STORMWATER & SUBSOIL DRAINAGE SYSTEMS VOLUME IV- TECHNICAL SPECIFICATIONS

17 CHAMBERS AND COVERS (SECTION 02607)

17.1 Part 1 General
17.1.1 Related Sections
Section 01300 - Submittals

Section 03300 - Cast-In-Place Concrete

17.1.2 References
BS 970 Part 4 - Specification for wrought steels for mechanical and allied engineering
zurposes. Valve steels.

BS 1387 - Specification for screwed and socketed steel tubes and tubulars and for
plastic and steel tubes suitable for welding or for screwing to BS 21 pipe threads.

BS 2789 - Specification for spheroidal graphite or modular graphite cast iron: Ductile
iron.

BS EN 124 – Gully tops and manhole tops for vehicular and pedestrian areas

BS EN 124-5 – Gully tops and manhole tops made of composite materials

BS 5911-3 Concrete pipes and ancillary concrete products – Part 3 Specification for

BS EN 1990 – Steel bridges, concrete and composite bridges. Specification loads

BS 7874 Specification for elastomeric for joints in pipework and pipelines

BS 1247 – Foundry Machinery. Safety requirements for ladles, pouring equipment,

centrifugal casting machines, continuous and semi continuous casting machines

17.1.3 Submittals for Review

A. Shop Drawings: Shop Drawings shall indicate details of chamber locations, elevations,
dimensions, sizes, configuration, lifting eyes and penetrations.

B. Product Data: Products data shall be submitted for covers, component construction,
features, configuration and dimensions.

C. Samples: Samples of material shall be submitted for testing and for approval by the
Engineer.

17.1.4 Qualifications
A. Manufacturer: The Company shall be certified and specialized in manufacturing
products specified in this section with documented experience.

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B. GRP composite manhole covers, kerb inlet covers, flush inlet covers, frames and
gratings shall be manufactured by a reputable company with the following
qualifications:

1. Minimum ten years of manufacturing & supply record for GRP composite manhole
frames & covers in GCC countries.

2. Quality, Environment & Occupational Health and Safety system certifications to ISO
9001, ISO 14001 and OHSAS 18001. The certification scope shall indicate GRP
manhole covers as a minimum.

3. Shall possess BSI KITEMARK for BS EN 124-5 standard certification for GRP manhole
covers or BSI KITEMARK certificate on any other product which produced using
the same type of raw materials as used in the GRP composite manhole covers.

4. Shall have a sustainability certificate which shows that GRP composite manhole covers
are undergone an assessment study by an approved consultant and comply
with ESTIDAMA requirements.

17.2 Part 2 Product

17.2.1 Materials
A. Precast Concrete Manhole Chambers: As BS 5911 Part 3 to the sizes given on the
Standard Drawings

B1. Non-recessed Covers and frames:

1. General

1.1. Covers and frames for access to pumping station sumps and valve chambers shall
comply with BS EN 124. A GRP sealing plate and heavy grease seal, to be formed
between the cover and frame, shall be provided to prevent the ingress of sand.
1.2. Covers and frames shall be unvented and made of spheroidal graphite cast iron (ductile
iron) as per ISO 1083:2018 Or GRP composite that meet or exceed the requirements of
BS EN 124-1 & BS EN 124-5, and covers (for manholes, kerb inlet, flush inlets),shall
comply with all relevant and applicable requirements of the Abu Dhabi standards published
by Abu Dhabi QCC. They shall be supplied to suit the clear openings shown in the
Drawings.
1.3. Unless otherwise shown on the drawings or instructed by the Engineer or specified in this
Section the class of covers and frames shall be as per Figure 5 in BS EN 124-1-2015.
Along or adjacent with carriage ways Class D400 shall also be used in bus stops, taxi
stops, lay byes and any parking alongside carriageways and parking area subject to full
vehicular loading, C250 in pedestrian areas or block paved areas outside the carriageway

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as shown in Figure 5 in BS EN 124-1-2015 and Class B125 in locations not subject to

vehicular traffic.
1.4. All covers to storm water drain manholes, kerb inlet covers, flush inlet covers, in trafficked
areas shall be classified as non-rocking and single piece. In case for larger sizes to
facilitate removal and lifting, GRP composite covers made in multiple sections may be
accepted on the condition of compliance with BS EN 124-5. Clear opening for covers to
inlets, catch basins and chambers shall be as shown on the drawings.
1.5. Provide the following cover face badging(in addition to what is required in the standards)
in Arabic and English:-

a) STORMWATER
YEAR OF PROJECT
STANDARD
b) Purpose of application (STORMWATER..etc)
for 150x150m surface boxes

1.6. Multiple ducts covers and frames shall be cast iron, water proof and non-rocking. They
shall be of the type incorporating integral removable intermediate beams to give the
required clear pit opening shown in the Drawings. All covers frames and supporting metal
work shall be designed for loading to BS EN 1990.
1.7. Covers and frames and multiple ducts covers and frames shall be coated in accordance
with Section 09900, table 9.1, exposure class C2. Coated covers and frames shall not be
handled and transported until full cure has been achieved. An original of the approved
coating specialist's quality control report for each itemised component shall be provided
with each delivery. The report shall bear an original company stamp and signature.
1.8. Covers and frames to be provided with proper key holes for easy lifting, heavy covers to
be provided with special lifting hooks.
1.9. Surface boxes shall include a cast iron heavy duty or Polyester powder coated cast
Aluminum Alloy LM6 cover and frame and be suitable for wheel loads of 11.43 tons.
Surface boxes may be used if requested by the Engineer. Cast iron shall be coated in
accordance with section 09900, table 1-1, exposure class C2. Surface boxes shall have a
150mm diameter clear opening and the cover shall be attached to the frame by a hinge.
1.10. If the chamber is located in the walkway or hard landscape area, then ventilation box
shall be provided as follows:
 Ventilation box body, Lid and dust cap shall be cast Aluminum Alloy LM6
 Polyester powder coated
 180mm Dia with removable bottom plate and 80 mm dust /ventilated cap pipe for easy
cleaning
 14 mm Dia Stainless steel C 316 lifting key
 6mm stainless steel C316 connecting bolt

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1.11. Cover badging shall include: in addition to what is required by EN 124-2008 standards
Cast iron/ductile iron/GRP, size (clear opening), foundry logs and name, foundry batching
number to covers and frames and class.
1.12. Cover slabs of the manhole and inlets falling in asphalt should be terminated minimum
below the wearing course or lower to ensure no concrete part will be exposed to the traffic.

2. Spheroidal Graphite Cast Iron (Ductile Iron) Covers and Frames

2.1. The spheroidal graphite cast iron (ductile iron) cover contact surfaces shall be machined
on two faces or shall incorporate on EPDM seal on the frame set into a reversed taper.
2.2. Unless otherwise indicated on Drawings Spheroidal graphite cast iron (ductile iron) cover
sizes are as stipulated on the following for respective sizes of Manholes:
750mm dia: for pipe dia up to 800mm
900mm dia: for pipe dia greater than 800mm

2.3. Spheroidal graphite cast iron (ductile iron) Covers and frames shall be coated with
minimum 50 microns of metallic zinc primer plus minimum 500 microns (applied in two
coats) of abrasion resistant solvent free epoxy. Minimum adhesion of the coating system
to the substrate shall be 2.0 MPa

2.4. Spheroidal graphite cast iron (ductile iron) Covers used in ADM shall be attached to the
frames by a hinge for easy lifting, hinges shall comply with BS EN 124.

3. GRP Composite Covers and Frames

The use of GRP composite covers ( for manholes. kerb inlets, flush inlets),and frames is
allowed in projects under the jurisdiction of ADM. As for projects under the jurisdiction of
AACM, the use of these covers shall be mainly for green areas only if mentioned in BOQ.
Types of GRP composite materials shall be as per clause 4.2 of BS EN 124-5
This clause is not applicable to:
— manhole tops and gully tops manufactured by means of hand lay-up method;
— gratings/covers as part of prefabricated drainage channels according to EN 1433;
— floor and roof gullies in buildings which are specified in EN 1253 (all parts); and
— Surface Boxes

a) Material
GRP composite material, from which the covers or frames are made, shall meet or exceed
the requirements of BS EN 124 -5:2015 Clause 4.

b) Requirements

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The GRP composite material used in gully tops and manhole tops shall meet or exceed
the design and performance requirements, and the material specific characteristics of BS
EN 124 -5:2015 Clause 5,6 and 7.

c) Testing
GRP composite covers and frames shall be tested as complete units in their intended
position of use where cover/grating is suitably positioned within the frame in accordance
with EN 124-1:2015, clause 8. In addition, they should be tested according to clauses 6.2
to 6.6 of BS EN 124 -5:2015.

d) Performance
The assessment and verification of constancy of performance, and the compliance of GRP
gully tops and manhole tops with the requirements shall be tested according to clauses 7.2
and 7.3 of BS EN 124 -5:2015.
e) Color
Unless otherwise specified, colour of the GRP composite gully tops and manhole tops
(frames, covers and gratings) shall be black for the storm water network in all areas and
black or green for the irrigation network, based on the area of installation.

B2 Recessed Covers and Frames

5. In areas of high amenity or prestigious value the Engineer may instruct the use
of recessed covers, these being covers to which a decorative surface finish can
be inserted to match the surrounding area, such as paviors or setts. The
relevant parts of Section B1 above shall apply in addition to the sub-sections
below.

6. Face badging shall not be provided.

7. The Covers and frames shall be coated with minimum 50 microns of metallic
zinc primer plus minimum 500 microns (applied in two coats) of abrasion
resistant solvent free epoxy. Minimum adhesion of the coating system to the
substrate shall be 2.0 MPa

8. Recessed covers may be designed by the manufacturer as requDMATng

structural infill, such as reinforced concrete, or with non-structural infill such as
paviors or setts.

9. Where the manufacturer produces covers which are designed to have a

structural infill applied on site, the manufacturer shall state the relevant physical
properties of the infill required to achieve the desired load capacity. The
Contractor shall ensure that the applied structural infill meets these

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requirements and that it cannot detach, degrade or crack during normal use and
maintenance.

10. Where the manufacturer produces covers which are designed to have non-
structural infill they shall be designed to have adequate load capacity without
the infill.

11. The Contractor shall ensure that all in fills match the immediately surrounding
area in terms of material, colour and surface finish.

12. Covers shall be of sufficient depth to receive infill items such as paviors or sets
of the same thickness as the adjoining area and be laid on a suitable bedding.
Paviors and sets shall not have their thickness cut down when used as cover
infill without the approval of the engineer.

C. Grab Handles:

1. Provide an internal grab handle in all cover slabs above circular access shafts
to chambers in open areas where the cover is raised above the natural ground
level. Form the grab handle from a 20mm stainless steel bar Grade 316S16 to
BS970:Part 4 or mild steel bar shot blasted and resin sealed, coated with vinyl
ester resin rich GRP laminate.

D. Sealing Plates:

1. Sealing plates shall be provided to chambers and sump access covers where
there is risk of ingress of surface water.

2. The sealing plate thickness shall be a minimum 5mm and the minimum design
load is 7.5 kN/sq.m.

3. The sealing plate shall be in the form of a plug with a flange to prevent the
plate dropping into the manhole.

4. The sealing plate shall incorporate a peripheral retained rubber ring such that
when the cover is closes a gas tight seal formed.

5. The plate shall be designed such that a watertight seal is obtained without the
use of bolts.

6. The rubber rings shall be made from nitrile rubber, SBR or EPDM formulations,
in compliance of BS7874 and BS EN 681.

7. The sealing plates shall have two securely laminated GRP lifting handles.

8. The underside of the plate shall be protected with a resin only liner 1.5
millimeters thick. Fibers shall not protrude into the resin layer or form bridges
to the free surface.

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9. Cuts and/or drilled faces shall be sealed with resin only.

10. Pigments shall not be added to the GRP formulations.

11. GRP sealing plates shall be seated on the lips of the frames without causing
any reduction to the dimensions of the specified openings.

E. Ladders:

1. The ladders shall be made of GRP as detailed on the Drawings.

F. Step Irons:

1. Step Irons shall be plastic encapsulated and shall comply with BS1247: part 2
and be of the general purpose or precast concrete manhole pattern as
applicable.

G. Tanking:

1. All manholes and chambers shall be protected externally with tanking.

H. Safety Chains:

1. Safety Chains shall be high density polyethylene or stainless steel of accepted

size and strength with suitable hooks at one end to permit access.

I Hand railing:

1. Hand railing shall be moulded GRP as detailed in the Drawings.

J Aluminium Covers:

1. Aluminium covers are to be obtained from an approved experienced

manufacturer.

2. The covers shall be capable to withstand 750kg/m2 without deflecting more

than 1% and without damage or permanent deflection.

3. Dissimilar materials to be separated by gaskets.

4. Sealing to be provided around entire frame by 33kg density polyethylene

sealing strip 25mm wide.

5. Surface boxes to be provided at appropriate locations for access to valves

extension spindles (grade OPC 25 for superstructure) if required.

6. Faces of the frame which comes into contact with cement mortar or concrete to
be painted with 2 coats of bituminous paint before installation of the frame.

7. Housing box shall be continuously aluminium welded.

8. Locking bars to be provided with stainless steel pad locks and master key.

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K Oil Separators:

1. Oil separators can be fitted to surface water drainage systems to protect the
environment from pollution by oils. They separate the oil from the water, and
then retain the oil safely until it is removed. They are installed to contain oil
leaks from vehicles and plant and accidental spillages. To be effective, oil
separators need to be correctly designed, installed and maintained.
2. Surface water may be contaminated by oil at a number of different sites. These
sites need to have measures in place to prevent this oil from polluting the
environment. These sites include:
a) Car parks typically larger than 800m2 in area or for 50 or more car parking
spaces

b) Smaller car parks discharging to a sensitive environment

c) Vehicle maintenance areas

d) Roads

e) Industrial sites where oil is stored or used

f) Re-fuelling facilities

g) Any other site with a risk of oil contamination.

3. Oil Separators should be provided by an access arrangement for inspections,

repair and maintenance purposes.

4. Separators standard and Types

a) Prefabricated GRP oil separators with concrete surround.

b) Concrete oil separators.

c) Oil separators shall be designed, constructed, and operated in accordance

with BS EN 858-1.

17.2.2 Quality Control

A. Shop testing and inspection of covers shall be provided as per Section 01400.

B. Sample covers shall be tested by an approved laboratory.

C. Testing frequency per batch delivery shall be as follows:

1 - 50 units One unit for each size and class

Up to 250 units Two units for each size and class

Up to 500 units Three units for each size and class

Over 500 units Four units for each size and class

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17.3 Part 3 Execution

17.3.1 General
A. In the carriageway and parking areas, the cover frame shall be set on a 15mm thick
bed of cement mortar No.2. which shall sit on a minimum of four 75mm thick fibre
concrete bedding rings. Concrete surround Class ‘B’ shall be applied to the bedding
rings and frame as shown on the Drawings. The minimum distance from the top of the
road surfacing to the manhole cover slab shall be 450mm.

B. In paved areas the chamber cover shall be set accurately to the level and slopes of the
surrounding surface. In unpaved areas the top of the cover shall sit 100mm above the
surrounding surface.

C. Where the height of the curb stone is 100mm, part of the asphalt area (equal to length
of grating) should have slope towards the curb inlet grating to get the minimum height
required for the curb inlet grating to insure proper road drainage

D. Immediately prior to the inspection of the works all covers and frames shall be cleaned
thoroughly by accepted means to the satisfaction of the Engineer.

E. Holes will not be allowed to be made through the shaft rings and liners.

F. Unless otherwise directed, cut-off walls shall be constructed to prevent the formation of
drainage paths within the pipe bedding. They shall be extended from the base to both
sides of the excavation and keyed into the native soil to a depth of 150mm. They shall
be constructed 300mm above the top of the pipe bedding as detailed on the Drawings.

17.3.2 Examination
A. Items provided by other sections of Work shall be verified for proper size and location.

B Built-in items shall be verified for proper location, and for being ready for roughing into
Work.

17.3.3 Preparation
A Placement of inlet and outlet pipe or duct sleeves required by other sections shall be
coordinate.

17.3.4 Construction of New Chambers on Existing Storm water

Pipelines
A. Where new chambers are to be constructed on existing storm water pipelines the
Contractor will be responsible for providing temporary bypass arrangements to ensure
the continuing operation of the storm water network.

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B. The Contractor shall be deemed to have included all the necessary costs for the
required temporary works in his rates. The Contractor shall not be entitled to any
additional costs or extension of time arising from these temporary works.

C. The Contractor shall obtain permission from the Engineer in writing before carrying out
any work on the existing system.

D. Adequate precautions shall be taken to ensure the existing pipelines bedding and
stability are not disturbed as a result of excavation, dewatering or any other
construction works.
END OF SECTION

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