Vol 4 Specifications 010823

URBAN SANITATION PROJECT
Project Nº P161777
CONSTRUCTION OF TETE WASTEWATER TREATMENT PLANT AND SEWERAGE

NETWORK
RFB No.:MZ-AIAS-331803-CW-RFB
REQUEST FOR BIDS
VOLUME 4 of 6: TECHNICAL SPECIFICATIONS
CONTENTS:
VOLUME 4 OF 6: WORKS REQUIREMENTS - SPECIFICATIONS
BIDDING PROCEDURES, CONDITIONS OF CONTRACT AND CONTRACTOR FORMS (UNDER
VOLUME 1)
SCOPE OF WORKS (UNDER VOLUME 2)
BILL OF QUANTITIES (UNDER VOLUME 3)
SPECIFICATIONS
ENVIRONMENTAL AND SOCIAL MANAGEMENT PLAN (UNDER VOLUME 5)
DRAWINGS (UNDER VOLUME 6)
August 2023
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TABLE OF CONTENTS
1. ITEMS OF GENERAL APPLICATION ..................................................................... 5

1.1. General ......................................................................................................................... 5
1.2. Standards, Codes and Abbreviations ............................................................................ 8
1.3. Licenses and Permits .................................................................................................. 10
1.4. Project management .................................................................................................... 10
1.5. Project Language ......................................................................................................... 10
1.6. Access and Possession of Site .................................................................................... 10
1.7. Engineers Normal Working Hours ............................................................................. 11
1.8. Site Conditions ........................................................................................................... 12
1.9. Site Working Arrangements ....................................................................................... 12
1.10. Temporary Facilities .................................................................................................. 25
1.11. General Obligations .................................................................................................... 26
1.12. Contractor's Designs ................................................................................................... 28
1.13. Submissions by the Contractor ................................................................................... 29
1.14. Quality Assurance ...................................................................................................... 35
1.15. Environmental Protection ........................................................................................... 37
1.16. Health and Safety ....................................................................................................... 39
1.17. Quality of Materials .................................................................................................... 41
1.18. Project handover ......................................................................................................... 43
2. GENERAL REQUIREMENTS FOR CIVIL WORKS .............................................. 45
2.1. Prior Site Inspection and Survey Works ..................................................................... 45
2.2. Earthworks ................................................................................................................. 45
2.3. Pipelaying ................................................................................................................... 60
2.4. Testing ........................................................................................................................ 61
2.5. Concrete...................................................................................................................... 63
2.6. Formwork ................................................................................................................... 78
2.7. Reinforcement ............................................................................................................ 83
2.8. Geotextiles .................................................................................................................. 85
2.9. Building Work and Miscellaneous Works .................................................................. 86
2.10. Metalwork .................................................................................................................. 87
3. GENERAL MECHANICAL REQUIREMENTS ...................................................... 90
3.1. General Specifications ................................................................................................ 90
3.2. Pipework .................................................................................................................... 98
3.3. Mechanically Cleaned Bar Screen ........................................................................... 107
3.4. Gates......................................................................................................................... 108
3.5. Open channel flow meter ......................................................................................... 108
3.6. Electromagnetic Flow Meter .................................................................................... 109
3.7. Vertical Screens ....................................................................................................... 109
3.8. Compressed Air Vessel ............................................................................................ 110
3.9. Other Mechanical Specifications ............................................................................. 110
4. GENERAL ELECTRICAL REQUIREMENTS ...................................................... 112
4.1. Electrical Supply ...................................................................................................... 112
4.2. Standards and Approvals .......................................................................................... 114
4.3. Selection Criteria ...................................................................................................... 119
4.4. E-Works Implementation.......................................................................................... 121
4.5. Installation of Conduits ............................................................................................ 122
4.6. Wire and Cable Installation ...................................................................................... 123
4.7. Dimensioning of Power Cables ................................................................................ 126
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4.8. Mounting of Starters ................................................................................................. 126
4.9. Earthing .................................................................................................................... 126
4.10. Local Equipotential Bonding .................................................................................... 127
4.11. Lightning Protection ................................................................................................. 128
4.12. Testing ...................................................................................................................... 129
4.13. Underground Ductwork ............................................................................................ 129
4.14. Lighting .................................................................................................................... 129
4.15. Ultrasonic sensor and Grid - Installation and Commissioning ................................. 131
4.16. Wire and Cable ......................................................................................................... 131
4.17. Cable Trenches ......................................................................................................... 134
4.18. Local Devices ........................................................................................................... 135
4.19. Switchboards, Sub-panels and Sub-main Distribution Boards ................................. 137
4.20. Mains Decoupling Relay .......................................................................................... 142
4.21. Programmable Control Relay ................................................................................... 142
4.22. 24V DC Power Supply Unit ..................................................................................... 143
4.23. Data Logger .............................................................................................................. 144
4.24. Axial Fans................................................................................................................. 144
4.25. Power Factor Compensation ..................................................................................... 144
4.26. Electric Direct Heating ............................................................................................. 145
4.27. Multi-turn Actuators for OPEN-CLOSE Duty ......................................................... 145
4.28. Lighting .................................................................................................................... 145
5. GENERAL REQUIREMENTS FOR INSTRUMENTATION, CONTROL AND
AUTOMATION....................................................................................................... 149
5.1. Instrumentation ......................................................................................................... 149
5.2. Control Systems........................................................................................................ 149
5.3. Automation System .................................................................................................. 149
5.4. Testing of Instrumentation, Control and Automation Installations........................... 151
6. PARTICULAR SPECIFICATIONS FOR WORKS IN TETE ................................. 153
6.1. Background .............................................................................................................. 153
6.2. Location of the Works.............................................................................................. 154
6.3. Right of Access to the Site ....................................................................................... 154
6.4. Contractor's Designs ................................................................................................. 154
6.5. Submittals................................................................................................................. 155
6.6. Particular Specifications: Electrical Installation ....................................................... 157
6.7. Particular Specifications: Mechanical installations ................................................... 161
6.8. Particular Specifications: Operational Technology and SCADA ............................ 173
7. ENVIRONMENTAL AND SOCIAL (ES) REQUIREMENTS............................... 184
7.1. Environmental and Social Policy (Statement) .......................................................... 184
7.2. ES Minimum Requirements ..................................................................................... 185
7.3. Payment for ES Requirements .................................................................................. 185
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LIST OF FIGURES
Figure 1. 1: Project area, sewer network, pumping stations, and WWTP - Right Bank ........................ 7
Figure 1. 2: Priority Areas of Sewerage Network, Condominium Sewer, and WWTP in the right bank
...............................................................................................................Error! Bookmark not defined.
LIST OF TABLES
Table 6. 1: Lengths of the Proposed Sewers per Phase – Right Bank ............................................... 153
Table 6. 2: Lengths of the Proposed Sewers per Phase – Left Bank.................................................. 153
Table 6. 1: Technical specification for the submersible pumps of PS01 at the Right
Bank…………169
_Toc112412329
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Construction of Tete WWTP and Sewerage Network: Volume 3 - Specifications
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1 ITEMS OF GENERAL APPLICATION

1.1 General
1.1.1 Introduction
The project of ‘’Development of Feasibility Assessment, Detailed Design and Supervision of
priority Sewerage Works in Tete’’ was financed by the International Development Association (IDA)
and tendered under the Reference MZ-AIAS-116233-CS-QCBS. The objective of the project is to
provide the services for the upgrade and expansion of the sewerage network, including condominial
sewer systems, Wastewater Treatment Plants (WWTPs) and rehabilitation of the storm water system.
These Technical Specifications cover principles, responsibilities and requirements for items which will
be applicable to all engineering and construction Works pertinent to the project, including, the Plant,
Materials, workmanship and side services, it’s commissioning, training of the Operator personnel and
the transference of the Works to the Employer or designated Operator.
The Contractor shall, unless otherwise specified herein, supply all materials, equipment, temporary
works, plant and labour necessary to install, complete and maintain the Works required under the
Contract. The Works shall include but not be limited to, preparing the sites including all setting out,
excavation, fill, backfill, transport to approved dump site; all civil, mechanical and electrical works
necessary for the buildings and installing the telemetry cable and implementing of the CTMS
(Centralized technical Management system), roads, fences and external arrangements; the removal of
surplus material, clean-up site of works and compliance with the environmental, social and Health and
Safety requirements, for the specified duration of the Contract.
The specifications are to be read in conjunction with the Detail Design Report, which includes
description of the works, Bill of Quantities presented, drawings and the Conditions of Contract.
1.1.2 Scope
The scope of works shall include, all general works preparatory to the construction of the works and
materials and work of any kind necessary for the due and satisfactory construction, completion and
maintenance of the works to the intent and meaning the specifications and instructions that may be
issued by the Engineer from time to time, during construction works, whether specifically mentioned
or not in the clauses of this specifications.
The scope of works is defined in the detailed design report of the project and presented in the Volume
2 – Scope of Works of the presented bid documents.
The project implementation area was defined based on the short-term measures proposed up to 2030
(Phase 1) in the detailed design, and are planned to be carried out on the left and right banks of the
Zambezi River. The main components of the project are summarized in the following table.
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Left Bank Right Bank
Conventional Sewerage System: Conventional Sewerage System:
• No action required • Rehabilitation of 2.23 km collectors
• Construction of 14.14 km collectors
• Construction of 1.80Km of Pressure main.
• Project Manholes: 427
o Newly construction 187 manholes
o Rehabilitation of 85 manholes
o To be reused 155 existing manholes
• Construction 2,682 house connections
• Improvement of 100 house connections
• Construction of 1 pumping station
Construction of 1.8 km of pressure
mainConstruction of a WWTP (composed by
headworks, 2 anaerobic ponds, 2 facultative and 2
maturation ponds).
Condominial System: Condominial System:
• Construction of 5.25 km of collectors • Construction of 2.6 km of collectors
• Construction 400 house connections • Construction 200 house connections
• Construction of 278 inspection boxes • Construction of 400 inspection boxes
• Construction of 1,350m of gravity
main
• Construction of WWTP (composed
of ABRAF principle)
Storm Water: Storm Water:
• No actions required • Rehabilitation of 2 km of existing collectors
• Replacement of 3.8 km of existing collectors
• New construction and connection of 279 gutters.
• Disconnection of 102 sewerage illegal
connections, 20 bypass lines on the equal number
of manholes, and 6 sewer from stormwater
outfall chambers/manholes at discharge points.
• Cleaning and reshaping of 2.5 km of earth
channel at Nhartanda valley before the WWTP.
• Reshaping and lining of 6.13km of existing open
channel after the WWTP.
Roads and Pavement Roads and Pavement reinstatement:

reinstatement: 17,870m2 of roads to be reinstated
900m2 of roads to be reinstated
The proposed works are spatially represented in the figure below.
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Figure 1. 1: Project area, sewer network, pumping stations, and WWTP - Right Bank
1.1.3 Definitions
1.1.3.1 General
Acceptable/ Approved (Approval) - Acceptable to/ approved (Approval) by the Employer (or by the
Engineer, if so authorised by the Employer);
Agreed - Agreed in any form of written documentation agreed amongst and made available to other
Party(-ies);
As Detailed - As detailed in the drawings;
Authorised/ Ordered/ Rejected - Authorised/ ordered/ rejected by the Employer (or by the
Engineer, if so authorised by the Employer);
Indicated - Indicated in or reasonably to be inferred from the Contract, or indicated in writing by the
Engineer;
Instructed/ Directed/ Permitted - Instructed/ directed/ permitted by the Engineer;
Satisfactory - Capable of fulfilling or having fulfilled the intended function;
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1.1.3.2 Tolerances
Deviation - The difference between the actual (i.e. measured) size or position and the specified size or
position
Permissible Deviation - The specified limit(s) of deviation
Tolerance - The range within which a size or position must lie
1.2 Standards, Codes and Abbreviations

1.2.1 Reference Standards and Codes
The Works shall be carried out in accordance with the relevant quality standards, test procedures or
codes of practice, collectively referred to as Reference Standards, listed in the relevant parts of the
Specifications. The Contractor shall familiarize himself fully with the requirements of such standards.
If no standard is indicated then the applicable ISO or IEC Standard or, in the absence of such standard,
the latest edition at the date of the proposal submission applicable Euro Norm (EN), German (DIN),
British (BS), North American (ASTM, ANSI, ASHRAE, ASME, ICC, PMI) South African (SANS and
SABS) or Southern Africa Transport and Communications Commission (SATCC) standards shall
apply, subject to agreement with the Engineer. The use of other standards will be limited to the cases
of absence of applicable standards from the previous organizations and subject to agreement with the
Engineer. Where there is conflict between this General Specification and the relevant specified
Standard or IS, the one posing stricter requirements will take precedence.
The Contractor may propose, at no extra cost to the Employer, the use of any alternative relevant
authoritative internationally recognized standard, which shall be not less exacting, in the opinion of the
Engineer, than the corresponding Reference Standard quoted in the Specification. The Contractor shall
demonstrate to the Engineer that the alternative standard is suitable and equivalent to the specified
Reference Standard. The Contractor shall further provide proof of previous successful use. The
Engineer shall decide whether the use of such an alternative standard as a Reference Standard will be
permissible.
The Contractor shall obtain and keep on Site at least one copy of each Reference Standard and each
Reference Standard referred to in the Specifications, and will make these accessible to the Engineer at
any time upon request.
1.2.2 Equivalency of Standards and Codes

Wherever reference is made in the Contract to specific standards and codes to be met by the goods and
materials to be furnished, and work performed or tested, the provisions of the latest current edition or
revision of the relevant standards and codes in effect shall apply, unless otherwise expressly stated in
the Contract. Where such standards and codes are national, or relate to a particular country or region,
other authoritative standards which ensure an equal or higher quality than the standards and codes
specified will be accepted subject to the Engineer's prior review. Differences between the standards
specified and the proposed alternative standards must be fully described in writing by the Contractor
and submitted to the Engineer at least 28 days prior to the date by which the Contractor desires the
Engineer's agreement. If the Engineer determines that such proposed deviations do not ensure equal or
higher quality, the Contractor shall comply with the standards specified in the documents.
1.2.3 Metric Units

The International System of Units (SI) shall be used generally throughout the Contract. All information
and data originating in another system shall be transferred by the Contractor into the SI. system.
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1.2.4 Units’ Abbreviations
Symbol Description
% Percent
< smaller/ less than
> larger/ more than
° degree(s)
°C degree(s) Celsius
Symbol Description
ASTM American Society for Testing and Materials
ASHRAE American Society of Heating, Refrigerating and Air-
Conditioning Engineers ASME American Society of Mechanical Engineers
AWWA American Water Works
Association ICC International Code
Council
PMI Project Management Institute
DIN Deutsche Industrie Norm (German Standard)
EN European Norm
ISO International Standards Organization
BSI British Standards Institution
IEC International Electrotechnical Commission
ANSI American National Standards Institute
SABS South African Bureau of Standards
SATCC Southern Africa Transport and Communication
Commission g/cm³ gram(s) per cubic centimetre
° degree(s)
°C degree(s) Celsius
C- ESMP Contractor’s Environment and Social Management Plan
g/m² gram(s) per square metre
h hour(s)
cm centimetre(s)
d day(s)
kg kilogram(s)
kg/mm² kilograms per
square millimetre km kilometre(s)
kN kilonewton(s)
kPa kilopascal(s)
kW kilowatt(s)
l litre(s)
l/s litre(s) per second
m metre(s), running metre
m/s metre(s) per second
m² square metre(s)
m³ cubic metre(s)
m³/d cubic metre(s) per day
m³/h cubic metre(s) per hour
m³/s cubic metre(s) per second
masl metre(s) above sea level
Symbol Description
mBar Millibar
mg/l milligram(s) per litre
mm millimetre(s)
MPa Megapascal(s)
mWc metre(s) water column
h.p. Horse power
N Newton(s)
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N/mm² Newton(s) per square millimetre
s second(s)
Ton tonne (mass) i.e. 1 000 kg
µg/l microgram(s) per litre
Ppm parts per million
OD Outer (external) Diameter
dia./Ø Diameter
T Temperature
TWL Top Water Level
DN Nominal Diameter
ID Internal Diameter
SN Nominal Stiffness
PN Nominal Pressure
PPc Corrugated Polypropylene
GRP Glass Fiber Reinforced Plastic
DCI Ductile Cast Iron
PVC Polyvinyl Chloride
PC Prestressed Concrete
HDPE High-Density Polyethylene
AC Asbestos Cement
1.3 Licenses and Permits

It is the responsibility of the Contractor to identify and obtain all licenses, permits, concessions and
approvals required for setting out and carrying out the Works under this Contract.
1.4 Project management

Where applicable, the contractor shall comply with the project management approaches recommended
by the Project Management Institute (PMI), namely on the PMIBook. Other approaches may be adopted
if requested to and approved by the Engineer.
1.5 Project Language

All communication shall be in English. All reports, manuals, drawings and other project documentation
shall be prepared in English. The operation manuals shall be also translated into Portuguese.
1.6 Access and Possession of Site

1.6.1 The Site
The Site includes any designated areas and any temporary working areas necessary for carrying out the
Works under this Contract. The Site includes any designated areas and any temporary working areas
necessary for carrying out the Works under this Contract. For the sewerage system, it contains most of
the right bank area of the Tete City. The WWTPs are designed and constructed in both the right and
left banks of the Zambezi River.
1.6.2 Access to Site

The access road to the WWTP will be constructed under the contract. The Contractor will be responsible
for the construction of the access roads into Tete Wastewater Treatment Plants.
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1.6.3 Temporary Way Leaves, Access Costs

The Contractor shall be responsible for obtaining any temporary way leaves that may be necessary for
carrying out the Works. Accordingly, he shall, well in advance of the commencement of the work,
obtain permission for the undertaking of the work from all land or property owners who may be affected
by the Work. He shall also provide temporary access to the affected land or property wherever this is
necessary for the Work to be carried out.
No costs of obtaining such temporary wayleaves as well as costs of providing access to these wayleaves
shall be borne by the Contractor. In an event that the Works affects landowners, any compensation that
may arise shall be handled separately
The Contractor shall give notice to the occupiers of each wayleave at least 21 calendar days of his
intention to enter, the extent of each temporary wayleave and the period of time for which it will be
occupied. The Contractor shall ensure that his methods of working cause the minimum of disturbance
to the land and to its owners and occupiers.
The Contractor shall at all times provide proper facilities for access and inspection of the Works by the
Engineer, his assistants, inspectors, agents and representatives of public agencies having jurisdiction.
The Contractor shall reinstate any temporary working areas to the condition prevailing prior to his initial
entry as soon as possible after the work in those areas has been completed, thus keeping the period of
occupation to a minimum. The Contractor shall in any event restore the areas to a tidy and workmanlike
condition.
Prior to commencing work near overhead power lines, the Contractor shall acquaint himself with all
the regulations of the responsible electricity supply authority and ensure that these regulations are
complied with at all times while the Works are being executed. The Contractor shall be responsible for
ensuring that all persons working near overhead power lines are made aware of the relatively large
distance over which high voltage electricity can "short" to earth when cranes or other large masses of
steel are in the vicinity of power lines.
1.6.4 Access to Adjoining Property

If Contractor's work will cause unavoidable interference with access to adjoining property, the
Contractor shall first give 21 calendar days’ notice to the occupier of such property and shall provide
temporary means of access for vehicles, animals and pedestrians.
Convenient access to driveways, houses and buildings adjoining the work shall be maintained at all
times and temporary approaches to intersecting streets and roads shall be provided and kept in good
condition by the Contractor.
1.7 Engineers Normal Working Hours

Unless otherwise stated at particular Conditions, the Engineer’s normal working hours shall be defined
as 7.30 to 17.00 on weekdays and 8.00 to 12.00 on Saturdays. Sundays and public holidays shall be set
aside for rest. The Contractor shall submit in writing to the Engineer which hours shall be considered
normal working hours and which day of the week is to be set aside for rest, and these, when approved,
shall be maintained throughout the continuance of the Contract. Where the Contractor wishes to execute
permanent work outside these hours he shall obtain the written permission of the Engineer at least two
days in advance to enable the Engineer to make provisions for proper inspection of such work.
The Contractor shall be responsible for additional costs incurred by the Employer due to work outside
normal hours (including payment for the Engineer’s staff) and such costs shall be reimbursed in full by
the Contractor to the Employer, including an approved percentage for administrative overheads.
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1.8 Site Conditions

1.8.1 General
The Works of the construction and expansion of the sewerage network including one pumping station
and two Wastewater Treatment Plants to be conducted in Tete City, Mozambique.
The existing sewerage drainage shall not be compromised by the Contractor’s activities except as
agreed with the Engineer.
In addition to the information provided in the written documents of the detail design, the contractor
should conduct all additional verifications deemed necessary to characterize the site and evaluate the
work conditions for the execution of the contract (e.g., weather, geology, hydrology, etc.)
The Contractor shall keep all construction activities of whatever nature clear of and isolated from the
existing facilities, and prevent any interference with the operation of the existing facilities, including
the existing system components, except when working on or in these facilities in accordance with the
Shop Drawings, Contractor’s method statement and programme, released for application by the
Engineer.
1.8.2 Method Statement and Programme

Based on the Works Requirements and the findings of the prior site inspections, the Contractor shall
prepare and submit to the Engineer, a detailed method statement and a programme, complete with Shop
Drawings where appropriate, for the implementation of the required Works. The detailed method
statement shall be submitted to the Engineer for discussion and agreement well in advance, and never
less than 2 weeks before the date on which the Contractor intends to commence the Works in question.
The Contractor’s detailed method statements and programmes shall be such that the Works can be
executed with minimal risk of accidental interference with the Employer’s existing installations or
operations. The method statements and programmes shall include sequences and timetables for the
temporary facilities in order to guaranty the sewage drainage and the effluent treatment during the
construction works. These sequences and timetables shall be prepared by the Contractor in consultation
with the Engineer and the Employer so as to minimize the risk of unforeseen problems being
encountered during the implementation of the work. Further, the method statement shall include a set
of 'Emergency Procedures' (reference is made to Clause1.9.5).
The method statements shall be complete with all sketches, photographs, etc. required to amplify and
clearly explain the proposals to the Engineer. These sketches, photographs, etc. shall be such that they
also facilitate the carrying out of the Works by the Contractor’s personnel without ambiguity or
avoidable delay.
1.9 Site Working Arrangements

1.9.1 Temporary Fencing and Marking of Sites
Temporary fencing shall be provided by the Contractor at all construction sites that are not already
enclosed by permanent fencing. All open excavations shall be marked and barricaded as necessary to
ensure the safety of workmen and to keep out members of the public and livestock.
At Tete WWTP temporary fencing shall be provided by the Contractor, where necessary, before the
installation of the permanent fence.
At construction sites in public areas, the Contractor shall be responsible for watching, signage and
lighting and shall comply with the requirements of the Employer, Police and other competent
Authorities in this regard.
Entire pipe trenches are not allowed to be left open during non-working hours. The open parts of linear
excavation shall be kept to a minimum, i.e. in area of pipe installation ends.
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1.9.2 Site Drainage
The Contractor shall keep the construction sites of the Works well drained until it is substantially
complete and shall ensure that, as far as it is practicable, all Works are carried out in the dry. The
Contractor shall, for this purpose, provide, operate and maintain sufficient pumping equipment, well
points, pipes and other equipment and shall construct, operate and maintain all temporary coffer-dams,
sumps, ditches, drains and other temporary works as may be necessary for the removal of water from
the Works while construction is in progress. Any costs resulting in site drainage shall be considered in
the unit prices. Any damage resulting from site drainage shall be on Contractor’s own cost.
1.9.3 First Aid

The Contractor shall make arrangements for the treatment of injuries on the Site. The Contractor shall,
for this purpose, provide, staff and operate sufficient first-aid units for proper treatment of injured
persons and shall make arrangements for seriously injured persons to be transported by ambulances to
nearby hospitals. The first-aid service shall be available to employees of the Employer and the Engineer
who are directly involved with the Contract as well as to the Contractor's personnel and all his Sub-
Contractors’ personnel.
Contractor should keep on site a minimum of two kits of first aids which shall include, at least, the
following:
• Antiseptic povidone-iodine (Betadine)
• Normal (physiological) saline
• Thermometers
• Paracetamol
• Anti-malaria tablets
• two blankets
• Doxycycline (INN) for the Rickettsia disease (African tick fever) frequent on the area
• Resuscitation equipment, such as a resuscitation bag, airway, or pocket mask
• Range of bandage sizes
• Two elastic wraps
• Scissors
• Plasters
• Gauze
• Cotton
• Safety pins
• Sticking plasters
• Adhesive tape
The outfit shall be replenished and maintained as use demands at Contractor’s charge.
The Contractor shall have available at all times a vehicle or vehicles for the conveyance of sick or
injured people to hospital.
The Contractor shall notify the Public Emergency Service (Fire, Police, Ambulance) of the location and
intended duration of all works at each site prior to commencing work at each site.
1.9.4 Fire Protection

No naked fire shall be used by the Contractor on or about the Site other than in the open air in areas
where there is minimal risk of fires spreading. If, the use of naked fire may cause a fire hazard, the
Contractor shall, at no extra cost to the Employer arrange for additional precautions and provide in case
fire-fighting equipment.
The term "naked fire" shall be deemed to include electric arcs and oxyacetylene or other flames used in
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welding or cutting metals.
1.9.5 Site Safety

The Contractor shall be responsible for all aspects of Health and Safety for each Section of the Works
during the entire Contract Period. The requirements and recommendations from international and
national relevant organizations shall be observed, namely the International Labour Organization, The
Occupational Safety and Health Administration and the government of Mozambique. The applicable
European Directives (e.g., Directive 1989/391/EEC, Directive 1992/57/EEC, Directive 2009/104/EEC,
Directive 1989/656/EEC, Directive 1989/106/EEC, Directive 1989/686/EEC, Directive 2003/10/EEC,
Directive 2002/55/EEC, Directive 1990/269/EEC) shall be observed, as well as one applicable
standards such as ANSI/ASSE A10 series of standards, ANSI/ASSE Z15.1, ANSI/ASSE Z359,
ANSI/ISEA 107, ANSI Z535.5, ANSI/ASME B30, BS 8411,
BS 7212, BS 7121, ISO 10819, ISO 1999, ISO 12480-3 or EN 17076. The Contractor shall comply
with the latest ILO (https://www.ilo.org/actemp/publications/WCMS_744033/lang--en/index.htm) and
OSHA (https://www.osha.gov/SLTC/covid-19/construction.html) recommendations to deal with the
COVID-19. For any matter outside of the scope of the previous references, the Contractor shall propose
for approval by the Engineer an applicable reference guideline (e.g., standard, recommendation, best
practice). In this regard, the Contractor shall also:
• At all times in the conduct of the Works and that of his Sub-Contractors adhere to the applicable
rules and regulations concerning all Health & Safety matters at Site
• Implement safe working and reporting procedures and promote safety awareness in every
element of construction, operation and maintenance
• Appoint a properly qualified and ISO45001, OHSAS 18001:2007, NEBOSH or similar certified
Safety Officer and authorize him to issue instructions to the Contractor's personnel and other
persons on the construction sites regarding protection measures to prevent accidents
• Report accidents and hazards and take appropriate and effective corrective actions. Covid-19
infections and Serious accidents and fatalities should be reported within two working days to
the Employer
• Prepare and maintain a Safety file
• Take all other necessary measures to ensure that healthy and safe conditions are maintained at
all times at all construction sites and places of work associated with the Contract
• The Contractor shall be responsible for all aspects of the implementation of the Contractor
ESMP (C-ESMP) as well as the Health and Safety Plan (HSP) for each Section of the Works
during the entire Contract Period.
The C-ESMP and HSP will be prepared and implemented by the Contractor. The Contractor hires
qualified and experienced Environmental, Social and Health & Safety Specialists for this purpose
The Engineer shall be permitted to stop all work at a construction site if (s)he or the Employer considers
that unhealthy or unsafe conditions exist at that site, in which event the Contractor shall immediately
take such corrective actions as are deemed to be necessary by the Engineer or the Employer. The
Contractor will only be permitted to re-commence work at that site once he has implemented the
necessary measures, and will not be permitted to claim any extensions of time in respect of such work
stoppages. Compliance with the requirements of the Engineer with regard to such situations shall not
relieve the Contractor of any of his obligations under the Contract, nor shall the absence of such action
at a construction site be construed to be agreed by the Engineer.
The Contractor shall be responsible for all damages or injury which may be caused on any property by
trespass by the Contractor's or his Sub-Contractor's employees in the course of their employment,
whether the said trespass was committed with or without the consent or knowledge of the Contractor.
As part of the above, the Contractor shall develop and maintain a set of 'Emergency Procedures'. These
procedures shall identify the accidents and emergencies might occur at the various work sites, prescribe
procedures that are to be adopted to minimize the risk of such incidents occurring and set out clear
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plans of action to be taken if any of these incidents occur. The Contractor shall ensure that his
employees are aware of and adhere to the prescribed procedures and shall display, in prominent
positions, posters describing these procedures and the associated plans of action, including emergency
telephone contact details.
The Contractor shall agree emergency procedures with the relevant emergency services and carry out
emergency drills in accordance with statutory requirements and when recommended by the emergency
services.
The Contractor shall immediately notify the Employer, via the Engineer, if any Covid-19 infections and
serious or fatal accidents occurs on the Site which results in any injury to any person, whether directly
concerned with the Contract or a third party. Such notification may initially be verbal and shall be
followed by a written report within 24 hours of the accident. The Contractor shall, in a similar manner,
report any accident that occurs off the Site in connection with any activity forming part of the Contract
to the Employer, via the Engineer.
1.9.6 Location and Protection of Underground Utilities

The Contractor will be responsible for locating and protecting all underground structures and utilities
including contacting/ coordination with the relevant organisations/ Authorities. He shall proceed with
caution in all excavation so that the exact location of underground structures and utilities, either known
or unknown, may be determined and he shall be held responsible and pay for the repair of such
structures or utilities if these are broken or otherwise damaged by him.
1.9.7 Protection of Overhead and Underground Services

The Contractor will be held responsible for any damage to Services and he shall take all necessary
measures to protect them from damage. All Works or protective measures in this regard shall be subject
of coordination with the related infrastructure holders. In the event of a Service being damaged, the
Contractor shall not repair the Service unless instructed to do so.
Where no underground services are shown on the Drawings or scheduled but the possibility of their
presence can reasonably be inferred, the Contractor shall, investigate whether any such services exist
within the relevant Section of the Site. The Contractor shall complete such an investigation well in
advance of the start of the Works in the said Section and he shall make whatever arrangements are
necessary for the protection, removal or diversion of the services before any construction Works
commences.
As soon as any underground service not shown on the drawings is discovered, it shall be deemed to be
a known service and the Contractor will be held responsible for any subsequent damage to it. If such a
service is damaged during the course of its discovery, the cost of making good such damage shall also
be borne by the Contractor.
Where an Authority concerned elects to carry out on its own account any alterations or protective
measures, the Contractor shall co-operate with and allow such Authority reasonable access and
sufficient space and time to carry out the required work.
1.9.8 Signboards
Signboards shall be placed and repositioned up to once each by the Contractor as instructed by the
Engineer. They shall be in English and Portuguese language and contain information about the project,
the project funder and the Employer plus the names of the Engineer, the Contractor. The signboards’
dimensions are shown in the Drawings. They shall be of durable construction capable of withstanding
the effects of the climate until the end of the Defects Notification Period.
Besides these signboards, the Contractor shall not, except with the agreement of the Engineer, exhibit
or permit to be exhibited on the Site any other form of advertisement.
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1.9.9 Site Roads

The Contractor shall provide and maintain such access to the various Sections of the Works as he
requires for the proper implementation of the work. Access roads shall be so arranged so as to minimize
inconvenience to adjoining landowners or occupants and to the public. Temporary roads shall be
removed when they are no longer required is not requested otherwise by the local users through the
Engineer.
1.9.10 Measurements of Works

The Contractor shall measure the quantities of all Works he intends to claim for in his Statements in
form of measurement sheets. The format of the measurement sheets shall be agreed with the Engineer.
In absence of Contractor’s measurement sheets and wherever levels, measurements, quantities, etc. of
any work done cannot be checked at a later stage, then measurements made by the Engineer while the
work was accessible shall be taken to be the correct measurements of the work. If no such measurements
were made by the Engineer, (s)he shall determine the measurements using any other available
information and these shall be deemed to be the correct measurements of the Works.
The Contractor shall provide all survey instruments and measuring equipment required. The cost for
the measurement of Works will be deemed to be included in the rates submitted by the Contractor for
the respective items.
1.9.11 Contractor’s Temporary Facilities

The Contractor shall make his own arrangements for all yards, stores, workshops, offices and other site
installations. The location of all site installations shall be agreed beforehand with the Employer. Special
attention shall be paid to the safe storage of fuel and lubricants in tanks and safety catchment basins in
order to avoid the contamination of soil, subsoil and groundwater. Similar pollution prevention
measures shall be taken at all workshops or other repair facilities. These measures shall be in
compliance with the C-ESMP.
The Contractor shall give strict instructions to all persons employed by him to comply with any
measures required or prescribed for prevention of pollution of sites or water sources. If the Contractor
fails to implement adequate precautions to avoid any contamination, he shall, at his cost, exchange soils
contaminated by him and shall bear full responsibility for any water pollution.
The Contractor shall erect an office for his own use. The office shall be substantially built,
weatherproof, well-lit and suitably furnished. A meeting room suitable to accommodate at least 12
external elements, in addition to the contractor staff participating, must be considered. The Contractor’s
office shall be properly secure. The Contractor’s office shall not be removed from the Site until the
Works have been completed or until the Engineer, by notice in writing, calls upon the Contractor to
remove it.
The Contractor shall not permit any person to live on the Site except where this is required for security
purposes, nor shall he allow any animals to be brought onto the Site.
The Contractor shall be responsible for providing and maintaining such temporary facilities (including
separate toilet facilities for male and female) e.g. hard standings, fences, gates, etc. as may be required
for the purpose of constructing the Works. On completion of the Contract, the Contractor shall remove
all his equipment and temporary works from the Site and leave the Site in a clean and tidy condition.
The Contractor shall provide site personnel with all the welfare requirements required to meet the
applicable statutory provisions and supply all necessary safety equipment and clothing.
Before starting mobilization, the Contractor shall submit a scaled layout drawing for his proposed site
facilities to the Engineer for information, approval and verification.
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Within the Contractor facilities, the Contractor shall ensure that a GRM is accessible to all workers and
that information of the Workers GRM is adequately disposed so that all workers can have access to the
GRM. The Contractor shall as well ensure that a code of conduct is visibly displayed in multiple
locations on the Contractor’s Site facilities.
The Contractor shall provide 01 car to the employer and/or the Engineer during the project
implementation period.
1.9.12 Sanitary Arrangements and Waste Disposal

The Contractor shall provide adequate sanitary and toilet facilities separately for men and women, as
required to meet the applicable statutory provisions, for use by his employees on the Site as well as by
the employees of the Employer and the Engineer that are directly involved with the Contract. If there
are no requirements in national standards or regulations, the ANSI/PSAI Z4.3-2016 and the
Occupational Safety and Health Administration (OSHA) rules and regulations shall apply.
The Contractor shall be responsible for disposing of sewage and waste in accordance with the
applicable environmental regulations.
1.9.13 Water Supply

The Contractor shall make his own arrangements at his own cost for all water supplies required by him
for purposes of the Contract. The BS 8551:2015 providing and managing temporary water supplies and
distribution networks shall be observed.
Where possible and requested by the Contractor, the Employer will provide water from his supply
system for use by the Contractor at metered connection points installed by the Employer. The
Contractor shall pay the Employer for such water supplies at the going tariff for water supplied to
commercial consumers and shall make his own arrangements for taking water from such connection
points and transporting or pumping it and storing it where it is required. Alternatively, the contractor
may construct the borehole and the water reservoir in advance the works.
1.9.14 Power Supply

The Contractor shall make his own arrangements at his own cost for all electricity supplies required by
him for purposes of the Contract. The BS 7375 shall be observed.
The Contractor may, on specific request and at the Employers’ sole discretion, be permitted to obtain
electricity from existing supply systems at the Employer’s facilities. However, the Employer will not
be responsible for the reliability or quality of such supplies or for any effect that these might have on
the progress of the Works. The Contractor shall, at his own cost, provide electricity meters at such
connection points and provide all switchgear, enclosures, cables and other equipment required for
making connections to such points which comply with the electricity supply authority’s regulations and
standards. The Employer will charge the Contractor for electricity consumed at such supply points at
the tariffs applicable to its supplies for the systems in question.
Since with electric short cuts is to be counted for, the Contractor shall, at his own cost, provide and
operate any stand-by electricity generating equipment which may be necessary for undertaking the
Contract and will not be entitled to any extensions of time on account of the temporary unavailability
of the electricity supplies arranged by him for his own use.
1.9.15 Cleaning-up of Sites

Before application is made for the Employer or the Engineer to accept any substantially completed
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Section of the Works, all items shall be completed, all required documents submitted and all trash,
debris, unused building materials and temporary facilities as well as construction equipment shall have
been removed from the Site.
1.9.16 Handover of Surplus Materials

Upon completion of the Works, the Contractor shall collect from the Site any surplus pipes and fittings,
which have been provided. Where the purchase of these materials has been agreed and paid for, the
surplus pipes and fittings shall be handed over to the Employer. Where the purchase of these materials
has not been agreed they shall be removed from site and no payment made to the Contractor for them.
Where these surplus materials have been imported free of customs and duties under the Project, the
Contractor shall either pay the relevant customs and duties to the responsible authorities or else re-
export the material out of the country.
1.9.17 Engineer, Employer and CMT facilities

A minimum area of 120 m2 will be prepared for installation of the Employer and CMT facilities
on site. This area should be adjacent to the contractor offices on site, levelled, with a view to
the construction area but safe from the operations and with provisions of water, sewer and
electricity.
1.9.17.1 Offices for the Employer and CMQ

The Contractor shall provide an office for the Employer and CMQ representatives, including
the costs of electricity, water, and maintenance. The site office facilities must also include
washing facilities with hot and cold water and hygienic toilet facilities.
The Contractor shall supply, erect and establish three modules office type WC with minimum
width of 3.00m, for the Engineer, Employer and CMQ (3.00m x 3.00m).
The office modules shall have thermally insulated walls, ceiling and floor and shall be equipped
with air- conditioning units capable of maintaining the temperature inside at 20ºC. The modules
shall have electrical and internet installation compatible with the number of workstations. The
window area shall be at least 1/10 of the floor area. There will be separate compartments inside
the modules at least for the Engineer office and the meeting room.
The bathroom modules shall be equipped with toilet and basin. At least one of the two-
bathroom modules shall have also a shower. The washing facilities should be equipped with
hot and cold water and hygienic toilet facilities.
The office shall be securely locked and the Contractor shall be responsible for providing
effective guarding as well as all cleaning and servicing facilities for the office.
The Contractor shall adequately furnish the office with the following:
Each office module:
• 3 desks for the offices.
• 3 swivel office arm chairs.
• 6 office chairs.
• 2 lockable filing cabinets, one of them of big size with doors.
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• 1 plan chest.
• Drawing material and office consumables.
• Printer, scanner, copier and internet.
Meeting room module office:

• 1meeting table for 15 persons.
• 15 office arm chairs.
• Internet.
• 1 coffee table.
Photographic equipment (digital camera with at least 15 Megapixels and a 20x
optical zoom lens) will be made available for the duration of the Contract for the
sole use of the Engineer and the Employer.
1.9.17.2 Vehicles for the Employer’s Representative

The Contractor shall provide two (2) 4x4 vehicles being one double cab and one
single cab according to the specifications presented below, licensed and
comprehensively insured for full replacement value and shall maintain and provide
experienced licensed drivers, fuel, oil and replacement parts during the whole of the
contract period. These vehicles shall be for the exclusive use of the Employer’s
representative. The Contractor shall also insure the vehicles and passengers fully
comprehensively for any driver at all times throughout the Contract.
All vehicles shall be approved by the Engineer prior to ordering.
All vehicles shall be printed with AIAS, IP logo.
The Contractor shall install the car tracking safety system for all vehicles and shall
maintain it during the execution of the Works.
The Contractor shall service and maintain in good working order the vehicle at all
times using the manufacturer´s representative. In the event of any vehicle being
unavailable for use due to accident, damage or its being maintained or repaired, the
Contractor shall immediately provide a substitute acceptable to the Employer.
In the event of the Contractor defaulting on this obligation, the Engineer shall be
authorized to hire a substitute similar vehicle for the period of non-availability of
the Contractor's vehicles and the cost incurred will be recovered from the
Contractor.
The Contractor shall, at the completion, bring the vehicles, with full-service history,
to the appropriate dealers for testing. The dealers shall recommend to the Engineer
what repairs in addition to the ordinary service are required to be carried out on the
vehicles. A certificate of roadworthiness and satisfactory mechanical condition to
be upon completion of the Contract, the vehicles shall become the property of the
Employer at the end of the Works. They shall be handed over to the Employer in
good condition, accepting fair wear and tear. The maintenance book proper filled
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by the service representative of the vehicle should be handed over to the Employer.
Vehicles Requirements
Table 1.2 – Specification for the Double cab 4x4 Vehicle
Double Cab 4X4

GENERAL The Vehicle must be Factory new when it is supplied.
Make Model The make shall have a well-established Service infrastructure in
and Type Quelimane. The model should be of current production and is
common on the Mozambican market.
Country of Vehicles can be from any eligible country but manufactured to

Manufacture conform to all road conditions in the tropical (Africa) countries
including Mozambique.
BODYTYPE Double Cab Pick-Up, 4 doors, 4WD
ENGINE • Minimum capacity: 2.8 cm3 diesel engine with minimum 5-speed
Automatic Transmission.
• 4 Cylinder Diesel, in line DOHC, (1GD-FTV) Diesel.
• Power: 150kw@3400 rpm); Torque 500Nm@1600-2800 rpm.
• The Engine should be Standard Water Cooled with heavy duty.
• Sump Guard.
• Diesel propelled.
• Engine technical Service Manual (Workshop manual) in English.
BRAKES • Hydraulic front disc and rear drum brakes- Front Brakes –
Ventilated Disc.
• 4-wheel Anti-Lock Brake System (ABS) with Electronic Stability
Program (ESP) with Hill Descent Control/Brake Assist (BA).
• Locking rear differential.
TRANSMISSION • 4WD with Automatic Transmission.
• Minimum five forward gears plus reverse.
• Differential or selectable (if selectable 4-wheel drive, then front
wheel to be fitted with free-wheeling Hubs).
• Automatic transmission floor mounted.
• Limited slip function fitted on rear diff only.
• Transmission technical manual (Workshop manual) in English.
• Transfer box protector.
STEERING • Right Hand Drive (RHD), with power steering having tilt or
adjustable steering wheel.
• Steering wheel leather wrapped with Audio and Bluetooth
controls.
FUELTANK • 80-liter fuel tank minimum, fuel tank lid with safety chain and
lockable type.
• Fuel tank protector.
TIRES/WHEELS SIZE • 265/65R17 with 17” Alloy Wheels.
• Aluminum rims.
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INTERIOR • Front seating for driver plus one passenger, 8-way power-adjustable
driver and front-passenger seats with head rests, bucket seats with
lumbar support and map pockets.
• Inertia seat belts for driver and front-passenger.
• Rear seats with head rests and fitted with seat belts
for three passengers.
• Front and rear passenger hand braces.
• Seating capacity for double cabin vehicle shall be 5 including
driver and 1 passenger in front.
• Automatic headlamps (Ambient lighting).
• Satellite Navigation, AM/FM/MP3/CD 4.2” – 6.1” color display,
auxiliary input jack, USB port and Bluetooth voice control with at
least 4 Speakers and 2 tweeters.
• Air conditioning – dual-zone electronic automatic temperature
control (DEATC) non CFC.
• Heater/demister or defroster.
• Interior mirror-Auto-dimming rear view.
• Sun visors on Driver and Front passenger with mirror on Front
passenger side only.
• Automatic Windows – power front and rear with one – touch down
• Lockable fuel tank lid with facility for local and remote opening
• Illuminated and lockable stowage bin.
• Rear of cab fitted with Ventilation Windows.
• Fire extinguisher inclusive.
• Body technical manual (Workshop Manual) in English and
Portuguese.
• Center Console – Cooled.
• Floor mats front and rear with Make or Model Logo.
• Power points – 12-volt auxiliary in front in rear of center console
• Steering wheel-Leather-wrapped with mounted audio and Bluetooth
controls.
• External temperature display.
• Cruise Control.
• Bottle holders – doors.
• Under rear seat storage tray.
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EXTERIOR • Laminated wind screen with green tint.

• Side and rear Privacy glass.
• Outer door mirrors, chrome, heated, electrically adjustable &
retractable with integrated turn signal indicators, puddle lamp’s
• Mudguards/flaps front and rear.
• Rear Window defroster.
• Windshield wipers - front, variable-intermittent with washer and
with Rain Sensing.
• Side steps / Step bars.
• Sports/roll bar with high-mounted stop lamp.
• Rear parking assist with rear view camera.
• Loading Bed Liner.
• Head lamp sand fog lights should be of the halogen type.
• Dusk sensing headlights.
• Roof rails.
• Rear bump-step.
SAFETY/SECURITY • Airbags – driver and front-passenger front.
• Airbags – Side-curtain/ Side impact beams on side doors.
• Front seat side airbags.
• Rear differential lock.
• Vehicle Stability Control.
• ISO-FIX child restraint system.
• Engine immobilizer.
• Belt minder - driver and front passenger.
• Power Door Locks.
• Power central locking with selective unlocking.
• Remote Keyless Entry.
• Fuel flap - Push release.
• Alarm.
WHEELBASE Minimum of 2850mm.
GROUND 220mm to 280mm.

CLEARANCE
CHASSIS Rigid steel chassis with rust protection.
SUSPENSION • Double wishbone front suspension with coil springs.
• Rear suspension - leaf springs with double tube shock absorbers.
• Heavy duty.
ELECTRIC 12-volt alternator-based system heavy duty battery.
COLOUR Dark Grey metallic or Silver Metallic/ Black.

INSTRUMENTS •Speedometer.
• Tamperproof Odometer.
• Fuel gauge.
• Low fuel warning light.
• Engine temperature gauge.
• Oil pressure gauge.
• Tachometer/Trip meter fitted.
• External temperature display.
• Cargo sensor system.
• Cruise Control.
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TOW IN FIXTURE • Front and rear towing eye.

• Towbar, Townball and Trailer Wiring Harness.
• Electrical towing connector.
KEYS • Three sets of keys, separated, with each set fitted on spring
washer with metal / plastic lag showing key numbers.
Table 1.2 – Specification for the Single cab 4x4 Vehicle
Single Cab 4X4

Component Technical Specifications Requirement
General The Vehicle must be Factory new when it is supplied.
Make The make shall have a well-established Service infrastructure in

Quelimane. The model should be in current production.
Model and type The model should be in current production and is common on the
Mozambican market.
Country of Vehicles can be from any Eligible country but manufactured to

manufacture conform to all road conditions in the tropical (Africa) countries
including Mozambique.
Drive Must be right hand drive and comply with Mozambique use.
Number of doors 2 doors easily accessible.
Passenger cab Passenger cab to accommodate 3 persons including driver:
•Seats with headrests.
•Inertia seat belts for all passenger positions.
•Interior lighting provision.
• Heater/demister or defroster.
• Laminated windscreen with green tint.
• Dual windscreen wipers, intermittent with washer.
• Interior rear-view mirror.
• Headlamps and fog lights should be of the halogen type.
• Driver and passenger side sun visors.
• Adjustable and Folding External view mirrors left and right.
• Automatic Windows.
• Lockable fuel tank lid with facility for local and remote opening.
• Lockable Glove box.
• With air conditioner.
• Fire extinguisher inclusive.
• Mudguards / flaps.
• Body technical manual (Workshop Manual) in English.
Chassis Rigid steel chassis with rust protection.

Color White color.
Gross vehicle weight maximum 4 ton.
Warranty minimum 2 years / 100 000 km for the engine and gear box and three years for
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the body work.
Engine Diesel fueled Engine with water cooling system engine suitable for hot
climate.
Engine capacity Not to exceed 3000 cc.
Cylinders 4 in line.
Air/Fuel supply The vehicle can either be normal aspirated or turbo- charged.
Power (Kw) The vehicle to have minimum peak power output of 85 Kw.
Transmission type 5 forward speeds with manual shift mechanism.
Drive wheels The vehicle to be fitted with none permanent four-wheel drive facility.
Front brakes Discs.
Read brakes Drum.
Fuel tank capacity Minimum tank capacity must be 80 liters.
Keys • Three sets of keys, separated, with each set fitted on spring
washer with metal / plastic lag showing key numbers.
Miscellaneous / • Full tropical specifications
Equipment • With vinyl upholstery.
• Fitted with FM & Shortwave radio & CD, with at least 2
Speakers.
• Manufactures approved Jack and toolkit.
• Manufactures approved antitheft / hijack device.
• Emergency first aid kit.
• Two reflector red warning triangles.
• Owner’s manual.
• 2 spare parts catalogues (English).
• One full size spare wheel and tire secured by lockable device.
• Loading Bed Liner.
• Front grill guard (Nudge Bar).
• Rear black cover for load area.
LIGHTING • Two adjustable headlights with high and low beams.
• Two parking lights.
• Two stop and tail light combination.
• Reverse lights.
• Indicators (amber).
• Interior overhead light.
• Instrument panel light.
• Reflectors.
Power steering Power assisted power steering to be fitted on the vehicle.
1.9.17.3 Maintenance of offices

The offices shall be securely locked and the Contractor shall be responsible for providing
effective guarding as well as all cleaning and servicing facilities for the offices.
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Two photographic equipment (digital camera with at least 15 Megapixels and a 20x optical
zoom lens) will be made available for the duration of the Contract for the sole use of the
Engineer and Employer representative when requested.
The Contractor shall, when required by Employer or Engineer, supply labour and necessary
measuring aids such as levelling instruments, theodolite for assisting the Engineer in various
tasks such as measuring, levelling and setting out.
1.10 Temporary Facilities

1.10.1 General
The Works will be implemented with the existing sewer network and with the existing wastewater
treatment plant in operation, and the Contractor will, therefore, be required to liaise closely with the
Engineer and to plan and execute the work in a phased way without discharges of the untreated effluent
in the river.
The Contractor shall pay special attention to this requirement when he prepares the method statements
and programmes specified in Sub-Clause 1.8.2 and shall execute all Works in accordance with such
method statements and programmes.
If a sewage discharge cannot be avoided, the Contractor shall, at least 14 days’ notice of his intention
to commence any Works that might result in a disruption of the treatment or in a sewage discharge,
give notice to the Employer, via the Engineer, of the potential disruption, including its envisaged
duration and a description of the extent to which the operation might be affected. The duration of the
disruption of the treatment cannot be longer than 8 hours.
1.10.2 Temporary Diversions of Wastewater Flow

The Contractor shall ensure regular and continuity of the sewage drainage and of the treatment during
the building works, without discharge to the drainage system / waterline / river, including pumping if
necessary, collector plugging, interim piping and connections. The costs of these diversions shall be
included in the rates and prices tendered for the relevant items in the Bill of Quantities.
The Contractor may, at his own cost and subject to the agreement of the Engineer and the Authorities
concerned, make such temporary diversions as may be required for the carrying out of the Works. Such
temporary diversions shall be reinstated to the satisfaction of the Engineer and the relevant Authorities
on completion of the Works.
1.10.3 Traffic Safety and Control

1.10.3.1 General
The Contractor shall programme the Works in such a way that, wherever the temporary closure of
public roads or thoroughfares cannot be avoided, the duration of traffic diversion can be minimized.
No roads or thoroughfares shall be closed, no detours shall be introduced and no traffic shall be diverted
until the Contractor's proposals have been coordinated with the appropriate Authorities.
If not otherwise instructed by the Authorities, the Contractor shall be responsible for traffic safety and
control and shall comply with the requirements of the Police and appropriate Authorities and have due
regard for all regulations that may be in force at the time of carrying out the Works.
The Contractor shall inspect all existing roads and bridges which he proposes to use and shall make
any arrangements with the appropriate Authorities, Police, and owners as may be necessary for the
movement of special loads.
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1.10.3.2 Traffic Control

Where it is necessary for traffic to pass through the Works, the Contractor shall carry out the Works in
such a manner as to facilitate the safe passage of traffic and minimize delays. The Contractor shall
ensure that excavations and other hazards are protected with barriers and are clearly illuminated at
night. Any damage caused to the Works by the passage of public traffic shall be made good at the
expense of the Contractor.
Where single lane traffic operation is necessary, the Contractor shall provide and operate "Stop" and
"Go" boards and flags to control traffic (i.e. women and men flag persons).
Temporary road diversions proposed by the Contractor shall be of a suitable standard to provide the
safe and convenient passage of traffic, having regard to the standard of the road that is to be closed.
Adequate temporary lighting and signage shall be provided and maintained in good condition at all
times.
The Contractor shall designate or otherwise employ personnel to furnish continuous surveillance of the
traffic control operations. The designated personnel shall be available day and night to respond to calls
involving damage due to vandalism or traffic accidents.
At Sections where traffic is in operation, the movements of the Contractor's equipment from one place
of work to another shall be subject to traffic control. Spillage resulting from construction operations
along public roads shall be removed immediately by the Contractor at his expense.
1.10.4 Provision of Temporary Services

When the rehabilitation or replacement of existing Services requires their temporary disconnection, the
Contractor shall provide temporary services of at least the same standard as the original Services.
1.10.5 Protection of Adjoining Property

The Contractor shall control the movement of his personnel and equipment in such a way as to minimize
damage to crops and property. All damage caused by the Contractor’s activities shall be rectified by
him at his cost and all land, crops or assets affected and/or loss of income caused by the Contractor’s
operations shall be restored by him as closely as possible to its original condition before taking-over of
the Works.
1.11 General Obligations

1.11.1 Responsibility for Information
The Contractor will be deemed to have fully informed himself, by his own independent observations,
enquiries, site visits and investigation, etc. about local and site conditions.
The Contractor is expected to conduct his own research on all important matters related to the Contract.
Any negligence or failure on the part of the Contractor to obtain reliable information about the site or
conditions or any other matter affecting the Contract shall not relieve the Contractor from any of his
obligations or liabilities arising from the Contract.
1.11.2 Site Organization

The Contractor will be responsible for the proper execution of all the Works within the Time for
Completion offered by him and shall, therefore, ensure that sufficient staff/ personnel and equipment
for this purpose are available on site at all times.
The Contractor shall at his own expense provide on the Site all offices, stores, water and electricity
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supplies, communication facilities and other services and facilities required for the undertaking of the
Works.
Along with all pertinent documents that shall be posted in information panels available and visible to
the workers and visitors (e.g., ES and health and safety policies and general rules; list of subcontractors
in the site at a given moment), a detailed updated organization chart of the contractor at the site must
be present at all times.
1.11.3 Contractor’s Supervision

The Contractor shall appoint a Contractor’s Representative and sufficient other managerial and
supervisory staff members for proper supervision of all design and construction work from the
commencement of the work until completion and commissioning.
On commencement of the Works, the Contractor shall hand over a list of the names, designations/ titles
and addresses of his managerial and supervising staff members to the Engineer, together with their
telephone, mobile phone and e-mail contact details.
1.11.4 Co-operation with the Engineer

The Contractor shall co-operate with the Engineer in arranging the time and dates of site meetings and
in preparation of Minutes of Meetings.
The Contractor shall co-operate with the Engineer in taking photographs for the documentation of the
Works progress.
The Contractor shall provide every assistance to the Engineer and his duly authorized assistants in the
carrying out of their duties and shall, when requested, provide personnel and equipment to assist them
with the checking, sampling, testing, setting out and measurement of the Works done. This includes the
adequate preparation and implementation of the Contractor ESMP (C-ESMP) and Health and Safety
Plan (HSP).
1.11.5 Co-operation with Resettlement Action Plan Expert

The Contractor shall co-operate with the Employer’s Expert responsible for the Resettlement Action
Plan (RAP). The objectives of the RAP are to:
• assess any adverse impacts of the proposed Project on the communities living near or on the
proposed Project impact area
• assess the severity of the impacts
• guide payment of compensation and resettlement activities to ensure that the project affected
persons (PAPs) are compensated fairly and, if required, have been resettled with ease and
minimum disruption to their lives
The RAP is expected to be elaborated, respectively in its final stage of elaboration at time of physical
Works commencement.
1.11.6 Co-operation with Employer Site Representative

The Contractor shall co-operate with the Employer’s Site Representative providing any additional
clarification regarding doubts and the project.
1.11.7 Co-operation with other Contractors

The Contractor may have to co-operate with other contractors, whether it be related to this project or a
separate project. This co-operation does not automatically entitle for any additional time extension or
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payments, and covers activities such as but not limited to: Coordination and adjustment site possession,
coordination and adjustment of time schedules, working space, manpower, timing, traffic regulation;
attending of coordination meetings called in by the Employer or as might be necessary for optimum
coordination of activities.
1.12 Contractor's Designs

1.12.1 General
Where required in terms of the Works Requirements included in these documents, the Contractor shall
prepare detailed execution designs, including additional drawings and complete specifications of
materials and workmanship, in such detail that the Works can be executed on site and the plant or
equipment can be manufactured and installed, and that the Engineer can release Contractor's designs
and intentions for the implementation of the Works.
The detailed execution designs shall comply with the solution defined by the detailed engineering
design included in the contract. Any required calculations and drawings shall be collated in execution
design reports, with a separate report being prepared for each facility designed by the Contractor. The
draft reports shall be submitted in time for incorporation of the Engineer’s comments into the final
reports without delaying the programmed implementation of the Works.
The Engineer's review of the Contractor’s drawings, calculations, etc. shall serve as a spot check only
to ascertain whether the execution designs have been prepared in accordance with the engineering
design and the requirements.
1.12.2 Prior Site Inspection

The Contractor shall base his execution designs on the engineering design included in the contract,
complemented by all additional information deemed necessary. This may include thorough site
inspections carried out to determine and record all the data required for undertaking the designs. All
information given in the tender drawings and documents shall be verified by the Contractor and
corrected where necessary.
The Contractor must base his designs on the actual situations as determined by the prior site inspections
and he shall pay particular attention to dimensions and elevations of existing structures, plinths, etc.
1.12.3 Numbering System

The Contractor shall design and propose one or more system(s) for numbering of:
• all documents and manuals
• all drawings
The system(s) shall provide easy identification of all numbered items, and it shall be easy to see if
drawings are made by the Contractor or one of his sub-Contractors (if any).
The Engineer shall agree to the numbering system(s), and all sub-Contractors shall apply the agreed
numbering system(s).
1.12.4 Technical Standards and Regulations

The execution designs, the Contractor's Documents, the implementation of the Contract and the
completed Works shall comply with the Country's technical standards, building, construction and
environmental laws and regulations, laws applicable to the product being produced from the Works,
and other standards specified in the Works Requirements, applicable to the Works, or defined by the
applicable Laws.
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1.13 Submissions by the Contractor

1.13.1 Insurances
The Contractor shall, in accordance with Clause 18 of the General Conditions of Contract (GCC),
provide evidence of and copies of the policies for the following insurances:
• Insurance of the Works and Contractor’s Equipment, including insurance of the materials
supplied by the Employer
• Insurance against Injury to Persons and Damage to Property
• Insurance for Contractor’s Personnel
1.13.2 Work Programme

In accordance with Clause 8.3 of the GCC, the Contractor shall submit a Detailed Work Program to the
Engineer. This program shall be coordinated with the Employer and the relevant Authorities and
organizations so as to minimize interference with public services. The program shall be in the form of
time sequence bar charts for the overall project and for sub-components of the project and shall be
supported by method statements demonstrating how the various phases of the Works are to be carried
out so as to comply with the requirements of the Contract.
1.13.3 Working Drawings

Working Drawings (also referred to as Shop Drawings) shall be submitted by the Contractor to the
Engineer as called for under the Contract. Working Drawings shall include, but not be restricted to,
reinforcement drawings and bending schedules.
It shall be the Contractor's responsibility to prepare such Working Drawings as he may require for the
proper setting out and construction of all structures and facilities and the installation of all equipment,
pipework and fittings. The Contractor shall not commence work on any structure or facility until the
relevant Working Drawings have been released by the Engineer.
All dimensions shall be in metric units and each drawing shall be properly identified by a title and
number inserted in a sheet layout and title block agreed with the Engineer. ISO or DIN standard size
sheets shall be used. Drawings shall not be smaller than 210 x 297 mm (DIN A4) or larger than 841 x
1189 mm (DIN A0). Drawings in sizes A3 will be preferred, respectively drawn in A1 but printed to
A3. Prior to submitting them, the Contractor shall check any drawings for accuracy and completeness.
Any changes or modifications to the Working Drawings that the Engineer considers to be necessary
shall be made by the Contractor promptly and the drawings resubmitted for release for implementation.
Working Drawings will be released for implementation by the Engineer in the form of signing the
Working Drawings together with the date of release. Only those Working Drawings carrying the
signature and date shall be used for execution.
Should it be found at any time to a released Working Drawing that the said Working Drawing does not
comply with the terms and conditions of the Contract or that the details do not agree with the Working
Drawings previously released, such alterations and additions as may be deemed necessary by the
Engineer shall be made by the Contractor to the drawing concerned and the associated work carried out
accordingly without extra payment to the Contractor, except where such alternations and additions are
made in compliance with a written order from the Engineer to vary the Works.
No examination by the Engineer of any document submitted by the Contractor or of the Contractor's
Working Drawings, nor the release expressed by the Engineer of the same, either with or without
modification, shall absolve the Contractor from any liability imposed on him by any provision of the
Contract. Notwithstanding the Engineer’s release of the Working Drawings, the Contractor shall be
responsible for any dimensional or other errors.
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1.13.4 Monthly Progress Reports

The Contractor shall provide the Engineer with monthly progress reports. The reports shall be submitted
in a format agreed with the Engineer and shall contain the following information:
• physical progress for the reported month and expected progress for the next month, incl.
description of activities completed and in progress
• completion schedules (target and actual) based on the current program
• updated time schedules for physical progress at different Sections of the Works
• trend graphs of key activities
• inspection/ taking over schedule
• financial overview, incl. actual and forecast cash-flow
• summaries of e.g. site instructions, variation orders etc.
• contractor’s personnel and constructional plant
• labor matters
• weather condition records
• photographic/ video record of the sites
• any other information which may be specifically requested by the Employer and/ or the Engineer
• progress on procurement of key materials and equipment forming part of the works
• progress on services to be provided by other entities (e.g., water and power supply)
• planned activities for the next month
• challenges and plan to resolve them
• status and challenges of the preparation and implementation of the C-ESMP and HSP
• accidents and other incidents
A separate specific report should be submitted for environment, social and health and safety related
matters (according to Particular Conditions of Contract, Part D - ES metrics for progress reports).
The monthly reports shall be submitted not later than the 5th day of each report month (reporting period
01/mm/yy – 30/mm/yy).
1.13.5 Record Photographs

The Contractor shall periodically take photographs that record his progress with the Works and show
Works that will be hidden later on. The photographs shall be collated monthly into documents in which
they shall be colour printed, at a size of 6 photos per one A4 page, dated and accompanied by comments.
A hard copy of each monthly set of record photographs shall be annexed to each hard copy of the
associated monthly progress report, and an electronic copy shall also be submitted to the Engineer.
1.13.6 As-Built Documents

The Contractor shall prepare, and keep up-to-date, a complete set of "as-built" records of the
implementation of the Works, showing the exact as-built locations, sizes and details of the work as
executed. These records shall be kept on Site.
The Contractor shall prepare and submit to the Engineer before completion of each Part of the Works/
Section, duly amended as-built documents.
1.13.7 As-Built Drawings

All As-Built Drawings (ABD) shall be fully dimensioned to show the locations, elevations, dimensions
and other pertinent details of the Works implemented under this contract.
Those ABD shall contain but not limited to:
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• Drawing reference number as agreed with the Engineer;

• All coordinates given as in the Tender Drawings or otherwise as instructed by the Engineer;
• Drawings with the identification of the study area and its main existing sewage infrastructures;
• Standard detailed drawings (ring and concrete manholes, valves, transition chambers (if any),
and others);
• Drawings with the clear identification and location of the new sewerage infrastructures to be
built (exact positions of pipe axis and pipe depths) and their interconnection with the existing
systems, when applicable;
• X,Y,Z co-ordinates of all manholes and concrete chambers;
• For sewage house connections, the particular house identification number according to street
name and house number as to be provided by the Employer; in case that a house identification
system is not available the numbering system shall be agreed with the Employer;
• Crossings with all other services such as sewer/ water supply, optical, telephone and electricity
cables etc.;
• Reference points/ Landmarks (e.g. buildings, solid fences, etc.) for structures;
• Detailed drawings of river crossings; Detailed drawings resulting from Tete wastewater
treatment plant rehabilitation and expansion design, including implantation, modelling platform
plan and profiles, process and instrumentation (P&ID) diagrams; hydraulic profile; treatment
devices and service buildings details;
• Detailed drawings resulting from Structures Design;
• Detailed drawings resulting from Electrical and Mechanical Installations Design;
• Detailed drawings resulting from Architectural Design;
• All other drawings related to the equipment installed that shall be correlated to the Operation &
Maintenance manuals
• In any case the ABD shall form part of all Operation & Maintenance Manuals they shall be
properly cross- referenced and indexed
The ABD shall be compatible with the existing Client’s GIS.
The ABD are subject of review by the Engineer at the latest at the date of the commissioning of the
respective Works. The ABD shall be provided electronically in AutoCAD and/ or GIS format and in
hard copies, in size (e.g. A3) and quantities as agreed with the Engineer. However, not bigger than A2
and not more than four copies.
1.13.8 Operation and Training Manuals

The Contractor shall prepare comprehensive Operating and Maintenance Manuals covering all items
of the Works and equipment, including all manufacturer's instructions, references and lists. The
manuals shall include an outline of the general principles of operation and maintenance of the items
and shall make specific reference to the particular equipment provided. Sales brochures may be
included only as additional information.
The manuals shall also include a list of addresses with contact details of the suppliers’ representatives
within the country or abroad which can provide after sales service, spare parts or operation support.
The manuals shall be submitted at least in three copies and shall cover the testing, operation, control,
maintenance, dismantling and repair of all plant and components thereof, provided in the Works. All
information shall be supported by:
• Catalogues and brochures
• Dimension drawings
• Data sheets
• Descriptive text
• Comprehensive drawings, sketches, plans, sections as may be required
The greatest importance shall be drawn to the completeness and clearness of the Manuals.
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It is emphasized that a collection of standard pamphlets of general nature unaccompanied by drawings
and descriptions referring to the actual as-built or as-installed situation will not be acceptable. In
particular, information supplied by Sub-Contractors and manufacturers employed by the Contractor
shall be prepared to form a comprehensive manual. Cross-references of descriptive texts, drawings and
spare part lists must be included and shall be related to the ABD described above.
The Contractor shall deliver to the Engineer loose leaf copies of draft operation and maintenance
manuals for the Works and the auxiliary Plant in reasonable time before issue of the taking over
certificate. The manuals shall be divided into several volumes (e.g. function, operation, maintenance,
and overhaul) and shall fully and clearly set out the Contractor's own recommendations and instructions
for the satisfactory operation, maintenance and overhaul of the Works and equipment as far as part of
this Contract.
The text or accompanying diagrams shall in addition show the electrical wiring, handling and erection
instructions. Draft manuals shall, during the testing and commissioning of the Works, be carefully
checked by the Contractor, updated and modified to ensure that they are fully descriptive and applicable
to the final layout of the Works.
The finally agreed manuals shall be securely bound in A4 sized loose leaf binders, clearly titled, index
linked and cross referenced. If prepared on computer, standard PC word processor software such as
Word for Windows shall be used, and a copy of the data file for each volume, on CD or USB Flash
Drive, shall be supplied in order to facilitate updating and searching for information. No section of the
Works will be taken over by the Engineer as completed unless this requirement has been met.
If during the defect notification period, the Contractor or the Engineer has found that the manual
requires modification or enlargement as a result of subsequent operational and maintenance experience
in the Works, the Contractor shall provide such modification for each relevant manual.
For the systems, these shall include depending on its specifics:
• Detailed procedures for operation, repair and maintenance
• Listing required daily, weekly, monthly, yearly or other regular maintenance procedures,
including for e.g. bar screens, sluice gates, movable weirs, stop logs, ultrasonic level meter, solar
power system.
• Complete overhaul, dismantling and reassembly, testing and re-commissioning
• Recommendations for pipe repair material
• Detailed descriptions of how to make house connections on the supplied pipe material
• Description on how to adjust the level of street caps, in case e.g. the surface/ road level will be
changed
• Guidelines for protection of Works and equipment
• Maintenance of protective coating
• Health and safety and environmental and social management measurements for operation
• For any equipment installed, the manual shall also include:
• Checklists for daily, weekly, yearly maintenance procedures
• Maintenance and service time schedules
• Systematic failure and troubleshooting procedures
• Easy understandable procedures for change of weir parts, repair works and re start-up
• Clear and visually supported installation schemes of the equipment
• Lists of supplies for repair and maintenance material
• Health and safety and environmental and social management measures for operation
• Outline of training conducted for operating personnel (Training Manual)
The operating instructions shall be harmonized between the electrical and mechanical systems and
contain the function of the electric equipment as well as the process itself, which is controlled with it.
The instructions shall clearly specify the function of each device and how it has to be operated. All
signals and indicated values shall be explained; necessary instructions shall be added.
The Contractor shall in preparing these documents cooperate with the Engineer. However, the
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Contractor shall present their own format at first.
Within 21 days after receipt of the subsequently to be delivered as-built documentation, the Engineer
shall return to the Contractor 1 copy of each document showing any amendments required by the
Engineer. Within 21 days after receipt of the amended documents, the Contractor shall issue the
amended documents.
The Taking-Over Certificate will not be issued before receipt of the final as-built documents. Any delay
in issuing the Take-Over Certificate caused by late submission of the as-built documents by the
Contractor will be classified as a delay caused by the Contractor and the corresponding penalties will
be applicable.
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1.13.9 Summary of Contractor’s Documents
The schedule below gives a summary of the documents that shall be submitted by the Contractor in
accordance with the Contract. The schedule is not exhaustive, but provides an overview of Contractor’s
submittals. If not specifically mentioned, all documents shall be submitted in Original (if applicable,
e.g. Securities, Insurance policies), two hard copies as well as soft copies, either in editable (e.g. -.doc,
-.xls) or noneditable version or both.
Table 1.3 – Summary of Contract Documents

Item Document Description/ Reference Timing
A2 Insurance Policies Policies of concluded insurances in

accordance with the Contract
A3 Work Programme Initial detailed time programme of
Works to be prepared in project (to
be updated as and when needed/
required)
A4 Cash Flow Initial detailed cash flow forecast (to
be updated at least quarterly)
A5 Quality Assurance Plan Sub-Clause 1.14
(QAP) Not more than 28 days
after the Commencement
A6 Contractor’s PCC 4.1 & 4.18 Date
Environment and Social Sub-Clause 1.15
Management Plan (C-
ESMP), including the
ESMP implementation
plan, and Contractor’s
Code of Conduct
A7 Health and Safety Plan PCC 4.8 Within 21 days of the
Sub-Clause 1.16 Commencement Date
Labour Management Plan Special Provisions Prior to site mobilization
Sub-Clause 4.1
B Schedules, Method Statements and Working Drawings
B1 Method statements and Sub-Clause 1.8.2 Not less than 2 weeks

programmes for each site before Works are due to
start
B2 Working Drawings Sub-Clause 1.13.3 To suit Work Programme
C As-Built Documents
C1 Draft as-built documents Sub-Clause 1.11.6 Progressively as the Works

for each site at each site or facility is
completed
C2 Full set of final As-Built Sub-Clause 1.13.6 in 2 weeks before the
documents six hard copies intended issuing of the
"Taking-Over Certificate”
D Reports and Certificates
D1 Monthly reports and Sub-Clauses 1.13.4 and 1.11.5 28th day of each report
record photographs month
D2 Records of Contractor’s GC 6.10 Monthly
Personnel & Equipment
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Item Document Description/ Reference Timing
D3 Test certificates and numerous within the Specifications In accordance with Work
reports programme
1.14 Quality Assurance

1.14.1 Quality Assurance System
1.14.1.1 General
In order to ensure that the contractual requirements concerning quality are achieved, a Quality
Assurance system incorporating the following principles shall be established.
1.14.1.2 Standards and Recommendations

The Contractor shall ensure that the quality control complies with the effective Mozambique standards
and shall obtain guidance from the following international standards, as relevant:
ISO 9000 Standards for the quality control and assurance - Guideline for selection and utilization.
ISO 9001 Quality system - Model for the quality assurance in conception development,
production, installation, and after-sales support.
ISO 9002 Quality system - Model for the quality assurance in production and installation.
ISO 9003 Quality system - Model for the quality assurance in controlling and final tests.
ISO 9004 Quality control and element of the quality system - Guidelines.
ISO 8402 Quality management and quality assurance - Vocabulary.
1.14.1.3 Preparation of the Quality Assurance Procedure

The compilation of the quality assurance procedure will start when the Contractor submits the Quality
Assurance Plan (QAP).
The Contractor shall ensure that the quality assurance procedures of his Sub-Contractors comply with
the QAP.
The following parties shall be represented in meetings arranged for preparation of the quality assurance
procedure: The Employer, the Engineer, the Contractor and all physical or legal persons contributing to
the Contract. The first such meeting shall be arranged by the Contractor not later than 3 weeks after the
Engineer receives the Quality Assurance Plan from the Contractor.
On the basis of the organizational scheme of the Quality Assurance procedure, the Contractor shall
develop the Quality Assurance Plan (QAP) for this Contract.
The QAP shall record all arrangements for Quality Assurance that are to be implemented by the
Contractor and his Sub-Contractors, suppliers and manufacturers in a simple but exhaustive way.
The Contractor shall ensure that all documents remain traceable (list of documents, indication of the
revision in course, nature of validation, etc.).
Finally, the Contractor will be responsible for keeping the QAP up-to-date in accordance with the
Quality Assurance Procedure and the events of the Contract.
1.14.1.4 Quality Audits

The Engineer shall be permitted to audit any aspect of the Quality Assurance procedure and the C-ESMP
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and HSP implementation of the Contractor at any time during the Contract, in which case an audit report
shall be completed not later than 3 weeks after the performance of the audit.
If the Engineer establishes, by means of such an audit or in the course of performing his obligations
under the Contract, that the Contractor or his Sub-Contractors or suppliers are not complying with any
aspect of the QAP or procedure, (s)he shall notify the Contractor of such non-compliance, with a copy
to the Employer.
The Contractor shall, on receipt of such a notification, take immediate action to achieve compliance and
shall, within a period of 10 working days from the date of receiving the notification, respond to it in
writing indicating what corrective actions have been taken by him and what measures have been
implemented by him to prevent the recurrence of such a non-compliance.
1.14.2 General Inspection and Acceptance

The Engineer may appoint Inspectors to check and test materials, plant and equipment on his behalf
prior to their dispatch to the Site. The Inspectors will examine, test and, if necessary, analyze all materials
and articles to be used in the Works, including all items of fabricated or finished Works, unless the
Engineer directs otherwise and shall be granted access for this purpose at all reasonable times to the
premises of the Contractor and/ or any Sub- Contractor, and shall be afforded every facility for making
such inspections and tests and for taking samples for testing and analysis.
The inspection of all items of fabricated or finished Works will only be carried out against Working
Drawings and design documents that have been released by the Engineer for implementation.
Accordingly, neither the Engineer nor the Inspector will undertake the inspection of any item of
fabricated or finished Works until such time as the Contractor shall have forwarded to the Engineer the
related Working Drawings covering the items to be inspected.
The Contractor shall give adequate notice to the Engineer or the Inspector as to when any materials,
articles or fabricated work will be ready for inspection. The Engineer shall be kept properly informed of
the progress of any work being carried out on materials and articles that are to be inspected or tested so
as to enable them to make such arrangements for inspection, testing and analysis as they may consider
to be appropriate.
Manufactured items and materials delivered to the Site shall be inspected by the Contractor on arrival or,
in the case of materials supplied by the Employer, on handing-over. Any defects shall be notified to the
Engineer. Minor defects to surface finishes and the like in manufactured items supplied by the
Contractor shall be made good by the Contractor to the satisfaction of the Engineer. Items with more
serious defects shall be returned to the suppliers for correction or replacement as appropriate.
1.14.3 Certificates
Where certificates are required by the Specifications or relevant Reference Standards, the original and
one copy of each such certificate shall be submitted to the Engineer by the Contractor. Certificates shall
be clearly identified by serial or reference number and shall include information required by the relevant
Reference Standard or Specification clause.
1.14.4 Daily Log Book

The Contractor shall keep a Daily Log Book at each site. This Daily Log Book shall be in a form agreed
with the Engineer and shall contain, but not be limited to, the following items of information:
• Name of Contractor and Contract No.
• Date
• Weather conditions (max/min temperature, amount and duration of rainfall)
• Data and results of daily read or online environmental monitoring stations
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• Work carried out during the day (description, quantities)

• Major equipment used (on contractual work, on extra work ordered, operating time for either)
• Labour employed (on contractual work, on extra work ordered, hours worked on either)
• Delays (cause, effects)
• Unusual events (earthquakes, floods, fires, storms, accidents, etc.)
• Sub-Contractors working on site
• Visitors to site
Each daily log shall be signed by the responsible site manager of the Contractor and all daily logs shall
be submitted to the Engineer on a weekly base.
1.15 Environmental Protection

1.15.1 General
The Contractor shall take all necessary measures and precautions and otherwise ensure that the
implementation of the Works and all associated operations, both on or off the Site, are carried out to
protect the environment and in conformity with statutory and regulatory environmental requirements,
as well as the approved C-ESMP and HSP.
The Contractor shall also take all measures and precautions necessary to avoid or limit any damage,
nuisance or disturbance to people and property arising from pollution, noise and other results of the
implementation of the Works (Contractor’s operations and/ or activities). Such measures and
precautions shall, wherever possible, target suppression of the nuisance at source rather than abatement
of the nuisance once created.
The provisions of the following Sub-Clauses shall only be disregarded in respect of emergency work
required for the saving of life or property or the safety of the Works.
In the event of any spoil or debris or silt from the Site being deposited on any adjacent land or damage
to the environment, property and/or nuisance to people, on or off Site, the Contractor shall immediately
restore the affected area to its original state to the satisfaction of the Engineer.
1.15.2 Management Strategies and Implementation Plans

Within contractual terms, the Contractor shall submit detailed Management Strategies and
Implementation Plans (MSIPs) to the Engineer for review and approval showing how he intends to
address environmental and social and health and safety risks and impacts and comply with
environmental and labour laws and regulations and other environmental, social, health and safety
requirements described in ESIA and ESMP that form of the Contract. The MSIP shall include, but are
not limited to the ones described in ITB 11.1(h) of the Bid Data Sheet.
All MSIPs (the ones submitted as part of the BID and agreed as part of the Contract and any additional
ones as are necessary to manage ES and H&S risks and impacts of Works) collectively comprise the
Contractor’s Environmental and Social Management Plan (C-ESMP) and H&S Plan (HSP).
Besides provisions, measures, precautions and plans described in this regard to other Sub-Clauses
(Licenses and Permits; Access and Possession of Site; Site Working Arrangements; Temporary
Facilities; General Requirements for Civil Works; and also, Co-operation with RAP Expert and Health
and Safety), the following mitigation measures apply, all of which shall be implemented by the
Contractor:
• Traffic Safety Management Plan
• Preservation of top soil (humus layer), which shall be removed and temporarily stockpiled for
incorporation into the landscaping Works
• Dust control measures
• Limit exhaust emissions
• Measures for abating noise at source
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• Effective erosion control measures

• Measures for prevention of contamination, sedimentation or other disturbance of all streams and
rivers
• Measures of controlling emissions and by-products of technological processes
• Solid and liquid waste management and collection and environmentally safe disposal
arrangements
• Preparation of an action plan for dealing with environmental and health and safety incidents
• Enforcement of the Code of Conduct (CoC) and GBV/ SEA Action Plan
• Enforcement of the Labour Management Plan (LMP)
• HIV/AIDS Awareness Program
Reference in this regard is also made to General Conditions - Appendix C and Particular Conditions of
the Contract-Part D.
1.15.3 Fuel and Chemical Storage

All fuel and chemical storage tanks and containers shall be sited on an impervious base within a bund
and secured by fencing. The base and bund walls shall be impermeable and of sufficient capacity to
contain 110% of the maximum volume of the largest tank and container. Filling and refueling shall be
carried out on an impervious base, including an oil-water separator and strictly controlled and subject
to formal procedures to be communicated to all operators of the tanks. Written instructions and/ or clear
icons displaying the correct/ incorrect procedure shall be installed at place of tanks in adequate size.
All valves and trigger guns shall be resistant to unauthorized interference and vandalism and shall be
turned off and securely locked when not in use.
The contents of any tank or container shall be clearly marked.
Measures shall be taken to ensure that no contaminated discharges enter drains or water courses.
Adequate binders shall be at place of permanent dealing with fuel and chemicals.
1.15.4 Water Quality

The Contractor shall prevent any interference with or pollution of water resources (including
underground water) during the implementation of the Works.
All water and other liquid waste products arising on the Site shall be collected and disposed of at a
location on or off the Site and in a manner that shall not cause either nuisance or pollution. The
procedures shall be agreed with the Engineer.
The Contractor shall not discharge or deposit any matter arising from the implementation of the Works
into any waters except with the permission of the Engineer and the regulatory Authorities concerned.
The Contractor shall at all times ensure that all existing stream courses and drains within and adjacent
to the Site are kept clean and free from any debris and any materials arising from the Works.
The Contractor shall submit details of his temporary drainage systems (including all surface channels,
sediment traps, washing basins and discharge pits) to the Engineer for approval prior to commencing
work.
1.15.5 Air Quality

The Contractor shall devise and arrange methods of working to minimize dust, odours and gaseous or
other airborne emissions, and shall carry out the Works in such a manner as to minimize adverse
impacts on air quality (Air quality standards can be found in the World Bank Group General
Environmental, Health and Safety Guidelines of April 2007).
The Contractor shall utilize effective water sprays during the delivery and handling of materials when
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dust is likely to be created and shall dampen stored materials during dry and windy weather.
Stockpiles of materials shall be sited in sheltered areas or within hoarding, away from sensitive areas.
Stockpiles of friable material shall be covered with clean tarpaulins, with application of sprayed water
during dry and windy weather. Stockpiles of material or debris shall be dampened prior to their
movement, except where this is contrary to the Specification.
All trucks transporting soil or other potentially dust producing materials through populated areas shall
be covered with clean tarpaulins in good condition. The tarpaulins shall be properly secured and extend
at least 300 mm over the edges of the side and tail boards.
Construction vehicles and machinery shall be kept in good working order and engines turned off when
not in use. Appropriate measures shall be taken to limit exhaust emissions from construction vehicles,
machinery and plant, and the Contractor shall include details of such proposed measures in the EPP.
1.15.6 Noise
The Contractor shall take effective measures to minimize noise when planning and executing of the
Works (Noise quality standards can be found in the World Bank Group General Environmental, Health
and Safety Guidelines of April 2007).
The Contractor shall use plant and equipment conforming to national or international standards and
directives on noise and vibration emissions and shall include details of measures for abating noise at
source in the EPP and shall maintain all plant and silencing equipment in good condition so as to
minimize the amount of noise emission created by his activities.
1.15.7 Preservation of Existing Landscape

The Contractor shall exercise care to preserve the natural landscape in the vicinity of the Works and
shall conduct his operations so as to prevent any unnecessary destruction, scarring or defacing of
existing landscape features. The removal of trees, bushes, and other natural vegetation shall only be
carried out with the prior agreement of the Engineer or responsible Authority. On completion of
substantial parts of the Works, the Contractor shall make proposals for reinstating the landscape and
natural vegetation and, with agreement of the Engineer, shall carry out such reinstatement.
1.15.8 Cleanliness and Waste Management

The Contractor shall make every effort to keep the site tidy and orderly and shall take at all times every
possible precaution against the contamination of soil, subsoil, surface water and groundwater.
The Contractor shall be responsible for making all arrangements for the adequate and environmentally
safe disposal of solid and liquid wastes from the Site at his own expense. Furthermore, he shall ensure
that all persons employed by him use the sanitary accommodation provided at Site.
If the Contractor fails to keep the Site clean, the Engineer will instruct a third party to carry out any
necessary cleaning work at the cost of the Contractor, within the limits of the contractual conditions.
In addition to comply with any national laws and regulations, the Contractor should implement waste
management principles set internationally, namely the EU Construction and Demolition Waste Protocol
and Guidelines.
1.16 Health and Safety

1.16.1 General
The Contractor shall comply with all relevant local Health and Safety legislation at all times during the
period of the Contract and shall prepare and implement a Health and Safety Plan (HSP), which needs
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to be approved by the Engineer. The Contractor recruits for this purpose an ISO 45001, OHSAS
18001:2007, NEBOSH or similar certified Health & Safety Specialist.
The Contractor shall be responsible for the safe implementation of the Works. He shall ensure that all
operations are carried out safely and that any person made responsible for the safe conduct of any part
of the operations carries out his duties in a proper manner.
Where any part of the Works is not covered by the Contractor’s Safety Policy, or includes a high-risk
activity, the Contractor shall, before commencing work on that part of the Works or activity, submit to
the Engineer a safe system of working statement. He shall immediately submit to the Engineer any
subsequent additions to, or amendments of, this statement. No work covered by any safe system of
working statement shall be commenced unless the Engineer has indicated that (s)he has no objection to
the methods proposed.
The Contractor shall provide all necessary qualified medical staff, ambulance, toilet (urinal or toilet
plus a washbasin) and other facilities for the welfare of his employees at Site. The facilities shall be to
at least the standard required by law, local regulations or agreements between Trade Unions and
Employer’s, and shall not be less than the more stringent between OSHA regulations, ANSI and BS
standards and HSE recommendations. A high standard of hygiene and cleanliness shall be maintained
at all times.
1.16.2 Labour Management Plan

The Contractor shall enforce the Labour Management Plan following the proposed measures and
identifying necessary resources to address labour issues accordingly with main labour risks associated
with civil works.
As stipulated in the LMP, the contractor will be required to have a written contract with his workers
materially consistent with the Mozambican Labour laws, in particular about child and forced labour,
following procedures as specified in the World Bank’s Procurement Regulations.
Regarding the risk of unaccounted working hours and lack (or insufficiency) of compensation for
overtime, the contractor will seek to address the risk through informing Workers their rights and
establishing a Grievance Redress Mechanisms for Workers as specified in the LMP.
Adequate attention is given to:
• ensure that workers are being paid adequately accordingly with Mozambican minimum wage
for construction;
• ensuring Social Security payments to the (INSS) are made for all workers;
• ensuring that all workers have a bank account and that their salaries are transferred to their Bank
accounts on a monthly base;
• ensure extra hours are paid according to the Mozambican Labour law;
• ensure that working time does not exceed worktime limits stipulated by the Mozambican labour
law;
• ensure proper work conditions (transportation, toilets, etc.);
• Ensure that female workers are entitled to the same salary benefits as male workers;
• ensure the GRM is operational and accessible (to workers and to the community).;
• ensure all workers have signed an adequate code of conduct addressing Gender Based Violence
(GBV);
1.16.3 Health and Safety Plan

The Contractor shall submit a document titled "Health and Safety Plan" (HSP) giving a detailed
description of his proposed methods for ensuring that the Works are executed in a safe manner and
without risk to the health of any person directly involved with or coming into contact with any activities
forming part of the Contract.
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The HSP shall document how the Contractor will ensure that:
• The implementation of Health and Safety procedures is properly managed and recorded
• Adequate attention is given to site safety including:
• Preparation of safe working procedures for all construction, operation and maintenance
activities
• Promoting cleanliness and care of the components of the Works
• Reporting of accidents and hazards
• Promoting safe practice in pumping stations, water treatment works, water reservoirs and
towers, pipeline construction, etc.
• The Safety file is maintained and updated
The HSP shall be sufficiently detailed that there can be no ambiguity in its interpretation at a later date.
The HSP shall be subject to the approval of the Engineer, who will not allow any work on site to proceed
until such time as it has been fully and formally approved. Approval of the HSP shall not relieve the
Contractor of any of his responsibilities with regard to safety.
1.16.4 Confined Space Working

The Contractor’s attention is drawn to the hazards of working within chambers, shafts, channels or tanks
and poorly ventilated areas. The Contractor shall ensure that the safety and ventilation equipment
required for working is such structures and areas in a safe and healthy manner is available, properly
maintained and diligently used at all times.
Labourers working under such conditions shall be adequately trained and certified.
1.16.5 Simultaneous Installation

In order to decrease the disturbance of the local population, the Contractor is required to install the
Valves, Fittings, Hydrants, House Connections etc. together with the mains as much as possible.
1.16.6 Electricity
The Contractor shall ensure that any person having access to the locations on Site where open or only
partly protected power supply cables and contacts are present, is safeguarded against accidental contact
with electricity. The Contractor shall also ensure that any person working with or near to electrical
equipment and plant is properly trained, skilled and equipped to avoid any accidental contact with
electricity.
The Contractor shall inform the local electricity company about any work which might affect their
power supply network and he shall implement any measures prescribed by the company for the
undertaking of such work.
1.16.7 Fire Fighting Equipment

The Contractor shall take all necessary precautions to prevent fire, provide all fire-fighting equipment
necessary for the working environment, including training of responsible employees and provide for
effective means of escape in case of fire or emergency for any personnel working on or visiting the Site.
1.17 Quality of Materials

1.17.1 Manufactured Materials
All materials, fixtures, fittings, and supplies provided by the Contractor for the Contract shall be new
and unused, and of good quality, workmanship and design. No inferior or low-grade materials, supplies
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or articles will be accepted, and all work of assembly and construction shall be done in a proper and
workmanlike manner.
When obtaining quotations for materials intended for delivery to the Site and incorporation into the
Works under any portion of these Specifications, the Contractor shall provide the manufacturer or
supplier with all information necessary for achieving compliance with this clause and he shall, in every
case, quote this clause in full to each manufacturer or supplier.
Manufacturer’s Certificate of Compliance. For off-the-shelf labelled stock products of standard
manufacture which have a record of satisfactory performance in similar work over a period of not less
than two years, the Contractor shall obtain notarized statements from the manufacturers or suppliers
certifying that the products conform to the Specifications.
1.18 Submissions of Materials and Equipment

1.18.1 General
All materials and equipment intended to be incorporated into the Works shall be subject to release for
application by the Engineer prior to being ordered by the Contractor.
No materials or equipment shall be shipped or transported from their point of original supply,
manufacture or final shop assembly to the Site before they have been agreed with the Engineer.
1.18.2 Materials Orders

Whenever requested, copies of material and equipment orders and lists of stock material or equipment
shall be provided to the Engineer. All orders and stock lists shall state the standard specification under
which the goods are to be furnished, pertinent drawing and part numbers if any, and the required
delivery date, and shall state that the goods are subject to inspection and testing by the Engineer before
acceptance.
1.18.3 Submission of Samples and Data

Samples, drawings, catalogues, diagrams and other descriptive data for all materials, components and
equipment which the Contractor proposes to incorporate into the Works shall be submitted by him to
the Engineer.
Such samples and data shall be clearly labelled to indicate the Contract Number, Contractor, source of
supply, manufacturer, contract item number, and other data required by the Specifications.
All such samples and data shall be submitted to the Engineer in sufficient time, but not later than 28
days prior to purchase, for the release procedure to be completed prior to the proposed date for ordering
of the goods concerned.
Items released for application shall be shipped prepaid by the Contractor and the Contractor shall give
the Engineer advance notice of all items shipped.
1.18.4 Testing of Samples

The Contractor shall arrange for the specified tests to be carried out, either at the Site, the supplier’s
premises or an independent laboratory agreed with the Engineer. Such laboratory may be outside the
country.
Samples shall be submitted and tests carried out sufficiently early to enable further samples to be
submitted and tested, if required by the Engineer.
Samples that are of value after testing shall remain the property of the Contractor.
The Contractor shall give the Engineer at least 21 days’ notice of the date on which any of the goods
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will be ready for testing or inspection at the supplier’s premises or at a laboratory agreed with the
Engineer. Unless the Engineer attends at the appointed place and time, the test may proceed in his
absence. The Contractor shall, in all cases, submit the test results to the Engineer within seven days
after the test, respectively in due time after test completion.
1.18.5 Test Laboratory Certificates

Commercial testing laboratories agreed with the Engineer shall provide certificates, for each product
tested, confirming that the product has been tested and that it complies with the requirements of the
Specifications. The results of any tests undertaken by such laboratories shall be appended to the
certificates.
1.18.6 Service Record

If a demonstrably satisfactory service record is available for a product, certain specified tests may be
waived by the Engineer.
1.18.7 Responsibility for defective Materials

Inspection and Engineer’s release for application of any materials or equipment shall in no way relieve
the Contractor of any of his contractual responsibilities for meeting the requirements of the
Specifications and shall not prevent subsequent rejection of such materials or equipment if they are
found to be defective or not compliant with the Specifications.
1.18.8 Use of Materials before Approval

No materials or equipment for which samples are required shall be used on the Works until Engineer’s
consent has been reached.
Consent to any sample shall be only for the characteristics or for the uses named in such consent and
no other. No consent to a sample shall be taken in itself to constitute a change or modification to any
Contract requirement.
1.19 Project handover

1.19.1 Handover of Parts of the Works
Each Section of the Works shall be handover as soon as it has been completed and tested so as to
minimize disruptions to the Employer’s operations.
Once the Contractor considers that work on a Section of the Works has been completed, including any
prescribed tests on completion, he shall notify the Engineer that the Section of the Works is ready for
handover. This notification shall be accompanied by:
• A statement from the Contractor that, in his opinion, the Section of the Works has been
completed and has passed all the prescribed tests
• Copies of all test results and reports in a digital version
• Financial estimation of the value of the Works, based on relevant items of the BoQ, variation
order or Engineer’s determination; in absence of the latter a solid cost estimation
• Copies of any licenses and approvals from relevant Authorities; and
• Related form for a Handover Certificate
• The issuing of a taking-over certificate for the Section of the Works by the Employer will, in
addition, take place after the following demands have been fulfilled.
• The As-Built documents for the Section of the Works to be handed-over to the Employer.
Drawings are to be summitted in addition as AutoCAD files.
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• Where applicable, operation and maintenance manuals, as part of the As-Built documents, for
the Section of the Works to be handed-over to the Engineer.
1.19.2 Completion of handover

The Handover Certificate will be issued once all Sections of the Works have been taken over in the
manner prescribed above and the Contractor has met all other requirements pertaining to the issuing of
the Handover Certificate including:
Collating of as-built documents for the various Sections into a full set of As-Built Documents
Where applicable, the sign off of training and issue of final copies of the Operation and Maintenance
Manuals requirements need to be complied.
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2 GENERAL REQUIREMENTS FOR CIVIL WORKS

2.1 Prior Site Inspection and Survey Works
2.1.1 Prior Site Inspection
The Contactor shall inspect each Site and the associated facilities (e.g., existing infrastructure)
individually and verify the actual conditions of pipes, manholes, chambers, etc. and obtain all other
information necessary for him to plan and implement the Works.
The Contactor shall also inspect the sites of the pumping stations and wastewater treatment plant and
verify the actual conditions of lagoons, of buildings, channels, pipework, chambers, internal roads,
streetlights etc. and obtain all other information necessary for him to plan and implement the Works.
The inspection shall also concern existing others’ properties and/ or infrastructure that might be affected
by the Works.
2.1.2 Setting-out of Works

The Contractor shall set out and establish such pegs, benchmarks, reference points and grid lines as may
be necessary for the setting out of the Works and shall be held responsible for the accuracy and
sufficiency thereof.
The Works shall be set out and tied to the Local or Regional Coordinate and Level Systems that are
shown on the Drawings or that are in use by the Employer.
The Contractor shall establish temporary benchmarks and survey stations at suitable locations and
reasonable distances on the Site of the Works and he shall, during the progress of the Works,
periodically check the levels of the benchmarks and the co-ordinates of the stations against the original
points, lines and levels. Temporary benchmarks and survey stations shall consist of steel pegs set into
concrete or other suitable markers and shall, wherever possible, be located clear of the Works. The
Contractor shall submit to the Engineer drawings showing the locations and levels and/ or co-ordinates,
as appropriate, of all the temporary benchmarks and survey stations used for the setting out of the
Works.
The Contractor shall identify setting out dimensions for all structures by relating them to existing
facilities and by interpretation of the documentation. The gradients of pipes, manholes, chambers, river
pipe crossing structures, etc. should be as shown in the Drawings, unless otherwise agreed with the
Engineer. The anaerobic pond, the operators building, guard shelters, channels and electro-mechanical
equipment, chambers and manholes, pipes, fence, power backup system etc. shall be as shown on the
Drawings unless otherwise agreed with the Engineer.
2.1.3 Control Survey

If directed by the Engineer, the Contractor shall, prior to the start of the Works, conduct a control survey
of the main points of the structures of the WWTP site, pumping station, and sewer pipes included in the
Works.
2.1.4 Survey Labour

The Contractor shall provide all labour, instruments and materials for survey work and measurements
in connection with the Works. On request by the Engineer, calibration certificates from an authorised
institution/ company for the instruments shall have been provided.
2.2 Earthworks
2.2.1 General
Earthworks under this Chapter include excavation, trench sheeting and piling, and backfilling for
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embankments, pipe trenches, structures (e.g. chambers, pipes, pipe supports), foundations of buildings,
and reinforced concrete structures. The BS 6031 Code of practice for earthworks shall be followed.
Everything contained in the Specification with regard to the implementation of the excavations, disposal
of excavated material, etc. shall equally apply to the various types or classes of excavated material
unless otherwise stated. The Contractor shall prepare the working area in such a manner that the Works
may be constructed without any danger or hindrance to persons or property.
The Contractor shall ensure that he is in possession of all required permits, local and national, prior to
commencing any Works. In addition, and well in advance of the commencement of the work, the
Contractor shall obtain permission for the undertaking of the work from all land or property owners
who may be affected by the Works, incl. permission for temporary access to the affected land or
property wherever this is necessary for the Works to be carried out.
Where pipelines pass through bush or fields, the Contractor shall clear a strip centred on the pipeline
centreline along the route of the pipeline. All trees, bushes, shrubs, logs, stumps, roots, weeds, rubbish
and other organic material within the strip shall be removed by the Contractor, who shall permit the
owners or occupiers of the affected land to utilize this material or who shall otherwise arrange for its
disposal in an environmentally acceptable manner. However, the Contractor shall obtain the approval
of the owners, responsible Authorities or occupiers of the designated strip before removing any large
trees i.e. trees with a circumference exceeding 500 mm measured 1 m above original ground level, and
shall endeavor not to remove any such trees unless this is unavoidable. Furthermore, in protected bush
areas, the Contractor shall also obtain the approval of the responsible Authorities before removing
smaller trees in the designated strip and shall do only such clearing as is essential for the undertaking
of the work.
The Contractor shall also permit the owners of fruit bearing trees and crops growing within the strip to
harvest the fruit or crops before he commences clearing of the strip and, if this is not practicable, he
shall record in writing and the quantities and condition of the trees and crops concerned and take
photographs before any work is done by him in the strip. The Contractor shall submit this information
to the Engineer for possible use in determining any compensation that may become due to the owners.
Failure by the Contractor to compile such records, complete with photographs, will result in the
Contractor being held liable for compensation of claims submitted by the owners, particularly if these
claims cannot reasonably be evaluated by the Employer or Engineer due to the lack of the relevant
records or photographs.
The Contractor shall search for and expose all buried pipes, cables or structures inside the cleared
working area. In this regard, the Contractor is to note that buried pipes, cables or structures other than
those of being informed by the relevant Authorities, as a follow up of Contractors inquiry, may be
encountered within the working area. The details and positions of all buried pipes, cables or structures
encountered during the Works shall be recorded by the Contractor and shall be shown on the as-built
drawings. In cases of occurrence of damage or necessity of removal or relocate the buried pipes, cables
or structures.
The Contractor shall protect all survey points. If any survey point has to be removed, the Contractor
shall reinstate that survey point after the work has been completed.
The Contractor shall strip/ remove the humus/ topsoil before commencing any excavations and shall
carefully store the same within the working area so that it can be used for re-instatement of the working
area after the Works are finished. Topsoil which is incorrectly removed or which becomes contaminated
due to carelessness on the part of the Contractor shall be replaced by the Contractor at no additional
cost to the Employer.
2.2.2 Standards
The Contractor shall carry out Works described in this Specification in accordance with the appropriate
EN and DIN Standards. These include but are not limited to the following:
• DIN 4124 Excavation and Trenches - Slopes, Planking and Strutting breadths of Working Spaces
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• DIN 18300 General technical code for earthworks

• DIN 18303 General technical code for excavation lining
• DIN 18305 Groundwater management
• EN 1610 Construction and testing of drains and sewers
• SANS 1200 D Standardized specification for civil engineering construction Section D:
Earthworks
• SANS 1200 DA Standardized specification for civil engineering construction Section DA:
Earthworks (small works)
• SANS 1921-5 Construction and management requirements for works contracts Part 5:
Earthworks activities which are to be performed by hand
• SANS 2001-BE1 Construction works Part BE1: Earthworks (general)
• SANS 2001-DP1 Construction works Part DP1: Earthworks for buried pipelines and
prefabricated culverts
The Contractor may carry out the Works or provide materials in accordance with local or other
international Standards provided their requirements are superior or equivalent to those described by the
Standards cited in the Specifications. The Contractor shall, if he wishes to use such other standards, be
responsible for submitting details of the proposed Standards to the Engineer so as to prove their
equivalency or superiority in advance, for the use of such other standards. Failure by the Contractor to
provide such Standards to the Engineer in advance may result in the Works in question being rejected.
2.2.3 Explosives and Blasting

If needed, the Contractor shall provide a special store for explosives in accordance with the applicable
regulations. The transporting and storing of explosives and blasting shall also be in accordance with the
Laws regulating their use, namely the European Directive 2014/28/EU and the standards of the series
EN 13630, EN 13631, EN 13763, EN 13857 and EN 13938.
The Contractor will only be allowed to use explosives with Engineer’s agreement. After having obtained
the said permission, all blasting shall be done by properly trained, qualified and licensed workmen under
the supervision of an experienced foreman, who shall be in possession of an official and authenticated
current blasting certificate.
The Contractor shall submit to the Engineer a method statement for each blasting operation. In case
blasting needs to be carried out property within 1000 meter of the blasting sites needs to be checked by
photographing pre- existing damage. The greatest care shall be taken when blasting to protect persons,
the Works and any other property. No blasting shall be done within 10 m of any existing structure. In
any case, the last 150 mm of rock above foundation level shall be removed by use of power tools or by
hand.
The Contractor shall provide proper buildings or magazines in suitable positions for the storage of
explosives in manner and quantities to be approved. He shall also be responsible for the prevention of
any unauthorized issue or improper use of any explosives brought on the works and shall employ only
licensed and responsible men to handle explosives for the purpose of the works.
The shots shall be properly loaded and tamped and where necessary, the Contractor shall use heavy
mesh blasting nets. Blasting shall be restricted to such periods and such parts of the works as the
Engineer may prescribe. If, in the opinion of the Engineer, blasting would be dangerous to persons or
property or to any finished work or is being carried out in a reckless manner, he may prohibit it, and
order the rock to be excavated by other means and payment will be made at the rate for rock for
excavation where blasting is permitted. The use of explosives by the Contractor in large blasts, as in
seams, drifts, pits, or large holes, is prohibited unless authorized in writing by the Engineer. In the event
of wasting of rock through any such blasting, the Contractor shall if required by the Engineer,
furnish an equivalent amount of approved materials for fill, 1 cubic meter of rock in-situ being taken to
equal 1.5 cubic meter of material in embankment.
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2.2.4 General and Foundation Excavation
2.2.4.1.1 General
Everything contained in this Chapter with regard to the implementation of excavations, disposal of
excavated material, etc. shall apply to all types of material, unless otherwise stated.
All excavations shall be carried out to the lines and limits shown on the excavation plans and other
drawings, or as defined in the Specification. The said lines and limits may be amended by the Engineer
to suit the materials and other conditions encountered during actual excavation and field inspection.
When excavating in any material other than rock for formation levels under any structure, the last 150
mm of excavation shall be taken out not more than 12 hours before the placing of foundations or fill.
The material in the bottom of excavations in “common” material shall be moistened and thoroughly
compacted before final trimming and shall, together with “excavations in “rock”, be trimmed to the
required lines and levels before placing of concrete of fill.
The Contractor shall well and effectively support the sides and ends of all trenches and excavations
wherever necessary with strong, close timbering so as to prevent any collapse of the sides or ends into
the trenches or excavations. If, despite such precautions, or by reason of their neglect, any portions of
the sides or ends of any trenches or excavations shall collapse, the Contractor shall at his own expense
excavate and remove all the ground thereby disturbed both inside and outside the limits of the trench or
excavation.
Should the Contractor exceed in depth or extend the excavation or be ordered to take out extra
excavation for the reasons given above, no payment will be made for such extra excavation and he shall,
if ordered by the Engineer and at the Contractor's expense, make the sides or bottoms of the excavation
good with well rammed fill or in such class of concrete as may be ordered by the Engineer.
Before commencing any pipe laying, building or backfilling, all shattered and loose material shall be
removed by hand and the excavation trimmed as necessary to ensure that the work sits on a sound and
clean foundation or abuts tightly against sound ground.
2.2.4.1.2 Preparation of Foundations

The Contractor shall prepare the areas of excavations against which concrete is to be placed in a manner
suitable for forming a foundation. Foundations in earth onto which concrete is to be placed shall be
finished accurately to the dimensions shown on the Drawings, brought to a proper moisture content by
sprinkling as required, and thoroughly compacted with suitable tools or equipment. No boulders shall
be left projecting within the minimum excavation lines shown on the Drawings or indicated in the
Specification.
Foundations for concrete on bedrock shall be trimmed to the prescribed lines, thoroughly cleaned of
mud and debris, and moistened in advance of placing concrete. All foundation surfaces shall be free
from pools of water at the time of placing concrete. Wherever any excavation in earth has been made
below grade without the Engineer's instructions, it shall be treated with anti-termite and refilled as
directed by the Engineer at the Contractor's expense.
For hard soils when the depth of excavation is less than 1.5 m, the side faces of the foundation pit do
not need any external support. If the soil is loose or the excavation is deeper than 1.5 m, some protection
materials such as Sheet pile walls or Wooden piles are required to support the sides from falling.
2.2.5 Excavation for Pipes

2.2.5.1 General
Unless authorised by the Engineer, no trench shall be opened up in advance of pipe laying for more
than 100 m in settled areas or more than 300 m in open space.
If these lengths of open trench are exceeded or if, in the opinion of the Engineer, undue delays occur in
the testing of pipelines, the removing of surplus material, the re-instatement of areas where pipes have
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been laid, or the initial restoration or maintenance of surfaces, the Engineer may order the Contractor
to stop all trench excavation until the outstanding work has been carried out at no extra costs.
2.2.5.2 Common soil

Trench excavations shall be carried out in accordance with
• DIN 4124 Excavations
• DIN 18303 Timbering to trenchwork
Pipe trenches shall be excavated, mechanically and/ manually to the levels as shown on the Drawings
(Longitudinal Profiles, as far as available respectively as indicated in the Standard Drawings). The
width of the trenches shall be, as specified in the Standard Drawings.
The sides of trenches shall where necessary be adequately supported to the satisfaction of the Engineer
by timber or other approved means.
The finished trench bottom shall provide a sound and uniform foundation for the pipes. Where the
material in the bottom of the trench does not provide such a sound and uniform foundation, it shall be
excavated as advised by the Engineer and refilled to the required level with well-compacted suitable
material. The Contractor will, where advised by the Engineer, be paid for excavation below the trench
bottom and its refilling with suitable material against the relevant items in the BoQ.
The Contractor shall keep the bottom of the pipe trench dry by excavating narrow channels in the trench
bottom to lead incoming ground water to temporary sumps from where it can be pumped out of the
trench. The Contractor shall arrange for water pumped from the excavations to be disposed of. The costs
of dealing with water in pipe trenches, whether this is done in the manner described above or in some
other manner, are deemed to be included in the items of the BoQ for excavation.
The trench bottom shall be finished off even and smooth and be free from stones, lumps, roots and other
hard objects that may injure the pipe or coating. The trench bottom shall then be refilled up to the
undersides of the pipes using appropriate material, either suitable excavated material or imported
bedding material. Pits shall be dug at no extra costs in the bedding material at all joint positions so as
to ensure continuous contact between the bedding and the pipe between coupling holes.
The side walls of the trench shall be battered back as necessary to ensure their stability unless they are
protected by sheeting/ bracing. Such side-sloping shall be done above the level of the top of the pipe,
with the trench below the top of the pipe being vertical sided. The sloping of the trench side walls will
not be permitted in streets/ roads and paved areas. The cost of sloping trench side walls shall be borne
by the Contractor and no extra payment will be made to him for the associated excavation and
backfilling done by him outside the specified minimum trench widths.
Wherever necessary, the trench side walls shall be adequately sheeted and braced in accordance with
internationally accepted standards. Where sheeting/ bracing is used, the net trench width after sheeting
shall not be less than the minimum trench width as indicated in the Standard Drawings. As backfill is
placed and if sheeting is to be withdrawn, it shall be withdrawn in increments of not more than 300 mm
and the voids left by the withdrawn sheeting shall be filled and compacted concurrently with the
backfilling of the trench. If, despite such precautions, or by reason of their neglect, any portions of the
sides or ends of the trench shall give way, the Contractor shall at his expense excavate and remove all
the ground thereby disturbed and make it good with well rammed fill or in such class of concrete as
may be ordered by the Engineer.
The Contractor shall provide bridges over the pipe trenches where necessary, e.g. entrances to houses/
yards, main pedestrian crossings.
The Contractor shall ensure that all excavated material which is suitable for reuse as backfill is separated
and stockpiled for reuse. If the Contractor fails to separate material suitable for reuse from other
excavated material, the Engineer shall be entitled to instruct the Contractor to replace this material at
no additional cost to the Employer.
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2.2.5.3 Excavation in rock

All solid rock, boulders and large stones which protrude into the trench excavations or which are to be
removed from the trench bottom shall be excavated using appropriate techniques and the resultant voids
shall be refilled with material agreed with the Engineer which has been moistened and thoroughly
compacted.
“Hard Rock” shall mean intact or slightly weathered solid rock as found in ledges or masses in its
original position, which can only be loosened by blasting or by pneumatic tools, or if excavated by
hand, by wedges and sledge hammers or specialized rock breaking hammers. Rock which is in a
shattered from moderately to highly weathered conditions and/or is capable of being loosened by rippers
of earthmoving plant up to 150 h.p. or giving way to pick-axes with some effort is excluded from the
definition of hard rock. The loose rock material as such may be classified as “soft rock” Boulders and
detached pieces of rock (as defined above having a volume of more than 0.1 cubic meter will also be
classed as hard rock.
Nothing in the Contract shall entitle the Contractor to be paid for excavation in rock unless, at the time
the excavation is open and visible, the Contractor shall have given notice in writing to the Engineer that
he claims to be paid for excavation in rock. After giving such notice the Contractor shall not fill in the
excavation or otherwise prevent the excavation from being inspected until the Contractor and Engineer
have jointly examined and measured the work. All agreements between the Contractor and the Engineer
as to whether or not excavation is in rock, and the quantity thereof, shall be duly recorded and signed
by the Contractor and the Engineer.
Compliance with the foregoing provision in relation to recording of excavation in rock and the quantities
thereof shall be a condition precedent to the right of the Contractor to be paid for excavation in rock
and such record shall be final and binding between the parties as to the quantity of excavation in rock.
2.2.6 Excavation for Structures

2.2.6.1 General
The material at the bottom of excavations for structures in “common material” shall be scarified,
moistened and compacted prior to the placing of blinding concrete.
The concrete blinding layer for structures shall be placed as soon as possible after the bottom of the
excavation has been prepared as specified above, and in no case longer than 72 hours after the
completion of the final 150 mm of the excavation to formation level.
2.2.6.2 In rock
All solid rock, boulders and large stones which protrude into the excavations for structures shall be
excavated using appropriate techniques and the resultant voids shall be refilled with material agreed
with the Engineer which has been moistened and thoroughly compacted.
2.2.7 Backfilling
2.2.7.1 General
Backfill shall generally be laid and compacted in maximum 300 mm thick so as to resemble as close as
possible the surrounding existing naturally consolidated soil state. If the Engineer deems this not
suitable material, the Contractor will be instructed whether the backfill is required to be imported or
selected.
Backfill material:
• Backfill material shall be evenly graded and not include constituents exceeding 75 mm or any
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clay or organic material
• Grading curve shall be 0/ 63 according to DIN 4226
• Excavated material can be used for main backfilling if the quality achieves the required grade
and if the fixed compaction grade can be achieved
• Backfill material shall consist of sand, gravel, crushed stones or equivalent material
• Backfill material shall be compactable to the required value, thus it shall consist of different
sizes of grains Compaction:
• The compaction shall be done by mechanical rollers, compactors, vibrators or other adequate
machinery and such that provide a dry density not less than 95% of the maximum dry density
• Heavy compaction equipment is not to be used with less than 300 mm cover above the crown
of the pipe
• Backfill shall be by distributing and compacting it in horizontal layers with a uniform thickness
and thickness of non-compacted material not exceeding 300 mm
• Trench backfilling shall commence as soon as possible after pipe laying to give the pipe
protection against damage from objects possibly falling into the trench
• The backfill compaction shall conform to the requirements placed upon it by the type of existing
construction (unpaved, road or the like) above the pipeline which shall be reinstated
All backfill material, either as excavated material or from an agreed quarry, shall be released for
application by the Engineer. It will be the responsibility of the Contractor to locate the sources of
backfill material (quarry). The Contractor shall inform the Engineer about the location and will provide
samples of the materials he proposes to use. It is not permitted to take any backfill material from areas
where the stability of slopes is endangered or where problems of infiltration may arise. On completion
of excavation from the backfill material source, the Contractor will restore the area to a satisfactory
state from the point of view of environment and aesthetic conditions, following the requirements of the
relevant authority.
The Contractor shall check carefully the moisture content of backfill material before and during
compacting, so that it is within the limits of values specified, in accordance with the material and method
of compacting.
During backfilling, the Contractor shall undertake the necessary tests to guarantee the required
parameters. If a sample does not reach the minimum specification requirement, the material placed in
the permanent works shall either be further compacted or removed completely and replaced on no
additional costs.
Backfilling shall take place immediately after placing of the pipeline in order to avoid temperature
differences and/ or pipe buoyancy effects. Covering shall generally take place within 12 hours if the air
temperature is above 30°C or within 24 hours if the air temperature is below 30°C.
During backfill the material shall be wetted if need be to optimum moisture content and compacted to
95% Proctor.
Normally, joints of pressure mains will be left exposed during testing of pipelines. However, the
Engineer may at any time order the Contractor to proceed with the complete backfilling of the trench
before testing, where the pipeline is laid in the right-of-way of a road, in built-up areas and wherever
for any other reason the pipe trench cannot be left open until after testing. In such cases it is
recommended that the positions of all joints are clearly marked by the Contractor outside of the trench
so that they can easily be located for the purpose of repair if and when required.
Any deficiency in the quantity of material for backfilling the trenches shall be supplied by the
Contractor. The Contractor shall make good any settlement of the trench backfills occurring after
backfilling and until the expiry of the DNP.
2.2.7.2 Imported Material

In cases where the Contractor excavates in rock or other material unsuitable for backfilling and where
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there is not sufficient soft material specific for backfilling the Contractor shall transport suitable
material from other parts of the work or from borrow pits. The material shall be similar or better as that
for selected excavated material unless otherwise instructed by the Engineer. If required, the Contractor
shall submit the way leave bills on site showing that the material is according to Specification.
The same installation parameters as for selected excavated material shall apply.
2.2.7.3 Structures
Before beginning backfilling around structures, all foreign material, including water, shall be removed
from the space to be backfilled and the area to be backfilled shall be inspected and agreed with the
Engineer.
No backfill shall be placed around or on a structure until the concrete has attained sufficient strength.
The concrete strength shall be determined by tests on representative cubes or cylinders cured under
conditions similar to those prevailing at the Site.
Backfill shall be placed in uniform layers and brought up evenly on opposite sides of structures so as to
minimize unbalanced loading of the structures. The Contractor shall inform the Engineer of the
sequence of backfilling which he proposes to follow around each structure.
Backfill around and over structures shall be placed in horizontal layers of thicknesses which suit the
type of compaction equipment being used, but in no case shall the lifts be more 200 mm thick after
compaction. Each layer shall be evenly spread and moisture-conditioned to the optimum moisture
content (OMC) ± 3 percent, as determined using the Proctor method, and then compacted to at least the
densities specified below.
The backfill shall be laid partially humid and evenly across the entire surface either manually or
mechanically. During the laying the material shall be wetted evenly across the surface and compacted.
Compaction of the material shall be done in back & forth motions in both X and Y directions with
overlapping of the previous compacted areas so as to reach a minimum of 95% Proctor.
Unless otherwise instructed by the Engineer, all backfill for objects or pipe ancillaries (e.g. valve
chambers and the like, thrust blocks and buried valves) along the line shall be of the same type as per
the requirement for trench backfilling. The backfill shall be wetted to optimum moisture content and be
compacted however in maximum 15 cm layers to minimum 95% Proctor.
If required, and in case of imported material, the Contractor shall submit for each case the loading way
leave bill to the Engineer, attesting that the imported material matches the requirements.
2.2.7.4 Tests
The compaction, as specified hereunder, will be checked by a “Penetration Test (DPH)” to ensure a
minimum 95% Modified Proctor. The Engineer will decide, on which spot the penetration test shall be
performed. The tests shall be performed only in the presence of the Engineer. For each test a written
protocol shall be compiled by the Contractor. In the event one test fails / the compaction does not reach
the required quality, the Contractor shall perform an additional test at his own costs.
In the event the compaction does not reach the required quality the backfill shall be removed and
replaced by the Contractor. The section where the backfill shall be re-excavated will be defined by the
Engineer.
Further tests may be carried out during backfilling as directed by the Engineer, including tests on the
grading of the material using sieves on site, or physical testing of the soil to check the organic and/ or
clay content.
Dynamic plate loading test of each layer shall be done. A drop penetration test with the 10 kg weight
according to DIN 4094 shall be executed after the last layer of the backfill material is compacted on the
same place where the dynamic plate loading test is executed.
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2.2.7.5 Rejection
Fill or backfill material shall be immediately rejected if the fill or backfill material, whether selected or
imported:
• Is saturated with water beyond its optimum moisture content prior to placement or is brought to
site in such a condition that results in excessive and unnecessary additional transportation costs
and thereby CO2 emissions.
• Contains swelling clay or a disproportionate amount of clay substances, humus, vegetation,
roots, and organic material or is contaminated with pollutants.
• For bedding material: It does not comply with bedding specifications.
The Engineer will order the Contractor the above situations to be rectified at his own costs, if they
occur.
2.2.8 Pipe Bedding/ Embedment

2.2.8.1 General
The material in the area between the bedding and the underside of the pipe should be worked in and
compacted before placing the remainder of the backfill.
In trenches where sheet piles are used, sheeting shall be removed in steps and pipe-zone backfill
compacted directly against the trench wall to ensure the best support to the pipe. It has to be ensured
that there are no voids or lack of backfill between the outside of the sheeting and the native soil up to
at least 1 m above the pipe crown.
Immediate backfilling after joining of pipes is suggested as it will prevent two hazards – floating of
pipe and thermal movements. Floating of pipe can damage the pipe and create unnecessary reinstallation
costs. Thermal movement caused by exposure to the elements can cause the loss of seal due to
movement of several lengths accumulated at one joint. If longer pipe stretches are placed into the trench
and backfilling is delayed, each length should have the centre section backfilled to the crown to help
minimize misalignment and movement. Proper selection, placement and compaction of pipe zone
backfill are important for controlling the vertical deflection and are critical for pipe performance.
Attention must be paid so that the backfill material is not contaminated with debris or other foreign
materials that could damage the pipe or cause loss of side support. Backfill placement and compaction
under the pipe (the “haunch” area) should achieve the required relative compaction as does the side-
fill. The depth of the layer being compacted must be controlled as well as the energy placed into the
compaction method.
Pipe Embedment (pipe surround material) covers pipe bedding material and shall be selected non-
cohesive granular material and is further required to be free draining. The Contractor may screen, wash,
or otherwise treat excavated material from pipe trenches or other excavations in order to produce
material suitable for bedding or covering the pipeline. Materials with humus, vegetation or sharp edges
shall be prohibited to be used as pipe surround material.
Pipe surround material shall be placed as pipelaying proceeds as follows:
• In layers not more than 15 cm thick up until the minimum bedding thickness onto which the
pipe shall be laid
• In one go up until the pipe cover
• Again in 15 cm thick from the pipe cover until the required pipe cover is reached
• The degree of compaction attained for bedding shall be 95% modified Proctor
For steeper sections or long slope sections the bedding material must be protected with sandbags barriers
in the trench in order to avoid the erosion of the bedding material. Distances of those sandbags depends
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on the slope, however not longer than 50 m. Those sandbags are to be placed at no extra costs.
Material:
• Excavated soil shall not be used for embedment unless instructed otherwise by the Engineer
• Embedment material shall not contain any organic material or any other material which can lead
to any damage of the pipes or fittings
• Sand, sand/ gravel mix or crushed stone fines (all non-cohesive granular material) are allowed
to be used and is further required to be free draining
• Particle size of round material shall not exceed 16 mm unless the pipeline supplier recommends
a smaller size; content of particles between 8 and 16 mm shall not exceed 10 %
• Particle size of crushed stone fines shall not exceed 11 mm unless the pipeline supplier
recommends a smaller size
• Embedment material shall be compactable to the required value, thus it shall consist of different
sizes of grains
• Compaction:
• Pipe surrounding bedding and later trench backfilling shall commence as soon as possible after
pipe laying to give the pipe protection against damage from objects possibly falling into the
trench
• Heavy compaction equipment not to be used with less than 300 mm cover above the crown of
the pipe
• Lower backfill can be compacted with heavy equipment
• Hollows, which occur after removal of trench wall supports, shall be filled and compacted.
2.2.8.2 Selected Material

The part of the trench above the top of the pipe, shall be filled and compacted with selected material
free from stones, swelling clays, vegetation, humus, contaminated soils etc. There shall be no stones
greater than 15 cm in their largest dimension and the backfill shall not contain more than 25% stones,
outside the Specifications for suitable backfill material.
2.2.9 Compaction Control

The compaction of material backfilled shall achieve the following minimum Proctor densities:
Table 2.1 – Standards of Compaction Control
Location Average Minimum individual value
Bases and sub-base of road 98% 95%
Foundation of structures 95% 93%
All other backfill 92% 90%
The compaction will be checked by in-situ density testing undertaken by an agreed testing laboratory.
The Engineer will determine when and where density tests shall be performed but the Contractor will
be responsible for arranging for the tests to be carried out. The tests shall be performed only in the
presence of the Engineer. A written report on each test shall be submitted to the Engineer by the
Contractor. If a test indicates that the compaction has not been done to the required standard, the
Contractor shall, at his cost, arrange for a second test to be done adjacent to the first test position. If this
second test confirms that the material has not been compacted to the required standard, the backfill shall
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be removed by the Contractor to the extent directed by the Engineer and replaced by the Contractor at
his cost.
2.2.10 Embankment (Ponds)

2.2.10.1 Moisture Content
The water content of the earth fill material prior to and during compaction shall be uniform throughout
each layer of material. In general, the overall placement water content shall be maintained as determined
by the laboratory test in order to obtain a maximum density at the optimum moisture (W opt). (Standard
Proctor compaction test), ±3% as directed by Engineer.
The density and the optimum water content shall be found by series of laboratory test and field tests on
trial fills.
At site, the Contractor shall make provisions for a well-functioning drainage system by means of
sufficient inclination of layer surfaces toward the outside of the embankment and by additional trenches
and drainage ditches of suitable size and area to provide a continuous run-off in case of rain, etc. The
entire site must be kept in such condition that water puddles do not occur on completed layers or
anywhere else considered undesirable by Engineer.
Compacted layers with water puddles on the surface may be subject to rejection upon the decision of
Engineer.
In order to facilitate compaction and drainage of the embankment during execution, the Contractor shall
maintain sufficient blade graders or other approved equipment to keep the embankment smooth and
free from dust. Surfaces muddy due to adverse weather conditions shall be removed before the next
layer may be placed.
Prior to excavating the impervious fill material in the excavation area, the Contractor will be required,
if necessary, to dry or wet the material. If moisture is added to the material in the excavation area by
sprinkler or other means, care shall be taken to sustain the material uniform, taking sufficient time and
avoiding both excessive run-off and accumulation of water in depressions. Whenever water shall be
added, the prior approval of the Engineer must be obtained. Prior to or during excavating operation, if
there is excessive moisture due to rainfall or other reasons, steps shall be taken to reduce the moisture
by excavating drainage ditches, by allowing adequate time for curing or drying, or by any other means
approved by Engineer.
The material so prepared shall be transported to the site of embankment in uniform and proper moisture
condition as far as practicable. If the material after placing is found to be too wet, the placed layer shall
be worked to reduce the moisture to the permissible amount by scarified or other suitable equipment. If
the moisture content is less than that required, water shall be added to the material by sprinkling content
in the placed layer within the allowed tolerances.
2.2.10.2 Placing of Fill Material

The distribution and gradation of the materials throughout the impervious core shall be such that the
placed materials will be free from lenses, pockets, streaks or layers of material differing substantially
in plasticity or gradation from the surrounding material.
The material shall be placed to the same depth of layer throughout the working area. The thickness of
each layer before compaction shall conform to the type of the Contractor's compaction equipment, but
shall not exceed 300 millimetres.
If the placed layer of material is judged by the Engineer not to be uniform, the Contractor shall be
required to mix it by means of scarified or other suitable equipment.
If the surface of a compacted layer is too dry or smooth for of the proper bonding with the layer of
material to be placed thereon, it shall be moistened and/or worked with scarified or other suitable
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equipment in an approved manner to a sufficient depth to provide satisfactory bonding.
If the compacted surface of any layer is judged to be too wet for proper placing and compaction of the
next layer of material due to rainfall or over-wetting, it shall be removed or be worked with scarified or
other suitable equipment in a manner to reduce the moisture content to the permissible amount and, if
necessary, the layer shall be recompacted before the next layer of material is placed. The removed
material may be reused, provided the moisture content is reduced to the acceptable amount.
In general, the filling shall be executed and maintained approximately in horizontal layer.
Each compacted layer shall be sloped adequately towards the upstream of downstream side of the
embankment to facilitate draining.
The requirement as specified by the Engineer after field test shall be met by the most efficient type of
equipment, thickness of layers, number of passes of compaction equipment and suitable material or
mixture of different materials.
Placement of impervious material will not be permitted when in the judgment of the Engineer a proper
placing due to weather conditions e.g. heavy rainfall, cannot be expected.
2.2.10.3 Compaction of Embankment Material

When each layer of material has been conditioned to have the required moisture, it shall be compacted
by passing the roller so that the dry density of the compacted layer in embankment shall be regular and
always more than 90% of the Standard Proctor density.
Each route of the roller shall partly overlap with adjacent ones to prevent portions where rolling passes
do not reach the require number, and the Contractor shall not be permitted to make abrupt turns of the
roller.
If the embankment work is discontinued for a lengthy time, the Contractor shall be required to protect
the material against loss of moisture by smoothing the surface of the layer with roller, truck or other
equipment approved by the Engineer and to add, if necessary, supplementary water by sprinkling. The
method of sprinkling shall be subject to the approval of the Engineer. When the embankment works is
resumed, the surface of the layer in place shall be worked with scarified or other suitable equipment
and reconditioned to obtain the optimum moisture content, and shall be recompacted.
Trucks transporting embankment material or another vehicle passing on the placed layer before
compaction shall be required not to disturb the surface of the layer immoderately, as far as practicable.
Then the route of vehicles concentrated immoderately on any portion of the compacted layer, such over
compacted portion shall be scarified thoroughly and to a depth satisfactory to Engineer before
recompaction.
If, in the opinion of the Engineer, the compaction is not satisfactory, the rolling work shall be suspended,
and the Engineer may direct the Contractor to recompact or to remove the material of said layer. In this
case the Contractor shall be required to follow the orders of Engineer without any delay, if ordered.
2.2.10.4 Clay Layer

The clay material to be used in the construction of the clay cover that integrates the required
waterproofing system must be clean, from roots, sods or other deleterious material.
Is full responsibility of the Contractor to obtain suitable material of acceptable quality obtained from
approved sources by the Engineer.
The sealing with compacted clay will be done with natural clay, obtained from a borrowed place (or a
mixture of local bentonite soils), with the desired sealing characteristics.
The clay coating shall have a thickness of 0.20 m.
The coating clayed material for the anaerobic pond interior shall have a 0,20 m thickness and comply
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with the following criteria:
• Having a permeability value (hydraulic conductivity) ≤ 10-9 m/s;
• At least have 20% of fine particles (with clay dimensions and thin silt)
• Having a plasticity index (PI) that shall be in between 10 ≤ IP ≤30;
• It must be free of stones larger than 25 mm;
During compaction, clods should be mechanically broken down to the smallest possible size by
compacting equipment, namely, sheepsfoot rollers.
2.2.11 Protection
The work under this subsection shall include slope protection for anaerobic ponds construction.
Where shown on the anaerobic ponds drawings, the slopes of embankments, shall be protected against
water or other action with concrete slabs.
2.2.12 Disposal of Surplus Materials

The Contractor shall immediately upon completion of backfilling load up and cart away all surplus
excavated material to temporary spoil heaps, if required for subsequent reuse, or to permanent licensed
and approved landfills if not required. The Contractor shall make his own arrangements for sites for
temporary stockpiling or final disposal of excavated material.
2.2.13 Restoration and Clean-up

2.2.13.1 General
The Contractor shall restore all disturbed or damaged kerbing, sidewalk paving, drains, shrubbery,
fences, structures, etc. to a condition at least as good as that before the Works began, all as specified in
the following Chapters, and shall furnish all labour and material required for the Works. In restoring
paved surfaces, new pavement shall generally be laid, except that concrete paving blocks and sound
bricks, flagstones and asphalt paving blocks may be re-used. No permanent surfacing shall be placed
within 30 days after the backfilling has been completed, except by order of the Engineer.
2.2.13.2 Surface Restoration other than Public Roads and Footpaths

The Contractor shall carefully replace all surface material and reinstate all surfaces of private roads,
paths, fields, gardens, open spaces, etc., and shall make good any subsidence and defects up until the
end of the Defects Notification Period.
2.2.14 Reinstatement of Roads

2.2.14.1 General
Where any public road surface is removed or damaged by the Contractor's operations it shall be replaced
or repaired to the satisfaction of the Authority responsible for the maintenance of the road. The materials
and methods used for such reinstatement shall be similar to those used for the original surface and shall
comply with the following standard specifications.
The procedure for reinstatement of roads shall be as follows:
• After completion of backfilling, the Contractor shall carry out the interim reinstatement of roads,
as specified below within 7 days from the date on which the backfilling is completed
• After completion of interim reinstatement, the road shall be opened to traffic for a period of not
less than 30 days, or a longer period if agreed with the Engineer
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• Once the adequacy of the interim reinstatement has been demonstrated, after agreement of the
Engineer, the Contractor shall carry out the permanent reinstatement
2.2.14.2 Interim Reinstatement

The top 600 mm of the trench shall be filled with 450 mm of compacted sub-base material placed in
three 150 mm thick layers followed by a 150 mm\ thick layer of compacted base material. The sub-base
material shall be gravel or other material that is commonly used for road construction in the vicinity of
the Site. The base material shall be a naturally occurring gravel acceptable to the relevant Authority or
crushed rock. The sub-base and base material shall respectively be compacted to at least 97% and 100%
of the maximum density determined in accordance with BS 1377-4.
2.2.14.3 Permanent Reinstatement

After the road has been opened to traffic for a period of 30 days or such longer period as may be
necessary for the adequacy of the interim reinstatement, sufficient material shall be removed to allow
for the permanent asphaltic or concrete surfacing to be laid.
The surface shall be cleaned of all loose material immediately before the application of the prime coat.
The prime coat shall consist of cutback bitumen applied at a rate of 5 litres per 6 square metres at a
temperature of 50 to 70 degrees Celsius. The application of the prime coat shall be followed
immediately by the laying of the asphaltic wearing course.
The asphaltic concrete shall consist of a hot-placed mixture of bitumen and aggregates spread and rolled
to a thickness of 50 mm or as otherwise shown on the Drawings.
The coarse aggregate for asphaltic concrete shall be hard, durable, clean crushed rock agreed with the
Engineer. The stone particles shall be angular but not flaky. Fine aggregate shall be approved clean
natural river or pit sand, or quarry sand produced by a secondary plant, free from organic impurities or
other deleterious matter. The sand particles shall be hard and non-absorbent but not necessarily sharp
grained.
2.2.14.4 Maintenance of Reinstatement of Roads

The surfaces of the temporary and permanent reinstatement shall be finished level with the adjacent
carriageway and shall be maintained in a safe condition at all times. The Contractor shall carry out any
necessary maintenance without delay in order to minimize danger to road users.
2.2.15 Site Formation

Site formation shall consist of bringing the surfaces of the various sites to the required original levels,
by excavation or fill prior to the commencement of other work.
The surfaces of site excavation shall be finished and levelled to the exact required lines and slopes.
Where required, the surfaces of the sites shall be brought up to the required levels by well compacted
selected material obtained from required excavations or elsewhere. Areas on which such fill is to be
placed shall be stripped of topsoil to a depth not exceeding 300 mm and the filling material shall be
spread in layers not more than 200 mm thick, moisture conditioned as necessary, compacted by the use
of rollers or hand operated mechanical tampers to not less than 95% of the Proctor density under
structures and 93% of the Proctor density elsewhere.
2.2.16 Water in excavations

All excavations shall be kept free from water, from whatever source, at all times during construction of
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works until in the opinion of the Engineer, any concrete or other works therein are sufficiently set. The
Contractor’s rates are deemed to cover compliance with this requirement.
The Contractor shall construct any sumps or temporary drains that the Engineer may deem necessary
and shall be responsible for the removal and disposal of all water entering the excavations from
whatever source and shall deal with and dispose of such water in a manner approved by the Engineer
so as to ensure that excavations are kept dry.
The Contractor shall provide all plant, labour and materials required for such work and all costs incurred
shall be deemed to be included in his rates for excavation.
2.2.17 Quality Assurance

2.2.17.1 Investigations
The Contractor shall investigate and take samples of the materials and water in and about the earthworks
and structures. Investigations shall be done by excavating auger holes or trial pits. The Contractor shall
employ staff experienced in site investigation to undertake the work involved.
Investigations shall be carried out in accordance with DIN 4420 and the corresponding codes or other
internationally accepted standards.
The Contractor shall prepare site investigation details and excavate exploratory pits in a timely manner
in advance of the commencement of work so as to timeously establish or confirm ground conditions
and to investigate the extent and location of existing services that may be incorporated and/ or affected
by the Works and prepare records of such existing services.
2.2.17.2 Inspections during Implementation of Earthwork

Earthworks shall only be commenced after the prepared surface and the original surface levels have
been recorded by the Contractor. Where successive stages of operations are to be executed, each stage
shall be tested before the next stage is started.
2.2.17.3 Quality Control Testing

The Contractor shall furnish all equipment and materials necessary for collecting samples and carrying
out laboratory and field tests on materials for earthworks. Laboratory equipment shall be housed in a
suitable building on site which shall also incorporate space for the storage of field test equipment and
samples. Alternatively, the Contractor may arrange for such laboratory and field tests to be undertaken
on his behalf by an authorised testing laboratory.
LEM - Laboratório de Engenharia de Moçambique shall be consulted to approve the quality control
implemented by the Contractor and carry out verification tests. The cost of LEM involvement will be
supported by the contractor.
2.2.17.4 Main Tests and Standards

The following quality control testing will be required on the various materials before and during
implementation of the Works:
• Compaction tests in accordance with BS 1377-4:1990 for preparation of moisture versus density
curves (for gravels used for road reinstatement)
• Proctor compaction tests for preparation of moisture versus density curves (for all other fill
materials)
• Sieve analyses including hydrometric tests
• Determination of Atterberg Limits
• Field density tests
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The Contractor shall perform as many tests as are necessary to ensure that the Works conform to the
requirements of the Contract. The number of tests shall be at least one test per 100 m³ of fill and per
day or two tests per structure, whichever is the greater.
The following DIN and British Standards will be applicable for tests on earthworks:
• DIN 18121: Moisture Test
• DIN 18122: Consistency Test
• DIN 18123: Grading Tests
• DIN 18124: Density Test (solid volume without voids)
• DIN 18125: Density Test for Soils (including voids)
• DIN 18127: Proctor Test
• DIN 18134: Loading Test
2.3 Pipelaying
2.3.1 General
Pipe laying shall be carried out according to internationally accepted standards and in accordance with
the laws of Mozambique.
2.3.2 Hauling and Handling of Pipes

When handling, transporting and laying pipes, care shall be taken to prevent damage to the pipes.
Special care shall be taken to avoid damage to the coatings, linings and machined ends of the pipes.
Damaged pipes that cannot be repaired shall be replaced at the Contractor's expense.
Pipes shall not be moved by dragging or rolling them on the ground, but shall be lifted and placed
carefully. Each pipe placed on the ground shall be blocked to prevent it from rolling.
The interior and machined ends of all pipe shall be kept free from dirt and foreign matter at all times.
Pipes shall be placed on the ground along the trench so as not to interfere with normal progress of the
Works. The Contractor shall see to it that the pipes do not obstruct or interfere with normal traffic and
with normal activities of the adjacent occupiers, and shall, if required, also obtain the consent of the
road authorities on the manner in which pipes shall be strung along alignments close to roadways.
The vehicles used for transporting the pipes shall be adequately equipped to prevent movement of pipes
and/ or damage to pipes or coatings. Pipes shall be well secured to the vehicles to ensure stability of the
load. All parts of the vehicles and all cables and ropes which might come into contact with the pipes
shall be well padded. Unloading of pipes shall be done by means of cranes or other suitable equipment
using slings or other tackle so as to ensure slow and careful lowering of each pipe. Pipes shall not be
gripped by hooks or other equipment that might damage or distort the pipe ends or damage the protective
coatings or linings.
Pipes shall not be dropped onto the ground or onto other pipes and shall not be moved by dragging or
rolling them on the ground, but shall be lifted and placed carefully.
In storage, pipes shall be arranged in such a manner that pipes placed on top of each other will not cause
cracking or deformation or damage to the underlying pipes. In addition, suitable padding material shall
be placed between the layers of pipes.
2.3.3 Lowering of Pipes into Trench

Pipes shall be inspected for defects prior to being lowered into the trench and any defective, damaged
or unsound pipes or accessories shall be replaced or repaired by the Contractor at his cost. All foreign
matter or dirt shall be removed from the interiors of the pipe before they are lowered into the trench.
Coated pipes shall not be allowed to come in contact with any metal tools or heavy equipment neither
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shall they be walked on by workers wearing boots with leather or metallic soles.
The implements, tools and facilities used by the Contractor shall be entirely suitable for the safe and
efficient implementation of the Works and shall be subject to the approval of the Engineer. All pipes
shall be carefully lowered into the trench in a manner that will prevent damage to them. Any damage
to protective linings and/ or coatings from any cause whatsoever shall be repaired by the Contractor at
his own expense and strictly in accordance with the manufacturers’ instructions.
Under no circumstance shall pipes be dropped or dumped into the trench or on to other pipes already in
the trench, and no pipe shall be rolled into position for lowering into the trench unless such rolling is
done on timber planking and controlled with ropes or other approved tackle.
2.3.4 Laying of Pipes

Each pipe shall be placed in position individually and shall be laid directly onto the prepared bedding.
Joint holes shall be excavated at predetermined joint positions before the pipes are laid so that the pipe
barrels are supported over their full lengths by the bedding. Pipes with integral sockets shall be laid
with the sockets at their upstream ends. The pipes shall be laid in straight lines in plan between
chambers.
Before pipes are jointed, they shall be thoroughly cleaned of all foreign matter or dirt that may have
entered the interior of the pipes. At the end of each working day, or whenever work is interrupted for
any period of time, the free ends of laid pipes shall be protected against the entry of dirt or other foreign
matter by means of approved covers or plugs.
When pipe laying is not in progress, the open ends of installed pipeline shall be closed by approved
means to prevent entrance of trench water into the line. Whenever water is excluded from the interior
of the pipeline, enough backfill shall be placed on the pipes to prevent floating or the pipelines shall be
weighed down with concrete encasement or blocks or securely anchored to the trench bottom. Any
pipes that have floated shall be removed from the trench and re-laid.
No pipes shall be laid in wet trench conditions that preclude proper bedding preparation or when the
trench conditions or the weather are unsuitable for proper pipeline installation.
2.3.5 General Jointing of Pipes

All joints on pipes shall be installed according to the manufacturers’ instructions, in the absence of
which the following shall serve as a guide.
2.3.5.1 Jointing of Socketed Pipes

Socket and spigot type PPc, GRP, Ductile Cast Iron and PVC pipes shall be jointed in accordance with
the manufacturers’ jointing instructions. In making the joints, the rubber gasket or ring shall be
lubricated with a soap solution and placed in position inside the socket. The spigot end shall then be
inserted into the socket up to the mark indicated on the pipe.
2.3.5.2 Cutting of Pipes

Where cutting of pipes is necessary, it shall be done plane and with a turning machine, cutting saw or
knife.
2.4 Testing
2.4.1 Water supply line pressure testing
All HDPE piping (pipe-lines with visco-elastic behaviour) shall be pressure testing as per Standard
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Specification EN 805: 2000 - Water supply – requirements for systems and components outside
buildings.
The section shall be tested to the pressure ordered by the Engineer. The Engineer shall take the pipeline
levels along the test section into consideration when determining the test pressure. The test pressure
shall not exceed the maximum field pressure recommended by the pipe manufacturer or the nominal
working pressure of the pipe plus 50%, whichever is the lesser, at any point along the test section.
Each section to be tested shall have been backfilled except at the joints, which shall be left open for
inspection, unless agreed with the Engineer otherwise. All anchor blocks on each line to be tested shall
have been cast at least seven days before testing.
All valves shall be operated and examined and a specifically shall be made operation tests of valves for
proper functioning. Particular care shall be taken that valves on each section to be tested are properly
closed.
Before testing any pipeline, the Contractor shall ensure that it is anchored adequately and that thrusts
from bends, branch outlets or from the pipeline ends are transmitted to solid ground or to a suitable
temporary anchorage. Open ends shall be stopped with plugs, caps or blank flanges properly jointed.
The Contractor shall provide all labour, testing equipment, interconnecting pipework or water tankers,
jointing material, end caps, blank flanges, etc. required and shall fill the pipes with water and
subsequently empty them after test. Water drained from the pipes shall be discharged in a way that does
not damage the Works or any other property or facilities, or cause inconvenience or a nuisance to the
Employer or other parties.
The Contractor shall notify the Engineer at least 3 working days beforehand of his intention to test a
section of pipeline. The test shall be made in the presence of the Engineer.
Should a line fail to pass any of the acceptance test, the Contractor shall, at his expense, determine the
source of the failure, make any necessary repairs, and retest the segment of piping in question at no cost
to the Employer.
All leakages shall be located and repaired by the Contractor. If leaks cannot be repaired while the line
is full, the water shall be drained and the necessary repairs made. The test procedure shall be repeated
until all leaks have been located and repaired.
On completion of each piping, the Contractor shall compile the data into a report, which shall be
submitted to the Engineer.
2.4.2 Inspection and testing of gravity sewer pipelines and manholes

The inspections/tests of gravity pipelines and manholes shall be out in accordance with EN 1610.
Testing for leak tightness of pipelines and manholes shall be conducted either with air (method “L”) or
water (method “W”).
The sequence of testing shall be as follows:
• Construction completed and all backfill and superimposed loads in place
• Landscaping over and around sewer appurtenances is completed
• Manholes completed
• Lines thoroughly cleaned
• Visual testing (“flashing”)
• Determination of ground water table
• Air Testing or Infiltration Testing
• Pipe
• Manhole
The Contractor shall provide all labour, testing equipment, interconnecting pipework or water tankers,
jointing material, end caps, etc. required. Water drained from the pipes shall be discharged in a way that
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does not damage the Works or any other property or facilities, or cause inconvenience or a nuisance to
the Employer or other parties.
The Contractor shall notify the Engineer at least 3 working days beforehand of his intention to test a
section of pipeline. The test shall be made in the presence of the Engineer.
Should a line or manhole fail to pass any of the acceptance test, the Contractor shall, at his expense,
determine the source of the failure, make any necessary repairs, and retest the segment of piping or
manhole in question at no cost to the Employer.
All leakages shall be located and repaired by the Contractor. The test procedure shall be repeated until
all leaks have been located and repaired.
On completion of each pipeline, the Contractor shall compile the data into a report, which shall be
submitted to the Engineer.
All new sewers must be inspected by Closed Circuit Television (CCTV) survey in a period of 30 days
from its complete installation with backfilled trench. The CCTV survey shall include profile verification
with laser light- line, measuring any deformation of the pipeline.
Acceptance of pipes shall be subject to approval of the Engineer based on its review of CCTV survey
reports. Appreciation of these reports shall also result in repairing or replacement of surveyed pipes
whenever quality requirements are not met, at the sole expense of the Contractor. In advance of the
CCTV survey, it is the Contractor’s responsibility to ensure that sewers are suitably cleansed.
For any inspected pipeline, the CCTV report shall evidence the evaluation of all surveyed pipes,
including: an inspection DVD with all relevant footage; a photo report of anomalies; a slope report; a
deformation assessment of the pipes; report of other occurrences.
Pipe defects, dips, back fall and poor jointing highlighted by these surveys will need to be repaired.
Pipes with deformation in excess of 1.0% must be replaced.
2.5 Concrete
2.5.1 Standards
Concrete shall, except where otherwise specified, comply with the relevant provisions of
• ISO 6935-2: Steel for the reinforcement of concrete — Part 2: Ribbed bars
• ISO 10144: Steels for the reinforcement and prestressing of concrete — Certification scheme
for steel bars and wires
• ISO 12696: Cathodic protection of steel in concrete
• ISO 13270: Steel fibres for concrete — Definitions and specifications
• ISO 14654: Epoxy-coated steel for the reinforcement of concrete
• ISO 14656: Epoxy powder and sealing material for the coating of steel for the reinforcement of
concrete
• ISO 15630-1: Steel for the reinforcement and prestressing of concrete — Test methods — Part
1: Reinforcing bars, rods and wire
• ISO 12439: Mixing water for concrete
• ISO 16204: Durability — Service life design of concrete structures
• ISO 19595: Natural aggregates for concrete
• ISO 19596: Admixtures for concrete
• ISO 22965-1: Concrete — Part 1: Methods of specifying and guidance for the specifier
• ISO 22965-2: Concrete — Part 2: Specification of constituent materials, production of concrete
and compliance of concrete
• ISO 22966: Execution of concrete structures
• EN 10080: Steel for the reinforcement of concrete - Weldable reinforcing steel - General
• EN 197-1: Cement. Composition, specifications and conformity criteria for common cements
• EN 14216: Cement. Composition, specifications and conformity criteria for very low heat
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special cements
• EN 14647: Calcium aluminate cement. Composition, specifications and conformity criteria
• EN 15743: Supersulfated cement. Composition, specifications and conformity criteria
• EN 12620: Aggregates for concrete
• EN 13055: Lightweight aggregates
• EN 13139: Aggregates for mortar
• EN 450: Fly ash for concrete. Definition, specifications and conformity criteria
• CEN/TR 15840: Evaluation of conformity of fly ash for concrete - Guidelines for the application
of EN 450- 2
• EN 15167-1: Ground granulated blast furnace slag for use in concrete, mortar and grout Part 1:
Definitions, specifications and conformity criteria
• EN 15167-2: Ground granulated blast furnace slag for use in concrete, mortar and grout Part 2:
Conformity evaluation
• EN 13263-1: Silica fume for concrete Part 1: Definitions, requirements and conformity criteria
• EN 13263-2: Silica fume for concrete Part 2: Conformity evaluation
• EN 934: Admixtures for concrete, mortar and grout
• EN 1008: Mixing water for concrete. Specification for sampling, testing and assessing the
suitability of water, including water recovered from processes in the concrete industry, as
mixing water for concrete
• EN 14889- 1: Fibres for concrete – Part 1: Steel fibres - Definitions, specifications and
conformity
• EN 14889- 2: Fibres for concrete – Part 2: Polymer fibres - Definitions, specifications and
conformity
• EN 206: Concrete. Specification, performance, production and conformity
• EN 1504-2: Products and systems for the protection and repair of concrete structures.
Definitions, requirements, quality control and evaluation of conformity. Surface protection
systems for concrete
Definitions, requirements, quality control and evaluation of conformity. General principles for
use of products and systems
Definitions, requirements, quality control and evaluation of conformity. Site application of
products and systems and quality control of the works
• EN 13670: Execution of concrete structures
• EN 12811-1: Temporary works equipment. Scaffolds. Performance requirements and general
design
• EN 12811-2: Temporary works equipment. Information on materials
• EN 12812: Falsework. Performance requirements and general design
• EN 13377: Prefabricated timber formwork beams. Requirements, classification and assessment
• EN 14487- 1: Sprayed concrete. Definitions, specifications and conform
• EN 14487- 2: Sprayed concrete. Execution
• DIN 1164: Cement
• DIN 1045-1: Concrete - specification, properties, production and conformity - Design
• DIN 1045-2: Concrete - specification, properties, production and conformity - Application rules
• DIN 1045-3: Concrete - specification, properties, production and conformity - Execution of
structures
• DIN 1045-4: Concrete - specification, properties, production and conformity - Execution of pre-
fabricated structures
• DIN 1048: Quality tests of concrete
• DIN 1084: Quality control of concrete
• DIN 4226: Concrete aggregates
• DIN 488: Reinforcing steel
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• BS 8500-1: Concrete – Complementary British Standard to BS EN 206 Part 1: Method of

specifying and guidance for the specifier
• BS 8500-2: Concrete – Complementary British Standard to BS EN 206 Part 2: Specification for
constituent materials and concrete
• BS 7979: Specification for limestone fines for use with Portland cement
• SANS 50197-1: Cement. Part 1, Composition, specifications and conformity criteria for
common cements
• SANS 1491-1. Portland cement extenders. Part 1, Ground granulated blast-furnace slag
• SANS 1491-2: Portland cement extenders. Part 2, Fly ash
• SANS 794: Aggregates of low density
• SANS 1083: Aggregates from natural sources - Aggregates for concrete
• SANS 1090. Aggregates from natural sources - Fine aggregates for plaster and mortar
• SANS 50934-3: Admixtures for concrete, mortar and grout, Part 3, Admixtures for masonry
mortar - definitions, requirements, conformity and marking and labelling
• SANS 50934-4: Admixtures for concrete, mortar and grout, Part 4, Admixtures for grout for
prestressing tendons - definitions, requirements, conformity, marking and labelling
• SANS 50934-5: Admixtures for concrete, mortar and grout, Part 5, Admixtures for sprayed
concrete - definitions, requirements, conformity, marking and labelling
• SANS 50934-6: Admixtures for concrete, mortar and grout, Part 6, Sampling, conformity
control and evaluation of conformity
• SANS 878: Ready-mixed concrete
• SANS 10100-2: The structural use of concrete. Part 2, Materials and execution of work
• SANS 282: Bending dimensions and scheduling of steel reinforcement for concrete
• SANS 920: Steel bars for concrete reinforcement
• SANS 1024: Welded steel fabric for reinforcement of concrete
• SANS 10144: Detailing of steel reinforcement for concrete
• This above list does include the applicable standards for testing concrete materials, fresh
concrete and hardened concrete and pre-cast concrete elements.
2.5.2 Classes of Concrete

Concrete used in the Works shall be of the class shown in the detailed design report, the drawings or
indicated in the Bill of Quantities. If not specified in the documents the classes of concrete are below
shall apply:
• Class A: Reinforced concrete for general use
• Class B: Reinforced concrete for special situations
• Class C: Reinforced concrete for watertight structures
• Class D: Mass concrete
• Class E: Concrete blinding or backfill
2.5.3 Concrete Mixes and Ingredients

Concreting in the Works shall not commence until the mix for the class of concrete required has been
determined, by means of trial mixes and tests arranged by the Contractor, and has been agreed with the
Engineer.
The Contractor shall not alter the mix proportions or the source of supply of any of the ingredients
without the advance agreement with the Engineer.
2.5.4 Compliance with Strength Requirements

All concrete shall comply with the strength requirements shown below as determined in accordance in
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EC2/ EN 206.
Table 2.2 – Requirements for strength compliance
Concrete Terminology Type of Maximum Additional

Class according to EC2/ cement Aggregat Requirements
EN 206 e Size Slump
A C20/25
B
32 mm S3/100-150
C30/37 mm
C W/C ≤ 0.55
OPC
D 64 mm
C12/15 S2/50-90 mm
E 32 mm
The two numbers in the terminology according to EC2/ EN 206 respectively represent the characteristic
28-day strength values of 150 mm diameter x 300 mm high test cylinders and of test cubes with 150
mm edge lengths when prepared and tested in accordance with ISO 4012 e.g. test cylinders and cubes
made from C20/25 concrete shall respectively have characteristic strength values of 20 and 25 MPa at
28 days.
The Contractor shall arrange for trial mixes to be made for each class of concrete using the same type
of equipment and the same concrete ingredients as he intends to use for the Works and shall arrange for
specimens to be made from these mixes and tested in an approved laboratory for compliance with the
strength and other requirements specified above. The Contractor shall give the Engineer 24 hours’
notice of his intention to initiate the trial mix exercise described above so as to enable the Engineer to
witness the making of the trial mixes. He shall also arrange for the specimens that are prepared to be
tested and for the results to be submitted to the Engineer in the form of a report which contains a
recommendation for the mix that is to be used for each class of concrete. The recommended mixes shall
be used for all concrete produced for the Works.
The trial mix procedure described above shall be repeated every time the Contractor wishes to change
any of the concrete ingredients or the agreed batching plant/ place of manufacture.
2.5.5 Cement
2.5.5.1 Standards
The cement used in the Works shall be ordinary Portland cement (OPC) complying with EN 196 or an
equivalent Standard unless the concrete will be coming into contact with aggressive water. Cement for
concrete that will be coming into contact with aggressive water shall comply with the classification
“increased sulphate resistant” according to EN 197. Samples of cement shall be supplied, when
requested by the Engineer, both from the Contractor's store on Site and from the place of manufacture.
2.5.5.2 Cement Delivery

Cement may be delivered in bulk or in bags, except that cement for grouting or for other uses that
require batching.
Cement bags shall be of standard dimensions, with the identification of the cement, the manufacturer’s
name and the mass of the cement content clearly marked on each bag.
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2.5.5.3 Cement Storage

Bulk cement on site shall be stored in watertight silos designed to prevent loss in storage.
Bagged cement shall be stored in a dry, fully enclosed and covered place sized to allow easy access for
identification, sampling, counting and moving the bags. All cement shall be stored clear of the ground
and protected against moisture absorption.
Cement shall be used in chronological order of its arrival. No cement stored for more than 4 months
shall be used unless a complete set of physical tests shows that is still complies with all the requirements
of the Specification.
Cement which has been exposed to the weather and has become wet, which has set, even partially,
which is from broken bags or which has otherwise been rejected for non-compliance with the
Specification shall not be used for the Works and shall be removed from the silos or stores.
2.5.6 Additives
All additives shall be in liquid form. Additives shall not contain chloride.
If additives are specified or permitted, the concrete batching plant shall be equipped to automatically
and accurately dispense the additives into the mix.
Additives which produce the following effects may be specified:
• Shrinkage reducers for certain sealing grout or mortars (such additive shall be free of
iron)
• Water reducing plasticisers to provide satisfactory workability within the water-cement
ratio specified
• Air entraining admixtures to improve workability and imperviousness
The cement content of a mix shall not be reduced below the specified minimum content whether or not
additives are used.
Before the Contractor uses any additive, he shall determine:
• the compatibility of proposed additive with the other concrete ingredients
• its influence on the proportion of water for comparable consistencies
• the mechanical strength of the concrete obtained
• the optimum proportion of additive for the mix
The Contractor shall submit his findings to the Engineer and shall only use the additive once it has been
agreed with the Engineer.
2.5.7 Water
The water used for making and curing concrete shall be at the time of use be free from polluting matter
in any quantity. The Contractor shall arrange for the water which he proposes to use to be tested in an
approved laboratory and shall submit the records of any such tests to the Engineer before placing any
concrete in the Works.
2.5.8 Aggregates for Concrete

Aggregates for concrete shall be coarse aggregate and fine aggregate conforming in all respects to the
relevant EC or DIN Standards. The grading should be such as to produce a concrete with the specified
proportions and consistency and one that is readily workable.
Aggregate for concrete shall consist of hard, dense, durable, clean, uncoated fragments of natural sand,
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crushed stone, or other suitable materials for use with the cement specified. It shall be free from clay,
shells, organic material or other deleterious substances and shall be furnished from agreed sources.
The Contractor shall arrange for all aggregates to be tested and shall provide such facilities as may be
necessary for procuring representative test samples. The tests shall include chemical analyses designed
to detect the presence of constituents which could adversely affect the concrete quality or longevity. If
any aggregate does not comply with specified grading, the Contractor shall correct the grading with no
extra cost for the Employer.
Aggregates shall be stored on concrete floors in order to avoid contamination. The different fractions
of the aggregates shall be stored separately and mixing of the different fractions shall be prevented by
means of partition walls or other approved methods.
All aggregates shall be washed with clean fresh water at no extra cost to the Employer if this is necessary
for them to comply with the Specifications.
2.5.9 Mixing of Concrete

If the Contractor proposes to use ready mixed concrete, he shall submit to the Engineer for his approval
full details and test results of the concrete mixes. The Engineer may approve the use of ready mixed
concrete provided that:
a) the proposed mixes, the material to be used and the method of storage and mixing comply
with the requirements of the Specification; and b) adequate control is exercised during
mixing.
The concrete ingredients shall be mixed in a sufficient number of mechanical batch mixers of adequate
capacity. Mixers that at any time produce unsatisfactory results shall be replaced promptly. Mixing shall
be until there is a uniform distribution of the materials and the mix is uniform in colour and consistency.
Water shall be added prior to, during and after the addition of aggregates and cement. Admixtures, if
specified, shall be dissolved beforehand in the mix water.
Batching and mixing plants shall be modern efficient equipment complying with the requirements of
applicable ISO, EN, DIN or BSI standards and capable of producing a uniform distribution of the
ingredients throughout the mass. Truck mixes shall comply with the requirements of applicable ISO,
EN, DIN or BSI standards and shall only be used with the prior agreement of the Engineer.
Before any plant for batching, mixing, transporting, placing, compacting and finishing concrete is
ordered or delivered to site, the Contractor shall submit to the Engineer full details including drawings
of all the plant which he proposes to use and the arrangements he proposes to make. Concrete for the
Works shall be and mixed using an automatic batching plant in one or more central location.
Approval for the use of ready mixed concrete may be withdrawn if the Engineer is not satisfied with
the control of the materials being used and control during mixing. The mixing of concrete shall be
carried out at central plant located at a site remote from place of discharge of mixed concrete. The mixed
concrete shall be transported from the central plant using transit lorry mixers and/or agitator trucks.
The Contractor shall appoint one qualified person, who shall be responsible for the concrete production.
All mixing operations shall be under the control of an experienced supervisor.
The aggregate storage bins shall be provided with drainage facilities arranged so that drainage water is
not discharged to the weigh hoppers. Each bin shall be drawn down at least once per week and any
accumulations of mud or silt removed.
Cement and aggregate shall be batched by weight. Water may be measured by weight or volume. The
weighing and water dispensing mechanisms shall be maintained in good order. Their accuracy shall be
maintained within the tolerances described in applicable standards and checked against accurate weighs
and volumes when required by the Engineer. The ingredients shall be accurately batched by mass
according to EN and DIN Standards, with maximum deviations of 2% being permitted for water and
cement and for aggregates and additives. The different aggregate fractions shall be batched separately
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before entering the mixer. The moisture contents of the aggregates shall be determined and the mixing
water content shall be adjusted correspondingly.
The Contractor shall provide standard test weights at least equivalent to the maximum working load
used on the most heavily loaded scale and other auxiliary equipment required for checking the
satisfactory operation of each scale or other measuring device. Tests shall be made by the Contractor at
least once a week or at intervals to be determined by the Engineer and shall be carried out in his
presence. For the purpose of carrying out these tests, there shall be easy access for personnel to the
weigh hoppers. The Contractor shall furnish the Engineer with copies of the complete results of all
check tests and shall make any adjustments, repairs or replacements necessary to ensure satisfactory
performance.
The nominal drum or pan capacity of the mixer shall not be exceeded. The turning speed and the mixing
time shall be as recommended by the manufacturer, but in addition, when water is the last ingredient to
be added, mixing shall continue for at least one minute after all the water has been added to the drum
or pan. The blades of pan mixers shall be maintained within the tolerances specified by the manufacturer
of the mixer and the blades shall be replaced when it is no longer possible to maintain the tolerances by
adjustment. Mixers shall be fitted with an automatic recorder registering the number of batches
discharged.
The water to be added to the mix shall be reduced by the amount of free water contained in the coarse
and fine aggregates. This amount shall be determined by the Contractor by a method agreed by the
Engineer immediately before mixing begins each day and thereafter at least once per hour during
concreting and for each delivery of aggregates during concreting. When the correct quantity of water,
determined as set out in the Specification, has been added to the mix, no further water shall be added,
either during mixing or subsequently.
After mixing for the required time, each batch shall be discharged completely from the mixer before
any materials for the succeeding batch are introduced. Mixers which have been out of use for more than
30 minutes shall be thoroughly cleaned before any fresh concrete is mixed and thereafter the first batch
of concrete through the mixers shall contain only half the normal quantity of coarse aggregate. This
batch shall be mixed for one minute longer than the time applicable to a normal batch. Mixers shall be
cleaned out before changing to another type of cement.
Concrete for structural purposes shall not be mixed by hand. Where non-structural concrete is required,
hand mixing may be carried out subject to the agreement of the Engineer. The mixing shall be done on
a hard impermeable surface. The materials shall be turned over not less than three times dry, water shall
then be sprayed on and the materials again turned over not less than three times in a wet condition and
worked together until a mixture of uniform consistency is obtained. For hand mixed concrete the
specified quantities of cement shall be increased by 10% and not more than 0.5 cubic meter shall be
mixed at one time. During windy weather efficient precautions shall be taken to prevent cement from
being blown away during the process of gauging and mixing.
2.5.10 Transporting Concrete

The methods and equipment used for transporting concrete shall be such that concrete having the
required composition and consistency is delivered to the Works without objectionable segregation or
loss of slump, and without undue delay. At no time shall a period of more than 1-hour elapse between
introduction of the cement to the mix and the placing of the concrete in the Works.
If required by the Engineer, concrete for which an appreciable time has elapsed after mixing due to
transportation or other reasons shall be tested at the point of placement for workability by means of
slump tests or other agreed methods before it is placed in the Works. If such tests indicate that the
concrete is no longer suitable for use, it shall be rejected and shall be disposed of by the Contractor in
a manner that is in accordance with the method statement. No payment will be made to the Contractor
for the production, delivery or disposal of such rejected concrete.
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2.5.11 Placing Concrete
2.5.11.1 Consent for placing
Concrete shall not be placed in any part of the Works until the Engineer’s consent has been given in
writing, and the Contractor shall give the Engineer at least 1 full working day’s notice of his intention
to place concrete. No concrete shall be placed before agreement from the Engineer is sought
respectively given. The release shall cover amongst others associated formwork, installation of parts to
be embedded, preparation of surfaces etc. Concrete shall be placed only in the presence of the Engineer,
unless permission is obtained by the Contractor for placing concrete in his absence.
If concrete placing is not commenced within 24 hours of the Engineer’s consent the Contractor shall
again request consent as specified above.
2.5.11.2 Preparation of surface to receive concrete

Excavated surfaces on which concrete is to be deposited shall be prepared to avoid contamination.
Unless otherwise instructed by the Engineer, surfaces against which concrete is to be placed shall
receive a prior coating of mortar mixed in the proportions similar to those of the fines portion in the
concrete to be placed. The mortar shall be kept ahead of the concrete. The mortar shall be well worked
into all parts of the excavated surface and shall not be less than 5mm thick. The amount of mortar placed
at any one time shall be limited so that it does not dry out or set before being covered with concrete.
Existing concrete surfaces shall be prepared to ensure adequate adherence. Before deposition of further
concrete, they shall be clean, hard and sound and shall be wet but without any free-standing water. Any
flow of water into an excavation shall be diverted through proper side drains to a sump, or be removed
by other suitable methods which will prevent washing away the freshly deposited concrete or any of its
constituents. Any underdrains constructed for this purpose shall be completely grouted up when they
are no longer required by a method agreed by the Engineer.
If any fissures have been cleaned, they shall be filled with mortar or with concrete as instructed by the
Engineer. All surfaces against which concrete is to be placed shall be well wetted before concreting.
Rock surfaces onto which concrete is to be placed shall be covered with a 20 mm thick layer of 1:3
cement: sand mortar immediately prior to the placing of the concrete. The mortar shall be well worked
into the surface with the aid of brushes.
2.5.11.3 Chutes
In general, transportation of concrete by the use of chutes will not be permitted unless approved by the
Engineer. The chute shall have a section with round corners and shall have a proper fixed slope so as to
allow the concrete to flow satisfactorily and without segregation. The lower end of chute shall be
provided with a drop chute not less than 0.6m in height to avoid segregation of falling concrete. The
height of drop shall not exceed 1.5m. Chutes shall be protected from direct sunlight, wind and rain.
2.5.11.4 Concrete pump or placer

The type and capacity of pump shall be determined to meet the specified requirements, taking into
account the placing speed, construction schedule, quality of concrete, location to which concrete is
poured, etc. Diameter of the delivery pipes shall be not smaller than 3 times of the maximum size of
aggregates to be used in the concrete.
Delivery pipes shall be so installed as to permit easy removal. Before starting the pump or placer
operation, about one cubic metre of mortar with the same proportion of water, admixture, cement and
fine aggregate as designated for the regular concrete mix shall be passed through the pipe. The pipe
shall be set as straight and horizontally as possible to prevent clogging of the concrete mix in the pipe.
The supports of the pipe line shall be stiff enough to fix the pipes firmly without adverse effect on forms
and reinforcing steel already set in position. Care shall be taken to prevent leakage of the concrete mix
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from the pipe line or any other part.
Air boosters shall not be used except in conditions where the outlet of the pipe is completely embedded
at least 2 metres in fresh concrete.
2.5.11.5 Placing procedures

The concrete shall be deposited as nearly as possible in its final position. It shall be placed so as to avoid
segregation of the concrete and displacement of the reinforcement, other embedded items, or formwork.
It shall be brought up in layers approximately parallel to the construction joint planes and not exceeding
500mm in compacted thickness unless otherwise permitted or directed by the Engineer, but the layers
shall not be thinner than four times the maximum nominal size of aggregate.
Layers shall be placed so that they do not form feather edges nor shall they be placed on a previous
layer which has taken its initial set. In order to comply with this requirement, a layer may be started
before completion of the preceding layer.
All the concrete in a single bay or pour shall be placed in a continuous operation. It shall be carefully
worked round all obstructions, irregularities in the foundations and the like so that all parts are
completely full of compacted concrete with no segregation or honeycombing. It shall also be carefully
worked round and between waterstops, reinforcement, embedded steelwork and similar items which
protrude above the surface of the completed pour.
All work shall be completed on each batch of concrete before its initial set commences and thereafter
the concrete shall not be disturbed before it has set hard. No concrete that has partially hardened during
transit shall be used in the Works and the transport of concrete from the mixer to the point of placing
shall be such that this requirement can be complied with.
Concrete shall not be placed during rain which is sufficiently heavy or prolonged as to wash mortar
from coarse aggregate on the exposed faces of fresh concrete. Means shall be provided to remove any
water accumulating on the surface of the placed concrete. Concrete shall not be deposited into such
accumulation of water.
In drying weather, covers shall be provided for all fresh concrete surfaces which are not being worked
on. Water shall not be added to concrete for any reason.
When concrete is discharged above its place of final deposition, segregation shall be prevented by the
use of chutes, downpipes, trunking, baffles or other appropriate devices, as approved by the Engineer.
Forms for walls, columns and other thin sections of significant height shall be provided with openings
or other devices that will permit the concrete to be placed in a manner that will prevent segregation and
accumulations of hardened concrete on the formwork or reinforcement above the level of the placed
concrete.
When it is necessary to place concrete under water the Contractor shall submit to the Engineer his
proposals for the method and equipment to be employed. The concrete shall be deposited either by
bottom-discharging watertight containers or through funnel-shaped tremies which are kept continuously
full with concrete up to level above the water and which shall have the discharging bottom fitted with
a trapdoor and immersed in the concrete in order to reduce to a minimum the contact of the concrete
with the water. Special care shall be taken to avoid segregation.
If the level of concrete in a tremie pipe is allowed to fall to such an extent that water enters the pipe, the
latter shall be removed from the pour and filled with concrete before being again lowered into the
placing position. During and after concreting under water, pumping or dewatering in the immediate
vicinity shall be suspended if there is any danger that such work will disturb the freshly placed concrete.
2.5.11.6 Interruptions to placing

If concrete placing is interrupted for any reason and the duration of the interruption cannot be forecast
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or is likely to be prolonged, the Contractor shall immediately take the necessary action to form a
construction joint so as to eliminate as far as possible feather edges and sloping top surfaces and shall
thoroughly compact the concrete already placed in accordance with Clause 406. All work on the
concrete shall be completed while it is still plastic and it shall not thereafter be disturbed until it is hard
enough to resist damage. Plant and materials to comply with this requirement shall be readily available
at all times during concrete placing.
Before concreting is resumed after such an interruption the Contractor shall cut out and remove all
damaged or uncompacted concrete, feather edges or any other undesirable features and shall leave a
clean sound surface against which the fresh concrete may be placed.
If it becomes possible to resume concrete placing without contravening the Specification and the
Engineer consents to a resumption, the new concrete shall be thoroughly worked in and compacted
against the existing concrete so as to eliminate any cold joints.
2.5.11.7 Dimensions of pours

Unless otherwise agreed by the Engineer, pours shall not be more than two meters high and shall as far
as possible have a uniform thickness over the plan area of the pour. Concrete shall be placed to the full
planned height of all pours except in the circumstances permitted in the present specifications or
authorized by the Engineer.
The Contractor shall plan the dimensions and sequence of pours in such a way that cracking of the
concrete does not take place due to thermal or shrinkage stresses.
2.5.11.8 Placing sequence

The Contractor shall arrange that as far as possible the intervals between placing successive lifts of
concrete in one section of the Works are of equal duration. This duration shall normally be not less than
three or more than seven days under temperate weather conditions unless otherwise agreed by the
Engineer.
Where required by the Engineer to limit the opening of construction joints due to shrinkage, concrete
shall not be placed against adjacent concrete which is less than 21 days old.
When the drawings call for contraction gaps in concrete, these shall be of the widths and in the locations
shown on the drawings and they shall not be filled until the full time interval shown on the drawings
has elapsed.
Separation of coarse aggregate due to concrete being dropped from too great height or being moved for
excessive distances after initial placing or bouncing off the formwork or reinforcement shall be avoided.
Where such separation would otherwise occur, the Contractor shall provide suitable drop chutes and
baffles to confine and control the falling concrete.
Concrete, shall be placed in continuous approximately horizontal layers which are between 300 mm
and 600 mm thick. The Contractor shall make such arrangements and shall time his operations such that
no layer of concrete starts setting before the next layer is placed on top of it. In no case shall the delay
between the placing of any two layers be such that the vibrator will not readily penetrate the lower layer
under its own weight.
Concreting should be carried out continuously between and up to construction joints, the positions and
details of which shall be as shown in the Drawings. The positions of any additional construction joints
that are required to suit the Contractor’s equipment or operations shall be predetermined by the
Contractor and agreed with the Engineer. The surface of the concrete during placing shall be maintained
reasonably level between construction joints, which shall be constructed as shown in the Drawings or
which shall, in the absence of such details or directions, be plane and vertical and be formed using
expanded metal mesh or timber boards with strips of timber planted onto them to form keyways.
No concrete shall be placed under water, except agreed with the Engineer.
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No concrete shall be placed when the ambient temperature is less than 5°C. When ambient temperatures
are high, measures shall be taken by the Contractor to maintain the temperature of freshly mixed
concrete below 32°C, failing which concreting shall be stopped until the ambient temperature has
dropped to a level at which the temperature of the freshly mixed concrete can be kept below 32°C
without any measures being taken to cool down the ingredients.
2.5.12 Compacting Concrete

Each layer of concrete shall be compacted to the maximum practicable density using immersion-type
mechanical vibrators supplemented by rodding and hand spading where necessary. The use of suitable
tamping vibrators of or in addition to immersion type vibrators may be required on horizontal slabs.
Only skilled and experienced operators shall be permitted to carry out compaction of concrete by
vibration. Vibration shall not be used to move concrete laterally as this may lead to segregation.
The concrete shall be fully compacted throughout the full extent of the placed layer. It shall be
thoroughly worked against the formwork and around any reinforcement and other embedded items,
without displacing them. Particular care shall be taken at arises and other confined spaces. Successive
layers of the same pour shall be thoroughly worked together.
Concrete shall be compacted with the assistance of mechanical immersion vibrators, unless the Engineer
agrees to another method.
Immersion vibrators shall operate at a frequency of between 7,000 and 10,000 cycles per minute. The
Contractor shall ensure that vibrators are operated at pressures and voltages not less than those
recommended by the manufacturer in order that the compactive effort is not reduced.
A sufficient number of vibrators shall be operated to enable the entire quantity of concrete being placed
to be Where the vibrated for the necessary period and, in addition, standby vibrators shall be available
for instant use at each place where concrete is being placed.
Concrete contains aggregate with a nominal size of 75mm or more, vibrators with a diameter of 100mm
or more shall be used.
Vibration shall be continued at each point until the concrete ceases to contract, a thin layer of mortar
has appeared on the surface and air bubbles have ceased to appear. Vibrators shall not be used to move
concrete laterally and shall be withdrawn slowly to prevent the formation of voids.
Vibration shall not be applied by way of reinforcement nor shall vibrators be allowed to touch
reinforcement or other embedded items. The vibrators shall be inserted vertically into the concrete to
penetrate the layer underneath at regular spacing. The spacing shall not exceed the distance from the
vibrator over which vibration is visibly effective.
2.5.13 Curing Concrete

Concrete shall, while it is curing, be protected against contamination and excessive or rapid loss of
moisture by covering exposed surfaces with sand or mats made with moisture retaining material, which
shall be sprayed regularly to keep them damp, ponding water on exposed surfaces, delaying the stripping
of formwork and/or applying agreed curing compounds to the surfaces.
Concrete shall be protected during the first stage of hardening from loss of moisture and from the
development of temperature differentials within the concrete sufficient to cause cracking. The methods
used for curing shall not cause damage of any kind to the concrete.
Curing shall be continued for as long as may be necessary to achieve the above objectives but in any
case, for at least seven days or until the concrete is covered by later construction whichever is the shorter
period.
The above objectives are dealt with separately, but nothing shall prevent both objectives being achieved
by a single method where circumstances permit.
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The curing process shall commence as soon as the concrete is hard enough to resist damage from the
process, and in the case of large areas or continuous pours, shall commence on the completed section
of the pour before the rest of the pour is finished.
Details of the Contractor’s proposals for curing concrete shall be submitted to the Engineer before the
placing of concrete commences in the Works. Formed surfaces may be cured by retaining the formwork
in place for the required curing period.
If the use of the foregoing methods is inappropriate, surfaces which will not have further concrete
bonded to them and which are not to receive an application of a finish may be cured by the application
of a curing compound having an efficiency index of at least 90 percent. Curing compounds shall contain
a fugitive dye to enable the extent of the spread to be seen easily.
Curing compound is used on surfaces exposed to the atmosphere shall contain sufficient finely divided
flake aluminum in suspension to produce a complete coverage of the surface with a metallic finish when
applied at the rate recommended by the manufacturer.
Curing compounds shall become stable and impervious to the evaporation of water from the concrete
surface within 60 minutes of application. The material shall not react chemically with the concrete
surfaces for at least the first four days of the curing period.
If instructed by the Engineer, the Contractor shall, in addition to the curing provisions set out above
provide a suitable form of shading to prevent the direct rays of the sun reaching the concrete surfaces
for at least the first four days of the curing period.
Exposed concrete surfaces shall be closely covered with impermeable sheeting, properly secured to
prevent its removal by wind and the development of air spaces beneath it. Joints in the sheeting shall
be lapped by at least 300mm.
If for some reason it is not possible to use impermeable sheeting, the Contractor shall keep the exposed
surfaces continuously wet by means of a water spray or by covering with a water absorbent material
which is kept wet, unless this method conflicts with requirements.
Water used for curing shall be of the same quality as that used for concrete mixing.
The Contractor shall limit the development of temperature differentials in concrete after placing by any
means appropriate to the circumstances including the following:
• Limiting concrete temperatures at placing;
• Use of low heat cement, subject to the agreement of the Engineer;
• Insulation of exposed concrete surface by insulating blankets. Such blankets shall have an
insulation value at least equivalent to 50mm of dry mineral wool;
• Leaving formwork in place during the curing period. Steel forms shall be suitably insulated on
the outside;
• Preventing rapid dissipation of heat from surfaces by shielding from wind;
• Avoiding the use of water sprays when such use would cause rapid cooling of the surface.
2.5.14 Protecting Concrete

Freshly placed concrete shall be protected from rainfall and from water running over the surface until
it is sufficiently hard to resist damage from these causes. No traffic shall be allowed on any concrete
surface until such time as it is hard enough to resist damage by such traffic.
Concrete placed in the Works shall not be subjected to any loading until it has attained at least its
nominal strength.
If the Contractor desires to impose loads on newly-placed concrete, he shall make at least three test
cubes and cure them in the same conditions as the concrete they represent. These cubes shall be tested
singly at suitable intervals in order to estimate the time at which the nominal strength is reached.
The Contractor shall prevent damage to concrete arising from exposure to extreme temperatures, and
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shall maintain in good working order all plant and equipment required for this purpose.
In the event that conditions become such that even with the use of the equipment the requirements
cannot be met, concrete placing shall immediately cease until such time as the requirements can again
be met.
During hot weather the Contractor shall take all measures necessary to ensure that the temperature of
concrete at the time of placing in the Works does not exceed 30 degrees centigrade and that the concrete
does not lose any moisture during transporting and placing.
Such measures may include but are not necessarily limited to the following: i) shielding aggregates
from direct sunshine; ii) use of a mist water spray on aggregates; iii) sun shields on mixing plants and
transporting equipment; iv) cooling the mixing water. If ice is used for this purpose it should preferably
be in flake form. Lump ice shall not be allowed to enter the tank supplying the mixer drum; and v)
covering skips closely with polythene sheet so that the latter is in contact with the concrete.
Areas in which concrete is to be placed shall be shielded from direct sunshine and rock or concrete
surfaces shall be thoroughly wetted to reduce absorption of water from the concrete placed on or against
them.
After concrete in any part of an area has been placed, the selected curing process shall be commenced
as soon as possible. If any interval occurs between completion of placing and start of curing, the
concrete shall be closely covered during the interval with polythene sheet to prevent loss of moisture.
2.5.15 Embedding Metal Fixtures

The Contractor may be required to embed into the concrete, at the time of pouring, various metal or
other fixtures such as bolts, sleeves, anchors, lugs, etc. All fixtures shall be set and fixed accurately in
position using templates or other suitable methods.
2.5.16 Testing Concrete

2.5.16.1 General
All tests on concrete as prescribed in this Clause and elsewhere in this Specification shall be made at a
laboratory agreed with the Engineer. The Contractor shall arrange test certificates to be submitted to the
Engineer.
In addition to arranging for workability and strength testing to be done on prepared concrete, the
Contractor shall arrange for regular mechanical analyses to be done, in accordance with DIN 4226, on
the fine aggregates and each nominal size of coarse aggregate in use. If the fraction of any aggregate
retained on any sieve differs from the corresponding fraction of that aggregate in the approved mix by
more than 5 % of the total quantity of fine and coarse aggregate, the Engineer may instruct the
Contractor to alter the relative portions of the aggregates in the mix to compensate for such.
In addition to the requirements set in applicable standards, namely the EN 206, the Contractor shall
arrange for one set of test specimens to be made for each concrete operation entailing the use of Class
A, B or C reinforced concrete in a particular component of a structure e.g. in the foundations or floors,
in different walls and sets of columns or beams, or in suspended slabs. Additional sets shall be made if
the concreting of the component takes more than one day (one set per day). The Engineer may, at his
discretion, waive the requirement for test specimens to be taken if the component in question is not
critical structural member and the quantity of concrete contained in it is small. Each set of test
specimens, which shall consist of 3 cubes, shall be made from a single batch of concrete batch taken
and shall be taken after at least 3 batches of concrete have been mixed for the particular operation. Two
of the 5 cubes in each set shall be tested 7 days after manufacture, and the remaining 3 cubes in each
set shall be tested 28 days after manufacture.
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2.5.16.2 Compliance with Specified Requirements
The concrete shall be deemed to comply with the specified strength requirements if:
• the average strength determined for the 3 cubes in each set that are tested at 28 days
exceeds the characteristic strength for the grade of concrete in question i.e. exceeds 25 MPa
for Class A (C20/25) concrete; and
• each of the 28-day test results exceeds 85% of the specified characteristic strength i.e.
exceeds 21.3 MPa for Class A (C20/25) concrete.
2.5.16.3 Non-Compliance with Specified Requirements

If the concrete from a particular mix fails to satisfy the specified strength requirements, no further
concrete of that mix shall be placed in the Works until the Contractor has established the cause of the
failure and applied such remedies as are agreed with the Engineer. The Contractor shall demonstrate by
trial mixes and test results that the revised mix is in accordance with the specified requirements.
The Contractor shall, within 24 hours of receipt of the test results, make proposals, for consideration by
the Engineer, for actions to be taken in respect of the concrete represented by test cubes which fail.
These proposals may include, but shall not be limited to, cutting and testing cores.
Concrete which ultimately does not comply with any of the requirements of the Specification shall be
broken out and replaced or otherwise dealt with as agreed with the Engineer, all at the expense of the
Contractor.
2.5.16.4 Cutting and Testing of Core Samples

As and where directed by the Engineer, cylindrical core samples shall be taken normal to the surface of
the hardened concrete for examination and testing. The procedure for drilling, examination,
measurement and testing the samples shall be in accordance with the quoted Standard. Prior to the
preparation for testing, the samples shall be made available for examination by the Engineer. If the
crushing strength of a specimen is less than the characteristic strength at 28 days for the grade of
concrete in question, the concrete in that part of the Works will be considered not to comply with the
specified requirements and adequate remedying measures shall be agreed with the Engineer. All related
Works shall be on Contractors cost.
2.5.17 Measurement and Payment for Concrete

Measurement of concrete for payment purposes will be made only to the neat lines and levels of the
structures as shown on the drawings.
2.5.18 Tolerances
Unless otherwise shown in the Drawings, the tolerances shown in the following table shall be applicable
to concrete structures (Note: For buried construction, the tolerances shall be twice those shown).
Table 1.7 – Acceptable tolerances
Variation of the linear outlines from established position in plan in 6 m 12 mm

in 12 m 20 mm
Variation of dimensions of individual structure elements from established in 24 m 30 mm

positions
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Variation from plumb, from the specified batter, or from the curved surfaces of in 3 m 12 mm
all structures, including piers, buttresses, arch sections, vertical joint grooves,
in 6 m 20 mm
and visible arises.
Variation from the level or from the grades indicated for slabs, beams, soffits, in 3 m 6 mm
horizontal joint grooves and visible arises.
in 6 m 12 mm
Variation in cross-sectional dimensions of columns, beams, buttresses, piers, Minus 12 mm

and similar members
Plus 12 mm
Variation in the thickness of slabs, walls, arch sections, and similar members Minus 6mm
Footings for columns, piers, walls, buttresses, and similar members:
Table 1.8 – Acceptable variuations
Variation of dimensions in plan Minus 12 mm

Plus 50 mm
Misplacement of eccentricity 2 percent of footing width in the

direction of misplacement but
not more than 50mm
Variation in the thickness of slabs, walls, arch sections, and Minus 6 mm

similar members
2.5.19 Repair of Concrete

Repair of concrete shall be done in accordance with EN 1504 by skilled workmen.
The Contractor shall correct all imperfections on the concrete surfaces within 24 hours after the removal
of forms. Concrete that has been damaged from any cause and concrete that is honeycombed, fractured,
or otherwise defective, shall be removed and replaced using appropriate methods. The removing of
defective concrete shall be done in such a way that the reinforcement is not damaged.
Concrete that has been removed shall be replaced with concrete complying with EN 206, with shotcrete
complying with DIN 18551, or with cement: sand mortar. Concrete additives shall be incorporated into
the replacement material where appropriate. Simple plastering of concrete surfaces will not be
permitted.
All materials, procedures and techniques used by the Contractor for the repair of concrete shall be
subject of Engineer’s agreement and shall be applied by the Contractor at his own cost.
2.5.20 Joints in Concrete

2.5.20.1 Expansion Joints
Expansion joints, which provide complete discontinuity with a clear gap between concrete elements,
are used to prevent structural distress arising from temperature variations or differential movements.
They incorporate a preformed filler and, for water retaining structures, incorporate one or two
waterstops, with one being in the centre of the concrete member and the other at the rear of the member.
In addition, a sealing compound is applied on the upper part of an expansion joint that will be in contact
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with water.
2.5.20.2 Contraction Joints

Contraction joints provide discontinuity without a gap between concrete elements (concrete cast against
concrete).
2.5.20.3 Construction Joints

Construction joints are used to separate construction phases. They provide continuity of both concrete
and reinforcement, and require special preparation of the concrete surface that is constructed first so as
to provide a good bond with the concrete that is placed against it.
Any vertical construction joints between elements of newly built water retaining structures shall
incorporate a central waters top.
Expanded wire mesh shall be used to form construction joints in water retaining structures. The mesh
shall be removed when the concrete has hardened sufficiently to leave a rough but sound surface on the
old concrete with which the fresh concrete can form a strong bond.
2.5.20.4 Examination of Works before Covering Up

Pouring of reinforced concrete is only permitted after the examination of the reinforcement and the
formwork by the Engineer and agreement there from for the de-fined parts of the Works.
The backfilling of pits and trenches is only permitted after successful testing and visual inspection of
pipes, chambers and other infrastructure by the Engineer and agreement there from for the defined parts
of the Works.
2.6 Formwork
2.6.1 General
Formwork means the surface against which concrete is placed to form a face, together with all the
immediate supports to retain it in position while concrete is placed. Falsework means the structural
elements supporting both the formwork and the concrete until the concrete becomes self-supporting. A
formed face is one which has been cast against formwork. An exposed face is one which will remain
visible when construction has been completed.
The Contractor shall be responsible for the design and construction of the formwork and shall supply
and fix all formwork required for the placing of concrete together with its attendant scaffolding,
timbering, shoring, strutting, etc.
Depending on the required surface finish, the Contractor will be permitted to use timber boards,
plywood, steel plate or timber for the construction of formwork. Where timber is used, the formwork
surfaces coming in contact with wet concrete shall be made of properly seasoned timber.
All formwork shall be correctly aligned and securely braced so as to be able to withstand, without
displacement or deflection, the movement of men, materials and plant and the pressure of wet concrete
whilst it is being poured and vibrated.
The formwork shall be constructed in such a manner that leakage of concrete is prevented.
All exposed concrete shall have the external angles chamfered 25mm x 25mm by means of moulding
strips fixed to the formwork.
Ferrules and wire ties shall not be used for the temporary connection of the opposite sides of formwork
for concrete walls and members of water retaining or conveying structures. The use of such connection
methods in other structures will be subject to the Engineer’s agreement. Wherever ferrule and wire
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connections are permitted, the ends of the ferrules or ties shall, after removal of the forms, be cut back
at least 15mm from the face of the concrete and covered with 1:2 cement: sand mortar containing a
shrinkage-reducing additive. The hole formed by the cutting process shall be thoroughly cleaned and
wetted before filing. The mortar shall be of damp, but not fluid consistency. The patch shall be properly
trowelled smooth to match the surrounding concrete surfaces and shall be thoroughly cured by keeping
it moist for at least three days. After the patch has hardened, the patch and the adjacent concrete shall
be ground smooth. The rates for concrete will be deemed to cover the costs of all these operations.
Embedded metal rods shall be used for the temporary connection of the opposite sides of formwork for
concrete walls and members of water retaining or conveying structures. Such rods shall, after removal
of the forms, be cut back at least 25 mm and 40 mm respectively below the formed surfaces of dry and
wet concrete faces. Embedded fasteners on the ends of such rods shall be such that their removal will
leave holes of regular shape. The holes left in the concrete surfaces by the removal of fasteners on
holding rods shall be filled and finished off in the manner described above.
Where necessary, parallel sided or tapered pockets for the casting-in of holding-down bolts, brackets
for pipes, ladders or other fittings, etc. shall be formed in the concrete using polystyrene formers or
wooden boxes fabricated in such a manner that they can be completely withdrawn or broken up and
removed after the concrete has set. The rates for concrete will be deemed to cover all costs associated
with the forming and grouting up of such pockets.
2.6.2 Construction
Before construction begins, the Contractor shall submit to the Engineer, drawings showing details of
the proposed formwork and falsework.
Formwork and falsework shall be so constructed that they will support the loads imposed on them by
the fresh concrete together with additional stresses imposed by vibrating equipment and by construction
traffic, so that after the concrete has hardened the formed faces shall be in the positions shown on the
drawings within the tolerances set out in ISO, EN, DIN and/or BSI standards.
Ground supports shall be properly founded on footings designed to prevent settlement. Joints in
formwork for exposed faces shall, unless otherwise specified, be evenly spaced and horizontal or
vertical and shall be continuous or form a regular pattern. All joints in formwork including formwork
for construction joints shall be tight against the escape of cement, water and fines. Where reinforcement
projects through formwork, the form shall fit closely round the bars.
Formwork shall be so designed that it may be easily removed from the work without damage to the
faces of the concrete. It shall also incorporate provisions for making minor adjustments in position if
required, to ensure the correct location of concrete faces. Due allowance shall be made in the position
of all formwork for movement and settlement under the weight of fresh concrete.
Where overhangs in formwork occur, means shall be provided to permit the escape of air and to ensure
that the space is filled completely with fully compacted concrete.
Formwork shall be provided for concrete surfaces at slopes of 30 degrees to the horizontal or steeper.
Surfaces at slopes less than 20 degrees may be formed by screeding. Surfaces at slopes between 20
degrees and 30 degrees shall generally be formed unless the Contractor can demonstrate to the
satisfaction of the Engineer that such slopes can be screeded with the use of special screed boards to
hold the concrete in place during vibration.
Horizontal or inclined formwork to the upper surface of concrete shall be adequately secured against
uplift due to the pressure of fresh concrete. Formwork to voids within the body of the concrete shall
also be tied down or otherwise secured against floating.
The internal and external angles on concrete surfaces shall be formed with fillets and chamfers of the
sizes shown on the drawings unless otherwise instructed by the Engineer.
Supports for formwork for non-water retaining structures may be bolted to previously placed concrete
provided the type of bolt used is acceptable to the Engineer. If metal ties through the concrete are used
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in conjunction with bolts, the metal left in shall not be closer than 50mm to the face of the concrete.
Supports for formwork for water retaining structures may be bolted to previously placed concrete
provided the type of bolts and positions of fixing are acceptable to the Engineer. After concreting the
Contractor shall remove all support bolts and seal all holes with well rammed cement/sand mortar
containing approved waterproofing cement additive. Metal ties which would be left in the concrete shall
not be permitted.
Formwork shall not be re-used after it has suffered damage which in the opinion of the Engineer is
sufficient to impair the finished surfaces of the concrete.
Where circumstances prevent easy access within the form for cleaning and inspection, temporary
openings for this purpose shall be provided through the formwork.
Shear keys shall be provided in all construction joints of the size and shape indicated on the drawings.
Where precast concrete elements are specified for use as permanent formwork, or proposed by the
Contractor and agreed by the Engineer, they shall comply with the requirements of the Specification.
Such elements shall be set true to line and level within the tolerances prescribed for the appropriate
class of finish in Clause 506 and fixed so that they cannot move when concrete is placed against them.
2.6.3 Preparation
Before any reinforcement is placed into position within formwork, the latter shall be thoroughly cleaned
and then dressed with a release agent. The agent shall be either a suitable oil incorporating a wetting
agent, an emulsion of water suspended in oil or a low viscosity oil containing chemical agents. The
Contractor shall not use an emulsion of oil suspended in water nor any release agent which causes
staining or discoloration of the concrete, air holes on the concrete surface, or retards the set of the
concrete.
In order to avoid colour difference on adjacent concrete surfaces, only one type of release agent shall
be used in any one section of the works.
In cases where it is necessary to fix reinforcement before placing formwork, all surface preparation of
formwork shall be carried out before it is placed into position. The Contractor shall not allow
reinforcement or prestressing tendons to be contaminated with formwork release agent.
Before placing concrete all dirt, construction debris and other foreign matter shall be removed
completely from within the placing area.
Before concrete placing commences, all wedges and other adjusting devices shall be secured against
movement during concrete placing and the Contractor shall maintain a watch on the formwork during
placing to ensure that no movement occurs.
2.6.4 Removal
Forms shall not be removed until the strength of the concrete is such that form removal will not result
in perceptible cracking, spalling or breaking of surfaces, or other damage to the concrete. Any concrete
so damaged shall be repaired in accordance with this Specification at the Contractor’s expense.
In no case shall forms to soffits be struck until test cubes from the actual concrete concerned have
yielded the targeted 7-days strengths. As a guide, and subject to the foregoing the following minimum
removal times are recommended for forms (*) Cement according to EN 197):
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Table 2.3 – Standards for formwork Removal
Cement Type by Formwork for Sides Formwork for Soffits of Props of Beams,
Strength of Wall, Beams, Pillars Slabs and Beams Frames and Slabs
32.5 4 days 10 days 28 days
32.5R / 42.5 3 days 8 days 20 days
42.5R / 52.5 / 52.5R 2 days 5 days 10 days
Formwork shall be carefully removed without shock or disturbance to the concrete. No formwork shall
be removed until the concrete has gained sufficient strength to withstand safely any stresses to which it
may thereby be subjected.
The minimum periods which shall elapse between completion of placing concrete and removal of forms
are given in the Table below and apply to ambient temperatures higher than 10 degrees centigrade. At
lower temperatures or if cement other than ordinary Portland are involved, the Engineer may instruct
that longer periods be used. Alternatively, formwork may be removed when the concrete has attained
the strength set out in the Table below, provided that the attained strength is determined by making test
cubes and curing them under the same conditions as the concrete to which they refer.
Compliance with these requirements shall not relieve the Contractor of his obligation to delay removal
of formwork until the removal can be completed without damage to the concrete.
Table 2.4 – Minimum period for formwork Removal
Min. period for temp Strength to be

over 10 degrees attained
Position of Formwork Centigrade
Vertical or near vertical faces of mass concrete 24 hours 0.2 C
Vertical or near vertical faces of reinforced walls, 48 hours 0.3 C

beams and columns
Underside of arches, beams and slabs (formwork only) 4 days 0.5 C
Supports to underside of arches, beams and slabs 14 days 1C
Arched linings in tunnels and underground works 24 hours 4 N/mm2
Note: C is the nominal strength for the class of concrete used.

If the Contractor wishes to strip formwork from the underside of arches, beams and slabs before the
expiry of the period for supports set out above, it shall be designed so that it can be removed without
disturbing the supports. The Contractor shall not remove supports temporarily for the purpose of
stripping formwork and subsequently replace them.
As soon as the formwork has been removed, bolt holes in concrete faces other than construction joints
which are not required for subsequent operations shall be completely filled with mortar sufficiently dry
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to prevent any slumping at the face. The mortar shall be mixed in the same proportions as the fine
aggregate and cement in the surrounding concrete and with the same materials and shall be finished
flush with the face of the concrete.
2.6.5 Cleaning and Oiling of Forms

The surfaces of the forms shall be cleaned immediately prior to concrete being placed in them and shall
then be coated with an appropriate commercial form oil that will effectively prevent the sticking of the
concrete to the forms but will not stain the concrete surfaces.
Forms for surfaces that are to be plastered or rendered shall not be oiled but shall be thoroughly wetted
about half an hour before concreting.
2.6.6 Classes of Forms and Concrete Finishes

The types of forms provided by the Contractor for the placing of concrete in various structures shall, in
each case, be subject of agreement with the Engineer.
2.6.6.1 Classes of Finish for Formed Concrete

The classes of finish for formed concrete surfaces are designated by use of symbols F1, F2 and F3. Bag
rubbing or sand blasting will not be required on formed surfaces, other than that necessary for the repair
of surface imperfections. The surface finishes to be achieved on formed concrete surfaces shall be as
specified in the particular specifications or shown on the Drawings.
• Finish F1
• Finish F1 applies to formed surfaces onto or against which fill material or concrete is to be
placed. Except for construction joints, the surfaces will not require treatment after form removal
except for repair of defective concrete and filling of holes left by the removal of fasteners for
the ends of tie-wires or rods. Correction of surface irregularities will be only be required for
depressions exceeding 30 mm in depth.
• Finish F2
• Finish F2 is for surfaces which are permanently exposed to view but where the highest standard
of finish is not required. Forms to provide a Class F2 finish shall be faced with tongue and
groove boards with square edges arranged in a uniform pattern and closely jointed, or with
suitable sheet material or with steel panels. The thicknesses of the boards, sheets or panels shall
be such that there they will not visibly deflect under the pressure exerted by the concrete placed
against them. Joints between boards, sheets or panels shall be horizontal or vertical unless
otherwise directed. The finish is intended to be left as struck. Surface irregularities shall not
exceed 6 mm for abrupt irregularities or 12 mm for gradual irregularities. While minor surface
blemishes and discolorations will be permitted, large blemishes and notable stains and
discoloration shall be corrected.
• In the absence of any information to the contrary, the Contractor shall provide a Class F2 finish
to all exposed surfaces and joints.
• Finish F3
• Finish F3 is for surfaces which will be in contact with flowing water and for surfaces
prominently exposed to view where good appearance is of special importance.
• To achieve this, finish the formwork shall be faced with steel, plywood or similar material that
is available in large sheets. The sheets shall be arranged in an appropriate uniform pattern.
Wherever possible, joints between sheets shall be arranged to coincide with architectural
features or changes in direction of the surface. All joints between panels shall be horizontal or
vertical unless otherwise directed. Suitable joints shall be provided between sheets to maintain
accurate alignment in the plane of the sheets. Standard steel panels will not be permitted for a
F3 Finish unless specifically detailed on the Drawings.
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After stripping of the formwork, all projections shall be removed, irregularities repaired and the surface
rubbed or treated as necessary to form a smooth finish of uniform texture, appearance and colour.
Surface irregularities shall not exceed 2 mm for abrupt irregularities or 6 mm for gradual irregularities.
Abrupt irregularities will not be permitted at construction joints.
2.6.6.2 Classes of Finish for Unformed Concrete

The classes of finish for unformed concrete surfaces are designated by the symbols U1, U2 and U3. The
surface finishes to be achieved on unformed concrete surfaces shall be as specified in the particular
specifications or on the Drawings.
• Finish U1 (Screeded Finish)
• Finish U1 is for unformed surfaces that will be covered by fill material or. Finish U1 is also the
first stage of Finish U2. Finishing operations shall consist of sufficient levelling and screeding
to produce even, uniform surfaces. Surface irregularities shall not exceed 10 mm.
• Finish U2 (Floated Finish)
• Finish U2 is for unformed surfaces not permanently concealed by fill material or concrete and
not required to receive a U3 finish. Finishing operations shall consist of sufficient levelling and
screeding to produce even surfaces in which the surface irregularities shall not exceed 6 mm.
Floating with hand or power-driven equipment shall be started as soon as the screeded surface
has stiffened sufficiently to prevent formation of laitance, and shall be continued until a surface
that is free from screed marks and that is uniform in colour and texture has been achieved.
• In the absence of any information to the contrary, the Contractor shall provide a Class U2 finish
to all exposed surfaces.
• Finish U3 (Trowelled Finish)
• Finish U3 is for unformed surfaces exposed to flowing water or for which particularly accurate
alignment and evenness of surfaces is required. Finish U3 shall be screeded and floated as
indicated for finishes U1 and U2, following which the floated surface shall be steel trowelled as
soon as it has hardened sufficiently to prevent an excessive quantity of fine material being drawn
to the surface. Steel trowelling shall be performed with firm pressure to flatten the sandy texture
of the floated surface and produce a dense and uniform surface free from blemishes and trowel
marks. Abrupt irregularities will not be permitted.
2.7 Reinforcement
2.7.1 General
Bar reinforcement shall be of mild steel and shall comply with the relevant DIN and EN Standards.
Only ribbed bars with a yield point of 590 N/mm² and an ultimate tensile strength of 620 N/mm² or
higher and mesh consisting of such ribbed bars shall be used in the Works.
Steel reinforcement shall be stored clear of the ground and supported to prevent distortion. Bars which
have become distorted shall not be straightened or re-bent for incorporation into the Works. The
reinforcement shall, at the time of incorporation into the Works, be clean and free from damage and
loose rust.
The Contractor shall ascertain for himself from the information given in the Drawings and in the
Specification the precise requirements of steel reinforcement to be obtained for the Works. Where
necessary, the Contractor shall prepare working reinforcement drawings and bending schedules. In
preparing such drawings and schedules, the Contractor shall allow for lapping of the bars in accordance
with standard practice and shall avoid unnecessary lapping of bars or excessive lap lengths.
The Contractor shall ensure that the reinforcement is rigidly fixed so that it remains in the position
shown on the drawings during placing of the concrete. Welding of the reinforcement is designated as
being weldable in accordance with EN10080. Spacers, either PVC or metallic, shall be subject to release
for application by the Engineer.
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The Contractor shall not place concrete around reinforcement until the Engineer has inspected the
reinforcement and has given his consent for concrete placing.
2.7.2 Bending reinforcement

Unless otherwise shown on the drawings, bending and cutting shall comply with Bending and cutting
of bars shall be in accordance with relevant ISO, EN and DIN standards.
The Contractor shall satisfy himself as to the accuracy of any bar bending schedules supplied and shall
be responsible for cutting, bending, and fixing the reinforcement in accordance with the drawings. Any
discrepancies should be brought to the attention of the Engineer prior to ordering the reinforcement.
Bars shall be bent cold by the application of slow steady pressure. At temperatures below 5 degrees
centigrade the rate of bending shall be reduced if necessary to prevent fracture of the steel.
After bending, bars shall be securely tied together in bundles or groups and legibly labelled as set out
in SRN 129.
Reinforcement shall be thoroughly cleaned and all dirt, scale, loose rust, oil and other contaminants
removed before it is placed in the Works.
2.7.3 Fixing reinforcement

Reinforcement shall be securely fixed in the design positions within a dimensional tolerance of 20mm
in any direction parallel to a concrete face and within a tolerance of 5mm at right angles to a face,
provided that the cover is not thereby decreased below the minimum shown on the drawings, or if not
shown shall be not less than 25mm or the diameter of the bar, whichever is the greater. Cover on
distribution steel shall not be less than 15mm or the diameter of the bar whichever is the greater.
Unless otherwise agreed by the Engineer, all intersecting bars shall either be tied together with 1.6mm
diameter soft annealed iron wire and the ends of the wire turned into the body of the concrete, or shall
be secured with a wire clip of a type agreed by the Engineer.
Spacer blocks shall be used for ensuring that the correct cover is maintained on the reinforcement.
Blocks shall be as small as practicable and of a shape agreed by the Engineer. They shall be made of
mortar mixed in the proportions of one part of cement to two parts of sand. Wires cast into the block
for tying in to the reinforcement shall be 1.6mm diameter soft annealed iron. Alternatively, another type
of spacer block may be used subject to the Engineer’s agreement.
Reinforcement shall be rigidly fixed so that no movement can occur during concrete placing. Any
fixings made to the formwork shall not be within the space to be occupied by the concrete currently
being placed.
No splices (laps) shall be made in the reinforcement except where shown on the drawings or agreed by
the Engineer. Splice lengths shall be as shown on the drawings. Mechanical splices shall not be used
unless the Engineer agrees otherwise.
Reinforcement shall not be welded except where required by the Contract or agreed by the Engineer. If
welding is employed, the procedures shall be as set out in applicable ISO, EN, DIN and BSI standards.
Full strength butt welds shall only be used for steel complying with ISO, EN, DIN and BSI standards,
and if used on high yield deformed bars complying with the permissible stresses in the vicinity of the
weld shall be reduced to those applicable to plain bars complying with that Specification.
The Contractor shall ensure that reinforcement left exposed in the Works shall not suffer distortion,
displacement or other damage. When it is necessary to bend protruding reinforcement aside temporarily,
the radius of the bend shall not be less than four times the bar diameter for mild steel bars or six times
the bar diameter for high yield bars. Such bends shall be carefully straightened before concrete placing
continues, without leaving residual links or damaging the concrete around them. In no circumstances
will heating and bending of high yield bars be permitted.
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Before concrete is placed in any section of the Works which includes reinforcement, the reinforcement
shall be completely clean and free from all contamination including concrete which may have been
deposited on it from previous operations.
The Engineer’s approval for concrete placing is to be sought in writing for each pour, leaving adequate
time to inspect and rectify any defects noted in the formwork, falsework, reinforcement, scaffolding,
concreting arrangements, etc.
2.8 Geotextiles
The geotextiles to be applied in the work must be submitted to the Engineer’s approval, accompanied
by certificates of origin and technical data sheet, as well as works in which it has been applied with
identical functions. They must be of the type and characteristics indicated in the Project, depending on
the work conditions. When used as geotextile for separation and filtration and drainage, they will be
non-woven and punctured (said, in slang, needled).
The material shall be not rotatable, insensitive to acids or bases and unassailable by microorganisms or
insects and shall have the minimum characteristics stipulated for each use. The material shall also have
a homogeneous texture and thickness, without defects, and shall be protected during storage from
sunlight, mineral salts, dust, rain or ice.
If transport, storage or handling has been impaired, the first turns of the defective geotextile roller must
be eliminated. The application of geotextile should be at least 0.30m overlapped.
On-site storage of the geotextile rollers shall be carried out by the Contractor at an appropriate location
and the protective covering shall only be removed from the factory at the beginning of the installation.
Special care should be taken to avoid prolonged direct exposure of the geotextile to the action of
sunlight, dust, clay soils, or other factors that may affect its quality.
Regardless of the size that has to be done for each particular case, it is recommended that the minimum
and maximum characteristics of landfill geotextiles be as follows:
• Ultimate tensile strength (EN ISO 10319), minimum 15kN/m
• Creep rupture (EN ISO 10319), minimum 40%
• Puncture resistance (EN ISO 12236) 1,5 kN
• Permittivity (prEN 12040), minimum 0,2 s-1
• Porometry (O90), maximum 150 m
• Materials to be applied to geotextile with separation function at the bottom of the landfill shall
be free of debris, organic matter or any other harmful substances, and shall meet the following
minimum characteristics:
• Maximum dimension 200 mm
• The percentage of material passing the ASTM (No.200) sieve 15%
• Liquid limit 25%
• Plasticity index 6%
• Sand equivalent 20%
The material to be applied over geotextiles for the purpose of forming a draining layer under landfills
for the drainage of waters resulting from the consolidation process of very compressible alluvial
formations shall be of uniform quality, free from organic matter or other harmful substances and shall
comply with: following minimum characteristics:
a) Sand
• Nominal size granulometry 0,06 / 6 mm
• Rocky Material
• Maximum dimension 200 mm
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• Los Angeles Abrasion (Testing grade - F) 50%
2.9 Building Work and Miscellaneous Works

2.9.1 Masonry Units - Concrete Bricks
Concrete bricks shall have approximate dimensions of 220 mm x 110 mm x 70 mm and shall have a
compressive strength of not less than 14 MPa.
2.9.2 Mortars and Renders

2.9.2.1 Mixes for mortar for masonry units
Mortar for masonry work shall comply with ASTM C270 except that the cement/lime: sand (in the
damp condition) ratios by volume shall be 1:2¼ to 3 and that the lime: cement ratio shall not exceed
1:3.
2.9.2.2 Mixes for Rendering (Cement or Cement-Lime Plastering)

The mixes for plaster rendering shall be:
Table 2.5 – Mix for rendering
Location/ Finish Mix proportions (by volume)
Cement Lime Sand
Exterior 1 1 5
Interior 1 1 6
Rough cast finish 1 2 9
Smooth finish 1 4 8
2.9.3 Construction of Masonry Structures

2.9.3.1 General
Masonry shall be laid plumb, true to line with level courses accurately spaced, and built to the thickness
and bond patterns specified which shall be Stretcher bond or English bond unless otherwise specified.
The top surfaces of foundations shall be cleaned of all dirt, projections and laitance before commencing
with masonry construction. Masonry units shall be cleaned of all dust and dirt before being laid and
shall be moistened so that the mortar remains plastic enough for the units to be plumbed and levelled
after laying without the bond being destroyed. However, when being laid, units shall have sufficient
suction to hold the mortar and absorb excess water from the mortar.
The ingredients for cement mortar shall be measured in proper gauge boxes on a boarded platform and
thoroughly mixed. Alternatively, mixing may be by means of a mechanical batch mixer. Only when the
dry ingredients have been thoroughly mixed and a mixture of uniform colour has been obtained may
the water be added in sufficient quantity to obtain mortar with the required consistency. Cement mortar
shall be used within two hours of adding water to the mix and it shall be turned over frequently until it
is used to prevent it from setting.
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All masonry work shall be carried up in a uniform manner with no portion being more than one metre
above an adjacent portion at any time. Walls are to be set raking where one length of wall is to be
bonded with another adjoining wall at a later stage, with the raking portion being wetted thoroughly
before work is recommenced.
Horizontal joints shall be neatly pointed around as the work proceeds.
Vertical joints shall not exceed one course in height and shall be staggered. All headers shall be bonded
lengthwise through solid walls and no bats shall be used except where required as closers.
2.9.3.2 Cleaning and Repair Pointing

At the conclusion of the masonry work, the Contractor shall clean all masonry which is to remain
exposed. Cleaning shall not be done until the mortar is thoroughly set and hard and shall be done without
the use of acid.
Imperfect jointing, nail holes, chipped edges or corners and all other defects shall be corrected or the
units replaced. All units which are chipped, stained, broken or do not match adjoining units as intended,
or which are otherwise damaged shall be replaced. During the completion of the masonry installation
and the tooling of joints, any voids or holes shall be enlarged and completely filled with mortar. Joints
at corners, openings and adjoining work shall be pointed to provide a uniform, neat appearance.
2.9.3.3 Plastering or Rendering (Cement or Cement-Lime Plastering)

The method of measuring materials for the render shall be such that the specified proportions of the
materials can be controlled and accurately maintained during the progress of the work. The quantity of
water shall be such as to obtain a satisfactory workability for the specific use of each render.
Any render that is not used within 30 minutes after the first water has been added shall not be
incorporated into the Works. Render which has started to set or has become dry or unworkable shall not
be used, nor shall it be re- tempered with water.
The equipment and tools used for transporting and for placing batched render shall be such that
contamination and loss of ingredients do not take place.
Blocks which are to receive rendering or plastering shall have a surface which will ensure good adhesion
of the applied finish. Projecting burrs of grout shall be removed and the surface shall be wire brushed
and cleaned with scrubbers. If the surface is smooth it shall be prepared by roughening with a pointed
tool to form pocks not less than 3 mm deep spaced not more than 50 mm apart. The surface shall be
wetted before plaster is applied.
Rendering shall be of uniform thickness applied in one layer at least 12 mm thick.
2.10 Metalwork
2.10.1 General
Before commencing fabrication of metal work, the Contractor shall verify all conditions affecting the
work and obtain accurate dimensions and arrangements of all existing or newly built supports.
Welding of galvanized steel work shall not be permitted. Instead, it shall be assembled using bolts and
nuts.
The permissible design stresses for materials, bolts, rivets, etc. shall be as given in DIN 18800. The
permissible design stresses for welds shall be as given in DIN 4100.
Rolled structural steel sections shall be mild steel, conforming to DIN 17100. The dimensions,
tolerances and properties of the structural sections shall conform to DIN 18201, DIN 18203 and DIN
18800. Where prefabricated proprietary designs are used, the Standards to which they are manufactured
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shall be at least equivalent to the foregoing.
For structural steel work assemblies, steel bolts, nuts and washers shall be high strength friction grip
bolts conforming to DIN 6914 up to DIN 6916 or black bolts including nuts and washers conforming
to DIN 7989 and DIN 7990.
All welding consumables (electrodes, wire, filler rods, flux, shielding gas and the like) shall comply
with the requirements of the appropriate DIN Standard and with the requirements of the appropriate
welding procedure.
All metal work shall be erected and installed to the lines and positions shown on the Drawings and shall
be well anchored to the concrete foundations or structures.
Unless the grouting in of anchor bolts in previously prepared recesses is agreed, anchor bolts and metal
parts to be embedded in concrete shall be placed in position before casting of the concrete and shall be
held firmly and accurately in place while the concrete is being placed.
Cast iron fittings such as chamber covers, spindle casings and step shall be of standard manufacture.
All other metal work such as pipe supports, holder bats, pipe anchor clamps, etc. shall be fabricated by
the Contractor.
Bolt holes shall be made by drilling only, and shall be accurately positioned so that bolts can be easily
inserted. Unless otherwise shown on the Drawings, bolts shall protrude from nuts not less than two
threads.
2.10.2 Nuts and Bolts

External bolts and fixing rag bolts, nuts and washers shall be sherardized steel. Assembly nuts, bolts
and washers on galvanized fittings or equipment shall be either galvanized or sherardized.
Nuts and bolts used in the fabrication of aluminum structures shall be cadmium plated and shall have
galvanized washers. The washers shall be separated from the aluminum structural members by fibre
washers of equal size.
2.10.3 Fixing and Building-In

Openings left in concrete walls for the subsequent fitting and concreting in of pipe work and fixtures
shall have the soffit of the opening inclined at not less than one in four to the horizontal. The periphery
of the opening shall be formed as specified for construction joints. After fixing the pipe or fixture in
place, the remaining void shall be carefully packed with concrete of the appropriate class to produce a
watertight joint. The concrete shall be retained by a shutter which shall be built up as concrete filling
proceeds. The Contractor shall obtain any special fixing instructions from the suppliers of prefabricated
or manufactured goods, shall inform the Engineer about such requirements and shall ensure that they
are implemented.
Where fixing bolts are positioned by means of a template they shall be firmly supported and braced so
as to remain in perfect alignment during the setting of the concrete or grout. Where it is necessary to
drill for fixing, the holes shall be the correct size and they shall be grouted solid with cement mortar.
When a metal work item is fixed permanently to a metal or any other surface, the metal surfaces that
come into contact shall be painted on Site with two coats of bituminous paint immediately prior to
fixing.
Under no circumstances shall aluminum be built into wet concrete or be fixed to green concrete. Where
it is necessary to join aluminum to steel or cast iron, the two surfaces shall be separated by a suitable
insulation not less than 1.5mm thick. Where aluminum or ferrous structural members are built into
brickwork, masonry or concrete, the contact surfaces shall first be painted with two coats of bituminous
paint. Where aluminum surfaces are in contact, the jointing compound shall be coated with zinc
chromate.
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Refer also to the “General Mechanical Requirements”
2.10.4 Fixing and Installation of Metalwork to Concrete

Where metal work is to be founded on and fastened to concrete, the Contractor shall use one of the
following methods for fixing it to the concrete:
• Bolting or screwing the metalwork to plates or angle sections with anchors set into the concrete
structure or set into pockets left in the concrete structure
• Setting the metalwork into pockets or recesses formed in the concrete structure
• Bolting the metalwork to bolts set into the concrete structure or set in pockets or holes in the
concrete structure
• Bolting the metalwork to self-anchoring epoxy resin fixed bolts placed in drilled holes
• Bedding the metalwork on cement-mortar placed on the concrete surface
Cement-mortar of 1 part of cement to 3 parts of sand shall be used for bedding access covers and the
like and for filling around metalwork or bolts set into pockets or holes that have a cross-sectional area
of less than 100 mm². For larger holes, concrete of the same grade as the structure shall be used instead
of mortar. The installation methods permitted for each type of metalwork are specified in the table
below:
Table 2.6 – Standard of installation of metalwork
Metalwork item Permissible methods of installation
Ladders 1, 3 and 4
Step irons 2
Hand railing 3
Access covers, surface boxes and gully gratings 2 and 3
During installation, each item of metalwork shall be temporarily supported and braced as necessary to
resist all forces which are likely to be applied to it during installation, fixing and building in. Any bolted
connections required as part of the installation shall be fitted and tightened before fixing bolts are
tightened or pockets are grouted. The nuts of grouted or resin fixed bolts shall not be tightened until the
grout has fully cured.
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3 GENERAL MECHANICAL REQUIREMENTS

3.1 General Specifications
3.1.1 Standards
All material and equipment installed and all work carried out as well as calculation sheets, drawings,
quality and class of goods, methods of inspection, constructional peculiarities of equipment and parts
and acceptances of partial plants, as far as these are beyond the special requirements of the
specifications, shall comply in every respect with ISO codes, the technical codes of the European Union
(EN), standards from South Africa (SANS) and Southern Africa (SATCC), the German Standards
(DIN) or the American Standards (ASTM).
Goods and special guarantees beyond the scope of ISO, EC or DIN shall conform at least to one of the
following standards and codes:
• German: VDE, VDI, or equivalent as far as these standards, codes and regulations are
available in an English language edition
• British: BSS, BSI
3.1.2 Equipment and Materials

The equipment provided shall be designed to facilitate inspection, cleaning, maintenance and repair.
The equipment shall be designed to operate satisfactorily under all variations of load, pressure and
temperature as may be met in normal usage and shall incorporate every reasonable precaution and
provision for safety of all those concerned in the operation and maintenance of the facility.
All equipment and materials to be incorporated in the Works, shall be new, unused products of
reputable, experienced manufacturers. Similar items in the project shall be the products of the same
manufacturer. All equipment and materials shall be of industrial grade and of standard construction,
shall be of sturdy design and manufacture. All submerged moving parts of the equipment, or the pins
and spindles of the submerged moving parts or the faces in contact with them, shall be of corrosion
resistant materials. All parts in direct contact with various chemicals shall be completely resistant to
corrosion, or abrasion by these chemicals.
Particular attention shall be given to the prevention of seizure by fretting where two corrosion resistant
metals are in contact, by the selection of materials of suitable hardness and surface finish and the
application of lubricants.
All wearing parts and all joint rings, seals and gaskets shall be replaceable, if not specified otherwise.
3.1.3 General Accessories

3.1.3.1 Flanged Joints
All flanges shall comply with the relevant standards stated elsewhere in this Specification. All flanges
applied in the contract shall be manufactured according the same standard.
3.1.3.2 Nuts, Bolts and Washers

All bolts and nuts shall be manufactured according the same standard. Bolts shall be of sufficient length
with minimum two threads shown through the nut when in the fully tightened condition. Isometric
hexagonal nuts and screws shall have a minimum strength of 460 N/mm².
3.1.3.3 Gaskets and Joint Rings

Unless otherwise specified, gaskets shall conform to the requirements of the standards stated elsewhere
in this Specifications. All gaskets shall be manufactured according the same standard. Gaskets and joint
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rings shall be manufactured from synthetic rubber. Flanged joint gaskets shall be of the inside bolt circle
type, unless specified otherwise.
3.1.4 Coating and Corrosion Protection

The protective systems specified in these following specifications are to be applied on ferrous and non-
ferrous and concrete structures as detailed below.
3.1.4.1 General
All metalwork that is to be painted shall be cleaned down to the bare metal and given a complete
treatment of surface preparation, priming coats and finishing coats to give a durable, protective system
consistent with the conditions which the metalwork will experience on Site. Surface preparation and at
least one priming coat shall be applied at the manufacturer’s premises.
All paints and materials shall be agreed with the Engineer and shall be used in accordance with the
manufacturers’ instructions. Undercoats shall be of distinctive tints and finishing colours shall be as
directed by the Employer.
In no case shall paint be applied during rainy or misty weather or to surfaces upon which there is
moisture condensation. At least 24 hours shall elapse between the application of successive coats unless
otherwise specified by the manufacturer. All surfaces of steelwork or iron work to be painted shall be
well rubbed down and wire- brushed to ensure that they are free from rust or scale.
Paintwork of more than one coat shall not consist of any two coats of the same colour. The colours of
the coats of paint shall be determined in consultation with the Engineer.
The paintwork must be free of drips, runs and blisters. Any areas of damaged paintwork, once
discovered, shall be de-rusted immediately with sharp scrapers and brushes, and directly thereafter re-
touched with the same paint as present on the surrounding surfaces.
Freshly painted components must not be moved or transported before the drying times recommended
by the paint supplier have elapsed. The transportation of wholly or partially painted components must
be arranged in such a way that the chances of the paint work being damaged are as limited as possible.
Components of the installation that are to be purchased from third parties shall be preserved with a paint
system similar to the system to be employed by the Contractor under his own control.
Components to be cast into concrete shall be preserved - prior to their being cast in - by means of the
galvanisation or metallization of all their surfaces that will be external to the concrete or internal to the
concrete up to a depth of approx. 100 mm; surfaces internal to concrete must never be painted.
Components that must remain uncovered in order to function properly shall be either carefully smeared
with water-repellent, acid-free grease or, if necessary, coated with preservation lacquer. All plain steel
fasteners, bolts, nuts, washers etc. that are to be employed in humid atmospheres should be hot-dip
galvanised.
The coating thickness referred to in the specifications apply to dried paint. Total coating thickness
includes any metallizing layers applied. The following coating specifications may, subject to the
Engineer’s agreement, be changed to equal alternatives according to coating supplier’s
recommendations.
3.1.4.2 Specifications
Cleaning
Before cleaning begins, steel components should be brought as far as possible into their final forms.
Steel components that would otherwise be rendered inaccessible (and therefore incapable of being
cleaned) as a result of welding operations shall be first cleaned, directly thereafter welded, and as soon
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as possible preserved. The number and dimensions of spaces that will be inaccessible after the
completion of components should be reduced to a minimum by appropriate design. Cleaning of steel
components shall incorporate thorough stripping-off of grease, good drying and subsequent thorough
de-rusting and abrasive-blast or pickle cleaning; accompanied with hot-dip galvanising. Blast-cleaning
shall be carried out with steel shot of maximum grain diameter 0.7 mm, or a mixture of similarly-sized
steel shot and chopped steel wire in equal proportions, or an inert medium.
After cleaning, all free surface slag and scale shall be chipped off, the rough surfaces shall be abraded,
and then the components shall once again be thoroughly cleaned. Cast-iron components shall be
thoroughly de-rusted and blast-cleaned until bright.
Metallizing and hot-dip galvanising

Where galvanizing of steel or wrought iron is specified, the galvanizing shall be done after all
fabrication has been completed. The articles that are to be galvanized shall be cleaned and pickled in
dilute sulphuric or hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They
shall then be thoroughly washed, dipped in molten zinc and brushed so that the whole of the metal is
evenly covered. The additional mass of an item after galvanizing shall be not less than 0.6 kg/m² of
surface galvanized, except in the case of tubes when it shall be not less than 0.46 kg/m². Edges shall be
clean and surfaces bright.
If a paint system is to be applied to a galvanised component, all zinc drainage spikes and flux residues
shall be removed from the zinc coating and the surfaces shall then be dried, cleaned and allowed to
cool. The first coat of paint should be applied on the same day as galvanisation: however, if that proves
to be impossible, large components shall be lightly blast-cleaned and small components shall be painted
with etch primer; thereafter, all components must be thoroughly rinsed and dried before being painted.
The light blast cleaning should be performed with an inert medium, from a distance of approximately 2
m and with a spraying-pressure of 1.5 to 3.0 bar. The zinc coating to be applied by metallization must
be homogeneous and uniform in thickness, with a coating mass of at least 350 g/m² (=50 microns).
The first coat of paint shall be applied to metallised steel components immediately after they have been
thoroughly dusted down subsequent to metallization, and no later than on the same day as metallization.
Bolts, nuts and washers including general grade high-tensile friction-grip bolts shall be hot-dip
galvanized and subsequently centrifuged. Nuts shall be tapped up to 0.4 mm oversize after galvanizing
and the threads oiled to permit the nuts to be finger-turned on the bolt for the full depth of the nut.
Small areas of the galvanized coating damaged in any way shall be restored by cleaning the area of any
weld slag and thorough wire brushing to give a clean surface.
Applying two coats of zinc-rich paint, or the application of a low melting point zinc alloy repair rod or
powder to the damaged area, which is heated to 300°C. After fixing, bolts heads, washers and nuts shall
receive two coats of zinc-rich paint. Connections between galvanized surfaces and copper, copper alloy
or aluminium surfaces shall be protected by suitable tape wrappings.
3.1.4.3 Application
All prime coatings and finish-paint shall be applied by brush or airless spray or a combination of these
methods, as recommended by the coating manufacturer.
Paint erroneously applied to items that are not to be painted shall be removed at the Contractor's
expense, leaving the surface clean, unstained and undamaged.
To the maximum extent practical, the coats shall be applied as a continuous film of uniform thickness
and free of pores. Overspray, skips, runs, sags and drips shall be kept to a minimum. The different coats
shall not be of the same colour.
Each coat of paint shall be allowed to harden before the next is applied. For epoxy paint the hardening
time before the next coat will normally be 12 - 14 hours. Suppliers' recommendations regarding
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hardening time of epoxy paints must be followed.
Particular attention must be paid to applying the full film thickness at edges.
3.1.4.4 Materials
All paint materials shall be first quality products manufactured for the exposures involved. The different
system materials shall be as follows:
System A
Primer Ferrous metal, un-primed:
• coat zinc chromate primer
• coats alkyd enamel semi-gloss
• Ferrous metal, shop primed
• Touch up with zinc chromate primer
• 1 coat alkyd enamel semi-gloss Galvanized and non-ferrous surfaces:
• 1 coat vinyl butyral etch primer
• 1 coat alkyd zinc phosphate primer
• 1 coat alkyd zinc phosphate primer
Intermediate 1 coat 2-component micaceous iron oxide epoxy Finish 1 coat 2-component aliphatic
polyurethane finish
System B
Primer Ferrous metal, un-primed:
• 1 coat zinc chromate primer
• 2 coats alkyd enamel semi-gloss Ferrous metal, shop primed
• Touch up with zinc chromate primer
• 1 coat alkyd enamel semi-gloss Galvanized and non-ferrous surfaces:
• 1 coat vinyl butyral etch primer
• 1 coat alkyd zinc phosphate primer Intermediate 1 coat alkyd enamel gloss Finish 1 coat
alkyd enamel gloss
System C
Primer 1 coat 2-component high solids coal tar epoxy Finish 2 coats 2-component high solids coal
tar epoxy Service Condition System A
Metals subject to corrosive chemical moisture, atmosphere, or condensation shall be prepared and
coated in accordance with the following requirements:
• Surface Preparation: all bare metal surfaces shall be field sandblasted. Weld surface, edges, and
sharp corners shall be ground to a curve and all weld splatter removed and all welds neutralized
with thinner. All surfaces shall be dry before applying any paints or coatings
• Coating System: use material specified for System A. Coatings shall be applied by airless spray
but by brush for small areas. Prime coat shall have a minimum thickness of 50 microns. An
intermediate coat shall have a minimum thickness of 100 microns, and finish coat shall have a
minimum thickness of 100 microns. The total system shall have a minimum dry film thickness
of 250 microns
• Time between Coatings: a minimum of 12 hours’ time is required before additional coats may
be applied to the prime coats, two hours for the intermediate coat, and two hours for the finish
coat
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Service Condition System B

Metal subject to normal indoor or outdoor exposure, not subject to chemical attack, shall be prepared
and coated in accordance with the following requirements:
• Surface Preparation: All bare metal surfaces shall be freed of dirt, dust, grease, or other foreign
matter before coating. Surfaces shall be sandblasted. Weld surfaces and rough edges shall be
ground and weld splatter removed. All surfaces shall be dry before applying any paints or
coatings
• Application: shall be in strict conformance with the manufacturer's printed 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 of each coat
• Coating System: use materials specified for System B. Prime coat shall have a minimum
thickness of 50 microns. An intermediate coat shall have a minimum thickness of 100 microns,
and finish coat shall have a minimum thickness of 50 microns. The total system shall have a
minimum dry film thickness of 200 microns
• Time between Coatings: a minimum of 12 hours’ time is required before additional coats may
be applied to the prime coats, two hours for the intermediate coat, and two hours for the finish
coat.
Miscellaneous Coatings
• Hydrants, indicator posts, traffic posts, guard rails and ladders, shall be in safety colour, or equal
applied using specified coating System "B"
• All surfaces shall be dry before applying any paints or coatings
Miscellaneous buried ferrous metal surfaces

• All buried valves, small pipes and other miscellaneous buried ferrous metal surfaces, after
receiving surface preparation and cleaning, shall receive not less than two coats of coal tar
mastic coating. No prime coat shall be applied under coal tar mastic. All surfaces shall be dry
before applying any paints or coatings
• Coating thickness shall be a minimum dry film thickness of 600 microns. The two-coat system
shall be as specified in System C. Coated surfaces shall be dry before backfilling.
3.1.5 Erection
3.1.5.1 Erection of Pipes
Care shall be taken during the erection of pipework, either during erection or during service. The
Contractor shall use end caps or plugs to prevent the entrance of dirt, water and other foreign matter
into pipes or fittings. Plates, plugs or caps may not be attached to the pipes by means of welding or any
other method, which will damage the pipe ends. The caps or plugs shall be installed after finishing daily
work or whenever work is interrupted for other than very short duration.
Joints shall be made strictly in accordance with the manufacturers’ instructions. The Contractor shall
make use of the technical advisory services offered by manufacturers for instructing pipe jointers in the
method of assembling joints. Where manufacturers recommend the use of special jointing methods, the
Contractor shall use these methods for the assembly of all joints to pipes.
Before making any joint all jointing surfaces shall be thoroughly cleaned and dried and maintained in
such condition until the joints have been completely made or assembled, using joint lubricant if
recommended by the pipe manufacturer. Notwithstanding the flexibility provided in the pipe joints,
pipes must be securely positioned to prevent avoidable movements during and after making the joint.
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The gap between the end of the spigot and the shoulder of the socket of flexibly jointed pipes shall be
as recommended by the manufacturer. All pipes shall be accurately marked prior to laying ensuring that
the correct gap is left in the joint.
All nuts and bolts used in jointing buried flanged pipes shall be of stainless steel SS316. The flanges or
flanged joints shall be correctly positioned and the component parts including any insertion gasket
cleaned and dried. Insertion gaskets shall be fitted smoothly to the flange without folds or wrinkles. The
flange faces and boltholes shall be brought fairly together and the joints shall be made gradually and
evenly by tightening bolts in diametrically opposed positions. Only standard-length spanners shall be
used to tighten the bolts. The protective coating, if any, of the flange shall be made good when the joint
has been completed.
3.1.5.2 Welding of Pipelines and Structures

All welding carried out during fabrication in the factory and erection on the Site shall be carried out in
accordance with the relevant DIN Standards. Details of the proposed welding procedures shall be
submitted to the Engineer for agreement at the same time as the Shop Drawings. All connections shall
be welded in such a manner that the finished connections are neat and smooth in appearance, and
suitable for painting. All slag shall be removed, and any sharp projections shall be ground smooth.
Before welding is commenced, either in the fabrication shop or on Site, weld procedure tests shall be
carried out.
All welders employed in the fabrication shop or at Site shall have passed qualification tests relevant to
the weld procedures in use in accordance with the appropriate DIN Standard. If the work of any welder
employed on the Contract is deemed, by the Engineer, to be unsatisfactory, the Contractor shall carry
out such further welder qualification tests as are necessary to demonstrate that the welder in question is
proficient.
Welds shall be subject to non-destructive testing by processes which may include but not necessarily
be limited to radiographic, ultrasonic, magnetic particle or dye penetration methods, depending on the
type of weld and its position in the structure. If any work shows defects or fails to comply with the
requirements of the Shop Drawings or the specification for any reason, it shall be repaired or exchanged,
even though it may have been carried out by qualified welders using agreed procedures.
No welding will be permitted on galvanized steel work and over zinc primers or paint.
The Contractor shall provide all necessary personnel, equipment and materials. The equipment shall
include, but not be limited to:
• Welding machines and generators suitable for welding pipes and structures
• Preheating equipment which ensures uniform preheating around the whole circumference of
welding ends
• Post weld heat treatment equipment
• Internal and external line-up clamps (the external clamp shall be hydraulically operated)
• Protective canopies (or umbrellas and wind shield collars) so that welding can be carried out
even under disadvantageous weather conditions
The Contractor shall supervise the site, the welders and their work during the entire working period.
For this purpose, the Contractor shall use a qualified welding engineer or alternatively an engineer with
documented thorough theoretical knowledge and practical experience in the performance and
evaluation of the welding work.
The welding shall be inspected by an independent inspection company engaged by the Contractor. It is
the sole responsibility of the Contractor to document that welding and welding inspections fulfil all
specified requirements.
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Materials
Attention shall be paid to obtaining a good working environment such as selection of low smoke
developing consumables, etc.
The weld filler metal selected shall give a weld metal matching the base metal properties as closely as
possible. The yield strength of consumables shall neither overmatch the base material yield strength by
more than one level in EN 499, nor shall under-matching be allowed.
Welding Processes
Acceptable welding processes are:
• Shielded Metal Arc Welding (Stick) SMAW
• Gas Tungsten Arc Welding (TIG) GTAW
• Gas Metal Arc Welding (MIG/MAG) GMAW
• Flux Cored Arc Welding FCAW
Processes may be used in combination if the same combination and sequence of processes have been
qualified by the welding procedure qualification test.
Welding Procedure Qualification

The Contractor shall submit detailed welding procedure specifications which shall be subject to
agreement with the Engineer. All dimensions, all combinations of materials to be joined and all repair
welding shall be covered by the procedure specifications.
For each procedure specification and prior to start of production welding the Contractor shall carry out
welding of test joints under site conditions following all of the details of the agreed procedure
specifications.
The qualification test shall be carried out on steel with the highest specified minimum yield strength/
maximum carbon equivalent which is expected to be covered by the Welding Procedure Specification.
All the results from the procedure qualification records shall be submitted to the Engineer.
Qualification of Welders and Welding Operations

Only skilled welders and welding operators who can document qualifications relevant for the foreseen
structures and pipes shall be employed for such Works. Prior to the performance of any production
welding operators shall qualify for the relevant welding procedures.
The qualification tests are acceptable if they meet the requirements for visual examination, destructive
testing and radiographic examination. The testing shall be carried out by an approved laboratory at the
Contractor's expense. Welder and welding operator performance test certificates shall be issued and
kept on site during the whole working period.
Welder and welding operator qualification tests may be performed together with welding procedure
qualification tests.
Welding Preparation
The material grades, wall thicknesses and pressure ratings of welded items shall conform to the
requirements laid down in the applicable drawings and specifications.
Each pipe or component shall be visually inspected to ensure that it has not sustained any visually
determinable damage.
All requirements for welding preparation contained in the qualified welding procedure specification
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shall be strictly adhered to.
Welding
Welding shall be suspended by the Contractor when prevailing weather conditions will impair the
quality of the work, e.g. airborne moisture, blowing sand, high winds or thunderstorms.
Stray arcing outside the weld groove is not permitted. Should stray arcing outside this area occur, this
shall be brought to the attention of the Engineer who may require any such damaged section to be
repaired or cut out at the Contractor's expense.
Earth connections for the welding shall always be positioned in the centre of the joint during root and
cap-bead laying. They shall be mechanically or magnetically connected to the pipe.
Each pass shall be completed around the whole circumference before the next pass is started. The
position of start/ stop on subsequent passes shall not be identical.
Upon completion of the cap bead, the weld and the pipe surface shall be cleaned of weld spatter and
other deposits, and shall then be wrapped with a dry waterproof insulating mat to ensure a slow cooling
of the weld zone and to give protection against rain.
Cleaning after Welding

The surface shall be dry and free of oil, grease, soil and concrete residues. All loose rust and mill-scale
shall be removed by wire brushing immediately before welding inspection. On straight pipes brushing
shall be done mechanically using sharp brushes to avoid polishing of the steel surface. Therefore, a
stock of readily accessible new brushes is required.
Welds fabricated with basic finer metals shall be washed with fresh water. Cleaning by sandblasting is
allowed as an alternative.
Post Weld Heat Treatment

Post Weld Heat Treatment of weld seams shall only be carried out if specified in the agreed welding
procedure or where this is indicated in the project material.
Welding Inspection
Examination may be performed according to this specification and the following codes and standards:
• Radiographic examination according to ISO 1106, Part 3, Recommended. Practice for
Radiographic Examination of Fusion Welded Joints in Steel Pipes of up to 50 mm Wall
Thickness.
• Ultrasonic examination according to ASME Boiler and Pressure Vessel Code Section V, Non-
destructive Examination, Article 5, Ultrasonic Examination Methods for Materials and
Fabrication.
• Magnetic particle examination according to ASME Boiler and Pressure Vessel Code, Section
V, Non- destructive Examination, Article 7, Magnetic Particle Examination.
• Liquid penetrant examination according to ISO 3452, Non-destructive Testing, Penetrant
Inspection, General Principles.
• Visual examination according to ASME Boiler and Pressure Vessel Code, Section V, Non-
destructive Examination, Article 9, Visual Examination.
• Hardness measurement according to ASTM El 10, Standard Test Method for Indentation
Hardness of Metallic Materials by Portable Hardness Testers.
The Contractor shall engage a qualified independent inspection company which shall perform, evaluate
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and document all welding inspection.
All non-destructive examination shall be performed according to a written procedure. The procedure
shall conform to the requirement of the adequate method standard and this specification. Procedures
shall be submitted to and agreed with the Engineer.
3.2 Pipework
All pipes must be approved by relevant Authorities for wastewater and water application.
3.2.1 PPc Pipework

3.2.1.1 General Provisions
The pipe to be used for surface runoff in domestic or storm sewage drainage systems shall be solid wall
corrugated polypropylene (PPc) profile of minimum SN8 (8 kN/ m²) specific circumferential stiffness
class.
The pipe material shall be of good quality, homogeneous, have a good finish, without fissures or blisters,
and shall comply with all existing standards and specifications, be certified by the competent authority
and subject to approval tests.
The pipes must be marked with the following inscriptions:
• Trademark;
• Manufacturer name;
• Type of material;
• Nominal outside diameter;
• Nominal inside diameter;
• Certificates;
• Specific circumferential stiffness class (SN in kN/m²);
• Application code;
• European standard;
• Date and order of manufacture (traceability);
When connecting pipes to concrete in buried chambers, due to poor adhesion between materials,
specific pipe fittings shall be used and shall be ensured that the surface of the fitting to be soaked must
be properly prepared so that it can have a good connection and maximum leaktightness provided by
these accessories.
The connection between the pipes shall be made by means of socket and spigot joints always with an
EPDM elastic joint interposed in order to guarantee a leaktightness between the smooth inner wall of
the pipe and/or fitting mouth and the corrugated profile of another pipe and/or accessory. No welding
or collage is allowed, as Polypropylene being a nonpolar material does not allow adhesion to paints and
glues.
3.2.1.2 Standards
EN 13476 - Plastics piping systems for non-pressure underground drainage and sewerage - Structured-
wall piping systems of unplasticized polyvinyl chloride (PVC-U), polypropylene (PP) and polyethylene
(PE).
3.2.2 Glass Fiber Reinforced Plastic Pipework

3.2.2.1 Supply Specification
This specification defines the requirements for Glass Fiber Reinforced Plastic (GRP) piping for
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wastewater.
GRP pipes and fittings covered by this specification will be classified according to their nominal
diameter (DN), nominal pressure (PN) and their nominal stiffness (SN), coupling type, service type and
installation type.
The nominal pressure (PN) shall be corresponding to the maximum working pressure of the piping at
steady state, including no fluid circulation, without regard to overpressures due to water hammer.
Maximum pressure must be ≤1.4 times nominal pressure (PN), so maximum pressure will be working
pressure plus water hammer overpressure.
The safety coefficient in the calculation of PN shall not be less than 4 for overhead or buried
installations. Higher safety coefficients may be defined for specific project conditions.
Additionally, prior to contracting, parameters of initial specific circumferential stiffness, initial flexural
strength, longitudinal tensile strength and circumferential tensile strength shall be agreed upon in
accordance with the manufacturer's standard parameters or in their implementation.
The piping to be supplied shall be of nominal diameter, nominal pressure and design as specified in the
detailed design documents. In the event of a contradiction between this specification and the detail
design report and drawings to put for bid, these shall prevail.
3.2.2.2 Dimensional characteristics

The declared pipe inner diameter shall be within the manufacturer's minimum and maximum table
values. The average inside diameter at any point along the length of the pipe shall not differ from the
declared inside diameter beyond what is permitted in the deviations defined in those tables.
The pipes shall be followed by a declaration that includes the minimum wall thickness of the pipe,
including the inner layer, liner, and shall not be less than 3 mm. Such compromised thickness shall be
adequate to meet the referenced specifications and standards.
The supplied pipes must have lengths accordingly to the following measures: 3, 5, 6, 10 or 12 meters.
The tolerance on the effective length of the supplied pipe will be +/- 60 mm.
3.2.2.3 Materials
The materials (resin and fibre) used in the manufacture of GRP pipes shall be certified, by the
manufacturer in such a way that their use allows obtaining a final product that exceeds the certification
tests by an accredited laboratory.
The glass fibre to be used should be of type E, consisting essentially of silica, aluminium and calcium
oxides (calcium aluminosilicate glass) or silicon, aluminium and boron (alumino-borosilicate glass).
The resins to be used in the manufacture will be certified, presenting the respective certificates upon
pipe delivery.
In order to reinforce the laminate and make it more rigid, silicon sand aggregates or other materials may
be used. These aggregates must comply with the supply specification in order to be correctly recognized
and to avoid impurities with unspecified dust or colourants. The loads shall be located in a single core
layer of the tube, with the aggregate particles not exceeding 1 mm.
The use of additives in the resin (for viscosity control or others) should not prejudice the product
characteristics or prevent the visual inspection of the final product.
The use of accelerators, catalysts and inhibitors for the complete polymerization of structural member
components shall be in full compliance with the resin supplier's recommendations.
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3.2.2.4 Constructive Prescriptions
Pipes:
The pipes will be manufactured according to “Automatic Helical Filament Winding” or “Automatic
Cross Filament Winding” processes with continuous glass filaments impregnated with polyester resin,
with or without inert fillers, and possible application of additives for specific resin properties.
The pipes will have their wall consisting of 3 layers, namely:
The inner liner shall be made of isophthalic thermostable resin (for non-aggressive fluids) without
aggregates and with glass and/or synthetic reinforcements. It is not allowed to manufacture liners
entirely with resin.
Structural layer shall be made of glass reinforcement and thermostable orthophthalic resin, possibly
with aggregates. The glass reinforcements will be either continuous or cut wire. The use of aggregates
is only permissible when jointly using cut glass fibre reinforcements.
The structural layer is the only layer that can include aggregates in its composition.
The outer layer shall be formed of a thermostable resin without aggregates or fillers with glass
reinforcements or synthetic filaments, capable of withstanding external aggression and the expected
aggressiveness of the external environment.
When there is a risk of corrosive fluids and/or high temperatures, or the risk of using chemical additive
mixtures, vinylester-type or equivalent high strength resins should be used in the inner layer as well as
the remaining layers. This resin should be studied as a function of fluid properties and design conditions.
The resin used in the structural layer must have a bending temperature of at least 70 ° C.
In the manufacture of pipes, the resin should be cured by supplying internal and external heat, and heat
derived from the exothermic reaction of the resin's own polymerization process will not be accepted as
the only means of cure.
The cure level of the resin shall be such that the amount of residual styrene in the laminate shall not
exceed 0,02% by weight as per the test as defined in ISO DIS 4901.
As a routine control of manufacture, Barcol hardness testing shall be performed in accordance with
ASTM D 2583; the minimum hardness value shall not be less than 35.
The inner and outer surfaces shall be free of irregularities that may affect the ability of piping
components to meet functionality requirements. The ends of the pipes should be perpendicular to their
longitudinal axis.
Fittings:
GRP fittings supplied by the manufacturer must be made by Chemical Rolling Certified personnel.
According to German Guide DVS 2220 and BS EN 13.121-3
The fitting diameter series shall be the same as the diameter series of the straight pipe length (s) to be
connected to the piping system.
The nominal pressure rating of the fitting shall not be less than the straight length (s) of the pipe to be
connected to the piping system.
For a given material, fitting of the same wall thickness and construction as a pipe of the same diameter
will have a stiffness equal to or greater than that of the pipe due to its own geometry.
Fittings shall be designed and manufactured in accordance with the appropriate sizing rules for the
purpose of achieving operation equal to or greater than the GRP pipe of the same pressure and stiffness
class. If the need is identified, the elements should be supported using anchored or recessed blocks.
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Connections:
Joints shall be classified as flexible or rigid as capable of withstanding axial or non-axial stresses.
Flexible joints include “bell and spigot” joints, with a leaktightness double-ring elastomer, and
mechanical joints with metal joints with rubber seals, suitable for use with plastic materials.
Rigid joints include flanged joints, butt joints (with resin welds, fleeces and fibre fabrics) and “bell and
spigot” joints with retaining ring pouches.
Marking:
All pipes and fittings shall be factory marked in a legibly way without cracking or other breakages with
the following data:
• Reference standard;
• Nominal diameter size (DN) and diameter series;
• Nominal pressure (PN);
• Nominal stiffness (SN);
• Manufacturer Identification;
• Date and code of manufacture;
• Angle and special parts (curves, leads or inserts);
• Nominal sizes DN1 and DN2 for reduction elements;
• Applicable flange standard (if any);
• Joint type and resistance to axial stress (if applicable);
• Standard Quality Mark (if exist). Reception Conditions
The allowable dimensional tolerances shall be in accordance with the values given above.
3.2.2.5 Tests
All pipes and fittings will have factory tests made to test pieces, according to previously agreed
methodology, with destructive tests that will include:
• Internal pressure tightness test (acc EN 1229 and/or EN 1796 standards);
• Proof of Nominal Stiffness and Circumferential Flexural Strength (acc EN 1228; any cracks and
tears acc EN 1796);
• Percentage of Glass and Resin of the product (acc EN 637);
• Circumferential tensile strength (acc EN 1394 method C);
• Long Longitudinal Tensile Strength (acc EN 1393 method A);
• Water Absorption Test (acc EN ISO 62);
Certificates of conformity to EN 10204: 2004, shall be issued at least until EN 10204 - 2.2.
3.2.2.6 Standards
The manufacture’s Quality must be certified to ISO 9000 or equivalent.
The materials will also comply with the following standards or equivalents:
• BS EN 14364 / EN 14364 plumbing systems in plastics for disposal and sanitation with or
without pressure.
• Glass fibre reinforced thermosetting plastics (GRP) made from unsaturated polyester resin (UP);
• ENV 1046 Piping and conduction system in plastic materials. Water conduction or sanitation
systems outside building structures. Best practices for overhead or buried installations;
• ISO 10467 Plumbing systems made of plastic for evacuation and sanitation with or without
pressure. Glass fibre reinforced thermosetting plastics (GRP) made from unsaturated polyester
resin (UP);
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• ISO 4901 Determination of residual styrene content by gas chromatography;

• TM ASTM D 2583 - Barcol Hardness Test.
3.2.3 Ductile Cast Iron Pipework

3.2.3.1 General
Ductile cast iron pipework shall be in accordance with EN 598. Flanges shall be drilled according to
EN 1092.
3.2.3.2 Pipes
Ductile cast iron pipes shall be thickness conform EN 598.
The pipes shall be standard length socket and spigot pipes or double-flanged pipes, as scheduled.
3.2.3.3 Fittings
Ductile cast iron fittings shall be in accordance with EN 598 and shall be manufactured with spigot,
socket or flanged ends as scheduled.
3.2.3.4 Gaskets for Socket and Spigot Joints

Joint gaskets shall comply with ISO 7483 and ISO 4633.
The seal for socket and spigot joints shall be achieved by means of a suitable retained gasket. The gasket
shall be of such size and design that, when joined in accordance with the manufacturer's instructions, it
shall prove a positive seal within the maximum joint deflection and slip specified by the manufacturer
at the specified pressure.
All gaskets shall be supplied loose and shall be packed and shipped separately from the associated pipes
and fittings. One gasket shall be provided for each socket and spigot joint.
3.2.3.5 Internal Lining of Pipes

The pipes shall be internally lined with polyurethane. The thickness and the composition of the lining
shall be in accordance with EN 15655.
Prior to application of the lining, the internal surfaces shall be shot-blast cleaned to the specified
standard. The lining shall be applied centrifugally.
3.2.3.6 Internal Lining of Fittings

Fittings shall be internally lined with polyurethane. The thickness and the composition of the lining
shall be in accordance with EN 15655.
Prior to application of the lining, the internal surfaces shall be shot-blast cleaned to the specified
standard.
3.2.3.7 External Coating of Pipes and Fittings

All pipes and fittings shall be externally coated in the factory with a metallic zinc coat in accordance
with EN 14901.
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3.2.3.8 Shop Testing and Inspection
Each pipe and fitting shall be inspected and checked at the factory for external appearance, shape,
dimensions and mass. All pipes and fittings shall be sound and free from surface defects.
The following tests shall be carried out at the factory:
Hydrostatic Test
Each pipe shall be tested to the hydrostatic test-pressure specified in EN 598. The hydrostatic pressure
test shall be performed prior to coating or lining of the pipes.
3.2.3.9 Marking
Each pipe shall, at the least, be marked with its nominal size, thickness and length.
Each fitting shall, at the least, be marked with its nominal size. In addition, each bend shall be marked
with its bend angle.
The marks may be cast on, painted on or cold-stamped and they shall be applied in such a way that they
do not affect the mechanical quality of the pipework nor the water tightness of the joints.
3.2.4 PVC Pipework

Rigid PVC pipes should only be used in cold water. When the fluid reaches temperatures of 40ºC or
higher, PVC
- U or PVC with molecular orientation should be used. These materials are characterized by greater
wall thickness, temperature resistance up to 90 ° C and greater impact resistance.
The materials will conform to the standards given in this specification or equivalent.
Rigid PVC pipes and fittings shall be of proper quality, homogeneous, of good finish, without fissures
or, and shall meet the requirements of:
EN 1329-1 - Plastics piping systems for soil and waste discharge (low and high temperature) within the
building structure – Unplasticized poly (vinyl chloride) (PVC - U) - Part 1: Specifications for pipes,
fittings and the systems.
EN 1401-1 - Plastics piping systems for non-pressure underground drainage and sewerage –
Unplasticized poly (vinyl chloride) (PVC - U) – Part 1: Specifications for pipes, fittings and the system.
The nominal length of the pipes, given by the distance between the ends, must be 3,00 m or 6,00 m,
whether or not they have a bell. In the case of bell end pipes, lengths of less than 3,00 m are allowed,
provided multiples of 0,5 m. The maximum permissible length deviations from the nominal value are
+ 10 mm and - 5 mm for pipes up to 1,0 m in length.
The resistance of the pipes to acetone, sulfuric acid and long-term internal pressure, determined
according to the tests referred to in EN1401-1 (buried sewerage without pressure).
The pipes must be certified and must be indelibly and clearly marked with the following:
• Manufacturer identification and trademark (name);
• Acronym “PVC - U” / “PVC with molecular orientation”;
• Nominal outer diameter;
• Nominal stiffness class (without pressure): > PN6 MPa or> SN4;
• Date of manufacture, batch and identifying code; - acronym of the certifying entity.
3.2.5 HDPE Pipework

HDPE pipes for drinking water distribution and transport, for network installed underground, shall
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comply with European standard:
• EN 12201: Plastics piping systems for water supply, and for drainage and sewerage under
pressure - Polyethylene (PE)
• High density polyethylene pipes for drainage and underground pressure sewage shall comply
with European standard:
• EN 13244: Plastics piping systems for buried and above-ground pressure systems for water for
general purposes, drainage and sewerage. Polyethylene (PE)
Pipes must be resistant against UV- radiation and frost.
For diameters of 110, 125, 160, 200, 250, 315mm, HDPE - PE 100 SDR17 tubes (σ = 8.0 MPa) shall
be used. The joining of HDPE pipes DN 110, and between them and fittings shall be by butt welding
For diameters of 32, 40 50, 63, 75 and 90 mm diameters, HDPE - PE 80 SDR 11 (σ = 6.3 MPa), shall
be used.
The HDPE DN 90 pipes jointing and between them and the fittings shall be with electrofusion fittings
It will be issued a CE certificate of conformity by the manufacturer which will have certification
accordingly with the EN ISO 9001 quality system or equivalent.
3.2.6 PP-R Pipework

3.2.6.1 Material and tests
PP-R pipes and fittings for cold and hot drinking water distribution and transport, for exposed
installation, shall comply with the following standards:
• EN TC 155 system standard 25.
• IS 15801 - Polypropylene Random Copolymer pipes for hot & cold water supplies
• DIN 8076 – Pressurized thermoplastic pipelines. Compression type metal fittings.
• DIN 8077 – Polypropylene PP pipes, dimensions.
• DIN 8078 – Polypropylene pipes. General quality requirements – tests.
• DIN EN ISO 15874.
• DIN 16962 – Parts 5, 6, 7, 8, 9 and 10.
• IS 9845 – Method of analysis for determination of specific and/or overall migration of
constituents of plastic material and articles intended to come into contact with food stuffs.
• IS.10500 - Specification for Polypropylene and its copolymers for its safe use in contact with
food stuffs, pharmaceuticals and drinking water.
Toxicity attested by a certificate issued by a certified authority or laboratory.
The PP-R pipes and fittings must resist any type of water hardness and withstand chemical substances,
with PH values between 1 and 14, to ensure high resistance therefore to acidic substances and alkalines
in a wide range of concentration and temperatures.
Pressure class – PN20.
Minimum PPR80 density 0.898 g/cm3 according to ISO/R 1183.
Minimum modulus of elasticity equals to 700N/mm2 according to ISO 527. Elongation at break ≥ 50%
according to ISO 527.
Thermal conductivity 0.24 W/mk according to DIN 52612.
Coefficient of linear thermal expansion 0.15 mm/mºK according to VDE 0304. Minimum dielectric
strength of 75 KV/mm according to DIN 53481.
The threaded accessories will be in PPR80 with a Brass insert CW602N (ADZ) according to
EN12164:98.
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The PP-R pipes and fittings to be implemented must be covered by civil liability insurance of a
minimum of 10 years, in accordance with EEC Directives 85/374.
3.2.6.2 Dimensional characteristics

The pipes shall comply with the dimensions set bellow. Other may be used with the permission of the
Engineer and without compromising the hydraulic performance and durability.
Table 3.1 – Dimensional characteristic
External SDR (-) Minimum Inner diameter

diameter (mm)
thickness
(mm) (mm)
16 6 2.7 10.6
20 6 304 13.2
25 6 4.2 16.6
32 6 5.4 21.2
40 6 6.7 26.6
50 6 8.4 33.2
3.2.6.3 Marking
As an example, the manufacturer must mark on the tube the identification data between which:
• Manufacturer name.
• Diameter and thickness.
• DIN 8077/78.
• SKZ A 214.
• ATG 98/2061.
• Pressure class PN20 – 20 °C.
• NSF 61.
3.2.6.4 Installation
The installation of the pipes must comply with EN 806 - 1/ 2/ 3/ 4/ 5/ 6.
It is recommended for thermofusion connection to use a proper Polyfuser with a temperature in the
matrices of 260 °C produced in accordance with the DVS2207 standard. The pipes will be cut
perpendicular to its central line and will be cleaned before starting the thermofusion. The heating and
assembly times should be respected, depending on the diameter of the pipe, as indicated in the supplier's
technical catalogue. Small alignment corrections may only be made immediately after insertion of the
pipe into the fitting.
It is recommended for electrofusion to use a proper welder. The pipes will be cut perpendicular to its
central line and they'll be perfectly cleaned before electrofusion starts. The installation instructions
given in the supplier's technical catalogue must be followed.
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Never heat the tube with a free flame.
Protect the tube at low temperatures from violent blows or shocks in the transport phase. In building
sites the pipes should be stored in a clean and protected place. Do not mount damaged pipes.
Do not expose the pipes to direct UV rays. For outdoor installations follow the manufacturer's
recommendations. Follow the manufacturer's provisions with regard to linear thermal expansion and
fixing/support systems.
The installations shall be tested as required by European standard EN806-4.
3.2.7 Gas Pipework

3.2.7.1 General
The piping system connects the biogas plant with the biogas appliances. It shall be carefully selected
materials and installation to avoid gas leakage during use.
3.2.7.2 Materials
Gas pipe shall be made in Galvanized steel (GI) or Polyvinyl chloride (PVC). GI is most commonly
used for gas pipe. GI pipes are certified as European Conformity Standards (CE).
GI pipes shall be installed inside biogas plant and buildings because they have high strength, good
impact resistance as well as resistance to chemical corrosion.
3.2.7.3 Standards
Standards for gas pipe shall follow the ISO and European norm (EN) standards as follows:
• BS EN 10255:2004: Manufacture standard for GI pipes
• ISO 17484-1:2014 Plastics piping systems — Multilayer pipe systems for indoor gas
installations with a maximum operating pressure up to and including 5 bar (500 kPa) — Part 1:
Specifications for systems
• ISO 17484-2:2009 Multilayer pipe systems for indoor gas installations — Part 2: Code of
practice
• ISO/TR 19480:2005 Polyethylene pipes and fittings for the supply of gaseous fuels or water —
Training and assessment of fusion operators
• ISO 23555-1:2022 Gas pressure safety and control devices for use in gas transmission,
distribution and installations for inlet pressures up to and including 10 MPa — Part 1: General
requirements
• ISO 23555-2:2022 Gas pressure safety and control devices for use in gas transmission,
distribution and installations for inlet pressures up to and including 10 MPa — Part 2: Gas
pressure regulator
• ISO/CD 23555-3 Gas pressure safety and control devices for use in gas transmission,
distribution and installations for inlet pressures up to and including 10 MPa — Part 3: Safety
shut-off devices
• ISO 4437-2: Plastics piping systems for the supply of gaseous fuels – Polyethylene – Part 2:
Pipes.
3.2.7.4 Classification
GI pipes are categorized into light, medium and heavy as follows:
• Light (Class A) - Marked in yellow color for identification.
• Medium (Class B) - Marked in blue color for identification.
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• Heavy (Class C) - Marked in red color for identification.
3.2.7.5 GI pipes specification

• Wall thickness: 0.3mm-12mm
• Length: 5-14m
• Outer diameter: 20mm-508mm
• Shape: Round, square, rectangle, oval
• Technology: Hot rolled, cold rolled, ERW
• Applications: water, gas, oil, pipeline shall use for indoor and outdoor construction.
3.3 Mechanically Cleaned Bar Screen

The mechanical bar screen will be entirely constructed by corrosion resistant materials. This equipment
must be suitable for assembly in an existing concrete rectangular channel.
3.3.1 Mechanical characteristics

The following minimum mechanical characteristics shall apply:
• Structure and covering shall be in stainless steel accordingly to 1.4301 (EN 10088-3) or
equivalent;
• Stainless steel bars according to 1.4301 (EN 10088-3) or equivalent;
• Cleaning combs in stainless steel according to 1.4301 (EN 10088-3) or equivalent;
• Frontal cleaning (upstream) through, a minimum of 2 cleaning combs equally spaced activated
by chains.;
• Moto-reducer to activate the cleaning combs which are installed in a higher plane, at the
maximum water level; protection type IP56;
• All movable parts which need lubrication/maintenance shall be installed in a higher plane, at the
maximum water level;
• Adjustable pivoting scraper in stainless steel 1.4301 (EN 10088-3), with a HDPE wear blade of
easy replacement to remove waste transported by the cleaning combs. The waste discharge is
made in the upper part of the mechanical bar screen.
• The shaft to activate the transportation chains allows the combs to move over the auto-
compensated bearings. These bearings have tight insulations, and can be vertically adjustable in
order to compensate chains wear.
• All movable parts shall be protected by a safe guard in order to prevent any accidental contact.
• Stainless steel screws 1.4401 (EN 10088-3) or equivalent;
3.3.2 Electricity
In the screen supply shall be include an electrical panel with all controllers, protection and sensors
which are necessary for the well-functioning of the equipment. It will also include the water level
measurement in order to activate the automatic cleaning and in alternative the adjustable timer.
The motor shall be asynchronous, three-phased, with rotor in short circuit, velocity 1 500 r.p.m.
The supply voltage shall be 3x400 V, 50 Hz. It shall be installed a torque limiter to protect the motor in
case of overload.
The protection shall IP 56, insulation class F, storm protection. Shall possess a fan attached directly to
the electrical motor shaft.
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3.3.3 Trials
It will be issued a CE certificate of conformity by the manufacturer which will have certification
accordingly with the EN ISO 9001 quality system or equivalent.
It will be issued CE certificate of conformity with the EN 10204 standard, at least until EN 10204 or
equivalent.
3.3.4 Standard rules

The manufacturer quality system shall be certificated accordingly with ISO 9000 standards or
equivalent e will present the CE conformity declaration.
Equipment will obey the following standards or equivalent:
• Directive 2006/42/CE – machinery directive
• ISO 12100:2010 – Security and risk in the mechanical equipment design
• ISO 8501:2006 – Metal surfaces preparation
• ISO 12944:2007 – Anticorrosion protection scheme
• SANS 10120-2 HC - Code of practice for use with standardized specifications for civil
engineering construction and contract documents Part 2: Project specification Section HC:
Corrosion protection of structural steelwork
3.4 Gates
The gates shall be rising spindle type sluice gates, consisting of frame, gate door, spindle, lifting set,
stem, sealing rubbers, anchor bolts, etc.
Frame shall be of stainless-steel and designed to withstand the required maximum hydraulic head. All
contact surfaces on the frame shall be machined to set stainless steel facing to be fixed to the frame with
flat head bolts or equivalent material. The stainless steel sheet shall conform to 1.4301 (EN 10088-3)
or equivalent. The wedge plate shall be made of stainless steel conforming to 1.4301 (EN 10088-3) or
equivalent and shall be tightly fastened with flat head bolts of equivalent material.
The door shall be of stainless steel according to 1.4301 (EN 10088-3), heavy duty and one-piece
construction with integrally cast horizontal and vertical ribs of sufficient cross. sectional area to
withstand the required maximum hydraulic head. The door shall be fitted with brass sheet conforming
to CuZn40 (EN 1652) or equivalent by flat head bolts of equivalent material and machined and scraped
to provide a good contact with the frame.
The Spindle shall be designed to withstand the thrust forces during the open and close operation of the
gates, and to withstand the specified hydraulic heads. The spindle shall be preferably of one piece
construction to facilitate the installation and maintenance, and shall be of stainless steel conforming to
1.4301 (EN 10088-3) or equivalent.
3.5 Open channel flow meter

The sensor shall be of the ultrasonic type, designed in PTFE or PVDF, with temperature compensation.
The protection level shall not be inferior to IP 68 and comply with the following requirements:
• The sensor will be installed in its own support, in stainless steel 1.4401 (EN 10088-3);
• The ultrasonic measure shall be transmitted through a galvanically isolated 4-20 mA sign which
is proportional to the measured level;
• The ultrasonic meter minimum precision shall be 0,25 % or ± 3 mm;
• Zero and scale adjustment shall be customized local through existing buttons on the ultrasonic
meter;
• The transmitter shall be installed in the exterior, in its own panel, 1.5 m above the pavement,
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with a protection index non inferior to IP 65 and with total protection of the “display” panel
against UV rays.
• The flow indicator shall allow, at least, the instantaneous flow and accumulated flow readings;
• The transmitter shall have an analogic signal output of 0/4-20 mA;
• For the alarm signaling, it shall exist 2 contact inverters potential free;
It will be issued CE certificate of conformity by the manufacturer that will possess the certification
accordingly with the EN ISO 9001 quality systems or equivalent.
The ultrasonic flow meter will comply with the following specific standards or equivalents.
• IEC 60695-2-11 - Electrical material;
• IEC 60811 - Electrical material;
• IEC 61000-4-2/3/4/5 e IEC 61000-3-2/4 - Electrical material;
• IEC 61000-4-2, IEC 61000-4-3, IEC 61000-4-4, IEC 61000-4-5, IEC 61000-4-6, IEC 61000-4-
8, IEC 61000-
• 4-11e IEC 61000-4-12 - Electromagnetic compatibility;
• EN 50178 – Electronic equipment.
3.6 Electromagnetic Flow Meter

The sensor shall be of the electromagnetic type. The electromagnetic flow meter will be suitable for the
fluid to be measured, with the following main features:
• The sensor element will be flanged, made of 1.0460 steel, painted or galvanized and with the
possibility of removing the coils with the piping in load;
• The electrodes of the sensor element will be made of C4 hastelloy, titanium or 1.4301 stainless
steel;
• The reading of the electromagnetic flow meter will be transmitted through a 4-20mA signal
galvanically isolated and proportional to the measured flow and also through pulses;
• The electromagnetic flow meter will be equipped with an internal totalizer with the possibility
of "reset";
• The minimum accuracy of the electromagnetic flow meter will be 0.3 % of the measured value;
• The adjustment of the zero and scale will be configured locally through the buttons on the
electromagnetic flow meter;
• For alarm signaling, there must be 2 potential-free inverter contacts;
• The electromagnetic flow meter and the metallic pipes should be connected to ground to ensure
a correct reading;
• In places with risk of explosion, the electromagnetic flow meter should have EEx IIC T6
characteristics.
The flow meter will comply with the following specific standards or equivalents.
• IEC 60695-2-11 - Electrical material;
• IEC 61000-4-2/3/4/5 e IEC 61000-3-2/4 - Electrical material;
• IEC 61000-4-2, IEC 61000-4-3, IEC 61000-4-4, IEC 61000-4-5, IEC 61000-4-6, IEC 61000-4-
8, IEC 61000-4-11e IEC 61000-4-12 - Electromagnetic compatibility;
• EN 50178 – Electronic equipment.
3.7 Vertical Screens

The vertical screens shall be in AISI 316L (1.4404 / DIN EN 10088-3), , with bars with 30 mm spacing.
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The solids discharge upstream or downstream directly into a reception box, as indicated in the Project
parts.
This vertical screen is operated by a strap or cable driven by one gearmotor.
The cleaning system shall be automatic, with the gravity closing debris removal tank and the strap in
polyester or cable in stainless steel.
3.8 Compressed Air Vessel

Compressed air vessels shall be vertical or horizontal, with a support structure welded to the body of
the tank, suitable anticorrosive treatment and prepared for outdoor installation.
The reservoir must consist of a cylindrical part with a circular cross-section, closed by cupped bottoms
with the concave side facing outwards and or flat bottoms with the same axis of revolution as the
cylindrical part. The reservoir shall have an interior butyl reinforced elastic membrane.
When applicable, the tanks will be self-supporting, to be mounted on a flat concrete massif, and must
have a tying system to this massif that gives it the necessary fixation to the action of the winds and
seismic impulses.
The following minimum mandatory characteristics must be observed:
• Materials: unalloyed construction steel, unalloyed aluminium or non-self-hardening aluminium
alloy;
• Anticorrosive treatment by hot-dip galvanisation (steel construction tanks), with primer and
final finishing, the total thickness being not less than 120 microns and respecting the
requirements of the standards referenced in this specification;
• Connections to the manometer, to the pressure switches, to the compressors, to a condensate
drain with automatic purging, to a safety valve and to the supply network.
The tanks must be supplied with characteristic stainless steel plates with the following data:
a) Manufacturer;
b) Model;
c) Number and year of manufacture;
d) Working/calculation/test pressure;
e) capacity;
f) void mass;
g) construction code;
h) date of test.
The manufacturer's Quality System shall be certified according to ISO 9000 or equivalent standards.
Metal containers shall also comply with the following standards and directives or equivalent:
• Directive 97/23/EC;
• Directive 2009/105/EC;
• BS EN 10028:2009 - Products made of steel for pressure applications;
• ISO 14713:2009 - Zinc plating of steel structures;
• ISO 8501:2006 - Preparation of metal surfaces;
• EN ISO 12944:2007 - Corrosion protection schemes.
3.9 Other Mechanical Specifications

3.9.1 Warning Tapes
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Underground warning tapes (UWT) shall be laid above the top of the pipe embedment material. UWT
shall be brown coloured polyethylene underground marker tapes with a printed warning message for
marking the underground buried sewer pipes.
• Material – Linear low density polyethylene.
• Warning text: “Caution: Sewer Pipe Below” in English language.
• Soil tolerance from pH 2.5 to pH 11.0 inclusive.
• Dimensions: 150mm x 0.05mm (or thicker).
3.9.2 Step Irons

Step irons in chambers and the like shall comply with the specifications of EN 13101 and shall be made
of cast iron with rubber/ plastic coatings. Unless shown otherwise in the Drawings, the step irons shall
be installed in a staggered pattern at not more than 300 mm centres.
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4 GENERAL ELECTRICAL REQUIREMENTS

4.1 Electrical Supply
4.1.1 General
4.1.1.1 Field of Application
General Specifications apply to the supply, installation, commissioning and operation of particular
electrical and corresponding mechanical devices and systems, including design, software,
documentation, spare parts and all associated items to be delivered within the frame of this contract.
4.1.1.2 Relation to other Sections

This Section includes specifications for products, common criteria and characteristics and methods of
execution that are common to one or more Sections of the Electrical Division, and it is intended as a
supplement to the required unit of work of each section and shall be read accordingly.
4.1.2 Uniformity of Products

Coordinate with the Sections of this Division and other Divisions of the Specification to supply products
of the same manufacturer when these products have similar functions and characteristics. When the
same manufacturer cannot be used by all sections for a similar product, and the product is installed in
finished areas, the products shall be similar in style and finish as directed by the Specification.
Following are examples of products which should be coordinated with other sections:
• Lighting
• Switches and sockets
• Products with special surface treatment or finish and colour
• Motor starters
• Disconnect switches and circuit breaker
• Contactors
• Cable terminals
• Control and protection relays
• Programmable control relays
• Analogue and digital instruments
• Sensors and Actors
• Automation equipment
• Command equipment installed in switchboards
4.1.2.1 Quality of Products

All manufactured products supplied and installed shall be new, free of all defects, and in accordance
with Contract Documents.
Fabricated products shall be assembled from new materials. All products to be located in non-air-
conditioned areas shall be approved for use in 50°C ambient and 100 % R.H. non-condensing unless
specified otherwise, including sunshine effect where exposed outdoors. The lower end of the
temperature range must be selected as adequate for the location of installation.
4.1.2.2 Qualifications of Manufacturers

Specified Products shall be manufactured by manufacturers regularly in the production of the specified
product.
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4.1.2.3 Electrical Supply

The electricity supply shall be made by a 220 -230 VAC for single phase and 380 - 400 VAC 4 wire for
3 phases at 50/60 Hz distribution grid, with a TN-C-S earthing system.
Voltage provided to equipment in this installation shall fall within minimum and maximum permissible
limits for equipment. Maximum voltage drop between main new switch boards to any point shall not
exceed 2.5 percent of the sending end supply Voltage.
4.1.2.4 Shop Drawings / As Built Documentation

Shop Drawings/ As Built Documentation shall comprise the followings:
• List of drawings: mentioning the drawings, diagrams, computing notes, etc. which will
constitute the document set to be submitted during the course of construction.
• Complete and itemized detailed list of all the components of the supply, showing for each item
whether main or accessory and whether electrical or mechanical, the reference number which
will be used in the drawings and documents throughout.
• Switchboard outline, with indication of:
• Weights and outline dimensions of the main parts, positioning of the original elements
(terminals, instruments)
• Floor loads etc.
• Fixing holes, cable passages and recommended depth etc.
• All information as required for the dimensioning of the structures and the elaboration of the civil
engineering drawings
• Computing note regarding the dimensioning and withstanding of the switchboards busbars
• Recommendation, computing notes and selectively charts for all the protective systems of the
supply, setting adjustment included
• Detailed drawings of the switchboards as built
• Complete wiring diagrams, connection and inter-connection diagrams
• Complete lists of the necessary interconnection cables with indication of the cross-sectional
sizes and lengths.
4.1.2.5 Operation and Maintenance Manuals

The Contractor shall prepare comprehensive set of operation and maintenance manuals covering all
items of the contracted works and equipment including all manufacturer's instructions, references, lists,
etc. The manuals shall include an outline of the general principles of operation and maintenance of the
items and shall make specific reference to the particular equipment provided. Sales brochures may be
included only as additional information.
The manuals shall also include a list of addresses with contact details of the suppliers’ representatives
locally or abroad which can provide after sales service, spare parts or operation support. The manuals
shall cover the testing, operation, control, maintenance, dismantling and repair of all the parts the
Works.
All information shall be supported by:
• Catalogues and brochures
• Dimension drawings
• Data sheets
• Photo documentation
• Descriptive text
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• Single line diagrams

• Cabling plans
• Parameter Settings lists
• Control system (PLC and SCADA) software: firmware and application software
• Comprehensive drawings, sketches, plans, sections as may be required
4.1.2.6 Training and Instructions

Instruct the Client's representatives in all respects of the operation and maintenance of system and
equipment. Obtain a list of the Client's Representatives qualified to receive instructions.
Arrange and pay for services of service engineers and other manufacturer's representatives required for
instruction on specialized portions of installation. Provide hardcopies of the relevant training
documents/ operation manuals.
4.2 Standards and Approvals

4.2.1 General
In general, great importance shall be given to accurate execution of Works so that the installation
permanently withstands the environmental stress and that reliable function is guaranteed.
It is under the responsibility of the Contractor to ensure that all electrical and mechanical devices are
constructed in line with the Specifications and that import, installation and operation is permitted. The
Contractor is responsible for any kind of legal obligation to obtain official approval.
4.2.2 Standards and Approvals

From all required standards, laws and requirements the latest version must be applied.
4.2.2.1 Country’s Technical Standards

The design, Contractor’s documents, the execution and the completed works shall comply with the
latest version of the country’s technical standards, building, construction and environmental laws, laws
applicable to the product being produced from the Works, and other standards specified in the
Employer’s requirements, applicable to the Works, or defined by the applicable laws.
4.2.2.2 International Electrotechnical Commission and Harmonized European Standards

In addition, to reach the specified requirements concerning quality, function, safety, reliability,
compatibility and Employer’s requirements, all electrical and mechanical devices and installations shall
comply not only to effective national standards and approvals but also to latest versions of relevant
international standards by the International Electrotechnical Commission (IEC) and by CENELEC, and
the Harmonized European Standards (EN). The devices must be marked accordingly.
It concerns such as installations, operation, installation materials, methods and specific climatic and
safety conditions as well as electric devices such as low and high voltage switchgear, switchgear
assemblies, motors, cables, transformer, soft starter, relays, frequency inverter, panels, control/
automation/ protection systems, earthing, lightning protection devices, etc.
4.2.2.3 CE-mark (Conformité Européen)

All electrical devices to be provided shall also conform to the European low-voltage directive and must
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be provided with a valid CE-mark (Conformité Européen), and also consider these as they are frequently
used in Mozambique (British standards, South African Bureau of Standards).
4.2.2.4 EMC-Directive
All electrical devices and installations to be provided must comply with the Electromagnetic
Compatibility (EMC) Directive.
The technical instructions of ARENE - AUTORIDADE REGULADORA DE ENERGIA (Energy
Regulatory Authority) and EDM - ELECTRICIDADE DE MOZAMBIQUE (Electricity of
Mozambique) shall be considered. Special attention shall be paid to the connections to the public local
ESCOM distribution grid. Selection of material and devices as well as the dimensioning and
construction of the grid connections shall correspond to the instructions of the local power supply utility
as well as to relevant IEC/EN standards and instructions given by manufacturers. All relevant
installations shall be clarified in cooperation with the power utility; their written authorization shall
be obtained before devices are procured, delivered and before construction works starts.
If appropriate technical instructions of the power utilities are not available or not sufficient to reach the
specified requirements concerning quality, function, safety, reliability, compatibility and Employer’s
requirements, electrical equipment and installations shall comply with the Harmonized European
Standards (IEC/EN) and not least with DIN VDE (German Industrial Standard), if IEC/EN is not
appropriate or not sufficient. The devices must be marked accordingly.
Regulations and instructions of the relevant power utility for putting devices and plants in operation
shall be observed. If not specified differently, the Contractor is in general responsible for relevant
applications and permissions.
4.2.3 Circuit Documents

Provided circuit documents of all types, tables, diagrams and descriptions are to be in accordance with
IEC 81346 standards.
Circuit documents are to be supplied for the complete electrical system. They have to explain the
function of circuits or power connections and provide information for the construction, installation,
operation, automation and maintenance of the electrical installations. All diagrams show the voltage-
free or current- free status of the electrical installation.
4.2.4 Marking of Electrical Equipment

All electrical equipment and cabling shall be marked in accordance with IEC 81346, including code
letters for type of equipment and for general functions.
The marking appears in an appropriate position as close as possible to the circuit symbol. The marking
forms the connection between the equipment in the installation and the various circuit documents
(diagrams, part lists, circuit diagrams, instructions).
4.2.5 Principle Design of Protection Devices and Circuits

4.2.5.1 Protection in the Event of Power Failure
Design of equipment and protection functions must be in accordance with IEC 60204. Individual
machines or parts thereof are only allowed to restart automatically on return of the voltage after a supply
failure, if no danger can be caused to persons or the machine. Additionally, the system must be switched
to automatic mode of operation. The protection system shall also have to have the built-in voltage
stabilizing unit in it to protect equipment and appliances from voltage fluctuations.
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4.2.5.2 Control Functions in the Event of a Fault

External influences or the failure of components can cause unwanted operation of the electrical
equipment of a machine. As this might result in the safety circuits being rendered ineffective,
appropriate measures, such as additional safety circuits and redundancy connected downstream, should
be taken to prevent any possible dangers arising.
A fault in the electrical equipment must not result in a dangerous situation or in damage. Suitable
measures must be taken to prevent danger from arising. Standard EN ISO 13849-1 shall be considered
by using the current operated control devices other than the voltage operated ones.
4.2.5.3 Emergency-Stop Device

All supplied and installed electrical machines must comply with IEC/EN 60204. Every machine which
could potentially cause danger or damage must be equipped with an Emergency-Stop device which, in
a main circuit may be an Emergency-Stop switch, and in a control circuit an Emergency-Stop control
circuit device. Actuation of the Emergency-Stop device must result in all current loads which could
directly result in danger, being disconnected by de-energization via another device or circuit, i.e.
electromechanical devices such as contactors, contactor relays or the under-voltage release of the mains
isolating device. For direct manual operation, Emergency-Stop control circuit devices must have a
mushroom-head push-button and positively opening contacts. Once the Emergency-Stop control circuit
device has been actuated, it must only be possible to restart the machine after local resetting. Resetting
alone must not allow restarting until the problem is resolved
Furthermore, the following apply for both Emergency-Stop switch and Emergency control circuit
device:
• The handle must be red with a yellow background
• Emergency-Stop devices must be quickly and easily accessible in the event of danger
• The Emergency-Stop function must take precedence over all other functions and operations
• It must be possible to determine functional capability by means of tests, especially in severe
environmental conditions
• Where there is separation into several Emergency-Stop areas, it must be clearly discernible to
which area an Emergency-Stop device applies
IEC/ EN 60204-1 Specifies under the generic term “Emergency operations” two specific functions:
• Emergency-Stop: This involves the possibility of stopping dangerous motions as quickly as
possible.
• Emergency-Off: Where there is a risk of an electric shock by direct contact, e.g. with live parts
in electrical operating areas, then an Emergency-Off device shall be provided.
4.2.5.4 Undervoltage Release

In case, this function switches off the circuit-breaker when no voltage is present. They are used for
safety tasks. The safety circuits are proof against wire breaks. Whenever applicable, appearances shall
be equipped with Undervoltage Release.
4.2.5.5 Closed Circuit Principle

Protection-, control- and interlocking circuits shall use the closed-circuit principle. They must also
respond to a broken wire in the corresponding circuit.
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4.2.6 Protective Measures
Type of System shall be to IEC 60364-1 latest version (e.g. TN, TT or IT).
Selection of appropriate protection against shock currents shall be to IEC 60364-4-41 latest version. It
includes protection against direct and indirect contact. The protective device must automatically
disconnect the faulty part of the installation. At no point of the installation may there be a touch voltage
or an effective duration larger than permitted to IEC 60364-4-41.
4.2.7 Risk Reduction in case of a Fault

A fault in the electrical equipment must not result in a dangerous situation or in damage. Suitable
measures must be taken to prevent danger from arising. The IEC/EN 60204 specifies a range of
measures which can be taken to reduce danger in the event of a fault, i.e.:
• All switching functions on the non-earthed side of control and interlocking circuits
• Use of break devices with positively opening contacts (not to be confused with interlocked
opposing contacts)
• Shut-down by de-excitation (fail-safe in the event of wire breakage)
• Circuit engineering measures which make undesirable operational states in the event of a fault
unlikely (e.g. simultaneous interruption via contactor and position switch)
• Switching of all live conductors to the device to be controlled
• Chassis earth connection of the control circuit for operational purposes (not used as a protective
measure)
• Redundancy: the existence of an additional device or system is required, which takes over the
function in the event of a fault
4.2.8 Overcurrent Protection of Cables and Conductors

Wiring and cables must be protected by means of overcurrent protective devices against excessively
high temperature rises, which can result from operational overloading as well as short circuits.
Overcurrent protective devices shall further be provided in all phase conductors. They must cause
disconnection of the conductor in which the overcurrent occurs, but not necessarily disconnection of
the other live conductors. It has to be ensured, that the disconnection of an individual phase cannot
cause danger. Suitable precautions have to be taken.
4.2.9 Arrangement of protective Devices for short-circuit Protection

Protective devices for short-circuit protection must be fitted at the start of every circuit, as well as at
every point at which the current-carrying capacity is reduced, if a protective device connected upstream
cannot ensure the required protection.
4.2.10 Protection of Phase Conductors

Overcurrent protective devices must be provided in all phase conductors. They must cause
disconnection of the conductor in which the overcurrent occurs, but not necessarily disconnection of
the other live conductors. If the disconnection of an individual phase conductor could cause danger,
suitable precautions have to be taken.
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4.2.11 Wiring
4.2.11.1 Minimum Cross-Section
The minimum cross-section for single-core and multi-core copper conductors inside control-panels is
1,5 mm².
4.2.11.2 Colour Code for Wires and Cables

When labelling single-core wires and cables, the following colours must be used:
• Protective earth conductor (PE) and equipotential bonding: yellow/green
• Neutral conductors of power circuits: light blue
• A.C. or D.C. power circuits: black or brown
• A.C. control circuits: red
• D.C. control circuits: dark blue
• Interlock circuits: orange
Cables, which are not laid in ducts, must be adequately supported. Control circuits should be laid in
separate ducts res. in case one common duct is used, they should be separated from power cables by
separating strips.
4.2.12 Technical Standard of Control Circuit Devices

All control circuit devices used for flush mounting, surface mounting or rear mounting in switchboard
panels or insulated enclosures must be in accordance with IEC/ EN 60 947, VDE 0660. The function is
guaranteed for an ambient temperature of Min/Max. –25/+40 C. The rated insulation low voltage is
500V.
The climatic proofing must be in accordance with damp heat, constant, to IEC 60 068-2-3 and damp
heat, cyclic, to IEC 60 068-2-30.
Degree of protection
The minimum degree of protection shall apply:
• for contact elements and lamp sockets: IP 20
• for switches, push button and key-operated actuators and indicator lights: IP 65
Colour Coding for Push-buttons

The colour coding must be in accordance with IEC 60073, as follows:
• Red: Action in case of “emergency stop” or “emergency off”
• Yellow: Intervention to suppress abnormal conditions or to avoid unwanted changes
• Green: “Start” or “On” resp. “in operation”
• Blue: Any specific meaning not covered by the above colours
• White: No specific meaning assigned
Colour Coding for Indicator Lights

The colour coding must be in accordance with IEC 60073, as follows:
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• Red: Danger or Alarm; Warning of potential danger or a situation which requires immediate
action
• Yellow: Caution; Change or impending change of conditions
• Green: Safety; Indication of a safe situation or authorization to protect, clear way
• Blue: Specific meaning assigned according to the need in the case considered
• White: No specific meaning assigned
Control Transformer
IEC 60204 requires the use of a control transformer on machines or separate parts of the electrical
system with more than five electro-magnetic coils. It must be connected downstream of the main switch
to allow for its isolation, and preferably between two phase conductors. The incoming supply cables to
the primary terminals of the control transformer must be protected against short circuits. On the
secondary side, a short circuit protective device is required in the non-earthed conductor.
Preferred secondary voltages are 24V, 48V, 110V, 220V at 50 Hz. Before using low voltages, it must
be checked whether fault-free operation is possible.
The control transformer must be adequately rated to keep the voltage drop within permissible limits
even under adverse conditions.
In non-earthed control circuits an insulation monitor must be fitted to indicate earth faults and to initiate
disconnection. In earthed systems, the auxiliary circuits must be earthed on one side and one side of the
coils must be directly connected to the earthed conductor.
Earth faults must neither lead to unintentional starting of the machine, nor prevent it from stopping. In
order to avoid this risk, auxiliary circuits have to be earthed on one side and one side of the coils must
be connected directly to the earthed conductor.
In non-earthed control circuits, an insulation monitor must be fitted to indicate earth faults or initiate
disconnection.
Measuring and recording instruments

All kind of instruments shall provide safe, proper and accurate functions. Last calibration shall be done
not more than 6 months ago. Testers and recorders for voltage, current, frequency, polarity, isolation,
loop resistance, etc. shall be acc. to IEC/ EN 61557.
4.3 Selection Criteria

All electrical devices, such as low and high voltage switchgear, switchgear assemblies, motors, cables,
transformer, soft starter, frequency inverter, panels, control/ automation/ protection systems, earthing
and lightning protection devices, etc. shall be selected under consideration of the criteria as given in the
General and Particular Specifications and under consideration of the following criteria.
4.3.1 Overcurrent Protective Devices

Fuses should be avoided as far as possible and if not specified in particular. Circuit-breaker and motor-
circuit-breaker shall be selected, as these devices can be immediately reclosed once a fault has been
cleared. Moreover, the high tripping accuracy makes them suitable for selective operation. The
preferential use of circuit-breakers is a major design criterion. It reduces the problem with replacement
of parts as they have no consumables such as fuses.
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4.3.2 Motor Protective Circuit Breakers
Inherently short-circuit-proof switches capable of coping with the highest prospective fault levels at the
point of installation without the need for back-up protection shall be selected. The setting devices shall
fully meet the requirements of the connected device.
4.3.3 Circuit Breakers

Fuse less installation shall be selected, as it offers greater safety and reliability in plant operation. By
the use of Din-rail miniature circuit breakers (MCB) the required selectivity criteria can be realized.
Miniature Circuit-breaker with visible contacts shall be selected if compliance with local accident
prevention regulations, requiring visible contacts is to be considered.
Quick-make and quick-brake operation shall be standard. Current-limiting circuit-breakers shall be used
where the prospective fault level is high. Effects of short-circuits must be reduced to a minimum.
Use selective operating circuit-breakers for time-selective progression of systems. In general selectivity
must ensure, that in the event of a fault arising, only the faulty section of the system shall be isolated.
4.3.4 Contactors
Contactors shall be selected whose entire range provides consistently reliable operation in the event of
voltage drops – consistency down to 80% of the nominal voltage should be aimed for - and whose
contact system will not assume an indeterminate position, either on closing or opening, in such
conditions. The contactors shall be 3 pole, 380V AC, 50Hz, and a control coil of 240V AC or 380V AC
for a 3 Phase, and 2 Pole for a single phase system.
In the course of selection and detail design of the electrical and mechanical system the Contactor shall
consider that it is probable that the voltage stability will - at least for some time - leave much to the
desired in many applications, as a result of long power lines, small local generators or under
dimensioned respectively overloaded transformer substations. Moreover, regular and long lasting power
failures and voltage fluctuations shall be considered.
4.3.5 Main Switches and Safety Switches

Devices with positive contact separation and clear switch position indication shall be selected. The
mechanical coupling of the actuating element with the contacts must ensure, that the OFF-position is
indicated only when all main contacts are separated by the prescribed distance, and only in this position
can the switch be padlocked. Safety must be guaranteed when maintenance or repair works are carried
out on the installation or machinery.
4.3.6 Emergency-Stop Control Devices

Design and function of all emergency-stop control devices shall be to IEC 204-60. When operating
these devices, all current loads which might lead to danger to personnel or damage to machinery, must
be disconnected indirectly by de-energization. For direct manual operation, emergency-stop control
devices must have a mushroom-head push-button and positively opening contacts.
Emergency-stop actuators for mounting in front panels must be designed to IP 65 and tamper-proof to
EN 418. They must have a yellow base and a red button with pull to release-function. The button must
have a minimum diameter of 25 mm.
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4.3.7 Enclosures
In buildings with difficult environmental conditions, such as dust, drip water, splashed water, humidity
and unusual high or low temperatures totally insulated enclosures with transparent covers shall be
selected. Consider special conditions in chemical environment.
In all other rooms’ enclosures according to the following specifications shall be supplied:
Heavy-duty indoor enclosure, capable of withstanding the most severe conditions to be expected, such
as dust, drip water, splash water, constant humidity and low temperatures. The enclosure complies with
IEC/EN 60439. It is made either from steel sheet with anti-corrosion protection and polyester-epoxy
coating inside and out or alternatively it can be made for small enclosures of self-extinguishing halogen
free polycarbonate. Degree of protection is IP 54 or higher. The degree of protection against mechanical
impacts as per EN 50102 is IK10.
Installations inside the enclosure shall provide protection in accordance to IP 32 or higher. Protection
class 2. Wall fixing shall be made by adjustable wall fixing lugs. The enclosure is equipped with one
gland plate with gasket, mounted on the bottom side only. All cables lead into the enclosure through
metric cable glands only, exactly dimensioned for the connected cable. Degree of protection of all
glands is IP 55 or higher. Each gland contains one cable only. A reserve of at least four tight glands for
later installation shall be installed. The rigid door is reversible and opens 120°. The thickness of the
cover/ door allows the installation of indicating lights, push buttons, instruments, etc. Doors shall be
equipped with a lock.
Earthing is provided by welded studs in the enclosure and on the door. The enclosure shall be equipped
with one mounting plate made from galvanized steel or insulating material for free installation of
devices. All equipment to be installed inside the enclosure shall be mounted on mounting rails to EN
60715. The enclosure shall be directly fixed to the wall using fixing straps.
Cables and devices inside the enclosure, such as fuses and terminals shall be marked accordingly. Single
line diagrams shall correspond to this marking.
4.4 E-Works Implementation

4.4.1 Measures
Accurate measures required for the routing of electrical wiring and cabling, and the layout of electric
equipment, shall be taken from architectural drawings or by actual site measurement.
4.4.2 Supports
Wall mounted equipment, where shown on tile wall, or other walls inadequate to support the equipment,
shall be mounted on a mounting frame manufactured of angle iron or channel supports, which shall be
capable to support the equipment independent of the wall type. Outlet boxes shall be adapted to their
respective locations and fastened to a rigid support independent of conduit.
4.4.3 Location of Outlets and Devices

Location of switches, thermostats, outlets and control devices are shown diagrammatically tabularly.
Keep all switches, thermostats and other controls as close to door jambs and other openings as possible
and check door swings prior to installation to locate switches on lock side of door.
All under surface boxes in finished areas shall be mounted so that covers will fit flush with the finished
surfaces. Where several separate boxes are mounted in a group, they shall be aligned vertically and
horizontally and a uniform parallel spacing shall be maintained.
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Mounting heights shall be as specified under "Mounting Heights". Where the location of any item is
shown on any architectural details or elevations, these locations shall govern.
4.4.4 Mounting Heights

If not specified differently in the Particular Specifications, mounting heights for outlets and local
devices shall be as follows and shall be from centre line of outlet box to finished floor.
• Light switches, combinations and thermostats: 1200 mm above finished ground level
• Sockets and cooker low level, connection outlet: 300 mm above finished ground level
• Distribution and control panels to be mounted at 1500 mm above finished floor level
• Above working tops, 200 mm above the finished work top level
4.4.5 Identification of Cables and Equipment

4.4.5.1 Cable and Wiring
Cable and wiring shall be identified by means of clip-on type wire markers of rigid PVC construction.
Marker colour shall be WHITE or YELLOW with BLACK engraved letters or numerals.
A number shall be installed on each cable at each junction point. Number control wires to coincide with
equipment shop drawings.
4.4.5.2 Nameplates
Nameplates in English language shall be provided for all pieces of electrical equipment including panel-
boards, motor control centres, terminal cabinets, disconnect switches, motor starters, contactors, push
button stations, junction boxes and pull boxes.
Nameplates shall be laminated rigid plastic on interior items and stainless steel in exterior items with ≥
5 mm high engraved letters. Nameplates shall be fastened to equipment in a conspicuous location.
Warning signs shall be provided on all removable equipment covers through which access may be
gained to live parts. Signs shall show electrical "lighting" symbol and the words "Danger - High
Voltage" in the specified languages; in white engraving on red background.
Buried cables and conduits shall be identified by cover plates with appropriate markings.
4.5 Installation of Conduits

Conduits, in all finished areas, shall be run concealed in ceiling spaces, walls, partitions, or in floor
slabs. Where conduits are run in floor slabs, they shall be laid between the layers of reinforcing steel or
wire mesh. Obtain structural engineer approval for conduits laying pattern.
Conduit ends shall be reamed and open ends capped with proper conduit caps immediately after
installation.
Flexible conduit shall be used only for final connections, as to motors and lighting fittings. For liquid
pumps and damp locations liquid-tight flexible conduit shall be used complete with insulated watertight
connectors. All coupling joining two conduits in the ceiling void or not concealed in solid walls and
concrete form shall be cemented to strengthen the joints using PVC solvent adhesive.
Where conduits run exposed, they shall be installed accurately in line and level (horizontal and vertical)
and parallel to building lines. Where run exposed on concrete or masonry walls, conduits shall be
supported using conduit clamps and lead anchors, or approved pre-set concrete inserts and where run
on building steel, beam clamps shall be used. Where conduit runs cross building expansion joints,
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expansion couplings shall be installed. Where conduits are installed as part of an empty raceway system,
conduits shall have sweep bends with a minimum bending radius of six (6) items conduit diameter
where change of direction occurs. No empty conduit run shall have more than two 90 degree bends
between pull boxes. All empty conduits shall contain a draw wire.
Where necessary for proper pulling of wiring, pull boxes shall be installed and located so as to be
accessible after completion of building.
Suspended conduits shall be supported from ceiling or roof slabs above with galvanized steel threaded
rods and fasteners on U channel brackets. Conduit clamps shall be heavy duty cadmium plated or PVC
with adjustable saddles. Wire as used for ceiling suspension and perforated pipe straps will not be
accepted. Cover screws on all conduit fittings and junction boxes shall be carefully cut to lengths to
avoid damage to wires.
Outdoor cable connections to motors, actuators, panels, etc. shall be made with cable and conduit glands
with plug-in-system. The glands shall provide tight connection and UV stabilized. Temperature range
shall be at least -25°C/+100°C.
4.6 Wire and Cable Installation

4.6.1 General
Cables and wires shall be installed on walls only in horizontal or vertical direction.
Power cables shall be installed either on cable trays or on surface throughout in rigid cable conduit. A
PVC- corrugated pliable conduit for heavy gauge (750N) to IEC 61386 – EN 3341 shall be installed.
Temperature range: -40°C up to +60°C. Only suitable fittings and clips for installation on surface shall
be used. The fittings shall be water- and sand tight. For connection to the switchboard pliable conduit
glands shall be used. The conduits shall be to IP 54. The protective cable conduits shall be marked in a
regular distance of 3 meter by use of water and UV resistant markers. The cables shall be marked on
both ends.
Splicing of conductors shall not be done unless permitted by Regulations. Conductors shall be joined
at a single or multiple connector block in boxes, cabinets or fittings.
Exposed cables shall be installed using manufacturer's recommended installation tools.
Where a number of cables on cable trays follow same general route, they shall be fixed on the tray
beside each other only. Single and multi-conductor cables shall be spaced to avoid de-rating the
conductor current carrying capacity. Cables shall not be bundled up anywhere. Signal, data and
telephone cables shall be separated from energy cables. For those separators shall be fixed on the cable
trays. The cables shall be fixed to the tray with suitable supporting clamps or cable straps in lines parallel
to run of track.
Termination of metallic sheath and interlocked armored cables shall be in accordance with the
manufacturer's recommendations and instructions. Termination and connectors shall be dust and
moisture tight and be shrouded with a heat shrinkable tubing of appropriate size, shrunk tight with a
heat gun as per manufacturer's instructions. Shrunk tubing shall cover connector completely, such that
no exposed metal shall show between connector and box or wiring device. Tubing shall also cover cable
leading to connector for a minimum length of 25 mm. Flexible conduit motor connections shall include
a green earth wire, bonding motor box to metal conduit.
Cables shall terminate through brass compression-type glands which grip the sheath, clamp the
armoring and seal the gland and outer sheath.
In case of aluminium single conductor sheathed cable, load end shall terminate in an insulating plate
(ferrous enclosure shall be slotted to prevent a closed magnetic loop). A copper bonding wire shall be
installed from supply end to load end, or a special aluminium/ copper cable terminal lug shall be used.
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Cable tails shall be adequately insulated and identified.
Cables shall be carefully taken from spools and reels, in manner recommended by manufacturer to avoid
kinks and twisting. Bends must be made with minimum bending radii recommended by manufacturer,
with all bends measured to inside diameter.
The minimum allowed temperature for installation, specified by the manufacturer, must be accepted
during cable installation.
Cables shall be run in single continuous lengths as no splices will be allowed.
Particular consideration shall be given to pulling tensions and cable lubricants during installation of
cable, which shall be in accordance with the cable manufacturer's recommendations and instructions.
Attach cables to cable trays with cable ties or clamps. On cable trays energy and control cables shall be
fixed in a distance of >100 mm. If metal separators are installed between the cables on the tray, the
distance is not required any more.
4.6.2 EMC-compliant Connection of Frequency Inverters

The EMC (Electromagnetic Compatibility) of a device is its ability to withstand electrical interference
while itself not emitting excessive electromagnetic interference into the environment. The IEC/ EN
61800-3 standard shall be considered. It describes the limit values and test methods for emitted
interference and noise immunity for variable-speed electrical drives.
The following measures for EMC-compliant installations shall be considered for design and installation:
• Earthing measures
• Screening measures
• Filtering measures
• Chokes
4.6.2.1 Earthing Measures

Earthing measures must be implemented to comply with the legal standards and are a prerequisite for
the effective use of further measures such as filters and screening. All conducting metallic enclosure
sections must be electrically connected to the earth potential (Local equipotential Bonding). For EMC,
the important factor is the cable’s surface, since this is where high frequency current flows to earth. All
earthing points must be low-impedance, highly conductive and routed directly to the central earthing
point (potential equalization bar or star earth). The contact points must be free from paint and rust. Use
galvanized mounting plates and materials.
4.6.2.2 Screening
Screening reduces emitted interference (noise immunity of neighbouring systems and devices against
external influences). Cables laid between the frequency inverter and the motor must be screened, but
the screen must not be considered a replacement for the PE cable. Power cables shall be equipped in
principle with a PE-wire. The screen must be connected to earth (PES) at both ends with a large-area
connection. Do not connect the screen with pigtails. Interruptions in the screen, such as terminals,
contactors, chokes, etc., must have a low impedance and be bridged with a large contact area. To do
this, sever the screen near the module and establish a large-area contact with earth potential (PES, screen
terminal). Free, unscreened cables must not be longer than about 100 mm.
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4.6.2.3 Filtering Measures
Radio interference filters and line filters shall be supplied and installed according to requirements and
acc. to instructions of manufacturer of the frequency inverter. The filters shall protect against conducted
high- frequency interference and shall reduce the frequency inverter’s high-frequency interference,
which is transmitted through or emitted from the mains cable, and which must be limited to a minimum
level (emitted interference).
Filters may produce leakage currents which, in the event of a fault (such as phase failure or load
unbalance), can be much larger than the rated values. To prevent dangerous voltages, the filters must
be earthed according to instructions of manufacturer. As the leakage currents are high-frequency
interference sources, the earthing connections and cables must have a low resistance and large contact
surfaces.
For leakage currents above 3,5 mA, one of the following must be fulfilled according to EN 60335:
• the protective conductor must have a cross-section greater than 10 mm2
• the protective conductor must be open-circuit monitored, or
• an additional conductor must be fitted
4.6.3 Outdoor Installation

Outdoor the contractor shall lay all power and control cables as far as possible in a trench together with
pipes. Co-ordinate the lines of the cable trenches with pipe trenches, as specified within subject General
Specifications.
Before execution of Works the Contractor shall fix the exact trench line and measure the exact cable
length required. Cables longer than 50 meter and/ or with a bigger diameter than 20 mm shall be
supplied on a cable drum. In general, all cables shall be installed in one unit. No cable joints or terminal
boxes are permitted.
Power and control cables shall be installed throughout in separate protective cable conduits. Inside the
cable trench cable cover plates shall protect cable and cable conduit. The Contractor shall supply and
install these plates in accordance with effective Specifications and Standards.
A galvanized round earthing wire 10 mm² shall be laid in each trench in the sand above the cable cover
plates. The wires shall be connected to the Local Equipotential Bonding Bars at both ends.
Latest one day after cable installation in the trench an insulation test of all cores to each other and to
earth and a resistance measurement of all cores shall be made. Within this test the phase sequence of
power cables shall be fixed. The cores shall be labelled accordingly with L1/ L2/ L3. The tests shall be
executed with professional instruments and in accordance with relevant Standards. A protocol shall be
issued which shall contain a description of the test method, the testing equipment, the test results
(measured data), time and date of test, name and signature of the Contractor.
Protective cable conduits for underground installation in trench shall have the following minimum
internal diameter:
• Cables with a diameter from 41 mm to 50 mm: ≥ 90 mm
• Cables with a diameter from 26 mm to 40 mm: ≥ 75 mm
• Cables with a diameter from 10 to 25 mm: ≥ 50 mm
• Cables with a diameter up to 10 mm: ≥ 30 mm
Depending on the total length of the conduit its diameter may even have to be increased respectively
ducts enabling pulling of cables have to be considered.
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4.7 Dimensioning of Power Cables

Connections up to a cable size of 10 mm² shall either be done with a cable type YSLYQY (LSYYQvY)
or PVC Insulated Single Core Cable type NYY (E-YY). Connections of size above 10 mm² shall be
done with high flexible power cables only. Motors operated with frequency-inverter shall be connected
to high flexible cables with shield only. All cores and cables shall be installed throughout short circuit
proofed. Maximum distance between cable fixing devices shall be two meters. Only short circuit-proof
and antimagnetic fixing devices which can withstand the environmental conditions shall be used.
Single core cables must be of identical length for each phase and for neutral. Unbalanced load conditions
are not permitted. Dimensioning shall be in accordance to relevant Standards, operating conditions and
especially considering the starting conditions. The maximum permitted voltage drop between the
switchboard and the terminals of the motor shall be 0,5% during nominal operation. The Contractor
shall provide a calculation prior to supply and installation.
In principle all cores and cables shall be installed in one unit only. Cable joints and/ or terminal boxes
are not permitted. Too short or damaged cables must neither be extended nor being repaired but have
to be replaced.
Dimensioning of cables shall be done according to the maximum power consumption of the connected
device respectively of the connected system under consideration of the cable length and including a
reserve capacity of at least 20%. The voltage drop between the low voltage terminals of the transformer
and the connected devices shall not exceed 3% of the nominal voltage during operation with rated
power.
4.8 Mounting of Starters

Separately mounted starters shall be mounted in enclosures according to environmental conditions and
relevant Specification. Panels shall be complete with wire trough, and all necessary fittings, labelling
and, if made of steel, finished with a primer coat and two coats of rust-resistant paint.
4.9 Earthing
4.9.1 General
Equipment requiring earthing by relevant Standards (IEC, IEE Electrical Code, EN, local Standards)
and regulations of Local Electricity Utility shall be earthed accordingly and included in the Work
regardless of whether it has been shown on drawings or called for in these Specifications.
Installations shall be made in accordance with Type of System being installed (e.g. TN-C-S). New
buildings and constructions shall be equipped with a foundation earthing. Galvanized flat or round iron
including suitable accessories in accordance with present-day installation standard shall be used for
installation in the foundation. In foundations the earthing iron shall be connected to the reinforcement
in a regular distance of at least 2 meters. Connection flags and local equipotential bonding bars shall be
provided wherever switchboards, sub-panels, enclosures, machines, motors or other installations
requiring grounding and/ or local equipotential bonding with electric installations are being installed.
PE-conductors shall be of green- yellow colour coding only and directly grounded.
In principle 10 mm round steel conductor with zinc coating = 50 µm mean value or 30x3,5 mm steel
tape with zinc coating = 70 µm mean value shall be supplied and installed.
The earth resistance shall not be higher than 10 Ohm. Great importance is attached to accurate execution
of works so that the installation permanently withstands the environmental stress and that reliable
protection and system function is guaranteed. All connections between parts of the earthing system must
be low resistive, with a maximal value of 0.2 Ohms. The total earth resistance and the low resistivity of
the connections must be measured and documented in the earthing protocol.
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Arrange earthing system in such a way that under normal operating conditions no injurious amount of
current will flow in any earthing conductor. Single phase loads shall be connected so that there is least
possible unbalance of three phase supply.
Earth lead-ins shall be corrosion protected. The protective coating shall be of bitumen or shrink sleeve.
The protection shall reach for a minimum of 0.3 m above and below the earth point.
Deep driven earth rods shall be made of hot-galvanized steel; they shall be joined together using spigot
and hole. Minimum earth rod length shall be 1500 mm; minimum rod diameter shall be 25 mm. Use
impact tips and driving heads for driving down into hard soils and with the cable clamp.
Connections of components/ conductors made of different materials such as steel or aluminium with
copper require additional measures against corrosion. Use bimetallic connectors or isolating clamps or
inlays made of double metal (copper-plated aluminium sheets or sleeves) according to requirements.
Intermediate lead layers are not permissible.
When bushings for water-proof and press-water-proof duct of walls are being installed, the connections
shall either be welded or clamp connections shall be protected by bitumen coating respectively bitumen
taping.
4.9.2 Foundation Earthing

Foundations shall be equipped with an earthing device. Supply and install either a round galvanised
wire 10 mm² or a galvanised flat iron 30x3,5 mm. Fix the earthing iron vertically inside the
reinforcement and connect it in a regular distance of max. 2 meter to the reinforcement. Connections
shall be made with special connectors and/ or cross clamps suitable for this purpose.
For the connection to an external lightning protection device isolated connection flags type “NYYI 50
mm²” shall be installed. They shall lead closed to the outside wall at least at all four corners of the
building.
The connection to the inside of the building shall be made with fixed earthing terminals.
4.10 Local Equipotential Bonding

All conductive steel parts such as water pipes, metal enclosures, railings and reinforcement shall be
connected to local equipotential bonding bars. Only green-yellow H07V-K (Yf; PVC Insulated Single
Core Wire) cable with a minimum size of 1x6 mm² shall be used. Pipelines, motor- and pump plinth’s
shall be connected with wires of a minimum dimension 1x16mm². The static temperature range shall
be –30°C up to +70°C. The installation including the contacts shall permanently withstand the
environmental conditions. The cables shall be installed throughout in cable conduits or on cable trays.
Cable glands shall be used for cable connections at switchboards or enclosures to ensure the required
degree of protection (IP). Inside the enclosure each wire shall be connected either on a separate terminal
or screwed to the local equipotential bonding bus bar.
Proper earthing shall be provided for bus bar risers, power panel boards, distribution equipment, metal
conduits, conductor enclosures, main neutral bars, non-current carrying metal parts of fixed cabinets,
motors, starters, socket outlets, lighting fittings, power and communication trunking, telephone
equipment, signal equipment and the like. Bond separate equipment sections or items less than 2 m
apart to each other or to a common earth bar with Yf wire ≥10mm².
At completion of installation, tests shall be conducted under consideration of relevant Standards and as
prescribed in Particular Specification. All tests in general shall include polarity, phasing, continuity,
earth loop resistance, voltage tests and empty conduit tests.
Resistance of earth electrodes shall not exceed the maximum permissible values for each type of
installation or equipment concerned. Electrodes shall consist of sectional solid copper rods, with
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concrete inspection box and cast iron cover.
4.11 Lightning Protection

The external lightning protection shall be installed acc. to IEC/ EN 62305. Only new components of
industrial standards with origin from a specialized manufacturer shall be supplied. Equipment and
installation shall be state of the art. Buildings shall be protected against lighting accordingly and
included in the Work regardless of whether it has been shown on drawings or called for in these
Specifications.
Using synthetic lightning protection components in connection with roof covers made of roof
sheeting’s, the material compatibility (long-term endurance) has to be checked with the manufacturer
of the roof cover or with the manufacturer of the lightning protection equipment.
Connections of components/conductors made of different materials such as steel or aluminium with
copper require additional measures against corrosion. Use bimetallic connectors or isolating clamps or
inlays made of double metal (copper-plated aluminium sheets or sleeves) according to requirements.
Intermediate lead layers are not permissible.
Air Termination Rods for protection of roof superstructures, chimneys, etc. and also for installation
with concrete bases shall be supplied and installed. The rods shall be chamfered, suitable for wedged
concrete bases, made of AlMgSI 16mm or St/tZn 16 mm. Use connecting sleeves for connections of
Air Termination Rods.
Use roof bushings for penetrating and sealing flat roofs or gable roofs to install down conductor systems.
Use high-voltage resistant insulating down conductor for keeping the separation distance from
conductive parts to prevent dangerous flashovers among parts of external lightning protection systems
and internal conductive parts (electrical installation, conduits, etc.). Equivalent separation distance s =
0.75 m
The sketches show principal installation standards and techniques. New installations and repair works
shall be made acc. to these installations and to relevant IEC standards.
Principal external lighting protection Arrangement of down conductors in mesh interception net
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Installation dimensions
4.12 Testing
At completion of installation, tests shall be conducted under consideration of relevant Standards. All
tests in general shall include polarity, phasing, continuity, earth loop resistance, voltage tests and empty
conduit tests.
Megger lighting and power circuits and if resistance to earth is less than 5.0 mega ohm such circuit shall
be considered defective and shall be replaced.
4.13 Underground Ductwork

Standard rigid heavy-wall PVC duct lengths and fittings shall be used wherever applicable. When
cutting is necessary, duct ends shall be cut square and cleanly. Joints shall be made by standard
coupling; ducts entering cable trenches, etc., shall be provided with end bells.
Ducts shall be thoroughly swabbed and cleaned by pulling through a cloth swab or large enough size to
properly clean ducts, and shall be capped or plugged at both ends immediately after cleaning, to prevent
entrance of foreign materials.
4.14 Lighting
4.14.1 General
The lighting system shall be designed and installed to comply at least to the following criteria:
• Minimal illumination intensity must be adequate for the particular use of the area, as e.g.:
• 200 lx in large machine halls, storage rooms, etc.
• 300 lx in operation rooms
• 500 lx in control rooms, offices, etc.
• The luminous colour shall adequate for the particular use of the area. For standard working
applications 4000 K or higher shall be used.
Fittings housing, frame or canopy shall provide a suitable cover for the fixture opening. Fittings shall
be installed at mounting heights.
Fittings located on the exterior of the building shall be installed with non-ferrous metal screws finished
to match the fittings.
Fittings and/ or fitting outlet boxes shall be provided with hangers to adequately support the complete
weight of the fitting.
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Flush mounted recessed fittings shall be suitable for the type of false ceilings used, and shall be installed
so as to completely eliminate leakage within the fitting and between the fitting and adjacent finished
surface.
Pendant fittings within the same room or area shall be installed plumb and at a uniform height from the
finished floor. Adjustment of height shall be made during installation. Fittings shall bear the
manufacturer's name. Lighting fittings employing tungsten filament lamps and having metal back plates
shall not be fixed direct to boxes of thermo plastic material. Only metal boxes shall be used in such
situations. Heat resistant type lamp holders shall be used with flexible cords and enclosed type lighting
fittings regardless of the lamp cap position, i.e. cap-up or cap down.
Lamp holders incorporated in weatherproof fittings shall be porcelain or brass. Fittings installed
externally shall be weatherproof and insect proof in general and shall conform to the specific IP ratings
mentioned in the particular cases.
Fittings installed in damp locations shall be totally enclosed and shall prevent the ingress of moisture.
Fluorescent fittings shall contain all associated control gear within the fitting. All metal fittings or metal
parts of fittings shall be effectively earthed. Fittings installed in positions subject to vibration shall be
of the antivibration type.
Recessed fittings shall be constructed so as to fit into tile suspended false ceilings, tile fixed to ceilings
or other suspended false ceilings or plastered ceilings without distorting either the fitting or the ceiling
and including all necessary labour for cutting and making good.
Fittings with hinged diffuser doors shall be provided with spring clips or other retaining devices to
prevent the diffuser from moving and the diffuser shall remain hanging, during relamping and
maintenance.
4.14.2 Fluorescent Fittings

Wherever a fluorescent lighting fitting is located over an expansion joint, one end of the fitting shall be
free to move or slide. Recessed fittings shall be constructed so that all components are replaceable
without removing housing from the ceiling. Consider the use of 22W, 220V AC LED energy saver
Fluorescent tubes.
Surface mounted fittings longer than 600mm shall have one additional point of support besides the
outlet box fitting stud when installed individually.
4.14.3 Incandescent Fittings

Incandescent fittings shall be equipped with porcelain, medium lamp holder, bayonet type lamp holders
for lamps up to and including 150 watts and right hand screws type lamp holders for lamps 200 watts
and above. Replacing the lamp shall be possible without having to remove the fittings from its place.
4.14.4 Lamps
4.14.4.1 General
In general LV halogen lamps shall have individual or groups, step down transformers of dimmable or
non- dimmable and magnetic type as shown on the drawings. The step down transformers shall conform
to relevant IEC Standards and marked in protective enclosures. Lamps shall be furnished and installed
in all lighting fittings furnished under this contract. Lamps used for temporary lighting service shall not
be used in the final lamping of fittings.
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4.14.4.2 Fluorescent Tubes
Lamps shall be of type, wattage and colour rendering index as herein specified unless otherwise
indicated on drawings. All fluorescent lighting luminaires shall be provided with capacitors to give P.F.
in excess of 0.9 lagging. Capacitors shall comply with relevant IEC Standards.
4.14.4.3 LED and Incandescent Lamps

LED lamps must provide sufficient lumen for the particular application. The LED lamps must be
replaceable by lamps of the same connection type. LED fittings/lamps, with a non-replaceable lamp,
need a particular approval of the Consultant prior to installation.
Lighting fittings shall be installed accurately in line and level. Fittings shall be left clean, free from dirt,
grease, fingerprints, etc.
4.15 Ultrasonic sensor and Grid - Installation and Commissioning

The ultrasonic sensor and the Grid machine on the distribution chamber will have to conform to the
specified standards EN ISO 13849-1, Category 3 PL d
It is under the responsibility of the contractor to ensure by suitable measures that the plants are entirety
installed correctly and operating to the set of standards.
4.16 Wire and Cable

4.16.1 General
Abbreviations key for wires according to DIN VDE standards or harmonized CENELEC HD standards.
All wires and cables must be type tested, approved and marked with the according CE label in
compliance with EN 50575 and EN 13501-6 regarding their smoke production (s), flaming droplets (d)
and acidity (a).
Wires installed outside of switchboards and enclosures shall be minimum size 1.5 mm2 single core
unless shown otherwise. All conductors shall be stranded soft annealed copper of high purity with PVC,
insulation. Notice particular specifications for wires and cables. No aluminium conductors shall be used.
Conductors for lighting fixtures and wiring through fixture channels shall be stranded copper with heat
resisting insulation and glass braid or equivalent type approved for such duty, minimum 300/ 500 V
nominal voltage.
MICC cable shall consist of copper conductors, mineral insulation and double copper sheath and shall
be complete with manufacturer's approved seals, gland and fittings. Follow manufacturer's instructions
on cable installation and terminations. Use MICC cable for fire alarm circuits and any other essential
services subject to fire or explosion hazard.
Single core cables shall have non-ferrous armour.
Single core cable shall be supported by non-ferrous clips.
4.16.2 NYM (PVC sheathed wire)

Solid or stranded copper conductor, core insulation of PVC, cores are stranded, common core covering,
PVC outer sheath.
The cables are suitable for use in, on and under the plaster, in dry, wet and damp rooms, as well as in
brickwork. Not accepted for laying directly in concrete, earth or outdoor without additional mechanical
protection.
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Nominal voltage Uo/U: 300/500 V. Approval: VDE 0250 part 204. Specific insulation resistance: 20
MOhm x km. Conformity to EEC directive 73/23 (Low Voltage Directive) CE. Temperature range after
installation: -20°C up to +70°C. Test voltage: 4 kV. Core identic code in acc. to VDE 0293.
4.16.3 YMS (PVC Sheathed Wire)

Adapted to DIN EN
Construction: Fine-stranded bare copper conductor. Cores are insulated with PVC and stranded.
Reinforced outer sheath of PVC.
Application: For middle mechanical stress in dry and humid locations as well as outdoors, not in earth.
Temperature range: -5°C till +70°C. Nominal voltage 600/1000V.
4.16.4 NYY (PVC Insulated Single - or Multicore Cable)

According to DIN VDE 0276-603.
Nominal voltage 0.6/ 1.0 kV. Single or multiple conductor of plain or stranded copper, PVC core
insulation, cores twisted concentrically, various core colours, common core sheathing, outer sheath of
PVC, standard colour black, flammability acc. to EN 60332-1-2. Temperature range after
installation:
-20°C up to +70°C. Test voltage: 4 kV
Application: Suitable for fixed installations, preferably in cable ducts, indoors, outdoors, in water or
underground if no mechanical damage is to be expected.
4.16.5 H05VVC4V5-K (PVC Control Cable with Copper Braiding)

According to DIN VDE 0281-13.
Construction: Fine stranded bare copper conductors, core insulation of soft PVC, compound type Y2,
one green-yellow core. All other cores are black with consecutive white numbers. Cores are stranded
in layers with adjusted twisting. Inner sheath of soft PVC, compound type YM2. Braiding of tinned
copper wires, outer sheath of soft oil resistant PVC, compound type YM2 according to VDE 0207 part
5.
Application: Suitable for dry, damp and wet locations, but not in the open air. It is used as a screened
termination and connection cable in the control, measuring and signal technology. Temperature range
for fixed installation: -20°C till +70°C.
4.16.6 YSLCY (PVC Control Cable with Copper Braiding)

Adapted to DIN VDE 0281.
Construction: Fine stranded bare copper conductors, core insulation of PVC. One green-yellow core in
the outside layer. All other cores are black with consecutive white numbers (starting with 1 inside).
Cores are stranded in layers and wrapped in a plastic foil. Braiding of oxidation protected tinned copper
round wires. PVC outer sheath. Increased oil resistant and flame-retardant.
Application: Suitable as a signal and impulse cable in the control, measuring and signal technology for
intrinsically safe circuits. The copper braiding optimizes protection against external interferences, like
electromagnetic fields and stray frequencies.
Nominal voltage Uo/U: 300/ 500 V. Temperature range for fixed installation: -20°C till +70°C. Specific
insulation resistance: 20 GOhm x cm. Test voltage: 2 kV.
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4.16.7 YSLYQY (PVC Control Cable with Steel Wire Braiding)

Adapted to DIN VDE 0281.
Construction: Fine stranded bare copper conductors, core insulation of PVC. One green-yellow core in
the outside layer. All other cores are black with consecutive white numbers (starting with 1 inside).
Cores are stranded in layers, inner sheath of PVC, Braiding of galvanised steel wires, PVC outer sheath,
increased oil resistant, transparent.
Application: Suitable as a power and control cable with increased mechanical stress-resistance for rough
operating conditions. Temperature range for fixed installation: -20°C till +70°C. Nominal voltage 300/
500 V.
4.16.8 H07V-U (Ye), H07V-R (Ym) (PVC Insulated Single Core Wire)
According to DIN VDE 0281-3
Construction: Solid or stranded copper bar conductor. Core insulation made of PVC.
Application: For indoor fixed installations in dry locations in switchboards and distributors, installed in
surface mounted or embedded conduits or directly on suitable insulated objects. Temperature range for
fixed installation: -5°C till +70°C. Nominal voltage 450/ 750 V.
4.16.9 H07RN-F (GMSuö), Rubber sheathed cable

Construction: Fine-stranded bare copper conductor, conductor insulation made of EPR rubber, cores
are stranded for the multicore types, outer sheath of polychloroprene compound (EM2), black, abrasion
and oil resistant, flame retardant.
Application: For general use in dry, humid and wet locations, for outdoor use or in locations subject to
explosion hazards. For fixed installations in temporary buildings as well as for connections of mobile
machines or tools for medium-level mechanical stress.
4.16.10 NSSHöu, Rubber sheathed cable for high mechanical stress

Construction: Fine-stranded tinned copper conductor, conductor insulation made of EPR rubber, cores
are stranded for the multicore types, inner sheath of rubber, outer sheath of polychloroprene (CR),
yellow, abrasion and oil resistant, flame retardant.
Application: For extreme mechanical stress in dry and humid locations as well as for outdoor use. For
connection of heavy equipment, for mines und industrial use.
4.16.11 SLCM, PVC Composite Connection Cable with Copper Braiding

According to DIN EN 60228.
Construction: fine-stranded bare copper conductors, core insulation of PVC, cores are stranded in
layers, PVC inner sheath, a screen of tinned copper braiding, PVC outer sheath, grey or black, increased
oil resistant.
Application: For fixed installations and for flexible use e.g. in machine and plant engineering for
medium- level mechanical stress in dry, damp and wet locations. With the copper braiding electrical
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and magnetic interferences exerted on other cables and wires or adjacent electric components are
effectively suppressed. They are especially suitable as supply cables between frequency converters and
motors.
4.17 Cable Trenches

4.17.1 General
Notice: In general, National Standards for cable trenches and cable installations are to be obeyed. As
far as the National Standards do not require different solutions, the sketches and referring data and
instructions as shown in this chapter of the Specifications are to be considered as standard solutions.
Notice, that the crossing of roads, rail roads or other infrastructure installations, may – beside other
measures - require a different depth of the trench, or sleeves usually at a depth of not less than 1000mm.
4.17.2 Protective Cable Conduit

4.17.2.1 For Underground Installation in Trench
Flexible twin walled cable conduit made from High Density Polyethylene (HD-PE) acc. to EN 50086.
The construction shall offer high flexibility and compression strength. The plain inner surface reduces
friction when drawing the cable. The conduit shall provide a high degree of shock resistance, even at
low temperatures. Static temperature range: -20°C up to +100°C. Only approved and suitable fittings
shall be used to connect the cable ducting. The fittings shall be water- and sand tight.
4.17.2.2 For On-Surface Installation in Buildings/ on Outdoor Walls

Inside the building power and control cables shall be installed on surface throughout inside a cable
conduit wherever they are not installed in cable trays.
Specifications: Flexible PVC-corrugated pliable conduit for heavy gauge (750 N) to IEC 61386
– EN 3341. Temperature range: -20°C up to +60°C. Only approved and suitable fittings and clips for
installation on surface shall be used. The fittings shall be water- and sand tight. For connection to the
switchboards PVC pliable conduit glands shall be used. The conduits shall be to IP 54. The protective
cable conduits shall be marked in a regular distance of 3 meter by use of water and UV resistant markers.
4.17.2.3 For Under-Surface Installation

Conduits embedded in walls and floor slabs shall be in high impact PVC.
4.17.3 Cable Cover Plates

Made from High Impact Resistant PVC resp. Polyethylene. The cover plates shall be provided with
interlocking fasteners which allow simple and effective connections on site. Temperature rating: -5 °C
to
+60°C. Min. width: 200 mm, Min. thickness: 1.8 mm.
4.17.4 PVC Underground Warning Tape

Flexible polyethylene twin walled high density polyethylene tape for underground installation. Suitable
for identification and warning of a potential hazard of underground services during excavation works.
Temperature range: -40°C up to +75°C; min. width: 35 mm; min. thickness: 0.40 mm.
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4.18 Local Devices

4.18.1 Outlets
Each light, switch, wall or floor receptacle (socket) or other outlet shall be provided with an outlet box.
Outlets and local devices used in this installation shall conform with the following requirements.
All outlet and junction boxes shall be complete with an earthing terminal.
All boxes shall be minimum 75mm square or round boxes used for attachment of fittings; they shall be
complete with fittings stud or clamp if required to support safely the weight of the light fittings. Where
the fitting weight is excessive for such devices, provide plates or channels fastened to ceiling structure.
Larger or extra deep boxes shall be used where required to accommodate the wiring and devices
contained therein without strain or crowding. Using suitable system boxes where several switches are
ganged and 2-gang boxes for twin socket outlets.
Notice particular specification for boxes. PVC boxes shall be equipped with metallic screw inserts and
stainless steel cover screws.
4.18.2 Raceways
Cable trays and ladders shall be of heavy duty galvanized steel or heavy duty GRC complete with
fittings, accessories and supports. They shall be of “lay-in” type. Trays will be manufactured with a
longitudinal T welded safety edge along the top edges. The tray shall be manufactured from steel wires,
welded together and bent into a final U-shape. Straight sections shall be provided in at least 3000 mm
length. The cable tray shall be electroplated with at least 12 microns of zinc. The cable tray internal
depth shall be 50 mm +/- 10 mm.
Trays made of steel wires shall be made with a minimum wire diameter of 4.5 mm for widths from 50
to 200 mm and 5 mm from 300 to 450 mm. Trays shall be constructed with a mesh configuration not
wider than 50 mm x 100 mm. All tray fittings (bends, risers, tees, crosses, reducers, etc.) shall be
constructed on- site using side action bolt croppers and fastened using 25 mm and 30 mm counter
clamps with bolts and nuts, all surfaces shall be treated as noted above.
Trays will be coupled together using either fast spring couplers or counter clamp with bolt and nut
combination with supporting fishplate if necessary, all surfaces shall be treated as noted above.
Trays shall be supported at 6-foot intervals by either trapeze, wall, floor or pendant mounting methods.
All welds will be manufactured to a tensile strength of 700 kg per weld.
Metal separator shall be installed on the trays between power and control/telecommunication cables.
4.18.3 Conduits
Conduits shall be rigid heavy wall type, of high impact PVC. Minimum internal diameter shall be 20
mm. Provide draw wires in all empty conduits.
4.18.4 Pull and Junction Bores

Indoor pull and junction boxes shall be of PVC only, complete with screw-on cover and conductor
terminals. Pull boxes shall have a minimum length of 8 times the diameter of the largest conduit entering
the box.
4.18.5 Outdoor Enclosure

Enclosure made of weather and impact resistant PVC or 2 mm aluminium/zinc sheets, E-coat primed,
powder painted. Frame made of PVC or stainless 135steel. Protection class IP55 or higher. Enclosure
__________________________________________________________________________________
equipped with one PVC-mounting plate inside. All metal parts shall be connected to Local Equipotential
Bonding. Enclosures tested in accordance with DIN IEC 60068, and IEC 60721. Connection value acc.
to nominal data of connected load. Consider also transformer overload capacity. Mains voltage
230/400V, 50 Hz. Cable inlets only from bottom or backside. Cable glands made for exterior purposes,
corrosion free, weather and impact resistant. Casing equipped with a PVC-mounting plate inside.
4.18.6 Sockets
Nominal data: 16 A/ 250 V AC, IP55.
Socket types acc. to the national standards, or to DIN VDE (Schuko type). Single or twin type as shown
on drawings. Protection against electric shock to IEC 536: Finger and back-of-hand proof. Type of
protection: IP X1
CEE 16A, 32A or 64A/400V AC, 5 pins, IP44, colour red. Socket types acc. to the national standards,
or to DIN VDE (CEE type). Protection against electric shock to IEC 536: Finger and back-of-hand
proof. Type of protection: IP X1
13 A, 250 V AC twin socket (MK, T & J, or CrabTree Types) Socket types acc. to the national standards,
or to DIN VDE (CEE type). Protection against electric shock to IEC 536: Finger and back-of-hand
proof. Type of protection: IP X1
Cover plates for weatherproof outlets and devices shall be die cast aluminium with stainless steel
fastenings of equivalent non-corrosive materials, with spring-loaded covers where applicable.
4.18.7 Light Switches and Dimmer

Light switches shall be rated at 250V, 10A and shall be single pole 1, 2, or 3 gang 2-way, intermediate
or DP as shown on drawings and as required for proper operating of switched circuits. Switches shall
be designed to safely carry inductive and resistive lighting loads up to their full ratings. All light
switches shall be flush mounted to the wall.
Dimmer switch shall be full solid state, with rotary dia permitting smooth control from full brightness
to complete "off" position, shall be equipped with RFI (radio frequency interference) filter to prevent
interference with radio, TV or telephone circuits. Minimum load capacity 50% above connected
nominal load.
4.18.8 Disconnects
Disconnect switches shall be kW-rated, quick-make, quick-break, with handle interlocked so that switch
door cannot be opened unless switch is in de-energized position. Switches shall be heavy duty, having
visible blade constructions and silver plated current carrying parts. Rating and number of poles shall
acc. to requirements. Provision shall be made for padlocking switch to "OFF" position. Where no rating
is shown, they shall be sized as per manufacturer's recommendations for the load of the circuit. All
enclosures shall be dust-tight and corrosion-resistant, rated for site conditions.
4.18.9 Miscellaneous Equipment

Control circuit relays shall be with dust-tight enclosure where mounted individually. Relays shall be
robust construction heavy duty for long life, silver to silver contacts and shall have contact
arrangements, time delay and current rating to suit control requirements.
Individually mounted control stations shall be complete with dust-tight enclosure and shall have
engraved laminated rigid plastic nameplate to designate services. Push buttons and selector switches
shall be double break silver contact unitized type,
136having readily interchangeable operators, contact
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blocks and legend plates. Pilot lights shall be provided as required and shown on drawings. In finished
areas control station shall be flush mounted.
Starters shall be housed in industrial dust-tight enclosures or grouped in motor control centres as shown.
Starters for certain items of equipment will be provided as part of the equipment assembly, as identified
in drawings and described in Particular Specification section.
4.19 Switchboards, Sub-panels and Sub-main Distribution Boards

4.19.1 General
Distribution boards shall be factory assembled and conform to relevant IEC Standards. Distribution
boards shall be rated for 400 V AC service and current rating according to connected load including a
reserve capacity of at least 30%. The main switchboard shall be constructed for safe, proper and reliable
operation. The design and arrangement details of the equipment shall be to the approval of the
Consultant. The switchboards shall consist of vertical sections joined together to form a free standing
cubical, rigid, floor fixing assembly which is extendable at either ends. The design and construction of
the switchboard shall be indoor floor type distributor and be of the size, rating and arrangement in
accordance with Particular Specification and be manufactured in accordance with Standards as given
in the table below. The cabling wells shall be provided with separate gland plates.
Cubicle covers shall be fitted with a hinged cover, to shroud all live parts, and be secured by thumb
screws.
Each board shall be fitted with a solid removable neutral link for isolation and an earth bar assembly.
TN- C-S-Type of System shall be installed, if not specified or required differently.
The arrangement of the equipment within the assemblies shall be such as to afford maximum
accessibility to all parts, incoming and outgoing cables and bust ducts.
The switchboard shall be equipped with finger proof terminals for all incoming and outgoing
connections. Terminals for signal and command circuits shall be separated from power circuits and
clearly marked as such. Terminals for signals and commands shall be equipped with disconnecting
links. Consider the following terminal-colouring:
• Phases L1, L2, L3: (Red, Yellow or Blue)
• Neutral: Black
• Earth: Green/Yellow
• Signals and commands: Grey
The distribution boards shall incorporate a fully fault rated, horizontal mounting Din-rail onto which
MCCB's can be mounted. The mounting of MCCB's will enable easy rearrangement and addition of
branch circuits. Spare ways on the stack shall be closed with blank plates. Minimum spare ways per
board shall be 20%. All plug on MCCB's shall be 230/400V AC, 50 Hz to relevant IEC rating. A sample
of the MCCB shall be submitted to the Consultant for approval. A full directory frame shall be fixed to
the inside of the door.
Table 4.1 – Switchboard distribution

■ Low voltage power distribution
Panels suitable for ■ High current bus-bar distributor
■ Control panel
Material of frame and add-on pieces
Sheet metal
Mounting boards galvanised and varnish coated steel plate ≥ 2,5 mm
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Protective coating of frame and add- ■ Priming colour
on pieces ■ Powder coating
Colour RAL according to specifications; otherwise RAL 7035
Degree of protection Min. IP 54 according to IEC 60529
Protection class I
Protection against direct contact Protection of all live parts against direct contact by insulation
Protective Measures of installed TN-C-S Type of System (notice Part. Spec.)

electrical system
Nominal voltage According to nominal voltage of installed energy and control
systems
Nominal insulation voltage Ui = 1.000V
AC testing voltage 3,5 kV
Inside measurements According to requirements incl. 20% reserve space per panel
Mounting options for built-in devices 35 mm standard size fixing bar
Doors Fixed on hinges; opening according to conditions in control room
Door lock Prepared for assembling with profile cylinder lock

■ For all incoming and outgoing cables through cable glands and
Cable entries over strain relief clamps
■ Numbered terminal blocks
Height in accordance to bending radius of cables and depth of cable

Pedestal duct under the switchboard
Depot for drawings One depot per panel door for drawings DIN A 4
Four pieces per panel; only required for transport and installation
Eye-bolts at site
Separate cable ducts and routing of energy, control and extra low-
Cable and wire routing voltage cables
Panel lighting One fluorescent lamp per panel; controlled by door positioning
switch
■ Earthing of frame and all add-on parts

Protective measures ■ Shock hazard protection of bus-bar, terminals and all electric
components
■ Proof according to IEC 60439-1 for:
■ Mechanical and thermal short circuit withstand
Short circuit withstand ■ Nominal current and temperature rise at nominal load
■ Power dissipation
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■ Material: E-CU; size according to requirements
■ Shock hazard protection
■ Rated-short-time current (1s) up to 50 kA
■ Rated peak withstand current (1s) up to 150 kA
Bus bar ■ Rated-short-time current of distribution bus-bar (1s) up to 30 kA
■ 3 or 5-conductor system (TN-C-S-Type of System)
■ Bus bar shroud in accordance with VBG4
■ Protection against direct contact
■ Type-tested to IEC 60 439-1, EN 60 439-1
Marking of electrical equipment in accordance with IEC 81346
Delivery to place of installation Tested, ready for connection
4.19.2 Installations inside Switchboards, Enclosures and Distribution Boxes

Wires, cables and other devices such as fuses, relays, contactors, switches, terminals, etc., shall be
marked accordingly. Terminals with universal foot for mounting on standard mounting rails shall be
used for all ingoing and outgoing cables and wires. Installations inside the enclosure shall provide
protection in accordance to IP 32 or higher. The terminals shall be equipped with approved and suitable
bridging material. End terminals shall be equipped with end plates. Phases, Neutral and Earth terminals
shall be separated by partition plates for visual and electrical separation. The exact terminal dimension
for the connected core shall be selected. Phase terminals shall be grey, terminals for Neutral shall be
blue, terminals for Earth shall be green-yellow. All appliances such as terminals and fuses shall be
mounted on mounting rails to EN 50022. Terminals for signal and command circuits shall be separated
from power circuits and clearly marked as such.
4.19.3 Low Voltage HBC Fuse Switch Disconnector

Applicable for single and three phases. Standards: IEC/EN 60 947.
Climatic proofing: Damp heat, constant to IEC 60 068-2-3. Damp heat, cyclical to IEC 60 068-2-30.
Ambient temperature: Min./Max. –25°C to +55°C. Altitude: up to 2000 masl. Mounting position:
Vertical, horizontal. Overvoltage category: III. Pollution degree: 3. Degree of protection from the front:
Operational state IP 20; front cover open IP10. Mechanical lifespan (operations): 1.700.
Rated operational voltage of contacts: 500/690V AC. Rated operational current: acc. to connected load.
Rated frequency: 40-60 Hz. Rated conditional short circuit current AC: 50 kA rms. Rated insulation
voltage of contacts: 750V AC.
4.19.4 Circuit Breaker

Circuit breaker must be built and tested to IEC/EN 60947 and/or VDE 0660.
The tripping characteristics of the circuit breaker must be in accordance with the operating
characteristics of the connected application. All characteristics and standards must be guaranteed for
the given altitude (m.a.s.l.) of the operating location.
Protective functions:
• 3-pole circuit breaker with protection characteristics of connected device (transformer, motor,
etc.)
• Short circuit protection
• Overload protection
• Earth-fault protection (if specified in Part. Spec.)
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• Differential indication of tripping due to overload, earth-fault or short circuit

• Main switch and isolating characteristics to IEC 947 and IEC 204
• Setting range of overload and short circuit releases in accordance with requirements of start- and
operational conditions of connected device
• Main switch characteristics including positive contact opening to IEC 204
• Isolating characteristics to IEC 408, over-dimensioned contact separation
• Quick-make, quick-break, irrespective of the actuating speed
• Clear indication of operating state
• Three switch positions: OFF / TRIPPED / ON
• Switching capacity independent of overload range, supply direction or enclosure
• Lifespan data valid without maintenance or changing of contacts, even as motor starter
• High tripping accuracy through long-term calibration
• Motor switching capacity AC-3 up to 660V to IEC 947
• Rated insulation voltage Ui = 1.000 V, insulation group C to VDE 0110
• Finger- and back-of hand proof to IEC 536
• Climatic proofing: Damp heat, constant, to IEC 60 068-2-3;
damp heat, cyclic, to IEC 60 068-2-30
• Rated uninterrupted current: in accordance with selected motor and frequency inverter
• Minimum rated switching capacity 65 kA
• All circuit breaker shall be equipped with trip indicating auxiliary contacts
• Each breaker shall incorporate an electronic trip indicator on its front face.
• All MCCB's installed in main panels shall be fitted in principle with auxiliary contacts for remote
indication.
4.19.5 Meter
4.19.5.1 General
kWh-and kVArh-meters shall be supplied and installed according to the following specification, if not
specified differently by the responsible Local Electricity Utility.
4.19.5.2 Specification for kWh-Meter

• Three phase, four wire
• for unbalanced load
• Nominal voltage: 230/400 V, 50 Hz
• Class 2 (if no higher class specified by Electricity Utility; e.g. class 1)
• Protection IP 40
4.19.5.3 Specification for kVArh-Meter

• Three phase, four wire
• for unbalanced load
• Nominal voltage: 230/ 400 V, 50 Hz
• Class 2 (if no higher class specified by Electricity Utility; e.g. class 1)
• Protection IP 40
4.19.5.4 kWh-Transducer Metering

Considered to be included with terminals with test and disconnection function. Accuracy of transducer
shall be to requirements of Local Electricity Utility.
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4.19.6 Mains Protection of Equipment

Co-ordinated lightning and surge protective system for power supply-, signal and control circuits. The
contractor shall provide a concept prior to supply of the necessary equipment. The provided system
shall consist of harmonized lightning current arresters, which are responsible for the conducting of high
energies without damage, and surge arrester protecting the terminal equipment. Lightning current
arresters have to be installed as close as possible to the service entrance of the electrical system and
surge arresters as close as possible to the equipment to be protected.
For the power supply, the potential short-circuits currents have to be taken into consideration. The
lightning current arrester must safely disconnect prospective short-circuit currents of up to 25 kA and
protect the employed back-up fuses against damage at the same time.
4.19.6.1 Lightning Arrester Class B

Class B arrester for the integration of power lines in lightning protection equipotential bonding systems,
for the protection of low voltage consumer's installations against surges, even at direct lightning strikes.
Applicable for the protection of installations and equipment of Overvoltage Categories I to IV. SPD
Class I according to IEC/ EN 61643- 11.
• Encapsulated, non-exhausting creepage discharge spark gap,
• Energy-coordinated with surge arresters, Class II and III directly with terminal units in
Overvoltage Category I at UN = 230 V ac
• Low voltage protection level
• Terminals for conductors and bus bars
• Nominal voltage: 230/400V AC
• Temperature range: -25°C up to +75°C
• Protection type to IEC 60529/EN 60529: IP 20
4.19.6.2 Surge Arrester Class C

Class C surge arresters for the use in the Lightning Protection Zones Concept at the boundaries of LPZ
0B – 1 and more. For the protection of low voltage consumer's installations against surges (Overvoltage
Category III according to DIN VDE 0110-1). SPD Class II according to IEC/EN 61643- 11.
• Energy coordination possible with upstream lightning current arresters
• High discharge capacity
• Fault indication by mark in the inspection window
• Terminals for conductors and bus bars
• Nominal voltage: 230/400V AC
• Temperature range: -25°C up to +75°C
• Protection type to IEC 60529/EN 60529: IP 20
4.19.7 Main Switch

Function: Main switch. It is used as ON-OFF switch to connect/ disconnect all three phases of the main
power supply. The switch is dimensioned according to the actual nominal power of the connected
installations including a reserve capacity of at least 50%. Nominal voltage is 230/ 400 V. The main
switch is equipped with a front plate showing clearly the positions ON and OFF. Protection against
electric shock to IEC/ EN 61140: Finger and back-of-hand proof. Degree of protection shall be IP 65.
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4.19.8 Miniature Circuit Breaker
The miniature circuit breaker shall comply with the following minimum requirements:
• Characteristics: B or C acc. to requirements
• Standard: IEC/EN 60 898
• Protection against electric shock to IEC/EN 61140. Finger and back-of-hand proof
• Degree of protection (terminals): IP 20
• Switching capacity to IEC/EN 60 898: 10 kA
• Nominal voltage of single phase MCB: 230 V AC
• Nominal voltage of three phase MCB: 230/400 V AC
4.19.9 Residual Current Device

The residual current device shall comply with the following minimum requirements:
• Standard: IEC/EN 61 008
• Protection against electric shock to IEC/EN 61140. Finger and back-of-hand proof
• Degree of protection (terminals): IP 40
• Ambient temperature: Min./Max.: -25°C - +40 °C
• Rated operational voltage: 230/400 V AC
• Rated uninterrupted current: acc. to requirements
• Rated fault current: 0.03 A for installations in damp environment, bathrooms, private rooms and
kitchen.
• Tripping time: 200 ms
4.20 Mains Decoupling Relay

The mains decoupling relay is used for independent 3-phase voltage and frequency supervision of the
power supply from the public grid. The relay is used for the control system of an Emergency Generator.
Required design standards are IEC 60947-5-1. If the measuring voltage drops below 70% Un,
supervision of the frequency is blocked. The relay must be equipped with a test push button for test
tripping of the unit. Switching hysteresis can be set to the required value for the proposed use.
• Rated Frequency range of measuring input circuit: nominal frequency (50Hz) 20%
• Minimum response time: 50 ms
• Two output relays; one changeover contact for each trip relay
• Temperature range: -25°C to +50°C
• Constant climate class F according to IEC 68: more than 56 days at 40°C and 95% relative
humidity
• Electrical fast transient acc. to IEC 801: 4kV/2.5 kHz, 15 ms
• Repeat accuracy: 1%
4.21 Programmable Control Relay

The relay shall provide electronic “wiring” by keystroke. It shall be equipped with an LCD (minimum
4 lines of 12 characters) and a keypad. In parallel programming via software from PC shall be enabled.
The relay shall provide a zero-voltage safe internal and external circuit configuration storage in
EEPROM memory.
Moreover, the relay shall provide the following features and standards:
• Temperature range –25°C to +55°C
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• Integral password protection for circuit configuration and relay value pre-sets
• Current flow display for circuit configuration testing
• Selection option from at least the following languages: English, German, French
• Integrated timing relays, including delay functions
• Integrated up- and down- counter relays
• Integrated timers
• Integrated analogue value comparators
• Separate or integrated LCD-display
• At least 16 auxiliary relays
• Integrated interface for network connection with other relays of same type
• Integrated interface for connection to a PC
• Degree of protection ≥IP 20
• Accuracy of timing relays +/- 1%
• Resolution in range “seconds”: 10 ms
• Resolution of analogue and digital signals: 0.1V
• Bit-resolution: 10
• Accuracy of actual value: +/- 2%
4.22 24V DC Power Supply Unit

The 24V DC power supply unit shall comply with the following minimum requirements:
• Type: Compact primary switched-mode power supply unit
• Approved for industrial use
• Suitable for supplying power to electrical and electronic components as to be provided and
operated
• Installation on 35mm mounting rail inside of enclosures and switchboards
• Input voltage: 230V AC
• Permitted voltage operation range: 187 – 264V AC
• Frequency range: 47 to 63 Hz
• Equipped with one input fuse
• Input and output equipped with surge voltage protection (e.g. varistor)
• Nominal output voltage: 24V DC
• Tolerance: +/- 3%
• Nominal output current: according to connected load including reserve capacity of 30%
• Function display via LED
• Efficiency >85%
• Limiting of line current harmonics to EN 61000-3-2
• Ambient operation temperature: 0°C….+45°C
• Permitted humidity: up to 95% at 25°C
• Electrical safety acc. to EN 60950/VDE 0805
• Electromagnetic compatibility (EMC) in conformance with EMC directive 89/336/EEC
• Ripple <100mV
• Emitted interference: EN 50 081-1
• Type of protection ≥ IP20
• Class of protection: I
• MTBF > 500 000 hours
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4.23 Data Logger

The data logger shall comply with the following minimum requirements:
• Accuracy: +/- 1%
• Power supply: 24V DC
• Minimum four analogue 4-20 mA inputs
• Minimum eight digital common point inputs
• Memory capacity: >60.000 readings
• Recording interval: 1 second to 60 minutes (on configuration)
• Starting recording on Programmed date and time
• Stop on memory full or alternatively overwrite oldest records
• Possible to download while still recording
• Real time clock
• Interface to PC (USB and/or RS 232)
• Ambient operation temperature: -20°C to +50°C
• Software for configuration and data evaluation in English and suitable for PC with Windows XP
and/or Windows Vista Operation System.
• Graphical display
• Statistical calculations
• Export of the data to EXCEL or in CSV format
4.24 Axial Fans

The axial fans shall comply with the following minimum requirements:
• Cased axial fan, cylindrical duct; for direct in-line installation in ducting
• Casing made of galvanised steel
• IP 55 terminal box on outer casing
• Suitable for air flow temperature from –40° to 60°C
• Protection against accidental contact to VDE 0700 and EN 294
• Air flow direction: pulling air over the motor
• The fan shall be equipped with anti-vibration mounts and flexible connectors. Vibration
transmission to building and technical equipment must be avoided.
• motor protection to IP 55
• motor standards to IEC 2J and IEC 61
• motor casing made of aluminium or cast iron, totally enclosed with cooling fins
• motor bearings maintenance free (sealed for life) and dust proof
• full immersion, tropical moisture protection to motor windings, insulation class F
• Motor equipped with thermal contacts
• If condensation is to be expected, the fan must be installed with condensation pores facing
downwards and must be open.
• Fans must be equipped with guards, made of spot welded zinc plated wire mesh
4.25 Power Factor Compensation

The power factor compensation unit shall be of industrial standard. It shall compensate the reactive
electrical energy used by the inductive receivers in order to reach a cos phi >0,90. The unit shall be built
in one separate panel of the switchboard. It shall be dimensioned exactly according to requirements and
provide as follows:
• Reactor-protected automatic capacitor banks in compact design, encapsulated for switchboard
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• contactors for leading load

• three-phase condensers
• overload protection unit
• timer-regulator of adjusting stages with sufficient steps (minimum 4 steps)
• collector bar system for reactive currents
• main switch
4.26 Electric Direct Heating

Nominal power shall be according to Particular Specification. Protection to IP 54; connection and
support construction made of strong profile steel (e.g. type “V2A”); anti-freeze thermostat, adjustable
between – 5°C and +20°C. Including connection boxes and all system-integrated accessories.
4.27 Multi-turn Actuators for OPEN-CLOSE Duty

The multi-turn Actuators for OPEN-CLOSE duty shall comply with the following minimum
requirements:
• Type of duty: short-time S2 -15 min
• Output speeds according to particular requirements (e.g. of 4 to 180 rpm at 50 Hz supply)
• 3-ph AC motor in insulation class F, with motor protection by three thermo-switches placed in
the windings
• Counter gear limit switching for end positions CLOSED/OPEN
• Tripping torque for closing/opening direction adjustable at calibrated torque dial and directly
readable in daNm
• Anti-condensation heater in switch compartment
• Precision potentiometer with reduction gearing for position monitoring
• Hand wheel for manual operation, which does not rotate during motor operation
• Valve attachment according to ISO 5210
• Connection actuator – controls via plug/socket connector
• Reversing contactors mechanically and electrically interlocked
• Four inputs OPEN-STOP-CLOSE-EMERGENCY galvanically isolated via opto-isolator
• Relays for output signals, freely programmable
• Programmable emergency operation function
• Galvanically isolated position feedback signal 0/4...20 mA
• Electronic name plate and logging of operating data
• Controls / local controls can be positioned at every 90°
• Permissible ambient temperature – 25 °C to + 70 °C, enclosure protection IP 67, corrosion
protection KN (suitable for atmosphere with low level of pollution)
• Finish coating: Two-component iron-mica combination, colour: silver-grey (similar to RAL
9007)
4.28 Lighting
4.28.1 Indoor Lighting
4.28.1.1 Twin-lamp moisture-proof diff. Luminary
For all indoor and outdoor applications without exposure to chemicals luminaries acc. to the following
specification shall be selected.
• Moisture-proof diffuser luminary
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• Iluminant: LED tube, e.g. one or two tubes approx. 20 W/ 4,000 lm/ 6,000 K
• LED lamps must provide sufficient lumen for the particular application. The LED illuminant
must be replaceable by illuminants of the same connection type. LED fittings/lamps, with a non-
replaceable lamp, need a particular approval of the Consultant prior to installation.
• Optionally: fluorescent tube (e.g. 2 x 22 W or 1 x 22 W)
• Duo circuit
• Type of protection IP 65
• For T26, low-loss conventional ballast
• Housing made of unbreakable polycarbonate
• One-piece diffuser made of polycarbonate with internal prismatic structure
• Reflector made of galvanised sheet steel, painted in white
• Through-wiring using standard cable shall be possible
• 5-pole push-in terminal
• Installed on ceiling, wall or trunking. Can also be suspended on chain using chain suspension
brackets.
For applications involving exposure to chemicals as well as moisture luminaries acc. to the following
specification shall be selected.
• Moisture-proof diffuser luminaire LED tube, e.g. one or two tubes approx. 20 W/ 4,000 lm/
6,000 K, optionally fluorescent tube 2 x 22W or 1x22W
• Duo circuit
• For T26, low-loss conventional ballast
• Rugged diffuser in conjunction with stainless steel catches shall be used
• Housing made of halogen-free glass-fibre reinforced polyester
• Non-ageing polyurethane foam seal
• Diffuser made of either PMMA or PC with internal prismatic structure
• Installed directly on ceiling or mounting track
• Can be installed on trunking
• Luminary consists of roll-formed reflector made of galvanised sheet steel, painted in white, can
be hinged
• Reflector made of white glass-fibre reinforced polyester
• 5-pole push-in terminal
• Heat stability with PM 650°C, with PC 850°C
4.28.1.2 Louvre Luminaries

Surface – mounted luminary for individual and continuous row installation
Use this type of luminaries in dry and continuous clean rooms only.
Surface mounted luminary with matt or semi-matt optic LED tube, e.g. one or two tubes approx. 20 W/
4,000 lm/ 6,000 K, optionally fluorescent tube 2 x 22 W, duo circuit, for T26, with low-loss
conventional ballast. Surface-mounted housing made of sheet steel white stove-enamelled, with plasma-
welded edges. Bivergent reflector optic made of matt anodized pure aluminium with transverse vanes
curved in V-shape; incl. optic; glare limitation L<1000 cd/m² at 65°. Wired ready to connect.
• Lamp Flux: 5200 lm
• Colour Rendering Index: 1B
• Connected Load: 134W, Lambda 0.99
• Compensation: D
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Surface-mounted luminary with prismatic diffuser

Diffuser luminary for individual installation with prismatic controller, for T26, with low-loss
conventional ballast. Made of sectional sheet steel, white stove-enamelled. Single-piece diffuser,
extruded, in transparent PMMA with prismatic structure for precise direction of light.
Round transparent diffuser luminary

Transparent diffuser luminary, round; protection ≥ IP 65; with high frequency ballast; round housing
made of clear unbreakable transparent polycarbonate with variable cable entry point; Diffuser made of
injection- moulded unbreakable polycarbonate; UV-stabilized with internal prisms, translucent white
reflector; 850°C glow-wire tested; Lamp Flux ≥ 4,000 lm;
4.28.1.3 Emergency Luminary

Ceiling-mounted emergency luminary with separate battery, in non-maintained mode, without
monitoring, with T16 8 watt with 410lm. The light emitted from the underside of the luminaire provides
improved escape route illumination. Polycarbonate housing. Minimum recognition range 25m; test key
integrated in housing; electronic ballast with integral emergency lighting control unit; hot start; deep-
discharge protection; reclosing interlock; NiMh battery;
Voltage: individual battery supply 220/ 240 V AC (local). Temperature range -5°C up to +m45°C.
Luminaire and cover comply with EN 60598-2-22, DIN 4844, EN 1838, VDE 0108. Mini um dimension
300 x 50 x 70 mm. Protection type IP40. Protection class: SC2.
4.28.2 Outdoor Lighting

4.28.2.1 Road Lighting Luminaries
Service friendly LED f lighting luminaries solar powered. Sealed construction resistant to weather and
impact, vandal resistant. UV-resistant polycarbonate refractor bowl. Mounting-module in non-
corrosive, die cast aluminium. Degree of protection IP65.
Luminaries shall be designed for lamps according to Particular Specification.
Starting time of fluorescent lamps shall be maximum one second. From manufacturer guaranteed
average lamp life shall be minimum 10,000 hours. Lamp shall be in accordance with IEC 968 and 969.
4.28.2.2 Lighting Poles

Steel pole, pot-galvanized inside and outside Construction in accordance with EN 402. Provided with
earth connection screw or strap and cable inlet. Poles can be one unit with arm or separately equipped
with arms for luminaries.
4.28.2.3 Pole Arms

Pole arms to be mounted separately on the pole shall be in accordance with the design as shown in the
drawing. The arms shall be made of steel, pot-galvanized inside and outside. Construction in accordance
with EN 40/2.Standard gradient of 15° if not differently required by luminaries. Screws made of
stainless steel.
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4.28.2.4 LED Lamps
High efficiency floodlight LED elements, e.g. 200 W/ 20,000 lm/ 6,000 K
4.28.2.5 Fluorescent Lamps

Starting time of fluorescent lamps shall be maximum one second. From manufacturer guaranteed
average lamp life shall be minimum 10,000 hours. Lamp shall be in accordance with IEC 968 and 969.
4.28.2.6 Low Pressure Sodium Vapour Lamp SOX-E

Low-pressure sodium vapour lamp with a U-shaped discharge tube containing sodium, enclosed in a
vacuum clear tubular outer bulb. Monochromatic yellow colour with non-existent colour rendering.
4.28.2.7 Twilight Switch

In weatherproof casing IP 54; with threaded joint; nominal operation voltage 230V AC; switching
capacity 10A/230V AC; adjustable illumination: ON at appr. 10 lX/OFF at appr.50 lx.
Switching of outdoor lighting shall be optional manually by off-switch and/or automatically by dimmer
switch. Installation of dimmer switch on appropriate location outside of Operation Building.
4.28.2.8 Cabling of Lighting Poles
4.28.3 Power Distributors for Construction Sites

All current distributors provided for construction sites have to comply with IEC/ EN 60439-4/A1. This
means that circuits ≤ 32A have to be operated via fault current protective device (RCD) with IFN=30
mA. All other circuits with plugs and sockets have to be operated as per the already existing regulation,
i.e. via fault current protective devices (RCD) IFN=500 mA.
In addition, the current distributors shall comply with the general technical regulations of the main
power supplier in charge.
Outdoor current distributors shall be equipped with a kWh-meter and sockets 230V and 400V as per
requirement.
All relevant characteristics such as size of the construction site, quantity and kind of machines as well
as their location have to be taken into consideration for a suitable planning of the power supply
equipment on the construction sites. In addition, it is essential to observe the distance between each
single equipment with respect to the lengths of leads and their resulting losses. The determination of
the total power for the construction site, the selection of the adequate distributors and other operating
devices, the coordination of connection requirements with the local current supply company and the
installation of all plant sections as per prevailing standards is under the responsibility of the Contractor
and shall be done only by authorized experts.
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5 GENERAL REQUIREMENTS FOR INSTRUMENTATION,

CONTROL AND AUTOMATION
5.1 Instrumentation
The scope for instrumentation includes supply and installation of all required equipment (sensors,
actors, remote units, auxiliary components and material), testing and documentation. All components
must be integrated into the control and automation system to form one functioning system.
The selected equipment must be proved for heavy industrial use and comply with the relevant
international industrial and IEC standards.
5.2 Control Systems

The control and protective equipment shall be so designed that a safe operation shall be ensured under
every operation condition without any danger to the operators and damage on the units.
5.3 Automation System

All facilities shall be designed and equipped with the required devices to provide monitoring data for
transmission to the Central SCADA System (to be installed in the future). For future use the SCADA
functionality of the facilities must be prepared as well to process remote-control function of the Central
SCADA System.
On the plant level a local control system to operate the facilities (as specified in the Particular
Specifications either in automatic / semi-automatic / manual operation mode) must be designed,
supplied and installed.
The level of automation, e.g. conventional control system, programmable relay, programmable logic
control device (PLC) and/or SCADA system, depends on the size and function/importance of the facility
and must follow the requirements in the Particular Specifications. The required and applied components
must be in accordance with the following specifications.
The system implemented should be able to operate within the control strategy described but shall be
flexible enough to be easily changed in case that the control philosophy would be changed.
5.3.1 PLC Equipment

5.3.1.1 General
Programmable logic control devices, where specified, shall be used for the monitoring and control of
the plant or process.
They shall be capable of operating as either a standalone unit providing local operator interface
information or form part of a supervised system complete with communications facilities.
The PLC shall be a modular unit capable of expansion. It shall support a minimum of 32 input/outputs
but shall be capable of expansion up to 512 I/O.
The PLC shall operate from a nominal power source of either 110 V or 240 V AC 50 Hz and incorporate
its own integral 24 V DC power supply for driving auxiliary modules, or accept an external 24V DC
power supply.
The programmable controller shall have adequate memory and I/O ports to receive all control and
sequencing signals and drive all indicator lamps, relays or solenoids as may be required to accurately
control all the necessary functions of the control system.
The controller shall indicate the operating state of the outputs by means of light emitting diodes
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(L.E.D.s) and be equipped with sets of L.E.D.s to indicate the controller status and to notify of any
internal faults.
An integral means of turning all outputs off and ceasing the processor operation shall be fitted.
The PLC shall perform the majority of sequential functions and shall drive, either directly or by
interposing relays, all the necessary outputs as detailed elsewhere.
Where the output load exceeds the rated capacity of an output port of the controller, suitably rated,
D.I.N. rail mounted interposing relays shall be installed in the cabinet to amplify output controls signals.
The maximum control voltage of the relays shall be 230 V AC.
D.I.N. rail mounted terminals shall be fitted in the bottom of the cabinet to allow the termination of all
control and sequencing cabling. The terminals shall accept up to 4mm2 stranded conductor.
All output ports from the controller shall be correctly fused in order to protect the controller (by means
of fused terminals)
The PLC shall be capable of supporting all the component parts either inherently or via expansion when
required and shall support all the required process I/O.
5.3.1.2 Analogue Input Requirements

The preferred input signal is 4-20mA; continuous; linear supporting a fully floating max 250 ohm input
impedance load. Analogue/Digital conversion shall have a minimum 12 bit resolution, linear to ±1%,
accepting signals in the range 0-10mA and 0-20mA and voltages 1-10V, 0-1V and 0-100mV as
required.
5.3.1.3 Analogue Output Requirements

Analogue output shall be 4 to 20mA D.C. electrical signal with a linear increasing output for increasing
measure and value, complying with the requirements of the actual IEC standards.
When the load resistance across the output terminals is varied from 0 to 1000 ohms the output signal
current shall not change by greater than 0.1% of span, over the full output range.
5.3.2 Programmable Logic Relays (PLR)

The PLR must be selected to meet the requirements of the particular application and the following
specifications:
The relay shall provide electronic “wiring” by keystroke. It shall be equipped with an LCD (minimum
4 lines of 12 characters) and a keypad. In parallel programming via software from PC shall be enabled.
The relay shall provide a zero-voltage safe internal and external circuit configuration storage in
EEPROM memory.
Moreover, the relay shall provide the following features and standards:
• Only one type of programmable control relays from the same manufacturer shall be provided.
• Relays and connected local and external expansions shall be dimensioned with a minimum
reserve of at least 30% reserve capacity of the required input/output signals capacity, if not
specified differently in the Particular Specifications.
• Power supply preferably 24V DC with wide range input power supply unit (min. 90-260V AC)
• Programmable control relays which are available with technical documentation in local language
(means language of country where the plant is located) shall preferentially being selected.
Program and documentation shall be worked out in the contract language and in English.
• Only relays shall be supplied of which the manufacturer guarantees the supply of spare parts and
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service for at least 5 years. If not specified differently the Contractor must guarantee the supply
of spare parts within 10 days.
• For each type of programmable relay, the contractor shall supply one original of the operation
software and two copies of the final version of Program installed, two on memory cards and two
on CD-ROM. Additionally two paper copies of the installed Program shall be submitted. These
copies shall contain remarks for each step of the Program, explaining the functions.
• Temperature range –25°C to +55°C
• Integral password protection for circuit configuration and relay value pre-sets
• Current flow display for circuit configuration testing
• Selection option from at least the following languages: English, German, French
• Integrated timing relays, including delay functions
• Integrated up- and down- counter relays
• Integrated timers
• Integrated analogue value comparators
• Separate or integrated LCD-display
• Integrated interface for network connection with other relays of same type
• Integrated interface for connection to a PC
• Degree of protection ≥IP 20
• Accuracy of timing relays +/- 1%
• Resolution in range “seconds”: 10 ms
• Resolution of analogue and digital signals: 0.1V
• Bit-resolution: 10
• Accuracy of actual value: +/- 2%
5.3.3 Communications
5.3.3.1 General
The Contractor shall supply install and commission all necessary communications equipment and
software to for data transmission between the facilities and the Central SCADA System, as specified in
the Particular Specifications.
5.3.3.2 Transmission and Protocol

The Contractor shall wherever possible use an industry standard transmission protocol. The Contractor
shall provide details of the proposed protocol to be used at the time of Tender.
5.3.3.3 Electronic Equipment
All communications equipment used in the communications system shall be of high reliability and shall
comply with the most recent edition of appropriate National and International Standards Specifications
and recommendations at the time of Tender.
5.3.3.4 Lightning Protection

The Contractor shall provide lightning and surge protection devices at each PLC on each
communications circuit and at the base station.
5.4 Testing of Instrumentation, Control and Automation Installations

The Contractor shall provide for system testing as detailed. The tests shall conform to the actual IEC
standards and local norms (code of practice for testing of computer based systems and code of practice
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for performance monitoring of computer based systems).
The testing procedure first shall be done on a single component level to confirm the correct functioning
of each device. Afterwards the operational and functional performance of the entire systems must be
confirmed by a suitable testing programme.
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6 PARTICULAR SPECIFICATIONS FOR WORKS IN TETE

6.1 Background
The Project horizons considered in this Study refer to the period between 2020 and 2050, separated into
short-term interventions (2030), intermediate-term interventions (2040) and long-term interventions
(2050). According to the Terms of Reference (ToR), the sewerage network, including pumps and the
Wastewater Treatment Plant are to be designed as well as stormwater flows in the above phases. The
number of components/processes designed for the Tete City are presented below.
Sewer Network:
The construction of the sewer network will be phased and explained in the following Table 6.1 and 6.2.
The total length of the sewer network proposed for the right bank for 2030 amounts to about 22 km, of
which about 9 km are main collectors, about 13 km secondary sewers, 130 m Effluent Sewer. For the
left bank, the total length of the proposed sewer network is only for 2030 with about 2.3 km.
Table 6.1: Lengths of the Proposed Sewers per Phase – Right Bank
Right Bank
Conventional Sewer
DN (mm) Length (km)
150 0.61
200 10.69
250 0.35
300 1.18
350 1.24
400 0.05
Sub-total 14.14
Condominium Sewer
150 2.59
Sub-total 2.59
Source: HYDROPLAN
Table 6.2: Lengths of the Proposed Sewers per Phase – Left Bank
Left bank
Condominium Sewer
DN (mm) Length (km)
150 4.48
250 0.73
Sub-total 5.22
Total 21.95
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Condominium Sewer
DN (mm) Length (km)
150 1.9
Construction of Tete WWTP and Sewerage200 0.63 - Specifications
Network: Volume
Sub Total 2.5
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Total Right Bank 24.5
Left Bank
Condominium Sewer
DN (mm) Length (km)
150 2.9
200 2.3
Total Left Bank 5.2
Total 29.7
Source: HYDROPLAN
The Wastewater Treatment Plant process:

The proposed process includes a mechanical stage consisting of screening devices, and an aerated grit
and grease chamber, with a subsequent Parshall flume for flow measuring. The biological stage consists
of anaerobic, facultative and maturation ponds. The generated sewage sludge from the biological
wastewater treatment process will be pumped to the sludge thickener and then to the drying beds. The
new Tete WWTP will consist of the following components:
• Faecal Sludge Acceptance Station.
• Coarse screens, (removal of rough particles).
• Fine screens, (removal of fine particles).
• Grit and grease chamber, (removal of grit, sand and grease).
• Venturi channel, (measurement of the inflow).
• Anaerobic, Facultative, and Maturation Ponds.
• Sludge drying beds, (dewatering of the sludge).
The design of the WWTP is based on Mozambican Standards. The process components will be
described in more detail in the following chapters.
Pump stations
One pumping station is installed in the right bank area. The design of pumping stations was followed
the guidelines of Decree with a minimum diameter of 200 mm sewer pipe and a minimum slope of
0.3%.
6.2 Location of the Works

The work items for this project are done for the Tete City, Mozambique.
6.3 Right of Access to the Site

The Contractor shall be granted such access to the Site as is required for the execution of the works
within the time stated in the subject to the provisions set out in the Conditions of Contract..
6.4 Contractor's Designs

The existence of an engineering detail design limits the need for contactor’s designs to execution
designs.
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Working (Shop) Drawings within the execution design will have a level of detail that enable the
Engineer evaluation of the solution proposed for the execution of the Works. They should be based, at
least, on/ to the same detailing grade of the detailed engineering design included in the competition
process.
6.5 Submittals
6.5.1 Inclusions
This includes submittal procedures for:
• Schedule of Values
• Construction Schedules
• Shop Drawings, Product Data, and Samples
• Operations and Maintenance Data
• Manufacturer's Certificates
• Construction Photographs
• Project Record Documents
• Design Mixes
• Video Tapes or DVD’s
• And all other submittals the owner deems necessary.
6.5.2 Procedures
A. Scheduling and Handling
1. Schedule submittals well in advance of the need for the material or equipment for construction. Allow
time to make delivery of material or equipment after submittal is approved.
2. Develop a submittal schedule that allows sufficient time for initial review, correction, resubmission
and final review of all submittals. The Owner Representative will review and return submittals to the
Contractor as expeditiously as possible but the amount of time required for review will vary
depending on the complexity and quantity of data submitted. In no case will a submittal schedule be
acceptable which allows less than 30 days for initial review by the Owner Representative. This time
for review shall in no way be justification for delays or additional compensation to the Contractor.
3. The Owner Representative’s review of submittals covers only general conformity to the Drawings,
Specifications and dimensions which affect the layout. The Contractor is responsible for quantity
determination. No quantities will be verified by the Owner Representative. The Contractor is
responsible for any errors, omissions or deviations from the Contract requirements; review of
submittals in no way relieves the Contractor from his obligation to furnish required items according
to the Drawings and Specifications.
4. Submit 3 copies of documents unless otherwise specified in the following paragraphs or in the
Specifications.
5. Revise and resubmit submittals as required. Identify all changes made since previous submittal.
6. The Contractor shall assume the risk for material or equipment which is fabricated or delivered prior
to approval. No material or equipment shall be incorporated into the Work or included in periodic
progress payments until approval has been obtained in the specified manner.
B. Transmittal Form and Numbering

1. Transmit each submittal to the Owner Representative with a transmittal form.
2. Sequentially number each transmittal form beginning
155 with the number 1. Resubmittals shall use the
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original number with an alphabetic suffix (i.e., 2A for first resubmittal of Submittal 2 or 15C for
third resubmittal of Submittal 15). Each submittal shall only contain one type of work, material, or
equipment. Mixed submittals will not be accepted.
3. Identify variations from requirements of Contract Documents and identify product or system
limitations.
4. For submittal numbering of video tapes or DVD’s, coordinate with the Owner Representative.
C. Contractor's Certification
1. Each submittal shall contain a statement or stamp signed and dated by the Contractor, certifying that
the items have been reviewed in detail and are correct and in accordance with Contract Documents,
except as noted by any requested variance.
6.5.3 Shop drawings, product data, and samples

A. Shop Drawings:
1. Submit shop drawings for review as required by the Specifications. Contractor's Certification
shall be placed on each drawing.
2. Contractor's Certification shall be placed on each drawing.
3. The drawings shall accurately and distinctly present the following:
• Field and erection dimensions clearly identified as such
• Arrangement and section views
• Relation to adjacent materials or structure including complete information for making
connections between work under this Contract and work under other contracts
• Kinds of materials and finishes
• Parts list and descriptions
• Assembly drawings of equipment components and accessories showing their respective
positions and relationships to the complete equipment package
• Where necessary for clarity, identify details by reference to drawing sheet and detail numbers,
schedule or room numbers as shown on the Contract Drawings.
4. Drawings shall be to scale, and shall be a true representation of the specific equipment or item to be
furnished.
B. Product Data:
1. Submit product data for review as required in Specification sections.
2. Contractor's Certification shall be placed on each data item submitted.
3. Mark each copy to identify applicable products, models, options to be used in this Project.
Supplement manufacturers' standard data to provide information unique to this Project, where
required by the Specifications.
4. For products specified only by reference standard, give manufacturers, trade name, model or
catalogue designation and applicable reference standard.
5. For products proposed as alternates to "approved" products provide all information required to
demonstrate the proposed products meet the level of quality and performance criteria of the
"approved product".
C. Samples
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1. Submit samples for review as required by the Specifications.
2. Contractor's Certification shall be placed on each sample or a firmly attached sheet of paper.
3. Submit the number of samples specified in Specifications; one of which will be retained by the
Owner’s Representative.
4. Reviewed samples which may be used in the Work are identified in Specifications.
6.5.4 Manufacturer's certificates

A. When specified in Specification sections, submit manufacturers' certificate of compliance for review
by Owner’s Representative.
B. Contractor's Certification shall be placed on front page of the certificate.
C. Submit supporting reference data, affidavits, and certifications as appropriate.
D. Certificates may be recent or previous test results on material or product, but must be acceptable to
Owner’s Representative.
6.5.5 Design mixes

A. When specified in Specifications, submit design mixes for review.
B. Contractor’s Certification shall be placed on front page of each design mix.
C. Mark each design mix to identify proportions, gradations, and additives for each class and type of
design mix submitted. Include applicable test results on samples for each mix.
D. Maintain a copy of approved design mixes at mixing plant.
6.5.6 Corrosion protection

The corrosion protection systems will comply with, at least, the requirements for Class C4, as defined
in the EN ISO 9223 and compatible with the environment type examples provided in the EN ISO 12944-
2. The following standards are applicable:
• • EN ISO 1461
• • EN ISO 2063
• • EN ISO 4628-3
• • ISO 8501-1
• • ISO 9223
• • EN ISO 12944 Parts 1 to 4
• • EN ISO 14713 Parts 1 and 2
• • EN 15773
• • GSB ST 663 International Quality Regulations for the Piecework Coating of Steel and
Galvanised Steel Building Components
• • BPR 1197
• • Evio code of practice
• • SANS 10064
• • SANS 12944 parts 1 to 4Electrical Works
6.6 Particular Specifications: Electrical Installation

6.6.1 Scope of Work
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The electrical installations at the pump and relevant components to the WWTP at Tete are presented in
this section. Equipment selection shall be made to be compatible with the existing installations of the
operator
The scope of work includes the supply and installation of the following main items. The list does not
include all that is required to provide a complete installation. The Tenderer shall allow for all items of
equipment required to provide a complete installation.
6.6.2 Lifting Pumping Station

Design, supply, install and commission:
• Publish grid to provide power to the lifting pumping station
• Standby diesel generator completes with sound attenuating weatherproof enclosure and AMF
panel.
• Domestic electrical installation (lights, sockets, etc.) as per the design.
• Motor control centre.
• Variable speed drives.
• Local motor emergency stop stations.
• Monitoring and control of motorised valves.
• Instrumentation including but limited to magnetic flow meters, ultrasonic level transducers,
pressure transducers, level probes, motor and pump temperature sensors, vibration sensors, float
switches and pump station temperature sensors.
• All brackets and Field Equipment Boxes.
• Power, control and instrument cables.
• Excavation, backfilling and compaction of cable trenches.
• Junction boxes.
• Luminaires, occupancy sensors & photo cell including conduit and wiring.
• Socket outlets including conduit and wiring.
• As built drawings and documentation
6.6.3 Power Supply

The power supply is provided by either the two Diesel generators also located in the Administration
Building or by solar panels. In general, the electrical power of the outdoor lighting should be carried
out separately via respective solar panels.
A solar system is considered to be installed on the roofs of the buildings. In case of power shut down
or insufficient electric power supply, electric power generators or solar panels should supply the
equipment.
Power supply, electrical and SCADA system is designed for the WWTP as follow:
1. Solar Panel Units for outdoor lighting and as backup
2. Diesel Generators as backup
3. Low Voltage (LV) Distribution switch boards which are the main control panel and sub
distribution panels for the following mechanical equipment:
• Air pump into a grit chamber
• Mechanical treatment
• Building distribution and lighting
• Measurement
• SCADA system PLCs in the LV distributions in the operator room
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The electrical power supply to the pumping stations shall be derived from the public power grid. In case
of loss of grid electrical power, Generators will be used to feed the pumping stations. The Generators
are designed and calculated to fulfil the requirements of the Particular Technical Specifications for both
WWTP.
6.6.3.1 Public Power Supply

Contractual issues regard to connection to the public grid will be directly arranged between Client and
the electric power provider. However, all required equipment for the power supply installations have to
be supplied under subject Contract. This will be for new outdoor transformer stations e.g. the required
poles as end-span-pole for mounting the required outdoor equipment, a standard distribution
transformer of adequate capacity (pole- or ground mounted), a pole mounted switching devises (air-
insulated switch- disconnector with manual drive or encapsulated with oil insulation and motor drive),
MV fuses, surge arrestors, LV switchboard for power distribution and Metering Station. The
transformer station then will be installed, operated and owned by the electric power provider.
Since the technical details of the transformer station will be determined by the electric power provider,
a provisional sum for the transformer station is included in the tender documents. The final specification
of the equipment has to be defined and supplied during the Works in close cooperation with owner and
the electric power provider.
6.6.3.2 Low Voltage Power Distribution

The low voltage electrical main distribution and sub distribution switchboards are installed in the Low
Voltage Room at the Maintenance Building. All consumers and sub distribution panels are provided
with low voltage power from that building.
The Sub distribution board include:
• Mechanical treatment.
• Biological treatment
• Sub distribution measurement for mechanical and biological treatment
• Programmable Logic Control (PLC).
• SCADA centre.
• Building distributions.
6.6.4 Electrical Switchboards

Because of the different types of facilities, the required type and number of switchboards for each
facility varies. The different types of switchboards shall be selected according to the technical
requirements for each individual facility.
The electrical equipment for the power supply and control units will be distributed to different
switchboards. All cabinets shall be located in the same room and as close as possible and convenient to
the related consumer. Easy access, operation and physical protection must be considered as well.
The cabinets shall be for indoor use, made of stainless steel or coated steel with IP55 isolation class,
suitable for operation with an ambient temperature of -5°C to +40°C. Appropriate cooling/ heating/
lighting devices are to be installed in the cabinets. The cabinets shall be floor mounted, however, the
Chlorination Station cabinet and the switchboard for lighting and sockets can be wall mounted as well.
The cable entries shall be through the bottom side. All labelling’s of the switchboards must be in English
language. In case that an existing switchboard will be extended, the same colour as the existing one
shall be used for the new cabinets.
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6.6.4.1 Power Distribution Switchboard
The power distribution switchboard shall comply with the following minimum requirements:
• Voltage: 230/ 400 VAC, 3 phases, 50Hz, TN-C-S earthing system
• Connection point for the incoming LV power cable from the transformer station or, if applicable,
from the PV system (the automatic switching over device is part of the PV system, providing
full-automatic switching under load between the supplier power supply from the transformer
station (public grid) and the PV system)
• Main circuit breaker: for short circuit and thermal overload protection, adjustable tripping
values, capacity as required
• Metering station: if required, including a suitable current transformer metering and display of:
kW, kWh, kVA, kVAh Display of currents I1/ I2/ I3
• Grid feeding monitoring relay
• Protection functions at least: over voltage, under voltage, over frequency, under frequency
• Display of: V (U1/U2/U3, U1-2/U2-3/U3-1), Hz
• LV busbar, 3 phases, 230/400V, 50Hz
• Overvoltage/Surge arresters, connected to the busbar
• Fuse disconnectors or circuit breakers in the feeders for the other switchboards. Fuse
disconnectors must be of A type, allowing a safe replacement of the fuse cartridges without
tools. The ratings of these switching devices must be selected in such a way that the protection
to the upstream equipment is acc. to IEC, and selective tripping of them related to the further
upstream switching devices is ensured.
6.6.4.2 Power, Lighting and Sockets Switchboard

All feeders must be equipped with MCBs and a RCDs, dimensioned acc. to IEC standards and 2 separate
bus bars for lighting circuits and the sockets circuits.
6.6.5 Electrical Installations

6.6.5.1 Earthing System
A complete earthing system as specified in the General Specifications must be installed in the new
pumping stations and reservoirs acc. to IEC standards or national standards.
The main components are foundation earthing in the concrete base plate, main and local earthing bars,
equipotential bonding for all electrically conductive metallic installations (electrical equipment,
cabinets, pipes, pumps, stairs, handrails, etc.).
The total earth resistance shall not be higher than 10 Ohm. All connections between the earthing system
components must be low resistive with a maximal value of 0.2 Ohm.
The total earth resistance and the low resistivity of the connections must be measured and documented
in the earthing protocol.
6.6.5.2 Lightning Protection

A complete lightning protection system as specified in the General Specifications must be installed in
the new pumping stations or reservoirs acc. to IEC standards or national standards.
The main components of the outer system are interception conductors on the roof, down conductors
with interruptible testing contacts, and connections to the earthing system. This can be the earthing
system for the electrical installations, or a separated earthing device exclusively for the lightning
protection.
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The total earth resistance shall not be higher than 10 Ohm. All connections between the components of
the lightning protection system and between the lightning protection system and the earthing system
must be low resistive with a maximal value of 0.2 Ohms.
The total earth resistance and the low resistivity of the connections must be measured and documented
in the lightning protection protocol.
6.6.5.3 General Electrical Installations

The sewer ponds, Offices, laboratory and the Distribution chambers must be equipped with complete
and fully functional general electrical installations in accordance with IEC standards.
The main components of the general electrical installations are:
• internal and external lighting: only LED luminaries are accepted, number, location and type to
be selected such to ensure bright lighting of all areas with approx. 300 lx.
• Indoor/ Outdoor: Diffuser luminaire LED damp-proof IP65, 230VAC, approx. 20W/ 4000 lm /
6000K
• Outdoor: StreetFlood light luminaire LED damp-proof IP65, 230VAC, approx. 200W / 20000
lm / 6000K
• switches for the lighting included, located close to entrance/exit doors, for easy access and
operation
• sockets (in each room distributed at least 2 twin schuko sockets, in each building at least 1 socket
CEE 16A 5 pins)
The general electrical installation must be fully integrated, compatible and form one total functional
unit with all other electrical equipment and systems of the pumping stations and reservoirs, which are
namely the earthing system, equipotential bonding, external lightning protection system, medium-
voltage transformer station, PV system, switchboards, power supply and control system for the pumps,
all instrumentation devices for the control systems, power supply and control system for the
Chlorination Stations and solar system (the latter two if applicable).
The general electrical installations must also include all required components and installations to
provide the total functionality of the other namely specified electrical systems, which are not covered
by them.
The principal layout of the general electrical installations is shown in the tender drawings “General
Electrical Installations”. This layout shows only the minimal requirements, which must be adapted and
completed by the Contractor if required in order to provide full functionality.
6.7 Particular Specifications: Mechanical installations

6.7.1 Scope
This specification covers the supply, delivery, transport, handling, installation, commissioning, testing,
adjustment, handling over in complete working order and upholding during the Defects Notification
Period. The scope of work includes the supply and installation of the following main items. The list
does not include all that is required to provide a complete installation. The Tenderer shall allow for all
items of equipment required to provide a complete installation.
• Pump,
• Mechanical Screens,
• Screening’s conveyor,
• Screenings wash press,
• Backup manually raked screen,
• Grit Classifiers, Grit Washers, and Grit Blowers
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• Waste Containers
• Air Blowers
• Grit Pump to Grit classifier
• Grit Pump and Pipework
• Sludge Drying bed inlet pipework
• Any pipework not included in any above item
• Borehole pumps
• Faecal Acceptance Station
• Gas motors
6.7.2 Pumps
Pumping stations for the Tete in the period of 2030 include 01 lifting pumping station (PS01) installed
in the right bank area . The lifting pump was selected as submersible pumps.
6.7.2.1 Submersible pumps

6.7.2.1.1 General
Scope:
This section provides for providing and installing submersible wastewater pumps with electric motors,
controls, and accessories.
Payment:
No separate payment will be made for equipment and work performed under this section. Include the
cost of such equipment and work in the bid item unit price for which this is related.
Quality Assurance:
Provide highest quality workmanship and materials throughout. Furnish standard equipment from a
manufacturer with at least five years of experience in the design and assembly of water and WWTP
equipment.
Submittal:
• Product Data: Submit three (3) copies of complete descriptive data for pumps and drivers,
including, but not to be limited to the following: pump curves (high lite project specific
performance points), NPSH requirements, horsepower requirements, project specific pump
efficiency at all service points, materials of construction for pump components, solids handling
capability and complete description of driver including horsepower, electrical characteristics,
bearing life ratings, motor jacket insulation and insulation ratings.
• Shop Drawings: Submit in accordance with applicable specification.
• Manufacturer's Report: The manufacturer shall review the systems design in all matters relative
to the proper operation of the equipment, including piping, valves, electrical service, automatic
controls, alarms, locations, and related items. With the shop drawings, the manufacturer must
submit a letter to the Owner’s Representative stating that the design is satisfactory to the
manufacturer and that the equipment will operate satisfactorily under the project design
conditions. Upon completion of installation and in addition to the operational letter, a service
engineer employed by the manufacturer will provide the Owner with a written report of start-up
set points and calibrations. Final settings will be reviewed.
Noise and Vibration:
Select equipment to operate with minimum of noise and vibration. If, in the opinion of the Owner’s
Representative, objectionable noise or vibration is produced or transmitted to or through building
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structure by equipment, piping ducts, or other parts of work, rectify such conditions without change in
the contract sum.
6.7.2.1.2 Products
Manufacturer:
As indicated provide non-clog pumps as manufactured by Flygt, ABS, GRUNDFOS or approved equal.
Each pump shall be furnished with a sufficient length of 13-2-1 hypalon jacketed type SPC cable to
extend from the pump to the junction box or control panel outside of the pump containment structure.
Each pump used in a submersible application shall be supplied with 316 stainless steel chain of adequate
strength, and length, to permit lifting and lowering the pump without wet well entry.
Capacity and Efficiency:

• Head losses through the pump are not included in the total pumping head and suction head. Use
pumping head and other terms as defined in the Standards of the Hydraulic Institute (ANSI/HI)
as currently amended.
• Supply pumps having peak design operating point within twenty Percent (20%) of peak
efficiency. Pumps with curves constantly rising toward shut-off are preferred. Standard
Maximum and minimum impellers are not to be used for initial conditions, except in special
cases, and then only with approval of the Owner’s Representative.
Pump Characteristics:
The pumps shall meet all of the design and performance requirements as outlined on the detailed
engineering design report or Bill of Quantities.
Pump Design:
The pump(s) shall be capable of handling raw unscreened sewage. The pump discharge piping shall
include either a connection elbow permanently installed in the wet well along with the discharge piping
or a threaded pipe connection on grinder units, 1.5 Hp and smaller. If a permanent elbow is used in a
submersible application, the pump(s) shall be automatically connected to the discharge connection
elbow when lowered in place, and shall be easily removed for inspection or service. Sealing of the
pumping unit to the discharge connection elbow shall be accomplished by a simple linear downward
motion of the pump. Using either type of connection system, there shall be no need for personnel to
enter the lift station wet well.
A sliding guide bracket shall be an integral part of the pump unit. The entire weight of the pumping unit
shall be guided by no less than two stainless steel guide bars or rails. When using a permanent elbow,
the pump shall be laterally supported by the guide bars (rails) and pressed tightly against the discharge
connection elbow, with metal-to-metal contact. All mating surfaces where watertight sealing is required
shall be machined and fitted with nitrile rubber Orings. Fitting shall be such that sealing is accomplished
by metal to metal contact between machined surfaces, resulting in controlled compression of nitrile
rubber O-rings without the requirement of a specific torque limit to affect this. No secondary sealing
compounds, rectangular gaskets, elliptical "O"-rings, grease or other devices shall be used. No portion
of the pump shall bear directly on the floor of the sump. The pump, with its appurtenances and cable,
shall be capable of continuous submergence underwater without loss of watertight integrity to a depth
of 60 feet. Submersible grinder pumps (where specified) may have the pump casing resting on the floor
via mounting legs and may use an O-ring sealing arrangement.
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Pump Construction:
Major pump components shall be of grey cast iron, Class 30, with smooth surfaces devoid of blow holes
and other irregularities. Where watertight sealing is required, O-rings made of nitrile rubber shall be
used. All exposed nuts and bolts shall be of stainless steel 316. All surfaces coming into contact with
sewage, other than stainless steel, shall be protected by an approved sewage resistant coating. Pump
exterior shall be sprayed with zinc primer and a high solids epoxy finish.
Cable Entry:
The cable entry seal design shall preclude specific torque requirements to insure a watertight and
submersible seal. The cable entry shall consist of dual cylindrical elastomer grommets, flanked by
washers, all having a close tolerance fit against the cable outside diameter and the entry inside diameter.
The grommets shall be compressed by the cable entry unit, thus providing a strain relief function. The
assembly shall provide ease of changing the cable when necessary using the same entry seal. The cable
entry junction chamber and motor shall be sealed from each other, which shall isolate the stator housing
from foreign material gaining access through the pump top. Epoxies, silicones, or other secondary
sealing systems shall not be considered acceptable.
Pump Motors:
Pump Motor 10 horsepower and below. Cooling characteristics suitable to permit continuous operation
in totally submerged, partially submerged, or non-submerged conditions without overheating. The
pump motor shall be a NEMA B design, induction type with a squirrel cage rotor, shell type design,
housed in an air filled, watertight chamber. The stator windings shall be insulated with moisture resistant
Class H insulation rated for 180°C (356°F). The stator shall be insulated by the trickle impregnation
method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%.
The motor shall be inverter duty rated in accordance with NEMA MG1, Part 31. The stator shall be
heat-shrink fitted into the cast iron stator housing. The use of multiple step dip and bake-type stator
insulation process is not acceptable. The use of bolts, pins or other fastening devices requiring
penetration of the stator housing is not acceptable. The motor shall be designed for continuous duty
handling pumped media of 40°C (104°F) and capable of no less than 15 evenly spaced starts per hour.
The rotor bars and short circuit rings shall be made of cast aluminium. Thermal switches set to open at
125°C (260°F) shall be embedded in the stator end coils to monitor the temperature of each phase
winding. These thermal switches shall be used in conjunction with and supplemental to external motor
overload protection and shall be connected to the control panel. The junction chamber containing the
terminal board shall be hermetically sealed from the motor by an elastomer compression seal.
Connection between the cable conductors and stator leads shall be made with threaded compression
type binding posts permanently affixed to a terminal board. The motor and the pump shall be produced
by the same manufacturer.
The pump shaft shall rotate on two bearings. Motor bearings shall be permanently grease lubricated.
The upper bearing shall be a single deep groove ball bearing. The lower bearing shall be a two row
angular contact bearing to compensate for axial thrust and radial forces. Single row lower bearings are
not acceptable.
The combined service factor (combined effect of voltage, frequency and specific gravity) shall be a
minimum of 1.15. The motor shall have a voltage tolerance of plus or minus 10%. The motor shall be
designed for operation up to 40°C (104°F) ambient and with a temperature rise not to exceed 80°C. A
performance chart shall be provided showing curves for torque, current, power factor, input/output kW
and efficiency. This chart shall also include data on starting and no-load characteristics.
The power cable shall be sized according to the NEC and ICEA standards and shall be of sufficient
length to reach the junction box without the need of any splices. The outer jacket of the cable shall be
oil resistant chlorinated polyethylene rubber. The
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motor and cable shall be capable of continuous
__________________________________________________________________________________
submergence underwater without loss of watertight integrity to a depth of 65 feet or greater. The motor
horsepower shall be adequate so that the pump is no overloading throughout the entire pump
performance curve from shut- off through run-out. Securely affix in a conspicuous place on each pump
and motor a standard stainless steel nameplate showing the serial number and name of the manufacturer.
Also, show the capacity in gallons per minute at rated rpm and head in feet, impeller diameter,
horsepower, speed and electric current characteristics. Nameplates with distributing agents only are not
acceptable.
Pump Shaft and Seals:

The pump and motor shaft shall be a single piece unit. The pump shaft is an extension of the motor
shaft. Shafts using mechanical couplings shall not be acceptable. The shaft shall be stainless steel –
ASTM A479 S43100- T. Shaft sleeves will not be acceptable.
Each pump shall be provided with a tandem mechanical shaft seal system consisting of two independent
seal assemblies. The seals shall operate in a lubricant reservoir that hydrodynamically lubricates the
lapped seal faces at a constant rate. The lower, primary seal unit, located between the pump and the
lubricant chamber, shall contain one stationary and one positively driven rotating, corrosion resistant
tungsten- carbide ring. The upper, secondary seal unit, located between the lubricant chamber and the
motor housing, shall contain one stationary and one positively driven rotating, corrosion resistant
tungsten-carbide seal ring. Each seal interface shall be held in contact by its own spring system. The
seals shall require neither maintenance nor adjustment nor depend on direction of rotation for sealing.
The position of both mechanical seals shall depend on the shaft. Mounting of the lower mechanical seal
on the impeller hub will not be acceptable. For special applications, other seal face materials shall be
available.
Each pump shall be provided with a lubricant chamber for the shaft sealing system. The lubricant
chamber shall be designed to prevent overfilling and to provide lubricant expansion capacity. The drain
and inspection plug, with positive anti-leak seal shall be easily accessible from the outside. The seal
system shall not rely upon the pumped media for lubrication. The motor shall be able to operate dry
without damage while pumping under load. Seal lubricant shall be FDA Approved, nontoxic.
Impellers:
Non-clog: The impellers shall be of grey cast iron, Class 35B, dynamically balanced, semi-open, multi-
vane, back-swept, non-clog design. The impeller vane leading edges shall be mechanically self-cleaned
upon each rotation as they pass across a spiral groove located on the volute suction which shall keep
them clear of debris, maintaining an unobstructed leading edge. The impeller(s) vanes shall have screw-
shaped leading edges that are hardened to Rc 45 and shall be capable of handling solids, fibrous
materials, heavy sludge and other matter found in waste water. The screw shape of the impeller inlet
shall provide an inducing effect for the handling of sludge and rag-laden wastewater. Impellers shall be
locked to the shaft and held by an impeller bolt. The pump volute shall be a single piece grey cast iron,
ASTM A-48, Class 35B, non-concentric design with smooth passages of sufficient size to pass any
solids that may enter the impeller. Minimum inlet and discharge size shall be as specified. The volute
shall have a replaceable volute insert ring containing spiral shaped, sharp-edged groove(s). The spiral
groove(s) shall provide the relief path and sharp edge(s) across which each impeller vane leading edge
shall cross during rotation so to remain unobstructed. The internal volute bottom shall provide effective
sealing between the multi-vane semi-open impeller and the volute. The insert ring shall be cast of
(ASTM A-48 Class 35B cast iron or ASTM A 532 (Alloy lll A), 25% chrome cast iron) A wear ring
system shall be installed to provide efficient sealing between the volute and impeller. The wear ring
shall consist of a stationary ring made of nitrile rubber moulded with a steel ring insert which is drive
fitted to the volute inlet and a rotating stainless steel ANSI 304 ring which is drive-fitted to the impeller
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eye.
Electrical Controls:
Are to be provided as part of the process control with all connections, wiring and circuitry. See
specification sections specific to electrical and controls.
Liquid Level Sensors:

Furnish and install the liquid level sensing system as indicated on the drawings or specified in process
control.
Access Hatch:
Were indicated on the plans provide an aluminium access hatch complete with frame, hinged access
doors with 316 stainless steel safety latch lockable hasp of size or dimensions shown on the plans and
as required to install or remove submersible pump. The access hatch assembly shall include stainless
steel springs for easy opening. This access hatch is to have 316 stainless steel tamper resistant nuts,
bolts and stainless steel anchors affixed to the frame for embedment in concrete top covers.
Each hatch shall include an internal fall-through prevention aluminium safety grate, OSHA orange
finish, with a minimum design capacity of 300 p.s.f. All mounting hardware shall be 316 stainless steel.
The safety grate shall be independent of the access hatch, the safety grate shall be hinged to swing up
and out of the way, leaving a clear access area as required to install or remove the submersible pump.
The safety grate shall be removable for maintenance purposes.
Process Control:
Provide a control panel complete with all mounting hardware, wiring, conduit, and components as
shown on the drawings and/or indicated below. Related component and electrical specifications are
found in Division 16 and/or indicated below.
• Control Panel
Provide a NEMA 4x stainless steel free standing enclosure with a minimum 4 inch mounting legs on
panel or as indicated on the drawings. The panel shall be affixed to corrosion resistant vertical mounting
supports, and shall have a minimum 36 inch mounting height. All Motor Control Panels shall be made
with external transformers for lighting and appurtenances.
• Controls
Provide all required relays, circuit breakers, motor starters, phase and surge protection, alarm horn and
light for a complete and operating system.
Transformers shall be mounted independently in NEMA 4x stainless steel enclosure.
6.7.2.1.3 Execution
Service:
A factory representative, as an advisor, shall be provided during the initial installation work; for the
inspection and checkout of the erected equipment; and during instruction for initial operation. These
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services are to be for two (2) periods not exceeding five (5) days each.
Furnish the Owner with a written report from a service engineer employed by the manufacturer denoting
start-points and calibrations. Obtain Owner’s Representative's approval of final setting. Arrange for
manufacturer to have service personnel on 24-hour call.
Warranty:
The manufacturer shall warrant the units being supplied to the Owner against defects in workmanship
and material for a period of two (2) year from the date of final project acceptance, under normal use,
operation and service. The warranty shall be in printed form and apply to all similar units. (Contractor's
responsibility shall end after the one year warranty period they are required to provide).
Each manufacturer shall review the systems design in all matters relative to the proper operation of their
equipment, including piping, electrical, automatic controls, locations, and related items. With their shop
drawings, the manufacturer must submit a letter to the Owner’s Representative stating that the design
is satisfactory to the manufacturer and that the equipment will operate satisfactorily under the design
conditions. Further, the manufacturer must review the final installation at site and write a second letter
stating that the installation is satisfactory to the manufacturer and that the equipment will operate
satisfactorily under the installed conditions.
Pump Test:
The pump manufacturer shall perform the following inspections and tests on each pump before
shipment form factory.
• Impeller, motor rating and electrical connections shall first be checked for compliance to the
customer's purchase order.
• A motor and cable insulation test for moisture content or insulation defects shall be made.
• Prior to submergence, the pump shall be run dry to establish correct rotation and mechanical
integrity.
• The pump shall be run for 30 minutes, submerged a minimum of six (6) feet under water.
• After operational test submerged, the motor and cable insulation test are to be performed again.
• A written report stating the foregoing steps have been done shall be supplied with each pump at
the time of shipment.
• The pump cable end will then be fitted with a shrink fit rubber boot to protect it from moisture
or water seepage prior to electrical installation.
6.7.2.1.4 Standards
The following standards will be used as reference for the quality of the submersible pumps to supply in
the contract:
• Directive 2006/42/CE
• ISO 12100:2010
• ISO 5199:2002
• DIN 24299
• ISO 7005-2
• EN 1092-2
• DIN2501:1997
• ISO 8501:2006
• ISO 12944:2007
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Table 6. 3: Technical specification for the submersible pumps of PS01 at the Right Bank
Technical specification description
Product name SL1.80.150.90.4.52H.S.N.61G.A
Product type Submersible wastewater pumps
Liquid Liquid temperature range (10 - 40 °C)
Technical
Actual calculated flow 33 l/s
Maximum flow 63.9 l/s
Head of the pump 11.34 m
Maximum head 19 m
Type of impeller S-TUBE
Maximum particle size 80 mm
Rated speed 1785 rpm
Materials
Pump housing Cast iron (EN 1561 EN-GJL-250)
Impeller Cast iron (EN 5.1301 EN-GJL-250)
Motor Cast iron (EN 5.1301 EN-GJL-250)
Electrical data
Power input - P1 10.3 kW
Rated power - P2 9 kW
Mains frequency 60 Hz
Rated voltage [V] 3 x 380-480/660-690 V
Voltage tolerance +10/-10%
Starting current 209/96 %
Motor efficiency at full load 88 %
Number of poles 4
Built-in motor protection KLIXON
Length of power cable 10 m
Cable type S1BN8-F
Cable size 7G4+5X1.5ST
Installation
Range of ambient temperature -20 - 40 °C
Maximum operating pressure 6 bar
Flange standard DIN
Type of inlet connection DIN
Type of outlet connection DIN
Size of inlet connection DN 150
Size of outlet connection DN 150
Pressure rating PN 10
Maximum installation depth 20 m
Inst dry/wet SUBMERGED
Auto-coupling 97695489
Frame range 52
Controls
Moisture sensor with moisture sensors
Water-in-oil sensor
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Performance
Eta pump 43.1 %
Eta pump+motor 37.6 %
6.7.2.2 Centrifugal pump

6.7.2.2.1 General
The pumps shall be built in materials compatible with the characteristics of the liquids / treated water
to transport and the environment where they are going to be installed.
The pump shall be equipped with a stainless Steel 316 pressure relief valve and an Automatic Air
Release Valve, along with a high pump temperature shutdown system and a bearing cavity oil level
sight gauge.
6.7.2.2.2 Installation
Before installation, inspect the pump for damage which may have occurred during shipment. Check as
follows:
• Inspect the pump for cracks, dents, damaged threads, and other obvious damage.
• Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying, check
for loose hardware at mating surfaces
• Check levels and lubricate as necessary.
• If the pump and power source have been stored for more than 12 months, some of the
components or lubricants may have exceeded their maximum shelf life. These must be inspected
or replaced to ensure maximum pump service.
If the maximum shelf life has been exceeded, or if anything appears to be abnormal the equipment
should be rejected. It is recommended that 18 inches (457 mm) of clearance be provided in front of the
back cover to permit removal of the cover and easy access to the pump interior. A minimum clearance
of 9 inches (229 mm) must be maintained to permit removal of the cover.
6.7.2.2.3 Suction and discharge piping

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid-wall,
reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not
recommended.
Keep suction and discharge lines as straight as possible to minimize friction losses. Make minimum use
of elbows and fittings, which substantially increase friction loss. If elbows are necessary, use the long-
radius type to minimize friction loss.
Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or couplings. Lines near the pump must be independently
supported to avoid strain on the pump which could cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type lines are used, they should have adequate support to
secure them when filled with liquid and under pressure.
Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these
gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less
than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installation closer
to the pump may result in erratic readings.
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6.7.2.2.4 Suction lines
To avoid air pockets which could affect pump priming, the suction line must be as short and direct as
possible. When operation involves a suction lift, the line must always slope upward to the pump from
the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction
run, air pockets will be created.
Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should
be the eccentric type, and should be installed with the flat part of the reducers uppermost to avoid
creating air pockets. Valves are not normally used in suction lines, but if a valve is used, install it with
the stem horizontal to avoid air pockets.
If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass through the pump itself.
If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total
area of the openings in the strainer is at least three or four times the cross section of the suction line,
and that the openings will not permit passage of solids larger than the solids handling capability of the
pump.
The pump should be designed to handle up to a minimum of 2 1/2-inch (63,5 mm) diameter spherical
solids.
Since even a slight leak will affect priming, head, and capacity, especially when operating with a high
suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight
seal. Follow the sealant manufacturer's recommendations when selecting and applying the pipe dope.
The pipe dope should be compatible with the liquid being pumped.
If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at
a distance equal to 1 1/2 times the diameter of the suction line.
If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suction
inlet because the inflow will carry air down into the sump, and air entering the suction line will reduce
pump efficiency.
If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into the suction inlet.
If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the suction inlets so that they are separated by a distance
equal to at least 3 times the diameter of the suction pipe.
The depth of submergence of the suction line is critical to efficient pump operation. The shows
recommended minimum submergence vs. velocity recommendation of the supplier shall be respected.
6.7.2.2.5 Discharge lines

Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a siphon
breaker is used in the line. Otherwise, a siphoning action causing damage to the pump could result.
If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a suction line.
With high discharge heads, it is recommended that a throttling valve and a system check valve be
installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation
when it is stopped.
Self-priming pumps are not air compressors. During the priming cycle, air from the suction line must
be vented to atmosphere on the discharge side. If the discharge line is open, this air will be vented
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through the discharge. However, if a check valve has been installed in the discharge line, the discharge
side of the pump must be opened to atmospheric pressure through a bypass line installed between the
pump discharge and the check valve. A self-priming centrifugal pump will not prime if there is sufficient
static liquid head to hold the discharge check valve closed.
In low discharge head applications (less than 30 feet or 9 meters), it is recommended that the bypass
line be run back to the wet well, and located 6 inches below the water level or cut-off point of the low
level pump. In some installations, this bypass line may be terminated with a six-to-eight foot length of
1 1/4 inch I.D. smooth-bore hose; air and liquid vented during the priming process will then agitate the
hose and break up any solids, grease, or other substances likely to cause clogging.
It is also recommended that pipe unions be installed at each 90_ elbow in a bypass line to ease
disassembly and maintenance. In high discharge head applications (more than 30 feet), an excessive
amount of liquid may be bypassed and forced back to the wet well under the full working pressure of
the pump; this will reduce overall pumping efficiency. Therefore, it is recommended that an Automatic
Air Release Valve be installed in the bypass line. Air Release Valves must be reliable, and require
minimum maintenance.
If the installation involves a flooded suction such as a below-ground lift station. A pipe union and
manual shut-off valve may be installed in the bleed line to allow service of the valve without shutting
down the station, and to eliminate the possibility of flooding.
If a manual shut-off valve is installed anywhere in the air release piping, it must be a full-opening ball
type valve to prevent plugging by solids.
6.7.2.2.6 Alignment
The alignment of the pump and its power source is critical for trouble-free mechanical operation. In
either a flexible coupling or V-belt driven system, the driver and pump must be mounted so that their
shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the
pump and piping are installed, and before operation.
When mounted at the factory, driver and pump are aligned before shipment. Misalignment will occur
in transit and handling. Pumps must be checked and realigned before operation. Before checking
alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver
mounting bolts should also be tightly secured.
When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in
both the horizontal and vertical planes. Most couplings require a specific gap or clearance between the
driving and the driven shafts. Refer to the coupling manufacturer's service literature.
Align spider insert type couplings by using callipers to measure the dimensions on the circumference
of the outer ends of the coupling hub every 90º.The coupling is in alignment when the hub ends are the
same distance apart at all points Check parallel adjustment by laying a straightedge across both coupling
rims at the top, bottom, and side. When the straightedge rests evenly on both halves of the coupling, the
coupling is in horizontal parallel alignment. If the coupling is misaligned, use a feeler gauge between
the coupling and the straightedge to measure the amount of misalignment.
When using drive belts, the power source and the pump must be parallel. Use a straightedge along the
sides of the pulleys to ensure that the pulleys are properly aligned. In drive systems using two or more
belts, make certain that the belts are a matched set; unmatched sets will cause accelerated belt wear.
6.7.2.2.7 Drive belt tensioning

For new drive belts, check the tension after 5, 20 and 50 hours of operation and re-tension as required.
Thereafter, check and re-tension if required monthly or at 500 hour intervals, whichever comes first.
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Ideal drive belt tension is the lowest tension at which the belt will not slip under peak load conditions.
Do not over-tension drive belts. Over-tensioning will shorten both drive belt and bearing life. Under-
tensioning will cause belt slippage. Always keep belts free from dirt, grease, oil and other foreign
material which may cause slippage.
6.7.3 Mechanical Screens

Mechanical screens shall be installed at the WWTP. This shall include Coarse and Fine Screens. The
installation shall be complete with all supports, associated pipe work, valves, controls and all items
necessary to provide a complete working package
Two (2) Coarse screens shall be installed. The coarse screen shall include screening belt and screening
wash press. Coarse screens shall be mechanically raked with clear spacing of 50 mm, maximum velocity
of 1 m/s. Width of each channel: 0.50 m, height of channel: 1.00 m. 2 containers (1.1 m 3) shall be
provided for the coarse screens.
Two (2) Fine screens shall be installed. The Fine screens shall include screening belt, screening wash
press, grit classifier and drainage pumps building for screens. Fine screens shall be mechanically raked
with clear spacing of 6 mm, maximum velocity of 1 m/s. Width of each channel: 0.60 m, height of
channel: 1.00 m. 2 containers (1.1 m3) shall be provided for the fine screens.
A manually raked backup screen shall be installed at the WWTP.
6.7.4 Aerated Grit and Grease Chamber

Aerated Grit chamber shall have a movable double scrapper bridge.
Grit classifier and washer capacity shall be 1 m3/h for the removal of grit, sand, and grease. The grit
classifier and washer shall be complete with all supports, associated pipe work, valves, controls and all
items necessary to provide a complete working package.
6.7.5 Air Blowers system

Two (2) Air Blower systems shall be installed complete with all supports, associated pipe work, valves,
controls and all items necessary to provide a complete working package.
6.7.6 Filtrate Pumps

A filtrate pump of power 2.0 kw shall be provided complete with all supports, associated pipe work,
valves, controls, and all items necessary to provide a complete working package.
6.7.7 Fire Fighting System

The Contractor shall supply four (4) x Portable fire extinguishers at the WWTP Workshop building.
Outside firefighting hydrants, including hose (20m) shall be provided.
6.7.8 Potable Water Supply

Provision shall be made to supply potable water to the WWTP facilities from pipeline located closely
the WWTP.
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6.8 Particular Specifications: Operational Technology and SCADA

6.8.1 Scope
This specification details the requirement for operational technology for entire wastewater and
supervisory Control and Data Acquisition (Operational Technology and SCADA) works for
Construction of the WWTP at Tete.
This section of specifications defines the general requirements of Instrumentation and Control system
to be installed at the WWTP. For selection of field instruments and control system or anything related
to instrumentation, the Contractor shall follow the specifications contained herein. The Contractor shall
be required to provide all equipment, accessories, cabling, earthing, providing necessary
transducers/sensors, system hardware/software, programming logic etc. to achieve the functional
requirements.
The control systems for the WWTP shall be based on the use of Programmable Logic Controllers
(PLCs). The various modes of controls shall be Auto, Semi-automatic and Manual. There shall be
computer based Supervisory Control and Data Acquisition (SCADA) at the Central Control System at
Wastewater Treatment Plant. Remote operation facilities shall be provided for operating the equipment
from the local SCADA system. The local SCADA systems and the PLCs shall be capable of interfacing
/ networking with the future industry standard SCADA system. In the event of failure of the automatic
controls or by operator choice it shall be possible to revert to semiautomatic or manual operation of
each item of Plant independent of the PLC functions.
6.8.2 SCADA System on the WWTP at Tete

The SCADA system installed to monitor and control the Tete WWTP, pumping station, and the sewage
system in town has to ensure the following:
• Operator equipment sized to monitor and control each treatment area within complete with:
• Operating system (PC, PLC, Monitor, Printer Screen etc.)
• All necessary data storage devices
• Communications equipment and cabling for communicating with the PLC equipment located
within the wastewater treatment plant
• Communications wireless equipment for communicating with the PLC equipment located within
the pumping station PS01
• WWTP operator workstation equipment
• WWTP SCADA system software.
• Communications network, including Lightning Protection Units, via a cable communications
network for the WWTP.
• Supply installation and commissioning of the communications network, including Lightning
Protection Units, via a GSM/ UHF/ radio for the lifting pumping stations The SCADA shall be
suitable and pre-pared to receive and process the operation and control data, which transmitted
via remote system lifting pumping stations
• PLC programming equipment, software and licenses both of the PLC’s in WWTP and of the
PLC in lifting pumping stations.
6.8.3 Design requirements of instrumentation and control system

6.8.3.1 General
• Instrumentation and Control system shall be designed, manufactured, installed and tested by an
experienced system integrator to ensure high standards of operational reliability. Instruments
mounted in field and on panels shall be suitable for continuous operation. All electronic
components shall be adequately rated and circuits shall be designed so that change of component
characteristics shall not affect plant operation.
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• All I&C equipment shall be new, of proven design, reputed make, and shall be suitable for
continuous operation. Unless otherwise specified, all instruments shall be tropicalized. The
outdoor equipment shall be designed to withstand tropical rain and temperature variation from
0 to + 500 C. Wherever necessary, space heaters, dust and waterproof cabinets shall be provided.
Instruments offered shall be complete with all the necessary mounting accessories. The control
equipment installed inside the control room should be designed to work at 350 C and the
instruments in sheltered place outside the control room at 500 C.
• Electronic instruments shall utilize solid state electronic components, integrated circuits,
microprocessors, etc., and shall be of proven design.
• For transmitting instruments, output signal shall be 4-20 mA DC linear having two wire system.
• Unless otherwise stated, overall accuracy of all measurement systems shall be ±1% of measured
value, and repeatability shall be ±0.5%.
• After a power failure, when power supply resumes, the instruments and associated equipment
shall start working automatically.
• The instruments shall be designed to permit maximum interchangeability of parts and ease of
access during inspection and maintenance.
• Unless otherwise stated, field mounted electrical and electronic instruments shall be
weatherproof to IP-65.
• The instruments shall be designed to work at extremes of the ambient conditions of temperature,
humidity, and chlorine contamination that may prevail. The instruments shall be given enough
protection against corrosion.
• Lockable enclosure shall be provided for the field mounted instruments wherever required.
• All field instruments, and cabinets / panel-mounted instruments shall have tag plates / name
plates permanently attached to them.
• The performance of all instruments shall be unaffected for the ±10% variation in power supply
voltage and ±5% variation in frequency simultaneously.
• All wetted parts of sensors shall be made out of non-corrosive material capable of working with
chlorine content of ppm.
• For all instruments (transmitting analogue signals) installed in the field (outside pump house),
surge protection devices (SPDs) shall be provided at both ends of the connecting cable for the
protection against static discharges / lightning and electromagnetic interference.
• Pressure transmitters shall be provided with two valve manifold and a test port, so that in situ
calibration can be carried out.
• Two wire transmitters shall be provided with on-line test terminals.
• The ranges of all instruments shall be suitable for the application in the process.
• Instruments of similar type shall be of same make for appropriate inventory of spares, ease of
maintenance and training.
• The imported equipment shall have establishment to provide after sales maintenance facilities.
6.8.3.2 Erection/Installation Requirements

• The locally mounted instruments shall be installed on appropriate rigid supports, having
minimum vibrations. The instruments shall be installed away from hot objects.
• The instruments shall be protected against physical damage or liquid splashing by providing
metallic (GI)/ FRP enclosures or canopies.
• All transmitters / transducers shall be installed nearest to the sensing point and at a place
convenient to get access for maintenance.
• The field instruments i.e., the instruments mounted outside the control panel shall be mounted
at a convenient height of approximately 1.5 m above grade platform.
• During installation of instruments, provision shall be made to carry out in-situ calibration
Isolation valves and drain valves shall be provided to the field instruments wherever required.
• Instrumentation cables shall be separately laid, away from electrical cables. The instrumentation
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cables from the field mounted instruments shall be terminated on the control panel without any
joints.
• Double compression glands shall be used for glanding the cable in field instruments and
instrument control panel.
• Metallic tag number plate shall be provided for each instrument. Instrument Power Supply
Cables and Instrumentation Signal Cables Cables shall be capable of satisfactorily withstanding
without damage, transportation to site, installation at site, and operation under normal and short
circuit conditions of the various systems to which the respective cables are connected when
operating under the climatic conditions prevailing at the site as indicated in this specification.
Cable joints in instrument signals and power supply cables shall not be permitted. Cables shall
be capable of satisfactory performance when laid on trays, in trenches, conduits, ducts and when
directly buried in the ground.
• Cables shall be capable of operating satisfactorily under a power supply system voltage variation
of ±15%, a frequency variation of ±5.0%. Laying of Cables, A distance of minimum 300mm
shall be maintained between the cables carrying low voltage AC and DC signals and a distance
of minimum 600mm shall be maintained between HT cables and signal cables. In outdoor areas,
the cables shall be directly buried. Each instrumentation and power supply cable shall be
terminated to individual panel/ terminal box. Identification of each cable shall be by proper
ferrules at each junction as per cable schedule to be prepared by Contractor. Cables shall be laid
in accordance with layout drawings and cable schedule which shall be prepared by Contractor
and submitted for approval. All cable routes shall be carefully measured, and cables cut to the
required lengths, leaving sufficient amount for the final connection of the cable to the terminals
on either end. Various cable lengths cut from the cable reels shall be carefully selected to prevent
undue wastage of cables. A loop of 1 meter shall be left near each field instrument before
terminating the cable. Cables shall be complete uncut lengths from one termination to the other.
All cables shall be identified close to their termination point by cable numbers as per cable
interconnection schedules. Identification tags shall be securely fastened to the cables at both the
ends.
6.8.3.3 Particular Specification of the control philosophy

The pumping control shall conform to the demand of a particular area and shall be agreed with Engineer
of the Project Implement Unit (PIU). All water supply shall be capable to be operated on full automated
run mode, Local mode or by remote manual mode.
The valve control shall depend on the operation of the wastewater supply scheme and agreed on with
the PIU engineer.
6.8.3.4 Site specific Instrumentation installation and earthing

Sump sites
The sump tanks shall be provided with the following complete with all required accessories:
• Each site should be fitted with a radio linking it to the control room SCADA
• Telemetry panel of suitable size with all mounting accessories
• PLC with power supply and input/ output modules
• Ultrasonic level transmitters.
• Float switches for high level (LSH) and low level (LSL) switching
• The telemetry panel to be secured with a suitable vandal proof locking mechanism. All the
enclosures installed outdoor shall be of weather protection rating.
• The mounting accessories shall be GI.
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Lift Pump Station sites
The pump station shall be provided with the following complete with all required
accessories:
• Each site should be fitted with a radio linking it to the main control room SCADA
• Telemetry panel shall be free standing and equipped with a local panel view (HMI min. 10”) of
suitable size.
• PLC with power supply and input / output modules
• Temperature, Vibration (DE & NDE side) and pressure transmitters for all the pumps.
• Pressure transmitters shall be installed on the suction and discharge of each pump.
• Multifunction meter (MFM) for each pump station with logging and trending capability.
• All the enclosures installed outdoor shall be of weather protection rating.
• The mounting accessories shall be GI.
6.8.3.5 Process monitoring for the treatment plant

▪ Automated/Unattended operation
The Contractor shall consider the consequences and operational response to treatment challenges,
equipment failure and loss of communications or power. Automated monitoring of all critical functions
with major and minor alarm features should be provided; dual or secondary alarms may be necessary
for critical functions. The designer should consider and document if automatic shutdown and manual
restart is necessary or desirable to ensure the safety of the water supply. The control system should have
response adjustment capability on all minor alarms. Built-in control system challenge test capability
should be provided to verify operational status of major and minor alarms throughout the extreme
conditions that can reasonably be expected during facility operation.
Provisions should be made to ensure security of the treatment facilities, pumping stations and storage
facilities at all times. Appropriate intrusion alarms should be provided and sound at location(s) which
shall be monitored 24 hours per day.
▪ Reliability and security of the system

A system and data recovery procedure shall be included in the project documentation which should also
be remotely accessible. The Contractor shall consider methods of improving reliability through transient
protection wherever possible (e.g., mains, filters and transient surge protectors). Radio accessories and
other data transmission equipment shall use methods to ensure the integrity of the data transmitted
against corruption/interference. Encryption of signals for data/control security shall be considered.
When long or very long instrument or equipment wiring is present, induced current protection shall be
installed. Network configurations shall be designed with security considerations. Protection of fibre
optic or local area network (LAN) cabling in conduits shall be considered to protect from physical
damage. Harmonics and other electrical related disturbances to signal integrity shall be taken into
consideration. Power supply design shall include backup power by using true online uninterruptible
power supply (UPS) or equivalent power systems. Buffered direct current (DC) power supply shall be
selected. Critical instrumentation shall be connected to the same back up power as the control system
to allow monitoring during power outages. Consideration of the impacts of power failures on critical
instrumentation and control shall be taken into account, especially with respect to the reset conditions
of the devices.
The computer human machine interfaces (HMI) shall be user-friendly to facilitate operation and on-line
monitoring. Where outside access is provided for remote control of the operator interface or other
control components, adequate security shall be provided. Reasonable computer security measures shall
be provided if computer or other control systems are part of a larger system or a wide area control
system or network. A vulnerability assessment 176document shall be provided to the employer. This
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document should identify all potential access points, the associated risks with each and ways to mitigate
those risks. Computer and programmable equipment, including calibration instruments, shall use
password protection and record accessing identity. Drives (including USB ports) shall be locked down
under regular operation whenever possible. The HMI shall not allow switching to other programs under
operator accounts (not even using combination keys). In larger systems which are part of an IT
infrastructure, a narrower security policy shall be defined that prevents disruption within the process
control network (PCN).
▪ Influent and effluent demand reporting

The PLC and SCADA system shall be configured to calculate influent received and effluent produced
/ used or lost along the piping and gravity systems to produce the following reports:
• Production reports on daily, weekly, monthly, and yearly basis

• Pump availability reports on monthly and yearly basis
• Energy usage reports on monthly and yearly basis
• VFD availability reports on daily, weekly, monthly, and yearly basis
• Any other equipment health report (vibration, Temperature)
• Control data network availability report on daily basis
• Accessibility for Calibration & Maintenance.
• The design should arrange for easy access to all instrumentation and control systems for
calibration and maintenance. Smart instrumentation is an emerging field that may be considered
for improving servicing, calibration, failure detection and predictive maintenance of critical
devices.
6.8.3.6 Programmable Logic Controllers

▪ Codes and Standards
The design material, construction features, manufacture, inspection and testing of Programmable Logic
Controllers (PLC) shall comply with all currently applicable statutes, regulations and safety codes. The
PLC shall comply with the latest applicable standards and codes. If any such standards are not applicable
then the same shall comply with the available recommendations of professional institutes.
Table 6. 4: Codes and Standards

Reference Definition
OHS Act 31 of 1973 Occupational health and safety act of Mozambique

OHS Act 85 of 1993 Occupational health and safety act of RSA
ANSI/ISA-95.00.01 Enterprise-Control system integration
ANSI/ISA-95.1-1984 Instrumentation Symbols and identification
IEC62305-4:2006 Protection against lighting
IEEC 802.3 Standard for information Technology
IEC 61131-3 Standard for PLC Programming
BOS 70: 2004 Telecommunications Commercial grounding (earthing) and bonding -
requirements.
BOS 148: 2005 Steel bars for concrete reinforcement (SANS 1200 G
Concrete (structural)
SANS 1200 H Structural Steelwork
177
__________________________________________________________________________________
British Standards Institution _BS EN 1993- Design of Steel Structures. Towers, Masts and
3-1 Chimneys, Towers and Masts
BOS ISO 9001:2015 fifth edition Quality Management Systems
ANSI TIA-222-G Structural Standard for Antenna Supporting Structures

and Antennas
Statutory and regulatory requirements

• Code of practice for wiring: IEE Wiring regulation 16th Edition or latest edition.
• Mozambique Communication and Regulatory Authority (BOCRA) regulation
• Civil Aviation Authority Mozambique (CAAB) Regulations for structures that exceed
surrounding building heights.
All on-site equipment and regulations, as laid down by the local authority regarding safety, building,
electrical, fire, water, traffic and health requirement
The latest revision or addition to the above regulation or other standard referred to in this specification
will apply.
▪ Design and Construction Requirements

• This shall comprise of programmable systems based on operational logic for safe and automatic
operation of the pumping station and the treatment plant to produce required quantity of drinking
water of specified parameters. PLC shall be provided as a hot-standby controller to perform
combinational and sequential logic functions, status monitoring and reporting functions with
counter and timer facilities, for each station.
• PLC shall comprise of necessary processors, Input /Output (I/O) modules, communication
interface modules and Human-machine interface at least 10” (HMI) required to perform the
desired functions.
• PLC shall have the following attributes as a stand-alone controller:
- It shall carry out sequential start/stop logic implementation for operation of the pumps.
- It shall carry out computation and interfacing for data acquisition, data storage and
retrieval.
- It shall accept downloaded program from a programmer.
- It shall have different functional modules to perform the desired functions.
- It shall scan the inputs in time cycles and update the status of inputs/outputs.
• To avoid spurious output because of output module failure, all commands shall be associated
with release signals. Release signals shall include information on healthiness of the hardware,
software and power supply modules.
• It shall have relays, counter/timer functions, internal registers/ flags, watch dog timer, set/reset
facilities, up-down counter etc.
• It shall have provision for spare input and output modules.
• The PLC system shall be expandable and shall be modular in construction so as to carry out the
future expansion without any hardware modifications.
• The PLCs shall have analog and digital signal monitoring capability for checking the healthiness
of the signals. In case of detection of any unhealthy signal "PLC trouble" alarm shall be
generated. In case of failure of a PLC, the status of all the outputs of the PLC shall stay put.
• PLC shall be 32-bit microprocessor based with state-of-the-art technology. System components
shall be carefully chosen so that the reliability of the PLC shall be high. PLC shall use open
standard bus protocols and structures for all communication within and outside the system.
• In case of system failure or power supply failure all the outputs shall attain pre-determined fail-
safe condition. Spurious signals shall not cause equipment operation. Check back before
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execution features shall be incorporated.
• The PLC used shall have a proven record in the type of application concerned and in the
prevailing environmental conditions.
• It shall be possible to perform the simulation functions and testing the program by changing the
status of contacts and monitoring the output.
• The PLC system shall support ‘hot swapping’ of I/O modules i.e., removal and insertion of I/O
modules under power on condition.
• The design of system configuration and development of PLC software shall be undertaken by
the PLC manufacturer or System Integrator authorized by the PLC manufacturer. They shall
have previous experience in similar applications and shall have a service center at a reasonable
distance so as to provide services at a short notice.
6.8.4 Specification for radio transmitter and antennas

6.8.4.1 Radio Transmitters
All radio equipment offered shall be licensed and type-approved by Mozambique Communications and
Regulatory Authority (BOCRA).
The Contractor shall be responsible for applying for frequencies to be used for the system
communication network.
Tenderers shall analyze and select the best path with a view to minimize repeaters and radio channel.
Tenderers response to the ITB shall be based on preliminary path evaluation based on sites coordinates
and client site visit brief.
Tenderers shall note that a final detailed site survey/radio path profile shall be carried out to guide the
system design layout.
6.8.4.2 Antennas
Antennas shall be supplied complete with mounting clamps and supports. All mounting materials shall
be stainless steel.
6.8.4.3 Lightning and Surge Protection

The Contractor shall supply and install all the necessary lightning protectors, arresters and other devices
to provide protection for people and equipment on the premises RF coaxial cables shall be provided
with in-line surge suppressors.
It is the responsibility of the contractor to indicate what steps have been taken to adequately protect the
entire installation against any damages that may be caused by lighting and static discharges.
6.8.5 Radio mast specification

6.8.5.1 Introduction
This specification entails Design, Supply and Installation of a Three-Legged Tapered Lattice Self-
supporting Steel Truss Towers.
The proposed tower should be constructed to structurally and safely support telemetry antennas,
microwave dishes and third-party cellular antennas for communication purposes. The tower should be
able to accommodate antennas/dishes of up to 1.8 meters diameter. Refer to anticipated antenna list for
loading calculation.
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6.8.5.2 Scope of Work
The scope shall include the works as below;
• Design, supply, and delivery to site of a high strength tapered self-supporting tubular steel truss
radio mast.
• Design of a suitable mast and reinforced concrete foundation based on soil test results carried
out by the contractor. The Contractor’s designs shall be subjected to review and approval by the
Engineer. The contractor shall involve an approved structural Engineer experienced in similar
works.
• Excavation, removal of soil, staged backfilling and compaction with appropriate backfill
material. These works will be subjected to compaction test as per the structural Engineer’s
instruction.
• Provision of civil works for the tower foundation including all necessary foundation bolts and
accessories for the tower.
• Installation of a comprehensive Earthing kit to the tower (Lightning Spike and Down Conductor
70 mm sq black PVC) including an earth mat.
• Erection of the tower on the prepared suitable foundation including all accessories required for
the tower as per design.
• Supply and installation of two (2) dual LED navigation lights including a controller with day
and bypass switches complete with power cables.
• Supply and installation of internal climbing steps and caged ladder. The tower shall have suitable
spaced rest platform along the caged ladder (minimum 4 along the tower)
• Painting of the towers as per the CAO regulation and standard tower colour coding (red and
white).
• Provision of rigid cable ladder link between the tower and building communication equipment
room for communication cable support.
• Installation of a galvanized cable tray alongside the length of the tower for securing radio
antenna cables
• Training client technicians on basic rigging (fall rescue course). The training shall be classroom
based + practical and conducted by an accredited trainer.
• Supply and delivery of two (2) specialized rigging kits complete with helmets, harness and carry
bag and accessories required by rigger.
6.8.6 Specification for control systems and instrumentation, design of control room
6.8.6.1 Design of control room
The design criteria for the control room should adhere to ISO 11064-5:2008 which presents principles
and gives requirements and recommendations for displays, controls, and their interaction, in the design
of control-centre hardware and software
A number of current standards provide engineering principles for detailed design of control room
elements. The following standards shall be used under this contract:
• Workstation design –ISO 11064-4, ISO 9241-5
• Display design –EEMUA 201
• Alarm system design –EEMUA 191
• ISO 11064-4:2004
• ISO 9241-5:1999 • ISO 9241-5:1999.
• ISO 11064-1 Ergonomic design of control centres
• ISO 11064-5: 2008, Requirements and recommendations for displays and controls, and their
interaction, in the design of control-centre hardware and software
• ISO 9241-3: 1992, Ergonomic requirements for office work with visual display terminals
180
__________________________________________________________________________________
6.8.6.2 Control system software

The contractor may use the ADROIT version 10 on other systems within Tete. This arrangement will
be subject to approval by the Engineer of the Project Implementing Unit.
6.8.6.3 Inter site and intra-site communication

Due to the PLCs broadcasting packets onto the network, the employer requires that each site packets be
constrained to that particular site and communication to other site be filtered using a OSI layer 3 devices
such as cisco router or layer 3 switch. The main data links should run on a separate backbone subnet
network which is different from site subnet network.
All radios should be broadband with bandwidth of about 10mbps or better to enable transferring of data
between sites optimally.
Table 6. 5: Server Computer
Make: Dell, or HP
Model Any latest model
Format Factor: Rack-mountable
Processor: 2 x 8-core, Intel architecture, current speed
Memory: 64 GB
OS: None
Storage Controller RAID 6/ADG capability
Drive Bays: 8 x drive bays
Hard Drives: 6 x SSD
Optical Drive None
NIC: Dual port 1GbE Base-T + Dual Port 10GbE Base-T
Power Supply: Redundant Power Supply and Fans
Other: Enterprise Server Management Software
Warranty: 6 years
Table 6. 6: Client computers specification

Make: Lenovo, HP or DEll
Model Latest
Format Factor: Tower
Processor: i7 Intel architecture, current speed
Memory: 16 or 32 GB
OS: Microsoft windows 10
Storage Controller RAID 6/ADG capability
Drive Bays: 2 x drive bays
Hard Drives: 2 x SSD, SAS
Optical Drive None
NIC: Dual port 1GbE Base-T + Dual Port 10GbE Base-T
Power Supply: Power Supply and Fans
Warranty: 3 years
181
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▪ Screen/ Monitoring hardware Specification
Individual standalone screens shall have the following specification:
• Diagonal Size32"
• Type Edge LED BLU
• Resolution1920*1080 (Full HD)
• Pixel Pitch(mm)0.360(H) x0.360(V)
• Active Display Area(mm)698.4(H) x 392.85(V)
• Brightness (Typ.)400 nit
• Contrast Ratio5000:1
• Viewing Angle(H/V)178/178
• Response Time(G-to-G)8ms(Typ.)
• Display Colors16.7M(True Display) 1.07B(Ditherd 10bit)
• Color Gamut72%
• Operation Hour16/7
• Haze2%
▪ Video wall
The contract should provide a video wall in addition to the individual 32 inch sized screen, the video
wall should provide the following;
• An overview of the total system – The “Eagle Eye view”
• Operators have personal data and Interactive processes at their desk
• The Videowall shows the whole process
Specification for the videowall (Preferred brands are LG & Samsung latest models)
• Diagonal Size 46"
• Type D-LED DID
• Resolution1920*1080 (Full HD)
• Pixel Pitch(mm)0.53025mm(H) * 0.53025mm(V)
• Active Display Area(mm)1018.08mm * 572.67mm
• Brightness (Typ.)500 nit
• Contrast Ratio4000:1
• Viewing Angle(H/V)178/178
• Response Time(G-to-G)8ms
• Display Colors8 bit - 16.7M
• Color Gamut72%
• Operation Hour24/7
• Haze25% (Outer Haze 23%)
• Quantity shall be 2 (two) video walls
6.8.6.4 Tag naming

SCADA tagging to be adopted from PLC tags as per P&ID and site location code name.
Instrumentation
(E.g., Level, Pressure, Flow transmitters)
Code: 000-AAA-111
Where:
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00- Site Number
AAA-ISA Function Number (Equipment)
111 –Sequential counting number (0 to xxx) for each site
Motor Control Centres
Code: 01-MC-111
Where: - 01 is Site/sub system number Example: 01-MC-001A High lift pump set 1 –pump
A; 01-MC-002A High lift pump set 2–pump A.
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7 ENVIRONMENTAL AND SOCIAL (ES) REQUIREMENTS

7.1 Environmental and Social Policy (Statement)
The Works’ policy goal, as a minimum, should be stated to integrate environmental protection,
occupational and community health and safety, gender, equality, child protection, vulnerable people
(including those with disabilities), sexual harassment, gender-based violence, Sexual Exploitation and
Assault (SEA), HIV/AIDS awareness and prevention and wide stakeholder engagement in the planning
processes, programs, and activities of the parties involved in the execution of the Works.
The ES policy may also address: climate adaptation, land acquisition and project affected persons. The
policy should set the frame for monitoring, continuously improving processes and activities and for
reporting on the compliance with the policy.
The policy shall include a statement that, for the purpose of the policy and/or code of conduct, the term
“child” / “children” means any person(s) under the age of 18 years.
The policy should, as far as possible, be brief but specific and explicit, and measurable, to enable
reporting of compliance with the policy in accordance with the Particular Conditions of the Contract
Sub-Clause 4.20 and Appendix C to the General Conditions of Contract.
As a minimum, the policy is set out to the commitments to:
• apply good international industry practice to protect and conserve the natural environment and
to minimize unavoidable impacts;
• provide and maintain a healthy and safe work environment and safe systems of work;
• protect the health and safety of local communities and users, with particular concern for those
who are disabled, elderly, or otherwise vulnerable;
• be intolerant of, and enforce disciplinary measures for illegal activities. To be intolerant of, and
enforce disciplinary measures for gender-based violence, inhumane treatment, sexual
exploitation, rape, sexual assault, sexual activity with children, and sexual harassment;
• incorporate a gender perspective and provide an enabling environment where women and men
have equal opportunity to participate in, and benefit from, planning and development of the
Works;
• work co-operatively, including with end users of the Works, relevant authorities, contractors and
local communities;
• engage with and listen to affected persons and organizations and be responsive to their concerns,
with special regard for vulnerable, disabled, and elderly people;
• provide an environment that fosters the exchange of information, views, and ideas that is free of
any fear of retaliation, and protects whistle-blowers;
• minimize the risk of communicable diseases and to mitigate the effects of communicable
diseases associated with the execution of the Works;
Contractor will be obliged to adhere to this policy that should be signed by the senior manager to signal
the intent that it will be applied rigorously and further, to develop, implement and follow the specific
Management Strategies and Implementation Plans (MSIP) to manage the ES risks and impacts.
184
__________________________________________________________________________________
7.2 ES Minimum Requirements

The provisions regard to ES requirements are stipulated ESIA/ESMP appended to the process and in
specific previous Sub-Clauses / chapters dealing with:
• Environmental Protection
• Health and Safety
• Co-operation with RAP Expert and Health and Safety
• Also, ES requirements are addressed together with the correspondent works specification,
defining related ES provisions, measures, precautions and plans to comply with. Reference is
made to Sub- Clauses:
• Licenses and Permits;
• Access and Possession of Site;
• Site Working Arrangements;
• Temporary Facilities;
• General Requirements for Civil Works (several sub-clauses).
In addition to the above-mentioned requirements, in preparing the specific Management Strategies and
Implementation Plans (MSIP), Contractor should refer to and consider, but not limited to, the following:
• Code of Conduct and GBV Action Plan
• HIV/ AIDS awareness Program
• Labour Management Plan
• COVID-91 Protection Plan for employees
• AIAS ES Requirements
• Environmental Rules for Construction Contractors
• Grievance Redress Mechanism
• Chance Find Procedures
• Project reports (e.g., Feasibility Study Report - Environmental and Social Assessment)
• World Bank Group Environmental, Health, and Safety Guidelines ("EHS Guidelines")
• National legal and/or regulatory requirements and standards and relevant international
conventions or treaties
• SEA prevention and management (including types of grievances to be recorded and how to
protect confidentiality of those reporting allegations of SEA)
7.3 Payment for ES Requirements

The Bill of Quantities consider specific payments for the C-ESMP and the Health and Safety Plan.
The payment for the delivery of ES requirements shall be a subsidiary obligation of the Contractor
covered under the prices quoted for other Bill of Quantity items. For example, the cost of implementing
work place safe systems of work, including the measures necessary for ensuring traffic and road safety,
shall be covered by the Bidder’s rates for the relevant works. This includes even the costs with measures
that are not included in the C-ESMP and Health and Safety Plan but are considered necessary in the
course of the work development (e.g. COVID-19 protection measures).
Provisional sums are set aside for discrete activities for example for HIV awareness and counselling
services, and, SEA awareness and sensitization or to encourage the contractor to deliver additional ES
outcomes beyond the requirement of the Contract.

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URBAN SANITATION PROJECT

CONSTRUCTION OF TETE WASTEWATER TREATMENT PLANT AND SEWERAGE

REQUEST FOR BIDS

VOLUME 4 of 6: TECHNICAL SPECIFICATIONS

1. ITEMS OF GENERAL APPLICATION ..................................................................... 5

1 ITEMS OF GENERAL APPLICATION

Roads and Pavement Roads and Pavement reinstatement:

The proposed works are spatially represented in the figure below.

1.2 Standards, Codes and Abbreviations

1.2.2 Equivalency of Standards and Codes

1.2.3 Metric Units

1.3 Licenses and Permits

1.4 Project management

1.5 Project Language

1.6 Access and Possession of Site

1.6.2 Access to Site

1.6.3 Temporary Way Leaves, Access Costs

1.6.4 Access to Adjoining Property

1.7 Engineers Normal Working Hours

1.8 Site Conditions

1.8.2 Method Statement and Programme

1.9 Site Working Arrangements

1.9.3 First Aid

1.9.4 Fire Protection

1.9.5 Site Safety

1.9.6 Location and Protection of Underground Utilities

1.9.7 Protection of Overhead and Underground Services

1.9.9 Site Roads

1.9.10 Measurements of Works

1.9.11 Contractor’s Temporary Facilities

1.9.12 Sanitary Arrangements and Waste Disposal

1.9.13 Water Supply

1.9.14 Power Supply

1.9.15 Cleaning-up of Sites

1.9.16 Handover of Surplus Materials

1.9.17 Engineer, Employer and CMT facilities

1.9.17.1 Offices for the Employer and CMQ

Meeting room module office:

1.9.17.2 Vehicles for the Employer’s Representative

Double Cab 4X4

Country of Vehicles can be from any eligible country but manufactured to

EXTERIOR • Laminated wind screen with green tint.

GROUND 220mm to 280mm.

COLOUR Dark Grey metallic or Silver Metallic/ Black.

TOW IN FIXTURE • Front and rear towing eye.

Table 1.2 – Specification for the Single cab 4x4 Vehicle

Single Cab 4X4

Make The make shall have a well-established Service infrastructure in

Country of Vehicles can be from any Eligible country but manufactured to

Chassis Rigid steel chassis with rust protection.

the body work.

1.9.17.3 Maintenance of offices

1.10 Temporary Facilities

1.10.2 Temporary Diversions of Wastewater Flow

1.10.3 Traffic Safety and Control

1.10.3.2 Traffic Control

1.10.4 Provision of Temporary Services

1.10.5 Protection of Adjoining Property

1.11 General Obligations

1.11.2 Site Organization

1.11.3 Contractor’s Supervision

1.11.4 Co-operation with the Engineer

1.11.5 Co-operation with Resettlement Action Plan Expert