The surface of anchor bolts, nuts, post and base material for connection to concrete barriers shall be

protected by galvanize in accordance with JIS H8641 HDZ35.

Table 13-14. Soundproof Barriers (Polycarbonate type)

Description Material Standard/Grade
Sound Absorbing Material Polycarbonate : 5t JIS K6735G
Top and Bottom Frame Aluminium JIS H4100 / A6063S-T5
Vertical Frame Aluminium JIS H4100 / A6063S
Supporting Material Aluminium JIS H4100 / A6063S

13.16.4 Fabrication

Soundproof and security barriers Manufacturer shall be approved by the Engineer and shall have an
experience in fabrication of soundproof and security barriers for the highway projects.

The Contractor shall submit a written description of fabricating capability including facilities, personnel
and list of similar completed projects, including testing and quality control capability and specifically
the type and extent of quality control procedure, which the manufacturer intends to employ on this
Project.

13.16.5 Installation

Soundproof and security barriers and incidental parts shall be carefully handled and stored on
blocking, racks or platforms so as not to be in contact with the ground and shall be protected from
corrosion, dust, oil and other foreign matters.

Surfaces to be coated shall be carefully protected both in the shop and in the field. Threads shall be
carefully protected from damage.

Soundproof and security barriers shall be carefully installed true to line and grade as shown on the
Drawings, and no construction shall be commenced before the inspection and approval by the
Engineer.

Soundproof barriers shall be fabricated and installed as indicated on the Drawings, and top of barriers
shall be parallel to the grade of the road. Posts shall be set truly vertical unless otherwise instructed
by the Engineer.

All exposed surfaces shall be thoroughly cleaned in an approved manner as a final operation under
this project.
The Contractor shall furnish for the approval of the Engineer working drawings for the particular type
of soundproof barriers to be installed.

13.16.6 Method of Measurement

The quantities of soundproof and security barriers to be measured by the number of linear metres of
soundproof and security barriers and accepted in accordance with the Drawings, these Specifications,
and as directed by the Engineer

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14 STRUCTURAL STEEL

14.1 Description

This Work consists of furnishing, fabricating, erecting, cleaning, and painting steel Structures and the
structural steel parts of non-steel Structures.

14.2 Materials

Materials shall meet the requirements of the following Section of Structural Steel and Related
Material.

Structural steel shall be classified as:

1. Structural carbon steel (to be used whenever the Plans do not specify another classification),
2. Structural low alloy steel, and
3. Structural high-strength steel.

Unless the Plans or Special Provisions state otherwise, the following shall be classified as structural
carbon steel: shims; ladders; stairways; anchor bolts and sleeves; pipe, fittings, and fastenings used
in handrails; and other metal parts, even if made of other materials, for which payment is not
specified.

All AASHTO M 270 material used in what the Plans show as main load-carrying tension members or
as tension components of flexural members shall meet the Charpy V-notch requirements of AASHTO
M 270 temperature zone 2. All AASHTO M 270 material used in what the Plans show as fracture
critical members shall meet the Charpy V-notch requirements of AASHTO M 270, Fracture Critical
Impact Test Requirements, temperature zone 2. Charpy V-notch requirements for other steel
materials shall be as specified in the Plans and Special Provisions.

The Contractor shall submit for the Engineer’s approval a written plan for visibly marking the material
so that it can be traced. These marks shall remain visible at least through the fit-up of the main load-
carrying tension members. The marking method shall permit the Engineer to verify: (1) material
Specification designation, (2) heat number, and (3) material test reports to meet any special
requirements.

For steel in main load-carrying tension members and in tension components of flexural members, the
Contractor shall include the heat numbers on the reproducible copies of the as-built shop plans.

14.2.1 Structural Carbon Steel

Structural carbon steel shall conform to AASHTO M 270 or ASTM A36 or SS400, Grade 36, except as
otherwise noted.

14.2.2 Structural Low Alloy Steel

Structural low alloy steel shall conform to AASHTO M 270 or ASTM A572 or SM490, Grade 50 or
50W as specified in the Plans or Special Provisions, except as otherwise noted.

14.2.3 Structural High-Strength Steel

Structural high-strength steel shall be high yield strength, quenched, and tempered structural steel
conforming to AASHTO M 270, Grades 70W, 100, or 100W as specified in the Plans or Special
Provisions, except as otherwise noted.

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14.2.4 Bolts

14.2.4.1 Unfinished Bolts

Unfinished bolts (ordinary machine bolts) shall conform to the Specification requirements of ASTM A
307 Grade A or B. Nuts shall comply with ASTM A 563 Grade A requirements. Washers, unless
otherwise specified, shall meet ASTM F 844 Specifications.

The Contractor shall submit a Manufacturer’s Certificate of Compliance for the bolts, nuts, and
washers prior to installing any of them.

14.2.4.2 High-Strength Bolts

High-strength bolts for structural steel joints shall conform to either ASTM A 325 Type 1 or 3 or ASTM
A 490 Type 1 or 3, as specified in the Plans or Special Provisions. Tension control bolt assemblies,
meeting all requirements of ASTM F 1852 may be substituted where ASTM A 325 high-strength bolts
and associated hardware are specified.

When specified in the Plans or Special Provisions to be galvanized, tension control bolt assemblies
shall be galvanized after fabrication in accordance with ASTM B 695 Class 55 Type I.
Bolts conforming to ASTM A 490 shall not be galvanized.

Bolts for unpainted and nongalvanized structures shall conform to ASTM A 325 Type 3, ASTM A 490
Type 3, or ASTM F 1852 Type 3, as specified in the Plans or Special Provisions.

Nuts for high-strength bolts shall meet the following requirements:

ASTM A 325 Bolts
Type 1 (black) ASTM A 563 Grade C, C3, D, DH, and DH3 AASHTO M 292 Grade 2H
Type 3 (black weathering) ASTM A 563 Grade C3 and DH3
Type 1 (hot-dip galvanized) ASTM A 563 Grade DH AASHTO M 292 Grade 2H ASTM A 490 Bolts
Type 1 (black) ASTM A 563 Grade DH and DH3 AASHTO M 292 Grade 2H
Type 3 (black weathering) ASTM A 563 Grade DH3

Nuts that are to be galvanized shall be tapped oversized the minimum required for proper assembly.
The amount of overtap shall be such that the nut will assemble freely on the bolt in the coated
condition and shall meet the mechanical requirements of ASTM A 563 and the rotational capacity test
specified in ASTM A 325.

Galvanized nuts shall be lubricated in accordance with ASTM A 563 including supplementary
requirement S2. Documentation shall include the name, method of application, and dilution of the
lubricant applied to the nuts.

Washers for ASTM A 325 and ASTM A 490 bolts shall meet the requirements of ASTM F 436 and
may be circular, beveled, or extra thick, as required. The surface condition and weathering
characteristics of the washers shall be the same as for the bolts being specified.

Direct Tension Indicators shall conform to the requirements of ASTM F 959 and may be used with
either ASTM A 325 or ASTM A 490 bolts. Direct tension indicators shall be galvanized by mechanical
deposition in accordance with ASTM B 695 class 55. Hot-dip galvanizing will not be allowed.

All bolts, nuts, and direct tension indicators shall be marked and identified as required in the pertinent
Specifications.

Lock-pin and collar fasteners which meet the materials, manufacturing, and chemical composition
requirements of ASTM A 325 or ASTM A 490, and which meet the mechanical property requirements
of the same Specification in full size tests, and which have a body diameter and bearing areas under

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lock-pin head and collar not less than those provided by a bolt and nut of the same nominal size may
be used. The Contractor shall submit a detailed installation procedure to the Engineer for approval.
Approval from the Engineer to use a lock-pin and collar fasteners shall be received by the Contractor
prior to use.

The Contractor shall provide Manufacturer’s Certificate of Compliance for all bolts, nuts, washers, and
load indicators. The Manufacturer’s Certificate of Compliance shall include certified mill test reports
and test reports performed on the finished bolt confirming that all of the materials provided meet the
requirements of the applicable AASHTO or ASTM Specification. The documentation shall also include
the name and address of the test laboratory, the date of testing, the lot identification of the bolts and
nuts, and coating thickness for galvanized bolts and nuts. Shipping containers (not lids) shall be
marked with the lot identification of the item contained therein.

Bolts shall be sampled prior to incorporating into a structure. For the purposes of selecting samples, a
lot of bolts shall be the quantity of bolts of the same nominal diameter and same nominal length in a
consignment shipped to the project site. The minimum number of samples from each lot shall be as
follows:

All testing of bolts, nuts, washers, and load indicating devices shall be performed on specimens as
they are to be installed.

All samples shall include a Manufacturer’s Certificate of Compliance for each lot of bolts provided as
defined in the specification.

14.2.5 Steel Castings

Steel castings shall conform to the requirements of AASHTO M 103, Mild to Medium Strength Carbon
Steel Castings for General Application, grade 70-36, unless otherwise designated in the Plans or in
the Special Provisions.

14.2.6 Steel Forgings and Steel Shafting

Steel forgings shall conform to the requirements of AASHTO M 102. The classes of forgings to be
furnished shall be those specified in the Plans or in the Special Provisions.

Steel shafting shall conform to the requirements of AASHTO M 169, Grade Designation 1016 to 1030
inclusive, unless otherwise specified.

14.2.7 Welded Shear Connectors

Welded shear studs shall be made from cold drawn bar stock conforming to the requirements of
AASHTO M 169. Grades 1010 through 1020, inclusive, either semi-killed or killed deoxidation.
The material shall conform to the following mechanical properties:

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Tensile Strength 60,000 psi min.
Yield Strength 50,000 psi min.
Elongation 20% min.
Reduction of Area 50% min.
Mechanical properties shall be determined in accordance with AASHTO Methods and Definitions T
244.

At the manufacturer’s option, mechanical properties of the studs shall be determined by testing either
the steel after cold finishing, or the full diameter finished studs.

14.2.8 Bolts, Washers, and Other Hardware

Ordinary machine bolts and flat head bolts shall be made from commercial bolt stock meeting the
Specifications of ASTM A 307, and shall be grade A. Drift bolts and dowels may be either wrought
iron or medium steel. Washers may be cast iron or malleable iron or may be cut from medium steel or
wrought iron plate.

All bolts and other hardware which are to be galvanized and which require bending or shaping shall
be hot forged to the required shape before galvanizing. Cold bending of such material will not be
permitted because of the tendency toward embrittlement during the galvanizing process. Galvanizing
shall be in accordance with AASHTO M 232.

Split rings for log cribbing of 4 inches inside diameter shall be manufactured from hot rolled, low
carbon steel conforming to ASTM A 711 AISI, Grade 1015. Each ring shall form a true circle with the
principle axis of the cross section of the ring metal parallel to the geometric axis of the ring. The
thickness of the metal section shall be 0.195 inch plus or minus 0.010 inch and the section shall be
beveled from the central portion toward the edges to a thickness of 0.145 inch plus or minus 0.010
inch. It shall be cut through in one place in its circumference to form a tongue and slot. Split ring
connectors shall be galvanized in accordance with AASHTO M 232.

Spike-grid timber connectors shall be manufactured according to ASTM A 47 for malleable iron
castings. They shall consist of four rows of opposing spikes forming a 4⅛-inch square grid with 16
teeth which are held in place by fillets which are diamond shaped in cross section.

Nails shall be round wire of standard form. Spikes shall be wire spikes or boat spikes, as specified in
the Plans. Bolts, dowels, washers, and other hardware, including nails, shall be black or galvanized
as specified in the Plans, but if not so specified shall be galvanized when used in treated timber
structures.

14.3 Construction Requirements

14.3.1 Facilities for Infection

The Contractor shall provide all facilities the Inspector requires to inspect material and workmanship.
Inspectors shall be given safe and free access to all areas in the mill and shop.

14.3.2 Inspector’s Authority

The Inspector may reject materials or workmanship that does not comply with these Specifications. In
any dispute, the Contractor may appeal to the Engineer whose decision shall be final.

By its inspection at the mill and shop, the Contracting Agency intends only to facilitate the Work and
prevent errors. This inspection shall not relieve the Contractor of any responsibility for identifying and
replacing defective material or workmanship.

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14.3.3 Rejections

Even if the Inspector accepts materials or finished members, the Contracting Agency may later reject
them if defective. The Contractor shall promptly replace or make good any rejected materials or
workmanship.

14.3.4 Mill Orders and Shipping Statement

The Contractor shall furnish as many copies of mill orders and shipping statements as the Engineer
requires.

14.3.5 Weighing

Structural steel need not be weighed unless the Plans or Special Provisions require it. When a weight
is required, it may either be calculated or obtained by scales. The Contractor shall furnish as many
copies of the calculations or weight slips as the Engineer requires. If scale weights are used, the
Contractor shall record separately the weights of all tools, erection material, and dunnage.

14.3.6 Shop Plans

The Contractor shall submit for approval all shop detail plans for fabricating the steel. These shall be
sent to the Authority.

If these plans will be submitted directly from the fabricator, the Contractor shall so notify the Project
Engineer in writing.

Prints of the plans shall be supplied in these quantities:

1. Eight sets to the Bridge and Structures Engineer (four more sets are required for each affected
railroad company on any grade separation Structure that carries a railroad over a Highway), and
2. Two sets to the Project Engineer.

The Bridge and Structures Engineer will return the plans to the Project Engineer, who will forward
copies to the Contractor. If any sheets require correction, the Contractor shall correct and resubmit
them in the quantities required above. No material shall be fabricated until: (1) the Bridge and
Structures Engineer has approved the plans, and (2) the State Materials Engineer has approved the
materials source and the fabricator.

In approving shop plans, the Contracting Agency accepts only the nature and scope of the details
without validating any dimensions.

Unless the Engineer permits it in writing, no changes shall be made in any drawing after its approval.

Before physical completion of the project, the Contractor shall furnish the Project Engineer one set of
reproducible copies of the as built shop plans. (One more set is required for each affected railroad
company on any grade separation Structure that carries a railroad over a Highway.) The reproducible
copies shall be clear, suitable for microfilming, and on permanent sheets that measure no smaller
than 11 by 17 inches. Alternatively, the shop drawings may be provided in an electronic format with
the approval of the Bridge and Structures Engineer.

Erection Methods
Before beginning to erect any steel Structure, the Contractor shall submit to the Engineer for review
and shall have received approval for the erection plan and procedure describing the methods the
Contractor intends to use.

The erection plan and procedure shall provide complete details of the erection process including but
not limited to:

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1. Temporary falsework support, bracing, guys, deadmen, and attachments to other Structure
components or objects;
2. Procedure and sequence of operation;
3. Girder stresses during progressive stages of erection;
4. Girder masses, lift points, and lifting devices, spreaders, glommers, etc.;
5. Crane(s) make and model, mass, geometry, lift capacity, outrigger size and reactions;
6. Girder launcher or trolley details and capacity (if intended for use); and
7. Locations of cranes, barges, trucks delivering girders, and the location of cranes and outriggers
relative to other Structures, including retaining walls and wing walls.

The Contractor may submit for approval the use of an engineered and fabricated lifting bracket bolted
to the girder top flanges providing the following requirements are satisfied:
1. The lifting bracket shall be engineered and supporting calculations shall be submitted with the
erection plan;
2. The calculations shall include critical stresses in the girder including local stresses in the flanges
at lifting bracket locations;
3. The calculations shall include computation of the lifting bracket and associated bolt hole locations
and the expected orientation of the girder during picking operation;
4. The lifting bracket shall be load tested and certified for a load at least 2 times the working load
and at all angles it will be used (angle of load or rigging). Certification documentation from a
previous project may be submitted for approval;
5. Bolt holes in girders added for the lifting bracket connections shall be shown in the shop plans
and shall be drilled in the shop. Field drilling of bolt holes for lifting brackets will not be permitted;
6. Bolt holes in girder top flanges shall be filled with high strength bolts after erection.

The erection plan shall include drawings, notes, catalogue cuts, and calculations clearly showing the
above listed details, assumptions, and dimensions. Material properties, Specifications, structural
analysis, and any other data used shall also be included. The plan, including lifting bracket working
drawings and calculations, shall be prepared by (or under the direct supervision of) a Licenced
Professional Engineer.

The Contractor shall submit the erection plans, calculations, procedure, and fabricator’s comments
directly to the Authority. After the plan is approved and returned to the Contractor, all changes that the
Contractor proposes shall be submitted to the Project Engineer for review and approval.

14.3.7 Substitutions

The Contractor shall not substitute sections that differ from Plan dimensions unless the Engineer
approves in writing. If the Contractor requests and receives approval to substitute heavier members,
the Contracting Agency shall not pay any added cost.

14.3.8 Handling, Storing, and Shipping of Materials

Markings applied at the mill shall distinguish structural low alloy steel from structural carbon steel. The
fabricator shall keep the two classes of steel carefully separated.

Before fabrication, all material stored at the fabricating plant shall be protected from rust, dirt, oil, and
other foreign matter. The Contracting Agency will accept no rust-pitted material.
After fabrication, all material awaiting shipment shall be subject to the same storage requirements as
unfabricated material.

All structural steel shall arrive at the job in good condition. As the Engineer requires, steel damaged
by salt water shipment shall be thoroughly cleaned by high pressure water flushing, chemical
cleaning, or sandblasting, and repainted with the specified shop coat.

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All material shall be stored so as to prevent rust and loss of small parts. Piled material shall not rest
on the ground or in water but on skids or platforms.

The loading, transporting, unloading, and piling of the structural steel material shall be so conducted
that the metal will be kept clean and free from injury from rough handling.

In field assembly of structural parts, the Contractor shall use methods and equipment not likely to
twist, bend, deform, or otherwise injure the metal. Any member slightly bent or twisted shall be
corrected before it is placed. The Contracting Agency will reject any member with serious handling
damage.

Girder sections shall be handled so as to prevent damage to the girders. If necessary, the Contractor
shall provide temporary stiffeners to prevent buckling during erection.

14.3.9 Straightening Bent Material

If the Engineer permits in writing, plates, angles, other shapes, and built-up members may be
straightened. Straightening methods shall not fracture or injure the metal. Distorted members shall be
straightened mechanically. A limited amount of localized heat may be applied only if carefully planned
and supervised, and only if the Engineer has approved a heat-straightening procedure in writing.
Parts to be heat-straightened shall be nearly free from all stress and external forces except those that
result from the mechanical pressure used with the heat.

After straightening, the Contractor will inspect the member for fractures using a method determined by
the Contracting Agency.

The Contracting Agency will reject metal showing sharp kinks and bends.

The procedure for heat straightening of universal mill (UM) plates by the mill or the fabricator shall be
submitted to the Engineer for approval.

14.3.10 Workmanship and Finish

Workmanship and finish shall be first-class, equalling the best practice in modern bridge fabrication
shops. Welding, shearing, burning, chipping, and grinding shall be done neatly and accurately. All
parts of the Work exposed to view shall be neatly finished.

Wherever the Plans show a surface finish symbol, the surface shall be machined.

14.3.11 Falsework

All falsework shall meet the requirements of Section 13.3.6 above mentioned.

14.3.12 Fabricating Tension Members

Plates for main load-carrying tension members or tension components of flexural members shall be:
1. Blast cleaned entirely or blast cleaned on all areas within 2 inches of welds to SSPC-SP6,
Commercial Blast Cleaning; and
2. Fabricated from plate stock with the primary rolling direction of the stock parallel to the length of
the member, or as shown in the Plans.

14.3.13 Edge Finishing

All rolled, sheared, and thermal cut edges shall be true to line and free of rough corners and
projections. Corners along exposed sheared or cut edges shall be broken by light grinding or another
method approved by the Engineer to achieve an approximate 1/16-inch chamfer or rounding.

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Sheared edges on plates more than ⅝ inch thick shall be planed, milled, ground, or thermal cut to a
depth of at least ⅛ inch.

Re-entrant corners or cuts shall be filleted to a minimum radius of 1 inch.

Exposed edges of main load-carrying tension members or tension components of flexural members
shall have a surface roughness no greater than 250-micro inches as defined by the American
National Standards Institute, ANSI B46.1, Surface Texture. Exposed edges of other members shall
have surface roughness no greater than 1,000-micro inches.
The Rockwell hardness of thermal-cut edges of structural low alloy or high-strength steel flanges, for
main load-carrying tension members or tension components of flexural members shall not exceed
RHC 30. The fabricator shall prevent excessive hardening of flange edges through preheating, post
heating, or control of the burning process as recommended by the steel manufacturer and approved
by the Engineer.

Hardness testing shall consist of testing thermal-cut edges with an approved portable hardness tester.
The hardness tester, and it’s operating test procedures, shall be submitted to the Engineer for
approval prior to use. The hardness tester shall be convertible to Rockwell C scale values.

At two locations, two tests shall be performed on each thermal-cut edge, one each within ¼ inch of
the top and bottom surfaces. The tests shall be located ¼ the length of each thermal-cut edge from
each end of the cut. If one or more readings are greater than RHC 30, the entire length of the edge
shall be ground or machined to a depth sufficient to provide acceptable readings upon further retests.
If thermal-cutting operations conform to procedures approved by the Engineer, and hardness testing
results are consistently within acceptable limits, the Engineer may approve a reduction in the testing
frequency.

14.3.14 Planning of Bearing Surfaces

Ends of columns that bear on base and cap plates shall be milled to true surfaces and accurate
bevels.

When assembled, caps and base plates of columns and the sole plates of girders and trusses shall
have a fit tolerance within 1/32 inch for 75 percent of the contact area. If warped or deformed, the
plates shall be heat straightened, planed, or corrected in some other way to produce accurate, even
contact. If necessary for proper contact, bearing surfaces that will contact other metal surfaces shall
be planed or milled. Surfaces of warped or deformed base and sole plates that will contact masonry
shall be rough finished.

On the surface of expansion bearings, the cut of the planer shall be in the direction of expansion.

14.3.15 Abutting Joints

Abutting ends of compression members shall be faced accurately so that they bear evenly when in
the Structure. On built-up members, the ends shall be faced or milled after fabrication.

Ends of tension members at splices shall be rough finished to produce neat, close joints. A contact fit
is not required.

14.3.16 End Connection Angle

On floorbeams and stringers, end connection angles shall be flush with each other and set accurately
in relationship to the position and length of the member. Unless the Plans require it, end connection
angles shall not be finished. If, however, faulty assembly requires them to be milled, milling shall not
reduce thickness by more than ¹/16 inch.

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14.3.17 Built Members

The various pieces forming one built member shall be straight and close fitting, true to detailed
dimensions, and free from twists, bends, open joints, or other defects.

When fabricating curved girders, localized heat or the use of mechanical force shall not be used to
bend the girder flanges about an axis parallel to girder webs.

14.3.18 Hand Holes

Hand holes, whether punched or cut with burning torches, shall be true to sizes and shapes shown in
the Plans. Edges shall be true to line and ground smooth.

14.3.19 Lacing Bars

Unless the Plans state otherwise, ends of lacing bars shall be neatly rounded.

14.3.20 Plate Girders

Web Plates
If web plates are spliced, gaps between plate ends shall be set at shop assembly to measure ¼ inch,
and shall not exceed ⅜ inch.

Web Splices and Fillers

Web splice plates and fillers under stiffeners shall fit within ⅛ inch at each end. In lieu of the steel
material specified in the Plans or Special Provisions, the Contractor may substitute ASTM A 1008 or
ASTM A 1011 steel for all filler plates less than ¼ inch thickness, provided that the grade of filler plate
steel meets or exceeds that of the splice plates.

14.3.21 Eyebars

Eyebars shall be straight, true to size, and free from twists or folds in the neck or head and from any
other defect that would reduce their strength. Heads shall be formed by upsetting, rolling, or forging.
Dies in use by the manufacturer may determine the shape of bar heads if the Engineer approves.
Head and neck thickness shall not overrun by more than ¹/16 inch. Welds shall not be made in the
body or head of any bar.

Each eyebar shall be properly annealed and carefully straightened before it is bored. Pinholes shall
be located on the centerline of each bar and in the center of its head. Holes in bar ends shall be so
precisely located that in a pile of bars for the same truss panel the pins may be inserted completely
without driving. All eyebars made for the same locations in trusses shall be interchangeable.

14.3.22 Annealing

All eyebars shall be annealed by being heated uniformly to the proper temperature, then cooled
slowly and evenly in the furnace. At all stages, the temperature of the bars shall be under full control.

Slight bends on secondary steel members may be made without heat. Crimped web stiffeners need
no annealing.

14.3.23 Pins and Rollers

Pins and rollers shall be made of the class of forged steel the Plans specify. They shall be turned
accurately to detailed dimensions, smooth, straight, and flawless. The final surface shall be produced
by a finishing cut.

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Pins and rollers 9 inches or less in diameter may either be forged and annealed or made of cold-
finished carbon steel shafting.

Pins more than 9 inches in diameter shall have holes at least 2 inches in diameter bored longitudinally
through their centers. Pins with inner defects will be rejected.

The Contractor shall provide pilot and driving nuts for each size of pin unless the Plans state
otherwise.

Boring Pin Holes

Pin holes shall be bored true to detailed dimensions, smooth and straight, and at right angles to the
axis of the member. Holes shall be parallel with each other unless the Plans state otherwise. A
finishing cut shall always be made.

The distance between holes shall not vary from detailed dimensions by more than ¹/32 inch. In
tension members, this distance shall be measured from outside to outside of holes; in compression
members, inside to inside.

Pin Clearances
Each pin shall be ¹/50 inch smaller in diameter than its hole. All pins shall be numbered after being
fitted into their holes in the assembled member.

14.3.24 Welding and Repair Welding

Welding and repair welding of all steel bridges shall comply with the AASHTO/AWS D1.5M/D1.5:
2010 Bridge Welding Code. Welding and repair welding for all other steel fabrication shall comply with
the AWS D1.1/D1.1M, latest edition, Structural Welding Code. The requirements described in the
remainder of this Section shall prevail whenever they differ from either of the above welding codes.

The Contractor shall weld structural steel only to the extent shown in the Plans. No welding, including
tack and temporary welds shall be done in the shop or field unless the location of the welds is shown
on the approved shop drawings or approved by the Engineer in writing.

Welding procedures shall be submitted for approval with shop drawings. The procedures shall specify
the type of equipment to be used, electrode selection, preheat requirements, base materials, and joint
details. When the procedures are not prequalified by AWS or AASHTO, evidence of qualification tests
shall be submitted.

Welding shall not begin until after the Contractor has received the Engineer’s approval of shop plans
as required. These plans shall include procedures for welding, assembly, and any heat-straightening
or heat-curving.
Any welded shear connector longer than 8 inches may be made of two shorter shear connectors
joined with full-penetration welds.
In shielded metal-arc welding, the Contractor shall use low-hydrogen electrodes.

In submerged-arc welding, flux shall be oven-dried at 288ºC (550ºF) for at least 2 hours, then stored
in ovens held at 121ºC (250ºF) or more. If not used within 4 hours after removal from a drying or
storage oven, flux shall be redried before use.
Preheat and interpass temperatures shall conform to the applicable welding code as specified in this
Section. When welding main members of steel bridges, the minimum preheat shall not be less than
38ºC (100ºF).

If groove welds (web-to-web or flange-to-flange) have been rejected, they may be repaired no more
than twice. If a third failure occurs, the Contractor shall:
1. Trim the members, if the Engineer approves, at least ½ inch on each side of the weld; or
2. Replace the members at no expense to the Contracting Agency.

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By using extension bars and runoff plates, the Contractor shall terminate groove welds in a way that
ensures the soundness of each weld to its ends. The bars and plates shall be removed after the weld
is finished and cooled. The weld ends shall then be ground smooth and flush with the edges of
abutting parts.

The Contractor shall not:

1. Weld with electrogas or electroslag methods, or
2. Use coped holes in the web for welding butt splices in the flanges unless the Plans show them.

Welding Inspection
The Contractor’s inspection procedures, techniques, methods, acceptance criteria, and inspector
qualifications for welding of steel bridges shall be in accordance with the AASHTO/AWS D1.5M/D1.5:
2010 Bridge Welding Code. The Contractor’s inspection procedures, techniques, methods,
acceptance criteria, and inspector qualifications for welding of steel Structures other than steel
bridges shall be in accordance with AWS D1.1/D1.1M, latest edition, Structural Welding Code. The
requirements described in the remainder of this Section shall prevail whenever they differ from either
of the above welding codes.

Non-destructive testing in addition to visual inspection shall be performed by the Contractor. Unless
otherwise shown in the Plans or specified in the Special Provisions, the extent of inspection shall be
as specified in this Section. Testing and inspection shall apply to welding performed in the shop and
in the field.

After the Contractor’s welding inspection is complete, the Contractor shall allow the Engineer
sufficient time to perform quality assurance ultrasonic welding inspection.

Visual Inspection
All welds shall be 100 percent visually inspected. Visual inspection shall be performed before, during,
and after the completion of welding.

Radiographic Inspection
Complete penetration tension groove welds in Railway bridges shall be 100 percent radiographically
inspected. These welds include those in the tension area of webs, where inspection shall cover the
greater of these two distances: (a) 15 inches from the tension flange, or (b) ⅓ of the web depth. In
addition, edge blocks conforming to the requirements of AASHTO/AWS D1.5M/D1.5: 2010 Bridge
Welding Code.

The Contractor shall maintain the radiographs and the radiographic inspection report in the shop until
the last joint to be radiographed in that member is accepted by the radiographer representing the
Contractor. Within 2 working days following this acceptance, the Contractor shall mail the film and two
copies of the radiographic inspection report to the Authority.

Ultrasonic Inspection
Complete penetration groove welds on plates thicker than 5/16 inch in the following welded
assemblies or Structures shall be 100 percent ultrasonically inspected:
1. Welded connections and splices in Highway bridges and earth retaining Structures, excluding
longitudinal butt joint welds in beam or girder webs.
2. Bridge bearings and modular expansion joints.
3. Sign bridges, cantilever sign Structures, and bridge mounted sign brackets excluding longitudinal
butt joint welds in beams.
4. Light, signal, and strain pole standards.

The testing procedure and acceptance criteria for tubular members shall conform to the requirements
of the AWS D1.1/D1.1M latest edition, Structural Welding Code.

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Magnetic Particle Inspection
1. Fillet and partial penetration groove welds:
At least 30 percent of each size and type of fillet welds (excluding intermittent fillet welds) and
partial penetration groove welds in the following welded assemblies or Structures shall be tested
by the magnetic particle method:
a. Flange-to-web connections in Highway bridges.
b. End and intermediate pier diaphragms in Highway bridges.
c. Stiffeners and connection plates in Highway bridges.
d. Welded connections and splices in earth retaining Structures.
e. Boxed members of trusses.
f. Bridge bearings and modular expansion joints.
g. Sign bridges, cantilever sign Structures, and bridge mounted sign brackets.
h. Light, signal, and strain pole standards

2. Longitudinal butt joint welds in beam and girder webs:

At least 30 percent of each longitudinal butt joint weld in the beam and girder webs shall be tested
by the magnetic particle method.

3. Complete penetration groove welds on plates 5/16 inch or thinner shall be 100 percent tested by
the magnetic particle method. Testing shall apply to both sides of the weld, if backing plate is not
used.

4. The ends of each complete penetration groove weld at plate edges shall be tested by the
magnetic particle method.

Where 100 percent testing is not required, the Engineer reserves the right to select the location(s) for
testing.

If rejectable flaws are found in any test length of weld in item 1 or 2 above, the full length of the weld
or 5 feet on each side of the test length, whichever is less, shall be tested.

14.3.25 Screw Threads

Screw threads shall be Indonesian Standard (SNI) or US Standard and shall fit closely in the nuts.

14.3.26 High-Strength Bolt Holes

At the Contractor’s option under the conditions described in this Section, holes may be punched or
subpunched and reamed, drilled or subdrilled and reamed, or formed by numerically controlled drilling
operations.

The hole for each high-strength bolt shall be ¹/16 inch larger than the nominal diameter of the bolt.
In fabricating any connection, the Contractor may subdrill or subpunch the holes then ream full size
after assembly or drill holes full size from the solid with all thicknesses of material shop assembled in
the proper position. If the Contractor chooses not to use either of these methods, then the following
shall apply:
1. Drill bolt holes in steel splice plates full size using steel templates.
2. Drill bolt holes in the main members of trusses, arches, continuous beam spans, bents, towers,
plate girders, box girders, and rigid frames at all connections as follows:
a. A minimum of 30 percent of the holes in one side of the connection shall be made full size
using steel templates.
b. A minimum of 30 percent of the holes in the second side shall be made full size assembled in
the shop.
c. All remaining holes may be made full size in unassembled members using steel templates.

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3. Drill bolt holes in crossframes, gussets, lateral braces, and other secondary members full size
using steel templates.

The Contractor shall submit for the Engineer’s approval a detailed outline of the procedures proposed
to accomplish the Work from initial drilling through shop assembly.

Punched Holes
For punched holes, die diameter shall not exceed punch diameter by more than ¹/16 inch. Any hole
requiring enlargement to admit the bolt shall be reamed. All holes shall be cut clean with no torn or
ragged edges. The Contracting Agency will reject components having poorly matched holes.

Reamed and Drilled Holes

Reaming and drilling shall be done with short taper reamers or twist drills, producing cylindrical holes
perpendicular to the member. Reamers and drills shall be directed mechanically, not hand-held.
Connecting parts that require reamed or drilled holes shall be assembled and held securely as the
holes are formed, then match-marked before disassembly. The Contractor shall provide the Engineer
a diagram showing these matchmarks. The Contracting Agency will reject components having poorly
matched holes.

Burrs on outside surfaces shall be removed. If the Engineer requires, the Contractor shall
disassemble parts to remove burrs.

If templates are used to ream or drill full-size connection holes, the templates shall be positioned and
angled with extreme care and bolted firmly in place. Templates for reaming or drilling matching
members or the opposite faces of one member shall be duplicates. All splice components shall be
match-marked unless otherwise approved by the Engineer.

Numerically Controlled Drilled Connections

In forming any hole described in, the fabricator may use numerically controlled (N/C) drilling or
punching equipment if it meets the requirements in this Subsection.
The Contractor shall submit for approval a detailed outline of proposed N/C procedures. This outline
shall:
1. Cover all steps from initial drilling or punching through check assembly;
2. Include the specific members of the Structure to be drilled or punched, hole sizes, locations of the
common index and other reference points, makeup of check assemblies, and all other information
needed to describe the process fully.

N/C holes may be drilled or punched to size through individual pieces, or may be drilled through any
combination of tightly clamped pieces.

When the Engineer requires, the Contractor shall demonstrate that the N/C procedure consistently
produces holes and connections meeting the requirements of these Specifications.

Accuracy of Punched, Subpunched, and Subdrilled Holes

After shop assembly and before reaming, all punched, subpunched, and subdrilled holes shall meet
the following standard of accuracy. At least 75 percent of the holes in each connection shall permit
the passage of a cylindrical pin ⅛ inch smaller in diameter than nominal hole size. This pin shall pass
through at right angles to the face of the member without drifting. All holes shall permit passage of a
pin ³/16 inch smaller in diameter than nominal hole size. The Contracting Agency will reject any pieces
that fail to meet these standards.

Accuracy of Reamed and Drilled Holes

At least 85 percent of all holes in a connection of reamed or drilled holes shall show no offset greater
than ¹/32 inch between adjacent thicknesses of metal. No hole shall have an offset greater than ¹/16
inch.

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Centerlines from the connection shall be inscribed on the template and holes shall be located from
these centerlines. Centerlines shall also be used for accurately locating the template relative to the
milled or scribed ends of the members.

Templates shall have hardened steel bushing inserted into each hole. These bushings may be
omitted, however, if the fabricator satisfies the Engineer (1) that the template will be used no more
than five times, and (2) that use will produce no template wear.

Each template shall be at least ½ inch thick. If necessary, thicker templates shall be used to prevent
buckling and misalignment as holes are formed.

Fitting for Bolting

Before drilling, reaming, and bolting begins, all parts of a member shall be assembled, well pinned,
and drawn firmly together. If necessary, assembled pieces shall be taken apart to permit removal of
any burrs or shavings produced as the holes are formed. The member shall be free from twists,
bends, and other deformation.

In shop-bolted connections, contacting metal surfaces shall be sandblasted clean before assembly.
Sandblasting shall meet the requirements of the SSPC Specifications for Commercial Blast Cleaning
(SSPC-SP 6).

Any drifting done during assembly shall be no more than enough to bring the parts into place. Drifting
shall not enlarge the holes or distort the metal.

14.3.27 Shop Assembly

Method of Shop Assembly

Unless the Contract states otherwise, the Contractor shall choose one of the five shop assembly
methods described below that will best fit the proposed erection method. The Contractor shall obtain
the Engineer’s approval of both the shop assembly and the erection methods before Work begins.
1. Full Truss or Girder Assembly – Each truss or girder is completely assembled over the full
length of the Superstructure.
2. Progressive Truss or Girder Assembly – Each truss or girder is assembled in stages
longitudinally over the full length of the Superstructure.
a. For Trusses – The first stage shall include at least three adjacent truss panels. Each truss
panel shall include all of the truss members in the space bounded by the top and bottom
chords and the horizontal distance between adjacent bottom chord Joints.
b. For Girders – The first stage shall include at least three adjacent girder shop sections. Shop
sections are measured from the end of the girder to the first field splice or from field splice to
field splice.
c. For Trusses and Girders – After the first stage has been completed, each subsequent stage
shall be assembled to include: at least one truss panel or girder shop section of the previous
stage and two or more truss panels or girder shop sections added at the advancing end. The
previous stages shall be repositioned if necessary, and pinned to ensure accurate alignment.
For straight sections of bridges without skews or tapers, girders in each subsequent stage
may be assembled to include one girder shop section from the previous stage and one or
more girder shop sections at the advancing end.
If the bridge is longer than 150 feet, each longitudinal stage shall be at least 150 feet long,
regardless of the length of individual continuous truss panels or girder shop sections.
The Contractor may begin the assembly sequence at any point on the bridge and proceed in
either or both directions from that point.
Unless the Engineer approves otherwise, no assembly shall have less than three truss panels
or girder shop sections.

3. Full Chord Assembly – The full length of each chord for each truss is assembled with geometric
angles at the joints. Chord connection bolt holes are drilled/reamed while members are

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 assembled. The truss web member connections are drilled/reamed to steel templates set by
relating geometric angles to the chord lines.
At least one end of each web member shall be milled or scribed at right angles to its long axis.
The templates at both ends of the member shall be positioned accurately from the milled end or
scribed line.
4. Progressive Chord Assembly – Adjacent chord sections are assembled in the same way as
specified for Full Chord Assembly, using the procedure specified for Progressive Truss or Girder
Assembly.

5. Special Complete Structure Assembly – All structural steel members (Superstructure and
Substructure, including all secondary members) are assembled at one time.

Check of Shop Assembly

The Contractor shall check each assembly for alignment, accuracy of holes, fit of milled joints, and
other assembly techniques. Drilling or reaming shall not begin until the Engineer has given approval.
If the Contractor uses N/C drilling, this approval must be obtained before the assembly or stage is
dismantled.

14.3.28 Welded Shear Connector

All welded shear connectors on steel girder top flanges shall be installed in the field after the forms for
the concrete bridge deck are in place. The steel surface to be welded shall be prepared to SSPC-SP
11, power tool cleaning, just prior to welding. Installation, production control, and inspection of welded
shear connectors shall conform to Chapter 7 of the AASHTO/AWS D1.5M/D1.5: 2010 Bridge Welding
Code. After the welded shear connectors are installed, the weld and the disturbed steel surface shall
be cleaned and painted in accordance.

14.3.29 Painting

All painting shall be in accordance with the specification, which for all steel bridge material will be hot
dipped galvanized with minimum thickness of 160 microns.

Erection Marks
Erection marks to permit identification of members in the field shall be painted on previously painted
surfaces.

Machine Finished Surfaces

As soon as possible and before they leave the shop, machine-finished surfaces on abutting chord
splices, column splices, and column bases shall be covered with grease. After erection, the steel shall
be cleaned and painted as specified.

All surfaces of iron and steel castings milled to smooth the surface shall be painted with the primer
called for in the specified paint system.
While still in the shop, machine-finished surfaces and inaccessible surfaces of rocker or pin-type
bearings shall receive the full paint system. Surfaces of pins and holes machine-finished to specific
tolerances shall not be painted. But as soon as possible and before they leave the shop, they shall be
coated with grease.

14.3.30 Alignment and Camber

Before beginning field bolting, the Contractor shall:

1. Adjust the Structure to correct grade and alignment,
2. Regulate elevations of panel points (ends of floor beams), and
3. Delay bolting at compression joints until adjusting the blocking to provide full and even bearing
over the whole joint.

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On truss spans, a slight excess camber will be permitted as the bottom chords are bolted. But camber
and relative elevations of panel points shall be correct before the top chord joints, top lateral system,
and sway braces are bolted.

Measuring Camber
The Contractor shall provide the Engineer with a diagram for each truss that shows camber at each
panel point. This diagram shall display actual measurements taken as the truss is being assembled.

14.3.31 Assembling and Bolting

To begin bolting any field connection or splice, the Contractor shall install and tighten to snug tight
enough bolts to bring all parts into full contact with each other prior to tightening these bolts to the
specified minimum tension. “Snug tight” means either the tightness reached by (1) a few blows from
an impact wrench or (2) the full effort of a person using a spud wrench.

As erection proceeds, all field connections and splices for each member shall be securely drift pinned
and bolted in accordance with 1 or 2 below before the weight of the member can be released or the
next member is added. Field erection drawings shall specify pinning and bolting requirements that
meet or exceed the following minimums:
1. Joints in Normal Structures – Fifty percent of the holes in a single field connection and 50
percent of the holes on each side of a single joint in a splice plate shall be filled with drift pins and
bolts. Thirty percent of the filled holes shall be pinned. Seventy percent of the filled holes shall be
bolted and tightened to snug tight. Once all these bolts are snug tight, each bolt shall be
systematically tightened to the specified minimum tension. “Systematically tightened” means
beginning with bolts in the most rigid part, which is usually the center of the joint, and working out
to its free edges. The fully tensioned bolts shall be located near the middle of a single field
connection or a single splice plate.
2. Joints in Cantilevered Structures – Seventy-five percent of the holes in a single field
connection and 75 percent of the holes on each side of a single joint in a splice plate shall be
filled with drift pins and bolts. Fifty percent of the filled holes shall be pinned. Fifty percent of the
filled holes shall be bolted and tightened to snug tight. Once all these bolts are snug tight, each
bolt shall be systematically tightened to the specified minimum tension. The fully tensioned bolts
shall be located near the middle of a single field connection or a single splice plate.

Cylindrical erection pins (drift pins) shall be placed throughout each field connection and each field
joint with the greatest concentration in the outer edges of a splice plate or member being bolted. Drift
pins shall be double-tapered barrel pins of hardened steel. The diameter of the drift pins shall be at
least 1/32 inch larger than the diameter of the bolts in the connection or the full hole diameter.

To complete a joint following one of the methods listed above, the Contractor shall fill all remaining
holes of the field connection or splice plate with bolts and tighten to snug tight. Once all of these bolts
are snug tight, each bolt shall be systematically tightened to the specified minimum tension. After
these bolts are tightened to the specified minimum tension, the Contractor shall replace the drift pins
with bolts tightened to the specified minimum tension.

The Contractor shall complete the joint or connection within ten calendar days of installing the first
bolt or within a duration approved by the Engineer. Any bolts inserted in an incomplete connection,
either loose or tightened snug-tight, which exceed the specified duration for completing the
connection, shall be subject to the following requirements:
1. Three assemblies for each size and length shall be removed from connection(s) that are to be
tensioned. Rotational capacity tests shall be performed on the removed assemblies to
demonstrate the assembly has sufficient lubricant to be tensioned satisfactorily.
2. Five assemblies shall be removed from the connection to establish the inspection torque.
3. In the case of tension-controlled bolts, three assemblies shall be removed and tested in
accordance with the specification to verify the minimum specified tension can be achieved prior to
shearing of the spline.

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Assemblies removed for the purpose of rotational capacity testing, determination of the inspection
torques, or verification of tension-controlled bolt performance shall be replaced with new bolts at no
additional expense to the Contracting Agency. To minimize the number of removed assemblies, the
Contractor may combine rotational capacity testing and inspection torque determination as approved
by the Engineer.

The Contractor may complete a field bolted connection or splice in a continuous operation before
releasing the mass of the member or adding the next member. The Contractor shall utilize drift pins to
align the connection. The alignment drift pins shall fill between 15 and 30 percent of the holes in a
single field connection and between 15 and 30 percent of the holes on each side of a single joint in a
splice plate. Once the alignment drift pins are in place, all remaining holes shall be filled with bolts and
tightened to snug tight starting from near the middle and proceeding toward the outer gage lines.
Once all of these bolts are snug tight, the Contractor shall systematically tighten all these bolts to the
specified minimum tension. The Contractor shall then replace the drift pins with bolts. Each of these
bolts shall be tightened to the specified minimum tension.

All bolts shall be placed with heads toward the outside and underside of the bridge. All high-strength
bolts shall be installed and tightened before the falsework is removed.

The Contractor may erect metal railings as erection proceeds. But railings shall not be bolted or
adjusted permanently until the falsework is released and the deck placed.

The Contractor shall not begin painting until the Engineer has inspected and accepted field bolting.

14.3.32 Bolted Connections

Fastener components shall consist of bolts, nuts, washers, tension control bolt assemblies, and direct
tension indicators. Fastener components shall meet the requirements of this specification.

The Contractor shall submit documentation of the bolt tension calibrator for approval by the Engineer
and shall include brand, capacity, model, date of last calibration, and manufacturer’s instructions for
use. The Contractor shall supply the approved bolt tension calibrator and all accompanying hardware
and calibrated torque wrenches to conduct all testing and inspections described herein. Use of the
bolt tension calibrator shall comply with manufacturer’s recommendations.

Fastener components shall be protected from dirt and moisture in closed containers at the site of
installation. Only as many fastener components as are anticipated to be installed during the Work shift
shall be taken from protected storage. Fastener components that are not incorporated into the Work
shall be returned to protected storage at the end of the Work shift. Fastener components shall not be
cleaned or modified from the as-delivered condition. Fastener components that accumulate rust or dirt
shall not be incorporated into the Work. Tension control bolt assemblies shall not be relubricated,
except by the manufacturer.

All bolted connections are slip critical. Painted structures require either Type 1 or Type 3 bolts. Bolts
shall not be galvanized unless specified in the Contract documents. Unpainted structures require
Type 3 bolts. AASHTO M 253 bolts shall not be galvanized and shall not be used in contact with
galvanized metal.
Washers are required under turned elements for bolted connections and as required in the following:
1. Washers shall be used under both the head and the nut when AASHTO M 253 bolts are to be
installed in structural carbon steel, as specified.
2. Where the outer face of the bolted parts has a slope greater than 1:20 with respect to a plane
normal to the bolt axis, a beveled washer shall be used.
3. Washers shall not be stacked unless otherwise approved by the Engineer.
4. It is acceptable to place a washer under the unturned element.

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All galvanized nuts shall be lubricated by the manufacturer with a lubricant containing a visible dye so
a visual check for the lubricant can be made at the time of field installation. Black bolts shall be
lubricated by the manufacturer and shall be “oily” to the touch when installed.

After assembly, bolted parts shall fit solidly together. They shall not be separated by washers,
gaskets, or any other material. Assembled joint surfaces, including those next to bolt heads, nuts, and
washers, shall be free of loose mill scale, burrs, dirt, and other foreign material that would prevent
solid seating.

When all bolts in a joint are tight, each bolt shall carry at least the proof load shown in Table 14-1
below:

Table 14-1. Minimum Bolt Tension

AASHTO M 164 and ASTM F
Bolt Size (inches) 1852 (pounds) AASHTO M 253 (pounds)
½ 12,050 14,900
⅝ 19,200 23,700
¾ 28,400 35,100
⅞ 39,250 48,500
1 51,500 63,600
1⅛ 56,450 80,100
1¼ 71,700 101,800

1⅜ 85,450 121,300

1½ 104,000 147,500

Prior to final tightening of any bolts in a bolted connection, the connection shall be compacted to a
snug tight condition. Snug tight shall include bringing all plies of the connection into firm contact and
snug tightening all bolts in accordance with the specification.

Final tightening may be done by the Turn-of-Nut Method, the direct-tension indicator method, or the
twist off-type tension control structural bolt/nut/washer assembly method. Preferably, the nut shall be
turned tight while the bolt is prevented from rotating. However, if required by either turn-of-nut or
direct-tension-indicator methods because of bolt entering and/or wrench operational clearances,
tightening may be done by turning the bolt while the nut is prevented from rotating.
1. Turn-of-Nut Method – After all specified bolting conditions are satisfied, and before final
tightening, the Contractor shall match-mark with crayon or paint the outer face of each nut and the
protruding part of the bolt. Each bolt shall be final tightened to the specified minimum tension by
rotating the amount specified in Table 14-2. To ensure this tightening method is followed, the
Engineer will (1) observe as the Contractor installs, snug tightens, and final tightens all bolts and
(2) inspect each match-mark.

Table 14-2. Turn-of-Nut Tightening Method Nut Rotational from Snug Tight Condition
Disposition of Outer Faces of Bolted Parts
Bolt Length Condition 1 Condition 2 Condition 3
L <= 4D ⅓-turn ½-turn ⅔-turn
4D < L < = 8D ½-turn ⅔-turn 5/6-turn
8D < L < = 12D ⅔-turn 5/6-turn 1-turn

Bolt length measured from underside of head to top of nut.

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 Condition 1 – Both faces at right angles to bolt axis.
Condition 2 – One face at right angle to bolt axis, one face sloped no more than 1:20, without
bevel washer.
Condition 3 – Both faces sloped no more than 1:20 from right angle to bolt axis, without bevel
washer.

Nut rotation is relative to the bolt regardless of which element (nut or bolt) is being turned.
Tolerances permitted plus or minus 30 degrees (1/12-turn) for final turns of ½-turn or less; plus, or
minus 45 degrees (⅛-turn) for final turns of ⅔-turn or more.
D = nominal bolt diameter of bolt being tightened.
When bolt length exceeds 12D, the rotation shall be determined by actual tests in which a suitable
tension device simulates actual conditions.

2. Direct Tension Indicator Method (DTIs) – Shall not be used under the turned element. DTIs shall
be placed under the bolt head with the protrusions facing the bolt head when the nut is turned.
DTIs shall be placed under the nut with the protrusions facing the nut when the bolt is turned.
Gap refusal shall be measured with a 0.005-inch tapered feeler gage. After all specified bolting
conditions are satisfied, the snug tightened gaps shall meet Table 13-3 snug tight limits.
Each bolt shall be final-tightened to meet Table 14-3 final-tighten limits. If the bolt is tensioned so
that no visible gap in any space remains, the bolt and DTI shall be removed and replaced by a
new properly tensioned bolt and DTI.
The Contractor shall tension all bolts, inspecting all DTIs with a feeler gage, in the presence of the
Engineer. DTIs shall be installed by two-person (or more) crews, with one individual (1)
preventing the element at the DTI from turning and (2) measuring the gap of the DTI to determine
the proper tension of the bolt.
If a bolt, that has had its DTI brought to full load, loosens during the course of bolting the
connection, it shall be rejected. Reuse of the bolt and nut are subject to the provisions of this
Section. The used DTI shall not be reinstalled.

Table 14-3. Direct Tension Indicator Requirements

Maximum Snug Tight Minimum Final Tighten
DTI Spaces
Bolt Size Refusals Refusals
(inches M 164 M 253 M 164 M 253 M 164 M 253
½ 4 5 1 2 2 3
⅝ 4 5 1 2 2 3
¾ 5 6 2 2 3 3
⅞ 5 6 2 2 3 3
1 6 7 2 3 3 4
1⅛ 6 7 2 3 3 4
1¼ 7 8 3 3 4 4

1⅜ 7 8 3 3 4 4

1½ 8 9 3 4 4 5

3. Twist Off-Type Tension Control Structural Bolt/Nut/Washer Assembly Method (Tension Control
Bolt Assembly) – Tension control bolt assemblies shall include the bolt, nut, and washer(s)
packaged and shipped as a single assembly. Unless otherwise approved by the Engineer, tension
control bolt assembly components shall not be interchanged for testing or installation and shall
comply with all provisions of ASTM F 1852. If approved by the Engineer, the tension control bolt
assembly components may be interchanged within the same component lot for girder web slices
or other locations where access to both sides of the connection is restricted.

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 The tension control bolts shall incorporate a design feature intended to either indirectly indicate,
or to automatically provide, the minimum tension specified in Table 13-1.
The Contractor shall submit the tension control bolt assembly to the Engineer for approval with:
bolt capacities; type of bolt, nut, and washer lubricant; method of packaging and protection of the
lubricated bolt; installation equipment; calibration equipment; and installation procedures.
The tension control bolt manufacturer’s installation procedure shall be followed for installation of
bolts in the verification testing device, in all calibration devices, and in all structure connections.
In some cases, proper tensioning of the bolts may require more than one cycle of systematic
partial tightening prior to final yield or fracture of the tension control element of each bolt. If yield
or fracture of the tension control element of a bolt occurs prior to the final tightening cycle, that
bolt shall be replaced with a new one.
Additional field verification testing shall be performed as requested by the Engineer.
All bolts and connecting hardware shall be stored and handled in a manner to prevent corrosion
and loss of lubricant. Bolts that are installed without the same lubricant coating as tested under
the verification test will be rejected, and they shall be removed from the joint and be replaced with
new lubricated bolts at no additional cost to the Contracting Agency.

AASHTO M 253 bolts, galvanized AASHTO M 164 bolts, and ASTM F 1852 tension control bolt
assemblies shall not be reused. Black AASHTO M 164 bolts may be reused once if approved by the
Engineer. All bolts to be reused shall have their threads inspected for distortion by reinstalling the
used nut on the bolt and turning the nut for the full length of the bolt threads by hand. Bolts to be
reused shall be relubricated in accordance with the manufacturer’s recommendation and as approved
by the Engineer. Used bolts shall be subject to a rotational capacity test as specified in Pre-Erection
Testing. Touching up or retightening bolts previously tightened by the Turn-of-Nut Method, which may
have been loosened by the tightening of adjacent bolts shall not be considered as reuse, provided the
snugging up continues from the initial position and does not require greater rotation, including the
tolerance, than that required by Table 14-2.

Pre-Erection Testing
High-strength bolt assemblies (bolt, nut, direct tension indicator, and washer), both black and
galvanized, shall be subjected to a field rotational capacity test, as outlined below, prior to any
permanent fastener installation. For field installations, the rotational capacity test shall be conducted
at the jobsite. Each combination of bolt production lot, nut production lot, washer production lot, and
direct tension indicator production lot shall be tested as an assembly, except tension control bolt
assemblies, which shall be tested as supplied by the manufacturer. Each rotational capacity test shall
include three assemblies. Once an assembly passes the rotational capacity test, it is approved for use
for the remainder of the project unless the Engineer deems further testing is necessary. All tests shall
be performed in a bolt tension calibrator by the Contractor in the presence of the Engineer. High-
strength bolt assemblies used in this test shall not be reused. The bolt assemblies shall meet the
following requirements after being pretensioned to 15 percent of the minimum bolt tension in Table
14-1. The assembly shall be considered as nonconforming if the assembly fails to pass any one of the
following specified requirements:
1. The measured torque to produce the minimum bolt tension shall not exceed the maximum
allowed torque value obtained by the following equation:

Torque = 0.25 PD

Where:
Torque = Calculated Torque (foot-pounds)
P = Measured Bolt Tension (pounds)
D = Normal Bolt Diameter (feet)

2. After placing the assembly through two cycles of the required number of turns, where turns are
measured from the 15 percent pretension condition, as indicated in Table 14-2,
a. The maximum recorded tension after the two turns shall be equal to or greater than 1.15
times the minimum bolt tension listed in Table 14-1.

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 b. Each assembly shall be successfully installed to the specified number of turns.
c. The fastener components in the assembly shall not exhibit shear failure or stripping of the
threads as determined by visual examination of bolt and nut threads following removal.
d. The bolts in the assembly shall not exhibit torsional or torsional/tension failure.

3. If any specimen fails, the assembly will be rejected. Elongation of the bolt between the bolt head
and the nut is not considered to be a failure.

Bolts that are too short to test in the bolt tension calibrator shall be tested in a steel joint. The
Contractor shall (1) install the high-strength bolt assemblies (bolt, nut, direct tension indicator, and
washer) in a steel joint of the proper thickness; (2) tighten to the snug tight condition; (3) match-mark
the outer face of each nut and the protruding part of the bolt with crayon or paint; (4) rotate to the
requirements of Table 14-2; and (5) record the torque that is required to achieve the required amount
of rotation. The assembly shall be considered as nonconforming if the assembly fails to pass any one
of the following specified requirements:
1. The recorded torque to produce the minimum rotation shall not exceed the maximum allowed
torque value obtained by the following equation:

Torque = 0.25 PD

Where: Torque = Calculated Maximum Allowed Torque (foot-pounds)

P = Specified Bolt Tension per Table 14-1, multiplied by a factor of 1.15 (pounds)
D = Normal Bolt Diameter (feet)

2. After placing the assembly through two cycles of the required number of turns, where turns are
measured from the snug tight condition specified in this specification.
b. Each assembly shall be successfully installed to the specified number of turns.
c. The fastener components in the assembly shall not exhibit shear failure or stripping of the
threads as determined by visual examination of bolt and nut threads following removal.
d. The bolts in the assembly shall not exhibit torsional or torsional/tension failure.

3. If any specimen fails, the assembly will be rejected. Elongation of the bolt between the bolt head
and the nut is not considered to be a failure.
The Contractor shall submit the manufacturer’s detailed procedure for pre-erection (rotational
capacity) testing of tension control bolt assemblies to the Engineer for approval and shall have an
approved procedure prior to testing.
Three DTIs, per lot, shall be tested in a bolt tension calibrator. The bolts shall be tensioned to 105
percent of the tension shown in Table 14-1. If all of the DTI protrusions are completely crushed (all
five openings with zero gap), this lot of DTIs is rejected.

Three twist off-type tension-controlled bolt assemblies, per assembly lot, shall be tested in a bolt
tension calibrator. The bolts shall first be tensioned to a snug tight condition. Tensioning shall then be
completed by tightening the assembly nut in a continuous operation using a spline drive installation
tool until the spline shears from the bolt. The bolt assembly tension shall meet the requirements of
Table 13-1. If any specimen fails, the assembly lot is rejected.

Bolting Inspection
The Contractor, in the presence of the Project Engineer, shall inspect the tightened bolt using a
calibrated inspection torque wrench, regardless of bolting method. The Contractor shall supply the
inspection torque wrench. Inspection shall be performed within seven calendar days from the
completion of each bolted connection or as approved by the Engineer.
If the bolts to be installed are not long enough to fit in the bolt tension calibrator, five bolts of the same
grade, size, and condition as those under inspection shall be tested using Direct Tension-Indicators
(DTIs) to measure bolt tension. This tension measurement test shall be done at least once each
inspection day. The Contractor shall supply the necessary DTIs. The DTI shall be placed under the
bolt head. A washer shall be placed under the nut, which shall be the element turned during the

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performance of this tension measurement test. Each bolt shall be tightened by any convenient means
to the specified minimum tension as indicated by the DTI. The inspecting wrench shall then be applied
to the tightened bolt to determine the torque required to turn the nut 5 degrees (approximately 1 inch
at a 12-inch radius) in the tightening direction. The job inspection torque shall be taken as the average
of three values thus determined after rejecting the high and low values.
Five representative bolts/nuts/washers and DTIs if used (provided by the Contractor) of the same
grade, size, and condition as those under inspection shall be placed individually in a bolt tension
calibrator to measure bolt tension. This calibration operation shall be done at least once each
inspection day. There shall be a washer under the part turned in tightening each bolt if washers are
used on the Structure. In the bolt tension calibrator, each bolt shall be tightened by any convenient
means to the specified tension. The inspection torque wrench shall then be applied to the tightened
bolt to determine the torque required to turn the nut or head 5 degrees (approximately 1 inch at a 12-
inch radius) in the tightening direction. The job-inspection torque shall be taken as the average of
three values thus determined after rejecting the high and low values.

Ten percent (at least two), or as specified by the Engineer, of the tightened bolts on the Structure
represented by the test bolts shall be selected at random in each connection. The job-inspection
torque shall then be applied to each with the inspecting wrench turned in the tightening direction, with
no restraint applied to the opposite end of the bolt. If this torque turns no bolt head or nut, the
Contracting Agency will accept the connection as being properly tightened. If the torque turns one or
more bolt heads or nuts, the job-inspection torque shall then be applied to all bolts in the connection.
Except for tension control bolt assemblies and DTIs with zero gap at all protrusion spaces, any bolt
whose head or nut turns at this stage shall be tightened and reinspected. Any tension control bolt
assemblies or DTIs that have zero gap at all protrusion spaces shall be replaced if the head or nut
turns at this stage.

The Contractor shall submit the manufacturer’s detailed procedure for routine observation to ensure
proper use of the tension control bolt assemblies to the Engineer for approval and shall have an
approved procedure prior to any assembling of bolted connections.

14.3.33 Adjusting Pin Nuts

All pin nuts shall be tightened thoroughly. The pins shall be placed so that members bear fully and
evenly on the nuts. The pins shall have enough thread to allow burring after the nuts are tightened.

14.3.34 Setting Anchor Bolts

Anchor bolts shall be set in masonry as required in Section 3. Anchor bolts shall be grouted in after
the shoes, masonry plates, and keeper plates have been set and the span or series of continuous
spans are completely erected and adjusted to line and camber.

14.3.35 Setting and Grouting Masonry Plates

The following procedure applies to masonry plates for all steel spans, including shoes, keeper plates,
and turning racks on movable bridges.

To set masonry plates, the Contractor shall:

1. Set masonry plates on the anchor bolts;
2. Place steel shims under the masonry plates to position pin centers or bearings to line and grade
and in relationship to each other. Steel shims shall be the size and be placed at the locations
shown in the Plans;
3. Level the bases of all masonry plates;
4. Draw anchor bolt nuts down tight;
5. Recheck pin centers or bearings for alignment; and
6. Leave at least ¾ inch of space under each masonry plate for grout.

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After the masonry plates have been set and the span or series of continuous spans are completely
erected and swung free, the space between the top of the masonry and the top of the concrete
bearing seat shall be filled with grout. Main masonry plates for cantilever spans shall be set and
grouted in before any steel Work is erected.

14.3.36 Setting Steel Bridge Bearings

Masonry plates, shoes, and keeper plates of expansion bearings shall be set and adjusted to center
at a normal temperature of 30ºC (or based on design criteria). Adjustment for an inaccuracy in
fabricated length shall be made after dead-load camber is out.

14.3.37 Placing Superstructure

The concrete in piers and crossbeams shall reach at least 80 percent of design strength before
girders are placed on them.

14.3.38 Swinging the Span

Forms weighing less than 5 pounds per square foot (25 kg/m2) of bridge deck area and uniformly
distributed along the steel spans may be placed before the spans swing free on their supports. Steel
reinforcing bars or concrete bridge deck shall not be placed on steel spans until the spans swing free
on their supports and elevations are recorded. No simple span or any series of continuous spans will
be considered as swinging free until all temporary supports have been released. Reinforcing steel or
concrete bridge decks shall not be placed on any simple or continuous span steel girder bridge until
all its spans are adjusted and its masonry plates, shoes, and keeper plates grouted. For this
specification, the structure shall be considered as continuous across hinged joints.

After the falsework is released (spans swung free), the masonry plates, shoes, and keeper plates are
grouted, and before any load is applied, the Contractor (or the Engineer if the Contracting Agency is
responsible for surveying) shall survey elevations at the tenth points along the centerline on top of all
girders and floorbeams. The Contractor shall calculate the theoretical top of girder or floorbeam flange
elevations and compare the calculated elevations to the surveyed elevations. The theoretical pad or
haunch depth shown in the Plans shall be increased or decreased by the difference between the
theoretical and surveyed top of girder or floorbeam elevations. The soffit (deck formwork) shall be set
based on the Plan bridge deck thickness and the adjusted pad or haunch depth.

The Contractor shall submit all survey data and calculations to the Engineer for review ten working
days prior to placing any load, beyond the maximum five pounds per square foot of form weight
allowed, on the Structure.

14.3.39 Draining Pockets

The Contractor shall provide enough holes to drain all water from pockets in trusses, girders, and
other members. Unless shown on approved shop plans, drain holes shall not be drilled without the
written approval of the Engineer.
All costs related to providing drain holes shall be included in the unit Contract prices for structural or
cast steel.

14.3.40 Surface Condition

As the Structure is erected, the Contractor shall keep all steel surfaces clean and free from dirt,
concrete, mortar, oil, paint, grease, and other stain-producing foreign matter. Any surfaces that
become stained shall be cleaned as follows:
- Painted steel surfaces shall be cleaned by methods required for the type of staining. The method
shall be submitted to the Engineer for approval.

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- Unpainted steel surfaces shall be cleaned by sandblasting. Sandblasting to remove stains on
publicly visible surfaces shall be done to the extent that, in the Engineers opinion, the uniform
weathering characteristics of the Structure are preserved.

14.3.41 Castings, Steel Forgings, and Miscellaneous Metals

Castings, steel forgings, and miscellaneous metals shall be built to comply with this specification.
Shop Construction, Castings, Steel Forgings, and Miscellaneous Metals
This Section’s requirements for structural steel (including painting requirements) shall also apply to
castings, steel forgings, and miscellaneous metals.
Castings shall be:
1. True to pattern in form and dimensions;
2. Free from pouring faults, sponginess, cracks, blow holes, and other defects in places that would
affect strength, appearance, or value;
3. Clean and uniform in appearance;
4. Filleted boldly at angles; and
5. Formed with sharp and perfect arises.

Iron and steel castings and forgings shall be annealed before any machining, unless the Plans state
otherwise.

14.4 Fabrication

14.4.1 General

The Contractor shall fabricate structural steel in the fabrication shop. Bolted or welded connection
shall be provided whether constructed on the shop or on the field as shown on the drawings or as
directed by the Engineer. High strength bolts for all bolted connections shall be used unless otherwise
shown on the drawings or directed by the Engineer.

All sharp edges and corners shall be ground to a minimum radius of 2mm and all sharp
irregularities,burrs, slag and spatters on welds shall be removed.
The tolerance shall not exceed those shown on the drawings and each unit assembled shall be
closely checked to ensure that all necessary clearances have been provided and that binding does
not occur in any moving part.
In order to maintain accurate finished dimensions and shape, appropriate reverse strain or restraints
shall be provided as required.

Any error or defect disclosed shall be immediately remedied by the Contractor.

Before disassembly for shipment, each piece of the structure shall be match-marked to facilitate
erection in the field.

14.4.2 Fabricator

Structural steel fabricator shall be approved by the Engineer and shall have an experience in
fabrication of structural steel for the projects of similar type. A fabricator’s shop shall have a suitable
space for trial assembly. The Contractor shall submit a written description of fabrication capability
including facilities, personnel and list of similar completed projects, including testing and quality
control capability and specifically the type and extent of quality control procedure, which the fabricator
intends to employ on this Project.

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14.4.3 Welding

Structural steel fabricator shall be approved by the Engineer and shall have an experience in
fabrication of structural steel for the projects of similar type. A fabricator’s shop shall have a suitable
space for trial assembly. The Contractor shall submit a written description of fabrication capability
including facilities, personnel and list of similar completed projects, including testing and quality
control capability and specifically the type and extent of quality control procedure, which the fabricator
intends to employ on this Project.

14.4.3.1 General

All welding shall be planned and executed using the most suitable materials and working methods for
the particular purpose. Site welding will only be permitted for fixtures and details of any fixture welding
roposed by the Contractor must be clearly identified on the Shop Drawings and referred to in the
accompanying submittal letter.

Welding requirements shall in all respects conform to the following sections of AWS D1.1-98: Section
2, Design of Welded Connections; Section 3, Workmanship; Section 4, Technique; Section 5,
Qualification; Section 6, Inspection; and Section 9, Design of New Bridges.

All welding shall be executed by skilled, experienced welders holding valid welder examination
qualifications based on the qualification tests specified in part C of Section 5 of AWS D1.1- 98 or
similar internationally recognized qualification tests. A welder shall be qualified for each process used.

Prior to commencement of any welding, the joint shall be carefully freed from rust, scale, slag, and
burrs. Where two welds for structural reasons have to cross each other the former has to be ground
flush.Where a flush surface is required, the excess weld metal shall be ground.

During the assembly work, the components shall be held in position and supported in such a manner
that no unfavourable inherent stresses or deformation shall develop. Drilling of holes for temporary
assembly for welding proposes shall not be accepted.
Minimum preheating and interpass temperature shall comply with the welding procedure and shall be
approved by the Engineer.

14.4.3.2 Welding Tolerances

The members to be connected by welding shall be so prepared that they fit exactly together, without
being forced into position.

The tolerances concerning gap between parts to be welded, eccentricity and departure from
theoretical alignment, dimensions of the cross section groove welded joints, etc. shall conform to
Section 3.3,Assembly, of AWS D1.1-98, except that the gap between parts to be joined by fillet welds
shall not exceed 1mm for fillet welds connecting flange to web in box girder and 5mm for all other fillet
welds. Tolerances of weld profiles shall correspond to section 3.6 of AWS D1.1-98.

14.4.3.3 Trials of Welding Procedures

The Contractor shall perform test welds of the types of welding seams to be applied in the structure,
according to a programme to be agreed upon with the Engineer. The quality of the test welds shall be
approved by the Engineer prior to execution of the welding work in question. The test welding shall be
made from working positions corresponding to the actual working positions during construction.

14.4.3.4 Inspection of Welding

The Contractor shall prepare and submit a detailed programme for welding control for the Engineer’s
approval, and the established programme shall not be changed without the Engineer’s consent.

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The Contractor shall assure the inspections to satisfy the requirements laid down in AWS D1.1 -98,
Section 9.25, at his own cost. The Contractor’s programme shall correspond to the following
schedule;

Preparation of Welding
Visual inspection of edge preparation.

Visual Inspection before and after welding

Visual inspection of surface conditions for cracks, gaps and other items that may cause any defect of
welding. All welds shall be visually inspected in accordance with AWS D1.1, Section 9.25.1.

Non-destructive Testing of Welds

Welds that are subject to radiographic or magnetic particle testing in addition to visual inspection shall
be unacceptable if the radiographic or magnetic particle testing show any of the types of
discontinuities given in AWS D1.1, Section 9.25.2.
Welds that are subject to ultrasonic testing, in addition to visual inspection, are acceptable if they
meet the requirements of table 9.25.3 in AWS D1.1-98. Welds that are subject to liquid penetration
testing, in addition to visual inspection, shall be evaluated on the basis of the requirements for visual
inspection.

Scope of Non-destructive Testing of Weld

Fillet welds shall be tested by the most suitable of either the magnetic particle test or liquid
penetration test. Groove welds shall be tested by the most suitable of either the radiographic test or
ultrasonic test.

Minimum Weld Test Requirements

Transverse butt welds in top and bottom flange plate shall be tested by radiographic test as follows:
1. Welds subject to tensile stress and reversal stress
a. Welding by automatic welding machine : 1 shot / each welding line
b. Welding by manual : 3 shots / each welding line

2. Welds subject to compressive stress

- Welding by automatic welding machine : 1 shot / 5 welding line
- Welding by manual : 1 shot / each welding line

3. Transverse butt weld in web plate

- Welding by automatic welding machine : 1 shot / 2 welding line
- Welding by manual : 1 shot / each welding line

Longitudinal fillet welds:

1. Top and bottom flange to web : 25%
2. Longitudinal rib to top and bottom flange : 10%
3. Horizontal stiffener to web : 10%

Diaphragm:
1. All butt welds : 25%
2. Fillet welds : 10%

Groove welds above the Bearing Shoe:

1. Groove welds above the bearing shoe shall be tested by ultrasonic test : 25%
2. Other welds not mentioned above : 20%

Note :
The place of shot for the radiographic test above mentioned shall be proposed by the Contractor and
approved by the Engineer.
The above figures are the minimum extent of testing and the Engineer may require additional tests.

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The result of test shall satisfy the followings.
The welds subject to tensile stress shall be equal to or better than class-2 specified in JIS Z3104 or
equivalent.
The welds subject to compressive stress shall be equal to or better than class-3 specified in JIS
Z3104 or equivalent.

Stud Welding
After the studs welding, visual inspection shall be carried out. All studs which are found defect on the
welding bead shall be carried out the bending test at his own expense.
Besides above, bending test shall be carried out randomly at least one percent of total quantities of
studs at his own expense.

Bending test
Testing procedure is as follows:
Step 1 : The stud shall be bended up to fifteen (15) degrees by the hammer. The quantities of tested
studs shall be at least 1% of total.
Step 2 : After bending, visual inspection of welding bead shall be carried out. Crack or defect is found
on welding bead?
Step 3 : If “Yes”, = Additional bending test shall be done at least 2% of total. Crack or defect is found
on welding bead?
If “No”, = Acceptable
Step 4 : If “Yes”, = All studs shall be removed and replaced with new studs. After welding,
bending test shall be done from Step 1

14.4.4 Templates and Jigs

The Contractor shall supply all templates, jigs and other appliances necessary to ensure the accuracy
of the work.
14.4.5 Straightening

Before any work is done on them, all plates shall be checked for flatness and all bars and sections
checked for straightness and freedom from twist. Any corrective action shall be taken so that when
assembled, adjacent surfaces shall be in close contact throughout. The methods adopted for the work
above shall be such as not to damage, mark or impair the strength of the material.

14.4.6 Cutting

Marking shall be performed accurately and elaborately using full size rules and templates. Prior to
marking, the dimensions and grade of materials shall be checked.

Cutting shall be done automatically. Hand cutting may be used exceptionally, in connection with the
erection, if approved by the Engineer. In such cases the joint edges shall receive a finishing
treatment, with planning and grinding tools.

Cutting by shearing machine may be used for plates not exceeding 10 mm in thickness provided that
the plate edge be fully enclosed in a weld.

Oxygen cutting may be used provided a smooth and regular surface free from cracks and notches is
secured and provided that the roughness of oxygen cut-surfaces shall be no greater than 50S in
accordance with JIS B 0601 by the use of a mechanical guide.

The edges of all cut plates that will not be welded shall be ground to radius 2mm profile.

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14.4.7 Drilling a Holes

Holes for bolts shall be drilled. Punching of holes shall not be permitted. If not otherwise indicated on
the drawings, the diameter of bolt holes shall be 2.5 mm larger than the nominal diameter of bolts.
The diameter of bolt holes of longitudinal ribs of box girder may be 4.5mm larger than nominal
diameter of bolts.

14.4.8 Bending

Bending of plate may be machined by cold processes, provided that the bending inner radius is at
least 15 times the thickness of the plate.

14.4.9 Sole plate for the bearing

The contact surface of Sole plates for bearing which are provided under bottom flange shall be
ground by machining. Its gradient shall be calculated by the vertical alignment and super elevation.
The top plate of the bearing shall be a level after completion of the bridge construction.

14.4.10 Trial Assembly

14.4.10.1 General

The Contractor shall carry out trial assembly for all structural steel bridges in his regular workshop.
The trial assembly shall be inspected by the Engineer.

14.4.10.2 Trial Assembly by the Contractor

The Contractor shall submit his proposal for Trial Assembly for the approval of the Engineer.

Trial assembly shall be carried out to examine/control the fitness of prefabricated members by
temporarily pre -assembling, to verify that the individual elements have the shape to fit exactly into
adjoining elements, to ensure that assembled structures have been fabricated within tolerance and to
inspect the camber geometry.

The Contractor shall perform measurement of structural members, and the trial assembly results shall
be recorded and submitted to the Engineer.

The Contractor shall inform to the Engineer that the trial assembly has been completed and
measured, and the structure shall not be dismantled until the trial assembly has been approved by the
Engineer.

14.4.10.3 Trial Assembly Inspection by the Engineer

Prior to the trial assembly inspection by the Engineer, the Contractor shall submit the Report of Trial
Assembly by the Contractor for the Engineer’s review. This Report shall include results of
measurement of structural member, trial assembly and non-destructive test.
The Contractor shall inform the Engineer of the scheduled date of the Engineer’s Trial Assembly
Inspection at least 28 days before the inspection.

In addition, the Contractor shall be responsible for the whole cost of trial assembly inspection by the
Engineer and the Employer which cost shall include traveling cost, accommodation cost, inspection
cost and others.

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14.5 Tolerances

The Contractor shall, through appropriate planning and continuous measurements in the workshop
and at the erection site, ensure that the tolerances given in the Specifications are strictly observed.
The Engineer will require any specific working procedure changed in case such procedure appears
not to afford sufficient security against exceeding the tolerances. Unless otherwise specified,
fabricated structural steel shall apply to the tolerances shown in below Table below.

Table 14-4. Tolerances

No. Inspecion Item Tolerance (mm)
1. Flange width b (m) ±2 ------- b < 0.5
Height of web plate (m) ±3 ------- 0.5 < b < 1.0
Web plate spacing (m) ±4 ------- 1.0 < b < 2.0
±( 3 + b/2 ) ---- 2.0 < b
2. Flatness of Plate :
Web Plate : h (mm) h / 250
Flange of Box : w (mm) w / 150
3. Squareness of Flange (mm) b / 200
4. Length of Member L :
Plate Girder (m) ±3 ------- L < 10m
±4 ------- 10m < L
Expansion (m) 0 ~ +30
5. Straightness of compression member L (mm) L / 1000
6. Total length of span length L (m) ±( 10 + L/10 )
L : Span (m)
7. Spacing centre to centre between main girder or main structure ±4 ------- B <2m
B (m) ±( 3 + B/2 ) ---- B > 2m
8. Assembled height of main structure H(mm) ±5 ------- H <5m
±( 2.5 + H/2 ) ---- H > 5m
9. Straightness of main girder or main structure L (m) ±5 + L/5 ------- L < 100m
25 --------------- L:> 100m
10. Deflection of main girder or main structure L(m) -5~+5 ----- L < 20 m
-5~+10 ---- 20 m < L < 40 m
-5~+15 ---- 40 m < L < 80 m
-5~+25 ---- 80 m < L < 200 m
11. Tolerance of main girder or main structure at the end line of 10
bridge (mm)
12. Vertically of main girder or main structure H(mm) 3 + H/1000
H (mm)
13. Gap of site connection (mm) 5

14.6 Camber

The Contractor is fully responsible for the calculation and provision of the necessary camber in the
preassembled elements to obtain the correct levels in the completed bridge, duly considering the
applied erection procedure and the sequence in the installation of the various dead load components.

The Contractor shall submit results of the camber calculation for the Engineer’s review and its camber
shall include Shop Drawings.

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14.7 Erection

14.7.1 General

Before erection work is commenced, all members shall be checked for flatness and all bars and
sections checked for straightness and free from twist. Any corrective action shall be taken so that
when assembled, adjacent surfaces shall be in close contact throughout. The methods adopted for
the work above shall be such as not to damage, mark or impair the strength of the material.

The Contractor shall be responsible for any damage caused to other components of the structure
including the substructures, by his operations for the duration of the Contract. In particular he shall
take all necessary precautions to minimize concrete splash onto completed steel work or rust staining
of concrete due to erected steel -work, and clean and/or repair all stains and other damage to
completed work prior to the Tests on Completion.

14.7.2 Bolted Connection

The surfaces of splice plates for high strength bolted joints shall be painted by inorganic zinc rich
paint in accordance with the Specifications.

Prior to assemble in the field, the rust on joint surfaces, including those adjacent to bolt head, nut and
washer, shall be removed by power tools and sand-paper. If the gap between splice plate and main
structural steel of bolted connections is 2mm or less, the surface of main structural steel shall be
tapered to eliminate the gap. The cap which is over 2mm shall install filler plate as required.

The minimum proof load of each high strength bolt shall be as follows:

Table 14-5. Bolt Size – Minimum Proof Load

Grade Bolt Size Minimum Proof Load (kN)
F8T M 20 133
F8T M 22 165
F8T M 24 192
F10T M 20 165
F10T M 22 205
F10T M 24 238

High strength bolts shall not be reused for the permanent structure. All high strength bolts shall be
tightened by torque wrenches or approved tightening method by the Engineer. Their setting bolts shall
be such as to induce a bolt tension of 10% in excess of the above value.

These wrenches shall be calibrated at least once each working day and shall decide torque value
(herein after “DTV”) for tightening. High strength bolts shall be tightened by DTV.

After bolt tightening, the torque value of bolts, at least ten percents (10%) of installed bolts in the one
splice plate, shall randomly be inspected torque value by the torque wrenches as below condition.

Step 1 : If the measured torque values of each bolts are within ten percent (10%) deviation of DTV,
these bolts are deemed to be tightened suitable torque value. However, if the measured torque values
are out of 10% deviation of DTV, “Step 2” shall be carried out.

Step 2 : The bolts which torque value is less than DTV shall be re-tightened up to DTV. The bolts
which torque value is more than DTV shall be replaced. And “Step 3 shall be carried out.

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Step 3 : At least, twenty percents (20%) of installed bolts in one splice plate shall randomly be
inspected the torque value by the torque wrenches. If the measured torque values are within ten
percent (10%) deviation of DTV, these bolts are deemed to be tightened suitable torque value.
However, if the measured torque values are out of 10% deviation of DTV, “Step 4” shall be carried
out.

Step 4 : The bolts which torque value is less than DTV shall be re-tightened up to DTV. The bolts
which torque value is more than DTV shall be replaced. And “Step 5 shall be carried out.

Step 5 : All of the installed bolts in one splice plate shall be inspected torque value by the torque
wrenches. If the measured torque values are within ten percent (10%) deviation of DTV, these bolts
are deemed to be tightened suitable torque value. However, if the measured torque values are out of
10% deviation of DTV, “Step 6” shall be carried out.

Step 6 : The bolts which torque value is less than DTV shall be re-tightened up to DTV. The bolt which
torque value is more than DTV shall be replaced.

14.7.3 Field Erection

The position of field splices as shown on the drawings is for information only and the Contractor is
free to propose alternative procedures providing they comply with all the relevant requirements of the
Specifications. The preparation of the calculations and detailed design to support the proposed
alternative shall be at the Contractor’s responsibility and cost.

The contractor shall provide the working drawings showing the details and installation method of
templates and anchor bolts to be embedded in concrete for the Engineer’s approval.

During erection, the members and sections shall be accurately assembled as shown on the approved
Shop Drawings and any match-marks shall be followed. The material shall be carefully handled so
that no sections will be bent, broken or otherwise damaged. Hammering which will damage or distort
the members shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be
cleaned before the members are assembled.
The correction of minor misfits involving harmless amounts of reaming, cutting and chipping will be
considered a legitimate part of the erection. However, any error in the shop fabrication or deformation
resulting from handling and transportation which prevents the proper assembling and fitting up of
parts by the moderate use of drift pins or by a moderate amount of reaming and slight chipping or
cutting, shall be reported immediately to the Engineer and his approval of the method of correction
obtained. The Contractor shall be responsible for correction for all misfits, errors and injuries and shall
make the necessary corrections and replacements.

The straightening of plates, angles, other shapes and built-up members, when permitted by the
Engineer, shall be done by methods that will not produce fracture or other damages. Distorted
members shall be straightened by mechanical means or, if approved by the Engineer, by the careful
planned and supervised application of a limited amount of localized heat, each application subject to
the approval of the Engineer.

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14.8 Railing (Hand Rail)

14.8.1 Bridge Railing ,Chainlink Fence and Stair Handrail

14.8.1.1 Description

This work shall consist of furnishing, fabricating and erecting steel pipe railings, aluminium railings
and chainlink fences for bridges, RC frames and incidental structures, all as indicated on the
Drawings and required by these Specifications and as directed by the Engineer.

14.8.1.2 Materials

a. Materials shall conform to the requirements of :

JIS G 3101 Rolled Steel for General Structures
JIS G 3452 Carbon Steel Pipes for Ordinary Piping
JIS G 3444 Carbon Steel Tubes for General Structural Purposes
JIS G 3466 Carbon Steel Square Pipes for General Structural Purposes
JIS G 3532 Low Carbon Steel Wires
JIS G 3552 Chainlink Wire Netting
JIS H 4040 Aluminium and Aluminium Alloy Rods, Bars, Wires
JIS G 4303 Stainless Steel Bars
SNI 1729:2015 The Use of Structural Steel in Buildings
ASTM A36 Specifications on carbon structure steel
ASTM A53 Specifications for pipe, steel, black and hot-dipped, zinc-coated welded
and seamless
AWS Regulations concerning the welding of steel structure

b. Mortar and grout shall conform to the provisions of these Specifications.

c. All steel railing, chainlink fencing, and fittings shall be galvanized unless otherwise specified, in
accordance with the requirements of these Specifications. All aluminium alloy shall be coated in
accordance with the Specifications of JIS H 8601. Galvanized areas damaged by welding
or other site works shall be cleaned and given 3 coats of an approved zinc based paint, to
the satisfaction of the Engineer.
d. Where painting is required, it shall be in accordance with the requirements of these
Specifications.

14.8.1.3 Construction

a. Pipe railings, fittings and incidental parts shall be carefully handled and stored on blocking, racks
or platforms so as not to be in contact with the ground and shall be protected from corrosion.
Materials shall be kept free from dirt, oil, grease and other foreign matter. Surfaces to be painted
shall be carefully protected both in the shop and in the field. Threads shall be carefully protected
from damage.
b. Railings and fences shall be carefully constructed true to line and grade as shown on the
Drawings, and no construction shall be commenced before the inspection and approval by the
Engineer, and before all centers, supports, and falsework or staging of bridge superstructure have
been removed.
c. The component parts of pipe railings shall be connected with threaded screws unless
otherwise specified on the Drawings. Fitting for railings on slopes shall be leveled to fit the
required grades. Screw thread fittings shall be coated with red lead and oil, and the threads shall
engage for a minimum length of 2 centimetres. Expansion shall be provided by omitting threads
on one side of fittings at designated posts. Where the rails are continuous through two or
more posts threads may be omitted between the rails and the fitting, but the rail must be
pinned at each post. Where welding of component parts is permitted, the details must be in
accordance with the Drawings or as approved by the Engineer.

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d. The Contractor shall provide for the erection of pipe railing by suitable fabrication in the shop.
Where railing is fitted between concrete posts, provision shall be made to allow the installation of
same.
Railing and fence shall be fabricated and erected as indicated on the Drawings, and rails shall be
parallel to the grade of the road. Posts shall be set truly vertical unless otherwise instructed by the
Engineer.
All exposed surfaces shall be thoroughly cleaned in an approved manner as a final operation
under this project.
e. The Contractor shall furnish for the approval of the Engineer working drawings for the
particular type of railing and fence to be installed.

14.8.1.4 Method of Measurement

The quantities of metal railing and chainlink fence to be measured by be the number of linear metres
of railings or chain-link fence satisfactorily completed and accepted in accordance with the Drawings,
these Specifications, and as directed by the Engineer.

14.9 Bridge Expansion Joints

14.9.1 Description

This work shall consist of the supply and installation of expansion joints in bridges and piled slabs.

14.9.2 Submittals

A sample of any expansion joint material that the Contractor proposes to use in the work, together
with a statement as to its source and test data giving its properties shall be submitted to the Engineer
and approved by him before furnishing the joints.

Before furnishing the joints the Contractor shall submit to the Engineer for approval a certificate by the
manufacturer certifying that the joints comply with the specification requirements. The Contractor shall
prepare documents which shall include the following minimum requirements and shall be
submitted to the Engineer for his approval.
 Details of all dimensions and/or shop drawings
 fabrication procedure
 Material specifications to be used
 Capability of the product
 Performance of the product and materials
 Durability, if any
 Details of protective coatings and protections of sliding surfaces against dust etc.
 Method of installation
 The name and address of the Manufacturer

Schedule of manufacture, testing and delivery, including name and address of testing laboratory.

14.10 Sheet Pile

14.10.1 Scope of Work

This work includes the procurement of materials, labor, tools, equipment, transportation and erection
of sheet piles and their completion in accordance with these Technical Specifications and according
to the requirements shown in the Working Drawings.

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14.10.2 Standards / Referrals

a. American Welding Society (AWS).

b. Manufacturing Standards.

14.10.3 General Procedures

14.10.3.1 Technical Data and Factory Certificates

a. Prior to procurement and delivery, the Contractor must submit material brochures / technical data
and a factory certificate stating that the sheet piles meet the requirements, to be approved by the
Engineer.
b. Steel sheet piles must be identified by the amount of heat or melting. If for some reason it cannot
show identification when bringing in stock materials, materials may be used without testing,
provided all the stock purchased by the supplier shows conformity to the material specifications
specified here and is accompanied by a factory analysis, test report and certified written
statement.
c. If the steel cannot be identified, or the source is in doubt, the Engineer may request a set of
physical tests to determine the quality of the steel. Testing, inspection and sampling must be
carried out by a laboratory approved by the Engineer at the Contractor's expense.
d. Upon request, submit a test report and acceptable evidence that the materials comply with the
specified requirements.

14.10.3.2 Implementation Detail Image

a. The contractor must prepare and submit a Detailed Implementation Image which provides
complete important information for fabrication and installation. It must be clearly distinguished
between bolts, rivets and welds in factories and fields.
Draw all holes for mounting or accommodating other work as shown in the Working Drawings.
State in the approval list the calculated steel weight material and the size, type and number of
fasteners needed for each connection.
b. Approval of Implementation Detail Image applies to the overall design, and does not relieve the
Contractor from the responsibility of dimensional accuracy, good design detail, number,
installation in the field, and perfection of connections with other work.

14.10.3.3 Work Schedule and Method

Before starting the drafting work, the Contractor must submit the proposed method of implementation
to the Engineer for approval, including transportation, storage, handling, piling equipment, manpower,
details of pile installation and work progress schedules.

14.10.3.4 Stamping Note

The Engineer will keep a record of each sheet pile erection. The data will include the date of erection,
actual base elevation and plans, unusual circumstances. After completion of each drafting area, the
Soil Expert and Contractor must sign a record stating agreement with the recorded data.

14.10.3.5 Experience

The erection must be carried out by an experienced company doing similar work, who has completed
at least 2 successful, successful erection projects that are similar in scope and type to the work
mentioned here.

14.10.3.6 Storage and Handling

All sheet piles must be stored and handled in such a way that they do not cause damage.

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Sheet stakes should not be stacked for more than 3 stacks.

14.10.3.7 Designer equipment

a. Before mobilizing the design equipment, the Contractor must submit a detailed work plan for
carrying out the operation. The Engineer has the right to reject inappropriate working tools if the
Contractor neglects these obligations, and the Contractor must bear all costs incurred due to this.
b. The contractor must consider the type of soil and rocks contained in it when selecting erection
equipment.
c. The contractor must propose the type of piling hammer and piling equipment so that the pile can
be pushed to reach the specified depth or the carrying capacity value obtained, without causing
damage to the pile due to excessive pressure caused by the pile.

14.10.4 Materials

14.10.4.1 General

a. Steel sheet piles must be produced and constructed in accordance with the details shown in the
Working Drawings and other conditions, as specified in this Technical Specification.
b. The length of steel sheet piles for permanent / permanent installation to be fabricated and erected
must be in accordance with the results of the load test carried out before piling in accordance with
the stipulated provisions and all results of the soil investigation.

14.10.4.2 Steel Sheet Piles

The type of steel sheet pile must be a profile of steel rollers that are interlocking continuously, and
have the following characteristics:
 Quality of steel according to JIS
 400mm wide,
 150mm high,
 13.1mm thick,

such as the U JIS Series type III A profile supplied by PT Oriental Sheet Piling.

14.10.4.3 Welding wire

If needed and as needed, welding wire must be of E70XX type.

14.10.4.4 Bolt

The bolt must be a masinal type that complies with ASTM A 307, or a high voltage A 325 type if
shown in the Working Drawings.

14.10.4.5 Surface Coating

The protective layer for the surface of the steel sheet pile must be in accordance with the
manufacturer's standard and must be applied in the steel sheet pile making plant.

14.10.5 Work Implementation

14.10.5.1 General

Steel sheet piles must be brought to the project site complete with surface coatings applied at the
factory, and other important accessories according to the standard manufacturer of sheet piles to
complete the installation.

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14.10.5.2 Erection

a. Equipment and Methods

The pile erection equipment must use a hammer that delivers enough kinetic energy to perfect the
work. The equipment proposed for use must be approved by the Engineer.
The pile must be kept piling up to the specified elevation.

b. Tolerance
Tolerance of the horizontal deviation from the location of the plan at the top of the pile is 25mm. If
this tolerance is exceeded, the Engineer will check the design to determine the size of the
correction needed.
There is no compensation for work or material that is carried out due to improvements ordered by
the Engineer.

c. Disturbance
If disturbances are found such as old foundations, wood, metal objects, seeds, large stones, or
stones that can prevent adequate penetration, which causes the piles to deviate from the location
of the plan, or damaged pile materials, Manager The project will determine the correction needed.
Costs needed to get rid of the disruption will be paid on the basis of negotiations. If a disturbing
stake is removed, it is considered finished and will be paid the appropriate price.
Any additional piles needed because the redesign will be paid for.

d. Preventive measure
Extra care must be taken when erecting piles adjacent to highways, building foundations, dirty
waterways and others.
The contractor is responsible for repairing any damage caused by the work carried out by him.

e. Connection
The connection if needed on the pile must obtain approval from the Engineer, and must be
welded in accordance with AWS provisions. Las must be made accurately to produce straight and
flat piles. The stake must contain no more than one connection without the written approval of the
Engineer. Every connection in the field must be checked and approved by the Engineer before
erection. Arrange the connection so that the pile is between the piles next to it.
f. Cutting
Cut piles at the specified elevation after getting approval from the Engineer.

g. Connection Cover / Gap

In the area as shown in the Working Drawings, make the pile joints waterproof so that they are
welding or other ways in the direction of the Engineer.

h. Inspection and Acceptance

The Engineer will examine the design work and accept it or order repairs.

i. Cleaning
Remove all excess materials and dirt from the work site after the work is done.

14.11 Transport Handling and Storage

Before dismantling the assembled structure at fabrication shop, all members and sections shall be
appropriately marked with their identification numbers as detailed on the Shop Drawings. The
Contractor shall submit all relevant drawings and lists showing all identification numbers and match
marks of the finished structure steels to the Engineer for his review and approval.

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The methods of transporting and handling shall be subject to the approval of the Engineer. Special
care to protect against damage shall be taken in the packing, supporting, lifting handling and
transporting of structural steel.
When the members are delivered to the Site, the Contractor shall check the material and immediately
report to the Engineer any damages or defects therein. The Contractor shall also report in writing to
the Engineer any such damage or defects, and give his proposals for the rectification or replacement
or damaged sections.

Material to be stored at fabrication shop and at site shall be placed on skids above the ground and
shall be kept clean and properly drained. Girders and beams shall be placed upright and shored.
Long members shall be supported on skids placed near enough together to prevent injury from
deflection.

Any structural steel materials (whether painted or unpainted) shipped to the Site by ocean
transportation, and positioned on board in such a way as to come into contact with salt water spray,
shall be thoroughly washed with clean fresh water, using pressure hoses and stiff bristle brushes,
prior to erection, whenever required.

14.12 Painting

14.12.1 Surface Treatment

14.12.1.1 General

This Sub -section covers the complete requirements for painting of steel works, including surface
preparation, priming and final protective coatings. Surface treatment of structural steel work shall be
considered in five classes as described Table 14.6 Classes of Surface Treatment. The material shall
conform to Steel Structure Painting Council (SSPC), Swedish Standard Institution (SSI) and Standard
of the Paint Manufacturer

Table 14-6. Classes of Surface Treatment

System Ref. Environment Application
Number
I Severe atmospheric External surface - General
II Severe atmospheric Internal surface - General
III Severe atmospheric External joint connection
IV Severe atmospheric Internal join connection

14.12.1.2 Surface Preparation

Before the application of any paint, the surfaces to be treated shall be thoroughly cleaned and freed
from all scale, loose paint, rust, oil and others. Oil and grease shall be removed from the surface by
washing with solvents or with a detergent solution before any blast cleaning operation. If any traces of
oil or grease remain after blasting, they shall be removed by solvent cleaning and the area re-blasted.
All welding areas shall be given special attention for removal of weld flux slag, weld metal splatter,
welt head oxides, weld flux fumes, silvers other foreign objects before blasting, If deemed necessary
by the Engineer acid washing and subsequent washing with clean water shall be used.
Any rough welding seams have to be ground and must be inspected and approved by the Engineer
before application of the coatings.

All structural steel which will be painted shall be cleaned by blast cleaning in accordance with SSPC-
SP 10 Near-White Blast cleaning. Mill scale, rust and foreign matter shall be removed to the extent

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that the only traces remaining are light stains in the form of spots or stripes. Finally, the surface is
cleaned with a vacuum cleaner or clean, dry compressed air.

The blast cleaning shall produce a surface roughness complying with the one specified by the paint
manufacturer for the primer concerned. If cleaned surfaces rust or are contaminated with foreign
material before painting is accomplished, they shall be re-cleaned by the Contractor at his expenses.

14.12.2 Painting Materials

All materials shall comply with the requirements of this specification. The basic colour of the
intermediate and final coats will be instructed by the Engineer.

14.12.3 Application of Paint

Unless otherwise specified, all painting and protective coating work shall be done in accordance with
the Specifications. The execution of the painting works shall be carried out in the most perfect and
workmanlike manner by experienced labor to the satisfaction of the Engineer. Furthermore, the
application of the paints shall be carried out in accordance with the manufacturer’s recommendations.

Planning and execution of the painting work shall be in conformity with the manufacturer’s
Specifications in respect to minimum and maximum intervals between the individual coats (layers).

Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be
avoided. When these occur, they shall be brushed out immediately or shall be removed, and the
surface shall be recoated. Each coat shall be allowed to dry for the time specified by the manufacturer
or as directed by the Engineer before application of any succeeding coat.

The surface must be completely dry, and its temperature should be at least 5 degrees Celsius above
the dew point. Paint should only be applied in suitable weather conditions and any fresh paint
damaged by weather shall be repaired or replaced at the Contractor’s expense. Measure shall be
taken to prevent dust or other extraneous matter from adhering to wet paint.

Brushes, when used, shall have sufficient body and length of bristle to spread the paint in a uniform
film. Paint shall be evenly spread and thoroughly brushed out. On all surfaces which are inaccessible
for painting by regular means, the paint shall be applied by sheepskin daubers, bottle brushes, or by
any other means approved by the Engineer. Rollers, when used, shall be of a type which do not leave
a stippled texture in the paint film.

A water trap acceptable to the Engineer shall be furnished and installed on all equipment used in
spray painting. Mechanical mixers shall be used to mix paint. Prior to applying, the paint shall be
mixed for sufficient time to thoroughly mix the pigment and vehicle together and shall be kept
thoroughly mixed during its application. The dry film thickness of the paint shall be measured in place
with an appropriate instrument.

All painting shall be in accordance with the specification, which for all steel bridge material will be hot
dipped galvanized with minimum thickness of 160 microns.

14.12.4 Dry Film Thickness

The specified film thicknesses for coating materials shall be strictly observed and shall be checked
with appropriate film thickness gauges furnished by the Contractor. The Contractor shall calibrate the
gauges for the thickness range to be checked. Calibration shall generally be carried out on a ground
and polished steel plate of a quality corresponding to the structural steel to be coated.

The dry film minimum thickness requirements, measure in accordance with the requirements of
SSPC-PA 2, Measurement of Dry Paint Thickness with Magnetic Gauges.

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14.12.5 Protection of Paintwork

The Contractor shall provide protective measures as necessary to prevent damage to the work and to
other property or persons from all cleaning and painting operations. Paint or paint stains which result
in an unsightly appearance on surfaces not designated to be painted shall be removed or obliterated
by the Contractor at his cost. All painted surfaces that in the opinion of the Engineer are marred or
damaged in any way, shall be repaired by the Contractor, at his cost, with materials and to a condition
equal to that of the requirements specified in this Specification. The Contractor’s proposal for re-
treatment of areas damaged by flame cutting and welding operations should be clearly stated in the
detailed painting plan. The painting shall be completed, and the surfaces shall be undamaged and
clean.

The areas for high-strength bolts shall be protected by masking tape against undercoats application at
the fabrication shop.

14.13 Method Measurement

Cast or forged metal (kind) shown in the Plans will be measured by the pound or whichever is shown
on the Proposal.

14.13.1 Structural Steel Furnished

The unit of measurement for payment for furnishing structural steel bridges shall be the mass of steel,
furnished in compliance with the Specifications and stocked in good condition at the site of the work.
The mass of steel shall include permanent structural steel, and shall be calculated as net weight by
approved Shop Drawings. But no reduction in mass shall only be applied for bolt holes. The mass of
welds, headed studs, slab anchors for deck slab, temporary bolts and nuts, paint and any other
temporary miscellaneous items for furnishing shall not be considered for calculation of the mass but
shall be included the unit price.

The unit price shall include procurement materials, labours, fabrication, equipment and tools for
fabrication, Inspection Agency, testing, inspections, shop painting, transportation to the site and stock
at the site. The mass of permanent high strength bolts and its washers and nuts, permanent bolts and
its nuts and washers shall include erection work.

The Contractor shall check and shall calculate the mass of the steel as shown on the approved
drawing

14.13.2 Structural Steel Erection

The unit of measurement for payment for erected structural steel bridges shall be the mass of steel,
erected in compliance with the Specifications.

The mass of steel shall include permanent structural steel, permanent high strength bolts and its
washers and nuts, permanent bolts and its nuts and washers. The mass shall be calculated as net
weight by approved Shop Drawings. But no reduction in mass shall only be applied for bolt holes. The
mass of welds, headed studs, slab anchors for deck slab, temporary bolts, field paint and any other
temporary miscellaneous items shall not be considered for calculation of the mass but shall be
included the unit price.
The unit price shall include labour, erection, equipment and tools for erection, testing, inspections and
field painting.

The Contractor shall check and shall calculate the mass of the steel as shown on the approved
drawing.

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15 DRAINAGE

15.1 Scope

This work shall consist of the construction of drainage pipes, culverts, U-ditches, and other drainage
facilities in accordance with these Specifications and the specifications for other work items involved,
all in conformity with the lines, grades and dimensions instructed by the Engineer.

The applicable provisions shall be read into and become part of this specification. The cost of
working in, or dealing with all ground water encountered in executing the work of this section will be
deemed to be included in the unit price for the pay item being installed or constructed.

The Engineer reserves the right to inspect and test all pre- cast concrete items before their delivery to
the site and at any time prior to and during laying. The drainage material shall be conform to SII 0013-
81 dan ASTM C 150-78A for Pre-cast U-Ditch Drainage and SII 0013-81 dan ASTM C 150-78A for
Pre-cast Pipe Drainage.

15.2 General

The types and characteristics of the drainage pipes and other drainage structures shown on the
Drawings and their estimated total quantities entered in the Bid Schedule are not to be taken as final.
To assist the Engineer in his review of the contract drawings, the Contractor will undertake a survey
of the site to determine the location, pipe or channel size, invert level and estimated discharge of all
storm water or foul sewer flows entering the Site. On the basis of the results of this survey the final
types, lines, characteristics and quantities will be decided by the Engineer, who will inform the
Contractor of them in writing in due time in relation to the approved schedule of work submitted by
the Contractor.

Responsibility for accurately locating all existing flows will rest with the Contractor and the cost of this
survey will be deemed to be included in the various pay items of this Section.

15.3 Sequence of Work

The Contractor shall so schedule the construction of drainage works that the discharge of runoff from
rain or other sources, both during and after construction, is properly provided for. To avoid damage to
works in course of construction the Contractor shall provide in due time adequate means of
protection, including all necessary temporary outlet ditches, dams, or diversion channels. Culverts or
other drainage works for the discharge of runoff water either during or after construction shall not be
built until adequate facilities for the inflow and outflow of the water have been completed, and they
shall be kept clear of all obstructions that might impede the flow of water. All culverts, ditches and
other drainage works shall be fully operative before work is begun on the construction of sub-grade,
sub-base or shoulders. These requirements shall be met without additional payment and all costs
thereof shall be included.

15.3.1 Box Culverts

Box culverts and associated wing-walls will be measured and paid for on the basis of individual pay
items described elsewhere in these Specifications. The relevant provisions will be deemed to be
applicable to all work on box culverts, except that groundwater encountered during structure
excavation for box culverts will be measured and paid.

The work shall consist of reinforced concrete box culverts furnished and installed in accordance with
the relevant Clauses of this Specification in conformity with the lines, levels, grades and dimensions

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shown on the Drawings or instructed by the Engineer. The material are from concrete which has to
follow SNI 2847:2013 of Indoensian Concrete Regulations.

15.3.2 Pumping/dewatering

The submersible pumps to be used should be suitable for clear and waste water and sewage-type
waste with sludge containing solids and fibrous material. The pumps should be with automatic
coupling system for below-ground level wet installation.

The pumps should also be suitable for horizontal or vertical dry installation. The permanent seals
and temperature monitoring and early warning system are also required to indicate whenever
inspection is required, ensuring longer durability along with low service costs and maintenance
requirements.

The Contractor shall propose for the Engineer’s approval all the details including the above for such
pumping/dewatering arrangement prior to the start of the related activities.

The cost associated with the above operation shall be deemed to be included, unless otherwise
provided elsewhere in the Contract, in the rates/prices provided for the other items included in the Bid
Schedule.

15.4 Drainage Pipes

15.4.1 Description

The work shall consist of reinforced concrete drainage pipes furnished and installed in accordance
with these Specifications and in conformity with the lines, levels and other details decided by the
Engineer as a result of the Contractor's survey mentioned in this specification.

15.4.2 Material

All concrete and reinforcement shall comply with the relevant requirements of these Specifications.
Pipe details shall be as shown on the Drawings and the Contractor shall submit for the Engineer's
approval, full details of his proposed arrangements for the manufacture, curing and handling of
reinforced concrete pipes.The material of Drainage Pipe shall be following to ASTM C 150-78A for
Pre-cast Pipe Drainage.
Formwork used in the manufacture shall be steel and of rigid construction.

15.4.3 Construction

15.4.3.1 Excavation

Prior to starting excavation the Contractor shall take all necessary measures to keep the excavation
free from free-surface water or surface water run-off.

In areas of fill, filling shall be completed to a depth of one pipe diameter above the top of the pipe,
before excavation begins. All excavation shall be carried out so as to minimize damage to existing
surfaces.

The sides of pits and trenches shall be adequately supported at all times. Except where otherwise
described in the Contract, they shall not be battered. The supports shall be left in pits or trenches only
where described in the Contract. Excavated material not required for backfilling shall be dealt with in
accordance with these Specifications.

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Soft spots in the bottom of drainage excavation shall be removed and the resulting void immediately
backfilled with Granular Backfill. When the Engineer instructs this additional treatment it will be paid
for under the relevant clauses of this Specification. Where the Engineer considers that soft spots are
due to the contractor's failure to fulfil his obligations under any clause of these Specifications then the
Contractor shall, at his own expense, undertake the additional excavation and replacement with
Granular Backfill to the satisfaction of the Engineer. Any suitable material below the level of the
concrete pipe bed which is removed unnecessarily shall be replaced at the Contractor's expense with
Granular Backfill in accordance with these Specifications. The Ecavation works has to follow the
Standard of ASTM D 1557, AASHTO T.99 & T.193.

15.4.3.2 Bedding, Laying and Surrounding of Pipes

All pipes shall be laid, using cradles if necessary, to the true line and level as directed by the
Engineer. Joints shall be sealed with 1:2 cement mortar, except where otherwise specified, so
that water will not leak. The inside of the joint shall be wiped and finished smooth and the outside
shall be protected for two days or as otherwise directed by the Engineer to prevent cracking.

After the Engineer has checked and approved the pipes and joints, the Contractor will complete the
concrete bedding and encasing or surrounding as instructed by the Engineer. Concrete shall be
thoroughly compacted below and around the pipe to the dimensions shown on the Drawings, but
special care should be taken to avoid dislodging the pipes or damaging the joints.

15.4.3.3 Backfilling and Reinstatement

Backfilling shall not commence until in the opinion of the Engineer, the concrete has achieved
sufficient strength. Backfilling shall be carried out in accordance with the requirements of the
specification, except that the maximum thickness of loose material shall not exceed 15 cm. Where
insufficient suitable material is available from any particular pipe excavation, surplus material from any
other excavation shall be used. On completion of backfilling, the area excavated shall be reinstated to
its original condition but the Engineer may waive or modify this requirement if the area is to be
overlaid or reconstructed under other Clauses of this Contract. The Backfilling works has to follow the
Standard of ASTM D 1557, AASHTO T.99 & T.193.

15.4.3.4 Method of Measurement

The quantity of reinforced concrete drainage pipe to be measured by the number of linear metres
measured along the centre-line of the pipe, between the inside faces of the headwalls, catch-basins
or manholes, as installed in accordance with these Specifications and the Engineer's instructions.

Pipes will be measured for according to the pipe diameter and the method of bedding or surrounding.
Type A pipe will have concrete bed and surrounding, and Type B pipe will have full concrete encased.
All details shall be as shown on the drawings.

15.5 U-Ditch, Inlets, Headwalls and Joint Boxes, etc.

15.5.1 Description

This item shall consist of all work in connection with the construction of ditches, inlets, pipe headwalls
and joint boxes along the shoulders, footpaths and where shown on the Drawings or where instructed
by the Engineer.

All work shall be done in accordance with these Specifications and in conformity with the lines, levels,
grades and dimensions shown on the Drawings or as directed by the Engineer.

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15.5.2 Materials

Materials shall be as shown on the Drawings and shall comply with the relevant clauses of this
Specification. Information about units which require reinforcement will be shown on the drawings.

Grating steel materials shall conform to the requirements of JIS G 3101: Rolled Steel for General
Structures -SS400 and shall be galvanized unless otherwise specified, in accordance with the
requirements of these Specifications.

15.5.3 Construction

15.5.3.1 Excavation

Excavation shall be performed in accordance with the requirements of "Structure Excavation" of these
Specifications and the relevant requirements. The Ecavation works has to follow the Standard of
ASTM D 1557, AASHTO T.99 & T.193.

15.5.3.2 Foundation

The foundation shall be prepared in accordance with the specification. When Class E concrete is
shown on the Drawings or instructed by the Engineer, this shall be in accordance with these
Specifications.

15.5.3.3 Layout

All work on U-ditches, inlets, pipe headwalls and joint boxes shall be carefully set out and constructed
with due recognition being taken of the fact that the upper surfaces must be incorporated exactly into
curbs, footpaths, etc. The Engineer may reject any item of work under this Clause when the upper
surfaces do not meet the tolerances for curb and footpath given elsewhere in these Specifications.

Bottom surface of ditches shall be smoothly and neatly finished. Where the Engineer considers that
any ditch, inlet or catch basin is likely to carry foul sewage, he may instruct that the 150 mm sand trap
as shown on the Drawings be deleted and replaced by benching formed in Class D concrete. All
details regarding the shape of benching and method of construction shall be in accordance with the
Engineer's instructions. Unless otherwise specified, joints of precast blocks shall be carefully
constructed using cement mortar of 1 part cement and 2 parts sand so as to prevent leakage. Hook
of U-ditches along steep slopes shall be constructed so as to effectively resist sliding, by excavating
soil to the shape of the hook and placing the concrete without disturbing the surrounding soil.

Cast-in-place concrete for waterways, drainage ditches, joint boxes, manholes, pipe headwalls, inlet
and outlet of waterways, shall be constructed according to the requirements of these Specifications.
These structures shall be exactly as shown on the Drawings and as directed by the Engineer. The
top portions of catch basins or inlets on which covers are to be placed shall be set exactly, and
carefully and smoothly finished.

To ensure uniformity in the horizontal and vertical alignment of the curb, the Engineer may instruct
that work on the upper sections of inlets, catch basins and U-ditches be deferred and carried out
immediately before or during work on the adjacent curb. Any additional expense incurred in complying
with this instruction will be deemed to be already included in the unit price for this work.

15.5.3.4 Backfill and Reinstatement

Backfill shall be performed in accordance with the requirements of these Specifications. Backfill
shall be carefully made so as to obtain a bearing capacity equal to the adjacent sub-grade. In
compacting sub-base or base course in contact with drainage structures, rammers or small
compactors shall be used and care taken to prevent damage to the adjacent structures. Backfill shall

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be carefully constructed so as to prevent erosion by overflow of drain water or rain. The Backfill works
has to follow the Standard of ASTM D 1557, AASHTO T.99 & T.193.

On completion of backfilling, the area excavated shall be reinstated to its original condition, but the
Engineer may waive or modify this requirement if the area is to be overlaid or reconstructed under
other Clauses of this Contract.

15.5.4 Method of Measurement

The quantities of ditches, catch basins, inlets, pipe headwalls and joint boxes completed and
accepted in accordance with the Drawings, these Specifications and as directed by the Engineer, will
be measured as follows:

The quantities of each type of ditch to be measured by the number of linear metres measured along
the centreline of the completed ditch. The length will be measured to the outside face of any inlet or
catch basin. In locations where P.C. piles are shown on the Drawings under any U-ditch type the
measurement will be made under the appropriate measurement.

The quantities of catch basins, manholes, inlet or outlet of waterway, pipe headwalls and joint boxes
to be measured for, will be the respective for each structure furnished and installed, complete in place
and accepted in accordance with the Drawings and the Engineer's instructions. The measurement for
the pipe headwalls will be deemed to include the mortared rubble apron as detailed on the Drawings
and no additional measurement will be made for this apron.

The measurement for ditches, inlets and catch basins will be independent of the depth and will be
deemed to cover any depth within the range shown on the Drawings. Where U-ditches are formed
with vertical walls of different heights, the combined height of walls will be compared with the
combined height of walls on standard U-ditches as shown on the Drawings, when determining the
compliance with this method of measurement. No additional measurement will be made for joints
between inlets or catch basins and ditches or drainage pipes. Any additional expense involved in
forming joints or junctions between individual measured items, will be deemed to be included.

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16 EARTHWORK

16.1 General

This Clause covers the requirements of all earthworks, which shall include, but not be limited to, the
following work activities:
- Furnishing adequate equipment and tools, materials, enough manpower to finish all necessary
work including temporary works as required.
- Excavation, backfilling and construction of earth structures including compaction for embankment,
foundations, ditches, culverts, utility lines and other necessary works.
- Cleaning and removal of all unsuitable materials at site and its disposal including transportation.
- Supply of material for backfill and/or earth structures.
- All other necessary works to complete the earthwork as required in this Employer’s
Requirements.

16.2 References

- Subsurface soils investigation results included in the Employer’s Requirements are reference
purpose only. The Contractor shall conduct soil investigations at his cost and time if necessary.
- Soil investigation report during the F/S study is available as the reference.
- Design properties of soils shall be determined by the Contractor and subject to the approval of the
Engineer.

16.3 Construction Requirement

16.3.1 Clearing

Unless otherwise specified, all trees, shrubs, brush and other debris shall be removed from the area
for the conveyor trace, stockpile pads, retention dam and building areas, and disposed to the area
designated by the Engineer within Bontang Coal Terminal area and so stored in the safe manner
acceptable to the Engineer.

16.3.2 Topsoil Removal

Unless otherwise specified or instructed, all topsoil in the construction areas to a depth of 150mm
shall be removed and stockpiled nearby in the safe manner acceptable to the Engineer.

16.3.3 Grubbing

Cleared areas shall be grubbed to remove all stumps and roots larger than 75mm in diameters
Grubbing shall extend to a depth of 500mm below the topsoil removal depth within the designated
area. When high levels of organic material are still present, additional depths of grubbing may be
required. All stumps and roots removed and also the topsoil contained high levels of organic materials
shall be disposed to the area designated by the Engineer within Trubaindo Coal Mining area and
stored in the safe manner acceptable to the Engineer.

16.3.4 Excavations, Backfilling and Compaction.

a. Excavation
Excavation works shall be conducted up to the specified elevations as shown in the Drawings
approved by the Engineer.
Excavated material which can be used for backfilling and/or constructions for earth structures
shall be stored in the approved temporary storage area. Other unsuitable material shall be

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 deposited at designated place as determined by the Engineer. Backfilling by the excavated
material shall be subject to the approval of the Engineer.

b. Fill material.
The approved material shall be used for backfilling. The materials shall be fit for purpose, of
reasonably uniform quality and shall be free of organic matter, tree roots, wood, masonry, plastic,
rubbish, building rubble, large stones, excessive clay or silt and any other deleterious material.
The fill material shall generally have a maximum lump size of 200mm in any direction, being 2/3
of the maximum layer thickness, with the maximum lump size limited to 150mm in the top 1 meter
of fill. However, lumps up to 300mm in any direction will be acceptable if the Contractor can
demonstrate the required degree of compaction can be achieved with a 450mm layer.
The material shall be capable of being compacted to the required degree as specified in the
requirements in below.

c. Placement of earth fill

Fill shall be placed in a systematic manner in horizontal layers of approximately equal thickness.
The depth of each layer shall not exceed the depth for which satisfactory compaction can be
guaranteed using the proposed plant and in any case, shall not exceed 300mm loose material
thickness unless otherwise approved by the Engineer.
No stone within the fill layer shall exceed 2/3 of the specified maximum lift thickness in any
dimension. Should any particle size from cut or borrow material exceed the 2/3 limit, then the
Purchaser representative may direct that the lift thickness be increased, providing satisfactory
compaction can be guaranteed.
Where existing soil surfaces are to be covered (excluding foundation preparation areas), with less
than 300mm of fill, the surface shall be scarified to a depth of at least 200mm, moisture
conditioned as required and re-compacted to the same density as that specified for filling.
The slope of compacted fill surfaces shall not be steeper than 1 in 2 or as shown on the Drawing
approved by the Engineer. The surface shall be re-trimmed to the required profile and uniformly
compacted.

d. Compaction
After stripping the topsoil, removing unsuitable material and gravel areas, all sub-grade areas
shall be proof rolled using 15 tons drum roller or pad foot travelling at a speed not exceeding that
recommended by the roller manufacturer. The proof rolling shall delineate soft, loose or
unsuitable soil spots in the sub-grade that shall be replaces with backfill material and compacted
to achieve the specified density. Foundation preparation shall be based on four passes of a 15
tons roller.
Construction areas where in-situ soil shows irregular soil conditions shall be tined to 500 mm
depth, mixed and re-compacted to achieve the specified density.
The degree of compaction specified is expressed as a percentage of the material’s standard
maximum dry density determined in accordance with ASTM D698 as specified hereunder. The
degree of compaction shall be specified in the Drawings approved by the Engineer according to
the requirements specified in the Moisture Control in below and subjected to the approval of the
Engineer.

e. Moisture control
Maximum dry density and optimum moisture content.
Maximum dry density and optimum moisture content of soils shall be determined in accordance
with ASTM D698 which is commonly known as the Standard Proctor Test.

Moisture control.
At the time of compacting areas where high density is required, fill material and the surface on
which it is placed shall be within the specified range of moisture content. The Contractor shall not
compact fill until it is within the range required for moisture content. The Contractor shall add an
accurately determined and carefully measured amount of water to materials or surfaces that are
too dry.

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 The Contractor shall pile or spread out to dry, material which is too wet, and if necessary, disk,
harrow or pulverize it by hand or mechanical means.

Density for cohesive soils.

For soil having 30% or more, by weight, of particles passing a No. 200 sieve, required relative
compaction, as determined by one of the method described in ASTM D698, and expressed as a
percentage of maximum dry density, and moisture content, at the time of compaction shall be as
stipulated in the table below.

MAX DRY MOISTURE

FILL AREAS DENSITY RANGE
(%) (%)*
General Fill 90 -3 Wo+3
Main Roads and Heavy Vehicle Parking (Top Meter) 95 -4 Wo+2
Connecting Roads and Light Vehicle Parking (Top 95 -4 Wo+3
Half Meter)
Building Pad (Top Half Meter) 90 -4 Wo+2
Trench Backfill (Except where superseded by higher
compaction requirement) 90 -3 Wo+3

Density for non-cohesive soils.

Soil having less than 30% by weight, of particles passing a No. 200 sieve, required relative
compaction as determined by one of the methods described in ASTM D698, and expressed as a
percentage of maximum dry density as follows:

Max. Dry Density

Fill Areas
(%)
Drainage blanket beneath No requirement. Compact with light buldozer
embankment (eg. D-6) traffic
Cushion fill beneath floor slabs 95
May be inspected by proofroling, at
COMPANY’s option
Road base 95
Trench backfill 92
Trench or chimney drains No requirement

16.4 Tolerance

The surface of all embankments constructed or disturbed shall be graded to a smooth surface. Unless
otherwise noted bulk earthworks levels grade surface, the finished surfaces of fill embankments and
cut surfaces shall be finished to the tolerances + 0mm, -75mm.

16.5 Quality Control

The Contractor shall perform compaction test for every layer of backfilling. Number of test for each
layer shall be proposed to the Engineer and approved prior to commencement of backfilling work.

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17 ARCHITECTURAL

17.1 Masonry

17.1.1 Brick Masonry Units

17.1.1.1 Description Of Work

This work shall consist of masonry units laid contiguously in mortar, including all related masonry work
as indicated in the Drawings and/or herein specified.
This work shall include but not be limited to the following:
- Installing brick masonry,
- Mortar and plaster,
- Application of joint sealant between wall and building columns, wall and openings, and wall with
equipment, as shown in the Drawings.

17.1.1.2 Reference Standards

- American Society for Testing and Materials (ASTM)

- Standar Nasional Indonesia (SNI):
o SNI 15-2094-2000 - Bata merah pejal untuk pasangan dinding (Solid Red Brick for walls)

17.1.1.3 Materials

- Brick masonry units of solid type shall be in square shape with sharp edges, flat surface on each
side, made from clay material and burnt at specified temperature, in nominal dimension of 52mm
x 100mm x 210mm,
Only smooth faced units with no visible checks, cracks, spalls or other defects will be acceptable.
- Unless otherwise noted, minimum ultimate crushing strength over the gross area shall be
50kg/cm², complying with the requirements of SNI 15-2094- 2000.
- Cement Mortar
Cement mortar shall conform to Specification 04060.
- Caulking
A plastic, non-staining compound shall be as specified in Specification 07920, for exposed joints
at the perimeters of door and window frame, window openings for equipment and others. Sample
materials shall be submitted for approval.
- Paints
Paints for finishing all plastered brick masonry surfaces shall be according to the requirements of
Specification 09910.

17.1.2 Autoclaved Aerated Concrete

17.1.2.1 Description Of Work

This work includes the procurement and installation of autoclaved aerated concrete at places as
shown in the Drawings and/or as specified in these Technical Specifications.

17.1.2.2 Reference Standards

- SNI 03-2156-1991 - Blok beton ringan bergelombang udara (aerated) dengan proses otoklaf.

17.1.2.3 Materials

- Light concrete bricks shall be of the autoclaved aerated concrete (AAC) type made from
ingredients of silica sand, cement, lime, water and aluminum powder and must comply with SNI

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 03-2156-1991 and/or BS 6073, and have a minimum compressive strength of 36kg/cm².
compressive strength must be at least 36kg/cm².
- Light concrete bricks shall have a nominal size of 600mm x 200mm x 100mm or as indicated in
the Working Drawings, such as Primacon made by PT Prima Rezeki Pertiwi or GE Blok made by
Grand Elephant or Neocon made by PT Neocon Graha Persada.

17.1.3 Concrete Masonry Unit

17.1.3.1 Description Of Work

This work shall consist of concrete masonry units laid contiguously in mortar, including all related
masonry work using hollow concrete masonry units with internally grouted steel reinforcement as
indicated in the Drawings and/or herein specified.

17.1.3.2 Reference Standards

- SNI 03-0349-1989 - Bata Beton untuk Pasangan Dinding.

- SNI 2052:2017 - Baja Tulangan Beton.

17.1.3.3 Materials

- Concrete masonry units shall be made with aggregate of gravel or crushed stone, and shall
conform to SNI 03-0349-1989, from Cisangkan or acceptable equivalent. Minimum ultimate
crushing strength over the gross area shall be 50kg/cm² (5Mpa).
- Whole block type of hollow concrete block shall be load-bearing concrete units and shall consist
of 2 core units with bottoms of 10mm thickness. Nominal dimension of the concrete unit shall be
100mm x 200mm x 400mm, unless otherwise shown in the Drawings.
- Halve block type of hollow concrete block shall consist of 1 core unit with bottoms of 10mm
thickness. Nominal dimension of this concrete unit shall be 100mm x 200mm x 200mm.
- Bond block type of concrete block shall be in U profile with nominal dimension 100mm x 200mm x
400mm.

17.2 Metal

17.2.1 Miscellaneous Metals

17.2.1.1 Description Of Work

The work under this specification shall comprise transportation, the supply of labour, materials, and
the performance of all work necessary to install metal works in relation to non-structural works as
indicated in the Drawings.

It shall include but is not limited to the following:

- Handrails, railing, bollards or protection posts,
- Laser cutting metal,
- Protections for columns,
- Grating,
- Tree grating,
- Gutter covers,
- Anchor bolts,
- Bolts, nuts and washers,
- Hangers/support,
- And others as indicated in the Drawings.

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17.2.1.2 Reference Standards

- American Society for Testing and Materials (ASTM):

- ASTM A36/A36M - Specification for Structural Steel.
- ASTM A123 - Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
- ASTM A153 / A153M - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware
- ASTM A780/A780M - Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip
Galvanized Coatings
- American Welding Society (AWS):
- D1.1-98 - Structural Welding Code- Steel (or latest edition).
- American Institute of Steel Construction (AISC).
- American National Standard Institute (ANSI).
- Standar Nasional Indonesia (SNI):
o SNI 1729:2020 - Spesifikasi untuk bangunan gedung baja struktural.

- Standard of the Manufacturer.

17.2.1.3 Materials

General
All metals shall be new and free from defects impairing strength, durability or appearance, and shall
be of the best commercial quality.
Unless otherwise specified, steel for light structural shapes such as angle, hollow, plates and others
as shown in the Drawings shall be made of steel grade Bj.37 having minimum yield strength of
2400kg/cm² conforms to the requirements of SNI 1729:2020 and/or ASTM A36. Items to be
substituted shall be approved by the Engineer.

Steel Pipe
Steel pipe for handrails, railing, bollards or protection post shall be black steel type of medium class
complying with SNI 0039:2013 and of diameter as required and as specified in the Drawings.
Diameter of pipe shall be as indicated in the Drawings.
Stainless steel pipe for handrails and railings in office are and others as indicated in the Drawings
shall conform to AISI 304, with minimum thickness of 2mm according to JIS G 3459. Diameter of
pipes shall be as specified in the Drawings.
Protection for Columns
Protection for columns shall be made from stainless steel plate with brush finish, in size and thickness
according to the Drawings.

Gratings
Grating of grille type for trenches covers shall be composed of steel bars and/or steel plates and other
steel profiles as specified, in sizes as shown in the Drawings, designed for a minimum live load of
500kg/m2, fabricated on site, or using prefabricated product, all finished with hot dip galvanizing in
minimum 85mirons thick, such as made by Webforge or acceptable equivalent.
Tree grating shall meet the following requirements:
- Laser cut metal sheet of 3mm think
- Flat bar of 40mm x 4.5mm think
- Stainless steel fastener
- All materials are hot-dipped galvanized with rough plastic coated finished.
- Size and pattern as shown in the Drawings

Gutter Covers
Standard (non heavy duty) gutter covers complete with support shall be fabricated from cast iron
having minimum tensile strength of 25kN/mm2, with minimum thickness of 20mm. Minimum thickness
of covers shall be 10mm with sizes as shown in the Drawings.

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Welded Wire Mesh Panel
Welded wire mesh for panel or partition as shown in the Drawings shall consist of galvanized steel
round wire of 4.06mm diameter with minimum spacing of 100mm x 100mm, having minimum yield
strength of 5000kg/cm², zinc coat of minimum 75microns, spot welded electrically at every crossing
point, complying with SNI 07-1590-1989.
Chequered Plate
Chequered plate in galvanized finish for platform, walkway/catwalks, stair's treads, kick plate and
others, shall have minimum thickness as shown in the Drawings (excluding thickness of pattern). All
finished with hot dip galvanizing in minimum 85mirons thick

Anchor Bolts, Bolts, Nuts and Washer

Anchor bolts shall be made of hot dip galvanized steel round bar having minimum yield strength of
2400kg/cm², complying with SNI 1729:2020 and/or ASTM A 36/A 36M, and in diameter and length as
indicated in the Drawings, with bolt and nut conforming to ASTM A 307.

Bolts and nuts conforming to ASTM A-307 shall be zinc plated, except where high strength bolts are
shown or specified.

Ring washers and others than those in contact with high strength bolt head and nuts shall conform to
ANSI B 18.22.1. All washers shall be zinc plated.

Chemical and or expansion anchor bolts shall be from Hilti, Ramset or Fischer. Diameter and length
of expansion anchor bolts shall as indicated in the Drawings and as recommended by the
manufacturer.

Hangers and Support

Hangers and/or supports for ceiling frame, lighting fixtures, fire extinguishers and other equipment,
shall be made of steel profile in sizes and forms as shown in the Drawings.

Grout
Grout for filling anchor's holes, baseplate's pad and others as indicated in the Drawings shall be made
of cement material, of non-shrinkage and non-metallic type

Galvanizing
- Hot-dip galvanizing is to be applied for all miscellaneous metals, base plates and anchor bolts as
shown in the Drawings.
- Method of hot-dipped galvanizing for all miscellaneous metals surfaces including plates shall
conform to ASTM A123 and method of hot-dipped galvanizing for all anchor bolts, bolts, nuts shall
conform to ASTM A153. All hot-dipped galvanizing coats shall have minimum 75microns or
530g/m2.

Painting
Except for miscellaneous metals with galvanized finish, all miscellaneous metals shall be finished with
anti corrosion finish

17.3 Thermal and Moisture Protection

17.3.1 Waterproofing

17.3.1.1 Description Of Work

This work shall include furnishing material, labour, tools and installation of waterproofing at places as
indicated in the Drawings.

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The works shall include but not be limited to the following:
– Exterior and interior horizontal and vertical waterproofing where shown.
– Flashing and sealing treatment.
– Setting flashing collars, clamping rings and like devices for pipe, conduit or structural penetration.

17.3.1.2 Reference Standards

– American Society for Testing and Materials (ASTM).

– Standard of the Manufacturer.

17.3.1.3 Materials

Waterproofing of Membrane Type

Waterproofing of membrane type shall be a minimum 1.5mm thick pre-formed self-adhesive
membrane composed of high-density polyethylene film and a self-adhesive rubber/bitumen
compound.

It shall adhere tightly and permanently to the substrate to form a continuous water barrier without
using job applied adhesives, hot materials, mechanical fastening or special equipment.

Waterproofing shall have the following characteristics:

– Capable of resisting a hydrostatic head when fully supported.
– Stable in dimension, high tear strength, puncture and impact resistance.
– Flexible and chemical resistant,
– Withstands extreme climates,
– Shall have uniform thickness,
– Quick installation,
– Performance properties complying with ASTM requirements (ASTM D 412, D 5385),

Primer for all concrete or masonry surface shall be from the same manufacturer of waterproofing
membrane.
Mastic seal that to be placed at all critical points such as terminations, drain, and pipe penetration
shall come from the same manufacturer as the waterproofing membrane.

Waterproofing of Liquid Type

Waterproofing of liquid type for concrete roof or floor exposed to UV shall be in white colour liquid.
Waterproofing shall have the following characteristics:
– Non-toxic and VOC compliant water based coating,
– Protecting concrete from deterioration,
– Withstands extreme climates,
– UV resistance,
– Preventing oil ingress into concrete,
– Quick installation and reducing maintenance costs,
– Slip resistance,
– Preventing water leaks and reinforcement corrosion,
– Creating a hydrophobic barrier inside the penetrated concrete.
– Complying with ASTM requirements, such as Sikalastic 590 by Sika or acceptable equivalent.

Waterproofing of Cementitious Type

Waterproofing shall be predosed, ready for use waterproofing slurry based on resin modified
cementitious material.
Waterproofing shall have the following characteristics:
– Easy to mix,
– Easy to use,
– Consistency can be chosen for application by brush or by trowel,

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– Excellent adhesion to sound substrates,
– Impermeable,
– Good resistance to abrasion and erosion,
– Non corrosive and non flammable,
– Non toxic,
– Slightly flexible,

Screed
Unless otherwise shown in the Drawings, screed material shall be in accordance with the requirement
of cement mortar

17.3.2 Building Insulation

17.3.2.1 Description Of Work

The work shall cover the furnishing and installation of building insulation materials for air
conditioned/temperature controlled rooms and others as specified in the Drawings, or hereinafter
specified.

17.3.2.2 Reference Standards

– American Society for Testing and Materials (ASTM).

– Standard of the Manufacturer.

17.3.2.3 Materials

General
All insulation materials shall be new, free from any defect and of first quality, from amanufacturer with
a proven record in this field of production.

Sound and Thermal Insulation

Wall Insulation
Insulation for sound and thermal shall be made from stone wool made of basalt, a volcanic stone,
having minimum characteristics as follows:
- Lightweight, with thickness 50mm as shown in the Drawings,
- Minimum density 60kg/m³,
- Thermal conductivity 0.034 at 20°C λ Value (W/mK) according to ASTM C518,
- Non-combustible according ASTM E-136,
- Blanket type

Roof Insulation
Roof insulation of fibre free type shall be constructed of one layer pure aluminium foil of at least 99%
attached to fire retardant non-dripping polyethylene foam sheeting in thermal process without glue or
chemical and one layer of aluminium foil, and shall have the following characteristics:
- High thermal resistance performance
- Non irritation, non asthmatic, non allergenic, non carcinogenic
- Rodent and insect resistance, formaldehyde free
- Surface burning according to class A (UL 723/E84)
- Effective in high humidity, acts as vapor barrier and water under sheeting
- Fast installation, reduce transportation and storage cost.
- Reflectivity of foil surfaces 97%,
- Nominal thickness of 4mm,
such as Net FR Polynum, Super ZT 01RBF by Zelltech or acceptable equivalent.

Vapour Barrier Aluminium Foil

Aluminium foil shall be of single-sided type and having characteristics as follows:

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- Minimum 3-layer laminates consisting of one layer aluminium foil, one layer kraft paper, and one
layer with cross line glass fibre yarn reinforcement and bitumen adhesive.
- Reflectivity of foil surfaces 95%,
- Basic weight of minimum ± 140gr/m², such as AB-711 S/S type by AB Foil or approved equal.

Tape
Self-adhesive aluminium foil tape shall be ABT 838 or Scapa.

Roofmesh
Roofmesh for supporting insulation shall be made of galvanized steel round wire in diameter of
1.5mm, spot welded electrically at every crossing point, with mesh spacing of 75mm x 75mm

17.4 Door and Windows

17.4.1 Steel Doors and Frames

17.4.1.1 Description of Work

The work shall cover the furnishing of materials, labour, tools, equipment, fabrication and installation
of steel door and frame as shown in the Drawings or as specified herein.

17.4.1.2 Reference Standards

o Standar Nasional Indonesia (SNI):

o SNI 1729:2020 - Spesifikasi untuk bangunan gedung baja struktural.
o American Society for Testing and Materials (ASTM).
o American Welding Society (AWS).
o Standard of the Manufacturer.

17.4.1.3 Materials

Doors and Frames

Steel door and frame shall be constructed from steel material complying with SNI 1729:2020 or ASTM
A36/36M standard and shall consist of the following materials:
o Steel sheet for door panel in specified thickness and size.
o Steel profile for door frame in specified shape and size.
o Mineral insulation for core of door panel.
o Vision panel of wired-glass, where specified.
o Steel louvers where specified.

Steel door and frame shall be constructed and fabricated in accordance with the design and
dimension as indicated in the Drawings and shall be pre-painted in the factory in colour as specified.

Hardware
All locks and fittings shall be corrosion proof, provided by one manufacturer

Door Panel
- Doors shall be minimum 43mm thick, formed of two panels of minimum 1.2mm thick for standard
type, and 0.8mm thick for light type, full flush to both faces of the frame, with seamless faces and
bevelled vertical edges. Seams or vertical edges shall be welded continuous full length. Top and
bottom edge seams shall be spot welded or continuous welded.
- All welding work shall be carried out in accordance with the requirements of AWS D1.1.
- Internal stiffeners shall be spaced as manufacturer's standard and according to the approved
Shop Drawings.

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- Adequate plate reinforcement shall be provided for hinges, lock boxes and other surface
hardware.
- Vision panel openings for glass lights in doors, if shown in the Drawings, shall have fixed glass
stops one side and removable glazing beads on the other side.
- Where external doors have openings for glass panels, fixed glass stops shall be on outside door
face.
- Double door shall be equipped with T shaped astragal made of aluminium.
- Bottom of the door panel of several steel doors as shown in the Drawings shall be equipped with
kick plate made of galvanized chequered plate as specified in Specification 05500. Thickness and
size of kick plate shall be as shown in the Drawings.

Frames
- Frames for doors shall be made of 2mm thick steel in profile as specified mby the manufacturer
and as indicated in the approved Shop Drawings.
- Frame shown fastened to the structure by means of exposed bolts shall have anchors fabricated
to detail.
- Frames not otherwise shown shall have anchors fabricated to standard pattern for the wall
construction as indicated.
- Adequate plate reinforcement shall be provided for hardware.

17.4.2 Fire-Rated Steel Doors and Frames

17.4.3 Description of Work

The work shall cover the supplying, fabrication and installation of fire-rated steel doors and frames
including hardware, as shown in the Drawings or as specified herein.

17.4.3.1 Reference Standards

- American Society for Testing and Materials (ASTM).

- National Fire Protection Association (NFPA).
- Standard of the Manufacturer
- Local Fire Department Regulation.
- American National Standards Institute/Underwriters Laboratories (ANSI/UL):
- ANSI/UL 10B-1988 - Fire Tests of Door Assemblies.

17.4.3.2 Materials

Fire-rated steel door and frame shall be constructed of steel sheet with steel grade conforming to
ASTM A36/36M
All fire-rated steel doors (including frames and hardware) shall be approved by local Fire Department
and shall bare UL stamp.

Door leaf shall be rebated with overlap of 24mm width around the door leaf.
Door leaf shall be reinforced, stiffened and insulated with thermal insulation such as mineral wool or
stone wool, according to the standard of the manufacturer.

Frames shall have form/shape and sizes according to the standard of the manufacturer, with minimum
thickness of 3mm. Jamb depth shall be 120mm, unless otherwise noted, or according to the standard
of the manufacturer.

Reinforcing of 4mm steel plate shall be provided for lockset, hinges and surface hardware.

The door, frame and hardware shall be designed for fire rating as shown in the Drawings.

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The fire-rated steel door leaf with 55mm overall thickness shall be fabricated from 1.5mm steel sheet,
in sizes according to the standard of the manufacturer and as indicated in the Drawings.

Where shown and required, and according to the recommendation of the fire door manufacturer,
vision panel of fire-resistant glass shall be provided.

Where shown and required, and according to the recommendation of the fire door manufacturer,
double door shall be provided with meeting stile seals (astragal).

17.4.4 Aluminium Doors, Windows and Frames

17.4.5 Description of Work

The work shall cover the provision and installation of aluminium doors, windows including louvers, and
frames as shown in the Drawings or as specified herein, including labour supervision, materials,
equipment and incidentals required and necessary to complete the system.

17.4.5.1 Reference Standards

- Standar Nasional Indonesia (SNI):

o SNI 07-0603-1989

- Produk Aluminium Ekstrusi untuk Arsitektur.

- American Society for Testing and Materials (ASTM): STM B221M
- Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes and Tubes.

17.4.5.2 Materials

Aluminium
Unless otherwise specified, all aluminium works of pre-fabricated profile to be used for doors,
windows (including sliding windows), louvers, grilles and frames shall be of clear anodized extruded
aluminium alloy 6063, temper T5 or T6 conforming to SNI 07-0603-1989 and or ASTM B 221 M
requirements,
Type of finishes of extruded aluminium shall be as follows:
– Clear anodized of minimum thickness 10microns for aluminium doors in factory area as shown in
the Drawings. Doors leaves shall be double skin type made of aluminium sheet.
– Powder coated finish of minimum thickness 80microns in white colour, for aluminium doors and
windows at main office and gate house as indicated in the Drawings

Unless otherwise indicated in the Drawings, thickness of all pre-fabricated profiles shall be 1.35mm
minimum, with shape and dimension as shown in the Drawings.
Dimension of profiles can change depending on the types of profile approved by the Engineer.
Exposed surfaces of aluminium shall be free of die marks, scratches, blisters, "leave-off" marks, or
other blemishes which are visible.

Door Panel
Unless otherwise shown in the Drawings, door panel shall be made of the following:
– Formaldehyde free plywood made of Kamper Wood complying with SNI 5008.2:2016
requirements, of thickness and size as shown in the Drawings.
– Medium density fibreboard (MDF) shall be made from wood fibers glued under heat and pressure
and shall be formaldehyde-free. Type of finish, thickness and size of MDF shall be as shown in
the Drawings.
– Fiber cement board as specified, of thickness as shown in the Drawings.

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17.4.6 Wood Doors and Frames

17.4.6.1 Description of Work

The work shall cover the provision and installation of wood doors and frames, including wood reveals
and frames to wood louvers, as shown in the Drawings or as specified herein, including labour
supervision, materials, equipment and incidentals required and necessary to complete the system.

17.4.6.2 Reference Standards

Standar Nasional Indonesia (SNI):

Standard of the Manufacturer.

17.4.6.3 Material

Door Frames
− Door frames made of wood shall be from kiln dried Kamper wood, with durability and strength of
class II as specified in SNI 7973:2013.
− Door frames made of steel, unless otherwise supplied by the door manufacturer.
− Door frames made of aluminium, unless otherwise supplied by the door manufacturer.

Flush Door Construction

o Internal Frame
- Internal frames (rails, stiles, lock rail and lock block) for internal and external doors shall be
kiln-dried Meranti or Kapur, with durability of class I and strength of class II complying with
SNI 7973:2013.
- Internal frames in hollow and solid core construction shall be nominally 100mm wide x 30mm
deep giving an overall thickness of door leaf as shown in the Drawings.

o Core Construction
- Core construction for external doors shall be solid core made of particle board according to
the standard of the approved manufacturer.
- Refer to the Drawings for locations of other required solid core doors.

o Facing
- Facing made of high pressure laminate of colour as required, shall comply with the
requirements of Specification 06200.
- Facing for all internal doors of flush type shall be 6mm thick plywood made of Teak wood or
as shown in the Drawings and shall comply with the requirements of Specification 06200.
- Facing made of veneer shall be according to the standard of the manufacturer, in colour as
shown in the Drawings.

Rail and Stile Door Construction

- Rails and stiles of engineering type for general internal doors shall be constructed from multi-
layered wood or Meranti core, and wood lipping, covered/laminated with 2mm thick veneer of teak
wood.
- Rails and stiles of solid type for public area such as dining room, music room and the like shall be
constructed of solid Meranti, covered/ laminated with 2mm thick veneer of teak wood.

Panels
- Panel of engineering type shall be constructed of multi-layered woodor particle board
covered/laminated with 0.5mm thick veneer of teak wood.
- Panels of solid type shall be constructed from kiln-dried solid Meranti covered/laminated with
0.5mm thick veneer of teak wood.

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Part-Glazed Doors and Doors with Vision Panels
Shall be hollow or solid core with internal framing all around the glazed opening. Provide rebated
frame for the glazing and all required beads.

Full-Glazed Wood Doors

Shall be fabricated from kiln-dried hardwood with frames glued and doweled or mortice and tenoned.
Frame size shall be minimum 150mm x 40mm
.
Double Doors
Provide rebated meeting stiles or approved alternative in all double doors.

17.4.7 Glass and Glazing

17.4.7.1 Description of Work

This work shall cover transportation, furnishing of manpower, equipment and tools and the installation
of all glass and glazing as shown in the Drawings and as specified herein.

17.4.7.2 Reference Standards

Standar Nasional Indonesia (SNI):

- SNI 15-0047-2005 - Kaca lembaran.
- SNI 15-0130-1999 - Kaca pengambangan.
- SNI 15-0131-2006 - Kaca pengaman diperkeras untuk bangunan dan panel.
- SNI 15-4756-1998 - Kaca cermin lembaran untuk penggunaan umum.

17.4.7.3 Materials

Plain Glass
Plain glass shall be selected clear float glass sheet which is flat and having uniform thickness, free
from any defect and from the best quality conforming to SNI 15-0047- 2005 and SNI 15-0130-1999,
such as Indoflot type by Asahimas or approved equal.
Unless otherwise indicated in the Drawings, thickness shall be 5mm in minimum with sizes as
required and as indicated in the Drawings.

Reflective Glass
Reflective glass shall be of a temperable magnetron coated glass with a strong and durable coating
that is able to go through tempering without compromising its appearance, specializing in blocking
heat and is a great fit for architectural glass applications where heavy sun makes excessive solar heat
gain, and also offers privacy, such as T-Sunluxl by Asahimas, in nominal thickness, colour and size as
required and as shown in the Drawings.

Double Glazing (Insulating Glass)

Double glazing (insulating glass) shall consist of two pieces of glass separated by hermetically sealed
dry air space. The units have both primary and secondary seals and a desiccant to prevent the
formation of condensation within the air space.
Double glazing shall use tempered glass made of glass with minimum U Value of 2m/2K, such as
Stopray 61T Glass by Asahimas of minimum 6mm thick outer glass, 12mm width airspace (argon)
and minimum 6mm thick inner glass, unless otherwise stated, manufactured in accordance with
ISO/DlS 9050 and DIN 6/507. Unless otherwise noted the spacer is black.

Laminated Safety Glass

Laminated safety glass shall consist of the following:
- Bullet-proof glass consisting of one or more sheets of flexible, tough and transparent polyvinyl film
laminated between two or more sheets of tinted glass through a heating and pressing process,

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 such as Lamisafe by Asahimas, in thickness of 4+4+4mm or 5+5+5mm or 6+6+6mm or others,
each in sizes and colour as shown in the Drawings.
- Laminated safety glass consisting of milky white film laminated between two sheets of clear float
glass through a heating and pressing process, such as
- Lamisafe by Asahimas, in thickness of 3+3mm and 4+4mm, with sizes according to the Drawings.
- Laminated safety glass consisting of one 1.5mm thick sheet of flexible, tough and transparent
polyvinyl film laminated between two sheets of tempered clear float glass through a heating and
pressing process, such as Lamisafe by Asahimas, in thickness of 8+8mm, with sizes according to
the Drawings.

Tempered Glass
Tempered glass shall be as follows:
- Flat heat-strengthened and flat fully tempered coated and uncoated glass used ingeneral building
construction complying with ASTM C1048 and SNI 15-0131-2006, with nominal thickness as
indicated in the Drawings or as directed by the Engineer.

Obscure Glass
Obscure glass shall be of plain glass that is flat, having uniform thickness, free from any defect and
from the best quality, from Asahimas or acceptable equivalent.
Nominal thickness and size shall be as indicated in the Drawings.

Wired Glass
Wired glass shall comply with ASTM C103, Type II (patterned and wired glass, flat), Class 1 (clear),
with thickness as required, of wired, polished both sides and of form and mesh square pattern, locally
produced.

Mirror
Mirror shall be as follows:
- Having high light reflection,
- Excellent resistance to natural atmospheric corrosion,
- No copper and greatly reduced levels of ammonia waste produced in the process,
- Improve resistance to chemical attack in the form of cleaners and adhesives,
- Complying with SNI 15-4756-1998

Size and thickness shall be as shown in the Drawings.

17.5 Finishes

17.5.1 Gypsum Boards

17.5.1.1 Description of Work

This work shall cover the furnishing and installation of all gypsum boards and frames for the work as
indicated in the Drawings and/or hereinafter specified.
The work shall include but not be limited to the following:
- Metal framing to receive gypsum board products as finish.
- Concealed acoustical insulation, where shown in the Drawings.
- Joint treatment.

17.5.1.2 Reference Standards

- American Society for Testing and Materials (ASTM).

- Australian Standard (AS).
- British Standard (BS).

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- Standar Nasional Indonesia (SNI):
o SNI 03-6384-2000 - Spesifikasi Panel atau Papan Gipsum.

17.5.1.3 Materials

Gypsum Board
Gypsum board with tapered/recessed edges shall be standard type having minimum thickness as
indicated in the Drawings
Gypsum board shall comply with the requirements of SNI 03-6384-2000, AS 2588, BS 1230 or ASTM
C 36.

Jointing Cement
Jointing cement for flush jointing on gypsum board shall come from the approved gypsum board
manufacturer to be used in this project.

Metal Frames
Metal frames for installation and supporting gypsum board, such as studs, runners, furring members,
channels, backing plates and others shall be prefabricated products made of aluminium-zinc coated
steel sheet such as Zincalume or Galvalum, in shape and size specially made for gypsum board
installation,

Fasteners
Fasteners such as screw from the type in accordance with the type of installation, shall be as
recommended by the gypsum board manufacturer and shall comply with AS 2589.

Miscellaneous Accessories
Other accessories for installing gypsum board, such as mentioned below, shall be as recommended
by the gypsum board manufacturer:
- Protection coated steel corner beads and edge trim, type designed to be concealed in finished
construction by tape and joint compound,
- Corner beads of manufacturer’s standard metal beads,
- Metal edge trim,
- Adhesive and perforated/reinforcing tape,
- Jointing cement/compound for gypsum board according to the standard’s of the manufacturer.
- Control joints with 4mm thick polyethylene air seal,
- Acoustical insulation of preformed mineral wool, friction fit type without integral vapour barrier, of
thickness as required to meet STC ratings as indicated,
- Acoustical sealant of type recommended for use in conjunction with gypsum board system,
paintable, non-shrinking and non-cracking where exposed,
- Prime coat specially made for gypsum board surfaces,
- And others as required, to complete the installation.

17.5.2 Ceramic Tiles

17.5.2.1 Description of Work

The work shall consist of the furnishing and installation of all ceramic tiles as shown in the Drawings
and/or hereinafter specified. The work shall include but not be limited to the following:
- Ceramic tiles for floor and wall,
- Accessories and other items recessed into or supported against tile work.

17.5.2.2 Reference Standards

- Standar Nasional Indonesia (SNI):

o SNI 03-4062-1996 - Ubin Lantai Keramik Berglasir.

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 o SNI 03-4061-1996 - Ubin Granito.

- Australian Standard (AS).

- American National Standards Institute (ANSI).

17.5.2.3 Materials

General
All tiles shall be new, free from any defect and of first quality, from a manufacturer with a proven
record in this field of production.
Tiles shall be of colour and type as shown in the Drawings.

Ceramic Tiles
Ceramic tiles shall consist of the following types:
- 200mm x 200mm and 300mm x 300mm semi-glazed ceramic tiles of non-slip type to be installed
on floor in wet area, and 200mm x 400mm and 300mm x 600mm glazed ceramic tiles for wall in
wet area.
- 400mm x 400mm semi-gloss/matt glazed interlocking natural stone type to be installed on all floor
of areas as indicated in the Drawings.
- Nosing tiles of semi-gloss/matt ceramic tile complete with "ribbed" non-slip surface for stair nosing
to concrete stairs.
- All ceramic tiles shall comply with SNI 03-4062-1996, such as from Asia Tile, Mulia or acceptable
equivalent.

Homogenous Ceramic Tiles

Homogenous ceramic tiles shall consist of the following:
- Homogenous ceramic tiles of polished type in size of 600mm x 600mm and 800mm x 800mm,
- Homogenous ceramic tiles of textured type in size of 600mm x 600mm.
- Homogenous ceramic tiles of polished type in size of 100mm x 600mm and 100mm x 800mm for
tile skirting.
- Step tiles to staircase of 300mm x 1200mm proprietary nosing complete with "ribbed" non-slip
surface as approved by the Engineer.
- All homogenous ceramic tiles shall comply with SNI 03-4061-1996

Transition Strip
Transition strip between ceramic tiles and other floor material shall be made from hairline stainless
steel in thickness and width as shown in the Drawings.

Tile Adhesive
Adhesive of thin bed of 3-6mm for floor and wall tiles, and submerged area or pools shall consist of
synthetic latex based liquid mixed with dry mortar to produce a superior mortar for use on concrete
slab or vertical surfaces.
Synthetic latex based liquid shall comply with AS 2358, BS 5358 Part 1, ANSI 118.4, 118.1 and 136.1
such as AM 30 or MU-422 for ceramic tiles on floors and walls in dry areas, AM 30 or MU-460 or
BASF MasterTile 30 for ceramic tiles in wet areas, AM 42 or MU-402 for homogenous tiles on floors
and walls, or BASF MasterTile 25 for general purpose tile adhesive.

Cement Mortar
Bedding (thick bed minimum generally 25mm) – Mixed on Site.
Cement mortar which shall be mixed with some admixture or as required by manufacturer.

Cement Grout
Cement grout shall be factory prepared portland powder mixture grout, factory precoloured in colour
as selected.

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17.5.3 Acoustical Ceilings

17.5.3.1 Description of Work

This work shall cover the furnishing and installation of a complete system of acoustical ceilings,
including frames, suspension assemblies and other necessary accessories as indicated in Drawings
and/or hereinafter specified.

17.5.3.2 Reference Standards

- IKEA Standard - 04-0510.Closed suspended ceilings (int&ext)

- American Society for Testing and Materials (ASTM).

17.5.3.3 Materials

Acoustical Panels
Acoustical panels shall be of low-sag mineral fiber material complying with ASTM E 1264 Class A (for
surface burning characteristic) and of RH-99 type
Each unit shall be for concealed grid installation with minimum thickness and size as indicated to the
Drawings.

Concealed Grid Ceiling System

Runners to hold acoustical ceiling panels shall be of concealed type, made of hot dipped galvanized
steel with oven-baked paint in the factory, such
Adjustable rod shall be of 4mm galvanized steel wire as recommended by the runners’ manufacturer
or of galvanized steel wire annealed either 1 strand or 2 interwoven strands of dimension as shown in
the Drawings.
Hold down clip shall be provided to hold each ceiling tile at its place. Hold down clip shall be made of
galvanized steel sheet in size and form as recommended by the runners’ manufacturer.

Structural Support Members

Structural support members for holding suspended system, adjustable rods, trafficable system,
lighting fixtures, air conditioning accessories and others as specified which are laid adjacent to the
ceilings shall be fabricated from steel profile in shape and sizes as indicated by the Drawings.

17.5.4 Gypsum Panels

17.5.4.1 Description of Work

This work shall cover the furnishing and installation of all gypsum panels for ceiling, including frames
and other necessary accessories as indicated in Drawings and/or hereinafter specified.

17.5.4.2 Reference Standards

American Society for Testing and Materials (ASTM).

17.5.4.3 Materials

Gypsum Panels
Gypsum panels for ceilings and wall with 600mm x 600mm and or 600mm x 1200mm size shall be
specially designed to be able to absorb sound from low to middle sound frequency. Each panel shall
have square edge for exposed grid tegular lay-in installation. Nominal thickness shall be according to
the standard of the gypsum panel manufacturer and as shown in the Drawings.

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Runners
Runners to hold gypsum panel shall be made of hot dipped galvanized steel with oven-baked paint in
the factory, such as from Jayaboard, Knauf AMF, Gyproc or acceptable equivalent.
Runners shall consist of the following:
- Main Tee of 15mm wide, 43mm deep.
- Cross Tee of 15mm wide, 43mm deep.
- Side Angle of 22mm wide, 22mm deep.

Adjustable Rod
Adjustable rod shall be of 4mm galvanized steel wire as recommended by the runners manufacturer
or of galvanized steel wire annealed either 1 strand or 2 interwoven strands of dimension as shown in
the Drawings.

Hold Down Clip

Hold down clip shall be provided to hold each gypsum panel at their place. Hold down clip shall be
made of galvanized steel sheet in size and form as recommended by the runner’s manufacturer.
Structural Support Members
Structural support members for holding adjustable rods, lighting fixtures, air conditioning accessories
and others specified, shall be of steel profile in shape and sizes as indicated by the Drawings. A Shop
Drawing is be submitted by the Contractor for Project Manager's approval.

17.5.5 Paints

17.5.5.1 Description of Work

This work shall consist of the provision and application of all shop and field painting work, for all
structural and non-structural components of the buildings, including all surfaces designated to be
painted as shown in Drawings or Colour Scheme, unless otherwise noted.

This work shall include but will not be restricted to supply of labour, materials, scaffolding and tools to
be used for preparation of surfaces, application of paint, making good any defect and cleaning of any
splash to other work. All coating shall be as required in this Specification or determined by the
Engineer.

Unless otherwise specified, all interior and exterior surfaces shall receive one coat of primer and two
coats of finish.

17.5.5.2 Reference Standards

- Steel Structure Painting Council (SSPC).

- Swedish Standard Institution (SIS).
- Standard of the Paint Manufacturer.

17.5.5.3 Materials

General
All coating materials shall conform to the specifications shown in the painting schedule herein and to
the requirements hereinafter specified. Paints shall not contain any toxic or harmful substances such
as lead, mercury or asbestos, and all paints (primers, undercoats and finish) shall have low VOC
(Volatile Organic Compounds).
All primers and finish paints to be used in this work shall be provided by the same designated
manufacturer, and shall not be mixed with paint from other sources or of dissimilar compositions.
For the purpose of establishing a basis of quality, the paints specified herein are based upon paints
as manufactured by Dulux, Jotun, or Propan, but the designation thereof shall not be construed as
being proprietary.

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The Contractor shall provide painting schedule for each type of material to be painted as stipulated in
this Specification and as shown in the Drawings.
General Procedures
− Full details and colour card of proposed materials and manufacturers shall be submitted before
construction. Failure to do so may lead to rejection of materials on site and failure to meet
program requirements.
− All materials shall be of such quality as to produce first class and durable finishes and to be at
least equal requirements of the relevant standards.
− Before painting with a particular system commences, the Contractor shall paint test areas or
sample panels to demonstrate that the specified thickness and finish to the paint film is being
obtained all shall be approved by the Engineer.
− The paints, equipment and method of application used for test areas or sample panels shall be
representative of those to be used for the work. Test areas or sample panels shall be retained
and shall form the standard for all subsequent work.
− Contractor shall be responsible in providing samples and sample panels.
− All coating shall be fresh stock and be of new and first quality, delivered at job site in unopened
original manufacturer's containers, and stored in the dry, watertight, lockable enclosure.
− All coating materials shall be in sealed containers and labeled so as to plainly show the
designated name, formula or specification number, batch number, colour, date of manufacture
and manufacturer's directions.
− Scaffolding used for painting shall be retained in position while work is being carried out and for a
period up to three days after completion, or alternatively, other means shall be provided to give
reasonable access for the Engineer to inspect prepared surfaces and paint films.
− The Engineer shall have free access to all work locations, and warehousing facilities and the right
to inspect the preparation of all surfaces and the application of all paintings.
− Before any deviation from this Specification, the Engineer shall be consulted. Failure to do so will
in no way relieve the Contractor of his responsibility for satisfactory compliance with standards
and procedures set forth in this Specification.
− The Engineer shall have the right to reject any work that is not carried out in accordance with this
or any other applicable Specifications. All expense incurred by the correction of rejected work
shall be borne by the Contractor. Causes for rejection of work or portions shall include but not be
limited to the following:
− Surface preparation considered unsatisfactory by the Engineer for any reason.
− Failure of Contractor to apply the minimum number of coats of the appropriate thickness.
− Failure of Contractor to allow minimum specified drying time between coats.

Materials
1. All coating materials shall conform to the specifications shown in the painting schedule herein and
to the requirements hereinafter specified. Paints shall not contain any toxic or harmful
substances such as lead, mercury or asbestos, and all paints (primers, undercoats and finish)
shall have low VOC (Volatile Organic Compounds).
2. All primers and finish paints to be used in this work shall be provided by the same designated
manufacturer, and shall not be mixed with paint from other sources or of dissimilar compositions.
3. For the purpose of establishing a basis of quality, the paints specified herein are based upon
paints as manufactured by Dulux, Jotun, or Propan, but the designation thereof shall not be
construed as being proprietary.
4. The Contractor shall provide painting schedule for each type of material to be painted as
stipulated in this Specification and as shown in the Drawings.
5. Primers
− Water-based sealer for interior masonry, fiber cements board and concrete surfaces.
− Water-based sealer for exterior masonry, fiber cements board and concrete surfaces.
− Alkyd based primer with zinc phosphate as an anticorrosion preventing pigment for steel and
miscellaneous metal surfaces.

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6. Undercoat for steel and miscellaneous metal surfaces shall be undercoat with pigment of titanium
dioxide and binder of alkyd.
7. Finish Paints
− High durable and washable emulsion (acrylic copolymer emulsion), fungus resistant, with a
mid sheen finish, for interior masonry, gypsum board, fiber cement board surfaces.
− Premium quality, 100% acrylic based emulsion paint, fungus resistant, for exterior masonry
surfaces.
− High quality alkyd enamel topcoat finish for steel, miscellaneous metals and plastic surfaces.

8. Colour and Tints

Designated areas shall be subject to colour selection stated in Colour Scheme or as approved by
the Engineer after samples showing alternative colours and textures recommended have been
furnished as per point above. The same thing shall be carried on for colour, tint or texture of
prefinish surfaces.
Shades of stain shall match the respective colour specimen selected by the Engineer and shall
conform to manufacturer's standard colour.
Construction Requirements
1. All paints shall be used in accordance with the manufacturer's application instructions and shall
comply with the specified standard in SSPC/SIS or equal.
2. Hardware, hardware accessories, machined surfaces, plate, lighting fixtures, and similar items in
contact with surfaces to be painted shall be removed, masked, or otherwise protected prior to
surface preparation and painting operations.
3. Such protection shall be done by workmen skilled in the trades involved. Exposed nails and other
ferrous metal on surfaces to be painted with water-based paints shall be spot primed with zinc
phosphate primer as appropriate to condition, and then a top coat shall be applied.
4. Surfaces to be painted shall be cleaned prior to application of paint or surface treatments. Existing
painted surfaces designated for re-painting shall be cleaned in a manner which shall provide the
surface a good adhesion to receive paint, or shall if unpainted, be wire brushed or buffed with a
light sanding tool, and touched up to remove all evidence of rust, corrosion or abrasion.
5. Oil and grease shall be removed with clean cloths and cleaning solvents which have low toxicity
and flash-point in excess of 38□C.
6. Cleaning and painting shall be scheduled in such a way that ensures dust and other contaminants
from the cleaning process do not fall on wet or newly painted surfaces.
7. Plastic surfaces to be painted (such as PVC) shall be gently roughed with 220 grit sandpaper.
Clean the plastic surface from loose dust with a damp cloth. The paint shall be applied when the
plastic surfaces are already clean and dry.
8. Masonry, Gypsum Board, Fiber Cement Board and Concrete Surfaces
− Masonry, gypsum board, fiber cement board and concrete surfaces to be painted shall be
prepared by removing chalk, dust, dirt, grease, oil, asphalt, tar, excessive mortar or mortar
droppings and by roughening the surfaces to remove glaze.
− Surface deposits of free iron shall be removed prior to painting. Immediately before coating,
all surfaces to be painted, except gypsum board, shall be uniformly and thoroughly
dampened, with no free surface water visible, by application of potable water using a fog
spray.
− Sufficient time shall be allowed to elapse between sprayings to allow water to be absorbed.

9. Steel and Metal Surfaces

− All steel and metal surfaces shall have all mill scales, dust and rust removed by dry
sandblasted to Sa 2/SP-6.
− Excessive wire-brushing with power operated, rotary, wire brushes, resulting in a burnished
effect to the steel surface, shall be avoided.
− All steel and metal surfaces contaminated by oil or grease shall be washed with clean white
spirit. Oil or grease may, in locations approved by the Engineer, be removed from the

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 surfaces of ferrous surfaces by washing with a proprietary water-soluble mixture of solvent
and detergent followed by rinsing with clean water.
− Washing of steel/metal surfaces, where required to remove soluble salt deposits shall be
carried out using clean water and where conditions permit, hose pipes and scrubbing brushes
shall be used.
− Surfaces shall be primed with priming paint as soon as possible after completion of the
preparation process. The rate of progress of surface preparation shall be controlled to ensure
that preparation and priming are carried out on the same day.
− Further surface preparation shall be carried out where there is evidence of rusting or
contamination resulting from prolonged exposure before priming.
− After the surface is prepared in a manner acceptable to the Engineer, one coat of zinc
chromate primer shall be applied to the steel work at the fabrication shop. Primer shall be
applied by brushing to ensure a continuous film without holidays. Primer coat shall be applied
immediately after the surface preparation without any time lag.
− Fabricated steel/metal with the shop coat of primer after its erection in the field shall be
carefully examined and shall be treated with a touch-up coat of zinc phosphate primer
wherever the shop coat has been abraded, removed or damaged during transit/erection,
defaced during welding/riveting and also over the field welds, bolts and nuts adopted for
structure.
− After touching up, the second coat of zinc chromate primer shall be applied over the erected
steelwork.
− Galvanized surfaces to be painted shall be roughened with chemical solvent specially
produced for the purpose, or brushed by wire brush. Clean the surfaces from dirty, dust, oil,
grease and leftovers of roughing work prior to applying primer coat.
− Galvanized surfaces not to be painted shall be solvent-cleaned.

10. Paint Application

− All finished surfaces shall be free from runs, drops, ridges, waves, laps, brush marks and
variation in colour, texture and finish. The covering of each coat shall be complete and each
coat shall be so applied as to produce film of uniform thickness.
− Special attention shall be given to insure that all surfaces including edges, corners, crevices,
welds and rivets receive a film thickness equivalent to that of adjacent painted surfaces.
− Adjacent areas and installation shall be protected using drop cloths or other approved
precautionary measures. Other material surfaces adjacent to surfaces to receive water-based
paints shall be primed and/or touched up prior to the application of water-based paints.
− The first coat of paint on concrete surfaces shall include such repeated touching up of suction
spots or overall applications of primer-sealer as necessary to produce a uniform colour and
gloss.

11. Coating Progress

− Sufficient time shall elapse between applications of successive coats to permit acceptable
drying. This period shall be modified as necessary to suit varying weather conditions.
− When the applied coating is left exposed for long periods, it may develop a whitish layer of
zinc salts. This salt layer shall be washed off with fresh water and dried subsequently to
facilitate secure intercoat bonding.
− Thinner shall not be added to any coating materials unless approved by the manufacturer as
necessary for proper application.
− Oil base or oleoresinois solvent-type paints shall be considered dry for recoating when the
paint feels firm, does not deform or feel sticky under moderate pressure of the thumb, and the
application of another coat of paints does not cause lifting or lessens adhesion of the
undercoat.
− Coating with reference thickness in dry condition shall be as follows:
 Interior masonry, fiber cement board and concrete surfaces: Prime coat : one (1) coat of
water-based sealer (8m²/litre). Finish coat : two (2) coats of high durable and washable
emulsion with a mid sheen finish (@12-14 m²/litre).

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  Interior gypsum board surfaces: Finish coat : two (2) coats of high durable and washable
emulsion with a mid sheen finish (@12-14 m²/litre).
 Exterior masonry, fiber cement board and concrete surfaces: Prime coat : one (1) coat of
water-based sealer (8m²/litre). Finish coat : two (2) coats of premium quality, 100% acrylic
based emulsion paint (@12-13m²/litre).
 Steel and miscellaneous metal surfaces :Prime coat : one (1) coat of alkyd based primer
with zinc phosphate (45microns or 12m²/litre). Undercoat : one (1) coat of undercoat
(30microns or 17m²/litre). Finish coat : two (2) coats of high quality alkyd enamel topcoat
finish (@30microns or 14m²/litre).
 Exterior plastic surfaces Finish coat : two (2) coats of high quality alkyd enamel topcoat
finish (@30microns or 14m²/litre)

− All paint thickness in dry condition mentioned above are for indicatives only. The nominal
paint thickness in dry condition shall be in accordance with the standard thickness of the
approved paint manufacturer.

12. Storage, Mixing and Thinning

− At time of application, paint shall show no sign of hard settling, excessive skinning, livering or
other deterioration.
− Paint shall be thoroughly mixed using electromixer, stirred, strained in a strict conformance
with the manufacturer's recommended procedure and kept uniform consistency during
application.
− Where necessary to suit conditions of surface, temperature, weather and method of
application, package paint may be thinned immediately prior to application in accordance with
the manufacturer's directions, but not in excess of 0.5liter to suitable thinner per 4liters.
− The use of thinner for any reason shall not relieve the Contractor from obtaining complete
surface coverage.
− No alteration or mixing of materials on premises shall be permitted, except as specified for
priming, sizing or undercoats, and where tinting is required to produce proper colour.

13. Paints other than water-based coatings shall be applied only to surfaces that are completely free
of surface moisture as determine by sight or touch. Paint shall be applied in an environment
conducive to controlled drying.
14. Surfaces that have been cleaned, pretreated and/or otherwise prepared for painting shall be given
a coat of the specified first coat material as soon as practicable after such preparation has been
completed, but in any event prior to any deterioration of the prepared surface.
15. Method of application shall be as recommended by the paint manufacturer.
16. Special Requirements :
− Rollers for applying enamels shall have a short nap.
− Brushes used for emulsion paint shall be soaked in water for a period of 2 hours prior to use.
− Upon completion of the work, staging, scaffolding and containers shall be removed from the
site or disposed of in an approved manner. Paint spots, oil or stains upon adjacent surfaces
shall be removed and the entire job left clean and acceptable to the Engineer on final
inspection. The scaffolding shall not affect floor or wall surface all damage is Contractors
responsibility.
− All protective masking applied to surfaces or designated items previous to painting shall be
removed after final coat has been allowed to firm-up sufficiently so that no smudged areas
result from removal of masking.

17. Following the completion of painting of each space, removed/covered items as indicated of this
Specification, shall be reinstalled by workmen skilled in the trade involved.
18. Clothes and cotton waste that might constitute a fire hazard shall be placed in closed metal
containers or destroyed at the end of each working day.

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Traffic Markings Paint
Traffic markings paint shall be made from waterbased acrylic suitable for marking interior and exterior
curbing and lanes on driveways, sidewalks, factory floors, parking lots and other areas where zone
markings are required.
It shall meet the following requirements:
– Excellent adhesion on concrete, asphalt or brick masonry surfaces that required quick dry and
frequent recoating,
– Fast drying and high visibility
– Abrasion resistant
– Glass beads can be added for making reflective markings
– Environmentally friendly,

Colour and Tints

Designated areas shall be subject to colour selection stated in Colour Scheme or as approved by the
Engineer after samples showing alternative colours and textures recommended have been furnished
as per point above. The same thing shall be carried on for colour, tint or texture of prefinish surfaces.
Shades of stain shall match the respective colour specimen selected by the Engineer and shall
conform to manufacturer's standard colour.

17.6 Specialities

17.6.1 Toilet Cubicles

17.6.1.1 Description of Work

The work shall cover the furnishing and installation of all toilet cubicles, including their frames,
partition panels and hardware as indicated in the Drawings or specified herein.

17.6.1.2 Reference Standards

Standard of the Manufacturer.

17.6.1.3 Materials

General
Cubicle panel shall be made from solid grade laminate or solid grade phenolic sheet with melamine
surface, aluminium skeleton internal frame and exposed PVC profiles to offer unique toilet cubicle
system.
Polyurethane is injected between two shells of solid grade laminate 3mm thick, acting as permanent
bonding agent laminate and frames. The polyurethane foam is rot free and resistant to chemicals and
shall not absorb any moisture.

The solid grade laminate is resistant to chemicals, chlorine, disinfectants and cleaning agents in safe
concentrations, impact resistant, shrink and abrasion resistant as well as heat resistant.
Panels shall be supplied in selected colour as determined in Colour Scheme to be issued later or as
directed by the Engineer.

17.6.1.4 Construction

Wall Connection
Wall connections shall be painted/anodized aluminium channels that are purpose-made to allow
attachment of dividers and end panels to walls and frontals with proprietary fixings.

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Head Rail
Head rail shall be painted/anodized aluminium extrusions that are fixed to tops of frontals to provide
lateral restraint.
Aluminium infill channels to door openings shall be cut neatly in one piece and fixed between frontal
panels.

Door
Doors shall be 1800mm x 600mm x 12mm solid core, highly moisture resistant solid grade phenolic
board.

Hardware
Hardware of manufacturer’s standard shall consist of two ‘hold open’ spring hinges, one slotted
indicator, one turn bolt and staple, a coat hook and bumper, and pedestal leg height 150mm.
Hardware shall be stainless steel 304 hairline finish.

17.6.2 Partition

17.6.2.1 Description of Work

This work shall cover the supply of labour, materials, tools and the performance of all works
necessary to install partition as indicated in the Drawings.

17.6.2.2 Reference Standards

Related Specifications:
– Building Insulation.
– Fiber Cement Boards.
– Glass and Glazing.
– Paints.

17.6.2.3 Materials

General
All materials used for partition work shall come from proven manufacturers as specified herein and as
approved by the Engineer.

Panel
Panel for partition made from fiber cement board with calcium silicate base shall be of partition type
with tapered edges in thickness as indicated in the Drawings.Fiber cement board shall be as specified
in the Specification. Partition panel made of tempered glass with thickness and size according to the
Drawings shall comply with the requirements of the Specification.

Frame
Metal frame for installation and supporting fiber cement board, such as studs, channels, backing
plates and others shall be prefabricated products made of aluminium-zinc coated steel sheet such as
Zincalume or Galvalum, in shape and size specially made for calcium silicate board installation, as
recommended by the partition installer. Frame for full height glass partition system shall be as follows:
Head and sill channels consisting of:
– Extruded 25mm aluminium, 2 piece glazing channels with brush seals.
– Setting blocks provided as required.
– End covers or channel end caps as required

Vertical wall trim consisting of:

– Extruded 25mm aluminium, 2 piece frame with brush seals for glazing joints.
– Extruded aluminium flush glazing drywall insert with brush seals for glazing joints.

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– Hardwood channel track.

Frame for freestanding glass partition system shall be as follows:

Bottom track consisting of:
- Extruded 25 mm aluminium, 2 piece glazing channels with brush seals.
- Setting blocks provided as required.
- Glazing gaskets molded or extruded shape to fit glazing channel retaining slot.
- End covers or channel end caps as required.

Vertical wall trim of extruded aluminium 25mm face size, 2 piece frame with brush seals for glazing
joints.

Glass Joints
Glass joints for full height partition shall be as follows:
- Vertical joints of translucent/crystal clear H sections made of PET-G that is recyclable.
- Corner joints of extruded aluminium 90º junction.

Glass joints for freestanding glass partition shall be as follows:

- Vertical joints of translucent/crystal clear H sections made of PET-G that is recyclable.
- Corner joints of extruded aluminium 90º sections with brush seals.

Sound Insulation
Sound insulation for filling partition core shall be as specified in Specification 07210 and as shown in
the Drawings.

Paint
Paint for finishing of fiber cement board surfaces shall be according to the Requirements Specification
of Paint

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18 ELECTRICAL AND ELECTRONIC

18.1 Electrical Installation Work

18.1.1 Installation Terms

a. Outlet, Doos, Cabinet and Installation Equipment

Includes the procurement and installation of outlets (sockets), pull boxes, cabinets, cables,
auxiliary tools and all other equipment needed to obtain a satisfactory completion of the
installation system.

b. Boxes (Doos) Outlet

The outlet boxes must comply with the requirements of VDE, PUIL, AVE or other standards.
These boxes can be in the form of a single/multi gang box, rectangular or octagonal. The ceiling
box and other hanging boxes are octagonal. For boxes that are installed on the floor must be
used the type of "Frame Adapter" waterproof (waterproof) and neatly closed, installed properly
and correctly.

c. Size
Each outlet box shall be provided with conduit openings only where required. Each box must be
large enough to accommodate the number and size of conduit, in accordance with the
requirements, but not less than the designated or required size.

d. Waterproof Type Equipment Outlet

The outlet boxes in the following places shall be of the type fitted with a weather-resistant gasket:
- Places exposed to the sun
- Places where it rains - Oily places
- Places exposed to humid air
- The places indicated in the picture

e. Outlet On Special Surface

Outlet boxes for "receptacles" and switch buttons mounted on countertops, partitions, concrete
blocks, marble, metal frames, brick or wood walls must be square in shape and must have upright
angles and sides.

f. Switches and Receptacles

Unless noted or otherwise required, wall switch outlet boxes and receptacles must be galvanized
steel and must not exceed 10.1 x 10.1 cm for single appliances and 111.9 x 11.9 cm for two
appliances and boxes. -"Multi Gang" box for more than two equipments.

g. Support And Binder

Steel plate boxes must be supported sufficiently to have a fixed shape.

h. Cable Support
Each pull box, including the boxes on top of the "Switch board" and motor control center, should
be provided with a sufficient number of clamps, etc. where the cables are installed in a neat and
orderly manner that allows identification, so that no cables are stretched without support.

i. Cabinet
All cabinets must be made of steel plate, except those that are frequently wet/rained which must
be made of moisture-resistant cast iron or special construction. The cabinet for the "panel board"
has a proportional size as required for the "panel board" which is as large as needed, so for the
number and size of cables there must be good ways to install, support and adjust the "panel
board" and its cover. Cabinets with wires "though feeder" must be arranged properly, neatly and
correctly.

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j. Finishing
All cabinet "back boxes", and doors for electric "panel board" must be given a powder coating
gray paint finish, pre-painted from the manufacturer.

k. Hidden Conduit
The pull box connected to the recessed conduit is mounted with the lid flush against the wall or
ceiling.

l. Key
Each cabinet must be equipped with a "catch and flat key lock" combination. Cabinet locks use
the "common key" type, and two keys must be provided for each cabinet.

m. Panel Installation HeighT

Installation in such a way that every equipment in the panel can still be easily reached, depending
on the type / type of panel, so if a base / foundation / support / hanger is needed, the contractor
must provide and install it even if it is not shown on the drawing

n. Panels on The Wall

Each panel mounted on the wall from the electrical shaft on the back must be installed with a
separate iron frame attached to the concrete. This is to allow the passage of cables to the next
floor.

o. Manhole and Handhole

Especially for the external network, both inside and the green line, so for connection, turning,
meeting, a manhole made of concrete is needed and covered with an iron plate with a thickness
of 1 cm and a frame. In some places it is needed too. Each cable manhole must be marked /
labeled which is pressed and wrapped so that it can be easily identified.

p. Label
All panels, switches and fuse units, switch group isolators and other equipment must be labeled
according to their function. This label is made of stainless steel with black letters.

18.1.2 Technical Specifications of Materials and Equipment A. Wire And Cable

1) General
Wire or cable for each building must include low voltage cables, control cables, accessories, tools
and other items necessary to complete and complete the installation and operation of all systems
and equipment.

2) Low Voltage Wire and Cable (600 V and Less)

Wires must meet the requirements of PUIL, VDE. For use as a machine tool wire "appliance"
except for individual systems as required or recommended by the manufacturer of the specific
systems and as approved by the government. All wires with a cross section of 10 MM2 and above
must be of the stranded type and no wire smaller than a cross section of 2.5 mm2 may be used,
except for the use of "Remote Control" controls that are less than 30 meters in length. Unless
otherwise required, the conductor must be of type NYY, NYFGbY, NYM. All cables must be in the
conduit, cable tray, and clamped/tied with cable tees. The cable used must be made SUPREME,
KABELINDO,Extrana or KABELMETAL.

3) Size
All electrical conduit, wires and connections must be complete. The conduit and wires must have
the size as designated or required to comply with the required applicable regulations.

4) Other
Wires for electric lighting, including outlets for extension and electrical power must be provided
and installed completely from the connection point of service to all outlets indicated on the

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 drawings. All cables must be in high impact PVC conduit. All branch circuit conductors must be at
least 2.5 mm2 in cross section, unless otherwise noted. "Home Run" for a 220 volt circuit whose
length is more than 40 meters from the panel to the first outlet must have a minimum cross-
section of 4 mm2 with a capacity of 20 A.

5) Splice/Branch
No spikes or connections are allowed in either the feeder or the branches, except for accessible
outlets or connecting boxes. Connections to the branch circuit wire must be mechanically and
must be electrically strong with a "Solderless Connector" of the compression cable type, of the
"Copression" or "Soldered" type. In making "Splic", the connectors must be connected to the
conductors well so that all the conductors are connected, no bare wires are visible and cannot be
separated by vibration.

6) Control Cable
Where indicated on the drawings or require motor control cables, starters and other equipment.
The conductors for the control cables must be intact or "Standard annealed copper". The
insulation shall be of butyl rubber, moisture and ozone resistant or a similar rubber-like synthetic
compound of a thickness suitable for 600 volts. Individually insulated conductors shall be provided
with neoprene wrap and be colour-coded. All cables must be wrapped in a neoprene case
suitable for installation in underground conduit in damp or damp places. The conductors shall
conform to those required for the satisfactory operation of the controlling apparatus, taking into
account the length of the circuit and so on.

7) Insulation Material
All insulating materials for splices, connections and others such as rubber, varnished cambric,
asbestos, glass, synthetic tape, resin, splice case, "Combination" and others must be of the type
approved for use, location, voltage etc. and must be installed using an approved method,
according to the recommendation of the government representative or manufacturer.

8) Wiring and Support

a. All cables must be fixed to cable trays or surface mounted with suitable clamps and supports.
Cable trays shall be perforated and galvanized after perforation, and fixed to the surface with
special supports painted with anti-rust paint. Tray cable used must be made THREE STAR,
NOBI or TRI ABADI.
b. All cables must be installed in a straight line and the radius of bend must not be less than the
manufacturer's requirements (15 times the cable diameter).
c. For the installation of cables, the Contractor must provide his own supports such as trays,
clamps, supporting iron, hangers for cables that are installed horizontally or vertically. and
these supports have been taken into account in the cost of installing the cable.
d. NYY, NYM cables in red, yellow, black, are used for all phases. Blue is for zero and yellow is
green for ground.

18.1.3 Low Voltage Systems and Accessories (Below 600 Volt)

18.1.3.1 General

Low voltage systems include: switches, buttons, circuit-circuit breakers, indicators, manetic
contractors, equipment accessories and other items needed for the perfect installation and operation
of all systems and equipment.

18.1.3.2 Panels

Panels shall be as shown on the drawings, unless otherwise indicated. The entire assembly including
housing, protective equipment shall be designed, fabricated, tested and where necessary repaired in
accordance with the minimum requirements with adjustments and/or additions as required herein:

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a. General
Panel board must be dead-front type, consisting of metal/steel plate with the following thickness:
Free Standing Panels (MDP, Lift Panels, Chiller Panels, Generator Panels etc.): minimum 2 mm
for the frame, 2 mm for the door panel, and 2 mm for the side panel.
Wall mounted panels (lighting panels, control panels and other small panels): made of steel plate
with a minimum thickness of 1.6 mm for the frame and 1.6 mm for the door.
Each panel must be equipped with a plate name and the name of the panel. On the inside
(behind) the door panel must be equipped with a box to store the wiring diagram. The inside of
the panel must be equipped with a cover, so that when the door is opened, only the front of the
MCB/MCCB is visible, while the cables are not visible. Panels must be finished with a gray
powder coating paint, pre-painted from the manufacturer. The structure shall be constructed of
reinforced and welded structural steel or steel profile frames, and shall not be damaged in transit
or installation. Resistant to voltage due to short circuit. The frame must be completely wrapped on
the bottom, top and sides with removable cover plates, accessible from the front or back. All
required gauges or "transfer" buttons must be grouped on the hinged front side. The hinged lid
must have a concealed hinge and a latch. All necessary sources for circuit control, transformers,
etc. must be installed on the back side of the hinged enclosure. There should be sufficient grille
for ventilation where it is necessary to limit the temperature rise of the current-carrying parts to the
values required in the VDE/IEC standard for enclosed equipment. The removable rear reach
panel must have a screw construction or (screwed on/bolted on). Stressed materials must be
completely prevented from splashing water.

b. Pull Box
Where indicated on the drawings or as required by installation conditions, a pull box shall be
installed at a sufficient height of the same type of construction as the switch board at the top of
each switch board. The top and sides of the pull box must be of parts that can be opened loosely.
The base of the pull box must consist of asbestos or similar fireproof board, and the cables to the
individual breakers must be perpendicular through the separate holes in the bottom of the pull
box. The top cover located at the rear of the structure should be easily removed to allow for the
necessary openings for cable or bus duck conduit. The supports for cables must be arranged so
as to allow arc proofing and wiring. The pull box must be of a suitable size to allow ventilation and
installation of movable circuit breaker equipment where necessary.

c. Construction
The panels shall be as required herein and as shown in the drawings to carry out the required
functions. The exact location and type of equipment shown may vary according to the need to suit
the manufacturer, to the extent that the intended function and operation can be achieved.
However, the identification of layout drawings, schedules, etc., must be followed in the proper
order to facilitate inspection and building inspection procedures. Site "bus" structures and
connections must be constructed and supported to withstand the flow of connections that may
occur at that particular location. Connections must be made or welded and clamped and adjusted
to ensure good box area.

d. Name Board
Each circuit breaker must be provided with a nameplate, on the door or panel near the breaker
and easily visible. The methods of naming must clearly indicate the circuit of the circuit breaker or
the devices connected to it. Information regarding this must be submitted in the shop drawings. A
blue mimic diagram must be provided on the circuit board, complete with components and
markings for those components.

e. Backup Connection
If it is stated in the drawing that there is a reserve, then these rooms must be equipped with
terminals, mounting clamps, supports and so on, for equipment that will be installed in the future,
including terminals. Possible connections in the future can be in the form of new panel equipment
switches, circuit breakers, magnetic contactors and others.

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f. Measuring Tools
Some panels must be equipped with measuring transformers as shown in the picture. The meters
are of the special moving ironvane type for panels, with a circular, flush or semi-flush scale, in a
vibration-resistant box, with a size of 15 x 15cm or 10 x 10 cm², with a linear scale and 1%
accuracy. The position of the rotary switch for the voltmeter should be clearly marked. The
measuring instruments used are from GAE, GENERAL ELECTRIC, or MERLIN GERIN products.

g. Flow Transformers
The current transformer is of the dry type, indoor window type with a coil ratio corresponding to an
accuracy of 0.3 with a burdan according to VDE standards. The installation must be strong
enough to withstand mechanical forces, when a symmetrical 3-phase short circuit occurs. A
current transformer for an ampere meter may also be used in conjunction with a KWH meter as
long as the accuracy is still good, if not, a special current transformer is used. The transformer
used must be made by GAE or equivalent.

h. Control Wires
The control wires of the panels must be factory/workshop installed complete and bundled and
protected against mechanical damage. The minimum size is No. 14 of the 600 volt type, PVC.

i. Brand/Factory
All safety equipment must be made by one factory. Similar equipment must be able to be moved
and interchanged in the frame panel. Low voltage panels used must be made of PMelectric,
Prastiwahyu or SYMETRI, with protection components from GENERAL ELECTRIC, SIEMENS, or
MERLIN GERIN. The arresters used are from DEHN or PHOENIX CONTACT products.

j. Safety Equipment/Power Breaker

The safety devices are oil-free circuit breaker with a current limiting fuse, a molded case breaker
with a current limiting fuse, and a fuse breaker. The working current of the circuit breaker must be
in accordance with the drawings, with an interrupting capacity of 5,000 - 60,000 A symmetrically
adjusted to the short circuit capacity at each load point, the fuse breaker must be of the type that
opens and closes quickly

k. Assistant Terminal
If going to a terminal on the panel consists of several cable cores that are connected to the
terminal, then if necessary, they are connected through auxiliary terminals. The Contractor shall
provide such auxiliary terminals on panels with suitable terminal holes.

18.1.3.3 Board Panel

1. Umum
Lighting panels and panels for other equipment must be of the "dead front" type (turn off from the
front), unless as required otherwise be equipped with a "circuit breaker" and must have a "trip
rating" and the number of poles as indicated in the schedule. This panel must be made by
Prastiwahyu, PMelectric or SYMETRI.

2. Circuit Breaker
Single-pole breaker for the use of a single-phase 220 volt circuit must have a trip rating as stated
in the schedule with an interrupting capacity of 5000 Ampere symmetrically. "Breaker" pole 2 and
3 220/380 volt system must have a trip rating as in the schedule and an interrupting capacity of
10,000 - 50,000 Ampere symmetrical. GENERAL ELECTRIC, SIEMENS, or MERLIN GERIN
products are used.

3. Grounding
Neutral Panels must be isolated from the cabinet and mounted on opposite ends of the "mains"
and have numbered terminals. Where spares are noted in the schedule drawings of the panel

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 board and others, the necessary connectors from the "Mounting bracket" and others, must be
provided for the possibility of inserting a "circuit breaker" in the future.

18.1.3.4 Low Voltage Breaker

a) General
The low-voltage circuit breaker is installed in a metal cabinet, can be removed by pulling out or
installed using clamps/screws. Manual circuit breakers must "trip face" mechanically. Electrically
operating circuit breakers, and their auxiliaries such as primary and secondary stationary
breakers, support rails must be made of the same manufacturer.

b) Working Electrically
The main circuit breaker and other circuit breakers with a working current of 500 to 1250 Ampere
must be equipped with an electrical mechanism. This electrical mechanism can be in the form of a
solenoid type or a stored energy type or otherwise shown in the figure.

c) Working Magnetically
Each phase of the low-voltage circuit breaker shall be provided with a selective and instantaneous
overcurrent trip, or magnetically in accordance with applicable standards such as NEMA, IEC or
equivalent.

18.1.3.5 Illumination System and Equipment

a) Umum
Illumination systems and equipment include armatures, lamps, accessories, tools and other tools
necessary for the complete and perfect operation of all lighting equipment. Fixtures shall be as
required and indicated on the drawings.

b) Quality and Workmanship

All materials and accessories, whether specifically named, are of the highest quality. The
workmanship must be first class, and produce an armature commensurate with mainstream
commercial standards. Armature must be in accordance with the drawings and schedule, or as
required herein. These materials and accessories must be made by PHILIPS, SITECO.OPPLE or
ARTOLITE.

c) Indoor Lights
All fixtures must be repaired working factor so that it reaches PF = 0.85 by using a capacitor. The
material is made of 0.6 mm thick steel plate, with burnt paint which previously had to be cleaned
and greasing, then just anti-rust using "Zincromate" so that a fairly good quality would be
obtained. .

18.1.3.6 Garden/Parking Lights

Fixtures must be in accordance with the drawings, the Mercury type must be wired in lead-lag. All
fixtures must be repaired working factor so that it reaches PF = 0.85 by using a capacitor. All
components must comply with PLN standards.

18.1.3.7 Down Light/Baret

Down light/beret, for corridor/toilet lighting or as shown in the drawing complete with ballast, capacitor
and armature with lid made of poly Ethylene/bjls 8 mm with a power factor of not less than 0.85.

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18.1.3.8 Exit Sign Light

For this project, an Exit Sign Light with a double-sided Ceiling Mounted type is used.□The material of
Epoxy painted 20 gauge mild steel is weatherproof and dustproof, with a service time of 4 hours after
being charged for 24 hours, the battery used is Nicad resistant to temperatures of 50

18.1.3.9 Ballast

The ballast must be leak proof, have a low working temperature, noise-less, ballast with a polyester
housing. Ballasts must be equipped with connection terminals that meet PLN standards.

18.1.3.10 Starter

Starters for fluorescent lamps have rediability. Made of high quality white polycarbonate, the light
starter is matched with the TL lamp rating.

18.1.3.11 Emergency Kit

power supply is 230 volts, 50 Hz, the capacity must be adjusted to the power of the lamp used.
Installed in several places according to the planning drawings, the lights are marked with arrows and
the ground is "OUT" in red or green, for lights that are installed on 2 (two) sides (double side) while
lights are on the wall on 1 side (single side). Material from polycarbonate with a service time of 2
hours after being charged for 24 hours, the battery used is Nicad resistant to temperatures of 50,
power supply is 230 volts, 50 Hz, the capacity must be adjusted to the power of the lamp used.

18.1.3.12 Grounding Installation Requirements

Any equipment operating with a voltage greater than the extra low voltage (50 VAC) must be
effectively grounded) Metal / metal materials from exposed electrical equipment, including cable
shields (sheath / armour), conduit, metal conduit, rack, tray, doos, socket, armature, metal switch
must be connected with a continuous conductor for grounding. The use of metal conduit as the sole
grounding conductor is not permitted. In this case, a separate grounding conductor made of copper
with high conductivity must be used. The minimum cross-sectional area of the grounding conductor is
between 6 sqmm and inserted into the conduit. Connection of the grounding conductor must use a
mechanical connector approved by Project Manager.
The required grounding resistance is as follows:
1. Transformer neutral grounding & Genset maximum 1 ohm.
2. Bus-bar and panel neutral grounding maximum 2 ohms.

18.1.3.13 Lightning Protection Installation Requirements

The lightning protection system used is a conventional system, designed by taking into account the
situation and field conditions. Minimum areas that use lightning protection are Crusher Station,
Transfer tower and Stacking area. The placement of the terminal rod is such that it covers the building
area up to a radius of 125 meters.

Rod terminals are connected to the grounding system by means of insulated cables. The conductor is
then connected to the building's grounding system in the form of a grid system or rod system. Ground
resistance must be < 5 ohms

18.1.3.14 UPS Installation Work

UPS Operating System:

The UPS Operating System must be able to operate as follows:

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a. Normal Power Source Condition The load is supplied from the mains source continuously through
the rectifier and inverter (On-line System, UPS, Sinusoidal) with the output voltage and frequency
within the allowable limits. The battery is charged at a continuous floating voltage by the rectifier.
b. Abnormal Power Source Condition If the power source is turned off or experiencing interference
beyond the allowable tolerance, the rectifier will stop working. And the inverter will be supplied by
the battery without causing a disconnection of the load supply and it will not result in abnormal
system performance.
c. The state of the power source is back to normal When the normal power source returns, the
inverter will be supplied again by the rectifier. And the battery will be fully charged by the rectifier
during a predetermined time interval.

18.2 Diesel Work Generator Set

a. The Contractor shall procure and install (install) and perform a complete DGS system test with
control equipment (including DGS panels) as specified. Protective equipment, control wiring
systems and interlock circuits which have not been specified or described but are necessary for
safe operation, shall also be provided. The established DGS system must meet the above
requirements as well as applicable local requirements. DGS system equipment and materials
used must be made, CUMMINS POWER GENERATION, Perkins, Doosan.

b. General Specifications Of Diesel Engine:

The diesel engine must be of a high speed stationary diesel engine which is specifically designed
for power generation prime movers, 4 stroke (four stroke), multi cylinder direct injection,
compression ignition type, smooth sound and vibration free when operating. the machine must
have heavy duty capability and meet BS 649 standard. The machine is equipped with a radiator,
fan (fan), cooling water circulation pump, lubricating oil pump, oil pressure gauge, speed
measuring instrument (tachometer), eletrical type governor, integrated hour man recorder, speed
guard (overspeed trip devices) and their equipment. The specified brake horse power capacity of
the engine and its equipment shall have a capacity not less than the full load rating of the
alternator (generator including power losses, plus a spare capacity of at least 10%. Engine
operating speed is 1500 rpm, with piston arrangement ( cylinder) vertical in-line (for 6 pistons or
smaller) or V (8 pistons or more). The machine is started with a DC electromotor connected to the
battery (battery started), and is equipped with a battery charger.

c. Alternator General Specifications

a) General
The alternator must be synchronous, foot mounted, drip proof, self ventilated, screen
protected and coupled directly to the engine with a flexible clutch. The aternator is equipped
with a damper cage. The full load (nominal) voltage must be 220/380 V, 3 phase, 4 wire, 50
Hz with the neutral point being brought out through a separate terminal. The full load capacity
of the generator is 200 kVA, cos phi 0.8 lag and can operate at full load prime and has a 10%
overload capability for 10 minutes continuously or intermittently in an 8 hour working period
Efficiency above 90% at load conditions varies between 50% to 110% of nominal load. The
maximum total distortion of the open circuit voltage waveform between phases should not
exceed 2%. The frequency should be kept at ±0.5 Hz. at any time under various load values,
including transient overloads caused by starting the motor. The alternator must be composed
of a main alternator (armature and field pole), a brushless amplifier (pilot exciter), a rotating
racifier module, all of which form a brushless alternator. Both the main alternator and pilot
exciter operate on the same axle and are mechanically and electrically balanced up to 125%
of nominal speed. The alternator must be designed to perform well in a tropical climate at 30
degrees C and 90% humidity. The insulation used is a non-hycroscopic type, class B for the
pilot exciter, class F for the main alternator stator and class H for the main exciter. The
alternative cooling must be axially by a fan.

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b) Subtransient Reactant
The alternator subtransient reaction should not be greater than 25%. The use of reactors or
resistors to obtain an equivalent reactance equal to the above requirements is not permitted.
The neutral point of the generator must be grounded separately from the grounding of the rest
of the system.

c) Voltage Settings:
Voltage build up must occur automatically by utilizing the residual voltage from the magnetic
remanence through a solid state static automatic voltage regulator (AVR). AVR must be able
to adjust the voltage + 1% independent of the power factor (pf 0.8 lag to 1) and 5% speed
variation. Response at full load and pf (cos phi) = 0.8 lag, the output voltage reaches steady
with a tolerance of + 2% can be met within 0.25 seconds. The output voltage must be
adjustable + 5% of the nominal voltage. AVR must be able to work in separate or parallel
operating conditions. Also in conditions of overload and symmetrical short circuit which is still
within the alternator operating limits. Phase, equipped with radio frequency interference
suppressor (at a distance of 10 meters not more than 50 oersted). The AVR must not use
electrolytic type capacitors. The semiconductor components used must comply with the
manufacturer's standards with a rating of 1.5 times the working conditions that may occur.

d) Rotating Rectifier Module

The rotating rectifier module must be impregnated with epoxy resin and must be able to
withstand, without being damaged, the effects of heat and centrifugal forces or other stresses
arising from normal operation or short circuits. The type of rectifier used must be a silicon
rectifier

e) Genset Control Panel

Diesel Genset (DGS) must be able to be operated in parallel with other units, either manually
or automatically to achieve the following operating conditions:
- Start stop automatically.
- Load sharing between units automatically.
- Automatic load release.
- Synchronize two generators.

The generator control panel must be able to perform the following control, measurement and
protection functions:
• Setting the speed, load, frequency, these settings must be done manually and
automatically so that a selector switch must be provided.
• On the panel must be provided measuring tools for generators such as: Volt meter,
equipped with VSS, Ampere-meter, Frequency-meter, Watt-meter, KWH-meter and Cos-
phi meter. All measuring instruments must be of Class Index 1.5 (IEC-51 BS 89: 177).
• The panel also functions as a protection system for the generator set and is equipped
with the following relays:
- Overcurrent relay (Over Curent Relay), this relay serves to detect overcurrent caused
by inter-phase interference, the characteristic of the relay is inverse time, so the time
required for the generator to trip depends on the fault current, the greater the fault
current the faster the relay responds so that equipment damage due to overcurrent
interference can be minimized.
- Each phase short circuit relay (ground fault relay), this relay functions for short circuit
current from phase to ground, the characteristics of the relay are the same as
overcurrent relays.
- Overload relay (Over Load Relay), this relay serves to detect if there is an overload
during normal operation.
- Reverse power relay which will detect if the generator rotation is reversed so that the
generator functions as a motor. - Over/Under Voltage Relay, this relay serves to
detect if there is less or more voltage during normal operation. - Under/Over

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 frequency Relay, this relay serves to detect if the electrical frequency from the
generator is below or above the proper frequency (50 Hz). - Over Speed Relay, this
relay serves to detect if the mechanical speed of the engine exceeds the speed that
should be 1500 RPM.

GENERAL CONDITIONS OF DIESEL GENERATOR SET

a. DATA DIESEL GENERATING SET REQUIRED:
1) DIESEL ENGINE :
- After Cooler.
- Bearings.
- Crankshaft.
- Engine Blocks.
- Cylinder Head.
- Fuel Systems.
- Lubricating Oil Coller.
- Lubrication System.
- Pistons.
- Thermostats.
- Turbochargers.
- Valves.
- Vibration Dampers.

2) GENERATORS:
- Bearings.
- Motor Housing Construction.
- Cooling System.
- Drive Couplings.
- Exciter.
- Insulation.
- Rotors. - Stators.
- Voltage Regulators.

b. The generator unit must be skid mounted, self contained in the form of a diesel power plant
complete with all the necessary equipment for starting, loading, unloading and stopping the unit at
any change of circumstances required and other controls. Each generator unit must have its own
direct-connected diesel, complete with the equipment specified.
c. EQUIPMENT INTERFACE/COORDINATION The equipment must be in a state of wiring and
piping, so that it is possible to connect the piping, power cable and control cable to the fuel tank,
control panel, compressed air piping, fuel piping, exhaust air system piping, in accordance with
the provisions provisions to obtain good coordination and operation of these units.
d. CONDITIONS FOR SAFETY The generator unit must be serviced by a technician who in carrying
out his work it is enough to use simple equipment, for example: gloves or conventional tools.
Cover plates that must be opened during operation or service must be equipped with a release
device that can be opened quickly and easily. All parts of the appliance which are placed in an
area that is hazardous to technicians due to high temperature conditions, movement, rotation or
sharp edges must be insulated, guarded or protected in accordance with the provisions to reduce
the possibility of danger. all equipment must be grounded.
e. MATERIALS AND MANPOWER All materials, tools and parts that complete the unit in
accordance with the specifications must be in a new condition from the factory and have never
been used and have good quality, have no defects or abnormalities that could affect its operation.
The workforce must be an expert who has experience with the tools specified by the
manufacturer. The relationship between diesel and generator must be strictly matched. This
provision also applies to the equipment installed, and other components/tools.
f. DIFFERENT METAL USE: For joining or joining metals with different materials, it must be
prevented from rusting by digalvanizing between the two metals.

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g. TROPICAL CLIMATE ADJUSTMENT: Equipment must be maintained to prevent mold and
damage from occurring with the following provisions:
1) Electrical components such as: switches, contractor fuses, heating elements, distributors,
magnetic tools, do not need to be cleaned. Materials and other components that have
protection against mold or are protected by insulation against the influence of outside air, do
not need to be cleaned again.
2) Circuit elements that are not closed and have a temperature rise of not more than 75 deg F
(24 deg C), when operating at full load must be coated with mold preventing material, i.e.
generator, coils from machines, control panels from machines. and capacitors.Also can be
done for switch panel cables, panel panels, terminals and junction boxes.
3) Circuit elements such as motor coils, generators, transformer windings and other similar
components, which have a temperature rise of more than 75 deg F (24 deg C) during full load
operation do not need to be coated with a toxic compound function.

h. INSTALLATION:
Each unit is equipped with a skid frame base made of steel of the appropriate size and can
properly support the units installed on it, complete with a spring vibration damper that is suitable
for the load of the generating set. Also equipped with 2 to 410 AWG (35 120 mm2 BC) grounding
conductor on the generator. The contractor must have thought about how to install the diesel
generator up to the foundation in the power house.

i. DIESEL ENGINEERING DATA

Diesel engines must be of the 4 stroke type, with piston placement In Line or V. DGS is designed
to work continuously to carry the load of the building.
Wear or maintain properly in accordance with the method (instructions) that have been outlined
for various operations including changing load changes from no-load to full-load conditions and
vice versa without sudden changes in sound. k. The characteristic limits of the machine at full
load operation, the output shall be:
1) Maximum brake mean effective pressure (BMEP) 4 cycles engine.
2) Maximum engine speed 1500 rpm.
The characteristic limits of the machine at full load operation, the output shall be: 1) Maximum
brake mean effective pressure (BMEP) 4 cycles engine.
3) Maximum engine speed 1500 rpm.

j. SPEED GOVERNING SYSTEM:

The governor is composed of an actuator, electronic speed controller and magnetic pick up
devices. The speed controller is placed inside the DGS panel with special wiring to avoid
electromagnetic interference. The governor must have two selectable operating modes, namely
isochronous (constant speed) and droop, and is equipped with a remote rotation control facility
from the DGS panel as well as an operating speed selector switch (idle and run).
To enable automatic paralleling, the governor system must also be equipped with a potentiometer
driven by a synchronous motor.

k. ENGINE FUEL SYSTEM

The diesel engine shall be equipped with an integral fuel delivery system with it, except for the
fuel tank, transfer pump and piping which are installed outside the unit. Engine fuel system
including engine drive booster pump, injector, nozzle, strainer/filter, control and other equipment
according to factory standards. The fuel required is fuel that has a counterpart such as no. 2D
with no. Octane 40, reliable 10,000 kcal/kg fuel price, equipped with oil cooled prelube and intake
air filter oil, fuel transfer pump and other equipment with the aim of continuous and independent
operation. Or the fuel specified for the engine in question.
l. MACHINE TYPE
The machine must be of type:
- Full compression ignition diesel.
- Four (4) stroke cycles.
- Single acting. - Solid injection.

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 - Water cooled or water cooled.
- In line or V type engine.

m. ENGINE LUBRICATING SYSTEM (ENGINE LUBRICATING):

Engines must be equipped with a full pressure lubricating oil system to lubricate and distribute
lubricating oil to all moving engine parts. The lubrication system must be complete with the
necessary equipment such as drains, piping fittings, valves, lubricating oil pumps with strainers,
filters and can be operated according to the criteria mentioned. The pipe must be clean of metal
grains and other impurities. Lubrication oil pump must be available for each unit. The pump must
be positioned in an adequate manner from engine crankshaft to camshaft. The pump must have
sufficient capacity to lubricate and cool the oil at a given engine speed. The pre lube oil pump
must be equipped with a full flow filter and strainer. A manual operated prelube pump shall also
be installed on the pump system for diesel lubrication before starting.

n. ENGINE COOLING SYSTEM:

For a radiator type engine outside of water cooled, it must be complete with a jacket water cooling
system integral to the engine which must be equipped with piping equipment, fittings and valves
to connect these tools to the specified parts. The system must include jacket water pump, radiator
and fan, expansion tank (if necessary), valves, controls and intercooler. Both water-cooled and
water-cooled types must also be equipped with engine cooling ducting which functions to channel
excess engine heat to the outside of the engine room.

o. AIR INTAKE & EXHAUST SYSTEM (EXHAUST SILENCER):

Air intake and exhaust systems must be installed on the diesel generator unit and equipped with
the necessary equipment: piping, fittings and expansion joints. Included in the equipment are
intake turbo chargers, scavenging air blowers if necessary, intercoolers, air intra filter cylinders,
exhaust silencers and expansion joints and piping between diesel and silencers, including all
fittings and flexible pipes. To ensure that the sound from the power plant does not disturb the
surrounding environment, the Contractor is required to provide and install residential/critical
silencers as exhaust noise suppression for each diesel, so that "NOISE LEVEL" is obtained at a
place 20 feet from the power house of no more than 80 decibels. . For all piping and equipment,
heat expansion in the power house must be prevented by covering it with heat-insulating
materials or other materials designated by the manufacturer with the approval of the
engineer/assigner.

p. MACHINE CONTROL
Appropriate engine controls installed outside the engine are equipped with the necessary engine
gauges, instruments and controls in accordance with the requirements for starting from the
factory, automatic loading, unloading and shutting down the engine when necessary. The engine
controls must be completely installed. Fuse and fuse blocks where necessary must be installed
on all outlets connected to the terminal block. All electrical connections outside the panel must be
furnished. Must be equipped with piping in accordance with the manufacturer's requirements. All
out-going piping must be installed on the balk head. Name plates must be installed on important
materials with clear letters and there must be a remote control panel in the control room. The
equipment listed below must be installed on each machine and can be remotely from the control
panel:
- Electrical Tachometer.
- Air manifold temperature gauge.
- Twin pyrometer on both right and left sides.
- Engine oil temperature gauge. - Jacket water temperature gauge.
- Engine oil pressure gauge.
- Fuel pressure gauge.
- Air pressure gauge.
- Run hour meter.
- Fuel level control. - Engine speed control.

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q. CONTROL AND PROTECTIVE SYSTEM
The control panel is equipped with a manual/Automatic selector switch. so that the diesel engine
can work and stop manually/automatically. The resulting voltage must be normal within 30
seconds. The transfer of load services is carried out with the Automatic Transfer Switch as well as
its release. All equipment needed for this must be supplied and installed by the Contractor under
the supervision of the Construction Management Consultant / Director. Even though the machine
is started manually by the operator, if there is a disturbance, the machine must stop automatically.

18.3 Telephone Installation Work

1. GENERAL
The Technical Terms of Telephone Works described here are the requirements that must be
carried out by the Contractor in terms of installation work as well as the procurement of materials
and equipment, in this case the General Technical Terms of Electrical Works are part of these
Technical Terms.
The IP PABX has the following requirements:
a) With minimum equipment can cover the maximum capacity: The PABX system used must
comply with the requirements set by PERUMTEL and have obtained the certificate. The
PABX used must be able to serve 24 (twenty four) TELKOM trunk lines, 32 digital lines, 156
analog lines and 16 ISDN lines, fully digital voice and data can be used simultaneously.
b) Allows expansion from the smallest to the largest capacity without replacing existing
equipment but only in the form of modular additions and can continue to be developed by
adding modules where each PTT module consists of 8 lines and the extension module
consists of 24 extension numbers.
c) It is "flexible" and new facilities can be added if needed.
d) IP PABX can be developed for a combination of voice and data systems.
e) Delivered / held in a state that has been tested and easy to maintain: Bidders should also
offer a program for training that is adequate for PABX Maintenance operations.
- Bidders are required to have an Electronic work-shop and sufficient spare parts to back
up the PABX operations offered
- Bidders are required to have an Electronic work-shop and sufficient spare parts to back
up the PABX operations offered.

2. IP PABX SYSTEM
a. IP PABX must be of the type designed and built with “Fully Digital” technology which is easy
to implement and adapt to the circumstances. Voice and data can be used simultaneously.
b. IP PABX is made in an expandable system where the design module developed for each card
must have the components required by each module, namely power supply, controller, buffer
or memory. With this system, it is hoped that each card module used by PABX is not
operationally dependent on each other, so that the possibility of Totally Downtown for the
entire system is not possible.
c. IP PABX is designed to be used as simple applications to more complex or in another sense
that this IP PABX must have a large range.
d. IP PABX must have Networking Communication capabilities such as ID, ATM, Frame Relay,
Pstn, ISDN, or leased lines.
e. All connections between the different units in the IP PABX are made via plug-in cables
manufactured at the factory. This is intended to prevent the need for us to reach/touch the
back of the cabinet in question.
f. The bidder should specify the types of memory & back-up memory used in the system.
g. The connection between the PABX, the main line and the branch line will take place through
the main divider box (MDF). The MDF is a separate unit that is connected to a
central/exchange with cables using multiple plugs.

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3. EQUIPMENT AND FACILITIES OF IPABX
a. Accound code charging
b. Automatic call back on busy trunk/bundle/network link
c. Automatic call back on busy extention
d. Call forwarding
e. Call pick up
f. Call waiting indication
g. Calling line identification restriction untuk internal call
h. Confrence corner
i. Controlled private call oleh PIN code atau Password
j. General night service
k. Internal / external music on hold
l. Speed dialing
m. Three party conference
n. Transfer in conversation on free / busy
o. 29 party meet confrence, direct or indirect
p. waiting call conversation

4. EQUIPMENT AND FACILITIES OF CONSOLE OPERATOR

a. The Operator Console is provided with a visual display unit, which among other things shows
the "progress of splicing" these calls.
b. The design of the tools must be adapted to the pleasure of the users so as not to cause
fatigue in its use.
c. The relevant Operator Console will be equipped with a "normal" aircraft grip and/or a
lightweight headset attached to one side of the "keyboard" with a plug and jack.
d. The following facilities and functions can be managed by the IP PABX console operator:
1) Call type.
2) The number of the branch aircraft calling and being called.
3) The number of the main line and the number of the route (route).
4) Branch planes are free or busy and so on.
5) For call forwarding, the number of the branch unit that diverts the call and the number of
the receiving branch.
6) Identification of the aircraft to which the caller is connected.
7) Data regarding the length of the call.
8) Number of calls that have not been served.
9) Alarm indication.

e. Key Board functions as follows:

1) Switching for On/Off.
2) It is possible to program branch planes from IP PABX for common and individual night
service.
3) Call acceptance and extending, automatic and manual.
4) Call holding with monitoring function.
5) Call Parking.
6) Call signaling, acoustic, continuous or single tone burst.
7) Call splitting.
8) Camp-om Busy.
9) Trunk offering (also combination with camp-on busy).
10) Forced releases.
11) Individual trunk line selection with instruction on busy lines.
12) Automatic call back-busy trunk.
13) Instruction with warning tone.
14) Manual initiation of ring signal to extension.
15) Serial calls.

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 f. All telephone wiring installations must use high impact conduit complete with Teedoss clamps
and other accessories. No telephone cable connection is permitted other than the terminal
box.
g. All telephone equipment (such as IP PABX, Operator Console, Handset, etc.) used must be
made by SIEMENS, ALCATEL, ERICKSON or PHILIPS, CISCO.

18.4 Sound Installation Work

1. GENERAL
2. The Technical Requirements for Sound System Work described herein are the requirements that
must be carried out by the Contractor in terms of installation work as well as procurement of
materials, equipment, and installation and testing at the Factory and at the Site.
3. MATERIAL AND EQUIPMENT SPECIFICATIONS:
1) The main equipment for the "Public Address System" Sound System, includes:
- power amplifier;
- chime microphone/remote microphone;
- chime generator;
- monitoring panel;
- speaker;
- speaker selector;
- blower;
- perforated panel & blank panel;
- sound system central rack
- tools and other supporting tools.

2) Technical specifications of the equipment "Public Address System" The following is all
equipment / equipment, both main and auxiliary equipment. This equipment must be new,
undamaged, never used, tested, and approved by the Board of Directors. This sound system
must be able to accept a supply voltage of 220 Volt ± 10% at 50 Hz.PR

a) POWER AMPLIFIER
- Power output (see picture).
- Input sensitivity 0.5V-10V at 1 kHz.
- Minimum input impedance of 10 kOhm.
- Maximum distortion 0.5%.
- Frequency range 50 - 20,000 Hz at -2 dB.
- Input levels can be up to +12 dBm at 1 kHz.
- Output to speakers can be 50 V, 70 V, or 100 Volts.
- Equipped with overload safety, short circuit, VU meter, Headphone socket, All Call
line. Products from Philips or TOA.

b) AUDIO CHANGE OVER SWITCH (SPEAKER SELECTOR)

- Minimum 12 line selectors, each line can serve 1 floor. Each line is equipped with
indicator lights and relevant floor instructions.
- Easy to operate. - Equipped with all call broadcast permitted.
- Equipped with a built in monitor speaker that can monitor every floor. Products from
Philips or TOA.

c) CEILING SPEAKER
- Flush mounted which is equipped with a bok from its partner.
- The front panel and the box must be made of the same material, namely high-impact
ABS plastic.
- Frequency response 100 - 12000 Hz.
- Equipped with matching transformers that can be tapped at 3 watts, and 1.5 watts.

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 - At 3 watts, the sound pressure level can reach 105 dB. - Equipped with a terminal for
input that is attached to the outside of the box from the clamp type. Products from
Philips or TOA.

d) M.D.F (MAIN DISTRIBUTION FRAME)

- The body is made of steel plate with a thickness of 1.5 mm, anti-rust painted and
finished.
- Cable connection with bolts.
- Equipped with door and lock. Products from GRAHA PANEL, NOBI, SYMETRI, ONI
PANEL or INDUSTIRA.

e) R A C K
- The construction of the rack must meet the applicable standards, as well as its
dimensions.
- The size of the rack used must be adjusted to the needs according to the equipment
installed and taking into account the ventilation requirements. If necessary, 2 shelves
can be used, for this the Contractor must have taken this into account in his bid.
- The shelf must be equipped with a glass door with a lock. - Shelves must be of the
upright type.

f) COLUMN SPEAKER
- Made of high-impact plastic that is resistant to ultraviolet light, rust, chemicals, and
water.
- This column speaker must be adapted to use in the tropics.
- Power handling capacity of 15 watts can be tapped at 10, 7.5, and 5 watts. - At 15
watts, impedance 670 Ohms.
- Sound pressure level 108 dB. - Frequency response 330 - 4500 Hz at ± 3 dB.
Products from Philips or TOA.

g) INSTALLATION CABLE
- Cables used for installation of NYMHY type 2 x 1.5 mm Kabelindo, Suprame or
equivalent products.
- All cables must be attached to High Impact Conduit Pipes from Ega or Clipsal
products.

h) ATTENUATOR/VOLUME CONTROL
- The capacity must match the number of controlled speakers.
- Can be bypassed in off position automatically for paging purposes.
- Installation must be in accordance with the plan drawings.
- Nominal input voltage 100 V.
- Minimum 5 steps using transformers.
- Flush mounting type equipped with a paired inbow box and knob. Products from
Philips or TOA.

i) Paging MICROPHONE
- The use/installation of this microphone must be able to make calls/notices per floor
without disturbing the background music on other floors and also functions as a
microphone for all calls.
- The microphone must be of the table stand type which is equipped with a switch,
indicator light and cables.
- Every switch on the table stand is turned on, it must produce a minimum of 4 tones of
ding dong (chime) and must also be able to operate without chime easily.
- All additional equipment must be equipped so that the system using the microphone
can function as above. Products from Philips or TOA.
- All installation of equipment on the rack must be equipped with additional equipment
so that the equipment can be installed perfectly and the system can work properly

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 according to the manufacturer's instructions, including installing grills in places where
needed as well as installing blank panels in open spaces in front and behind the rack.
A minimum of 2 blowers must be installed for ventilation in the rack.

j) INSTALLATION Included in the installation work include the work of sound system
terminal boxes, sound system wiring complete with conduit, attenuator and other
accessories needed for the perfection of sound system work.

18.5 Fire Alarm Installation Work

1. GENERAL
The Technical Requirements for Fire Alarm Works described here are the requirements that must
be carried out by the Contractor in terms of installation work as well as the procurement of
materials and equipment, in this case the General Technical Terms of Electrical Works are part of
these Technical Terms.
- The type of controller unit is from Semi Addressable where to connect Addressable Loop with
Conventional Transponder Unit is used.
- The type of fire alarm used is Presignal so that the alarm is given only on that floor, with a 4-
wire system whose purpose is to increase the reliability of the work of this alarm in the event
of a disconnected part.
- The ability of the fire detector to have a detection area of approximately 70 m² so that for
large parts of the room only a few fire detectors are needed. The use of the type of fire
detector is in accordance with the planning drawings.
- For wiring used cables with SPT and NYA Data types measuring 2x1.5 mm² according to the
planning drawings and each floor is installed with a terminal box which is placed near the
shaft.
- Master control is equipped with a changer and stand-by battery that can be used for at least
20 hours when the PLN electricity is cut off.
- Uses 90 dB vibrating Bell in each zone. - A manual station is installed on each hydrant box
which is equipped with a light that keeps on burning.
- All installation systems, detectors, annunciators, master control, and others in this Fire Alarm
work, must be supervised by a Class A installation system.

2. TECHNICAL SPECIFICATIONS OF MATERIALS AND EQUIPMENT

a. COMPONENTS
The components included in this Fire Alarm installation work are:
- Master Control Fire Alarm
- Annunciator
- Fire Detector, terdiri dari :
- Heat Detector
- Smoke Detector
- Heat dan Smoke Detector
- Duct Smoke Detection
- Alarm Bell
- Manual Station

The components used must be made by ESSER-GENT, SIMPLEX or NORTHIFIRE.

The three types of fire detectors as mentioned above have various types that are designed
according to the needs, as shown in the planning drawings.

3. MASTER CONTROL FIRE ALARM

This unit is the main control panel and can be developed into Semi Addressable type, the
maximum length of each loop is 1 km. From this control panel, it can be seen which part of the

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 protection area is experiencing interference, or which detects a fire, which is shown on the LCD
indicator. Also on the control unit is equipped with an emergency telephone facility that can be
connected to a telephone outlet on the hydrant box. This system is only used for internal
connections within the building in the event of a fire, and this system is independent of the normal
telephone system (IP PABX).
a. In the Master Control there are 3 kinds of color lights with codes:
1) Green is the AC pilot lamp (power supply light) which indicates that the power supply is
there, either from the battery or generator and the system is in normal operation.
2) Yellow is a nuisance light, for example there is a part of this fire alarm system that has a
broken cable and so on, a detector fault, or a problem with transmitting a data detector, or
a data detector to the control unit.
3) Red is an alarm light (fire light) which indicates a fire in a protected area (zone
protection). All of these conditions are supported by an LCD display that shows the status
of the disturbance and where the disturbance occurred.

b. On the Control Panel there are 3 buttons, each of which is:

1) Reset button.
2) Normal trouble/silence switch.
3) Test button.

c. This Control Panel must have the following facilities:

1) Connection to the local Fire Service.
2) Contacts for fire pump starter, smoke fan pressurized fan, etc.
3) Terminal for data retrieval of the status of each zone for remote monitoring.
4) Power Supply: The fire alarm system uses 48 volts DC and can be combined with
equipment with AC current, such as an AC bell, and must have a double power supply.
- Primary supply 220 Volt AC.
- Secondary supply 48 Volt DC.

Stand-by in an emergency must be a minimum of 20 hours and be located somewhere with a

control panel and rechargeable. The battery charger is located on the control panel, there is a
power supply booster to increase the required capacity or bell and others.

4. ANNUCIATOR UNITS
The Annunciation Unit is a remote display from the main control unit that can provide information
on disturbances so that officers can find out where the fire alarm disturbance is coming from.
Normal or fault signals are indicated by the condition of the indicator lights as on the control unit
and LCD monitor.

5. HEAT DETECTOR F per 20 seconds.

Combination rate of rise and fixed temperature with properties that are a combination of both.
What is used in this building is a combination type for heat detection.°F. The rate of rise detector
will work if the surrounding temperature rises at a rate of 5°Combination rate of rise and fixed
temperature or fixed temperature only or rate of rise temperature only. Where for fixed
temperature will give signals if the surrounding temperature reaches 136

6. SMOKE DETECTOR
This detector must be able to work in the presence of smoke or gas in the detected room. This
detector must be of the Photoelectric or ionization type that can work at a temperature of – 20 0 C
to 70 0 C with a room temperature between – 250 C to 77 0 C which is equipped with an indicator
light that will flash when normal and illuminates continuously during a warning condition.

7. HEAT AND SMOKE DETECTOR

For if there is smoke as much as 1-2% per foot.□Must be able to work if the room temperature
rises to 135

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8. MANUAL STATION
Manual station of the break glass type with semi flush mounting, the system works pull down and
remains in the on position before being reset again. The general alarm switch can only be
operated by authorized persons using a special key. For testing purposes, an alarm can be
sounded without breaking the glass. All panel stations must be equipped with spare glass rods. In
order to guarantee long operation, the alarm contact must be made of "gold plated". 8. ALARM
BELL Alarm bell must be of vibrating type, all bells must operate at 24 Vdc polarized with 6
gongs, unless otherwise stated in the drawings. Mounting at a height of 75 cm below the ceiling in
a "semi flush" manner, the minimum sound output is 90 dB or greater at a distance of 10 ft.

18.6 Access Control System

a) The working principle of Access Control is to regulate the exit/entry of employees in accordance
with a predetermined system of procedures. If the card is brought near to the reader board, the
reader board will send data to the control panel which is directly processed by the control panel,
and if the data is "yes" then the door will open but on the contrary if "no", the door will remain
locked, besides the results of the process is sent to the access server and to the integration
server to be integrated into the CCTV system to record the use of the access door.
b) Access Control work includes the Controller Panel, installation and equipment such as Reader,
Card Printer, Exit Button, keys, sensors and other necessary supporting equipment. All cables
from the equipment will be pulled to each control panel.
c) Access Control Panel is used to handle TCP/IP-based Access Door systems that are connected
to a network (LAN).
d) The Controller Panel is limited to only handling a maximum of 4 Readers and has the ability to
work alone if the connection is lost with a server with a minimum storage capacity of 2GB and
5,000 badges. All panels are connected to a communication/interface so that each panel can be
connected to the network. Each controller panel is equipped with a battery and back-up for the
panel itself.
e) Access control software will be connected to the software system integration via the network, so
that all point logs can be monitored by the integrated software system which will easily manage
the operating procedure system electronically. Access Control software must be able to display
user card pop-ups with photos to make it easier for operators to monitor who is doing activities at
locations where access control is installed.
f) The main function of the Access Control System is to control and monitor all designated access to
the selected door, area or building.
g) The Access Control System shall allow control of door entry access both by the card reader and
from the Access Control System workstation.
h) The Access Control System must support up to four (4) different Wiegand reader inputs
simultaneously. The number of each card format supported is unlimited.
i) Push button must be installed locally and must be provided to be able to exit the selected door as
specified by the user or as shown in the drawing
j) For highly secure areas as defined or further shown on the drawings, an exit card reader should
be provided to allow proper tracking of persons entering & exiting the designated area.
k) All access doors must be equipped with emergency break glass which is installed to open the
door to exit in an emergency. In addition, all special doors along the evacuation route will
automatically open upon activation of the fire alarm.
l) The Access Control System shall monitor and record all activity at each control point.
m) The Access Control System should provide configuration and programming for access groups,
where each access group contains a list of access points or door access that only authorized
cardholders can enter.
n) The Access Control System must provide a time schedule that can be configured to have
flexibility in programming for automatic locking and locking of access doors, as well as enabling

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 and disabling cardholder settings to restrict any access group from entering certain areas
according to a specified time schedule.
o) The Access Control System shall be designed in such a way that any failure in the system will not
affect the normal operation of the other sub-systems. The system will continue to operate even if
there is no connection with the management software.
p) The Access Control System management software provided shall allow card personalization. That
is, the tool should include tools for designing badges that support the import of bitmaps, text and
databases, such as name or badge numbers to create corporate badge designs that can be
printed on standard card printers that come with a Windows-compatible printer driver.
q) Server Access Control System must be based on centralized server.
r) The database for the Access Control System must be on the same server hardware.
s) All alarm processing, logging, operator response, data entry/input, system interface and system
operation and other management functions must be performed at Access Control System
workstations connected to the Access Control System network. The operating system should be
at least Windows 10 (32/64 Bit) Enterprise.
t) All Access Control System servers and workstations must be connected using standard IP
network via corporate Intranet or dedicated Internet/LAN

18.7 CCTV SYSTEM

18.7.1 General

These CCTV technical requirements contain details that clarify the technical matters and technical
specifications of each equipment. In the technical details used are standard TCP/IP based equipment
that is connected to the Backbone Network network system in the building by using a Singlemode
Fiber Optic cable riser.

18.7.2 CCTV Equipment

The equipment used in this CCTV system includes:

a. IP Camera
b. NVR (Network Video Recorder)

18.7.2.1 Indoor Fixed Dome Camera

Fixed Dome camera indoor will be placed on the ceiling or ceiling. The camera used is a color with a
night mode facility, which means the camera automatically changes modes when the light illumination
in the area is minimal. The camera must have a high resolution and must have settings menu buttons
such as level, white balance, Day and Night Mode, and the menu can be displayed on the monitor
(On Screen Display). The indoor fixed dome camera is used to monitor people who are not
employees/employees who enter the room, or employees who are working. Indoor Fix Dome Camera
technical requirements:
1. Camera is easy to install.
2. The camera must provide an automatic zoom/focus lens control for zoom and focus lenses
capable of Motorized Zoom Remote.
3. The camera has a resolution of 1920 x 1080p to 30 fps in normal conditions, changing from 5-15
fps in stand-by conditions.
4. The camera must be equipped with an automatic varifocal lens.
5. The camera must allow control of the camera and full configuration capabilities over the network.
6. The camera must comply with the minimum standards of ONVIF Profile S.
7. The camera must be able to capture and save images using H.264&H.265 (Main Profile)
compression standards.
8. The camera has several levels of users.

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9. The camera must have a micro SD card slot for backing up for at least 1 week (minimum 64GB)
with a setting of 30 in normal conditions and 5-15 fps in stand-by conditions.
10. Camera has Ingress Protection min IP51.
18.7.2.2 Outdoor Fixed Dome Camera

The Outdoor Fixed Dome Camera used must be equipped with a fixed lens, auto iris and other
accessories, it must be a universal type that can be mounted on a ceiling or wall. The camera used is
a color camera with Day/Night Camera facilities, which means it can automatically change from color
to B/W if the light illumination is very minimal below the minimum lux limit mentioned. The camera
must also be equipped with white balance levels, Automatic Gain Control, Image Stabilization.
Technical requirements for Outdoor Fix Dome Camera:
a. Camera is easy to install.
b. The camera must provide zoom/autofocus lens control for zoom and focus lenses capable of
Motorized Zoom Remote.
c. The camera has a resolution of 1920 x 1080p to 30 fps in normal conditions, changing from 5-15
fps in stand-by conditions.
d. The camera must be equipped with an automatic varifocal lens.
e. The camera must allow control of the camera and full configuration capabilities over the network.
f. The camera must comply with the minimum standards of ONVIF Profile S.
g. The camera must be able to capture and save images using H.264 & H.265 (Main Profile)
compression standards.
h. The camera has several levels of users.
i. The camera must have a micro SD card slot for Back up for at least 1 week (minimum 64GB) with
a setting of 30 fps in normal conditions and 5-15 fps in stand-by conditions. 10. Day/Night
(sensitive to infrared): The camera has normal color operation in situations where there is
sufficient lighting (day conditions), but when there is little light available (night conditions), the
sensitivity is increased.
j. Camera has Ingress Protection min IP66.
k. The camera has a minimum impact protection of IK10.

18.7.2.3 NVR

Network Video Recorder (NVR) has the capability of:

a. The NVR shall provide a user-friendly graphical user interface (GUI) for configuring the camera,
creating schedules for recording, performing video surveillance and recording operations, and
viewing various reports.
b. The NVR must be configured to store and view the images captured by the entire Camera
c. Record and monitor IP channels at @ 4CIF / VGA or @ 720p HD or @ 1080p (4 Mbps bitrate).
d. Sophisticated investigation and video archive search tool of NVR client.
e. Native device integration supporting new features of 4K resolution camera, H.265 compression
codec, 3D PTZ control, 360° camera support and intelligence analytics.
f. Capable of managing motion detection based recordings with pre-event and post-event recording
based on camera-based motion detection or Server-based motion detection events and
"advanced" search on footage from NVR clients.
g. Calendar Preview and Search which allows searching for videos or events based on the date and
time the user selects from the client. Smart motion search - fast and efficient forensic search and
investigation for objects/motions on video recordings using motion detection on client PCs without
affecting NVR Server load.
h. Simultaneous use of multiple video compressions including, MPEG-4, H.265.
i. Email on alarm
j. Instant clip creation from snapshot.
k. Dynamic IP Camera Discovery - Finds all NVR compatible cameras automatically.
l. Multi-level user access rights to view and manage access to recorder functions
m. Able to manage recording features continuously, scheduled, manual, event-based, and alarm-
based.

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n. Advanced security features with encryption support for communication between desktop clients
with NVR and secure https login for Web Clients and mobile apps.
o. Support for web clients and mobile apps.
p. The NVR must offer remote video monitoring via a desktop application, Web browser, or mobile
device based on iOS and Android.
q. The NVR shall offer remote network connectivity monitoring via a desktop application or Web
browser.

18.7.2.4 Monitor

All placed on the walls of Pam's control room

The wall monitor used is a type min 42 "LED consisting of 1 (one) unit Monitor to display alarm logs
and Graphics and display images or video displays that will inform events, whether it's an open door
alarm, or a graphic fire that works to make it easier for the operator to know the location of the
incident. The monitor has a high resolution specification of a tight pitch.

18.8 IP TV Technical Specification

a. Parabola
1. Material: Galvanized
2. Panel (Sector Devided) : 6
3. Aperture Diameter : 180Cm /6feet
4. C-Band Gain @4GHz : 35.89dB
5. F/D Ratio : 0.38
6. Focus Length : 68.4Cm
7. Mounting Type : Pole Mount
8. Elevation Alignment : 0---60°/0---90°
9. Azimuth Alignment : 0---360°
10. Ambient Temperature : -40 to +60
11. Relative Humidity : 0----100%
12. Survival Wind : 180Km/h

b. IPTV Encoder
1. Input : 4,8,32x Audio Video (bnc connector)
2. Video Signal : LEV 1.0Vp-p
3. Audio Signal : LEV 2Vp-p
4. Output channel : Minimal memiliki 8 ch IPTV with individual multicast address
5. TS Over IP : RJ-45 10/100 Base-TX , UDP/IP (Unicast, Multicast)
6. Code rate : 1.0~15Mbps Continuously adjustable per channel
7. Control : NMS(Ethernet Port), Keyboard+LCD
8. Video Coding
a) Compliance with ISO 11172(MPEG-1) &ISO 13818(MPEG-2)
b) MPEG-2 coding adopt MP@ML (4:2:0)
c) MPEG-2 Adaptive Field Frame (AFF)
d) MPEG-2 field based (FB)

9. Audio Coding
a) Sampling rate : 32KHz,44.1KHz,48KHz b)
Code rate : 64,128,192,256,384 Kbps
c) Property : MPEG-1 1/2 layer, Support stereo or dual-channel

10. Resolution
a) Standard : Compliance with CCIR601 standard, Support 1/2D1,2/3D1,3/4D1
b) PAL : 720*576,704*576,640*576,544*576,480*576,384*576,352*576

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 c) NTSC : 720*480,704*480,640*480,544*480,480*480,384*480,352*480

11. General
a) Size : Rack mounted 1U
b) Environment : 0 ~ 45(Operating);-20~ 80(Storage)
c) Power : 220VAC±10%,50Hz,25W

c. DVBS to IPTV
1. Input
a) ASI : BNC
b) RF : DVBS /S2,F connector

2. Output
a) ASI : BNC
b) TS Over IP : IP/UDP, Unicast/Multicast, IGMP V2

3. Simultaneous Streams : Up to 10 Stream

4. RF input range : 950 MHz—2150 MHz
5. Management : NMS(Ethernet Port), Keyboard+LCD
6. CI Interface : 2 CAM Card Slot
7. General
a) Size : Rack mounted 1U
b) Environment : 0 ~ 45(Operating);-20~ 80(Storage)
c) Power : 220VAC±10%,50Hz,25W

d. Multicast Switch IPTV

These devices will be provided by the data and network job packages.
1. Port : 24 Port 10/100/1000Mbps
2. Layer : support layer 3
3. IGMP Support : IGMP V.2

e. IPTV Middleware System

Vendors must provide local support engineers for software and design.
Hardware Middleware
Proccessor : Intel Xeon
Memory DDR : 6Gb DDR3
Harddisk : 250 Gb.
Operating System : Linux
Networking : Integrated 2x Gigabit Ethernet (10/100/1000 Mbps)
Optical Drive : DVD R/W
Interface : USB 2.0, Serial, VGA
Size : Rackmounted 1U

Features IPTV middleware

Basic Features :
1. Live TV
2. Video On Demand
3. Music on Demand
4. Weather Info
5. 5. Forex Info
6. 6. Important number information
7. Unlimited STB Client
8. Digital Signage
9. Content Management System
10. Integration ready to 3rd party server Application :

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 The IPTV system automatically functions to display programs in applications that are running
on an operating server, which is needed, to be displayed on TV, scheduled or unscheduled,
by interrupting any display that is running. The servers in question are as follows:
1) System Fire Alarm
2) Server CCTV/IP Camera
3) System Public Address

11. Integration Ready to Mobile Application: This system, if needed, is ready to be integrated with
the mobile application, so that the program in IPTV with all its facilities can be enjoyed via
Mobile Phones, Tablets. 12. Can be connected to the Cloud, so that all shows on IPTV can
be watched from any location, within the country or from abroad.
12. The template platform uses the interface provided by Navicom, so it can be interrupted for
special purposes, such as:
1) Advertisement,
2) Alarm,
3) Notification, iv.
4) Call
by using TEXT media, PICTURES are also VIDEO

13. Can function for Video Conference, Point To Point, Point to Multi Point and Multi Point to Multi
Point communication, Podcast Models, Classroom, Meeting Rooms and forms of
consultation.

f. Hardware Server
Proccessor : Intel Xeon
Memory DDR : 8Gb DDR3
Harddisk : 1Tb
Operating System : Linux
Networking : Integrated 2x Gigabit Ethernet (10/100/1000 Mbps)
Optical Drive : DVD R/W
Interface : USB 2.0, Serial, VGA
Size : Rackmounted 1U

g. HD IP STB Minimum :
Processor : SoC400Mhz MIPS
Memory : DRAM 256MB DDR2
FLASH 256MB NAND
Video Engine : Hardware Codec :
MPEG1 2/4
Vc1 WMV9
H264 AVS
RM/RMVB
Audio Engine
Hardware Codec : AC3 MPEG1(1,2,3) AAC PCM
WMA WMAPRO
Storage I/O : USB X1, support USB disk, optical diver, WIFI
AV I/O : Composite
Audio Stereo
HDMI
RCA X 1
RCA X 1
HDMI v1.3 X1
Power : DC JACK 12VDC
Other : External IR Jack
RJ45 100M ETH

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19 MECHANICAL WORKS

19.1 Description of Work

This work shall cover the providing of all materials, labour, equipment and installation of a complete
plumbing system as specified herein and/or as shown in the Drawings.

This system shall include but not be limited to internal distribution piping system for plant water from
1500mm outside the building up to the fixture outlets, internal sanitary piping up to 1500mm outside
the building, as well as testing, balancing and all other incidentals required so as to make all the
system perfect in every respect and ready for operation.
This work shall also include connection to distribution piping as shown by the Drawings.

19.2 General Procedures

19.2.1 Samples and Technical Data

a. Contractor shall submit samples and technical data and/or brochures of all materials to be used to
the Project Manager for approval, prior to delivery.
b. All the costs of samples shall be the Contractor's responsibility.
c. If the submittals differ from the requirements of the contract documents, the Contractor shall make
specific mention of such difference in a letter, with a request for substitution, together with his
reason for this, in order that, if acceptable, suitable action may be taken for proper adjustment.
Otherwise, the Contractor will not be relieved of the responsibility for executing the work in
accordance with the Contract Drawings.

19.2.2 Shop Drawings.

a. The Contractor shall prepare and submit detailed Shop Drawings for the piping work described
herein which is complex in nature, or which requires close coordination with other trades on the
job.
b. The Drawings are diagrammatic and indicate generally the location of materi- als and equipment.
These Drawings shall be followed as closely as possible. The architectural, structural and other
Drawings of related trades, and all elements thereby constructed shall be checked for dimensions
and clearance before installation of any work.
c. All Shop Drawings shall be submitted sufficiently in advance of field re- quirements to allow ample
time for checking, and no claim for extension of the contract time will be granted to this Contractor
by reason of his failure in this respect.
d. All submittals shall be complete and shall contain all required and detailed information.
e. The Contractor shall obtain, at his expense, all necessary permits and arrange for all inspection
that may be required in connection with the plumbing system specified herein.

19.3 Handling and Storage

a. Each length of pipe, fittings, trap, fixtures and device used in the piping system shall have cast,
stamped or indelibly marked on it the manufacturer's name and the classes of products when so
required by the standard mentioned.
b. All materials shall be stored at a proper place and shall be protected from damage.

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19.4 Non Conformity

a. The Contractor shall carefully check the Contract Drawings towards the possibility of mistakes in
dimensions, capacities, quantities, installation and others.
b. All plumbing fixtures and fittings delivered or installed without any trade mark shall be removed
and replaced with properly marked fixtures and fitting, without any extra cost to the Owner.

19.5 As Built Record

The Contractor shall prepare and maintain a set of "As Built" records.
a. "As Built" records shall be retained in the site office and kept up to date daily in regard to changes
in actual installation from the Plans and Specifications. Alterations to duct work, piping services,
etc. shall be noted and the revised arrangement drawn in accurately, complete with dimensions
from column lines. Every precaution shall be taken to protect the Drawings from damage and
loss.
b. The "As Built" records shall be made available to the Project Manager upon request and made
available at each site meeting. After no further alteration can be expected and the Contract is
nearing completion, the records shall be submitted for final approval.
c. The Contractor shall include on "As Built" records the dimensions location of all buried piping and
valves, and during construction plainly mark location of exterior services and valves to prevent
damage to these until the Project is completed.

19.6 Guarantee

The Contractor shall furnish to the Owner a written guarantee covering the satisfactory operation of
the plumbing installation in all its parts for a period of one year after date of final acceptance. During
this period the Contractor shall repair or replace any defective work and pay any repair or
replacement costs.

19.6.1 Materials

1. General
All materials, equipment and accessories furnished shall be brand new and of acceptable quality.
Water Supply System
1) Pipes and Fitting
a. Pipes for water supply shall be polypropylene random (PP-R) pipe PN 10 complying with
DIN 8077 and DIN 8078 standard, such as from ATP Toro, Agrusan and Fusioterm.
b. The pipework shall be suitable for maximum working pressure of 12kg/cm². Diameter of
pipes and fittings shall be as specified.
c. Fittings shall be of polypropylene random (PP-R) material PN 25 class and of the same
manufacturer as the pipes. Fittings shall be suitable for maximum working pressure of
12kg/cm².
d. Jointing system for pipes and fittings shall be compression fitting, butt-fusion welding,
electrofusion (heating system) or according to the manufacturer’s installation instruction.

2) Valve
a. All valves with working pressure, type and diameter as specified in the Drawings, shall be
new, unused product of reputable and experienced manufacturers and all valves as far as
possible of the same type shall be of one manufacturer, such as Kitz, Yuta, Okumura or
equal.
b. All valves shall have indelibly mark/sign of manufacturer's name, working pressure,
diameter and direction of flow on the body.

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 c. All valves shall be complete and ready for operation with all components and accessories
in accordance with the applicable standards and codes, and shall be capable of long,
reliable, trouble free service and shall require minimum maintenance.
d. Valves of diameter up to 65mm shall be of bronze body and shall have tapered threads
for screwed joint, and valves of diameter larger than 65mm shall be of cast iron body,
manual operated type, and shall be furnished with flanges of flat-faced type conforming to
ANSI B16.1 Class 125, forged integrally with valves' body.

3) Sand Filter
Sand filter shall have capacity according to the requirement as shown in the Drawings,
manufactured from mild steel sheet with interior liner made of fiberglass sheet, and epoxy
coating for the exterior part, such as F/S Series model manufactured by Southern Chemicals
or PT Angkasa Jaya Maju.
Sand filter tank shall be provided with necessary accessories according to the standard of the
manufacturer, such as filter pump which is also acted as backwash pump.

4) Pump and Accessories

a. Water Supply
Pump for water supply shall be booster type of capacity, power and working voltage as
indicated in the Drawings, from Grundfos, Ebara by Indobara and Wilo Pump by PT.
Wiguna.
b. Accessories
• Each pump shall be fitted with an air cock and cup, drain plug and a pressure gauge
on each side of the pump.
• Pressure gauge shall be 150 mm diameter and of dial type. Scale ranges shall be
suitable for the pressures and selected so that the normal operating point is in the
third quarter of the range.
• For those fitted on the suction side, they shall be of the Bourdon tube type with brass
siphon and cock with piping connections to the measuring point. Gauges shall have
black pointers, red overrun indicators, and red mark at normal working pressure.
Gauges must be calibrated in kilo pascals (Kpa).
• All exposed shafts, couplings and moving parts of pumps shall be provided with
suitable galvanized angle iron wire mesh guards which shall be stoutly constructed,
easily removable, and provided with lifting handles. Care shall be taken that these
guards do not cause "ring" and/or create vibration noise.
• Pump shall be provided with panel and water level control (WLC) in capacity as
specified in the Drawings.
• Panel and wiring diagram shall be as indicated in the Electrical Drawings.

c. Pressure Tank
Water storage tank with dimension and capacity as required and as shown in the
Drawings shall be constructed from glass-fibre reinforced polyester (GRP) panels that are
formed by vacuum injection moulding or matched metal die, supported by internal
bracing, bolt, nut, washer (galvanized and GRP coated) or shall be presented equal
protective coating of corrosion and mechanical impact.

d. Water Storage Tank

Water storage tank with dimension and capacity as required and as shown in the
Drawings shall be constructed from concrete and shall be presented equal protective
coating of corrosion and mechanical impact.

e. Fire Water Piping

• Pipes and Fitting
- Pipes for fire water shall be ERW carbon steel pipes of schedule 40 conforming
to ASTM A 53 grade B.

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 - All pipes and fittings such as elbow, tee, reducer, tee-reducer and others with
diameter up to 65 mm shall be threaded carbon steel while fittings larger than
65mm shall be furnished with flanges as specified in this Specification.
- Fittings of electric butt-welding shall be fabricated conforming to AWWA C 208.
- Fittings shall be of the same class with the related pipes and shall be new and of
acceptable quality.

• Valve
- All valves with working pressure of 10kg/cm² (150psi), shall be new, unused
product of reputable and experienced manufacturers, and all valves of the same
type as far as possible shall be of one manufacturer. All valves for fire fighting
shall be UL Listed and FM approved.
- All valves shall be made of cast iron material complying with ASTM A 126 Class
B, disc seat ring, cover gasket and O-ring complying with ASTM D 2000 AA 7008.
All valves shall have name’s manufacturer, working pressure, diameter and
direction of flow on the body.
- All valves shall be complete and ready for operation with all components and
accessories in accordance with the applicable standards and codes, and shall be
capable of long, reliable, trouble free service and shall require minimum
maintenance.
- Valves of diameter up to 65mm shall have tapered threads for screwed joint.
- Valves of diameter larger than 65mm shall be manual operated type, and shall be
furnished with flanges conforming to ANSI B 16.1 CL 125, forged integrally with
valves' body.
- SCI product manufactured by Siam Cast Iron Works Co. Ltd.

• Flange
Flanges shall be ANSI B 16.5 class 150 raised face and shall comply with ASTM A-
105. Flange of slip-on type shall have diameter as specified by equipment that shall
be connected.

• Packing/Gasket/Sealing Ring
- Unless otherwise specified, packing/gasket/sealing ring for fire water and fuel
piping shall be of ANSI 150 class, made of spiral wound rubber of minimum 3mm
thickness.
- Sizes of packing/gasket/sealing ring shall be as specified by the required flanges.
- The necessary amount plus 10% additional of packing shall be supplied.

• Bolt and Nuts for Flange

- Bolts and nuts which shall be completed with washers and are made of black
steel of ISO 8.8 with metric thread, shall be used for connection of flanges.
Diameter and length shall be as required by the specified flanges.
- Minimum 3 threads shall be left over after connection.
- The necessary amount plus 10% additional of bolts and nuts shall be supplied.

2. Sewer Piping
a. Pipes
Pipes for sewer and vent shall be from PVC which complies with SNI 06-0084- 2002 with a
working pressure of 8 kg/cm².
All piping shall be suitable for solvent cement jointing similar Rucika, Vinilon and Pralon.

b. Fitting
• Fittings for PVC pipes such as elbow, reducer, knee, tee and others shall come from the
same manufacturer and in accordance with SNI 06-0135- 1989 requirements. All fittings
shall be suitable for solvent cement jointing.

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 • Adhesive for PVC's pipes and fittings shall be as recommended by the PVC's
manufacturer.

c. Floor Drain
Floor drain cover for washroom area shall be chrome plated brass strainer with grid cover of
diameter as indicated in the Drawings, and shall be recessed 10mm into the floor, it shall be
equipped with air trap, from Toto or San-Ei.

d. Clean Out
Clean out cover shall be chrome plated brass of diameter as indicated in the Drawings, locally
manufactured

e. Plumbing Fixtures
Plumbing fixtures such as closets, lavatory, sinks, faucets and others required shall be in
accordance with the Drawings and/or Specification Architecture.

3. Construction Requirement
a. General
1) All labour shall be neat and workmanlike and qualified, and experienced tradesman
as approved by the Project Manager.
2) All dimensional locations of fixtures, equipment, floor drains, risers and pipe shall be
verified by the Architectural Drawings and manufacturer's catalogues.
3) All items, whether specifically mentioned or not, or indicated in the Drawings, shall be
furnished and installed if necessary to complete the system in accordance with the best
practices of the plumbing trade and to the satisfaction of the Project Manager.

b. Piping Installation
1) All plumbing systems to be installed in this building shall be kept clean, and in working
order through periodic testing by Contractor until the building has been turned over and
accepted by the Owner.
2) All pipes shall be installed to the defined coordinate outside of the buildings.
3) The Contractor shall be responsible for providing those portions of fittings which are not
provided with the fittings required for the complete installation. All fittings shall be carefully
checked to determine the portions which to be provided to complete the installation.
4) The pipes shall be used in a full length pipe wherever possible.
5) All changes in pipe size shall be made with reducing fittings or reducers.
6) Valves provided as specified for proper control system shall be placed in accessible
location with the ample room for full opening, repacking, and replacement of internal part
with operating stem horizontally or vertically upward.
7) Vent pipe shall extend above according to the height as shown in the Drawings and shall
be flashed with flexible sheet. The flexible flashing shall be returned on the inside of the
vent and finished in a neat manner as detailed in the approved Shop Drawings.
8) Sewer piping shall run a minimum grade of 10 mm per 100 cm length of pipe unless
otherwise noted in the Drawings. Before any waste piping is installed, the Contractor shall
field-check all proposed waste piping to verify the piping system so that the said piping
can be installed at the required grade.
9) All plumbing fixtures including floor equipment connected to the sanitary drainage system
of floor drain shall be equipped with a trap, as indicated in the Drawings.
10) Each fixture shall be provided with shut-off valves for water as positioned in the Drawings,
so that any fixture may be separately controlled without affecting any other fixtures
supplied.
11) Traps specified here are to be supplied with the fixtures exposed or accessible traps shall
be fitted with a thumb screw clean-out plug at the bottom of trap diameter.
12) No piping in any location shall be closed up, buried in or covered before testing and the
examination of some by the Project Manager.

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 13) Piping work which shall need excavation and backfilling shall be carried along in
accordance with the Specification.
14) The drainage, water supply and sewer lines are to be laid to alignment and gradients
shown in the Drawings but subject to such modifications as will be ordered by the Project
Manager from time to time to meet the requirements of the works. No deviations from the
lines, depths of cuttings or gradients of sewers shown on the Drawings shall be permitted
except by the explicit direction in writing of the Project Manager.
15) Water supply distribution pipe shall be connected to water supply pump in a manner as
shown in the Drawings and in accordance with the manufacturer's installation instruction.

Insulation for hot water piping shall be installed in strict accordance with the installation
instruction of the insulation manufacturer.

c. Tanks
The installation of sand filter tank shall be in accordance with the manufacturer's installation
instruction.

d. Support and Fastenings

• All pipes, fittings and equipment shall be supported and fastened in a safe and durable
manner.
• Inserts shall be safely anchored and the anchors shall be installed flush with the finished
wall and shall be completely concealed when the fixtures are installed.
• Pipes' support shall be installed in such a way that pipes direction and slope can be kept
in place and strong enough to hold the pipes and expansion caused by heat exchange.

Pipe support shall be installed with spacing as follows:

Pipe Diameter Maximum Spacing

(mm) Horizontal (m) Vertical (m)
Up to 20 1,8 2,0
25 to 40 2,0 3,0
50 to 80 3,0 4,0
100 to 150 4,0 4,0

• Types of support shall be as follows:

- Steel plate.
- Steel angle.
- Or other steel profile as indicated and as indicated in the Drawings.

Steel material shall be in accordance with the requirements of Specification.

• Support shall be placed at following location:

- Change of flow direction.
- Point of branch.
- Central load caused by valve and equipment installation.

e. Protection and Cleaning

• The Contractor shall provide and maintain adequate protection for all sanitary fixtures
until completion of whole work or as directed by the Project Manager. All damage sanitary
fixtures shall be replaced at the expense of the Contractor.
• Before handling over or when directed by the Project Manager, all sanitary fixtures shall
be cleaned to satisfaction of the Project Manager.

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 f. Protective Coating
• The exposed pipes, fittings, pipe's support and water tower shall be painted in colour as
specified in Colour Scheme that shall be issued later. All exposed pipes shall also be
sign-painted with flow direction.
• Paints and painting works shall be in accordance with the requirements of Specification.

4. Fire Fighting Equipment

a. Fire Hydrant Box
Fire hydrant box for outdoor shall be completed with the following items:
- Box which is made of steel plate 2 mm thick, complete with lockable door with breakable
glass for cover, in size as manufacturer's standard. Box shall be oven-painted in red
colour (RAL 3001).
- Fire hose of highcount rubber compound such as Pionier 400 by Ziegler, with coupling
type according to local standard, of 65mm in diameter and in length of 2 x 30meters.
- Hose nozzle of 65mm diameter with jet straight nozzle type.
- Fire hose valve of diameter 65mm.
- Made by Yamato, Appron, Hooseki or approved equal.

b. Fire Hydrant Pillar

Pillar hydrant shall be of two-way type with main valve, size of 65 mm x 65 mm x 100 mm,
such as manufactured by Yamato, Appron, Hooseki or approved equal.

5. Construction Requirement
a. General
- All labour shall be neat and workmanlike and qualified and experienced tradesman
as approved by the Project Manager.
- All dimensional locations of fixtures, equipment, floor and drains, risers and pipe shall be
verified on the Architectural Drawings and manufacturer's catalogues.
- All items, whether specifically mentioned or not, or indicated in the Drawings, shall be
furnished and installed if necessary to complete the system in accordance with the best
practices of the plumbing trade and to the satisfaction of the Project Manager.

b. Installation of Piping
- All utility piping to be installed shall be kept clean, and in working order through periodic
testing by Contractor until the work has been turned over and accepted by the Owner.
- All utility piping shall be installed to the defined coordinate outside of the site.
- The Contractor shall be responsible for providing those portions of fittings which are not
provided with the fittings required for the complete installation. All fittings shall be carefully
checked to determine the portions which to be provided to complete the installation.
- The pipes shall be used in full length pipe wherever possible.
- All changes in pipe size shall be made with reducing fittings or reducers.
- Valves provided as specified for proper control system shall be placed in accessible
location with the ample room for full opening, repacking, and replacement of internal part
with operating stem horizontally or vertically upward.
- Each fixture shall be provided with shut-off valves for water as positioned in the Drawings,
so that any fixture may be separately controlled without affecting any other fixtures
supplied.
- Pipework shall be adequately supported on both sides of the flexible connection to
eliminate all lateral forces on the joint except those due to vibration only.
- Any such supports on the pump side of the joint shall be mounted so as not to transmit
vibration to the adjacent building.
- Piping work which shall need excavation and backfilling shall be carried along in
accordance with Specification.

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c. Support and Fastening
- All pipes, fittings and equipment shall be supported and fastened in a safe and durable
manner.
- Pipes support shall be installed in such a way that pipes direction and slope can be kept
in place and strong enough to hold the pipes and expansion caused by heat exchange.
- Inserts shall be safely anchored and the anchors shall be installed flush with the finished
wall and shall be completely concealed when the fixtures are installed.

d. Installation of Pump
- All pumps shall be assembled and installed according to the manufacturer's instruction.
- Pumps shall be mounted horizontally or vertically and located as shown in the Drawings.
- Pump bases shall be mounted on structural concrete inertia blocks with vibration
isolators.
Concrete material shall comply with the requirements of Specification.
- Whether or not shown in the Drawings, pump bases shall incorporate inertia blocks of
galvanized structural channel sections bolted to the bed plate and in- filled with concrete
by the Contractor. The complete inertia block shall be provided by the Contractor.
- All holding down bolts and fixings shall be provided by the Contractor for incorporation in
the concrete work where required.
- The pump units shall be installed as indicated on the plans and after the units are bolted
down the pumps and motor shafts shall be checked for alignment and corrected if
necessary.
- The gauges shall be mounted on a hardwood gauge board on the wall or elsewhere as
directed by the Project Manager. All gauges shall be clearly labeled.
- All electrical works shall be carried out according to the manufacturer's instruction and the
requirements of Specification

e. Installation of Tank
The installation of pressure tank and water storage tank shall be in strict accordance with the
manufacturer's installation instruction.

f. Installation of Fire Fighting Equipment

All fire fighting equipment shall be installed at places as indicated in the Drawing and in
accordance with the manufacturer's installation instruction.

g. Roughing-In
- Roughing-in for pipes and fittings shall be carried along with building construction, and
shall be coordinated between Project Manager and Contractor.
- Correctly located openings of proper sizes for the passage of pipes shall be provided
when required. Locations shall be established on Drawings, coordination of final positions
shall be consulted with the Project Manager.
- All items such as gutter straps and like appurtenances to be embedded in concrete or
masonry shall be thoroughly cleared free from all rust, scale and paint.

h. Cleaning and Adjusting

- During construction, the Contractor shall properly cap all lines, so as to prevent entrance
of sand, dirt and others. Each system of piping shall be blown through with air after
completion for as long a time as necessary to thoroughly clean the systems.
- After the entire installation has been completed, Contractor shall operate the equipment
under normal conditions making all necessary adjustments to balancing valves, automatic
pressure controls and others, until all performance requirements are met.

i. Sewer System Test

- The entire sewer and vent system shall be supplied with all incidental appurtenances to
permit plugging as necessary to enable the entire system specified herein, to be filled
with water to the level of the highest vent stack and/or vent stack above the roof.

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 - The system shall hold water for a full 30 minutes during which time there shall be no drop
in the water's level.
- In the event that the Project Manager decides that additional tests are needed, such as
an air smoke test on the drainage system, the Contractor shall perform such tests without
any additional cost to the Owner.

j. Pressurized System Test

- Upon completion of the plumbing installation and of the roughing-in and before setting
fixtures, the entire piping system shall be tested at a hydrostatic pressure one and a half
times the nominal working pressure in the system in operation, and proved tight at this
pressure for at least 8 hours. The nominal working pressure for water supply and fire
water shall be as indicated in the Drawings.
- Where a portion of the piping system is to be concealed before completion, this portion
shall be tested separately at a pressure similar to that described for the entire system and
in the presence of the Project Manager.

k. Disinfecting of Water Supply

- Upon the completion of the entire water supply installation, the Contractor shall sweep,
mop and clean the water tanks and flush clean pump sets, distribution pipelines and
pumping mains as required taking due care that openings which connect to pipelines are
properly plugged up and foreign matter prevented from entering. Only water from the
public water supply shall be used for such cleaning.
- The water storage tanks shall then be filled with water mixed with sufficient decanted
solution of chloride of lime to give a concentration of 40ppm of free chlorine in the water.
- The chlorine water shall be left in the storage tanks and pipe work overnight and drained
out completely the next day. The water supply system shall then be put into operation.
- On completion of the chlorination procedure, water samples shall be taken by an authority
Laboratory for testing and certification as being fit for human consumption.
- Contractor to ensure that suitable warning notices are provides until certificate has been
received by the Project Manager.
- No worker shall be permitted to enter the tanks after chlorine water has been admitted,
the compliance with which shall be Contractor sole responsibility. Should he be negligent
in this matter, in the opinion of the Project Manager, he shall repeat the disinfecting
process until the Project Manager is satisfied, and at no extra cost, charges, expenses,
and others to the Contract.

l. Testing of Fire Fighting Equipment

Testing of fire fighting equipment shall conform to the requirements of local Fire Department.

m. Protective Coating
- All outside surface of steel pipes and fittings which shall be buried underground shall be
coated with a minimum of 40microns asphalt as a rust protective coating.
- All exposed pipes, fittings and pipe's support shall be painted in colour as specified in
Colour Scheme which shall be issued later. All exposed pipes shall also be sign-painted
with flow direction.
- Paints and painting works shall be in accordance with Specification.

n. Ventilating and Air Conditioning

- Description of Work
This work shall cover the delivery, furnishing and installation of ventilating and air
conditioning system equipment and devices as specified herein and/or as shown in the
Drawings.
The work shall include but not be limited to the following:
• Installing of air conditioning units, supplying and installing all associate pipe work and
control system.

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 • Supplying and installing of exhaust fans, ducting and other related accessories and
control system.
• Testing and balancing all the system and all other incidentals required to make all
system perfect and ready for operation.

- General Procedures
• Technical Data
Contractor shall submit all required technical data concerning this work to the Owner
for approval prior to delivery.
Technical data shall contain descriptions, characteristics, and installation and
maintenance instructions.

• Shop Drawing
 Prior to installation, the Contractor shall prepare and submit Shop Drawings to
the Project Manager for approval.
 The Contractor shall check all dimensions from the Drawings with the site
condition. No claims will be allowed arising from the slight discrepancies between
Drawings of other disciplines and/or measurements taken at the site of the
project.

 Shop Drawings shall include the following:

 Dimensions, sizes and layouts.
 Installation methods.
 Wiring diagram for each installation.

All documents shall be drawn up in accordance with models submitted to and

approved by the Project Manager.

• Factory Test
 All main equipment for ventilating and air conditioning system shall have been
tested at the factory.
 On the time of delivery, all equipment shall be delivered complete with mill test
certificate.

• Handling and Storage

Handling and storage of all materials and equipment for ventilating and air
conditioning system shall be in accordance with the manufacturer's recommendation
and as directed by the Project Manager.

• Waranty
Unless otherwise specified, the Contractor shall furnish to the Owner a written
warranty covering the satisfactory operation of the ventilating and air conditioning
installation in all its parts for a period of one year after date of final acceptance.
During this period the Contractor shall repair or replace any defective work and pay
any repair or replacement costs.

- Materials
• General
 All ventilating and air conditioning equipment and accessories shall be from the
best quality and in the best condition, shall comply with the related standard.
 The Contractor shall furnish and install a thermostat humidity controller inside the
room and on-out switch. Thermostat shall be a single pole, switch action.
Adjustable stops shall be incorporated in the control knob to enable the user to
pre-set maximum and minimum temperature. The accuracy shall be 2%.

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- Split System Air Conditioning
• General
 Split system air conditioning units shall be of equipment which are factory
assembled (provided with factory certificate) and shall consist of casing, coil
condensation drain, fan and motor, cleanable filter, unit control, expansion valve,
compressors, air cooled condenser, condenser fan and motor, pressure and
capacity control.
 The capacity and number of the unit shall be not less than as specified in the
Drawings.
 The air conditioning units shall be of Daikin, Mitsubitshi and LG.

• Tipe
The split system AC shall be split duct of air-cooled type and single split system of
wall mounted or ceiling cassette type as shown in the Drawings.

• Refrigerant
Type of refrigerant shall be R 410a.

- Exhaust Type
Exhaust fan of the type with mounting system as shown, each with capacity, size and
power as shown in the Drawings and having characteristics according to the standard of
the manufacturer, shall be similar or equal to KDK or Panasonic product.

- Piping
• Piping
 Drain Pipe
Drain pipe shall be made of PVC with working pressure 8kg/cm², complying with
SNI 06-0084-2002.
All piping shall be suitable for solvent cement jointing similar to Rucika, Vinilon
and Pipamas.
Pipes shall have insulation made of fibreglass covered with aluminium foil.
 Refrigerant Pipe
The refrigerant piping, including fittings and other accessories needed for air
conditioning equipment shall be made of copper pipe of phosphoric acid
deoxidized type, with dimensions as specified by the manufacturer, complying
with ASTM B 280, such as from Mueller, Toyooda or Kembla.
 Pipe Insulation
 Pipe insulation for refrigerant pipe shall have the following characteristics:
 Made of cross-linked polyethylene foam of low density and a closed
cellular structure, locally available such as Insuflex, K-Flex or Kemflex.
 Made of flexible, black, closed cell, elastomeric nitrile rubber, locally
available such as Armaflex by Armstrong,
 Minimum thickness of 32mm for pipe of diameter up to 25mm, thickness
of 38mm for pipe of diameter 32mm up to 80mm, thickness of 50mm for
pipe of minimum diameter 100mm,
 Minimum density of 62kg/m3,
 Minimum thermal conductivity of 0.035W/m K at 10□C,
 Fire resistant class 1 according to BS 476 Part 7.

 Adhesive tape shall be as follows:

 Thickness of 5mm and width of 50 mm, such as Insuflex, K-Flex or
Kemflex.
 Thickness of 3mm and width of 30 mm, such as Insuflex, K-Flex or
Kemflex

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20 MANUFACTURING

20.1 General

Manufacturing of the equipment shall be performed by qualified professionals by means of

internationally recognized process subject to approval by the Engineer.

The Contractor shall establish a manufacturing control system for checking the manufacturing works
to be carried out inside and outside the Contractor’s shops, as well as in the Sub Contractors’ shops
in order to ensure quality of the materials, parts, devices and systems for the steel structures,
mechanical devices, electrical facilities and auxiliary facilities of the equipment and to expedite the
manufacturing works.

20.2 Structural Works

20.2.1 Processing

Processing of the steel structural members shall be carried out by adopting the most advanced
technology to assure the required quality and performance of the equipment.

20.2.2 Welding

Welding for main structural members shall basically be submerged arc welding methods and shall be
carried out under the permanent supervision of qualified experts. Welding of all main structural
members and members to be exposed to outside weather shall be continuous. Intermittent welding
shall not be accepted except the secondary steel structures inside covered areas.

The welding procedure, workmanship and finish of the welding shall be in accordance with the
relevant standards subject to approval by the a and shall be carried out by the certified operator(s)
using modern submerged arc welding facilities or an equivalent method to be used by certified
welders. Pre-qualification tests of welders, operators and/or welding procedures shall be done at the
Contractor's expense. All welding rods used shall be of the relevant standards subject to approval by
the Engineer.

The welding of the main parts of the structural members of the equipment shall be fully inspected by
the Contractor's inspector and the authorized inspector appointed by the Engineer in accordance with
the requirements of the relevant standards subject to approval by the Engineer.

Welding in the main structure areas subjected to high stress shall be inspected by x-ray and/or ultra-
sonic inspection.

Welding inspection of load carrying members shall be performed in the following manners:
- All welding shall be inspected for exclusion of cracks, slag deposits, etc., by magnetic particle
and/or penetrating dye method.
- Plates subjected to tensile forces perpendicular to the plate surface shall be inspected by
ultrasonic method.
- Butt welds of highly stressed areas shall be inspected by x-ray method.

20.2.3 Assembly

After fabricating the structural steel members, all the members shall be assembled at the Contractor’s
shop and inspected for the accuracy of dimensions in accordance with the Employer’s Requirements
and the Drawings under the presence of the Engineer and/or his appointee as far as practical.

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20.2.4 High strength bolts

All high strength bolts shall be installed in accordance with the relevant specifications. Bolts may be
tightened by either the calibrated wrench method, the turn of nut method, or using load indicator
washers. At least 5 % of the bolts, uniformly distributed throughout the structure, shall be checked
with a calibrated torque wrench. The testing of the bolts shall be performed by the Contractor under
the supervision of the Engineer.

20.2.5 Holes

Holes shall not be made or enlarged by burning, nor shall the burning of unfair holes in the shop or
field be acceptable. Drift pins may be used only to bring together the several parts; they shall not be
used in a manner to distort or damage the metal. The use of gas-cutting torches in the field for
correcting errors will not be permitted on any major member in the structural framing. Its use will be
permitted on minor members when the member is not under stress and then only after the approval of
the Engineer has been obtained.

20.3 Mechanical Works

20.3.1 Processing

Processing of the mechanical components shall be carried out by adopting the most advanced
technology to assure the required accuracy, quality, and performance of the equipment.

20.3.2 Assembly

After machining the components, all the components shall be assembled at the Contractor’s shop and
inspected for the accuracy of dimensions in accordance with the Specifications under the presence of
the Engineer and/or his appointee.

20.4 Electrical Works

20.4.1 Processing

Processing of the electric components shall be carried out by adopting the most advanced technology
to assure the required quality and performance of the equipment.

20.4.2 Installation and Wiring

All the electric components and systems shall be installed including proper connection wiring on the
assembled equipment and to be subject for inspections and tests in accordance with the requirements
of the Employer’s Requirements and the Drawings under the presence of the Engineer and/or his
appointee.

20.5 Shop Assembly Works

20.5.1 General

After finishing all the manufacturing process, all the components, members, devices and systems
shall be assembled in the Contractor’s or Sub-Contractors’ shop for inspection and test to be carried
out by the Contractor under the presence of the Engineer. The inspection and test report shall be
prepared by the Contractor and submitted to the Engineer for approval.

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20.5.2 Partial Assembly

Steel Structures shall be assembled by each block for inspection. Mechanical devices shall be
assembled by each unit for inspection and test. Electrical facilities shall be assembled by each system
for inspection and test.

Component parts, sub-assemblies, equipment and structures shall be match marked and tagged with
metallic tags for ready identification during erection on site.

All sub-assembly drives and motorized units shall be run to assure that they are in proper operating
condition. These test runs shall be made in the presence of the Engineer, and /or the designated
inspector.

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21 PACKING, SHIPPING AND TRANSPORTATION TO SITE
The Contractor is responsible for ensuring that all Goods, Materials, Plants necessary to carry out
whole of the Works under this contract shall be packed, transported and delivered to the Site without
any damage and loss on time. The Contractor is also responsible to transport away the Goods and
Materials from the site when no longer required, including the existing facilities which have to be
removed to construct the Plant. The existing facilities so removed shall be transported by the
Contractor to the area designated by the Engineer within the Trubaindo Coal Mining Area and shall be
the property of the Employer.

The Materials and Plants shall be properly packed and protected before shipment so that they will
reach the Site without damage. In order to prevent damage during shipment, The Contractor shall
carefully pack and brace containers either. Each shipping unit shall be adequately protected by
means of a suitable barrier or cover so that dust, dirt and other forms of contamination do not
penetrate the package. The Containers shall bear the contract number, the manufacturer’s name and
product designation, batch number, date of manufacture and shelf life.

After completion of shop inspection and test, the Plants shall be properly disassembled and protected
suitably for transportation to the Site where they shall be erected by the Contractor. The Plant shall be
transported in assembled conditions as far as practicable, to shorten the period for the erection works
at the site, to minimize the disturbance of the port operation and to assure the quality and accuracy of
the works of the Plant.

Prior to shipment, the Contractor shall take all necessary care for the safe transportation up to the
Site, including a guarantee bond to cover any damage resulting from any accidents that may happen.
All parts of the Plant shall be protected with adequate protecting materials and methods. Loss,
damage or deterioration that will occur during the transportation to the Site shall be immediately
reported in writing by the Contractor to the Engineer.

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22 QUALITY ASSURANCE

22.1 Outline Quality Assurance Program

The Tenderer shall submit as part of his Tender an Outline Quality Assurance Program, to
demonstrate to institute a quality assurance system of compliance with the requirements of the
Contract, illustrating the intended means of compliance with the Employer’s Requirements and setting
out in summary form an adequate basis for development of the more detailed document required at
the post award stage. The Outline Quality Assurance Program shall contain sufficient information to
demonstrate clearly the proposed method of achieving the Tenderer’s quality objectives with regard to
the requirement of the Contract.

The Tenderer may be requested to amplify, explain or develop its Outline Quality Assurance Program
prior to the date of acceptance of the Tender and to provide more details with a view to reaching
provisional acceptance of such a program.

22.2 Quality Assurance Program

Within thirty (30) days from receiving the Letter of Acceptance of the Tender, the Contractor shall
submit to the Engineer, for his consent, his proposed Quality Assurance Program based on the
Outline Quality Assurance Program and the Employer’s Requirements. The quality manual should
address the quality system required by ISO 9000 series standards. Any supplement to the Quality
Assurance Program shall submit at least twenty eight (28) days before commencement of the relevant
work.

The Quality Assurance Program shall include i) Quality Assurance (QA) and Quality Control (QC)
activities performed by or upon suppliers and subcontractors or their products and ii) a draft schedule
relating dates of commencement and completion of major QA activities to the proposed production
schedule. This Quality Assurance Program will be reviewed by the Engineer and will provide any
alteration requested, if any, in the proposed Quality Assurance Program. The Contractor shall submit,
within 14 days after notification of the Engineer, the revised Quality Assurance Program that shall
incorporate the changes requested by the Engineer, along with a schedule providing the proposed
dates at which major production and QC activities will commence and conclude.

Upon the Engineer notifying his consent to the Quality Assurance Program, or any supplement
thereto, the Contractor shall, adhere to the principles and procedures contained in such document,
except where the Engineer gives his consent to any amended or varied version thereof. The
Contractor shall cause any sub-contractors to adhere to this Quality Assurance Program.

Compliance with the Quality Assurance Program shall not relieve the Contractor of any of his duties,
obligations or responsibilities under the Contract.

22.3 Manager of Quality Assurance Program

The Contractor shall appoint a suitable qualified and experienced person to act as manager of the
Quality Assurance Program and shall provide such other personnel and resources as required to
ensure effective operation of the Quality Assurance Program. The said manager shall carry out audits
of the application of the Quality Assurance Program, and ensure effective quality assurance and
delivery of quality assurance.

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22.4 Employer’s/Engineer’s Surveillance

The Contractor shall provide all necessary access, assistance and facilities to enable the
Employer/Engineer to carry out surveillance visits both on and off the Site to verify that the Quality
Assurance Program is being properly and fully implemented. No extra payment shall be made for
complying with the provisions of this clause and cost of the Works under this element shall be
deemed to be included in the Contract Price.

22.5 Responsibility of Contractor

The Contractor shall bear full responsibility for supply of the Plant and Materials to the Employer, in
part or in whole, which conform fully to the quality requirements given in the Employer’s Requirement
and the quality requirements necessary for the intended application. This responsibility shall include
all items or services provided to the Contractor by the Contractor's suppliers and/or subcontractors
which form, in part or in whole, the Plant and Materials provided to the Employer.

The Contractor shall be responsible for providing certification of materials, workmanship and
components utilized in the Work, and for performance of tests to verify the quality of the Work. Such
certifications and tests shall include, but not necessarily be limited to, those certifications and tests
specified in the portion of the Employer’s Requirements, which pertains to each aspect of the Work.

The Contractor shall bear all costs arising from the Contractor's failure, or the failure of the
Contractor's suppliers or subcontractors, to meet the quality requirements.
Design review, inspection or testing performed by the Employer/Engineer, or its omission, shall in no
way relieve the Contractor of the responsibility to provide product(s) of the required quality.

22.6 Material Control and Traceability

The Contractor shall employ adequate material control procedures to ensure that each different type,
grade, or size of material or component, remain identifiable until affixed to or wrought into the Work.

The Contractor shall maintain records to determine the disposition of each identifiable lot of each
type, grade or size of material received at Contractor's plant(s) into either being wrought into the
Work; or being consumed, scrapped, or forming part of future inventory.

These records shall list quantities received and dispositioned by weight, volume, piece count, or other
suitable measure, such that an audit of such records may be quantitatively balanced. All records are
to be dated, identified and titled. The Contractor shall make such records available to the Engineer
upon request.

When traceability is required for individual components or subassemblies, the specific requirements
will be given in the portion of the Employer’s Requirement, which pertains to the individual component
or subassembly.

22.7 Site Construction and Installation

It is the Contractor's responsibility to be familiar with site conditions and climate. The Contractor shall
provide the Engineer with written descriptions and procedures for special processes and test methods
to be performed on the site (e.g., welding, painting, bolt tensioning, NDT, etc.) which outline the
precautions to be employed to ensure that work performed on site meets required standards of
quality.

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22.8 Correction of Nonconformance

Prior to acceptance of the Works by the Employer, all nonconformances shall be corrected by the
Contractor at Contractor's cost. If the Engineer discovers nonconformance to the Employer’s
Requirements at any stage after acceptance by the Contractor's Quality Assurance Program, the
Engineer will immediately advise the Contractor verbally and as soon as practical, in writing, and will
request correction within a time period stipulated by the Engineer.

22.9 Gross Nonconformance by Contractor

In the event the Enployer’s/Engineer’s surveillance determines gross nonconformance to the

Employer’s Requirements on the part of the Contractor, as evidenced by:

A high proportion of defects in manufactured components, parts, subassemblies, or finished products;

Repeated failure of Contractor's Quality Assurance System to conform to approved, documented
procedures;

Repeated failure of Contractor's quality control to correctly identify defects in the work;
Repeated failure of Contractor to correct nonconformance in an approved and/or timely manner.
Then, the Engineer will issue written notification to the Contractor requiring the Contractor to correct
the cause of the gross nonconformance(s) within a limited period of time determined by the Engineer
and to provide written reports initially advising the Contractor's proposed action, and subsequently
advising status of the corrections and improvements measured.

When notification to the Contractor is issued, the Engineer reserves the right to instruct work
suspended on all or a specified portion of manufacturing and/or quality control, or to order shipment
halted, until the cause of the gross nonconformance is rectified and results are demonstrated to be at
an acceptable level.

If the Employer incurs additional costs due to additional testing or other causes stemming from gross
nonconformance by the Contractor, the Employer reserves the right to recover the additional costs
from the Contractor.

22.10 Quality Records

Copies of the Contractor's quality records shall be submitted to the Engineer, without charge, as
required by the Employer’s Requirements or as requested by the Engineer.
The Contractor’s quality records, in addition to those submitted to the Engineer, shall be retained by
the Contractor for a minimum five (5) years following taking over of the Work by the Employer. These
quality records shall be provided, without charge, to the Employer upon request of the Employer.

22.11 Quality Dossier

Within sixty (60) days from the date of the Taking Over of the Works by the Employer, a quality
dossier shall be submitted by the Contractor to the Engineer. It shall incorporate all quality related
documentation, including but not limited to:
 Material Certificates.
 Material map.
 Welder identification system and qualifications.
 Inspector identification system and qualification.
 Heat treatment records.
 As-built measurements of critical dimensions and tolerance.

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 Records of all tests and inspections, including mechanical, electrical, structural and surface
protection.
 Completed quality control plan.
 Non-conformance reports duly closed-out

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