance and Site Facilities ................................................................. 38

Public Relations ........................................................................................................... 43

Drawings and other information forming part of the Contract

Addresses of Statutory Organisations

Appendix III Source Countries

AL MADINA AL SHAMALIYA STP

Objective of the Works

Section 1 General Requirements;

Section 2 Process Specifications;

Section 3 Civil Specifications;